Yamaha YFZ450X, YFZ450SPX Manual

OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO

YFZ450X/YFZ450SPX

5D3-28199-62

YAMAHA MOTOR CO., LTD.

PRINTED IN JAPAN 2007.04-0.8x1 !

(E,F,S)

OWNER’S MANUAL

YFZ450X/YFZ450SPX

5D3-28199-62-E0

EBU17170

INTRODUCTION

EBU17320

Congratulations on your purchase of the Yamaha YFZ450X/YFZ450SPX. 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. It also includes basic maintenance and inspection procedures. 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.

EBU17330

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 WARNING or death to the ATV operator, a bystander, or a person inspecting or

repairing the ATV.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to the ATV.

	NOTE:		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

YFZ450X/YFZ450SPX

OWNER’S MANUAL ©2007 by Yamaha Motor Co., Ltd.

1st edition, April 2007 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 .................	4-1
Handlebar switches ...................................	4-2
Throttle lever .............................................	4-3
Speed limiter .............................................	4-4
Clutch lever ...............................................	4-5
Brake lever ................................................	4-5
Brake pedal ...............................................	4-5
Parking brake lever ...................................	4-6
Shift pedal .................................................	4-7
Fuel tank cap .............................................	4-7
Fuel ...........................................................	4-8
Fuel cock ...................................................	4-9

Starter (choke) “		..................................”	4-10
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 chart for the
emission control system ..........................	8-3
General maintenance and lubrication
chart ........................................................	8-5
Removing and installing the panel ............	8-9
Checking the spark plug ..........................	8-10

Engine oil and oil filter element ................	8-14
Coolant ....................................................	8-20
Cleaning the air filter element ..................	8-24
Cleaning the spark arrester .....................	8-28
Adjusting the carburetor ...........................	8-29
Checking the engine idling speed ............	8-30
Adjusting the throttle cable free play ........	8-30
Valve clearance .......................................	8-31

Checking the front and rear brake pads .. 8-31

Checking the brake fluid level ..................	8-32
Changing the brake fluid ..........................	8-35
Checking the front brake lever free
play ........................................................	8-36
Checking the brake pedal position ...........	8-36
Adjusting the parking brake free play ......	8-37
Brake light switches .................................	8-39
Adjusting the clutch lever free play ..........	8-39
Lubricating the drive chain .......................	8-41
Checking and lubricating the cables ........	8-41
Checking and lubricating the brake and
clutch levers ...........................................	8-42
Checking and lubricating the brake and
shift pedals.............................................	8-43
Checking the wheel hub bearings ............	8-43
Lubricating the swingarm pivots ..............	8-43
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
		1

EBU17591

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently 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

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

1-1

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 make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.

●Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation.

●Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

●Never operate on excessively rough, slippery or loose terrain until you have learned and practiced 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 de- 1 scribed 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 brak-

ing.

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

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 vapor, or get some gasoline in your eyes, seek medical help immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.

and may cause loss of consciousness and death within a short time.

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

1-4

EBU17660

LOCATION OF THE WARNING AND SPECIFICATION LABELS

2

5

2

3

1	4

6

7

7

2-1

EBU17670

Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation.

2Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replacement label from your Yamaha dealer.

2-2

1 For Europe

2 For Europe

YAMAHA MOTOR CO., LTD.

SHIZUOKA JAPAN

p4GB-2155A-00

	GB	Before you operate this vehicle,
		read the owner’s manual.
	D	Lesen Sie die Bedienungsanleitung
		bevor Sie dieses Fahrzeug fahren.
	E	Antes de conducir este vehículo,
		lea el Manual del Propietario.
	F	Lire le manuel du propriétaire avant
		d’utiliser ce véhicule.
	I	Prima di usare il veicolo,
		leggete il manuale di istruzioni.
	NL	Voor het gebruik van dit voertuig
		de handleiding met aandacht lezen.
	P	Antes de utilizar este veículo,
		leia o manual do proprietário.
	S	Innan du kör detta fordon,
		läs handboken.
		5FK-21568-00

3 For Oceania
	WARNING
				2
Improper ATV use can result in SEVERE
INJURY or DEATH.
ALWAYS USE	NEVER USE	NEVER CARRY	NEVER USE
AN APPROVED	ON PUBLIC	PASSENGERS	WITH DRUGS
HELMET AND	ROADS		OR ALCOHOL
PROTECTIVE
GEAR

NEVER operate :

9without proper training or instruction.

9at speeds too fast for your skills or the conditions.

9on public roads-a collision can occur with another vehicle.

9with a passenger-passengers affect balance and steering and increase risk

of losing control.

ALWAYS:

9use proper riding techniques to avoid vehicle overturns on hills and rough terrain and it turns.

9avoid paved surfaces-pavement may seriously affect handling and control.

