2009 YAMAHA WOLVERINE 450 boot

Checking the front brake lever free
play ......................................................... 8-42
Adjusting the rear brake lever free play
and checking the brake pedal position ... 8-42
Axle boots ................................................ 8-44
Brake light switches ................................. 8-45
Checking and lubricating the cables ........ 8-45
Checking and lubricating the front and
rear brake levers .................................... 8-46
Checking and lubricating the brake
pedal ...................................................... 8-46
Checking the wheel hub bearings ............ 8-47
Lubricating the steering shaft ................... 8-47
Battery ...................................................... 8-47
Replacing a fuse ...................................... 8-50
Replacing a headlight bulb ....................... 8-51
Adjusting a headlight beam ...................... 8-53
Replacing the tail/brake light bulb ............ 8-54
Removing a wheel .................................... 8-55
Installing a wheel ...................................... 8-55
Troubleshooting ....................................... 8-56
Troubleshooting charts ............................. 8-57
CLEANING AND STORAGE .......................... 9-1
Cleaning ..................................................... 9-1
Storage ....................................................... 9-2SPECIFICATIONS .......................................10-1
CONSUMER INFORMATION.......................11-1
Identification numbers ...............................11-1
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1-1
1
EBU17430
SAFETY INFORMATION
EBU17534AN ATV IS NOT A TOY AND CAN BE HAZARD-OUS TO OPERATE.An ATV handles differently from other vehicles, in-
cluding motorcycles and cars. A collision or roll-
over can occur quickly, even during routine
maneuvers such as turning and riding on hills or
over obstacles, if you fail to take proper precau-
tions.
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.
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5-2
5
Front brakeCheck operation. If soft or spongy, have Yamaha dealer bleed hy-
draulic system.
Check brake pads for wear, and replace if necessary.
Check brake fluid level in reservoir, and add recommended brake
fluid to specified level if necessary.
Check hydraulic system for leakage. Correct if necessary.5-4, 8-39, 8-40, 8-42
Rear brakeCheck operation. If soft or spongy, have Yamaha dealer bleed hy-
draulic system.
Check lever free play, and adjust if necessary.
Check brake pads for wear, and replace if necessary.
Check brake fluid level in reservoir, and add recommended brake
fluid to specified level if necessary.
Check hydraulic system for leakage. Correct if necessary.5-4, 8-39, 8-40, 8-42
Throttle leverMake sure that operation is smooth. Lubricate cable and lever hous-
ing if necessary.
Check cable free play, and adjust if necessary.5-5, 8-38
Control cablesMake sure that operation is smooth. Lubricate if necessary. 8-45
Wheels and tiresCheck wheel condition, and replace if damaged.
Check tire condition and tread depth. Replace if necessary.
Check air pressure. Correct if necessary.5-5, 5-6, 5-7
Brake pedal Make sure that operation is smooth. Lubricate pedal pivoting point if
necessary.8-46
Brake leversMake sure that operation is smooth. Lubricate lever pivoting points if
necessary.8-46
Axle bootsCheck for cracks or damage, and replace if necessary. 8-44
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened. 5-7
Instruments, lights and
switchesCheck operation, and correct if necessary. 5-7 ITEM ROUTINE PAGEU3C263E0.book Page 2 Thursday, May 15, 2008 10:44 AM

7-4
7 Apparel
Always wear an approved motorcycle helmet that
fits properly.
You should also wear:

