2010 YAMAHA YFZ450R clutch

6-1
6
EBU19882
OPERATION
EBU19902Read the Owner’s Manual carefully before riding
the ATV. If there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING
EWB00632Read 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. EBU29953Starting the engineNOTICEECB00151See 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 stopswitch to “ ”.
The following warning lights should come on
for a few seconds, then go off. 
Coolant temperature warning light
 Fuel level warning light
 Engine trouble warning light
NOTICEECB00825If a warning light does not go off, see page 4-2
for the corresponding warning light circuit
check. To avoid possible damage, do not oper-
ate the ATV if a warning light stays on. 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.TIPThis model is equipped with an ignition circuit cut-
off system. The engine can be started under the
following conditions.
The transmission is in neutral.
 The clutch is disengaged with the transmission
in gear. However, it is recommended to shift
into neutral before starting the engine.
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6-2
64. Completely close the throttle lever and start
the engine by pushing the start switch.
TIPIf the engine fails to start, release the start switch,
then push it again. Pause a few seconds before
the next attempt. Each cranking should be as
short as possible to preserve battery energy. Do
not crank the engine more than 10 seconds on
each attempt. NOTICEECB00164For maximum engine life, never accelerate
hard when the engine is cold! EBU20525ShiftingThis ATV has a 5-speed forward transmission. The
transmission allows you to control the amount of
power you have available at a given speed or for
starting, accelerating, climbing hills, etc.
To shift into neutral, release the throttle lever, ap-
ply the clutch, and then repeatedly depress the
shift pedal until it stops. When it stops, it will be in first gear. Raise the ped-
al slightly to reach the neutral position, and then
release the clutch.
EBU20595To start out and accelerate
1. Release the throttle lever, apply the front or rear brake, and then release the parking
brake.
2. Pull the clutch lever to disengage the clutch.1. Shift pedal
2. Neutral position
1
2 2 3
4 5
N1
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6-3
6
3. Shift into first gear, and then release the
brake. NOTICE: Always close the throttle
before shifting gears, otherwise damage
to the engine and drive train may result.
[ECB01220]
4. Open the throttle gradually and at the same time, release the clutch lever slowly.
WARNING! Opening the throttle abruptly or releasing the clutch lever too quickly
could make the ATV wheelie, which would
increase the chance of an accident, in-
cluding an overturn.
[EWB00732]
5. Once the ATV has attained adequate speed, release the throttle, and at the same time,
quickly pull in the clutch lever.
6. Shift the transmission into second gear. (Make sure not to shift the transmission into
neutral.)
7. Open the throttle part way and gradually re- lease the clutch lever.
8. Follow the same procedure when shifting to the next higher gear.
EBU20652To decelerate
When slowing down or stopping, release the
throttle and apply the brakes smoothly and evenly.
As you slow down, shift to a lower gear. Be sure
that the engine has sufficiently slowed before en-
gaging a lower gear. Improper use of the brakes or
shifting can cause the tires to lose traction, reduc-
ing control and increasing the possibility of an ac-
cident.
WARNING
EWB00711Make sure the engine has sufficiently slowed
before shifting to a lower gear. Engaging a low-
er gear when the engine speed is too high
could make the wheels stop rotating and lose
traction. This could cause loss of control, an
accident and injury. It could also cause engine
or drive train damage. NOTICEECB00181Even with the transmission in the neutral po-
sition, do not coast for long periods of time
with the engine off, and do not tow the ATV
for long distances. The transmission is prop-
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6-4
6erly lubricated only when the engine is run-
ning. Inadequate lubrication may damage
the transmission.
 Always use the clutch when changing gears.
The engine, transmission and drive train are
not designed to withstand the shock of
forced shifting and can be damaged by shift-
ing without using the clutch.
EBU20673Engine break-inTIPFor ATVs equipped with an odometer or an hour
meter, follow the figures given in km (mi) or the
figures given in hours.
 For ATVs not equipped with an odometer or
hour meter, follow the figures given in hours. There is never a more important period in the life
of your engine than the first 320 km (200 mi) or 20
hours of riding. For this reason, you should read
the following material carefully.
Since the engine is brand new, do not put an ex-
cessive load on it for the first 320 km (200 mi) or
20 hours. The various parts in the engine wear and
polish themselves to the correct operating clear- ances. During this period, prolonged full-throttle
operation or any condition that might result in en-
gine overheating must be avoided.
0–160 km (0–100 mi) or 0–10 hours
Avoid prolonged operation above 1/2 throttle.
Vary the speed of the ATV regularly. Do not oper-
ate it at one set throttle position.
160–320 km (100–200 mi) or 10–20 hours
Avoid prolonged operation above 3/4 throttle. Rev
the engine through the gears freely, but do not use
full throttle at any time.
320 km (200 mi) or 20 hours and beyond
The ATV can now be operated normally.
NOTICEECB00221If any engine trouble should occur during the
engine break-in period, immediately have a
Yamaha dealer check the ATV. EBU26762ParkingWhen parking the ATV, shift into first gear, stop
the engine, and then apply the parking brake.
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7-11
7Select a large, flat, unpaved area to become famil-
iar with your ATV. Make sure that this area is free
of obstacles and other riders. You should practice
control of the throttle, brakes, shifting procedures,
and turning techniques in this area before trying
more difficult terrain.
