2005 YAMAHA YFZ450 brake fluid

OPERATION ............................................6-1
Starting a cold engine ...........................6-3
Starting a warm engine .........................6-9
Warming up...........................................6-9
Shifting ................................................6-11
To start out and accelerate .................6-13
To decelerate ......................................6-17
Engine break-in ...................................6-19
Parking ................................................6-23
Parking on a slope ..............................6-25
Accessories and loading .....................6-29
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 ................................7-41
Climbing uphill.....................................7-47
Riding downhill ....................................7-57
Crossing a slope .................................7-61
Crossing through shallow water ..........7-65
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............ 8-17
Engine oil and oil filter element........... 8-23
Cooling system ................................... 8-41
Changing the coolant.......................... 8-45
Spark plug inspection ......................... 8-53
Air filter element cleaning ................... 8-65
Carburetor adjustment ........................ 8-73
Idle speed adjustment ........................ 8-75
Valve clearance adjustment ............... 8-75
Throttle lever adjustment .................... 8-77
Front brake pad inspection ................. 8-79
Rear brake pad inspection.................. 8-81
Brake fluid level inspection ................. 8-83
Brake fluid replacement ...................... 8-87
Front brake lever free play.................. 8-89
Brake pedal height adjustment ........... 8-91
Parking brake adjustment ................... 8-93
Adjusting the rear brake light switch ... 8-97
Clutch lever free play adjustment ....... 8-99
Drive chain slack check .................... 8-101
Drive chain slack adjustment ............ 8-103
Lubricating the drive chain................ 8-107
Cable inspection and lubrication....... 8-111
8
U5TG61.book Page 2 Friday, April 2, 2004 11:28 AM

5-1
EBU01130
1-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, 8-79,
8-83–8-89
Rear brakeCheck operation, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-81–8-87, 8-91
ClutchCheck operation, condition and lever free play. 8-99
Parking brakeCheck operation, condition and cable length. 8-93–8-95
FuelCheck fuel level.
Fill with fuel if necessary.5-9–5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13, 8-23–8-39
Coolant reservoirCheck coolant level in reservoir.
Fill with coolant if necessary.5-15–5-17,
8-41–8-51
Drive chainCheck chain slack and condition.
Adjust if necessary.5-17, 8-101–8-109
ThrottleCheck for proper throttle cable operation and free play. 5-17, 8-77
Wheels and tiresCheck tire pressure, wear and damage.5-21–5-27,
8-121–8-123
Fittings and fastenersCheck all fittings and fasteners. 5-19
Lights and switchesCheck for proper operation.5-19, 8-97,
8-133–8-141
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5-5
EBU11670
Front and rear brakes
Brake lever and brake pedal

Check that there is no free play in the brake le-
ver. If there is free play, have a Yamaha dealer
inspect the brake system.


Check for correct brake pedal height. (See
page 8-91.) If the pedal height is incorrect,
have a Yamaha dealer adjust it.


Check the operation of the brake lever and
brake pedal. They should move smoothly and
there should be a firm feeling when the brakes
are applied. If not, have a Yamaha dealer in-
spect the brake system.
Brake fluid level
Check the brake fluid level. Add fluid if necessary.
(See pages 8-83–8-87.)
Recommended brake fluid: DOT 4
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5-7
Brake fluid leakage
Check to see if any brake fluid is leaking out of the
pipe joints or brake fluid reservoirs. Apply the
brakes firmly for one minute. If there is any leak-
age, have a Yamaha dealer inspect the brake sys-
tem.
Brake operation
Test the brakes at slow speed after starting out to
make sure they are working properly. If the brakes
do not provide proper braking performance, in-
spect the brake pads for wear. (See pages 8-79–
8-81.)
WARNING
_ Always check the brakes at the start of every
ride. Do not ride the ATV if you find any prob-
lem with the brakes or you could lose braking
ability, which could lead to an accident. If a
problem cannot be corrected by the adjust-
ment procedures provided in this manual,
have a Yamaha dealer check for the cause. _
U5TG61.book Page 7 Friday, April 2, 2004 11:28 AM

8-8 * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
Engine oil filter element
Replace.Drive chain
Check and adjust slack/alignment/clean/lube.Front brake*Check free play/operation/fluid leakage/
See NOTE Page 8-9.
Correct if necessary.Rear brake*Check operation/fluid leakage/See NOTE Page 8-9.
Correct if necessary.Clutch*Check operation.
Adjust if necessary.Wheels*Check balance/damage/runout.
Replace if necessary.Wheel bearings*Check bearing assemblies for looseness/damage.
Replace if damaged.Steering system*Check operation.
Repair if damaged.
Check toe-in.
Adjust if necessary.Front and rear
suspension*Check operation.
Correct if necessary.Upper and lower arm
pivot and steering shaft*Lubricate every 6 months with lithium-soap-based grease.Rear arm pivot*
Lubricate every 6 months with lithium-soap-based grease.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
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
hours 20 75 150 150 300
U5TG61.book Page 8 Friday, April 2, 2004 11:28 AM

8-9
NOTE:

Recommended brake fluid: DOT4


Brake fluid replacement:
When disassembling the master cylinders or calipers, replace the brake fluid. Normally check the
brake fluid level and add fluid as required.
On the inner parts of the master cylinders and calipers, replace the oil seals every two years.
Replace the brake hoses every four years, or if cracked or damaged.
U5TG61.book Page 9 Friday, April 2, 2004 11:28 AM

8-83 1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimo
Front
Avant
Delantero1. Minimum level mark
1. Repère de niveau minimum
1. Marca de nivel mínimoRear
Arrière
Trasero
EBU12140
Brake fluid level inspection
Insufficient brake fluid may let air enter the brake
system, possibly causing the brakes to become in-
effective.
Before riding, check that the brake fluid is above
the minimum level mark and replenish if neces-
sary. A low brake fluid level may indicate worn
brake pads and/or brake system leakage. If the
brake fluid level is low, be sure to check the brake
pads for wear and the brake system for leakage. NOTE:_ To access the rear brake fluid reservoir, remove
the reservoir cover by removing the bolts. _
U5TG61.book Page 83 Friday, April 2, 2004 11:28 AM

8-85 1. Brake fluid reservoir cover 2. Bolt (× 2)
1. Cache du réservoir de liquide de frein
2. Boulon (× 2)
1. Cubierta del depósito de líquido de frenos
2. Perno (× 2)
Observe these precautions:

When checking the brake fluid level, make sure
the top of the brake fluid reservoir is level.


Use only the designated quality brake fluid, oth-
erwise, the rubber seals may deteriorate, caus-
ing leakage and poor brake performance.


Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reaction
and lead to poor brake performance.


Be careful that water does not enter the brake
fluid reservoir when refilling. Water will signifi-
cantly lower the boiling point of the fluid and
may result in vapor lock.


Brake fluid may deteriorate painted surfaces or
plastic parts. Always clean up spilled fluid im-
mediately.


Have a Yamaha dealer check the cause if the
brake fluid level goes down. Recommended brake fluid: DOT 4
U5TG61.book Page 85 Friday, April 2, 2004 11:28 AM