YAMAHA YFM45FAR, YFM450FAR SERVICE MANUAL

YFM45FAR

YFM450FAR

5ND2-AE1

SERVICE MANUAL

YFM45FAR/YFM450FAR

SERVICE MANUAL

First edition, March 2002

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd. is expressly prohibited.

EB001000

NOTICE

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.

OTE:

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

CAUTION:

NOTE:

Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine.

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

A NOTE provides key information to make procedures easier or clearer.

EB002000

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)

1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.

2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page.

3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations.

EXPLODED DIAGRAMS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.

2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

. The meanings of the symbol marks are given on the next page.

4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart.

GEN

INFO

SPEC

CHK

ENG

ADJ

COOL

CARB

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1 to 0 are printed on the top right of each page and indicate the subject of each chapter.

General information

Specifications

Periodic checks and adjustments

Engine

Cooling system

Carburetion

Drive train

Chassis

Electrical

Troubleshooting

DRIV

–+

ELEC

CHAS

TRBL SHTG

Illustrated symbols A to H are used to identify the specifications appearing in the text.

Can be serviced with engine mounted

Filling fluid

Lubricant

Special tool

Torque

Wear limit, clearance

Engine speed

, V, A

Ω

IJK

New

LMN

Illustrated symbols I to N in the exploded diagrams indicate the types of lubricants and lubrication points.

Apply engine oil

Apply gear oil

Apply molybdenum disulfide oil

Apply wheel bearing grease

Apply lithium-soap-based grease

Apply molybdenum disulfide grease

Illustrated symbols O to P in the exploded diagrams indicate where to apply a locking agent O and when to install a new part P.

Apply the locking agent (LOCTITE

Replace

)

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND ADJUSTMENTS

ENGINE

COOLING SYSTEM

GEN

INFO

SPEC

CHK

ADJ

ENG

COOL

CARBURETION

DRIVE TRAIN

CHASSIS

ELECTRICAL

TROUBLESHOOTING

CARB

DRIV

CHAS

– +

ELEC

TRBL SHTG

GEN

INFO

CHAPTER 1.

GENERAL INFORMATION

GEN

INFO

MACHINE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER ................................................. 1-1

MODEL LABEL ..................................................................................... 1-1

FEATURES

LIQUID COOLING ENGINE .................................................................. 1-2

PARK POSITION .................................................................................. 1-2

FRONT DIFFERENTIAL ....................................................................... 1-3

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL PROCEDURES ............................... 1-8

REPLACEMENT PARTS ...................................................................... 1-8

GASKETS, OIL SEALS AND O-RINGS ................................................ 1-8

LOCK WASHERS/PLATES AND COTTER PINS ................................. 1-9

BEARINGS AND OIL SEALS ................................................................ 1-9

CIRCLIPS .............................................................................................. 1-9

CHECKING OF CONNECTIONS

SPECIAL TOOLS

................................................................................................... 1-2

....................................................................................... 1-11

........................................................................ 1-1

...................................................................... 1-8

............................................................... 1-10

GEN

INFO

MACHINE IDENTIFICATION

GENERAL INFORMATION

MACHINE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped into the left side of the frame.

MODEL LABEL

The model label 1 is affixed to the frame. This information will be needed to order spare parts.

GEN

INFO

1 - 1

GEN

FEATURES

LIQUID COOLING ENGINE

Compact liquid cooled 45° inclined engine. A liquid cooling system has been incorporated for stable power and engine endurance.

Radiator

Thermo switch

Fan motor

PARK POSITION

When the drive select lever is shifted into the park position, a stopper lever is engaged into the stopper gear preventing the drive select lever and transmission from moving.

When the drive select lever is at the “L”, “H”, “N”, or “R” positions, the stopper lever end is moved away from the stopper gear 2 by the return spring 3. When the drive select lever is in the “P” position, the lever cam 4 at the side of the shift cam 5 lifts the stopper lever end 6 and the stopper lever end locks the drive axle 7.

