2013 YAMAHA YFZ450 maintenance

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EBU27111Owner’s manual and tool kit Be sure to put this owner’s manual in the plastic
bag and to always carry it as well as the owner’s
tool kit and the low-pressure tire gauge in their re-
spective compartments under the seat.
The service information included in this manual
and the tools provided in the owner’s tool kit are in-
tended to assist you in the performance of preven-
tive maintenance and minor repairs. However,additional tools such as a torque wrench may be
necessary to perform certain maintenance work
correctly.
TIPIf you do not have the tools or experience required
for a particular job, have a Yamaha dealer perform
it for you.
1. Low-pressure tire gauge
2. Owner’s tool kit
3. Owner’s manual
3
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U1PD61E0.book Page 2 Tuesday, February 14, 2012 10:06 AM

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EBU21743Periodic maintenance chart for the emission control system TIP●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 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 *Fuel line Check fuel hoses for cracks or other damage, and
replace if necessary. √√√
2 Spark plug Check condition and clean, regap, or replace if
necessary. √√√√√
3 *Valves Check valve clearance and adjust if necessary. √ √√√
4 *Carburetor Check starter (choke) operation and correct if nec-
essary.
Check engine idling speed and adjust if neces- sary. √√√√
5 *Crankcase breather
system Check breather hose for cracks or other damage,
and replace if necessary. √√√
U1PD61E0.book Page 3 Tuesday, February 14, 2012 10:06 AM

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6*Exhaust system Check for leakage and replac
e gasket(s) if neces-
sary.
Check for looseness and tighten all screw clamps and joints if necessary. √√√
7 Spark arrester Clean. √√√
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 320U1PD61E0.book Page 4 Tuesday, February 14, 2012 10:06 AM

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EBU21865General maintenance and lubrication chart TIP●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 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
U1PD61E0.book Page 5 Tuesday, February 14, 2012 10:06 AM

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5*Brake hoses Check for cracks or other damage, and replace if
necessary. √√√√
Replace. Every 4 years
6 *Parking brake Check operation and adjust if necessary. √√√√√
7 *Wheels Check runout and for damage, and replace if nec-
essary. √ √√√
8 *Tires Check tread depth and for damage, and replace if
necessary.
Check air pressure and balance, and correct if necessary. √ √√√
9 *Wheel hub bearings Check for looseness or damage, and replace if
necessary. √ √√√
10 *Swingarm pivots Check operation and for excessive play, and re-
place 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. √√√
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 320U1PD61E0.book Page 6 Tuesday, February 14, 2012 10:06 AM

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14*Chassis fasteners Make sure that all nuts, bolts, and screws are
properly tightened. √√√√√
15 *Shock absorber as-
semblies Check operation and correct if necessary.
Check for oil leakage and replace if necessary.
√√√
16 *Rear suspension re-
lay arm and con-
necting arm
pivoting 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. √√√
20 Engine oil Change.
Check ATV for oil leakage, and correct if neces-
sary. √ √√√
21 Engine 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
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 320U1PD61E0.book Page 7 Tuesday, February 14, 2012 10:06 AM

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EBU23071TIP●Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or
muddy areas, or at full-throttle.●Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinders and calipers, andchange the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.23 *Moving parts and
cables Lubricate.
√√√√
24 *Throttle lever Check operation.
Check throttle lever free play, and adjust if neces-
sary.
Lubricate cable and lever housing. √√√√√
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. 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 320U1PD61E0.book Page 8 Tuesday, February 14, 2012 10:06 AM

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EBU23080Removing and installing the panel The panel shown needs to be removed to perform
some of the maintenance jobs described in this
chapter. Refer to this section each time the panel
needs to be removed and installed.EBU23180Panel A
To remove the panel1. Remove the seat. (See page 4-12.)
2. Remove the quick fastener screw and thebolts, and then remove the panel by pulling it
out from the front of the ATV.1. Panel A
1
1. Quick fastener screw
2. Bolt
1. Bolt
1
2
1
U1PD61E0.book Page 9 Tuesday, February 14, 2012 10:06 AM