Summary of Contents for Yamaha GRIZZLY 450 YFM450DF
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READ THIS MANUAL CAREFULLY! It contains important safety information. LIRE ATTENTIVEMENT CE MANUEL! Il comprend d’importantes informations de sécurité. ¡LEA ESTE MANUAL ATENTAMENTE! Contiene indicaciones importantes acerca de la seguridad. OWNER’S MANUAL MANUEL DU PROPRIÉTAIRE MANUAL DEL PROPIETARIO YFM450DF YFM450PF/YFM450PHF 2LC-F8199-61...
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Original instructions Notice originale Manual original PRINTED IN USA 2014.02-0.5×1 CR (E,F,S)
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READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S MANUAL YFM450DF YFM450PF/YFM450PHF WARNING This ATV should not be ridden by anyone under 16 years of age. 2LC-F8199-61-E0...
Read this manual carefully before operating this vehicle. This manual should stay with this ve- hicle if it is sold. EC Declaration of Conformity conforming to Directive 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM450FWA (YFM450DF) (5Y4AJ14W0E0522767–) (Make, model)
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EC Declaration of Conformity conforming to Directive 2006/42/EC We, YAMAHA MOTOR CO., LTD. 2500 Shingai, Iwata, Japan, declare in sole responsibility, that the product YFM450FWAD (YFM450PF) (5Y4AJ47W0E0503801–) (YFM450PHF) (5Y4AJ48W0E0500601–) (Make, model) to which this declaration applies, conforms to the essential health...
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Congratulations on your purchase of the Yamaha YFM450DF/YFM450PF/YFM450PHF. This ATV repre- sents the result of many years of Yamaha experience in the production of fine sporting, touring, and pace- setting 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.
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EBU17331 IMPORTANT MANUAL INFORMATION EBU17343 FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards.
EBU17421 TABLE OF CONTENTS LOCATION OF THE WARNING AND Fuel cock ..........4-17 SPECIFICATION LABELS ......1-1 Starter (choke) ......... 4-18 Seat ............4-19 SAFETY INFORMATION ........ 2-1 Storage compartments......4-20 Front carrier ..........4-22 DESCRIPTION..........3-1 Rear carrier ..........4-22 Left view............
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Starting a warm engine .......6-3 Periodic maintenance chart for the Operating the drive select lever and emission control system......8-3 driving in reverse........6-3 General maintenance and lubrication Engine break-in ...........6-5 chart............8-5 Parking ............6-5 Removing and installing panels....8-10 Parking on a slope ........6-6 Checking the spark plug......
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Adjusting the rear brake lever and brake CLEANING AND STORAGE......9-1 pedal free play, and the brake pedal Cleaning............9-1 height ............8-41 Storage ............9-2 Axle boots ..........8-46 Brake light switches ........8-47 SPECIFICATIONS........10-1 Checking and lubricating the cables..8-48 Checking and lubricating the front and CONSUMER INFORMATION.......
Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a re- placement label from your Yamaha dealer. For Europe 9 10...
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11 YFM450DF YFM450FWA 2014 19.4 kW YAMAHA MOTOR CO., LTD. 276 kg < 2500 SHINGAI, IWATA, JAPAN 0.5 kg 1CU-F155A-60 ( 1 lb ) 37S-F816N-00 11 YFM450PF YFM450PHF YFM450FWAD 2014 19.4 kW YAMAHA MOTOR CO., LTD. 282 kg 2500 SHINGAI, IWATA, JAPAN...
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Familiarize yourself with the following pictograms and read the explanatory text, then make sure to check the pictograms that apply to your model. Read the Owner’s manual. NEVER use on paved roads. ALWAYS use an approved helmet and NEVER carry passengers. protective gear.
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This unit contains high-pressure nitrogen Turning 4WD-LOCK gas. (“DIFF.LOCK”) takes more effort. Operate at a slow speed and allow extra Mishandling can cause an explosion. Do not incinerate, puncture or open. time and distance for maneuvers to avoid loss of control. This pictogram shows the loading limits and/or maximum load capacity for this ATV.
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Year of construction Model Name ****** **** *** kW YAMAHA MOTOR CO., LTD. Max. Power *** kg 2500 SHINGAI, IWATA, JAPAN Mass In Running Order...
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WARNING Fuel vapors can be a fire or explosion hazard. To avoid injury or death, never store fuel or flammable liquids in this storage compartment. Storage should not exceed 1 lb (0.5 kg) 37S-F151F-00 1-11...
