2006 YAMAHA YFZ450 brake

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 ....................................... 4-17Brake pedal ...................................... 4-17
Parking brake lever .......................... 4-19
Shift pedal ........................................ 4-21
Fuel tank cap .................................... 4-21
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 ......................... 5-7
Fuel .................................................. 5-13
Engine oil .......................................... 5-17
Coolant ............................................. 5-19
Chain ................................................ 5-21
Throttle lever .................................... 5-21
Tires ................................................. 5-23
How to measure tire pressure .......... 5-27
Tire wear limit ................................... 5-29
Fittings and fasteners ....................... 5-29
EBU00150
CONTENTS
1
2
3
4
5
5TG-9-62 1-3 5/13/05 10:06 AM Page 12

Carburetor adjustment ...................... 8-75
Idle speed adjustment ...................... 8-77
Valve clearance adjustment ............. 8-77
Throttle lever adjustment .................. 8-79
Front brake pad inspection ............... 8-81
Rear brake pad inspection ............... 8-83
Brake fluid level inspection ............... 8-85
Brake fluid replacement .................... 8-91
Front brake lever free play ............... 8-93
Brake pedal height adjustment ......... 8-95
Parking brake adjustment ................. 8-97
Adjusting the rear brake light switch.... 8-101
Clutch lever free play adjustment .... 8-103
Drive chain slack check .................. 8-105
Adjusting the drive chain slack ....... 8-107
Lubricating the drive chain ............. 8-111
Cable inspection and lubrication .... 8-115
Brake pedal, brake lever and
clutch lever lubrication .................. 8-117
Front upper and lower arm pivot
lubrication ..................................... 8-121Rear arm pivot lubrication .............. 8-123
Wheel removal ............................... 8-125
Wheel installation ........................... 8-127
Battery ............................................ 8-129
Battery maintenance ...................... 8-133
Fuse replacement ........................... 8-135
Replacing a headlight bulb ............. 8-137
Headlight beam adjustment ............ 8-143
Tail/brake light ................................ 8-143
Troubleshooting .............................. 8-145
Troubleshooting chart ..................... 8-149
CLEANING AND STORAGE ................ 9-1
A. CLEANING ..................................... 9-1
B. STORAGE ..................................... 9-7
SPECIFICATIONS .............................. 10-1
Conversion table ................................. 11-1
9
10
11
5TG-9-62 1-3 5/13/05 10:06 AM Page 14

2-13
8Always 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 reduce the chance of skidding or slid-
ing out of control.
8Never 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.
8Always use the size and type of tires specified
in this manual.
8Always maintain proper tire pressure as
described in this manual.
5TG-9-62 1-3 5/13/05 10:06 AM Page 2-13

3-1
EBU00320
DESCRIPTION AND MACHINE
IDENTIFICATION
1. Seat 11. Tail/brake light
2. Fuel tank cap 12. Coolant reservoir
3. Radiator cap 13. Shift pedal
4. Oil filter element 14. Engine oil tank
5. Brake pedal 15. Clutch lever
6. Headlights 16 Handlebar switches
7. Fuel cock 17. Parking brake lever
8. Starter (choke) 18. Main switch
9. Throttle stop screw 19. Throttle lever
10. Fuse 20. Brake lever
NOTE:
The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
5TG-9-62 1-3 5/13/05 10:06 AM Page 3-1

4-17
1. Brake lever 2. Locknut 3. Adjusting bolt
4. Distance between brake lever and handlebar grip
1. Levier de frein 2. Contre- écrou 3. Boulon de réglage
4. Distance entre le levier de frein et la poignée
1. Palanca del freno 2. Contratuerca 3. Perno de ajuste
4. Distancia entre la palanca del freno y la empuñadura del
manillar
1. Brake pedal
1. Pédale de frein 1. Pedal del freno
EBU13860
Brake lever
The brake lever is located on the right handle-
bar. Pull it toward the handlebar to apply the
front brake.
The brake lever is equipped with a position
adjusting bolt. To adjust the distance between
the brake lever and the handlebar grip, hold the
lever away from the handlebar so it does not
contact the adjusting bolt, loosen the locknut,
turn the adjusting bolt, and then tighten the lock-
nut.
EBU09890
Brake pedal
The brake pedal is located on the right side of
the machine. Push down on the pedal to apply
the rear brake.
5TG-9-62 4 5/12/05 5:18 PM Page 4-17

4-19
1. Parking brake lever (Locked position)1. Levier de frein de stationnement (frein serré)1. Palanca del freno de estacionamiento (posición de bloqueo)
1. Parking brake lever (Unlocked position)
1. Levier de frein de stationnement (frein relâché)1. Palanca del freno de estacionamiento
(posición de desbloqueo)
EBU14072
Parking brake lever
Use the parking brake when you have to start
the engine or park the machine, especially on a
slope. To apply the parking brake, move the
parking brake lever in direction
a. To release
the parking brake, move the parking brake lever
in direction b.
w
8Always set the parking brake before start-
ing the engine. The ATV could start mov-
ing unexpectedly if the parking brake is
not applied. This could cause loss of con-
trol or a collision.
8Always be sure you have released the
parking brake before you begin to ride.
The brake could overheat if you ride the
ATV without releasing the parking brake.
You could lose braking performance
which could cause an accident. You could
also wear out the brakes prematurely.
5TG-9-62 4 5/12/05 5:18 PM Page 4-19

5-1
EBU01130
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brake9Check operation lever, free play, fluid level and fluid leakage. 5-7–5-11, 8-81,
9Fill with DOT 4 brake fluid if necessary. 8-85–8-91
Rear brake9Check operation, fluid level and fluid leakage. 5-7–5-11
9Fill with DOT 4 brake fluid if necessary. 8-83–8-89, 8-93
Clutch9Check operation, condition and lever free play. 8-103
Parking brake9Check operation, condition and cable length. 8-97–8-99
Fuel 9Check fuel level.
9Fill with fuel if necessary.5-13–5-15
Engine oil9Check oil level.
9Fill with oil if necessary.5-17, 8-25–8-41
Coolant reservoir 9Check coolant level in reservoir.
9Fill with coolant if necessary.5-19–5-21, 8-43–8-53
Drive chain9Check chain slack and condition.
9Adjust if necessary.5-21, 8-105–8-113
Throttle9Check for proper throttle cable operation and free play. 5-21, 8-79
Wheels and tires9Check tire pressure, wear and damage. 5-23–5-29, 8-125–8-127
Fittings and fasteners9Check all fittings and fasteners. 5-29
Lights and switches9Check for proper operation. 5-29, 8-99, 8-137–8-141
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5-7
EBU11670
Front and rear brakes
Brake lever and brake pedal
8Check that there is no free play in the brake
lever. If there is free play, have a Yamaha
dealer inspect the brake system.
8Check for correct brake pedal height. (See
page 8-93.) If the pedal height is incorrect,
have a Yamaha dealer adjust it.
8Check 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 inspect the brake system.
Brake fluid level
Check the brake fluid level. Add fluid if neces-
sary. (See pages 8-85–8-89.)
Recommended brake fluid: DOT 4
5TG-9-62 5-6 5/13/05 1:45 PM Page 5-7