2009 YAMAHA YFZ450R engine 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 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

EBU17680
DESCRIPTION
EBU17690
Left view
EBU17700
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

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

EBU19200
PRE-OPERATION CHECKS
EBU19223
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

EBU19540
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.
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 8-19.)
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.
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 8-33.) 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,

8-5
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 neces-
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.
√√√√
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

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

8-14
1
2
3
4
5
6
78
9
10
11
TIP

If a torque wrench is not available when installing
a spark plug, a good estimate of the correct torque
is 1/4–1/2 turn past finger tight. However, the spark
plug should be tightened to the specified torque as
soon as possible.
EBU29492
Engine oil and oil filter element
The engine oil level should be checked before
each ride. In addition, the oil must be changed and
the oil filter element replaced at the intervals spec-
ified in the periodic maintenance and lubrication
chart.
To check the engine oil level
1. Place the ATV on a level surface.
2. Start the engine, warm it up until the engine oil
has reached a normal temperature of 40 °C
(104 °F), let it continue to idle for ten seconds
or more, and then turn the engine off.
TIP

To achieve the proper engine oil temperature for
an accurate oil level reading, the engine must have
first completely cooled down, and then warmed up
again for several minutes to normal operating tem-
perature.
3. Remove the engine oil tank filler cap, and
wipe the dipstick off with a clean rag.
4. Insert the dipstick into the filler hole (without
screwing it in), and then remove it again to
check the oil level.TIP

The engine oil should be between the minimum
1. Engine oil tank filler cap
2. Dipstick
3. Maximum level mark
4. Minimum level mark
11
2
3
4