EBU17432 SAFETY INFORMATION SAFETY INFORMATION Never allow a child under age 16 to operate an EBU17506 ATV without adult supervision, and never allow AN ATV IS NOT A TOY AND CAN BE HAZARD- continued use of an ATV by a child if he or she OUS TO OPERATE.
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Never operate at speeds too fast for your skills Never operate the ATV on hills too steep for the or the riding conditions. Always go at a speed ATV or for your abilities. Practice on smaller hills that is proper for the terrain, visibility, operating before attempting larger hills.
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Never operate an ATV in fast flowing water or in technique described in this manual on level ground. Avoid crossing the side of a steep hill if water deeper than that recommended in this possible. manual. Remember that wet brakes may have ...
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Never maintain an ATV without proper knowl- vehicle. If the vehicle is in safe operating con- edge. Contact an authorized ATV dealer to in- dition and you can safely operate it, restart it form you on basic ATV maintenance. Certain and ride gently back to camp or other known maintenance can only be carried out by certified location where you can receive medical at-...
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While you may find aftermarket products similar in therefore, such accessories are not recom- design and quality to genuine Yamaha accesso- mended. ries, recognize that some aftermarket accessories Use caution when adding electrical accesso- or modifications are not suitable because of po- ries.
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Do not run engine outdoors where engine EWB00073 WARNING exhaust can be drawn into a building through openings such as windows and doors. Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, EWB02592 a deadly gas. Breathing carbon monoxide can WARNING cause headaches, dizziness, drowsiness, nau- When transporting the ATV in another vehicle,...
EBU17713 Controls and instruments The ATV you have purchased may differ slightly 6 7 8 from the figures shown in this manual. 1. Rear brake lever 2. Handlebar switches 3. Starter (choke) 4. Horn switch 5. Drive select lever 6. Multi-function display 7.
EBU17735 INSTRUMENT AND CONTROL FUNCTIONS EBU17761 Main switch The positions of the main switch are as follows: All electrical systems are supplied with power. The headlights and taillight come on when the light switch is on, and the engine can be started. The key cannot be removed.
EBU26696 Indicator lights and warning lights 1. Electric Power Steering warning light “EPS” (for EPS model) 1. On-Command differential gear lock indicator light “DIFF. EBU17991 LOCK” Low-range indicator light “ ” 2. Low-range indicator light “L” This indicator light comes on when the transmis- 3.
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“ON”. If the warning stop the engine as soon as it is safe to do so and light does not come on, have a Yamaha dealer allow it to cool down for about 10 minutes.
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If the engine is stopped using the engine stop Due to the synchronizing mechanism in the dif- switch and the key is in the “ON” position, the ferential gear case, the four-wheel-drive indica- EPS warning light comes on to indicate that the tor may not come on until the ATV starts power assistance for the steering is not func- moving.
an hour meter (which shows the total time the EBU18038 Multi-function display key has been turned to “ON”) Odometer and tripmeter modes Pushing the “TRIP/ODO” button switches the dis- play between the odometer mode “ODO” and the tripmeter modes “TRIP A” and “TRIP B” in the fol- lowing order: ODO →...
CLOCK → HOUR → CLOCK To set the clock 1. Set the display to the clock mode. 2. Push the “ / ” button until the clock starts flashing. 3. Set the hours by pushing the “H” button. 4. Set the minutes by pushing the “M” button. 5.
EBU18062 EBU18102 Start switch “ ” Handlebar switches Push this switch to crank the engine with the start- er. See the starting instructions on page 6-1 prior to starting the engine. EBU18155 Light switch “ /OFF” Set this switch to “ ”...
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Top speed is normally limited when operating in indicate a malfunction in the electrical system. In differential gear lock. If conditions require more this case, take the ATV to a Yamaha dealer at the engine power when riding forward, push and hold first opportunity.
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“4WD” (four-wheel drive): Power is supplied to es with the riding speed. You may lose control and have an accident if you cannot make a the rear and front wheels. sharp enough turn for the speed you are trav- To change from two-wheel drive to four-wheel eling.
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control and have an accident if you cannot EBU18256 On-Command differential gear lock switch make a sharp enough turn for the speed you “4WD”/“LOCK” are traveling. EWB00132 WARNING This ATV is equipped with a switch allowing you to Always stop the ATV before changing from lock the differential gear when in four-wheel drive.
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1. On-Command four-wheel-drive switch “2WD”/“4WD” 1. Differential gear lock lever 2. On-Command differential gear lock switch 2. On-Command four-wheel-drive switch “2WD”/“4WD” “4WD”/“LOCK” Stop the ATV, move the differential gear lock lever To lock the differential gear in four-wheel drive, to position (a), and then push the differential gear make sure the On-Command four-wheel-drive lock switch in to the “LOCK”...
