2006 YAMAHA YFZ450 brake fluid

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

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
5TG-9-62 5-6 5/13/05 1:45 PM Page 5-1

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

5-9
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
leakage, have a Yamaha dealer inspect the
brake system.
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 perfor-
mance, inspect the brake pads for wear. (See
page 8-81–8-83.)
5TG-9-62 5-6 5/13/05 1:45 PM Page 5-9

8-8
INITIAL EVERY
month 1 3 6 6 12
ITEM ROUTINEWhichever
km 320 1200 2400 2400 4800 comes first
(mi) (200) (750) (1500) (1500) (3000)
hours 20 75 150 150 300
Air filter element9Clean. Every 20–40 hours
9Replace if necessary. (more often in wet or dusty areas)
Clutch*9Check operation.
2222
9Adjust if necessary.
9Check free play/operation/fluid leakage/
Front brake*See NOTE Page 8-10.22222
9Correct if necessary.
9Check operation/fluid leakage/
Rear brake*See NOTE Page 8-10.22222
9Correct if necessary.
Wheels*9Check balance/damage/runout.
2222
9Replace if necessary.
Wheel bearings*9Check bearing assemblies for looseness/damage.
2222
9Replace if damaged.
Rear arm pivot*9Lubricate with lithium-soap-based grease.222
Upper and lower arm
pivot and steering 9Lubricate with lithium-soap-based grease.222
shaft*
Drive chain9Check and adjust slack/alignment/clean/lube.22222
Fittings and fasteners*9Check all chassis fittings and fasteners.
22222
9Correct if necessary.
Front and rear9Check operation.
22
suspension*9Correct if necessary.
5TG-9-62 8 5/13/05 1:48 PM Page 8-8

8-10
NOTE:
8Recommended brake fluid: DOT 4
8Brake fluid replacement:
9When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally
check the brake fluid level and add the fluid as required.
9On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two
years.
9Replace the brake hoses every four years, or if cracked or damaged.
5TG-9-62 8 5/13/05 1:48 PM Page 8-10

8-85
EBU16070
Brake fluid level inspection
Insufficient brake fluid may let air enter the
brake system, possibly causing the brakes to
become ineffective.
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.
1. Minimum level mark 1. Repère de niveau minimum 1. Marca de mínimo
FrontAvantDelantero
1
1. Minimum level mark 1. Repère de niveau minimum 1. Marca de mínimo
RearArrièreTrasero
5TG-9-62 8 5/13/05 1:48 PM Page 8-85

8-87
NOTE:
8To access the rear brake fluid reservoir cap,
remove the seat (see page 4-27), remove the
rear brake fluid reservoir bracket bolt, and
then pull the rear brake fluid reservoir out to
the side as shown.
8When installing the rear brake fluid reservoir,
make sure the projection on the rear brake
fluid reservoir bracket is inserted into the hole
in the frame.
cC
Do not tilt the rear brake fluid reservoir
excessively when removing or installing the
rear brake fluid reservoir. Also do not twist
or pull the hose of the reservoir.
2
4
13
1
1. Frame 2. Projection
3. Rear brake fluid reservoir bracket
4. Rear brake fluid reservoir bracket bolt
1. Armature 2. Saillie
3. Support du réservoir de liquide du frein arrière
4. Boulon de support du réservoir de liquide du frein arrière
1. Bastidor 2. Saliente
3. Ménsula del depósito del líquido de los frenos traseros
4.
Perno de la ménsula del depósito del líquido de los frenos traseros
1. Raer brake fluid reservoir 1. Réservoir de liquide du frein arrière1. Depósito del líquido de los frenos traseros
5TG-9-62 8 5/13/05 1:48 PM Page 8-87