Yamaha YFZ450SEW User Manual

This A
OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO
YFZ450SEW
5D3-28199-61
YAMAHA MOTOR CO., LTD.
PRINTED IN JAPAN
(E,F,S)
This A
OWNER’S MANUAL
YFZ450SEW
5D3-28199-61-E0
EBU17170

INTRODUCTION

EBU17320
Congratulations on your purchase of the Yamaha YFZ450SEW. This ATV represents the result of many years of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this ATV.
This manual includes important safety information. It provides information about special tech­niques and skills necessary to ride the ATV.
dures. If you have any questions regarding the operation or maintenance of your ATV, please consult a Yamaha dealer.
AN IMPORTANT SAFETY MESSAGE:
READ THIS MANUAL COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDER­STAND ALL INSTRUCTIONS.
PAY CLOSE ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV.
THIS ATV, AND ANY OTHER ATV OVER 90 cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF AGE.
THIS ATV IS A HIGH-PERFORMANCE ATV FOR OFF-ROAD USE ONLY, FOR SPORT-TYPE REC­REATIONAL AND COMPETITIVE USE BY EXPERIENCED OPERATORS.
It also includes basic maintenance and inspection proce-
EBU17330
WARNING
CAUTION:
NOTE:

IMPORTANT MANUAL INFORMATION

EBU17341
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN­JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the ATV operator, a bystander, or a person inspecting or repairing the ATV.
A CAUTION indicates special precautions that must be taken to avoid damage to the ATV.
A NOTE provides key information to make procedures easier or clearer.
* Product and specifications are subject to change without notice.
EBU17350

IMPORTANT NOTICE

EBU17370
Welcome to the Yamaha world of motor sports! This ATV is designed and manufactured for use on UNPAVED surfaces only. It is unsafe to operate this ATV on any paved surface, paved street, paved road or motorway. Please check your local riding laws and regulations before operating this ATV.
EBU17390
YFZ450SEW
OWNER’S MANUAL
©2006 by Yamaha Motor Co., Ltd.
1st edition, May 2006
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd. is expressly prohibited.
Printed in Japan.
EBU17420

