2009 YAMAHA YFZ450R engine coolant

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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 lights ............... 4-2
Handlebar switches ................................... 4-3
Throttle lever ............................................. 4-4
Speed limiter ............................................. 4-5
Clutch lever ............................................... 4-6
Brake lever ................................................ 4-6
Brake pedal ............................................... 4-7
Parking brake lever ................................... 4-7
Shift pedal ................................................. 4-8
Fuel tank cap ............................................. 4-8
Fuel ........................................................... 4-9
Seat ......................................................... 4-10Adjusting the front shock absorber
assemblies ............................................. 4-11
Adjusting the rear shock absorber
assembly ................................................4-16
Handlebar position ................................... 4-24
PRE-OPERATION CHECKS ..........................5-1
Pre-operation check list ............................. 5-1
Fuel ............................................................ 5-4
Engine oil ................................................... 5-4
Coolant ...................................................... 5-4
Front and rear brakes ................................ 5-4
Throttle lever .............................................. 5-5
Drive chain ................................................. 5-5
Tires ........................................................... 5-5
Measuring the tire pressure ....................... 5-6
Tire wear limit ............................................ 5-7
Chassis fasteners ...................................... 5-8
Instruments, lights and switches ................ 5-8
OPERATION...................................................6-1
Starting the engine ..................................... 6-1
Shifting ....................................................... 6-2
Engine break-in .......................................... 6-4
Parking ....................................................... 6-4
Parking on a slope ..................................... 6-5

Accessories and loading ........................... 6-5
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 ........................................................ 8-4
Removing and installing panels ................ 8-8
Checking the spark plug .......................... 8-13
Engine oil and oil filter element ............... 8-14
Coolant .................................................... 8-19Cleaning the air filter element .................. 8-23
Cleaning the spark arrester ..................... 8-27
Adjusting the throttle cable free play ........ 8-28
Valve clearance ....................................... 8-29
Checking the front and rear brake
pads .......................................................8-29
Checking the brake fluid level .................. 8-30
Changing the brake fluid .......................... 8-32
Checking the front brake lever free
play ........................................................ 8-32
Checking the brake pedal position ........... 8-33
Adjusting the parking brake free play ...... 8-34
Brake light switches ................................. 8-35
Adjusting the clutch lever free play .......... 8-36
Drive chain slack ...................................... 8-37
Lubricating the drive chain ....................... 8-39
Checking and lubricating the cables ........ 8-40
Checking and lubricating the brake and
clutch levers ........................................... 8-40
Checking the shift pedal .......................... 8-41
Checking and lubricating the brake
pedal ......................................................8-41
Checking the wheel hub bearings ............ 8-42
Lubricating the swingarm pivots .............. 8-42
Lubricating the upper and lower arm
pivots .....................................................8-42
Battery ..................................................... 8-43
Replacing the fuse ................................... 8-46
Replacing a headlight bulb ...................... 8-46

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

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DESCRIPTION
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Left view
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Right view
1. Front shock absorber assembly compression damping
force adjusting bolt (for fast compression damping)
2. Front shock absorber assembly compression damping
force adjusting screw (for slow compression damping)
3. Headlights
4. Front shock absorber assembly spring preload adjusting nut
5. Engine oil tank filler cap
6. Tail/brake light
7. Shift pedal
8. Coolant reservoir
9. Front shock absorber assembly rebound damping force
adjusting screw
6
7 8 934 1
5
2

1. Spark arrester
2. Fuse
3. Seat
4. Rear shock absorber assembly spring preload adjusting nut
5. Rear shock absorber assembly compression damping
force adjusting bolt (for fast compression damping)
6. Rear shock absorber assembly compression damping
force adjusting screw (for slow compression damping)
7. Radiator cap
8. Oil filter element
9. Brake pedal
10. Rear shock absorber assembly rebound damping force
adjusting screw
7
8 9 10 1
2
3
4
5
6

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

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Indicator light and warning lights
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Neutral indicator light “”
This indicator light comes on when the transmis-
sion is in the neutral position.
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Coolant temperature warning light “”
This warning light comes on when the engine over-
heats. When this occurs during operation, stop theengine as soon as it is safe to do so and allow it to
cool down for about 10 minutes.
The electrical circuit of the warning light can be
checked by turning the key to “ON”. If the warning
light does not come on, and then go off, have a
Yamaha dealer check the electrical circuit.
NOTICE
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 to
the engine.
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Fuel level warning light “”
This warning light comes on when the fuel level
drops below approximately 3.4 L (0.90 US gal,
0.75 Imp.gal). When this occurs, refuel as soon as
possible.
The electrical circuit of the warning light can be
checked by setting the engine stop switch to “ ”
and turning the key to “ON”. If the warning light
does not come on, and then go off, have a Yamaha
dealer check the electrical circuit.
1. Fuel level warning light “ ”
2. Engine trouble warning light “ ”
3. Coolant temperature warning light “ ”
4. Neutral indicator light “N”
12 3 4

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

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PRE-OPERATION CHECKS
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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.4-9, 5-4
Engine oil

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

Check ATV for oil leakage. Correct if necessary.5-4, 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.5-4, 8-19

5-4
1
2
3
45
6
7
8
9
10
11

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Fuel
Make sure that there is sufficient fuel in the tank.
(See page 4-9.)
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.
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Engine oil
Make sure that the engine oil is at the specified lev-
el. Add oil as necessary. (See page 8-14.)
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Coolant
Make sure that the coolant is at the specified level.
Add coolant as necessary. (See page 8-19.)
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.
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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 8-33.) 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,

6-1
1
2
3
4
56
7
8
9
10
11

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OPERATION
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Read the Owner’s Manual carefully before riding
the ATV.
WARNING

EWB00630
Read the Owner’s Manual carefully to become
familiar with all controls in order to help pre-
vent any loss of control, which could cause an
accident or injury. If there is a control or func-
tion you do not understand, ask your Yamaha
dealer.
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Starting the engine
WARNING

EWB00640
Always make sure all control cables work
smoothly before you begin riding in cold
weather. If the control cables are frozen or do
not work smoothly, you could be unable to
control the ATV, which could lead to an acci-
dent or collision.NOTICE
ECB00150
See the “Engine break-in” section on page 6-4
prior to operating the engine for the first time.
1. Set the parking brake.
2. Turn the key to “ON” and the engine stop
switch to “ ”.
NOTICE

ECB00950
The coolant temperature warning light, fuel
level warning light and engine trouble warning
light should come on, then go off.
If a warning light does not go off, see page 4-2
for the corresponding warning light circuit
check.
3. Shift the transmission into neutral. The neutral
indicator light should come on, if it does not
come on, have a Yamaha dealer check the
electrical circuit.
TIP

This model is equipped with an ignition circuit cut-
off system. The engine can be started under the

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

20 Engine oil

Change.

Check ATV for oil leakage, and correct if neces-
sary.
√ √√√
21Engine oil filter ele-
ment

Replace.
√√√
22 Cooling system

Check coolant level and ATV for coolant leakage,
and correct if necessary.
√√√√√

Replace coolant. Every 2 years
23
*
Moving parts and
cables

Lubricate.
√√√√
24
*
Throttle lever hous-
ing and cable


Check operation and correct if necessary.

Check throttle cable free play and adjust if neces-
sary.

Lubricate throttle lever housing and cable.
√√√√√
25
*
Front and rear brake
switches

Check operation and correct if necessary.
√√√√√
26
*
Lights and switches

Check operation and correct if necessary.

Adjust headlight beams.
√√√√√
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