engine YAMAHA YFZ450R 2009 Owner's Manual

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not designed to withstand the shock of
forced shifting and can be damaged by shift-
ing without using the clutch.
EBU20672
Engine break-in
TIP


For ATVs equipped with an odometer or an hour
meter, follow the figures given in km (mi) or the
figures given in hours.

For ATVs not equipped with an odometer or
hour meter, follow the figures given in hours.
There is never a more important period in the life of
your engine than the first 320 km (200 mi) or 20
hours of riding. For this reason, you should read
the following material carefully.
Since the engine is brand new, do not put an ex-
cessive load on it for the first 320 km (200 mi) or 20
hours. The various parts in the engine wear and
polish themselves to the correct operating clear-
ances. During this period, prolonged full-throttle
operation or any condition that might result in en-
gine overheating must be avoided.
0–160 km (0–100 mi) or 0–10 hours
Avoid prolonged operation above 1/2 throttle. Vary
the speed of the ATV regularly. Do not operate it at
one set throttle position.
160–320 km (100–200 mi) or 10–20 hours
Avoid prolonged operation above 3/4 throttle. Rev
the engine through the gears freely, but do not use
full throttle at any time.
320 km (200 mi) or 20 hours and beyond
The ATV can now be operated normally.NOTICE

ECB00220
If any engine trouble should occur during the
engine break-in period, immediately have a
Yamaha dealer check the ATV.
EBU26760
Parking
When parking the ATV, stop the engine, shift into
first gear, and then apply the parking brake.

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EBU20860
Parking on a slope
WARNING

EWB00850
Avoid parking on hills or other inclines. Park-
ing on a hill or other incline could cause the
ATV to roll out of control, increasing the
chance of an accident. If you must park on an
incline, place the ATV transversely across the
incline, shift into first gear, stop the engine, ap-
ply the parking brake, and then block the front
and rear wheels with rocks or other objects.
Do not park the ATV at all on hills that are so
steep you could not walk up them easily.
1. Bring the ATV to a stop by applying the brakes
in first gear.
2. Stop the engine and release the clutch lever.
3. With the rear brake applied, apply the parking
brake and slowly release the brake pedal.
EBU20910
Accessories and loading
EBU20920
Accessories
Accessories can affect the handling and control of
your ATV. Keep the following in mind when consid-
ering an accessory or operating an ATV which has
accessories.
1. Locked position
1

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with engine size greater than 90 cc. Use by chil-
dren of ATVs that are not recommended for
their age can lead to severe injury or death of
the child.
This ATV is designed to carry operator only –
passengers prohibited.
WARNING

EWB01400
Never carry a passenger. The long seat is to al-
low the operator to shift position as needed
during operation. It is not for carrying passen-
gers. Carrying a passenger on this ATV greatly
reduces your ability to balance and control this
ATV. It could cause an accident, resulting in
harm to you and/or your passenger.
Apparel
Always wear an approved motorcycle helmet that
fits properly.
You should also wear:

eye protection (goggles or face shield)

gloves

boots

long-sleeved shirt or jacket

long pants

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page 5-1 before riding for proper care of the ATV
and to ensure safety.
WARNING

EWB01430
Always inspect your ATV each time you use it
to make sure the ATV is in safe operating con-
dition. Always follow the inspection and main-
tenance procedures and schedules described
in the Owner’s Manual. Failure to inspect the
ATV before operating or failure to properly
maintain the ATV increases the possibility of
an accident or equipment damage.
WARNING

EWB01440
Always use the size and type tires specified in
the Owner’s Manual for this ATV on page 5-5.
Always maintain proper tire pressure as de-
scribed in the Owner’s Manual on page 5-6.
Use of improper tires on this ATV, or operation
of this ATV with improper or uneven tire pres-
sure, may cause loss of control, increasing
your risk of an accident.Do not operate at speeds too fast for your
skills or the conditions.
WARNING

EWB01450
Always go at a speed that is proper for the ter-
rain, visibility and operating conditions, and
your experience. Operating this ATV at speeds
too fast for your skills or the conditions in-
creases your chances of losing control of the
ATV, which can result in an accident.
Speed limiter
For riders less experienced with this model, the
throttle lever housing is equipped with a speed lim-
iter. The speed limiter keeps the throttle from fully
opening, even when the throttle lever is pushed to
the maximum. Turning in the adjusting screw limits
the maximum engine power available and de-
creases the maximum speed of the ATV. Turning
in the adjusting screw decreases top speed, and
turning it out increases top speed. (See page 4-5.)

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WARNING

EWB01550
Always mount a caution flag on the ATV to
make you more visible when operating in areas
where you might not be seen by other vehicles.
Watch carefully for other vehicles.
Do not ride in areas posted “no trespassing”.
Do not ride on private property without getting per-
mission.Select a large, flat, unpaved area to become famil-
iar with your ATV. Make sure that this area is free
of obstacles and other riders. You should practice
control of the throttle, brakes, shifting procedures,
and turning techniques in this area before trying
more difficult terrain. Always avoid riding on paved
surfaces: the ATV is designed for use on unpaved
surfaces only, and handling maneuvers are more
difficult to perform on pavement.
Set the parking brake and follow the instruction on
page 6-1 to start the engine. Once it has warmed
up you are ready to begin riding your ATV. As you
get on the ATV, be sure not to accidentally move
the shift pedal. Remember that the engine and ex-
haust pipe will be hot when riding and afterwards;
do not allow skin or clothing to come in contact with