Riding before the differential gear lock is prop- erly engaged (e.g., when the indicator and indi- cator light are flashing) will cause the vehicle speed to be limited until engagement is com- plete. When the ATV is in four-wheel-drive differential gear lock, the maximum traveling speed is limit- ed to 35 km/h (22 mi/h).
decrease the maximum engine power avail- able and the maximum speed of the ATV, turn the adjusting screw in direction (b). Do not turn the adjusting screw out more than 12 mm (0.47 in) or the throttle cable could be damaged.
3. Tighten the locknut. EBU18392 Front brake lever The front brake lever is located on the right han- dlebar. To apply the front brake, pull the brake le- ver toward the handlebar grip. 1. Brake pedal 1. Front brake lever EBU18443 Brake pedal and rear brake lever The brake pedal is located on the right side of the...
EBU18612 Drive select lever The drive select lever is used to shift your ATV into the low-range, high-range, neutral, reverse and park positions. See the “Operating the drive select lever and driving in reverse” section on page 6-3 for the drive select lever operation. 1.
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of sparks, open flames, or other sources of Recommended fuel: ignition such as the pilot lights of water heat- Regular unleaded gasoline only ers and clothes dryers. For Europe: Regular unleaded gasoline only 2. Do not overfill the fuel tank. When refueling, with a research octane number of 95 or be sure to insert the pump nozzle into the fuel higher...
1. Arrow mark pointing to “ON” 1. Arrow mark pointing to “RES” With the fuel cock lever in this position, fuel flows This indicates reserve. With the fuel cock lever in to the carburetor. Turn the fuel cock lever to this this position, the fuel reserve is made available.
Move the starter (choke) in direction (b) to turn off the starter (choke). See the “Starting a cold engine” section on page 6-1 for proper operation. 1. Seat 2. Seat lock lever To install the seat Insert the projections on the front of the seat into 1.
The front storage compartment is located at the front right side of the ATV. To access the storage compartment, remove the storage compartment cover by turning it counterclockwise. 1. Projection 2. Seat holder EBU29253 Storage compartments 1. Front storage compartment cover This ATV is equipped with two storage compart- ments.
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When storing any documents in the storage com- partments, be sure to wrap them in a plastic bag so that they will not get wet. When washing the ATV, be careful not to let any water enter the stor- age compartments. ...
EBU18963 Front carrier Do not exceed the load limit of 40.0 kg (88 lb) for the front carrier. Do not exceed the maximum load of 210.0 kg (463 lb) for the ATV. EBU18973 Rear carrier Do not exceed the load limit of 80.0 kg (176 lb) for the rear carrier.
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1. Special wrench Spring preload setting: Minimum (soft): Standard: Maximum (hard): 1. Spring preload adjusting ring 2. Position indicator A special wrench can be obtained at a Yamaha dealer to make this adjustment. 4-23...
EBU19184 Maximum rated capacity for the auxiliary DC Auxiliary DC jack jack: The auxiliary DC jack is located at the front right DC 12 V, 10 A (120 W) side of the ATV. The auxiliary DC jack can be used for suitable work lights, radios, etc.
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:...
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ITEM ROUTINE PAGE • Check operation. If soft or spongy, have Yamaha dealer bleed hy- draulic system. • Check brake pads for wear, and replace if necessary. Front brake 5-3, 8-38, 8-39, 8-40 • Check brake fluid level in reservoir, and add specified brake fluid to specified level if necessary.
Check that there is no free play in the front EBU19591 Final gear oil brake lever. If there is free play, have a Yamaha Make sure that the final gear oil is at the specified dealer check the brake system.
If there is any leakage, the brake proper tire pressure may cause severe injury or system should be checked by a Yamaha dealer. death from loss of control or rollover. Tire pressure below the minimum specified could...
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YFM450DF MAXXIS/MU14 dent. (EUR)(FRA)(GBR) YFM450PF CHENG SHIN/C-828 After extensive tests, only the tires listed below (AUS)(NZL) have been approved for this model by Yamaha YFM450PF MAXXIS/MU14 Motor Manufacturing Corporation of America. (EUR)(FRA)(GBR) YFM450PHF MAXXIS/MU14...
Size: AT25 x 10-12 Type: Tubeless Aftermarket tires and rims The tires and rims that came with your ATV were designed to match the performance capabilities and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate.
Read the Owner’s Manual carefully before riding light should come on, if it does not come on, the ATV. If there is a control or function you do not have a Yamaha dealer check the electrical understand, ask your Yamaha dealer. circuit.
