2009 YAMAHA YFZ450 oil

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 light and warning light ................. 4-1
Handlebar switches ................................... 4-2
Throttle lever ............................................. 4-3
Speed limiter ............................................. 4-4
Clutch lever ............................................... 4-5
Brake lever ................................................ 4-5
Brake pedal ............................................... 4-6
Parking brake lever ................................... 4-6
Shift pedal ................................................. 4-7
Fuel tank cap ............................................. 4-7
Fuel ........................................................... 4-8
Fuel cock ................................................... 4-9Starter (choke) “ ” ................................. 4-10
Seat ......................................................... 4-11
Adjusting the front shock absorber
assemblies ............................................. 4-12
Adjusting the rear shock absorber
assembly ................................................ 4-17
PRE-OPERATION CHECKS ..........................5-1
Pre-operation check list ............................. 5-1
Fuel ............................................................ 5-3
Engine oil ................................................... 5-3
Coolant ...................................................... 5-3
Front and rear brakes ................................ 5-3
Throttle lever .............................................. 5-4
Drive chain ................................................. 5-4
Tires ........................................................... 5-4
Measuring the tire pressure ....................... 5-5
Tire wear limit ............................................ 5-6
Chassis fasteners ...................................... 5-7
Instruments, lights and switches ................ 5-7
OPERATION...................................................6-1
Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-3
Shifting ....................................................... 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 ............ 7-8
TURNING YOUR ATV ............................. 7-12
CLIMBING UPHILL .................................. 7-14
RIDING DOWNHILL................................. 7-16
CROSSING A SLOPE.............................. 7-17
CROSSING THROUGH SHALLOW
WATER .................................................. 7-18
RIDING OVER ROUGH TERRAIN .......... 7-20
SLIDING AND SKIDDING ........................ 7-20
WHAT TO DO IF... ................................... 7-21
WHAT TO DO... ....................................... 7-21
PERIODIC MAINTENANCE AND MINOR
REPAIR .......................................................... 8-1
Owner’s manual and tool kit ...................... 8-1
Periodic maintenance chart for the
emission control system .......................... 8-3
General maintenance and lubrication
chart ........................................................ 8-5
Removing and installing the panel ............ 8-9
Checking the spark plug .......................... 8-10Engine oil and oil filter element ................ 8-14
Coolant .................................................... 8-20
Cleaning the air filter element .................. 8-24
Cleaning the spark arrester ..................... 8-28
Adjusting the carburetor ........................... 8-29
Checking the engine idling speed ............ 8-30
Adjusting the throttle cable free play ........ 8-30
Valve clearance ....................................... 8-31
Checking the front and rear brake
pads ....................................................... 8-31
Checking the brake fluid level .................. 8-32
Changing the brake fluid .......................... 8-35
Checking the front brake lever free
play ........................................................ 8-36
Checking the brake pedal position ........... 8-36
Adjusting the parking brake free play ...... 8-37
Brake light switches ................................. 8-39
Adjusting the clutch lever free play .......... 8-39
Drive chain slack ...................................... 8-41
Lubricating the drive chain ....................... 8-43
Checking and lubricating the cables ........ 8-43
Checking and lubricating the brake and
clutch levers ........................................... 8-44
Checking and lubricating the brake and
shift pedals ............................................. 8-45
Checking the wheel hub bearings ............ 8-45
Lubricating the swingarm pivots .............. 8-45
Lubricating the upper and lower arm
pivots ..................................................... 8-46

3-1
1
23
4
5
6
7
8
9
10
11

EBU17680
DESCRIPTION
EBU17690
Left view
EBU17700
Right view
1. Headlights
2. Fuel cock
3. Starter (choke)
4. Throttle stop screw
5. Fuse
6. Tail/brake light
7. Coolant reservoir
8. Shift pedal
9. Engine oil tank
1
23456
7
8
9

1. Spark arrester
2. Seat
3. Fuel tank cap
4. Radiator cap
5. Oil filter element
6. Brake pedal
1
2
3
4
5 6

4-16
1
2
34
5
6
7
8
9
10
11
NOTICE

ECB00090
Never turn an adjusting mechanism beyond
the minimum and maximum settings.
TIP

Although the total number of clicks of a damping
force adjusting mechanism may not exactly match
the above specifications due to small differences in
production, the actual number of clicks always rep-
resents the entire adjusting range. To obtain a pre-
cise adjustment, it would be advisable to check the
number of clicks of each damping force adjusting
mechanism and to modify the specifications as
necessary.
WARNING

EWB00420

Suspension components become hot during
operation. Never touch the compression
damping force adjusting screw, the rebound
damping force adjusting screw or the oil res-
ervoir with your bare hand or skin until sus-
pension components have cooled.