LOCATE AND READ OWNER'S MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS.

5FE-21568-11

2-3

3 For Europe

2Use PREMIUM unleaded gasoline with min. 97 octane(RON).

Nur Super Bleifrei mit Mindestoktanzahl 97 (ROZ) tanken.

Utilice gasolina sin plomo que tenga como mínimo 97 octanos (RON).

Utiliser une essence SUPER sans plomb d’un indice

d’octane (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 índice de octano mínimo de 97 (RON).

Använd blyfri PREMIUMBENSIN av 97 oktan (RON) eller mer. 5TG-2415E-00

3 For Oceania

Use PREMIUM unleaded gasoline with min. 97 octane (RON).

5TG-2415E-10

4 For Europe	4 For Oceania
		WARNING
<		UNDER
	16
		the age of 16 increases your chance
16		of severe injury or death.
		Operating this ATV if you are under
		NEVER operate this ATV if you are
		under age 16.
5FK-21697-00
		5FE-21697-01

2-4

2

5 For Europe

5 For Oceania

WARNING

NEVER ride as a passenger.

Passengers can cause a loss of control,

resulting in SEVERE INJURY or DEATH.

5FK-2151H-00

5FE-2151H-01

2-5

6 For Europe

6 For Oceania

2

27.5 kPa	30 kPa
0.275 kgf/cm 2	0.30 kgf/cm2
4.0 psi	4.4 psi
GB Set with tires cold .	I Impostare a pneumatici
	freddi .

DBei kalten Reifen . NL Wanneer de banden

			koud zijn .
E	Ajuste con los	P	Regular com pneus
	neumáticos an frío .		frios .
F	Pneus à froid .	S	Ställ in med kalla däck .
			5TG-21696-40

7

27.5kPa, {0.275kgf/cm 2}, 4.0psi 30kPa, {0.30kgf/cm 2}, 4.4psi 24.5kPa, {0.245kgf/cm 2}, 3.5psi 27kPa, {0.27kgf/cm 2}, 3.9psi

30

2-6

EBU17680					DESCRIPTION
EBU17690						EBU17700
Left view						Right view
1	2	3	4	5	6	1	2	3	3
					7				4
9		8						6	5

1.	Headlights	1.	Spark arrester
2.	Fuel cock	2.	Seat
3.	Starter (choke)	3.	Fuel tank cap
4.	Throttle stop screw	4.	Radiator cap
5.	Fuse	5.	Oil filter element
6.	Tail/brake light	6.	Brake pedal

7.Coolant reservoir

8.Shift pedal

9.Engine oil tank

3-1

EBU17712	from the figures shown in this manual.
Controls and instruments

2

3	2	3	4	5	6
1

1.Clutch lever

2.Handlebar switches

3.Parking brake

4.Main switch

5.Throttle lever

6.Brake lever

NOTE:

The ATV you have purchased may differ slightly

3-2

EBU17730

INSTRUMENT AND CONTROL FUNCTIONS

EBU17740

EBU17802

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

All electrical systems are off. The key can be removed.

Indicator light and warning light

1	2	4

OFF ON

1

1. Main switch

4-1

1.Neutral indicator light “N”

2.Coolant temperature warning light “”

EBU17860

Neutral indicator light “”

This indicator light comes on when the transmission is in the neutral position.

EBU17930

Coolant 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 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

4

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 cir-

cuit.

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.

EBU18060

Handlebar switches

1

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”.

4-2

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

return to an idle any time the hand is removed from the throttle lever.

4

1. Throttle lever

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.

EWB00250

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-

4-3

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

4pushed 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).

3

1

2

(b)

(a)

1.Locknut

2.Adjusting screw

3.No more than 12 mm (0.47 in)

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).

4-4

(See page 8-30.)

EBU18382

Clutch lever

The clutch lever is located on the left handlebar 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 released slowly for smooth clutch operation. (See page 6-1 for a description of the ignition circuit cutoff system.)

1. Clutch lever

EBU18411

Brake lever

The brake lever is located at the right handlebar grip. To apply the front brake, pull the brake lever toward the handlebar grip.

2 3

1

4

4

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.

4-5

1

4

1. Brake pedal

1. Parking brake lever (locked position)

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).

1. Parking brake lever (unlocked position)

4-6

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.

EBU18530

Shift 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 combination with the clutch when shifting.

4

1

1. Shift pedal

EBU18720

Fuel tank cap

Remove the fuel tank cap by turning it counterclockwise.

4-7

4

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.

1.Fuel level

2.Filler tube

Recommended fuel:

PREMIUM UNLEADED GASOLINE ONLY For Europe: PREMIUM UNLEADED GASOLINE 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)

NOTE:

If knocking or pinging occurs, use a different brand

4-8