INFO

When the stopper lever end 1 is not synchronized, a torsion spring 8 retains the rotation force of the shift cam 5 until it is synchronized.

1 - 2

FRONT DIFFERENTIAL

1 Adapter 2 Drive clutch 3 Differential side gear (left) 4 Differential pinion gear 5 Ring gear 6 Differential side gear (right)

FEATURES

7 Drive pinion gear 8 Gear motor

È To front wheel É From the middle gear

GEN

INFO

1 - 3

GEN

FEATURES

2WD

Power is transmitted as follows: middle gear → front drive shaft → drive pinion gear 7 → ring gear 5 → differential pinion gear 4. In the 2WD mode, the left differential side gear 3 and the drive

clutch 2 are not engaged, therefore, the left side gear runs idle and does not transmit power to the left front constant velocity joint.

INFO

1 - 4

GEN

FEATURES

4WD

When the 4WD mode is selected, the gear motor is operated, and the drive clutch 2 moves to the right and engages with the left differential side gear 3. Accordingly, power is transmitted as follows: ring gear 5 → differential pinion gear 4 → left differential side gear 3 → drive clutch 2 → adapter 1 → left front constant velocity joint. Meanwhile, power from the differential pinion gear 4 is transmitted to the right front constant velocity joint via the right differential side gear 6. The ring gear 5 and the drive clutch 2 are not engaged at this time. Therefore, the rotational difference that occurs between the right and left wheels, while the handlebar is being turned, is absorbed by the difference in the rotational speeds of the ring gear 5 and the left differential side gear 3.

INFO

1 - 5

GEN

FEATURES

4WD (Diff-Lock)

When the 4WD (Diff-Lock) mode is selected, the gear motor moves the drive clutch 2 further to the right, which causes the ring gear 5 and the drive clutch 2 to engage. As a result, power is transmitted directly from the ring gear 5 to the drive clutch 2, then to the left front constant velocity joint via the adapter 1. Meanwhile, because the ring gear 5 and the drive clutch 2 are engaged, the ring gear 5, the drive clutch 2, and the right differential side gear 6 become locked coaxially. Thus, power is transmitted as follows: differential pinion gear 4 → right differential pinion gear 6 → right front constant velocity joint. When the ATV is in the 4WD (Diff-Lock) mode, the right and left wheels rotate constantly at the same speed, which affects the maneuverability of the ATV (e.g., making it difficult to steer). Therefore, the maximum traveling speed is limited to 35 km/h (22 mph).

INFO

1 - 6

GEN

FEATURES

In addition, the 4WD (Diff-Lock) mode can be engaged only when the ATV is stopped. Even if an attempt is made to select this mode when the ATV is traveling, it will only result in a standby condition (i.e., when the differential lock select switch and the differential gear are not matched). (1) When the ATV is traveling Even if the 4WD (Diff-Lock) mode is selected, the gear motor will stand by, instead of operating. Therefore, the ATV can be driven in the normal 4WD mode. When this occurs, the differential gear lock indicator light “” in the speedometer unit will flash to alert the driver that the control is on standby. When the ATV is stopped, the control transfers to the condition described in (2).

(2) When the ATV is stopped The gear motor operates to connect the drive clutch to the differential case, thus resulting in the differential lock condition. When this occurs, the differential gear lock indicator light “” in the speedometer unit changes to a constant illumination. * Until the drive clutch and the differential case mesh together (i.e., the splines are unmeshed) the engine misfires to control the engine speed. During this time, the differential gear lock indicator light in the speedometer unit continues to flash.

DIFF. LOCK

INFO

DIFF. LOCK

1 - 7

IMPORTANT INFORMATION

EB101000

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL PROCEDURES

1.Remove all dirt, mud, dust and foreign material before removal and disassembly.

2.Use proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS” section.

