2006 YAMAHA WOLVERINE 450 engine

EBU17420
TABLE OF CONTENTS
SAFETY INFORMATION .............................. 1-1
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................ 2-1
DESCRIPTION .............................................. 3-1
Left view ...................................................... 3-1
Right view.................................................... 3-1
Controls and instruments ............................ 3-2
INSTRUMENT AND CONTROL
FUNCTIONS .................................................. 4-1
Main switch ................................................ 4-1
Indicator lights and warning light ................ 4-2
Speedometer unit ....................................... 4-3
Handlebar switches .................................... 4-4
Throttle lever .............................................. 4-6
Speed limiter .............................................. 4-6
Front brake lever ........................................ 4-7
Brake pedal and rear brake lever ............... 4-7
Drive select lever ........................................ 4-8
Fuel tank cap .............................................. 4-8
Fuel ............................................................ 4-9
Fuel cock .................................................. 4-10Starter (choke) ..........................................4-11
Seat ..........................................................4-12
Storage compartment ...............................4-13
Adjusting the front shock absorber
assemblies ................................................4-14
Adjusting the rear shock absorber
assembly ...................................................4-15
PRE-OPERATION CHECKS ..........................5-1
Pre-operation check list ..............................5-1
Fuel .............................................................5-3
Engine oil ....................................................5-3
Final gear oil ...............................................5-3
Differential gear oil ......................................5-3
Coolant .......................................................5-3
Front and rear brakes .................................5-4
Throttle lever ...............................................5-5
Tires ............................................................5-5
Measuring the tire pressure ........................5-6
Tire wear limit .............................................5-7
Chassis fasteners .......................................5-7
Instruments, lights and switches .................5-7U3C260E0.book Page 1 Tuesday, August 2, 2005 9:52 AM

OPERATION .................................................. 6-1
Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-3
Operating the drive select lever and driving
in reverse ................................................... 6-3
Engine break-in .......................................... 6-5
Parking ....................................................... 6-5
Parking on a slope ..................................... 6-6
Accessories and loading ............................ 6-6
RIDING YOUR ATV ...................................... 7-1
GETTING TO KNOW YOUR ATV............... 7-2
RIDE WITH CARE AND GOOD
JUDGEMENT .............................................. 7-2
BE CAREFUL WHERE YOU RIDE ............. 7-9
TURNING YOUR ATV .............................. 7-12
CLIMBING UPHILL ................................... 7-14
RIDING DOWNHILL.................................. 7-17
CROSSING A SLOPE............................... 7-18
CROSSING THROUGH SHALLOW
WATER ..................................................... 7-19
RIDING OVER ROUGH TERRAIN ........... 7-22
SLIDING AND SKIDDING ......................... 7-22
WHAT TO DO IF... .................................... 7-23
WHAT TO DO... ........................................ 7-23PERIODIC MAINTENANCE AND MINOR
REPAIR ..........................................................8-1
Owner’s manual and tool kit .......................8-1
Periodic maintenance and lubrication
chart ............................................................8-3
Removing and installing cowlings and
panels .........................................................8-8
Checking the spark plug ...........................8-14
Engine oil and oil filter cartridge ................8-16
Final gear oil .............................................8-21
Changing the differential gear oil ..............8-23
Coolant .....................................................8-25
Cleaning the air filter element ...................8-30
V-belt cooling duct check hose .................8-32
V-belt case drain plug ...............................8-33
Adjusting the carburetor ............................8-33
Adjusting the engine idling speed .............8-34
Adjusting the throttle cable free play .........8-35
Valve clearance ........................................8-35
Adjusting the drive select lever safety
system cable .............................................8-36
Checking the front and rear brake pads ...8-36
Checking the brake fluid level ...................8-37
Changing the brake fluid ...........................8-39
Checking the front brake lever free play ...8-39
Adjusting the rear brake lever free play and
checking the brake pedal position ............8-40U3C260E0.book Page 2 Tuesday, August 2, 2005 9:52 AM

1-1
1
EBU17430
SAFETY INFORMATION
EBU17531AN ATV IS NOT A TOY AND CAN BE HAZARD-OUS TO OPERATE.
An ATV handles differently
from other vehicles including motorcycles and
cars. A collision or rollover can occur quickly, even
during routine maneuvers such as turning and
riding on hills or over obstacles, if you fail to take
proper precautions.
SEVERE INJURY OR DEATH can result if you do
not follow these instructions:

Read this manual and all labels carefully and fol-
low the operating procedures described.
Never operate an ATV without proper training or
instruction.
Always follow the age recommendation:
– A child under 16 years old should never oper-
ate an ATV with engine size greater than 90 cc.
Never allow a child under age 16 to operate an
ATV without adult supervision, and never allow
continued use of an ATV by a child if he or she
does not have the abilities to operate it safely.
Never carry a passenger on an ATV.