TABLE OF CONTENTS

SAFETY INFORMATION .............................. 1-1
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................ 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 light ................. 4-2
Handlebar switches ................................... 4-3
Throttle lever ............................................. 4-3
Speed limiter ............................................. 4-4
Clutch lever ............................................... 4-5
Brake lever ................................................ 4-6
Brake pedal ............................................... 4-6
Parking brake lever ................................... 4-6
Shift pedal ................................................. 4-7
Fuel tank cap ............................................. 4-8
Fuel ........................................................... 4-8
Fuel cock ................................................... 4-9
Starter (choke) “ ” ................................. 4-11
Seat ......................................................... 4-11
Adjusting the front shock absorber
assemblies .............................................4-12
Adjusting the rear shock absorber
assembly ................................................4-17
PRE-OPERATION CHECKS ..........................5-1
Pre-operation check list ............................. 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
Measuring the tire pressure ....................... 5-6
Tire wear limit ............................................ 5-7
Chassis fasteners ...................................... 5-8
Instruments, lights and switches ................ 5-8
OPERATION...................................................6-1
Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-3
Shifting ....................................................... 6-3
Engine break-in .......................................... 6-5
Parking ...................................................... 6-5
Parking on a slope .................................... 6-6
Accessories and loading ........................... 6-6
RIDING YOUR ATV ......................................7-1
GETTING TO KNOW YOUR ATV.............. 7-2
RIDE WITH CARE AND GOOD
JUDGEMENT ...........................................7-2
BE CAREFUL WHERE YOU RIDE............ 7-8
TURNING YOUR ATV ............................. 7-12
CLIMBING UPHILL .................................. 7-14
RIDING DOWNHILL................................. 7-16
CROSSING A SLOPE.............................. 7-17
CROSSING THROUGH SHALLOW
WATER ..................................................7-18
RIDING OVER ROUGH TERRAIN .......... 7-20
SLIDING AND SKIDDING........................ 7-20
WHAT TO DO IF... ................................... 7-21
WHAT TO DO... ....................................... 7-21
PERIODIC MAINTENANCE AND MINOR
REPAIR.......................................................... 8-1
Owner’s manual and tool kit ...................... 8-1
Periodic maintenance and lubrication
chart ........................................................ 8-3
Removing and installing the panel ............ 8-8
Checking the spark plug ............................ 8-9
Engine oil and oil filter element ............... 8-13
Coolant .................................................... 8-19
Cleaning the air filter element .................. 8-23
Cleaning the spark arrester ..................... 8-26
Adjusting the carburetor ........................... 8-28
Checking the engine idling speed ............ 8-29
Adjusting the throttle cable free play ........ 8-29
Valve clearance ....................................... 8-30
Checking the front and rear brake
pads .......................................................8-30
Checking the brake fluid level .................. 8-31
Changing the brake fluid .......................... 8-34
Checking the front brake lever free
play ........................................................8-34
Checking the brake pedal position ........... 8-35
Adjusting the parking brake free play ...... 8-36
Brake light switches ................................. 8-37
Adjusting the clutch lever free play .......... 8-38
Drive chain slack ...................................... 8-39
Lubricating the drive chain ....................... 8-41
Checking and lubricating the cables ........ 8-42
Checking and lubricating the brake and
clutch levers ...........................................8-42
Checking and lubricating the brake and
shift pedals .............................................8-43
Checking the wheel bearings ................... 8-43
Lubricating the swingarm pivots .............. 8-44
Lubricating the upper and lower arm
pivots .....................................................8-44
Battery ..................................................... 8-45
Replacing the fuse ................................... 8-46
Replacing a headlight bulb ...................... 8-47
Adjusting a headlight beam ..................... 8-49
Replacing the tail/brake light bulb ........... 8-50
Removing a wheel ................................... 8-50
Installing a wheel ..................................... 8-50
Troubleshooting ...................................... 8-51
Troubleshooting charts ............................ 8-52
CLEANING AND STORAGE.......................... 9-1
Cleaning .................................................... 9-1
Storage ...................................................... 9-2
SPECIFICATIONS ...................................... 10-1
CONSUMER INFORMATION ...................... 11-1
Identification numbers ............................. 11-1
EBU17430