eye protection (goggles or face shield)
gloves
boots
long-sleeved shirt or jacket
long pants1. Protective clothing
2. Goggles
3. Gloves
4. Boots
5. Helmet
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8-6
8
8*SwingarmCheck for excessive play, and correct if necessary.√√√
9*V- b e l tCheck for wear, cracks or other damage, and re-
place if necessary.√ √√√
10*Chassis fastenersMake sure that all nuts, bolts, and screws are
properly tightened.√√√√√
11*Shock absorber as-
sembliesCheck operation and correct if necessary.
Check for oil leakage and replace if necessary.√√√
12*Steering shaftLubricate with lithium-soap-based grease.√√√
13*Steering systemCheck operation and repair or replace if damaged.
Check toe-in and adjust if necessary.√√√√√
14*Engine mountCheck for cracks or other damage, and replace if
necessary.√√√
15*Axle bootsCheck for cracks or other damage, and replace if
necessary.√√√√√
16 Engine oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√ √√√
17Engine oil filter car-
tridgeReplace.√√√
18*Engine oil strainerClean.√√√
19 Differential gear oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√√ NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320
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8-44
8 Checking the brake pedal position
The top of the brake pedal should be positioned
67.0–77.0 mm (2.64–3.03 in) above the top of the
footboard bracket. If the brake pedal position is in-
correct, have a Yamaha dealer adjust it.
WARNING
EWB02070Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
After servicing:
Make sure the brakes operate smoothly and
that the free play is correct.
Make sure the brakes do not drag.

Make sure the brakes are not spongy. All air
must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These proceduresshould be performed by a Yamaha dealer.EBU24230Axle boots The axle boots must be checked for damage at the
intervals specified in the periodic maintenance and
lubrication chart. Check the axle boots for tears or
damage. If any damage is found, have them re-
placed by a Yamaha dealer.
1. Brake pedal position
1. Axle boot (each side)
U3C263E0.book Page 44 Thursday, May 15, 2008 10:44 AM

INDEX
AAccessories and loading ................................................ 6-6
Air filter element, cleaning ............................................ 8-31
Axle boots .................................................................... 8-44BBattery .......................................................................... 8-47
Brake fluid, changing .................................................... 8-41
Brake fluid level, checking ............................................ 8-40
Brake lever free play and brake pedal position (rear),
adjusting and checking .............................................. 8-42
Brake lever free play, checking the front ...................... 8-42
Brake lever, front ............................................................ 4-8
Brake levers, checking and lubricating ......................... 8-46
Brake light switches ..................................................... 8-45
Brake pads, checking the front and rear ...................... 8-39
Brake pedal and rear brake lever ................................... 4-8
Brake pedal, checking and lubricating ......................... 8-46
Brakes, front and rear .................................................... 5-4CCables, checking and lubricating ................................. 8-45
Carburetor, adjusting .................................................... 8-36
Chassis fasteners ........................................................... 5-7
Cleaning ......................................................................... 9-1
Coolant .................................................................. 5-3, 8-27
Coolant temperature warning light ................................. 4-2
Cowlings and panels, removing and installing ............... 8-9DDifferential gear oil ......................................................... 5-3Differential gear oil, changing ....................................... 8-25
Drive select lever ............................................................ 4-9
Drive select lever and driving in reverse ........................ 6-3
Drive select lever safety system cable, adjusting ......... 8-39
EEngine break-in .............................................................. 6-5
Engine, cold start ........................................................... 6-1
Engine idling speed ...................................................... 8-36
Engine oil ....................................................................... 5-3
Engine oil and oil filter cartridge ................................... 8-17
Engine, starting a warm ................................................. 6-3
Engine stop switch ......................................................... 4-4FFinal gear oil .......................................................... 5-3, 8-22
Four-wheel-drive indicator .............................................. 4-3
Fuel ......................................................................... 4-9, 5-3
Fuel cock ...................................................................... 4-10
Fuel tank cap .................................................................. 4-9
Fuses, replacing ........................................................... 8-50HHandlebar switches ........................................................ 4-4
Headlight beam, adjusting ............................................ 8-53
Headlight bulb, replacing .............................................. 8-51IIdentification numbers .................................................. 11-1
Indicator lights and warning light .................................... 4-2
Instruments, lights and switches .................................... 5-7
U3C263E0.book Page 1 Thursday, May 15, 2008 10:44 AM