2004 YAMAHA WOLVERINE 450 differential

5-1
EBU00113
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brakeCheck operation, lever free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-89, 8-93–8-99
Rear brakeCheck operation, lever free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-91–8-97,
8-101–8-103
FuelCheck fuel level.
Fill with fuel if necessary.5-9–5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13, 8-31–8-41
Coolant reservoirCheck coolant level in reservoir.
Fill with coolant if necessary.5-19–5-21,
8-53–8-63
Final gear oil and
differential gear oilCheck for leakage.5-15–5-17,
8-41–8-51
ThrottleCheck for proper throttle cable operation and free play. 5-21, 8-87
Wheels and tiresCheck tire pressure, wear and damage.5-25–5-31,
8-111–8-113
Fittings and fastenersCheck all fittings and fasteners. 5-21
Lights and switchesCheck for proper operation.5-23, 8-105,
8-125–8-129
Axle bootsCheck for damage. 8-63
U5ND61.book Page 1 Thursday, June 5, 2003 7:02 PM

5-17
EBU00678
Differential gear oil
Make sure the differential gear oil is at the speci-
fied level. Add oil as necessary. (See pages 8-47–
8-51 for details.)
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
U5ND61.book Page 17 Thursday, June 5, 2003 7:02 PM

8-7
EBU00262
PERIODIC MAINTENANCE/LUBRICATION
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
km 320 1,200 2,400 2,400 4,800
hours 20 75 150 150 300
Valves*Check valve clearance.
Adjust if necessary.
Cooling systemCheck coolant leakage.
Repair if necessary.
Replace coolant every 24 months.Spark plugCheck condition.
Adjust gap and clean.
Replace if necessary.Air filter elementClean.
Replace if necessary.Every 20–40 hours
(More often in wet or dusty areas.)
Carburetor*Check and adjust idle speed/starter operation.
Adjust if necessary.Crankcase breather
system*Check breather hose for cracks or damage.
Replace if necessary.Exhaust system*Check for leakage.
Retighten if necessary.
Replace gasket(s) if necessary.Fuel line*Check fuel hose for cracks or damage.
Replace if necessary.Engine oil
Replace. (Warm engine before draining.)Engine oil filter cartridge
Replace.Engine oil strainer*
Clean.Final gear oil
Check oil level/oil leakage.
Replace every 12 month.Differential gear oil
Front brake*Check operation/fluid leakage. (See NOTE page 8-8.)
Correct if necessary.Rear brake*Check operation/fluid leakage.(See NOTE page 8-8.)
Correct if necessary.U5ND61.book Page 7 Thursday, June 5, 2003 7:02 PM

8-47 1. Differential gear oil
2. Differential gear oil filler bolt
3. Specified level
1. Huile de différentiel
2. Boulon de remplissage d’huile de différentiel
3. Niveau d’huile spécifié
1. Aceite de engranajes del diferencial
2. Perno de relleno de aceite de engranajes del diferencial
3. Nivel especificado
EBU07061
Differential gear oil
Differential gear oil measurement
1. Place the machine on a level surface.
2. Remove the differential gear oil filler bolt and
check the oil level. It should be up to the brim
of the filler hole. If the level is low, add suffi-
cient oil of the recommended type to raise it
to the specified level.CAUTION:_ Be sure no foreign material enters the differen-
tial gear case. _3. Install the differential gear oil filler bolt.
U5ND61.book Page 47 Thursday, June 5, 2003 7:02 PM

8-49 1. Differential gear oil drain bolt
1. Boulon de vidange de l’huile de différentiel
1. Perno de drenaje de aceite de engranajes del diferencial
Differential gear oil replacement
1. Place the machine on a level surface.
2. Place a container under the differential gear
case to collect the used oil.
3. Remove the differential gear oil filler bolt and
differential gear oil drain bolt to drain the oil.
4. Install the differential gear oil drain bolt and
tighten it to the specified torque.
Tightening torque:
Differential gear oil drain bolt:
10 Nm (1.0 m·kgf)
U5ND61.book Page 49 Thursday, June 5, 2003 7:02 PM

8-51
5. Fill the differential gear case with the recom-
mended oil.CAUTION:_ Be sure no foreign material enters the differen-
tial gear case. _6. Install the differential gear oil filler bolt.
7. Check for oil leakage. If oil leakage is found,
check for the cause. Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
Oil quantity:
0.23 L
U5ND61.book Page 51 Thursday, June 5, 2003 7:02 PM

10-3
Quantity:
Without oil filter cartridge replacement
With oil filter cartridge replacement2.30 L
2.40 L
Final gear oil:
Type SAE 80 API GL-4 Hypoid gear oil
Quantity 0.23 L
Differential gear oil:
Type SAE 80 API GL-4 Hypoid gear oil
Quantity 0.23 L
Radiator capacity (including all routes): 1.30 L
Air filter: Wet type element
Fuel:
Type Unleaded gasoline only
For Europe: Regular unleaded gasoline only with a
research octane number of 91 or higher
Fuel tank capacity 15.0 L
Fuel reserve amount 4.5 L
Carburetor:
Type/quantity BSR33/1
Manufacturer MIKUNIModelYFM450FA
U5ND61.book Page 3 Thursday, June 5, 2003 7:02 PM

10-6
Bulb voltage, wattage
× quantity:
Headlight 12 V, 30/30 W
× 2
Tail/brake light 12 V, 5/21 W
× 1
Neutral indicator light LED
Reverse indicator light LED
Coolant temperature warning light LED
Park indicator light LED
High-range indicator light LED
Low-range indicator light LED
Differential gear lock indicator light LED
Fuse:
Main fuse 30 A
Headlight fuse 15 A
Ignition fuse 10 A
Auxiliary DC jack fuse 10 A
Four-wheel-drive fuse 3 A
Signaling system fuse 10 A
Backup fuse 10 AModelYFM450FA
U5ND61.book Page 6 Thursday, June 5, 2003 7:02 PM