3.When disassembling the machine, always keep mated parts together. This includes gears, cylinder, piston and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly.

4.During machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts.

5.Keep all parts away from any source of fire.

GEN

INFO

EB101010

REPLACEMENT PARTS

1.Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

EB101020

GASKETS, OIL SEALS AND O-RINGS

1.Replace all gaskets, seals and O-rings when overhauling the engine. All gasket surfaces, oil seal lips and O-rings must be cleaned.

2.Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.

1 - 8

IMPORTANT INFORMATION

EB101030

LOCK WASHERS/PLATES AND COTTER PINS

1.Replace all lock washers/plates 1 and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification.

EB101040

BEARINGS AND OIL SEALS

1.Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips. Oil bearings liberally when installing, if appropriate.

Oil seal

GEN

INFO

CAUTION:

Do not use compressed air to spin the bearings dry. This will damage the bearing surfaces.

Bearing

EB101050

CIRCLIPS

1.Check all circlips carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1, make sure that the sharp-edged corner 2 is positioned opposite the thrust 3 it receives. See sectional view.

Shaft

1 - 9

CHECKING OF CONNECTIONS

EB801000

CHECKING OF CONNECTIONS

Check the connectors for stains, rust, moisture, etc.

1.Disconnect:

●

Connector

2.Check:

●

Connector Moisture → Dry each terminal with an air blower. Stains/rust → Connect and disconnect the terminals several times.

3.Check:

●

Connector leads Looseness → Bend up the pin 1 and connect the terminals.

GEN

INFO

4.Connect:

●

Connector terminals

OTE:

The two terminals “click” together.

5.Check:

●

Continuity (using a pocket tester)

OTE:

●

If there is no continuity, clean the terminals.

●

When checking the wire harness be sure to perform steps 1 to 3.

●

As a quick remedy, use a contact revitalizer available at most part stores.

●

Check the connector with a pocket tester as shown.

1 - 10

GEN

SPECIAL TOOLS

EB102001

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country. In such a case, two types are provided. When placing an order, refer to the list provided below to avoid any mistakes.

For US and CDN

P/N. YM-, YU-, YS-, YK-, ACC-

Except for US and CDN

P/N. 90890-

Tool No. Tool name/How to use Illustration

INFO

Bolt

90890-01083

Weight

90890-01084

Set

YU-01083-A

90890-01135

YU-01135-A

90890-01225

YM-01225-A

90890-04017

YM-04017

Slide hammer bolt (M6)/weight/set

These tools are used to remove the rocker arm shaft.

Crankcase separating tool

This tool is used to separate the crankcase.

Valve guide remover (7.0 mm)

This tool is needed to remove and install the valve guide.

Valve guide installer (7.0 mm)

This tool is needed to install the valve guide.

Valve guide reamer (7.0 mm)

90890-01227

YM-01227

90890-01235

YU-01235

90890-04088

Bolt

90890-01275

This tool is needed to rebore the new valve guide.

Rotor holding tool This tool is needed to hold the starter pulley when removing/installing the starter pulley bolt or camshaft sprocket bolts.

Buffer boss installer set Crankshaft installer bolt

These tools are used to install the crankshaft.

1 - 11

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

Crankshaft installer set

YU-90050

These tools are used to install the crankshaft.

INFO

Adapter

YM-33279

Spacer

90890-04060

YM-90070-A

90890-01304

YU-01304

90890-01311

YU-08035

90890-01312

YM-01312-A

Adapter (#11) Spacer (crankshaft)

These tools are used to install the crankshaft.

Piston pin puller set

This tool is used to remove the piston pin.

Tappet adjusting tool (3 mm)

This tool is necessary for adjusting the valve clearance.

Fuel level gauge

This gauge is used to measure the fuel level in the float chamber.

Radiator cap tester

90890-01325 YU-24460-01

90890-01352

YU-33984

90890-01348

90890-04134

YM-04134

This tool is used to check the cooling system.