Always avoid operating an ATV on any paved
surfaces, including sidewalks, driveways, park-
ing lots and paved streets.
Never operate an ATV on any paved street,
paved road or motorway.
Watch carefully for other vehicles when operat-
ing on unpaved public streets or roads. Make
sure you know your country’s laws and regula-
tions before you ride on unpaved public streets
or roads.
Never operate an ATV without wearing an ap-
proved motorcycle helmet that fits properly. You
should also wear eye protection (goggles or face
shield), gloves, boots, a long-sleeved shirt or a
jacket, and long pants.
Never consume alcohol or drugs before or while
operating this ATV.
Never operate at speeds too fast for your skills
or the riding conditions. Always go at a speed
that is proper for the terrain, visibility, operating
conditions, and your experience.
Never attempt wheelies, jumps, or other stunts.
U3C260E0.book Page 1 Tuesday, August 2, 2005 9:52 AM

1-3
1 hill. If you stall or roll backwards, follow the spe-
cial procedure for braking described in this man-
ual. Dismount on the uphill side or to a side if
pointed straight uphill. Turn the ATV around and
remount, following the procedure described in
this manual.

Always check for obstacles before operating in a
new area.
Never attempt to operate over large obstacles,
such as large rocks or fallen trees. Always follow
proper procedures when operating over obsta-
cles as described in this manual.
Always be careful when skidding or sliding.
Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth
terrain. On extremely slippery surfaces, such as
ice, go slowly and be very cautious in order to re-
duce the chance of skidding or sliding out of con-
trol.
Never operate an ATV in fast flowing water or in
water deeper than that recommended in this
manual. Remember that wet brakes may have
reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several
times to let friction dry out the linings.

Always be sure there are no obstacles or people
behind you when you operate in reverse. When
it is safe to proceed in reverse, go slowly.
Always use the size and type of tires specified in
this manual.
Always maintain proper tire pressure as de-
scribed in this manual.
Never modify an ATV through improper installa-
tion or use of accessories.
Never exceed the stated load capacity for an
ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow in-
structions in this manual for carrying cargo. Al-
low greater distance for braking.
WARNING
EWB00060
Always turn off the engine when refueling.
Do not refuel right after the engine has been
running and is still very hot.
Do not spill gasoline on the engine or ex-
haust pipe/muffler when refueling. Never re-
fuel while smoking, or in the vicinity of
sparks, open flames, or other sources of ig-
nition such as the pilot lights of water heat-
ers and clothes dryers. Gasoline can catch
fire and you could be burned.
U3C260E0.book Page 3 Tuesday, August 2, 2005 9:52 AM

1-4
1

When transporting the ATV in another vehi-
cle, be sure it is kept upright and that the fuel
cock is in the “OFF” position. Otherwise, fuel
may leak out of the carburetor or fuel tank.
Gasoline is poisonous. If you should swal-
low some gasoline or inhale a lot of gasoline
vapor, or get some gasoline in your eyes,
see your doctor immediately. If gasoline
spills on your skin, wash with soap and wa-
ter. If gasoline spills on your clothing,change your clothes.
WARNING
EWB00070Always operate your ATV in an area with ade-
quate ventilation. Never start or run the engine
in a closed area. Exhaust fumes are poisonous
and may cause loss of consciousness anddeath within a short time.
U3C260E0.book Page 4 Tuesday, August 2, 2005 9:52 AM

3-1
3
EBU17680
DESCRIPTION
EBU17690Left view
EBU17700Right view
1. Front shock absorber assembly spring preload adjusting
ring
2. Fuel cock
3. Air filter case
4. Fuses
5. Storage compartment and tool kit
6. Seat lock lever
7. Rear shock absorber assembly spring preload adjusting
ring
8. Engine oil dipstick
9. Oil filter cartridge
10.Coolant reservoir
11.V-belt cooling duct check hose
1. Tail/brake light
2. Spark plug
3. Rear brake fluid reservoir
4. Radiator cap
5. Front shock absorber assembly spring preload adjusting
ring
6. Brake pedal
7. V-belt case
U3C260E0.book Page 1 Tuesday, August 2, 2005 9:52 AM

4-1
4
EBU17730
INSTRUMENT AND CONTROL FUNCTIONS
EBU17770Main switch The positions of the main switch are as follows:
ON
All electrical systems are supplied with power. The
headlights, meter lighting and taillight come on
when the light switch is on, and the engine can be
started. The key cannot be removed.
OFF
All electrical systems are off. The key can be re-
moved.
1. Main switch
U3C260E0.book Page 1 Tuesday, August 2, 2005 9:52 AM

4-2
4
EBU17810Indicator lights and warning light EBU17840Reverse indicator light “”
This indicator light comes on when the transmis-
sion is in the reverse position.NOTE:If the indicator light flashes or the speedometer
does not show the speed while riding, have aYamaha dealer check the speed sensor circuit.
EBU17860Neutral indicator light “”
This indicator light comes on when the transmis-
sion is in the neutral position.EBU17920Coolant temperature warning light “”
This warning light comes on when the engine over-
heats. When this occurs during operation, stop the
engine as soon as it is safe to do so and allow it to
cool down for about 10 minutes.CAUTION:ECB00010
The engine may overheat if the ATV is over-
loaded. In this case, reduce the load to spec-
ification.
Start the engine after making sure that the
warning light is out. Continuous use while
the warning light is on may cause damage tothe engine.EBU26590Four-wheel-drive indicator “”
This indicator comes on when the 2WD/4WD
switch is set to the 4WD position.
1. Coolant temperature warning light “”
2. Neutral indicator light “N”
3. Reverse indicator light “R”
4. Park indicator light “P”
5. Four-wheel-drive indicator “”U3C260E0.book Page 2 Tuesday, August 2, 2005 9:52 AM