2005 YAMAHA YFZ450 clutch

EBU00150
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 ............... 3-5
Model label ........................................... 3-7
CONTROL FUNCTIONS ......................... 4-1
Main switch........................................... 4-1
Indicator and warning lights.................. 4-3
Handlebar switches .............................. 4-7
Throttle lever ...................................... 4-11
Speed limiter ...................................... 4-13
Clutch lever ........................................ 4-15
Brake lever ......................................... 4-17
Brake pedal ........................................ 4-17
Parking brake lever ............................ 4-19
Shift pedal .......................................... 4-21
Fuel tank cap ...................................... 4-21
1234
Fuel cock............................................ 4-23
Starter (choke) .................................. 4-25
Seat.................................................... 4-27
Front shock absorber adjustment ...... 4-29
Rear shock absorber adjustment ....... 4-39
PRE-OPERATION CHECKS ................... 5-1
Front and rear brakes .......................... 5-5
Fuel ...................................................... 5-9
Engine oil ........................................... 5-13
Coolant............................................... 5-15
Chain.................................................. 5-17
Throttle lever ...................................... 5-17
Fittings and fasteners......................... 5-19
Lights ................................................. 5-19
Switches............................................. 5-19
Tires ................................................... 5-21
How to measure tire pressure ............ 5-25
Tire wear limit..................................... 5-27
5
U5TG61.book Page 1 Friday, April 2, 2004 11:28 AM

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
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Brake pedal, brake lever and
clutch lever lubrication.................... 8-113
Front upper and lower arm pivot
lubrication ....................................... 8-117
Rear arm pivot lubrication ................ 8-119
Wheel removal ................................. 8-121
Wheel installation ............................. 8-123
Battery .............................................. 8-125
Battery maintenance ........................ 8-129
Fuse replacement............................. 8-131
Replacing a headlight bulb ............... 8-133
Headlight beam adjustment.............. 8-139
Tail/brake light bulb replacement ..... 8-141
Troubleshooting................................ 8-143
Troubleshooting chart....................... 8-147
CLEANING AND STORAGE ................... 9-1
A. Cleaning ........................................... 9-1
B. Storage ............................................ 9-7
SPECIFICATIONS ................................ 10-1
CONVERSION TABLE .......................... 11-1
91011U5TG61.book Page 3 Friday, April 2, 2004 11:28 AM

3-1
EBU00320
1-DESCRIPTION AND MACHINE
IDENTIFICATION1. Seat
2. Fuel tank cap
3. Radiator cap
4. Oil filter element
5. Brake pedal
6. Headlights
7. Fuel cock
8. Starter (choke)
9. Throttle stop screw
10. Fuse11. Tail/brake light
12. Coolant reservoir
13. Shift pedal
14. Engine oil tank
15. Clutch lever
16. Handlebar switches
17. Parking brake lever
18. Main switch
19. Throttle lever
20. Brake leverNOTE:_ The machine you have purchased may differ
slightly from those shown in the figures of this
manual. _
U5TG61.book Page 1 Friday, April 2, 2004 11:28 AM

4-3 1. Neutral indicator light “N”
2. Coolant temperature warning light “”
1. Témoin de point mort “N”
2. Témoin d’avertissement de la température du liquide de
refroidissement “”
1. Luz de control de punto muerto “N”
2. Luz de aviso de la temperatura del refrigerante “”
EBU08020
Indicator and warning lights
EBU06030
Neutral indicator light “N”
This indicator light comes on when the transmis-
sion is in neutral.
EBU13850
Coolant temperature warning light “”
When the coolant temperature reaches a specified
level, this light comes on to warn that the coolant
temperature is too hot. If the light comes on during
operation, stop the engine as soon as it is safe to
do so and allow the engine to cool down for about
10 minutes.
The electrical circuit of the warning light can be
checked according to the following procedures.
1. Set the engine stop switch to “RUN” and turn
the key to “ON”.
2. Shift the transmission into the neutral position
or pull the clutch lever.
U5TG61.book Page 3 Friday, April 2, 2004 11:28 AM

4-15 1. Clutch lever
1. Levier d’embrayage
1. Palanca de embrague
EBU00690
Clutch lever
The clutch lever is located on the left handlebar
and the ignition circuit cut-off system is incorporat-
ed in the clutch lever holder. Pull the clutch lever to
the handlebar to disengage the clutch, and release
the lever to engage the clutch. The lever should be
pulled rapidly and released slowly for smooth
clutch operation. (Refer to “Starting a cold engine”
for a description of the ignition circuit cut-off sys-
tem.)
U5TG61.book Page 15 Friday, April 2, 2004 11:28 AM

4-21 1. Shift pedal
1. Pédale de sélection
1. Pedal del cambio
1. Fuel tank cap
1. Bouchon du réservoir de carburant
1. Tapón del depósito de combustible
EBU00820
Shift pedal
This machine is equipped with a constant-mesh
5-speed transmission. The shift pedal is located
on the left side of the engine and is used in combi-
nation with the clutch when shifting.
EBU00920
Fuel tank cap
Remove the fuel tank cap by turning it counter-
clockwise.
U5TG61.book Page 21 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
U5TG61.book Page 1 Friday, April 2, 2004 11:28 AM