2012 YAMAHA YFZ450 fuel cap

EBU17420
TABLE OF CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................ 1-1
SAFETY INFORMATION .............................. 2-1
DESCRIPTION .............................................. 3-1Left 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 .................. 4-2
Handlebar switches .................................... 4-3
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 .............................................. 4-8
Fuel ............................................................ 4-8 Fuel cock ..................................................4-10
Starter (choke) ..........................................4-11
Seat ..........................................................4-12
Adjusting the front shock absorber
assemblies ..............................................4-13
Adjusting the rear shock absorber assembly .................................................4-14
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 a cold engine .................................6-1
Starting a warm engine ...............................6-3
Shifting ........................................................6-3
Engine break-in ...........................................6-5U1PD60E0.book Page 1 Monday, June 13, 2011 2:57 PM

1-5
1
**.* kPa
*.** kgf/cm²*.* psi **.* kPa
*.** kgf/cm²
*.* psi
NEVER use with drugs or alcohol.
NEVER store fuel or flammable liquids.
This unit contains high-pressure nitrogen
gas.
Mishandling can cause an explosion. Do not
incinerate, puncture or open.
Use unleaded gasoline only.
Measure the tire pressure when the tires are
cold. Adjust the tire pressure.
Improper tire pressure can cause loss of
control.
Loss of control can result in severe injury or
death.
Turning the ATV in 4WD-LOCK
(“DIFF.LOCK”) takes more effort.
Operate at a slow speed and allow extra
time and distance for maneuvers to avoid
loss of control.
This pictogram shows the loading limits
and/or maximum load capacity for this ATV.
Follow all load limits and other loading
guidelines in this manual.
Load may include the driver, passenger,
human protective gear, accessories, goods,
luggage, and all other load related items.
Make sure you do not exceed the load limits.
Overloading can cause loss of control.
Loss of control can result in severe injury or
death.
U1PD60E0.book Page 5 Monday, June 13, 2011 2:57 PM

3-1
3
EBU17680
DESCRIPTION
EBU17690Left view
EBU17700Right view
1. Headlights
2. Fuel cock
3. Starter (choke)
4. Fuse
5. Tail/brake light
6. Coolant reservoir
7. Shift pedal
8. Engine oil tank
123 45
6
7
8
1. Spark arrester
2. Seat
3. Fuel tank cap
4. Radiator cap
5. Oil filter element
6. Brake pedal1
23
4
5
6
U1PD60E0.book Page 1 Monday, June 13, 2011 2:57 PM

4-8
4
EBU18720Fuel tank cap Remove the fuel tank cap by turning it counter-
clockwise.
EBU18814Fuel Make sure there is sufficient gasoline in the tank.
WARNING
EWB02521Gasoline and gasoline vapors are extremely
flammable. To avoid fires and explosions and
to reduce the risk of injury when refueling, fol-
low these instructions.1. Before refueling, turn off the engine and besure that no one is sitting on the vehicle. Nev-
er refuel while smoking, or while in the vicinity
1. Shift pedal
1
1. Fuel tank cap
1
U1PD60E0.book Page 8 Monday, June 13, 2011 2:57 PM

4-9
4of sparks, open flames, or other sources of ig-
nition such as the pilot lights of water heaters
and clothes dryers.
2. Do not overfill the fuel tank. When refueling, be sure to insert the pump nozzle into the fuel
tank filler hole. Stop filling when the fuel reach-
es the bottom of the filler tube. Because fuel
expands when it heats up, heat from the en-
gine or the sun can cause fuel to spill out of
the fuel tank.
3. Wipe up any spilled fuel immediately.NOTICE: Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since fuel may
deteriorate painted surfaces or plastic
parts.
[ECB00981]
4. Turn the fuel tank cap fully clockwise to make sure it is securely closed.
WARNING
EWB02531Gasoline is poisonous and can cause injury or
death. Handle gasoline with care. Never siphon
gasoline by mouth. If you should swallow
some gasoline or inhale a lot of gasoline vapor,
or get some gasoline in your eyes, see your
1. Maximum fuel level
2. Fuel tank filler tube
Recommended fuel:PREMIUM UNLEADED GASOLINE ONLY
For Europe: PREMIUM UNLEADED GASO-
LINE ONLY with a research octane number
of 97 or higher
Fuel tank capacity: 10.0 L (2.64 US gal, 2.20 Imp.gal)
Fuel reserve amount: 1.9 L (0.50 US gal, 0.42 Imp.gal)
U1PD60E0.book Page 9 Monday, June 13, 2011 2:57 PM