SAFETY INFORMATION

SAFETY INFORMATION
EBU17591
AN ATV IS NOT A TOY AND CAN BE HAZARD­OUS TO OPERATE.
from other vehicles, including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions:
Read this manual and all labels carefully and fol­low the operating procedures described.
Never operate an ATV without proper training or instruction.
Always follow the age recommendation: – A child under 16 years old should never oper­ate an ATV with engine size greater than 90 cc.
Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she
An ATV handles differently
does not have the abilities to operate it safely.
Never carry a passenger on an ATV.
Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, park­ing lots and paved streets.
Never operate an ATV on any paved street, paved road or motorway.
Watch carefully for other vehicles when operat­ing on unpaved public streets or roads. Make sure you know your country’s laws and regula­tions before you ride on unpaved public streets or roads.
Never operate an ATV without wearing an ap­proved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or a jacket, and long pants.
Never consume alcohol or drugs before or while operating this ATV.
Never operate at speeds too fast for your skills or the riding conditions. Always go at a speed
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1-1
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that is proper for the terrain, visibility, operating conditions, and your experience.
1
Never attempt wheelies, jumps, or other stunts.
Always inspect your ATV each time you use it to
2
make sure it is in safe operating condition. Al­ways follow the inspection and maintenance
3
procedures and schedules described in this manual.
4
Always keep both hands on the handlebars and both feet on the footrests of the ATV during op-
5
eration.
Always go slowly and be extra careful when op-
6
erating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the
7
ATV.
Never operate on excessively rough, slippery or
8
loose terrain until you have learned and prac-
9
ticed the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.
Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds and never turn at excessive speeds.
Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills
before attempting larger hills.
Always follow proper procedures for climbing hills as described in this manual. Check the ter­rain carefully before you start up any hill. Never climb hills with excessively slippery or loose sur­faces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.
Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the ve­hicle to lean sharply to one side. Go straight down the hill where possible.
Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose sur­faces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning tech­nique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.
Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stall-
1-2
ing, use the proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight up­hill. Turn the ATV around and remount, following the procedure described in this manual.
Always check for obstacles before operating in a new area.
Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obsta­cles as described in this manual.
Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to re­duce the chance of skidding or sliding out of con­trol.
Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.
Always use the size and type of tires specified in this manual.
Always maintain proper tire pressure as de­scribed in this manual.
Never modify an ATV through improper installa­tion or use of accessories.
Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow in­structions in this manual for carrying cargo or pulling a trailer. Allow greater distance for brak­ing.
EWB00061
WARNING
Always turn off the engine when refueling.
Do not refuel right after the engine has been running and is still very hot.
Do not spill gasoline on the engine or ex­haust pipe/muffler when refueling. Never re­fuel while smoking, or in the vicinity of sparks, open flames, or other sources of ig­nition such as the pilot lights of water heat­ers and clothes dryers. Gasoline can catch fire and you could be burned.
When transporting the ATV in another vehi­cle, be sure it is kept upright and that the fuel
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11
1-3