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Position (3): short as possible to preserve battery energy. Do Cold engine start with ambient temperature not crank the engine more than 10 seconds on above 25 °C (80 °F). each attempt. Ambient temp./starter (choke) position 7. If the engine is started with the starter (choke) in position (1), the starter (choke) should be returned to position (2) to warm up the en- gine.
EBU20292 Starting a warm engine Follow the same procedure as for starting a cold engine, with the exception that the starter (choke) is not required when the engine is warm. Instead, start the engine with the throttle slightly open. EBU20442 Operating the drive select lever and driving in reverse ECB00171...
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6. P (Park) When in reverse, the reverse indicator light should come on. If the indicator light does not come on, have a Yamaha dealer check the elec- trical circuit. Due to the synchronizing mechanism in the en- gine, the indicator light may not come on until the ATV starts moving.
There is never a more important period in the life engine break-in period, immediately have a of your engine than the first 320 km (200 mi) or 20 Yamaha dealer check the ATV. hours of riding. For this reason, you should read the following material carefully.
Yamaha for use on your ATV. Many companies with no connection to Yamaha manufacture parts and accessories or offer other modifications for Yamaha vehicles. Yamaha is not in a position to test the products that these aftermarket compa- nies produce. Therefore, Yamaha can neither en-...
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Yamaha or modifications not specifically bulky object attached to the handlebars which recommended by Yamaha, even if sold and in- could make steering difficult, an accessory that stalled by a Yamaha dealer. limits your ability to move around on the seat, or one that limits your view.
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Never exceed the weight limits shown. An over- just the load in the trailer, if necessary, to reduce loaded ATV can be unstable. the weight on the hitch. If you are carrying cargo and towing a trailer, include the tongue weight MAXIMUM LOADING LIMIT in the maximum ATV load limit.
RIDE WITH CARE AND GOOD JUDGMENT EBU30791 Get training if you are inexperienced. GETTING TO KNOW YOUR ATV EWB01382 This ATV is for recreation and utility use. This sec- WARNING tion, Riding your ATV, provides general ATV riding Do not operate this ATV or allow anyone else instructions for recreational riding.
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the time to learn the basic techniques well before This ATV is designed to carry the operator and attempting more difficult maneuvers. Become fa- cargo only – passengers prohibited. miliar with this ATV at slow speeds first, even if you The long seat is to allow the operator to shift posi- are an experienced operator.
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Apparel Always wear the following to reduce risk of injury in an accident: Approved motorcycle helmet that fits properly Eye protection (goggles, helmet face shield, or protective eyewear) Over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants An approved helmet and other personal protective equipment can reduce the severity of injuries in an accident.
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1. Protective clothing Pre-operation checks 2. Goggles Always inspect your ATV each time you use it to 3. Gloves make sure the ATV is in safe operating condition. 4. Boots 5. Helmet Perform the pre-operation checks listed on page 5-1. Always follow the inspection and mainte- Do not operate after or while consuming alco- nance procedures and schedules described in the hol or drugs.
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Do not exceed the maximum loading limits fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting for the vehicle (see “MAXIMUM LOADING screw limits the maximum engine power available LIMIT” in this section or vehicle labeling). ...
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During operation MAXIMUM LOADING LIMIT Always keep your feet on the footboards during ATV loading limit (total weight of cargo, rid- operation; otherwise, they may contact the rear er, accessories, and tongue): wheels. WARNING! Removing even one hand or 210.0 kg (463 lb) foot can reduce your ability to control the ATV Front carrier: or could cause you to lose your balance and...
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ATV should during operation or after leaving the ATV, do not be genuine Yamaha or equivalent components let brush, grass and other materials collect under designed for use on this ATV and should be in- the vehicle, near the muffler or exhaust pipe, or stalled and used according to instructions.
To prevent burns, avoid touching the exhaust sys- BE CAREFUL WHERE YOU RIDE tem. Park the ATV in a place where pedestrians or This ATV is designed for use on unpaved surfaces children are not likely to touch it. only. WARNING! Paved surfaces may seriously affect handling and control of the ATV, and may cause the ATV to go out of control.
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know your country’s laws and regulations before ful when operating on unfamiliar terrain. Al- you ride on unpaved public streets or roads. Do ways be alert to changing terrain conditions not ride on any paved public street, road or motor- when operating the ATV.
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terrain could cause loss of traction or ATV con- trol, which could result in an accident, includ- ing an overturn. [EWB01542] Do not ride in areas posted “no trespassing”. Do not ride on private property without getting permission. When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV.
