Periodic Checks And Adjustments; Introduction; Periodic Maintenance/Lubrication - Yamaha YFZ450S 2003 Service Manual

PERIODIC MAINTENANCE/LUBRICATION

EBS00029

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

This chapter includes all information necessary to perform recommended checks and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable machine operation
and a longer service life. The need for costly overhaul work will be greatly reduced. This information
applies to machines already in service as well as to new machines that are being prepared for sale.
All service technicians should be familiar with this entire chapter.
EBS00030
PERIODIC MAINTENANCE/LUBRICATION
ITEM
• Check valve clearance.
Valves*
• Adjust if necessary.
• Check for coolant leakage.
Cooling system • Repair if necessary.
• Replace coolant every 24 months.
• Check condition.
Spark plug • Adjust gap and clean.
• Replace if necessary.
• Clean.
Air filter element
• Replace if necessary.
• Check starter (choke) operation.
Carburetor*
• Adjust engine idling speed.
Crankcase breather • Check breather hose for cracks or damage.
system* • Replace if necessary.
• Check for leakage.
Exhaust system* • Tighten if necessary.
• Replace gasket if necessary.
• Check fuel hose for cracks or damage.
Fuel line*
• Replace if necessary.
Engine oil • Replace (Warm engine before draining).
Engine oil filter ele-
• Replace.
ment
Drive chain • Check and adjust slack/alignment/clean/lube.
• Check free play/operation/fluid leakage/See NOTE.
Front brake*
• Correct if necessary.
• Check operation/fluid leakage/See NOTE.
Rear brake*
• Correct if necessary.
• Check operation.
Clutch*
• Adjust if necessary.
• Check balance/damage/runout.
Wheels*
• Replace if necessary.
• Check bearing assemblies for looseness/damage.
Wheel bearings*
• Replace if damaged.
• Check operation.
• Repair if damaged.
Steering system*
• Check toe-in.
• Adjust if necessary.
Front and rear • Check operation.
suspension* • Correct if necessary.
Upper and lower arm
• Lubricate every 6 months with lithium-soap-based
pivot and steering
grease.
shaft*
• Lubricate every 6 months with lithium-soap-based
Rear arm pivot*
grease.
INTRODUCTION/
ROUTINE
3 - 1
CHK
ADJ
INITIAL
1 3 6
month months months
Every 20~40 hours
(More often in wet or dusty areas.)
EVERY
6 1
months year