cock is in the OFF position. Otherwise, fuel may leak out of the carburetor or fuel tank.
1
Gasoline is poisonous. If you should swal­low some gasoline or inhale a lot of gasoline
2
vapor, or get some gasoline in your eyes, seek medical help immediately. If gasoline
3
spills on your skin, wash with soap and wa­ter. If gasoline spills on your clothing,
4
change your clothes.
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6
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11
EWB00070
WARNING
Always operate your ATV in an area with ade­quate ventilation. Never start or run the engine in a closed area. Exhaust fumes are poisonous
and may cause loss of consciousness and death within a short time.
1-4
EBU17660

LOCATION OF THE WARNING AND SPECIFICATION LABELS

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2-1
EBU17670
1
Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation.
2
Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace­ment label from your Yamaha dealer.
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2-2
For Europe
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2
For Europe For Oceania
3
1
YAMAHA MOTOR CO., LTD.
SHIZUOKA JAPAN
p
4GB-2155A-00
Before you operate this vehicle,
GB
read the owners manual. Lesen Sie die Bedienungsanleitung
D
bevor Sie dieses Fahrzeug fahren. Antes de conducir este vehículo,
E
lea el Manual del Propietario. Lire le manuel du propriétaire avant
F
dutiliser ce véhicule. Prima di usare il veicolo,
I
leggete il manuale di istruzioni. Voor het gebruik van dit voertuig
NL
de handleiding met aandacht lezen. Antes de utilizar este veículo,
P
leia o manual do proprietário. Innan du kör detta fordon,
S
läs handboken.
2-3
5FK-21568-00
Improper ATV use can result in SEVERE
WARNING
INJURY or DEATH.
ALWAYS USE
AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS
HELMET AND ROADS PROTECTIVE
NEVER
9
without proper training or instruction.
9
at speeds too fast for your skills or the conditions.
9
on public roads-a collision can occur with another vehicle.
9
with a passenger-passengers affect balance and steering and increase risk of losing control.
ALWAYS :
9 use proper riding techniques to avoid
vehicle overturns on hills and rough terrain and it turns.
9
avoid paved surfaces-pavement may seriously affect handling and control.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
NEVER USE
NEVER CARRY NEVER USE
GEAR
operate :
LOCATE AND READ OWNER'S MANUAL.
5FE-21568-11
OR ALCOHOL
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For Europe
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For Oceania
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11
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Use PREMIUM unleaded gasoline with min. 97 octane(RON). Nur Super Bleifrei mit Mindestoktanzahl 97 (ROZ) tanken. Utilice gasolina sin plomo que tenga como mnimo 97 octanos (RON). Utiliser une essence SUPER sans plomb un indice dÕoctane (RON) de min. 97. Utilizzare benzina PREMIUM super senza piombo con almeno 97 ottani (RON). Gebruik loodvrije SUPERBENZINE met een octaangetal (RON) van minstens 97. Utilize gasolina sem chumbo com ndice de octano mnimo de 97 (RON). Anvnd blyfri PREMIUMBENSIN av 97 oktan (RON) eller mer.
5TG-2415E-00
For Europe
Use PREMIUM unleaded gasoline with min.
97 octane(RON).
For Oceania
4
WARNING
UNDER
5TG-2415E-10
16
<
16
5FK-21697-00
2-4
Operating this ATV if you are under the age of16increases your chance of severe injury or death.
NEVER
operate this ATV if you are
under age16.
5FE-21697-01
For Europe For Oceania
5
5
1
2
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5FK-2151H-00
2-5
WARNING
NEVER ride as a
passenger.
Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.
5FE-2151H-01
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For Europe For Oceania
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3
27.5 kPa
0.275 kgf/cm
2
4.0 psi
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5
6
GB
Set with tires cold.
Bei kalten Reifen.
D
Ajuste con los
E
neumticos an fro. Pneus froid.
F
Impostare a pneumatici
I
freddi. Wanneer de banden
NL
koud zijn. Regular com pneus
P
frios. Stll in med kalla dck.
S
7
8
30 kPa
0.30 kgf/cm
4.4 psi
5TG-21696-40
7
2
27.5kPa, {0.275kgf/cm2}, 4.0psi 30kPa, {0.30kgf/cm2}, 4.4psi
24.5kPa, {0.245kgf/cm2}, 3.5psi 27kPa, {0.27kgf/cm2}, 3.9psi
30
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2-6
EBU17680
EBU17690
Left view

