2004 YAMAHA WOLVERINE 450 check oil

EBU00015
1-CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ...................... 1-1
SAFETY INFORMATION ......................... 2-1
DESCRIPTION AND MACHINE
IDENTIFICATION ................................... 3-1
Identification number records ............... 3-3
Key identification number ..................... 3-5
Vehicle identification number ............... 3-7
Model label ........................................... 3-9
CONTROL FUNCTIONS ........................ 4-1
Main switch........................................... 4-1
Indicator and warning lights.................. 4-3
Speedometer unit ................................. 4-9
Fuel gauge ......................................... 4-15
Handlebar switches ............................ 4-17
Throttle lever ...................................... 4-35
Speed limiter ...................................... 4-37
Front brake lever ................................ 4-39
Brake pedal and rear brake lever ....... 4-41
Drive select lever ................................ 4-43
Recoil starter ...................................... 4-43
1234
Fuel tank cap ..................................... 4-45
Fuel cock............................................ 4-47
Starter (choke) ................................... 4-49
Seat.................................................... 4-51
Storage compartment ........................ 4-53
Front carrier ....................................... 4-55
Rear carrier ........................................ 4-55
Front shock absorber adjustment ...... 4-57
Rear shock absorber adjustment ....... 4-61
Auxiliary DC jack ................................ 4-63
PRE-OPERATION CHECKS .................. 5-1
Front and rear brakes .......................... 5-5
Fuel ...................................................... 5-9
Engine oil ........................................... 5-13
Final gear oil ...................................... 5-15
Differential gear oil ............................. 5-17
Coolant............................................... 5-19
Throttle lever ...................................... 5-21
Fittings and fasteners......................... 5-21
Lights ................................................. 5-23
Switches............................................. 5-23
Tires ................................................... 5-25
How to measure tire pressure ............ 5-29
5
U5ND61.book Page 1 Thursday, June 5, 2003 7:02 PM

Tire wear limit......................................5-31
OPERATION ...........................................6-1
Starting a cold engine ...........................6-3
Starting a warm engine .........................6-9
Warming up...........................................6-9
Drive select lever operation and
reverse driving ..................................6-11
Engine break-in ...................................6-17
Parking ................................................6-19
Parking on a slope ..............................6-21
Accessories and loading .....................6-23
RIDING YOUR ATV..................................7-1
Getting to know your ATV .....................7-3
Ride with care and good judgement .....7-5
Be careful where you ride ...................7-27
Turning your ATV ................................7-39
Climbing uphill.....................................7-45
Riding downhill ....................................7-55
Crossing a slope .................................7-59
Crossing through shallow water ..........7-63
Riding over rough terrain ....................7-69
Sliding and skidding ............................7-71
What to do if ........................................7-75
What to do...........................................7-75
67
PERIODIC MAINTENANCE AND
ADJUSTMENT ........................................ 8-1
Owner’s manual and tool kit ................. 8-3
Periodic maintenance/lubrication.......... 8-7
Panel removal and installation............ 8-15
Engine oil and oil filter cartridge ......... 8-31
Final gear oil ....................................... 8-41
Differential gear oil.............................. 8-47
Cooling system ................................... 8-53
Changing the coolant.......................... 8-57
Axle boots ........................................... 8-63
Spark plug inspection ......................... 8-65
Air filter element cleaning ................... 8-71
V-belt cooling duct check hose ........... 8-79
V-belt case drain plug ......................... 8-79
Carburetor adjustment ........................ 8-81
Idle speed adjustment ........................ 8-83
Valve clearance adjustment ............... 8-85
Throttle lever adjustment .................... 8-87
Front brake pad check ........................ 8-89
Rear brake pad check ........................ 8-91
Inspecting the brake fluid level ........... 8-93
Brake fluid replacement ...................... 8-97
Front brake lever free play.................. 8-99
Rear brake lever adjustment ............ 8-101
Brake pedal position adjustment ...... 8-101
8
U5ND61.book Page 2 Thursday, June 5, 2003 7:02 PM