8-11
8
To remove the spark plug
1. Remove the seat. (See page 4-12.)
2. Remove the bolts and the quick fastener screws shown.
3. Remove the fuel tank cap by turning it coun- terclockwise. WARNING! Never remove the
fuel tank cap while smoking, or in the vi-
cinity of sparks, open flames, or other
sources of ignition such as pilot lights of
water heaters and clothes dryers. Always
turn off the engine before removing the
fuel tank cap. Do not remove the fuel tank
cap immediately after the engine has been
running, as it is still very hot. Do not spill
gasoline on the engine, exhaust pipe or
muffler.
[EWB01871]
4. Pull the panel backward, and then remove the panel.
5. Install the fuel tank cap by turning it clockwise.
6. Remove the bolt, and then lift the rear of the fuel tank while sliding the tank slightly rear-
ward.1. Panel
2. Bolt
3. Quick fastener screw
4. Fuel tank cap
2
4 3 1
U1PD60E0.book Page 11 Monday, June 13, 2011 2:57 PM

8-14
8To install the spark plug
1. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any
grime from the spark plug threads.
2. Install the spark plug with the spark plug wrench, and then tighten it to the specified
torque.
TIPIf a torque wrench is not available when installing
the 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.3. Install the spark plug cap.
4. Place the fuel tank in the original position, and then install the bolt.
5. Remove the fuel tank cap by turning it coun- terclockwise.
6. Place the panel in the original position. 7. Install the fuel tank cap by turning it clockwise.
8. Install the bolts and the quick fastener screws.
9. Install the seat.
EBU23307Engine 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.
Tightening torque:
Spark plug:13 Nm (1.3 m ·kgf, 9.4 ft ·lbf)1. Projection
2. Slot
2 1
U1PD60E0.book Page 14 Monday, June 13, 2011 2:57 PM

9-2
9
EBU25933Storage Short-term
Always store your ATV in a cool, dry place and, if
necessary, protect it against dust with a porous
cover. NOTICE: Storing the ATV in a poorly ven-
tilated room or covering it with a tarp while it is
still wet, will allow water and humidity to seep
in and cause rust. To prevent corrosion, avoid
damp cellars, stables (because of the presence
of ammonia) and areas where strong chemi-
cals are stored.
[ECB00721]
Long-term
Before storing your ATV for several months: 1. Follow all the instructions in the “ Cleaning”
section of this chapter.
2. Turn the fuel cock lever to “OFF ”.
3. Drain the carburetor float chamber by loosen- ing the drain bolt; this will prevent fuel deposits
from building up. Pour the drained fuel into the
fuel tank.
4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel from deteriorat-
ing. 5. Perform the following steps to protect the cyl-
inder, piston rings, etc. from corrosion.a. Remove the spark plug cap and spark plug.
b. Pour a teaspoonful of engine oil into the spark plug bore.
c. Install the spark plug cap onto the spark plug, and then place the spark plug on the
cylinder head so that the electrodes are
grounded. (This will limit sparking during
the next step.)
d. Turn the engine over several times with the starter. (This will coat the cylinder wall with
oil.)
e. Remove the spark plug cap from the spark plug, and then install the spark plug and
the spark plug cap.
6. Lubricate all control cables and the pivoting points of all levers and pedals.
7. Check and, if necessary, correct the tire air pressure, and then block up the ATV so that
all of its wheels are off the ground. Alternative-
Specified amount:
7.5 ml of stabilizer to each liter of fuel (or 1
oz of stabilizer to each gallon of fuel)U1PD60E0.book Page 2 Monday, June 13, 2011 2:57 PM