Select a large, flat, unpaved area to become famil- ECB00252 NOTICE iar with your ATV. Make sure that this area is free of obstacles and other riders. You should practice Do not shift from low-range to high-range or control of the throttle, brakes, shifting procedures, vice versa without coming to a complete stop.
As you approach a curve, slow down and begin to may continue to go straight. If the ATV doesn’t turn the handlebars in the desired direction. As turn, come to a stop and then practice the proce- you do so, put your weight on the footboard to the dure again.
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Never operate the ATV on hills too steep for the ATV or for your abilities. The ATV can overturn more easily on extremely steep hills than on level surfaces or small hills. Always check the terrain carefully before you start up any hill.
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Do not attempt to climb hills until you have mas- If you are climbing a hill and you find that you have tered basic maneuvers on flat ground. Always not properly judged your ability to make it to the check the terrain carefully before attempting any top, you should turn the ATV around while you still hill.
Always check the terrain carefully before you around and remount, following the procedure de- scribed in the Owner’s Manual. WARNING! Stall- start down any hill. Never operate the ATV on hills too steep for ing, rolling backwards improperly dismounting while climbing a hill could result in the ATV or for your abilities.
Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction. When this ATV is in “4WD”, all wheels (front and rear) are interconnected by the drive train.
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 tech- nique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill.
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The ATV can be used to cross slow moving, shal- braking ability. WARNING! Wet brakes may have low water of up to a maximum of 35 cm (14 in) in reduced stopping ability, which could cause depth. Before entering the water, choose your loss of control.
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1. Air filter case check hose 1. Storage compartment check hose 1. V-belt case drain plug 1. V-belt cooling duct check hose (left front side of ATV) 7-20...
accident. Be sure to keep your feet firmly mounted on the footboards at all times. Avoid jumping the ATV as loss of control and damage to the ATV may result. SLIDING AND SKIDDING EWB01663 WARNING Skidding or sliding improperly may cause you to lose control of this ATV.
To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help. With practice, over a period of time, skill at con- trolled sliding can be developed. The terrain should be chosen carefully before attempting If the rear wheels of your ATV start to slide side- such maneuvers, since both stability and control...
If your ATV is traversing a sloping surface: WHAT TO DO... If your ATV doesn’t turn when you want it to: Be sure to ride with your weight positioned to- Bring the ATV to a stop and practice the turning wards the uphill side of the ATV to maintain maneuvers again.
The intervals given in the periodic maintenance vice or while using the vehicle. If you are not fa- charts should be considered as a general guide miliar with vehicle service, have a Yamaha under normal riding conditions. However, DE- dealer perform the service.
Put the owner’s tool kit and low-pres- If you do not have the tools or experience required sure tire gauge under the seat. for a particular job, have a Yamaha dealer perform it for you. 1. Owner’s manual 2.
However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should still be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
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INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours • Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system • Check for looseness and tighten all screw clamps and joints if necessary.
However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should still be followed. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
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INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ √ necessary. Brake hoses •...
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INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours • Check for cracks or other damage, and replace if √ √ √ Stabilizer bushes necessary. √ √...
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INITIAL EVERY month Whichev- CHECK OR MAINTENANCE ITEM er comes 1300 2500 2500 5000 km (mi) first (200) (800) (1600) (1600) (3200) hours • Change. √ √ √ √ Final gear oil • Check ATV for oil leakage, and correct if neces- sary.
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EBU28392 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 cylinder and calipers, and change the brake fluid.
EBU23091 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1. Panel B 2.
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2. Install the seat. To install a panel 1. Place the panel in its original position. 8-11...
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Panel B To remove the panel 1. Remove the carrier top bolts. 1. Carrier bolt (under the fenders) 3. Remove the quick fastener screws, and then pull the panel upward to remove it. 1. Carrier bolt (top) 2. Remove the carrier bolts under the fenders, and then take the carrier off.
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Panel D To remove the panel Remove the bolts, and then take the panel off. 1. Quick fastener screw 2. Panel B To install the panel 1. Place the panel in the original position, and 1. Panel D then install the quick fastener screws. 2.
EBU23224 Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in ac- cordance with the periodic maintenance and lubri- cation chart.
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Do not attempt to diagnose such problems yourself. In- stead, have a Yamaha dealer check the ATV. 2. Check the spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.
Tightening torque: Spark plug: 18 Nm (1.8 m·kgf, 13 ft·lbf) If 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 speci- fied torque as soon as possible.
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If the engine was started before checking the oil The engine oil should be between the tip of the level, be sure to warm up the engine sufficiently, dipstick and the maximum level mark. and then wait at least ten minutes until the oil set- tles for an accurate reading.