Adapter

This tool is used to check the cooling system.

Locknut wrench

This tool is needed when removing or installing the secondary sheave spring.

Sheave spring compressor

This tool is needed when removing or installing the secondary sheave spring.

1 - 12

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

Sheave fixed block

INFO

90890-04135

YM-04135

90890-01404

YM-01404

90890-01327

YM-01327

90890-01426

YU-38411

90890-01430

YM-38404

This tool is needed when removing or installing the secondary sheave spring.

Flywheel puller

These tools are needed to remove the rotor.

Damper rod holder (30 mm)

This tool is needed to loosen and tighten the steering stem bearing retainer.

Oil filter wrench

This tool is needed to loosen or tighten the oil filter cartridge.

Ring nut wrench

This tool is needed to removing and installing the middle driven shaft bearing retainer.

90890-01467

YM-01467

90890-01475

YM-01475

90890-01474

YM-01474

YM-01477

90890-01701

YU-01880

Gear lash measurement tool

This tool is used to measure the gear lash.

Ball joint remover/installer set

This tool is used to remove and install the ball joint.

Ball joint remover/installer attachment set

This tool is used to remove and install the ball joint.

Sheave holder

This tool is needed to hold the primary sheave when removing or installing the sheave bolts.

1 - 13

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

INFO

Compression gauge

90890-03081

YU-33223

Adapter

90890-04082

YU-33223-3

90890-03112

YU-03112

90890-03113

YU-8036-A

Compression gauge Adapter

These tools are needed to measure engine compression.

Pocket tester

This instrument is needed for checking the electrical system.

Engine tachometer

This tool is needed for observing engine rpm.

Inductive tachometer

This tool is needed for observing engine rpm.

Timing light

90890-03141

YM-33277-A

90890-04019

YM-04019

Middle driven shaft

bearing driver

90890-04058

YM-04058-1

Mechanical seal installer

90890-04078

YM-33221

90890-04050

YM-04050

90890-04062

YM-04062

This tool is necessary for checking ignition timing.

Valve spring compressor

This tool is needed to remove and install the valve assemblies.

Middle driven shaft bearing driver Mechanical seal installer

These tools are used to install the water pump seal.

Bearing retainer wrench

This tool is needed when removing or installing the final drive shaft bearing retainer.

Universal joint holder

This tool is needed when removing or installing the universal joint yoke nut.

1 - 14

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

Clutch holding tool

INFO

90890-04086

YM-91042

90890-04128

YM-04128

90890-04129

YM-04129

90890-06754

This tool is needed to hold the clutch carrier when removing or installing the carrier nut.

Bearing retainer wrench

This tool is needed when removing or installing the middle driven pinion gear bearing retainer.

Pinion gear fix clamp

This tool is used to hold the shift cam.

Ignition checker

This instrument is necessary for checking the ignition system components.

Dynamic spark tester

YM-34487

Bond

90890-85505

Sealant

ACC-11001-05-01

This instrument is necessary for checking the ignition system components.

Yamaha bond No. 1215 Sealant (Quick Gasket

This sealant (bond) is used on crankcase mating surfaces, etc.

)

1 - 15

SPEC

CHAPTER 2.

SPECIFICATIONS

SPEC

GENERAL SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

ENGINE ................................................................................................. 2-4

CHASSIS ............................................................................................. 2-14

ELECTRICAL ...................................................................................... 2-18

HOW TO USE THE CONVERSION TABLE

GENERAL TORQUE SPECIFICATIONS

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE ............................................................................................... 2-21

COOLANT FLOW DIAGRAMS

OIL FLOW DIAGRAMS

CABLE ROUTING

.............................................................................. 2-24

...................................................................................... 2-27

..................................................................... 2-1

............................................................ 2-4

............................................... 2-20

................................................... 2-20

................................. 2-21

.................................................................. 2-22

SPEC

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