Always adjust the shock absorber assem-
blies on the left and right side to the same
1. Compression damping force adjusting screw (for slow
compression damping)
Compression damping setting (for slow com-
pression damping):
Minimum (soft):
20 click(s) in direction (b)*
Standard:
10 click(s) in direction (b)*
Maximum (hard):
1 click(s) in direction (b)*
* With the adjusting screw fully turned in di-
rection (a)
(b)(a)
1

4-23
1
2
34
5
6
7
8
9
10
11
NOTICE

ECB00090
Never turn an adjusting mechanism beyond
the minimum and maximum settings.
TIP

Although the total number of clicks of a damping
force adjusting mechanism may not exactly match
the above specifications due to small differences in
production, the actual number of clicks always rep-
resents the entire adjusting range. To obtain a pre-
cise adjustment, it would be advisable to check the
number of clicks of each damping force adjusting
mechanism and to modify the specifications as
necessary.
3. Install the seat.WARNING

EWB00440
Suspension components become hot during
operation. Never touch the compression
damping force adjusting screw, the rebound
damping force adjusting screw or the oil reser-
voir with your bare hand or skin until suspen-
sion components have cooled.
1. Compression damping force adjusting screw (for slow
compression damping)
Compression damping setting (for slow com-
pression damping):
Minimum (soft):
20 click(s) in direction (b)*
Standard:
11 click(s) in direction (b)*
Maximum (hard):
1 click(s) in direction (b)*
* With the adjusting screw fully turned in di-
rection (a)
(b)(a)
1

5-1
1
2
3
45
6
7
8
9
10
11

EBU19200
PRE-OPERATION CHECKS
EBU19222
Pre-operation check list
Before operating this ATV, be sure to check the items listed in the following table.
WARNING

EWB00480
Always inspect your ATV each time you use it to make sure it is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in the Owner’s
Manual. Failure to inspect increases the possibility of an accident or equipment damage.
TIP

The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic
maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
ITEM ROUTINE PAGE
Fuel


Check fuel level in fuel tank, and add recommended fuel if neces-
sary.

Check fuel line for leakage. Correct if necessary.4-8, 5-3
Engine oil

Check oil level in engine, and add recommended oil to specified
level if necessary.

Check ATV for oil leakage. Correct if necessary.5-3, 8-14
Coolant

Check coolant level in reservoir, and add recommended coolant to
specified level if necessary.

Check cooling system for leakage. Correct if necessary.5-3, 8-20

5-3
1
2
3
45
6
7
8
9
10
11

EBU19540
Fuel
Make sure that there is sufficient fuel in the tank.
(See page 4-8.)
WARNING

EWB00520

Do not overfill the fuel tank. Fuel expands
when it heats up. If the fuel tank is overfilled,
fuel could spill out due to heat from the en-
gine or the sun.

Be careful not to spill fuel, especially on the
engine or exhaust pipe which can cause a
fire and severe injury. Wipe up any spilled
fuel immediately.

Do not refuel right after the engine has been
running and is still very hot.

Be sure the fuel tank cap is closed securely.
EBU19560
Engine oil
Make sure that the engine oil is at the specified lev-
el. Add oil as necessary. (See page 8-14.)
EBU19630
Coolant
Make sure that the coolant is at the specified level.
Add coolant as necessary. (See page 8-20.)
TIP

The coolant level must be checked on a cold en-
gine since the level varies with engine tempera-
ture.
WARNING

EWB00510
Wait for the engine and radiator to cool before
removing the radiator cap. You could be
burned by hot fluid and steam blown out under
pressure. Always put a thick rag over the cap
when opening. Allow any remaining pressure
to escape before completely removing the cap.
EBU19710
Front and rear brakes
Brake lever and brake pedal

Check that there is no free play in the brake le-
ver. If there is free play, have a Yamaha dealer
check the brake system.

Check for correct brake pedal height. (See
page 8-36.) If the pedal height is incorrect, have
a Yamaha dealer adjust it.

Check the operation of the lever and pedal. They
should move smoothly and there should be a
firm feeling when the brakes are applied. If not,

8-6
1
2
3
4
5
6
78
9
10
11

10
*
Swingarm pivots

Check operation and for excessive play, and
replace bearings if necessary.

Lubricate with lithium-soap-based grease.
√√√
11
*
Upper and lower
arm pivots


Lubricate with lithium-soap-based grease.
√√√
12 Drive chain

Check chain slack and adjust if necessary.

Check rear wheel alignment and correct if necess-
sary.

Clean and lubricate.
√√√√√
13
*
Drive chain rollers


Check for wear and replace if necessary.
√√√
14
*
Chassis fasteners


Make sure that all nuts, bolts, and screws are
properly tightened.
√√√√√
15
*
Shock absorber
assemblies


Check operation and correct if necessary.

Check for oil leakage and replace if necessary.
√√√
16
*
Rear suspension
relay arm and con-
necting arm pivot-
ing points


Check operation and correct if necessary.

Lubricate with lithium-soap-based grease.
√√√√
17
*
Steering shaft


Lubricate with lithium-soap-based grease.
√√√
18
*
Steering system


Check operation and repair or replace if damaged.

Check toe-in and adjust if necessary.
√√√√√
19
*
Engine mount


Check for cracks or other damage, and replace if
necessary.
√√√
NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth 1 3 6 6 12
km
(mi)320
(200)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320