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8. Install the panel. Skip steps 6–10 if the oil filter cartridge is not be- To change the engine oil (with or without oil fil- ing replaced. ter cartridge replacement) 1. Place the ATV on a level surface. 6. Remove panels C and D. (See page 8-10.) 2.
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1. Oil filter wrench 1. O-ring An oil filter wrench is available at a nearby Yamaha Make sure that the O-ring is properly seated. dealer. 9. Install the new oil filter cartridge with an oil fil- 8. Apply a thin coat of engine oil to the O-ring of ter wrench, and then tighten it to the specified the new oil filter cartridge.
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12. Refill with the specified amount of the recom- mended engine oil, and then install and tight- en the engine oil filler cap. Recommended oil: See page 10-1. Oil quantity: Without oil filter cartridge replacement: 2.30 L (2.43 US qt, 2.02 Imp.qt) With oil filter cartridge replacement: 2.40 L (2.54 US qt, 2.11 Imp.qt) 1.
The final gear case must be checked for oil leak- age before each ride. If any leakage is found, have 1. Final gear oil filler bolt a Yamaha dealer check and repair the ATV. In ad- 2. Gasket dition, the final gear oil level must be checked and 3.
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4. Remove the final gear oil filler bolt, the final Tightening torque: gear oil drain bolt and their gasket to drain the Final gear oil filler bolt: oil from the final gear case. 22 Nm (2.2 m·kgf, 16 ft·lbf) To change the final gear oil 1.
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6. Refill with the recommended final gear oil to However, when using this oil, noise from the final the brim of the filler hole as shown. NOTICE: gear case may occur when applying the rear Be sure no foreign material enters the final brake.
The differential gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the ATV. In addition, the differential gear oil level must be checked and the oil changed as follows at the in- tervals specified in the periodic maintenance and lubrication chart.
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To change the differential gear oil 5. Refill with the recommended differential gear 1. Place the ATV on a level surface. oil to the brim of the filler hole as shown. NOTICE: Be sure no foreign material en- 2. Place an oil pan under the differential gear case to collect the used oil.
Tightening torque: Differential gear oil filler bolt: The coolant should be between the minimum and 23 Nm (2.3 m·kgf, 17 ft·lbf) maximum level marks. 8. Check the differential gear case for oil leak- age. If oil is leaking, check for the cause. EBU23471 Coolant The coolant level should be checked before each...
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If the engine overheats, see page 8-65 for fur- water has been added to the coolant, have ther instructions. a Yamaha dealer check the antifreeze con- tent of the coolant as soon as possible, EBU23606 otherwise the effectiveness of the coolant To change the coolant will be reduced.
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4. Remove the front carrier and panel B. (See page 8-10.) 5. Remove the radiator cap. 1. Coolant drain bolt 2. Gasket 1. Radiator cap 6. Remove panel C. (See page 8-10.) 7. Remove the coolant reservoir cap. 8. Disconnect the coolant reservoir hose on the coolant reservoir side, and then drain the coolant from the coolant reservoir.
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freeze with distilled water only. However, if distilled water is not available, soft water may be used for refilling. Do not use hard water or salt water since they are harmful to the engine. [ECB00992] 13. Pour the recommended coolant into the radi- ator until it is full.
16. Start the engine, and then check for coolant leakage. If any leakage is found, have a Yamaha dealer check the cooling system. 17. Install the panels and the front carrier. EBU23647 Cleaning the air filter element The air filter element should be cleaned at the in- tervals specified in the periodic maintenance and 1.
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1. Air filter case cover holder 1. Air filter element 2. Air filter case cover 5. Pull off the air filter element lock plate, and 4. Pull the air filter element out of the air filter then remove the sponge material from the air case.
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2. Sponge material damaged. 3. Air filter element lock plate 9. Apply Yamaha foam air filter oil or other qual- 6. Wash the sponge material gently but thor- ity foam air filter oil to the sponge material. oughly in solvent. WARNING! Always use...
case. Never operate the engine with the air filter element removed. This will allow un- filtered air to enter the engine, causing rapid engine wear and possible engine damage. Additionally, operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating.
EWB02341 WARNING Do not start the engine when cleaning the spark arrester, otherwise it could cause injury to the eyes, burns, carbon monoxide poison- ing, possibly leading to death, and start a fire. Always let the exhaust system cool prior to touching exhaust components.
If water drains from the V-belt case after removing fore, most carburetor adjustments should be left the plug, have a Yamaha dealer check the ATV as to a Yamaha dealer, who has the necessary pro- the water may affect other engine parts.