Set the parking brake and follow the instruction on
page 6-1 to start the engine. Once it has warmed
up you are ready to begin riding your ATV. As you
get on the ATV, be sure not to accidentally move
the shift pedal. With the engine idling, pull the
clutch lever to disengage the clutch and shift into
1st gear, and then release the parking brake.
Open the throttle gradually, and at the same time,
release the clutch lever slowly. Once the ATV has
attained adequate speed, release the throttle lever
and at the same time, quickly pull in the clutch le-
ver and shift into 2nd gear. Open the throttle part
way and gradually release the clutch.
WARNING!
If the throttle is applied too abruptly or if the
throttle is not released during shifting, or if the
shift pedal is not released before applying the
throttle, the front wheels may lift off the
ground, resulting in a loss of directional con- trol.
[EWB02632]

NOTICE: Do not shift gears without
releasing the throttle. Damage to the engine or
drive train may occur.
[ECB01072]
Use this same procedure as you move into the
higher gears. Be sure to coordinate the use of the
throttle and shift pedal properly.
Avoid higher speeds until you are thoroughly fa-
miliar with the operation of your ATV.
When slowing down or stopping, release the
throttle and apply the brakes smoothly and evenly.
As you slow down, shift to a lower gear. Be sure
that the engine has sufficiently slowed before en-
gaging a lower gear. Improper use of the brakes or
shifting can cause the tires to lose traction, reduc-
ing control and increasing the possibility of an ac-
cident.
TURNING YOUR ATV
WARNING
EWB01772Always follow proper procedures for turning as
described in this Owner’s Manual. Practice
turning at low speeds before attempting to turn
at faster speeds. Do not turn at speeds too fast
for your skills or the conditions. ATV could go
out of control, causing a collision or overturn.
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8-5
8
EBU21868General maintenance and lubrication chartTIPFor ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
 For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter-
vals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance
intervals should still be followed.
 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills. NO. ITEM CHECK OR MAINTENANCE
JOB INITIAL
EVERY
Whichev-
er comes first month136612
km (mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 320
1 Air filter element • Clean and replace if necessary. Every 20–40 hours (more often in wet or
dusty areas)
2 *Clutch • Check operation and adjust if necessary. √ √√√
3 *Front brake • Check operation and correct if necessary.
• Check fluid level and ATV for fluid leakage, and
correct if necessary. √√√√√
• Replace brake pads. Whenever worn to the limit
4 *Rear brake • Check operation and correct if necessary.
• Check fluid level and ATV for fluid leakage, and
correct if necessary. √√√√√
• Replace brake pads. Whenever worn to the limit
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8-19
811. Install the crankcase engine oil drain bolt, the
engine oil tank drain bolt and their new gas-
ket, and then tighten the bolts to their speci-
fied torques.
12. Refill with the specified amount of the recom- mended engine oil through the engine oil tank
filler hole, and then install and tighten the en-
gine oil tank filler cap.
TIPBe sure to wipe off spilled oil on any parts after the
engine and exhaust system have cooled down. NOTICEECB00301In order to prevent clutch slippage (since the
engine oil also lubricates the clutch), do not
mix any chemical additives. Do not use oils
with a diesel specification of “CD” or oils of
a higher quality than specified. In addition,
do not use oils labeled “ENERGY CONSERV-
ING II” or higher.
 Make sure that no foreign material enters the
crankcase. 13. Start the engine, and then let it idle for several
minutes while checking it for oil leakage. If oil
is leaking, immediately turn the engine off and
check for the cause.
14. Turn the engine off, and then check the oil level and correct it if necessary.
Tightening torques:
Crankcase engine oil drain bolt:20 Nm (2.0 m·kgf, 14 ft·lbf)
Engine oil tank drain bolt: 20 Nm (2.0 m·kgf, 14 ft·lbf)
Recommended oil: See page 10-1.
Oil quantity: Without oil filter element replacement:1.40 L (1.48 US qt, 1.23 Imp.qt)
With oil filter element replacement: 1.45 L (1.53 US qt, 1.28 Imp.qt)
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8-34
8
The brake light switch for the brake pedal can be
adjusted as follows, but the front brake light
switch should be adjusted by a Yamaha dealer.
Turn the rear brake light switch adjusting nut while
holding the brake light switch in place. To make
the brake light come on earlier, turn the adjusting
nut in direction (a). To make the brake light come
on later, turn the adjusting nut in direction (b).
EBU30153Adjusting the clutch lever free playThe clutch lever free play must be checked and, if
necessary, adjusted at the intervals specified in
the periodic maintenance and lubrication chart. The clutch lever free play should measure 8.0–
13.0 mm (0.31–0.51 in) as shown. If the free play is
incorrect, adjust it as follows.
1. To increase the clutch lever free play, turn the clutch lever free play adjusting nut at the
clutch lever in direction (a), and to decrease it,
turn the nut in direction (b).
If the specified free play cannot be obtained,
proceed with the following steps.
2. Fully turn the adjusting nut at the clutch lever in direction (a) to loosen the clutch cable.
3. Slide the rubber cover back.
4. Loosen the locknut.1. Rear brake light switch
2. Rear brake light switch adjusting nut
1
2(a) (b)
1. Clutch lever free play
2. Clutch lever free play adjusting nut (clutch lever)
1
(a)
(b)
2
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