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these components.
With the engine idling, pull the clutch lever to dis-
engage the clutch and shift into 1st gear, and then
release the parking brake. Open the throttle grad-
ually, and at the same time, release the clutch le-
ver slowly. Once the ATV has attained adequate
speed, release the throttle lever and at the same
time, quickly pull in the clutch lever and shift into
2nd gear. Open the throttle part way and gradually
release the clutch. Use this same procedure as
you move into the higher gears. Be sure to coordi-
nate the use of the throttle and shift pedal properly.
If the throttle is applied too abruptly or if the throttle
is not released during shifting, or if the shift pedal
is not released before applying the throttle, the
front wheels may lift off the ground, resulting in a
loss of directional control. Avoid higher speeds un-
til you are thoroughly familiar with the operation of
your ATV.
WARNING

EWB01720
Always open the throttle gradually and release
the clutch lever slowly. Otherwise, the ATV
could wheelie which would increase the
chance of an accident.
NOTICE
ECB00230
Do not shift gears without releasing the throt-
tle. Damage to the engine or drive train may oc-
cur.
When slowing down or stopping, release the throt-
tle and apply the brakes smoothly and evenly. As
you slow down, shift to a lower gear. Be sure that
the engine has sufficiently slowed before engaging
a lower gear. Improper use of the brakes or shifting
can cause the tires to lose traction, reducing con-
trol and increasing the possibility of an accident.
WARNING

EWB01560
Make sure the engine has sufficiently slowed
before shifting to a lower gear. Engaging a low-
er gear when the engine speed is too high
could cause the wheels to stop rotating.
TURNING YOUR ATV
To achieve maximum traction on unpaved surfac-
es, the two rear wheels are mounted solidly on one
axle and turn together at the same speed. There-
fore, unless the wheel on the inside of the turn is al-
lowed to slip or lose some traction, the ATV will
resist turning. A special turning technique must be

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EBU28782
PERIODIC MAINTENANCE AND MINOR REPAIR
EBU21670
Safety is an obligation of the owner. Periodic in-
spection, adjustment and lubrication will keep your
ATV in the safest and best operating condition
possible. The most important points of inspection,
adjustment, and lubrication are explained on the
following pages.
The intervals given in the periodic maintenance
and lubrication chart should be considered as a
general guide under normal riding conditions.
However, DEPENDING ON THE WEATHER,
TERRAIN, GEOGRAPHICAL LOCATION, AND
INDIVIDUAL USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORTENED.
WARNING

EWB01840
Never service an engine while it is running.
Moving parts can catch clothing or parts of the
body, causing injury. Electrical components
can cause shocks or start fires. Turn off the en-
gine when performing maintenance unless
otherwise specified. Have a Yamaha dealer
perform the service if you are not familiar with
maintenance work.
EBU29570
Owner’s manual and tool kit
Be sure to always keep the owner’s manual, the
owner’s tool kit and the low-pressure tire gauge
with the vehicle. Make sure to protect the owner’s
manual by putting it in the plastic bag, then by plac-
ing the bag in the document pouch.
1. Low-pressure tire gauge
2. Owner’s tool kit
3. Owner’s manual
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10
*
Swingarm pivots

Check operation and for excessive play, and
replace bearings if necessary.

Lubricate with lithium-soap-based grease.
√√√
11
*
Upper and lower
arm pivots


Lubricate with lithium-soap-based grease.
√√√
12 Drive chain

Check chain slack and adjust if necessary.

Check rear wheel alignment and correct if neces-
sary.

Clean and lubricate.
√√√√√
13
*
Drive chain rollers


Check for wear and replace if necessary.
√√√
14
*
Chassis fasteners


Make sure that all nuts, bolts, and screws are
properly tightened.
√√√√√
15
*
Shock absorber
assemblies


Check operation and correct if necessary.

Check for oil leakage and replace if necessary.
√√√
16
*
Rear suspension
relay arm and con-
necting arm pivot-
ing 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.
√√√
NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth 1 3 6 6 12
km
(mi)320
(200)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320

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20 Engine oil

Change.

Check ATV for oil leakage, and correct if neces-
sary.
√ √√√
21Engine 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
23
*
Moving parts and
cables

Lubricate.
√√√√
24
*
Throttle lever hous-
ing and cable


Check operation and correct if necessary.

Check throttle cable free play and adjust if neces-
sary.

Lubricate throttle lever housing and cable.
√√√√√
25
*
Front and rear brake
switches

Check operation and correct if necessary.
√√√√√
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*
Lights and switches

Check operation and correct if necessary.

Adjust headlight beams.
√√√√√
NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320

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EBU29440
Checking the spark plug
The spark plug is an important engine component,
which should be checked periodically, preferably
by a Yamaha dealer. 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.
The porcelain insulator around the center elec-
trode of the spark plug should be a medium-to-light
tan (the ideal color when the vehicle is ridden nor-
mally). If the spark plug shows a distinctly different
color, the engine could be operating improperly.
Do not attempt to diagnose such problems your-
self. Instead, have a Yamaha dealer check the ve-
hicle.
If a spark plug shows signs of electrode erosion
and excessive carbon or other deposits, it should
be replaced.
Before installing a spark plug, the spark plug gap
should be measured with a wire thickness gaugeand, if necessary, adjusted to specification.
Clean the surface of the spark plug gasket and its
mating surface, and then wipe off any grime from
the spark plug threads.
Specified spark plug:
NGK/CR8E
1. Spark plug gap
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Tightening torque:
Spark plug:
12.5 Nm (1.3 m·kgf, 9.4 ft·lbf)