brake YAMAHA YFZ450R 2009 Owner's Guide

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Make sure the brakes operate smoothly and
that there is no free play.

Make sure the brakes do not drag.

Make sure the brakes are not spongy. All air
must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
EBU24611
Checking the brake pedal position
The brake pedal position must be checked and, if
necessary, adjusted at the intervals specified in
the periodic maintenance and lubrication chart.
The top of the brake pedal should be positioned
11.7 mm (0.46 in) below the top of the footrest as
shown. If the brake pedal is not positioned as spec-
ified, have a Yamaha dealer adjust it.
WARNING
EWB02110
Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
After servicing:

Make sure the brakes operate smoothly and
that the brake pedal position is correct.

Make sure the brakes do not drag.

Make sure the brakes are not spongy. All air
must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
1. Brake pedal position
1

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should be performed by a Yamaha dealer.
EBU24710
Adjusting the parking brake free play
The parking brake free play must be checked and,
if necessary, adjusted at the intervals specified in
the periodic maintenance and lubrication chart.
Cable length “A” should measure 47–51 mm (1.9–
2.0 in). Adjust the parking brake free play as fol-
lows.
1. Release the parking brake by moving theparking brake lever to the right.
2. Fully loosen the locknut and the adjusting bolt
at the rear brake caliper.
3. Loosen the locknut on the brake cable.
4. Turn the adjusting nut on the brake cable in di-
rection (a) to increase the cable length, and in
direction (b) to decrease it.
TIP
If the cable length cannot be adjusted to specifica-
tion, consult a Yamaha dealer.
5. Tighten the locknut on the brake cable.
1. Adjusting bolt
2. Cable length “A”
3. Locknut
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1. Locknut
2. Adjusting nut
(a)
(b)
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6. Turn in the adjusting bolt at the rear brake cal-
iper until it feels tight, then turn it out 1/8 turn
and tighten its locknut to the specified torque.
NOTICE

ECB00520
When tightening the locknut, hold the adjust-
ing bolt with a wrench so that it does not turn
together with the locknut.
WARNING

EWB02090
Operating with improperly serviced or adjust-
ed brakes could cause the brakes to malfunc-
tion, resulting in reduced braking
performance. This could increase the chance
of a collision or accident. After adjusting the
parking brake free play, block the rear of the
ATV off the ground and spin the rear wheels.
Check to make sure there is no brake drag. If
brake drag is noticed, perform the adjustment
again.
EBU24740
Brake light switches
The operation of the brake light switches must be
checked and, if necessary, adjusted at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
The brake light switch for the brake pedal can be
adjusted as follows, but the other brake light
switches should be adjusted by a Yamaha dealer.
TIP

The brake light switch is properly adjusted when
the brake light comes on just before braking takes
effect.
Turn the adjusting nut while holding the brake light
switch in place. To make the brake light come on
earlier, turn the adjusting nut in direction (a). To
make the brake light come on later, turn the adjust-
ing nut in direction (b). Tightening torque:
Locknut (rear brake caliper):
16 Nm (1.6 m·kgf, 11 ft·lbf)

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EBU29541
Adjusting the clutch lever free play
The clutch lever free play must be checked and, if
necessary, adjusted at the intervals specified in
the periodic maintenance and lubrication chart.
The clutch lever free play should measure 8.0–
13.0 mm (0.31–0.51 in) as shown. If the free play
is incorrect, adjust it as follows.1. To increase the clutch lever free play, turn the
adjusting nut at the clutch lever in direction (a),
and to decrease it, turn the nut in direction (b).
If the specified free play cannot be obtained,
proceed with the following steps.
2. Fully turn the adjusting nut at the clutch lever
in direction (a) to loosen the clutch cable.
3. Loosen the locknut at the crankcase.
4. To increase the clutch lever free play, turn the
adjusting nut at the crankcase in direction (a),
and to decrease it, turn the nut in direction (b).
1. Brake light switch
2. Brake light switch adjusting nut
1
2(a)(b)

1. Clutch lever free play
2. Clutch lever free play adjusting nut
1
(a)
(b)
2

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NOTICE

ECB00570
To prevent damaging the O-rings, do not clean
the drive chain with steam cleaners, high-pres-
sure washers or inappropriate solvents.
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive chain with a
special O-ring chain lubricant.
NOTICE

ECB00580
Do not use engine oil or any other lubricants
for the drive chain, as they may contain sub-
stances that could damage the O-rings.
EBU24900
Checking and lubricating the cables
The operation and the condition of all control ca-
bles should be checked before each ride, and the
cables and cable ends should be lubricated if nec-
essary. If a cable is damaged or does not move
smoothly, have a Yamaha dealer check or replace
it.
WARNING
EWB02130
Inspect cables frequently and replace if dam-
aged. Corrosion can result when the cable
sheaths become damaged, and cables can
also become frayed or kinked, which could re-
strict the operation of controls and lead to an
accident or injury.
EBU24922
Checking and lubricating the brake and
clutch levers
The operation of the brake and clutch levers
should be checked before each ride, and the lever
pivots should be lubricated if necessary.
Recommended lubricant:
Engine oil
Recommended lubricants:
Brake lever:
Silicone grease
Clutch lever:
Lithium-soap-based grease

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Brake lever
Clutch lever

EBUM0170
Checking the shift pedal
The operation of the shift pedal should be checked
before each ride. If operation is not smooth, have
a Yamaha dealer check the vehicle.
EBU28871
Checking and lubricating the brake
pedal
The operation of the brake pedal should be
checked before each ride, and the pedal pivot
should be lubricated if necessary.
Recommended lubricant:
Lithium-soap-based grease