3-1
EBU00032
DESCRIPTION AND MACHINE
IDENTIFICATION1. Rear shock absorber
assembly spring preload
adjusting ring
2. Storage compartment
and tool kit
3. Spark plug
4. Rear brake fluid reservoir
5. Radiator cap
6. Front shock absorber
assembly spring preload
adjusting ring
7. V-belt case
8. Brake pedal
9. Front shock absorber
assembly spring preload
adjusting ring
10. Fuel cock
11. Air filter case
12. Fuses13. Tail/brake light
14. V-belt cooling duct check
hose
15. Coolant reservoir
16. Oil filter cartridge
17. Engine oil dipstick
18. Rear brake lever
19. Left handlebar switches
20. Starter (choke)
21. Horn switch
22. Drive select lever
23. Speedometer unit
24. Main switch
25. Fuel tank cap
26. Auxiliary DC jack
27. Right handlebar switch
28. Throttle lever
29. Front brake leverNOTE:The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
U5ND61.book Page 1 Thursday, June 5, 2003 7:02 PM

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

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

8-8
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.NOTE:

Recommended brake fluid: DOT 4


Brake fluid replacement:
When disassembling the master cylinders or caliper cylinders, replace the brake fluid. Normally
check the brake fluid level and add fluid as required.
On the inner parts of the master cylinders and caliper cylinders, replace the oil seals every two years.
Replace the brake hoses every four years, or if cracked or damaged.
V-belt*Check operation.
Check for cracks or damage.Wheels*Check balance/damage/runout.
Repair if necessary.Wheel bearing*Check bearing assemblies for looseness/damage.
Replace if damaged.Front and rear
suspension*Check operation.
Correct if necessary.Steering system*Check operation./Replace if damaged.
Check toe-in./Adjust if necessary.Drive shaft universal
joint*Lubricate with lithium-soap-based grease.Engine mount*
Check for cracks or damage.Axle boots*Check operation.
Replace if damaged.Fittings and fasteners*Check all chassis fittings and fasteners.
Correct if necessary.Lights and switches*Check operation.
Adjust headlight beams.
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
km 320 1,200 2,400 2,400 4,800
hours 20 75 150 150 300
U5ND61.book Page 8 Thursday, June 5, 2003 7:02 PM

8-31 1. Engine oil filler cap
1. Bouchon de remplissage d’huile de moteur
1. Tapa de relleno de aceite de motor
1. Maximum level mark 2. Minimum level mark
1. Repère de niveau maximum 2. Repère de niveau minimum
1. Marca de nivel máximo 2. Marca de nivel mínimo
EBU10991
Engine oil and oil filter cartridge
The engine oil level should be checked before
each ride. In addition, the oil must be changed and
the oil filter cartridge replaced at the intervals
specified in the periodic maintenance and lubrica-
tion chart.
To check the engine oil level
1. Remove panel F. (See page 8-29 for panel
removal and installation procedures.)
2. Place the ATV on a level surface.
3. Start the engine, warm it up for several min-
utes, and then turn it off.
4. Wait a few minutes until the oil settles.
5. Remove the engine oil filler cap and wipe off
the dipstick with a clean rag.
6. Insert the dipstick in the oil filler hole (without
screwing it in), and then remove it again to
check the oil level.NOTE:_ The engine oil should be between the minimum
and maximum level marks. _
U5ND61.book Page 31 Thursday, June 5, 2003 7:02 PM

8-41
‘1. Final gear oil
2. Final gear oil filler bolt
3. Correct level
1. Huile de transmission finale
2. Boulon de remplissage d’huile de transmission finale
3. Niveau correct
1. Aceite de la transmisión final
2. Perno de relleno de aceite de la transmisión final
3. Nivel adecuado
12. Start the engine and warm it up for several
minutes. While warming up, check for oil
leakage. If oil leakage is found, turn the en-
gine off immediately and check for the cause.
13. Turn the engine off, and then check the oil
level and correct it if necessary.
14. Install panel F.
EBU11452
Final gear oil
Final gear oil measurement
1. Place the machine on a level surface.
2. Remove the oil filler bolt, and then check the
oil level in the final gear case.NOTE:_ The oil level should be at the brim of the filler hole. _3. If the oil is below the brim of the filler hole,
add sufficient oil of the recommended type to
raise it to the correct level.CAUTION:_ Be sure no foreign material enters the final
gear case. _4. Install the oil filler bolt.
U5ND61.book Page 41 Thursday, June 5, 2003 7:02 PM