2013 YAMAHA YFZ450R check engine

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 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 ............................................................ 4-9 Seat ..........................................................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 ......................................6-5U18P67E0.book Page 1 Wednesday, May 9, 2012 3:30 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 ....................................................... 8-9 Checking the spark plug ...........................8-15
Engine oil and oil filter element .................8-16
Coolant .....................................................8-22
Cleaning the air filter element ...................8-23
Cleaning the spark arrester ......................8-27
Adjusting the throttle lever free play .........8-29
Valve clearance ........................................8-30
Brakes .......................................................8-30
Checking the front and rear brake pads ...8-30
Checking the brake fluid level ...................8-32
Changing the brake fluid ...........................8-33
Checking the front brake lever free play ...8-33
Checking the brake pedal height ..............8-34
Adjusting the parking brake free play .......8-34
Brake light switches ..................................8-36
Adjusting the clutch lever free play ...........8-36
Drive chain slack .......................................8-38
Lubricating the drive chain ........................8-40
Checking and lubricating the cables .........8-40
Checking and lubricating the brake and
clutch levers ............................................8-41
Checking the shift pedal ...........................8-42
Checking and lubricating the brake pedal .......................................................8-42
Checking the wheel hub bearings .............8-42
Lubricating the swingarm pivots ...............8-43
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2
In the event of an accident
1. If serious injuries are incurred, you may be safer staying next to your vehicle; it may
shield you from oncoming riders. Depending
on your injuries and position in the trail; you
must make a judgment call as to whether you
should move to a position off the trail. If you
have sustained head, neck, or back injuries,
or cannot feel your limbs, you should not
move. Keep your helmet on and remain mo-
tionless. Lie down next to your vehicle and
wait for help.
2. If less serious injuries are incurred and you can walk, then move to a position off the trail.
Check yourself for injuries and apply first aid
as needed.
3. If your injuries are light, when safe to do so, move your vehicle off the trail to avoid colli-
sions with oncoming riders. Check for injuries
and apply first aid as necessary. If you can
physically operate your vehicle, inspect your
vehicle. If the vehicle is in safe operating con-
dition and you can safely operate it, restart it
and ride gently back to camp or other known
location where you can receive medical atten- tion. If necessary, contact your riding party or
local authorities to let them know where you
are and what has happened.
In the event of a breakdown 1. If your vehicle will not restart or is not in safe operating condition, turn off the main switch
and engine stop switch. If the breakdown oc-
curs at twilight or night, leave the main switch
on so that your lights may warn other riders of
your stopped vehicle.
2. Get out of danger. Check for oncoming vehi- cles and when safe, push your vehicle to the
side of the trail or even off the main trail to
avoid any possible collisions with oncoming
riders. If you cannot move your vehicle by
yourself, when safe, walk to the nearest van-
tage point and signal an oncoming rider to
help you push your vehicle to a safe place off
the trail.
3. Inspect your vehicle for any immediate haz- ardous conditions. The most obvious hazard-
ous conditions are leaking fuel and
ungrounded or broken wiring. Visually check
for broken wiring and leaking fuel. Leaking
fuel can be confirmed by the odor of gasoline.
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24. Once immediate safety hazards are con-
firmed not to exist, you may remove your hel-
met to more closely inspect your vehicle.
Check for external signs of wear, broken
parts, fluid leaks, cracks in the frame, suspen-
sion damage, wheel damage, and so on. Fuel,
oil, and coolant usually give off a noticeable
odor.
5. If your vehicle will not restart or if it is unsafe to ride, then turn off all vehicle systems (en-
gine stop switch, main switch, and fuel cock),
and then signal or go for help.
Aftermarket Parts, Accessories, and Modifica-
tions
While you may find aftermarket products similar in
design and quality to genuine Yamaha accesso-
ries, recognize that some aftermarket accessories
or modifications are not suitable because of poten-
tial safety hazards to you or others. Installing after-
market products or having other modifications
performed to your vehicle that change any of the
vehicle’s design or operation characteristics can
put you and others at greater risk of serious injury
or death. You are responsible for injuries related to changes in the vehicle. Keep the following guide-
lines in mind, as well as those provided under
“Loading” when mounting accessories.