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EBU26920
Tail/brake light
This model is equipped with an LED type of tail/
brake light.
If the tail/brake light does not come on, have a
Yamaha dealer check it.
EBU25651
Removing a wheel
1. Place the ATV on a level surface.
2. Loosen the wheel nuts.
FrontRear
3. Elevate the ATV and place a suitable stand
under the frame.
4. Remove the nuts from the wheel.
5. Remove the wheel.
EBU25681
Installing a wheel
1. Place the ATV on a level surface.
2. Install the wheel and the nuts.
TIP


When installing a front wheel, make sure its ar-
row mark points toward the rotating direction
1. Wheel nut
1. Wheel nut

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EBU25860
CLEANING AND STORAGE
EBU25900
Cleaning
Frequent, thorough cleaning of your ATV will not
only enhance its appearance but will improve its
general performance and extend the useful life of
many components.
1. Before cleaning the ATV:
a. Block off the end of the exhaust pipe to
prevent water entry. A plastic bag and
strong rubber band may be used.
b. Make sure the spark plug and all filler caps
are properly installed.
2. If the engine case is excessively greasy, apply
degreaser with a paint brush. Do not apply de-
greaser to the chain, sprockets or wheel ax-
les.
3. Rinse the dirt and degreaser off with a garden
hose. Use only enough pressure to do the job.
NOTICE

ECB00710
Excessive water pressure may cause water
seepage and deterioration of wheel bearings,
brakes, transmission seals and electrical de-
vices. Many expensive repair bills have result-ed from improper high-pressure detergent
applications such as those available in coin-
operated car washers.
4. Once most of the dirt has been hosed off,
wash all surfaces with warm water and mild,
detergent-type soap. An old toothbrush or bot-
tle brush is handy for hard-to-reach places.
5. Rinse the ATV off immediately with clean wa-
ter and dry all surfaces with a chamois, clean
towel or soft absorbing cloth.
6. Dry the chain and lubricate it to prevent it from
rusting.
7. Clean the seat with a vinyl upholstery cleaner
to keep the cover pliable and glossy.
8. Automotive type wax may be applied to all
painted and chrome plated surfaces. Avoid
combination cleaner-waxes. Many contain
abrasives which may mar the paint or protec-
tive finish. When finished cleaning, start the
engine and let it idle for several minutes.
WARNING

EWB02310
Wet brakes may have reduced stopping ability,

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increasing the chance of an accident. Test the
brakes after washing. Apply the brakes several
times at slow speeds to let friction dry out the
linings.
EBU27260
Storage
Short-term
Always store your ATV in a cool, dry place and, if
necessary, protect it against dust with a porous
cover.
NOTICE

ECB00720

Storing the ATV in a poorly ventilated room
or covering it with a tarp while it is still wet,
will allow water and humidity to seep in and
cause rust.

To prevent corrosion, avoid damp cellars,
stables (because of the presence of ammo-
nia) and areas where strong chemicals are
stored.
Long-term
Before storing your ATV for several months:
1. Follow all the instructions in the “Cleaning”section of this chapter.
2. Fill up the fuel tank and add fuel stabilizer (if
available) to prevent the fuel from deteriorat-
ing.
3. Perform the following steps to protect the cyl-
inder, piston rings, etc. from corrosion.
a. Remove the spark plug cap and spark
plug.
b. Pour a teaspoonful of engine oil into the
spark plug bore.
c. Install the spark plug cap onto the spark
plug, and then place the spark plug on the
cylinder head so that the electrodes are
grounded. (This will limit sparking during
the next step.)
d. Turn the engine over several times with
the starter. (This will coat the cylinder wall
with oil.)
e. Remove the spark plug cap from the spark
plug, and then install the spark plug and
the spark plug cap.
4. Lubricate all control cables and the pivotingSpecified amount:
7.5 ml of stabilizer to each liter of fuel (or 1 oz
of stabilizer to each gallon of fuel)

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Operation:
Left foot operation
1st:
35/14 (2.500)
2nd:
30/15 (2.000)
3rd:
31/19 (1.632)
4th:
28/21 (1.333)
5th:
23/21 (1.095)
Chassis:
Frame type:
Aluminum die-cast and steel tube frame
Caster angle:
5.0 °
Trail:
21.0 mm (0.83 in)
Front tire:
Type:
Tubeless
Size:
AT21 x 7R-10
Manufacturer/model:
DUNLOP/KT351 Radial
Rear tire:
Type:
Tubeless
Size:
AT20 x 10R-9Manufacturer/model:
DUNLOP/KT356 Radial
Loading:
Maximum loading limit:
100.0 kg (220 lb)
(Total weight of rider, cargo, accessories, and tongue)
Tire air pressure (measured on cold tires):
Recommended:
Front:
27.5 kPa (0.275 kgf/cm
2

, 4.0 psi)
Rear:
30.0 kPa (0.300 kgf/cm
2

, 4.4 psi)
Minimum:
Front:
24.5 kPa (0.245 kgf/cm
2

, 3.6 psi)
Rear:
27.0 kPa (0.270 kgf/cm
2

, 4.0 psi)
Front wheel:
Wheel type:
Panel wheel
Rim size:
10 x 5.5AT
Rear wheel:
Wheel type:
Panel wheel
Rim size:
9 x 8.5AT
Front brake:
Type:
Dual disc brake