check engine YAMAHA YFZ450 2013 User Guide

7-8
7
questions, consult an authorized ATV dealer.
WARNING! Operating this ATV with improper modifications may cause changes in handling
which in some situations could lead to an acci-
dent.
[EWB01491]
Exhaust system
WARNING
EWB01501●Dry grass or brush or other combustible ma-
terial accumulated around the engine area
could catch fire. Do not operate, idle, or park
the ATV in dry grass or other dry ground cov-
er. Keep the engine area free of dry grass,
brush, or other combustible material.●Someone touching the exhaust system dur-
ing or after operation could be burned. Do
not touch the hot exhaust system. Do not
park the ATV in a place where others might
be likely to touch it.The muffler and other engine parts become ex-
tremely hot during operation and remain hot after
the engine has stopped. To reduce the risk of fire
during operation or after leaving the ATV, do not let
brush, grass and other materials collect under the
vehicle, near the muffler or exhaust pipe, or next to other hot parts. Check under the vehicle after op-
erating in areas where combustible materials may
have collected. Do not idle or park the vehicle in
long dry grass or other dry ground cover.
To prevent burns, avoid touching the exhaust sys-
tem. Park the ATV in a place where pedestrians or
children are not likely to touch it.U1PD61E0.book Page 8 Tuesday, February 14, 2012 10:06 AM

8-3
8
EBU21743Periodic maintenance chart for the emission control system TIP●For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.●For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter-
vals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance
intervals should be followed.●Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.NO.ITEM CHECK OR MAINTENANCE
JOB INITIAL
EVERY
Whichev- er comes first month136612
km
(mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 320
1 *Fuel line Check fuel hoses for cracks or other damage, and
replace if necessary. √√√
2 Spark plug Check condition and clean, regap, or replace if
necessary. √√√√√
3 *Valves Check valve clearance and adjust if necessary. √ √√√
4 *Carburetor Check starter (choke) operation and correct if nec-
essary.
Check engine idling speed and adjust if neces- sary. √√√√
5 *Crankcase breather
system Check breather hose for cracks or other damage,
and replace if necessary. √√√
U1PD61E0.book Page 3 Tuesday, February 14, 2012 10:06 AM

8-7
8
14*Chassis fasteners Make sure that all nuts, bolts, and screws are
properly tightened. √√√√√
15 *Shock absorber as-
semblies Check operation and correct if necessary.
Check for oil leakage and replace if necessary.
√√√
16 *Rear suspension re-
lay arm and con-
necting arm
pivoting points Check operation and correct if necessary.
√√√√
17 *Steering shaft Lubricate with lithium-soap-based grease. √√√
18 *Steering system Check operation and repair or replace if damaged.
Check toe-in and adjust if necessary.
√√√√√
19 *Engine mount Check for cracks or other damage, and replace if
necessary. √√√
20 Engine oil Change.
Check ATV for oil leakage, and correct if neces-
sary. √ √√√
21 Engine oil filter ele-
ment
Replace.
√√√
22 Cooling system Check coolant level and ATV for coolant leakage,
and correct if necessary. √√√√√
Replace coolant. Every 2 years
NO. ITEM
CHECK OR MAINTENANCE
JOB INITIAL EVERY
Whichev- er comes first month136612
km
(mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 320U1PD61E0.book Page 7 Tuesday, February 14, 2012 10:06 AM

8-10
8To install the panel
1. Place the panel in the original position, and
then install the quick fastener screw and the
bolts. 2. Install the seat.
EBU23245Checking the spark plug The spark plug is an important engine component,
which is easy to check. Since heat and deposits
will cause any spark plug to slowly erode, the spark
plug should be removed and checked in accor-
dance with the periodic maintenance and lubrica-
tion chart. In addition, the condition of the spark
plug can reveal the condition of the engine.1. Projection
2. Slot
1
1
2
2
U1PD61E0.book Page 10 Tuesday, February 14, 2012 10:06 AM

8-13
8
To check the spark plug
1. Check that the porcelain insulator around the center electrode of the spark plug is a medi-
um-to-light tan (the ideal color when the ATV
is ridden normally).
TIPIf the spark plug shows a distinctly different color,
the engine could be operating improperly. Do not
attempt to diagnose such problems yourself. In-
stead, have a Yamaha dealer check the ATV.
2. Check the spark plug for electrode erosionand excessive carbon or other deposits, and
replace it if necessary.
3. Measure the spark plug gap with a wire thick- ness gauge and, if necessary, adjust the gap
to specification.
1. Spark plug wrench
1
Specified spark plug:NGK/CR8E1. Spark plug gapSpark plug gap:0.7–0.8 mm (0.028–0.031 in)
U1PD61E0.book Page 13 Tuesday, February 14, 2012 10:06 AM

8-14
8To install the spark plug
1. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any
grime from the spark plug threads.
2. Install the spark plug with the spark plug wrench, and then tighten it to the specified
torque.
TIPIf a torque wrench is not available when installing
the spark plug, a good estimate of the correct
torque is 1/4–1/2 turn past finger tight. However,
the spark plug should be tightened to the specified
torque as soon as possible.3. Install the spark plug cap.
4. Place the fuel tank in the original position, andthen install the bolt.
5. Remove the fuel tank cap by turning it coun- terclockwise.
6. Place the panel in the original position. 7. Install the fuel tank cap by turning it clockwise.
8. Install the bolts and the quick fastener screws.
9. Install the seat.
EBU23308Engine oil and oil filter element The engine oil level should be checked before
each ride. In addition, the oil must be changed and
the oil filter element replaced at the intervals spec-
ified in the periodic maintenance and lubrication
chart.
Tightening torque:
Spark plug:13 Nm (1.3 m·kgf, 9.4 ft·lbf)1. Projection
2. Slot
21
U1PD61E0.book Page 14 Tuesday, February 14, 2012 10:06 AM