●Never install accessories that would impair the
performance of your ATV. Carefully inspect the
accessory before using it to make sure that it
does not in any way reduce ground clearance,
limit suspension travel, steering travel or control
operation.●Accessories fitted to the ATV can create instabil-
ity due to improper weight distribution.●Bulky or large accessories may seriously affect
the stability of the ATV.●Certain accessories can displace the operator
from his or her normal riding position. This im-
proper position limits the freedom of movement
of the operator and may limit control ability,
therefore, such accessories are not recom-
mended.●Use caution when adding electrical accessories.
If electrical accessories exceed the capacity of
the ATV’s electrical system, an electric failure
could result, which could cause a dangerous
loss of lights or engine power.
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EBU29382Indicator light and warning lights EBU17860Neutral indicator light “ ”
This indicator light comes on when the transmis-
sion is in the neutral position.
EBU29921Coolant temperature warning light “ ”
This warning light comes on when the engine over-
heats. When this occurs during operation, stop the
engine as soon as it is safe to do so and allow it to
cool down for about 10 minutes.
The electrical circuit of the warning light can be
checked by turning the key to “ ” (on). The warn-
ing light should come on for a few seconds, and
then go off.
If the warning light does not come on initially when
the key is turned to “ ” (on), or if the warning light
remains on, have a Yamaha dealer check the elec-
trical circuit.NOTICEECB00010●The engine may overheat if the ATV is over-
loaded. In this case, reduce the load to spec-
ification.●Start the engine after making sure that the
warning light is out. Continuous use while
the warning light is on may cause damage to
the engine.
1. Fuel level warning light “ ”
2. Engine trouble warning light “ ”
3. Coolant temperature warning light “ ”
4. Neutral indicator light “N”
12 3 4
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EBU29931Fuel level warning light “ ”
This warning light comes on when the fuel level
drops below approximately 3.4 L (0.90 US gal,
0.75 Imp.gal). When this occurs, refuel as soon as
possible.
The electrical circuit of the warning light can be
checked by setting the engine stop switch to “ ”
and turning the key to “ ” (on). The warning light
should come on for a few seconds, and then go off.
If the warning light does not come on initially when
the key is turned to “ ” (on), or if the warning light
remains on, have a Yamaha dealer check the elec-
trical circuit.EBU29942Engine trouble warning light “ ”
This warning light comes on or flashes when an
electrical circuit monitoring the engine is not work-
ing correctly. When this occurs, have a Yamaha
dealer check the self-diagnosis system.
The electrical circuit of the warning light can be
checked by turning the key to “ ” (on). The warn-
ing light should come on for a few seconds, and
then go off.If the warning light does not come on initially when
the key is turned to “ ” (on), or if the warning light
remains on, have a Yamaha dealer check the elec-
trical circuit.
EBU18061Handlebar switches EBU18080Engine stop switch “ / ”
Set this switch to “ ” before starting the engine.
The engine stop switch controls the ignition and
stops the engine when it is running. Use this switch1. Light switch “ / /OFF”
2. Engine stop switch “ / ”
3. Start switch “ ”
1
23
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to stop the engine in an emergency situation. The
engine will not start or run when this switch is set
to “ ”.
EBU18101Start switch “ ”
Push this switch to crank the engine with the start-
er. See the starting instructions on page 6-1 prior
to starting the engine.EBU18154Light switch “ / /OFF”
Set this switch to “ ” to turn on the low beams
and the taillight. Set the switch to “ ” to turn on
the high beams and the taillight. Set the switch to
“OFF” to turn off all the lights.NOTICEECB00043Do not use the headlights with the engine
turned off for an extended period of time, oth-
erwise the battery may discharge to the point
that the starter motor will not operate properly.
If this should happen, remove the battery and
recharge it. (See page 8-45.)
EBU18282Throttle lever Once the engine is running, pushing the throttle le-
ver will increase the engine speed.
Regulate the speed of the ATV by varying the
throttle position. Because the throttle is spring-
loaded, the ATV will decelerate, and the engine will
return to an idle any time the throttle lever is re-
leased.
Before starting the engine, check the throttle to be
sure it is operating smoothly. Make sure it returns
to the idle position as soon as the lever is released.1. Throttle lever
1
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EBU19201
PRE-OPERATION CHECKS
EBU19224Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always
follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
EWB00481Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equip-
ment damage. Do not operate the vehicle if you find any problem. If a problem cannot be corrected
by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer.Before using this vehicle, check the following points:
ITEMROUTINE 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 oil tank, and add recommended oil to spec-
ified level if necessary.
Check ATV for oil leakage. Correct if necessary. 5-4, 8-16
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, 8-22
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