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(a), and to decrease it, turn the screw in direction (b). If the specified idling speed cannot be obtained as described above, have a Yamaha dealer make the adjustment. 5. Install the panel. 8-36...
The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the inter- vals specified in the periodic maintenance and lu- brication chart.
Therefore, the safety system cable should be specified in the periodic maintenance and lubrica- checked and adjusted by a Yamaha dealer at the tion chart. intervals specified in the periodic maintenance and lubrication chart.
EBU30321 Rear brake friction plates Specified brake fluid: The rear brake friction plates must be checked DOT 4 and, if necessary, replaced by a Yamaha dealer at the intervals specified in the periodic maintenance EWB02721 and lubrication chart. WARNING Improper maintenance can result in loss of braking ability.
If the brake fluid level goes down sud- mance. denly, have a Yamaha dealer check the cause be- Clean the filler cap before removing. Use fore further riding. only DOT 4 brake fluid from a sealed contain-...
1. No brake lever free play 1. Brake lever free play 1. Loosen the locknut at the brake lever. EBU30345 Adjusting the rear brake lever and brake pedal free play, and the brake pedal height The rear brake lever and brake pedal free play, and the brake pedal height must be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart.
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If the specified brake lever free play could be ob- tained as described above, skip steps 3-8. 3. Fully turn the adjusting bolt in direction (a) to loosen the brake cable. 4. Slide the rubber cover back. 1. Locknut 2. Distance A 3.
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(0.87 in) or less. If distance B reaches 22 mm (0.87 in), adjust the brake lever free play at the brake lever again. If distance A exceeds 12.7 mm (0.50 in), have a Yamaha dealer check the vehicle. [ECB01153] 7.
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1. Footboard 1. Locknut 2. Bolt and nut 2. Adjusting bolt 3. Bolt 3. Turn the adjusting bolt in or out until the brake 2. Loosen the locknut. pedal height is within the specified limits. 4. Tighten the locknut. Tightening torque: Locknut: 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 5.
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1. Footboard bolt A Tightening torques: 2. Footboard bolt B Footboard bolt A: 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Footboard bolt B: Tighten the footboard bolts in the order shown. 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Adjusting the brake pedal free play The brake pedal free play should measure 20.0 mm (0.79 in).
The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart. Check the axle boots for tears or damage. If any damage is found, have them replaced by a Yamaha dealer. 8-46...
The rear brake light switch for the brake pedal can be adjusted as follows, but the other brake light switches should be adjusted by a Yamaha dealer. Turn the rear brake light switch adjusting nut while holding the brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction (a).
EBU28712 essary. If a cable is damaged or does not move Checking and lubricating the front and smoothly, have a Yamaha dealer check or replace rear brake levers The operation of the front and rear brake levers should be checked before each ride, and the lever Recommended lubricant: pivots should be lubricated if necessary.
Front brake lever EBU28872 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary. Recommended lubricant: Lithium-soap-based grease Rear brake lever EBU24964 Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart.
Recommended lubricant: ly, have a Yamaha dealer check the wheel hub Lithium-soap-based grease bearings. Front EBU24973 Lubricating the drive shaft universal 1. Grease nipple joint The drive shaft universal joint must be lubricated at the intervals specified in the periodic mainte- nance and lubrication chart.
For parts equipped with a grease nipple, use a Have a Yamaha dealer replace the stabilizer bush- grease gun. es if necessary. Recommended lubricant:...
Lubricating the steering shaft eyes or clothing. Always shield your eyes when The steering shaft must be lubricated by a working near batteries. Yamaha dealer at the intervals specified in the pe- Antidote: riodic maintenance and lubrication chart. EXTERNAL: Flush with water.
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[ECB01002] To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional elec- trical accessories.
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2. Connect the positive battery lead first, then ECB00932 NOTICE connect the negative battery lead by installing their bolt. NOTICE: When installing the bat- To charge a VRLA (Valve Regulated Lead Acid) tery, the main switch must be off, and the battery, a special (constant-voltage) battery charger is required.
EBU30801 Replacing a fuse The main fuse, the EPS fuse, and the fuse box are 1 2 3 4 5 6 located under the seat. (See page 4-19.) For non-EPS models 1. Headlight fuse 2. Ignition fuse 3. Auxiliary DC jack fuse 4.
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For EPS models 1 2 3 4 5 6 1. Headlight fuse 1. Main fuse 2. Signaling system fuse 2. Fuse box 3. Ignition fuse 3. EPS fuse 4. Four-wheel-drive motor fuse 4. Spare main fuse 5. Backup fuse (for clock) 6.
