YAMAHA YFZ450R 2011 Owners Manual

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EBU21865General maintenance and lubrication chart 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. 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
1 Air filter elementClean and replace if necessary.Every 20–40 hours (more often in wet or
dusty areas)
2*ClutchCheck operation and adjust if necessary.√ √√√
3*Front brakeCheck operation and correct if necessary.
Check fluid level and ATV for fluid leakage, and
correct if necessary.√√√√√
Replace brake pads. Whenever worn to the limit
4*Rear brakeCheck operation and correct if necessary.
Check fluid level and ATV for fluid leakage, and
correct if necessary.√√√√√
Replace brake pads. Whenever worn to the limit
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5*Brake hosesCheck for cracks or other damage, and replace if
necessary.√√√√
Replace. Every 4 years
6*Parking bra keCheck operation and adjust if necessary.√√√√√
7*WheelsCheck runout and for damage, and replace if nec-
essary.√ √√√
8*TiresCheck tread depth and for damage, and replace if
necessary.
Check air pressure and balance, and correct if
necessary.√ √√√
9*Wheel hub bearingsCheck for looseness or damage, and replace if
necessary.√ √√√
10*Swingarm pivotsCheck operation and for excessive play, and re-
place bearings if necessary.
Lubricate with lithium-soap-based grease.√√√
11*Upper and lower
arm pivotsLubricate with lithium-soap-based grease.√√√
12 Drive chainCheck chain slack and adjust if necessary.
Check rear wheel alignment and correct if neces-
sary.
Clean and lubricate.√√√√√
13*Drive chain rollerCheck for wear and replace if necessary.√√√ 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 320U18P64E0.book Page 6 Thursday, May 13, 2010 6:00 PM

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14*Chassis fastenersMake sure that all nuts, bolts, and screws are
properly tightened.√√√√√
15*Shock absorber as-
sembliesCheck operation and correct if necessary.
Check for oil leakage and replace if necessary.√√√
16*Rear suspension re-
lay arm and con-
necting arm
pivoting pointsCheck operation and correct if necessary.√√√√
17*Steering shaftLubricate with lithium-soap-based grease.√√√
18*Steering systemCheck operation and repair or replace if damaged.
Check toe-in and adjust if necessary.√√√√√
19 Engine oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√ √√√
20Engine oil filter ele-
mentReplace.√√√
21*Cooling systemCheck coolant level and ATV for coolant leakage,
and correct if necessary.√√√√√
Replace coolant. Every 2 years
22*Moving parts and
cablesLubricate.√√√√ 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 320U18P64E0.book Page 7 Thursday, May 13, 2010 6:00 PM

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EBU29430TIP
Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or
muddy areas, or at full-throttle.
Replace the fuel hose every five years and if cracked or damaged.
Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.23*Throttle lever hous-
ing and cableCheck operation and correct if necessary.
Check throttle lever free play and adjust if neces-
sary.
Lubricate throttle lever housing and cable.√√√√√
24*Front and rear brake
switchesCheck operation and correct if necessary.√√√√√
25*Lights and switchesCheck 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 320U18P64E0.book Page 8 Thursday, May 13, 2010 6:00 PM

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EBU30130Removing and installing the cowling
and panels The cowling and panels shown need to be re-
moved to perform some of the maintenance jobs
described in this chapter. Refer to this section each
time a cowling or panel needs to be removed and
installed.
EBU29536Panel A
To remove the panel1. Remove the seat. (See page 4-10.)
2. Remove the fuel tank cap by turning it coun-
terclockwise. (See page 4-8.) NOTICE: Make
sure that no foreign material enters the
fuel tank.
[ECB01051]
3. Remove the bolts.
1. Panel A
2. Panel B
3. Cowling
1
2
3
1. Panel C
1
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84. Remove the quick fasteners, and then slide
the panel backward and pull upward.5. Install the fuel tank cap by turning it clockwise.
To install the panel
1. Remove the fuel tank cap by turning it coun-
terclockwise.
2. Place the panel in the original position, and
then install the quick fasteners. NOTICE:
When installing the panel, be sure not to
pinch the cables or wires.
[ECB00381]
3. Install the bolts.
4. Install the fuel tank cap by turning it clockwise.
5. Install the seat.
1. Bolt
1. Quick fastener
1
1
1
1. Projection
2. Slot
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2
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8 Panels B and C
To remove one of the panels
1. Remove panel A.
2. Pull the panel off.
To install one of the panels1. Place the panel in the original position.2. Install panel A.
Cowling
To remove the cowling
1. Remove panels A, B and C.
2. Remove the bolts, and then take the cowling
off.
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8-12
8To install the cowling
1. Place the cowling in the original position, and
then install the bolts.
2. Install panels B, C and A.EBU29441Checking 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 the spark plug shows signs of electrode erosion
and excessive carbon or other deposits, it should
be replaced.
1. Bolt
1. Bolt
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1
1
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8 Before installing the spark plug, the spark plug gap
should be measured with a wire thickness gauge
and, 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.
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.EBU29498Engine 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.
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. Specified spark plug:
NGK/CR8E
1. Spark plug gapSpark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Tightening torque:
Spark plug:
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
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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
wipe 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 minimum
level mark, add sufficient oil of the recom-
mended type through the engine oil tank filler
hole to raise it to the correct level. NOTICE:
Be sure the engine oil is at the correct lev-
el, otherwise engine damage may result.
[ECB00851]
1. Engine oil tank filler cap
2. Engine oil dipstick
3. Maximum level mark
4. Half-level mark
5. Minimum level mark11
2
3
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