2011 YAMAHA YFZ450R clutch

EBU17420
TABLE OF CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................ 1-1
SAFETY INFORMATION .............................. 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 ................................................ 4-5
Brake lever ................................................. 4-6
Brake pedal ................................................ 4-6
Parking brake lever .................................... 4-7
Shift pedal .................................................. 4-8
Fuel tank cap .............................................. 4-8
Fuel ............................................................ 4-9Seat ..........................................................4-10
Adjusting the front shock absorber
assemblies ..............................................4-11
Adjusting the rear shock absorber
assembly .................................................4-16
Handlebar position ....................................4-24
PRE-OPERATION CHECKS ..........................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
Chassis fasteners .......................................5-7
Instruments, lights and switches .................5-7
OPERATION...................................................6-1
Starting the engine ......................................6-1
Shifting ........................................................6-2
Engine break-in ...........................................6-4
Parking ........................................................6-4
Parking on a slope ......................................6-5U18P64E0.book Page 1 Thursday, May 13, 2010 6:00 PM

Accessories and loading ............................ 6-6
RIDING YOUR ATV ...................................... 7-1
GETTING TO KNOW YOUR ATV............... 7-2
RIDE WITH CARE AND GOOD
JUDGMENT .............................................. 7-2
BE CAREFUL WHERE YOU RIDE ............. 7-9
TURNING YOUR ATV .............................. 7-12
CLIMBING UPHILL ................................... 7-13
RIDING DOWNHILL.................................. 7-16
CROSSING A SLOPE............................... 7-18
CROSSING THROUGH SHALLOW
WATER ................................................... 7-19
RIDING OVER ROUGH TERRAIN ........... 7-20
SLIDING AND SKIDDING ......................... 7-21
WHAT TO DO IF... .................................... 7-22
WHAT TO DO... ........................................ 7-22
PERIODIC MAINTENANCE AND
ADJUSTMENT ............................................... 8-1
Owner’s manual and tool kit ....................... 8-2
Periodic maintenance chart for
the emission control system ..................... 8-3
General maintenance and
lubrication chart ........................................ 8-5
Removing and installing the cowling and
panels ....................................................... 8-9Checking the spark plug ...........................8-12
Engine oil and oil filter element .................8-13
Coolant .....................................................8-19
Cleaning the air filter element ...................8-20
Cleaning the spark arrester ......................8-24
Adjusting the throttle lever free play .........8-26
Valve clearance ........................................8-27
Brakes .......................................................8-27
Checking the front and rear brake pads ...8-27
Checking the brake fluid level ...................8-29
Changing the brake fluid ...........................8-30
Checking the front brake lever free play ...8-30
Checking the brake pedal height ..............8-30
Adjusting the parking brake free play .......8-31
Brake light switches ..................................8-32
Adjusting the clutch lever free play ...........8-33
Drive chain slack .......................................8-34
Lubricating the drive chain ........................8-36
Checking and lubricating the cables .........8-37
Checking and lubricating the brake and
clutch levers ............................................8-38
Checking the shift pedal ...........................8-38
Checking and lubricating the brake
pedal .......................................................8-38
Checking the wheel hub bearings .............8-39
Lubricating the swingarm pivots ...............8-39
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3-2
3
EBU17712Controls and instrumentsTIPThe ATV you have purchased may differ slightly
from the figures shown in this manual.1. Clutch lever
2. Parking brake lever
3. Handlebar switches
4. Fuel tank cap
5. Main switch
6. Front brake fluid reservoir
7. Throttle lever
8. Brake lever
2
1
3
7
6
5
8
4
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4-5
4
EBU18323Speed limiter Your ATV is equipped with an adjustable speed
limiter. The speed limiter keeps the throttle from
fully opening, even when the throttle lever is
pushed to the maximum.
1. Loosen the locknut.
2. To increase the maximum engine power avail-
able and the maximum speed of the ATV, turn
the adjusting screw in direction (a). To de-
crease the maximum engine power available
and the maximum speed of the ATV, turn the
adjusting screw in direction (b). Do not turn
the adjusting screw out more than 12 mm
(0.47 in) or the throttle cable could be dam-
aged. Always make sure the throttle lever free
play is adjusted to 2.0–4.0 mm (0.08–0.16 in).
(See page 8-26.) WARNING! Improper ad-
justment of the speed limiter and throttle
could cause throttle cable damage or im-
proper throttle operation. You could lose
control, resulting in an accident.
[EWB00241]
3. Tighten the locknut.EBU18382Clutch lever The clutch lever is located on the left handlebar
and the ignition circuit cut-off system is incorporat-
ed in the clutch lever holder. To disengage the
clutch, pull the clutch lever toward the handlebar
grip. To engage the clutch, release the clutch lever.
The clutch lever should be pulled rapidly and re-1. Locknut
2. Adjusting screw
3. No more than 12 mm (0.47 in)
3
1
2
(a)
(b)
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4-6
4 leased slowly for smooth clutch operation. (See
page 6-1 for a description of the ignition circuit cut-
off system.)
EBU18423Brake lever The brake lever is located on the right handlebar.
To apply the front brake, pull the brake lever to-
ward the handlebar grip.
The brake lever is equipped with a position adjust-
ing bolt. To adjust the distance between the brake
lever and the handlebar grip, hold the brake lever
away from the handlebar so it does not contact the
adjusting bolt, loosen the locknut, turn the adjust-
ing bolt, and then tighten the locknut.
EBU18432Brake pedal The brake pedal is located on the right side of the
ATV. To apply the rear brake, push down on the
brake pedal.
1. Clutch lever
1. Brake lever
2. Locknut
3. Brake lever position adjusting bolt
4. Distance between brake lever and handlebar grip
1
4
23
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4-8
4
WARNING
EWB00220
Always set the parking brake before starting
the engine. The ATV could start moving un-
expectedly if the parking brake is not ap-
plied. This could cause loss of control or a
collision.
Always be sure you have released the park-
ing brake before you begin to ride. The brake
could overheat if you ride the ATV without re-
leasing the parking brake. You could lose
braking performance which could cause an
accident. You could also wear out the brakes
prematurely.EBU18530Shift pedal This ATV is equipped with a constant-mesh 5-
speed transmission. The shift pedal is located on
the left side of the engine and is used in combina-
tion with the clutch when shifting.
EBU18720Fuel tank cap Remove the fuel tank cap by turning it counter-
clockwise.1. Shift pedal
1
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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, 8-27, 8-29, 8-30
Rear 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, 8-27, 8-29, 8-30
ClutchCheck operation, and correct if necessary.
Lubricate cable if necessary.
Check lever free play, and adjust if necessary.8-33
Throttle leverMake sure that operation is smooth. Lubricate cable and lever hous-
ing if necessary.
Check lever free play, and adjust if necessary.5-5, 8-26
Control cablesMake sure that operation is smooth. Lubricate if necessary. 8-37
Drive chainCheck chain slack, and adjust if necessary.
Check chain condition. Lubricate if necessary.5-5, 8-34, 8-36
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
Shift pedalMake sure that operation is smooth.
Correct if necessary.8-38
Brake pedal Make sure that operation is smooth. Lubricate pedal pivoting point if
necessary.8-38 ITEM ROUTINE PAGE
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5-3
5
Brake and clutch leversMake sure that operation is smooth. Lubricate lever pivoting points if
necessary.8-38
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 PAGEU18P64E0.book Page 3 Thursday, May 13, 2010 6:00 PM