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YFM450PF 40.0 A YFM450PHF 40.0 A 3. Turn the key to “ON” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 8-57...
EBU25482 Replacing a headlight bulb If a headlight bulb burns out, replace it as follows. 1. Remove the cover at the rear of the headlight by pulling it off. 1. Headlight bulb holder cover 3. Remove the headlight bulb holder by pushing it in and turning it counterclockwise.
ECB00691 moistened with alcohol or thinner. [ECB00652] NOTICE It is advisable to have a Yamaha dealer make this adjustment. To raise a headlight beam, turn the headlight beam adjusting screw in direction (a). To lower a headlight beam, turn the adjusting screw in direction (b).
1. Headlight beam adjusting screw 1. Tail/brake light assembly 2. Nut EBU25623 2. Remove the tail/brake light bulb holder (to- Replacing the tail/brake light bulb gether with the bulb) by turning it counter- If the tail/brake light bulb burns out, replace it as clockwise.
1. Tail/brake light assembly 1. Tail/brake light bulb holder 2. Tail/brake light bulb holder 2. Tail/brake light bulb 3. Remove the burnt-out bulb by pushing it in 4. Insert a new bulb into the bulb holder, push it and turning it counterclockwise. in, and then turn it clockwise until it stops.
Tapered nuts are used for both the front and rear wheels. Install the nuts with their tapered side towards the wheel. 1. Wheel nut 3. Elevate the ATV and place a suitable stand under the frame. 4. Remove the nuts from the wheel. 1.
The following troubleshooting charts represent quick and easy procedures for checking these vi- tal systems yourself. However, should your ATV require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary 1. Tapered nut tools, experience, and know-how to service the 3.
Have a Yamaha dealer check the ATV. Check the compression. 4. Compression There is compression. The engine does not start. Have a Yamaha dealer check the ATV. Operate the electric starter. Have a Yamaha dealer check the ATV. There is no compression.
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Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.
EBU25861 CLEANING AND STORAGE and deterioration of wheel bearings, EBU25882 Cleaning brakes, transmission seals and electrical Frequent, thorough cleaning of your ATV will not devices. Many expensive repair bills have only enhance its appearance but will improve its resulted from improper high-pressure de- general performance and extend the useful life of tergent applications such as those avail- many components.
EBU25934 Specified amount: Storage 7.5 ml of stabilizer to each liter of fuel (or 1 oz of stabilizer to each gallon of fuel) Short-term Always store your ATV in a cool, dry place and, if 5. Perform the following steps to protect the cyl- necessary, protect it against dust with a porous inder, piston rings, etc.
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tively, turn the wheels a little every month in order to prevent the tires from becoming de- graded in one spot. 8. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month.
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Rear: Rear suspension: 22.0 kPa (0.220 kgf/cm², 3.2 psi) Type: Front wheel: Double wishbone Wheel type: Spring/shock absorber type: Panel wheel Coil spring/oil damper Rim size: Wheel travel: 12 x 6.0AT 180 mm (7.1 in) Rear wheel: Electrical system: Wheel type: Ignition system: Panel wheel DC CDI...
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Coolant temperature warning light: Backup fuse: YFM450DF 10.0 A Park indicator light: YFM450PF 5.0 A YFM450PHF 5.0 A On-Command four-wheel-drive/differential gear lock Four-wheel-drive motor fuse: indicator: 10.0 A High-range indicator light: EBU30402 Low-range indicator light: For Europe only The figures quoted are emission levels and are not Differential gear lock indicator light: necessarily safe working levels.
Record the vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number (front left side)
INDEX Drive select lever ............4-15 Drive select lever and driving in reverse ......6-3 Accessories and loading ..........6-6 Drive select lever safety system cable, adjusting ..8-38 Accessories, auxiliary jack ...........4-24 Drive shaft universal joint, lubricating ......8-50 Air filter element, cleaning ..........8-30 Axle boots ..............8-46 Engine break-in ..............
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Indicator lights and warning lights ......... 4-2 Instruments, lights and switches ........5-7 Safety information ............2-1 Seat ................4-19 Label locations ............... 1-1 Shock absorber assemblies, adjusting the front and Light switch ..............4-7 rear ................4-22 Low-range indicator light ..........4-2 Spark arrester, cleaning ..........
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EBU26173 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. NEVER USE ALWAYS USE NEVER USE NEVER CARRY AN APPROVED PASSENGERS WITH DRUGS ON PAVED HELMET AND OR ALCOHOL ROADS PROTECTIVE GEAR NEVER ALWAYS operate: • without proper training or instruction. •...