8-15
8
To check the engine oil level
1. Place the ATV on a level surface.
2. Start the engine, warm it up until the engine oil has reached a normal temperature of 40 °C
(104 °F), let it continue to idle for ten seconds
or more, and then turn the engine off.
TIPTo achieve the proper engine oil temperature for
an accurate oil level reading, the engine must have
first completely cooled down, and then warmed up
again for several minutes to normal operating tem-
perature.3. Remove the engine oil tank filler cap, and thenwipe the engine oil dipstick off with a clean
rag.
4. Insert the dipstick into the filler hole (without screwing it in), and then remove it again to
check the oil level.
TIPThe engine oil should be between the minimum
and maximum level marks.5. If the engine oil is at or below the minimumlevel mark, add sufficient oil of the recom-
mended type through the engine oil tank filler
hole to raise it to the correct level. NOTICE:1. Engine oil tank filler cap
2. Engine oil dipstick
3. Engine oil tank
4. Crankcase engine oil filler cap
5. Maximum level mark
6. Minimum level mark
4
3
1
1
2
5
6
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8-19
8
12. Refill with the specified amount of the recom-
mended engine oil through the engine oil tank
filler hole, and then install and tighten the en-
gine oil tank filler cap.
13. Refill with the specified amount of the recom- mended engine oil through the crankcase en-
gine oil filler hole, and then install and tighten
the crankcase engine oil filler cap.
TIPBe sure to wipe off spilled oil on any parts after the
engine and exhaust system have cooled down.NOTICEECB00300●In order to prevent clutch slippage (since the
engine oil also lubricates the clutch), do not
mix any chemical additives. Do not use oils
with a diesel specification of “CD” or oils of
a higher quality than specified. In addition,
do not use oils labeled “ENERGY CONSERV-
ING II” or higher.●Make sure that no foreign material enters the
crankcase.14. Start the engine, and then let it idle for severalminutes while checking it for oil leakage. If oil
is leaking, immediately turn the engine off and
check for the cause.
15. Turn the engine off, and then check the oil lev- el and correct it if necessary.
Recommended oil:
See page 10-1.
Oil quantity: Without oil filter element replacement:Quantity in oil tank: 1.55 L (1.64 US qt, 1.36 Imp.qt)
Quantity in crankcase: 0.20 L (0.21 US qt, 0.18 Imp.qt)
With oil filter element replacement: Quantity in oil tank: 1.55 L (1.64 US qt, 1.36 Imp.qt)
Quantity in crankcase: 0.30 L (0.32 US qt, 0.26 Imp.qt)
U1PD61E0.book Page 19 Tuesday, February 14, 2012 10:06 AM

8-20
816. Install the engine guard by installing the bolts,
and then tighten them to the specified torque.
NOTICE: Be sure to apply LOCTITE
® to the
engine guard bolts before installing them.
[ECB00371]
EBU23470
Coolant The coolant level should be checked before each
ride. In addition, the coolant must be changed at
the intervals specified in the periodic maintenance
and lubrication chart.EBU27942To check the coolant level 1. Place the ATV on a level surface.TIPThe coolant level must be checked on a cold en-
gine since the level varies with engine tempera-
ture.2. Check the coolant level in the coolant reser- voir.
TIPThe coolant should be between the minimum and
maximum level marks.3. If the coolant is at or below the minimum levelmark, remove the coolant reservoir cap, add
coolant or distilled water to the maximum level
mark, and then install the reservoir cap.
NOTICE: If coolant is not available, use
distilled water or soft tap water instead. Do
not use hard water or salt water since they
Tightening torque:
Engine guard bolt:7 Nm (0.7 m·kgf, 5.1 ft·lbf)1. Maximum level mark
2. Minimum level mark
3. Coolant reservoir
4. Coolant reservoir cap
1
2 4
3
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8-21
8
are harmful to the engine. If water has
been used instead of coolant, replace it
with coolant as soon as possible, other-
wise the cooling system will not be pro-
tected against frost and corrosion. If water
has been added to the coolant, have a
Yamaha dealer check the antifreeze con- tent of the coolant as soon as possible,
otherwise the effectiveness of the coolant
will be reduced.
[ECB01011]
TIP●The radiator fan is automatically switched on or
off according to the coolant temperature in the
radiator.●If the engine overheats, see page 8-58 for fur-
ther instructions.
EBU23564To change the coolant
WARNING
EWB01890Wait for the engine and radiator to cool before
removing the radiator cap. You could be
burned by hot fluid and steam blown out under
pressure. Always place a thick rag over the cap
when opening. Allow any remaining pressure
to escape before completely removing the cap.1. Place the ATV on a level surface.
2. Remove panel A. (See page 8-9.)
3. Place a container under the engine, and then remove the coolant drain bolt and its gasket.
(Use a trough or a similar object as shown.)
Coolant reservoir capacity (up to the maxi-
mum level mark):
0.29 L (0.31 US qt, 0.26 Imp.qt)
U1PD61E0.book Page 21 Tuesday, February 14, 2012 10:06 AM