DESCRIPTION

EBU17700
Right view
1
2
1
1. Headlights
2. Fuel cock
3. Starter (choke)
4. Throttle stop screw
5. Fuse
6. Tail/brake light
7. Coolant reservoir
8. Shift pedal
9. Engine oil tank
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34
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6
1
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8
9
1. Spark arrester
2. Seat
3. Fuel tank cap
4. Radiator cap
5. Oil filter element
6. Brake pedal
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EBU17712
2
Controls and instruments
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2
from the figures shown in this manual.
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1. Clutch lever
2. Handlebar switches
10
3. Parking brake
4. Main switch
11
5. Throttle lever
6. Brake lever
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3
5
4
NOTE:
The ATV you have purchased may differ slightly
6
3-2
EBU17730

INSTRUMENT AND CONTROL FUNCTIONS

EBU17740
Main switch
The positions of the main switch are as follows:
ON
All electrical systems are supplied with power, and the engine can be started. The key cannot be re­moved.
OFF ON
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2
1
3
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OFF
All electrical systems are off. The key can be re­moved.
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1. Main switch
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4-1
EBU17802
Indicator light and warning light
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1. Neutral indicator light “N”
2. Coolant temperature warning light “
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EBU17860
9
Neutral indicator light “”
This indicator light comes on when the transmis-
10
sion is in the neutral position.
11
EBU17930
1
Coolant temperature warning light “”
This warning light comes on when the engine over­heats. 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.
2
The electrical circuit of the warning light can be checked according to the following procedure.
1. Set the engine stop switch to “ ” and turn the key to “ON”.
2. Shift the transmission into the neutral position or pull the clutch lever.
3. Push the start switch. If the warning light does not come on while the start switch is pushed, have a Yamaha dealer check the electrical cir­cuit.
ECB00010
CAUTION:
The engine may overheat if the ATV is over­loaded. In this case, reduce the load to spec­ification.
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.
4-2
EBU18060
Handlebar switches
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2
3
1. Light switch “LIGHTS”
2. Engine stop switch “ENG. STOP”
3. Start switch “START”
EBU18070
Engine stop switch ENG. STOP
Set this switch to “RUN” before starting the engine. The engine stop switch controls the ignition and stops the engine when it is running. Use this switch to stop the engine in an emergency situation. The engine will not start or run when this switch is set to “OFF”.
EBU18090
Start switch START
Push this switch to crank the engine with the start­er.
ECB00050
CAUTION:
See the starting instructions on page 6-1 prior to starting the engine.
EBU18120
Light switch LIGHTS
Set this switch to “LO” to turn on the low beams and the taillight. Set the switch to “HI” to turn on the high beams and the taillight. Set the switch to “OFF” to turn off all the lights.
NOTE:
The headlights and the taillight can be turned on only when the engine is running.
EBU18280
Throttle lever
Once the engine is running, movement of the throt­tle lever will increase the engine speed. Regulate the speed of the ATV by varying the throttle position. Because the throttle is spring­loaded, the ATV will decelerate, and the engine will
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4-3
return to an idle any time the hand is removed from the throttle lever.
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7
1. Throttle lever
8
Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns
9
to the idle position as soon as the lever is released.
EWB00250
10
11
WARNING
Malfunction of the throttle could make it diffi­cult to speed up or slow down when you need to. This could cause an accident. Check the op­eration of the throttle lever before you start the engine. If the throttle does not work smoothly, check for the cause. Correct the problem be-
fore riding the ATV or consult a Yamaha dealer.
EBU18321
Speed limiter
Your ATV was delivered 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 avail­able and the maximum speed of the ATV, turn the adjusting screw in direction (a). To de­crease the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (b).
4-4
3
1. Locknut
2. Adjusting screw
3. No more than 12 mm (0.47 in)
(a)
(See page 8-29.)
1
2
EBU18382
Clutch lever
The clutch lever is located on the left handlebar
(b)
and the ignition circuit cut-off system is incorporat­ed 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
2
3
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5
leased slowly for smooth clutch operation. (See page 6-1 for a description of the ignition circuit cut-
6
off system.)
7
3. Tighten the locknut.
EWB00240
WARNING
Improper adjustment of the speed limiter and throttle could cause throttle cable damage or improper throttle operation. You could lose control, have an accident or be injured. Do not turn the adjusting screw out more than 12 mm (0.47 in) or the throttle cable could be dam­aged. Always make sure the throttle lever free play is adjusted to 2.0–4.0 mm (0.08–0.16 in).
8
9
10
11
1. Clutch lever
4-5
EBU18411
Brake lever
1
The brake lever is located at the right handlebar grip. To apply the front brake, pull the brake lever
2
toward the handlebar grip.
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5
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11
3
2
1
1. Brake lever
2. Locknut
3. Brake lever position adjusting bolt
4. Distance between brake lever and handlebar grip
EBU18432
Brake 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
4
1. Brake pedal
EBU18520
Parking brake lever
Use the parking brake before starting the engine or parking the ATV, especially on a slope. To apply the parking brake, move the parking brake lever in direction (a). To release the parking brake, move the parking brake lever in direction (b).
4-6
1. Parking brake lever (locked position)
EWB00220
WARNING
Always set the parking brake before starting the engine. The ATV could start moving un­expectedly if the parking brake is not ap­plied. This could cause loss of control or a collision.
Always be sure you have released the park­ing brake before you begin to ride. The brake could overheat if you ride the ATV without re­leasing the parking brake. You could lose braking performance which could cause an accident. You could also wear out the brakes prematurely.
1
2
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7
1. Parking brake lever (unlocked position)
EBU18530
Shift pedal
This ATV is equipped with a constant-mesh 5­speed transmission. The shift pedal is located on the left side of the engine and is used in combina­tion with the clutch when shifting.
4-7
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9
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11
1
2
3
4
5
6
1. Shift pedal
7
EBU18720
1
Fuel tank cap
8
Remove the fuel tank cap by turning it counter­clockwise.
9
10
11
1
1. Fuel tank cap
EBU18810
Fuel
Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.
4-8
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