Yamaha YFM45FAR, YFM450FAR. Service Manual - part 4

 

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Yamaha YFM45FAR, YFM450FAR. Service Manual - part 4

 

 

2 - 29

SPEC

1

Sub-wire harness

2

Headlight lead

3

Auxiliary DC jack lead

4

Four-wheel drive relay 3

5

Fan motor breather hose

6

Differential gear case breather hose

7

Coolant reservoir breather hose

8

Meter assembly coupler

CABLE ROUTING

2 - 30

SPEC

1

Starter cable

2

Cylinder head breather hose

3

Fuel hose

4

Carburetor drain hose

5

Coolant reservoir breather hose

6

Radiator outlet hose

7

Coolant reservoir hose

8

Sub-wire harness 

9

Differential gear case breather hose

0

Thermo switch 2

È

Insert the fuel tank breather hose into the hole of
the handlebar cover.

É

Fasten the sub-wire harness, differential gear
case breather hose, coolant reservoir hose,
coolant reservoir breather hose, thermo switch
lead 2 and fan motor breather hose with a plastic
band.

CABLE ROUTING

2 - 31

SPEC

1

Cylinder head breather hose

2

Final drive gear case breather hose

3

Wire harness

4

Starter motor lead

5

Negative battery lead

6

Air filter case check hose

7

Water pump breather hose

8

Radiator outlet hose

9

Starter cable

0

Float chamber air vent hose

A

Cylinder head breather hose

B

Fuel hose

C

Low-range switch

D

High-range switch

E

Neutral switch lead

F

Reverse switch lead

G

Rectifier/regulator

CABLE ROUTING

2 - 32

SPEC

È

Fasten the wire harness with a plastic band.

É

Fasten the starter motor lead, wire harness, negative battery lead, final gear case breather hose,
rectifier/regulator lead, low-range switch lead, high-range switch lead, neutral switch lead, reverse switch
lead, speed sensor lead and A.C. magneto lead with a plastic band.

Ê

Fasten the wire harness, starter motor lead with a plastic band.

Ë

Fasten the low-range switch lead, high-range switch lead, neutral switch lead, reverse switch lead, speed
sensor lead, A.C. magneto lead, rectifier/regulator lead and negative battery lead with a plastic band.

CABLE ROUTING

2 - 33

SPEC

1

Throttle cable

2

Radiator inlet hose

3

Spark plug lead

4

Main switch

5

Wire harness

6

Rear brake light switch lead

7

Rear brake fluid reservoir hose

8

Select lever control cable

9

Rear brake cable

0

Rear brake hose

È

Fasten the radiator inlet hose and spark plug
lead with a plastic band.

CABLE ROUTING

2 - 34

SPEC

1

Front brake hose

2

Float chamber air vent hose

3

Throttle cable

4

Wire harness

5

Final drive gear case breather hose

6

Starter cable

7

Rear brake cable

CABLE ROUTING

2 - 35

SPEC

1

Battery

2

Positive battery lead

3

Tail/brake light lead

4

CDI unit

5

Negative battery lead

CABLE ROUTING

2 - 36

SPEC

1

Final drive gear case breather hose

2

Rear brake hose

3

Air filter case check hose

CABLE ROUTING

CHK

ADJ

CHAPTER 3.

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION 

........................................................................................... 3-1

PERIODIC MAINTENANCE/LUBRICATION 

............................................... 3-1

SEAT, CARRIERS, FENDERS AND FUEL TANK 

...................................... 3-3

SEAT AND SIDE PANELS .................................................................... 3-3
FRONT CARRIER, FRONT BUMPER AND FRONT FENDER  ............ 3-4
REAR CARRIER AND REAR FENDER ................................................ 3-6
FUEL TANK ........................................................................................... 3-8

FOOTREST BOARDS 

.................................................................................. 3-9

ENGINE 

...................................................................................................... 3-10

ADJUSTING THE VALVE CLEARANCE  ............................................ 3-10
ADJUSTING THE IDLING SPEED ...................................................... 3-13
ADJUSTING THE THROTTLE LEVER FREE PLAY  .......................... 3-14
ADJUSTING THE SPEED LIMITER  ................................................... 3-16
ADJUSTING THE STARTER CABLE  ................................................. 3-17
CHECKING THE SPARK PLUG  ......................................................... 3-19
CHECKING THE IGNITION TIMING ................................................... 3-20
MEASURING THE COMPRESSION PRESSURE .............................. 3-21
CHECKING THE ENGINE OIL LEVEL  ............................................... 3-23
CHANGING THE ENGINE OIL  ........................................................... 3-24
CLEANING THE AIR FILTER  ............................................................. 3-26
CHECKING THE COOLANT LEVEL ................................................... 3-29
CHANGING THE COOLANT  .............................................................. 3-30
CHECKING THE V-BELT .................................................................... 3-33
CLEANING THE SPARK ARRESTER  ................................................ 3-34

CHK

ADJ

CHASSIS 

.................................................................................................... 3-36

ADJUSTING THE REAR BRAKE ........................................................ 3-36
CHECKING THE BRAKE FLUID LEVEL  ............................................ 3-38
CHECKING THE FRONT BRAKE PAD  .............................................. 3-39
CHECKING THE REAR BRAKE PAD ................................................. 3-39
CHECKING THE BRAKE HOSE ......................................................... 3-40
BLEEDING THE HYDRAULIC BRAKE SYSTEM  ............................... 3-41
ADJUSTING THE SELECT LEVER CONTROL CABLE 

AND SHIFT ROD  ............................................................................ 3-42

ADJUSTING THE REAR BRAKE LIGHT SWITCH  ............................. 3-43
CHECKING THE FINAL GEAR OIL LEVEL ........................................ 3-44
CHANGING THE FINAL GEAR OIL .................................................... 3-45
CHECKING THE DIFFERENTIAL GEAR OIL ..................................... 3-46
CHANGING THE DIFFERENTIAL GEAR OIL  .................................... 3-46
CHECKING THE CONSTANT VELOCITY JOINT DUST BOOT  ........ 3-47
CHECKING THE STEERING SYSTEM  .............................................. 3-48
ADJUSTING THE TOE-IN ................................................................... 3-48
ADJUSTING THE FRONT SHOCK ABSORBER ................................ 3-50
ADJUSTING THE REAR SHOCK ABSORBER  .................................. 3-50
CHECKING THE TIRE  ........................................................................ 3-50
CHECKING THE WHEEL  ................................................................... 3-53
CHECKING AND LUBRICATING THE CABLE ................................... 3-53
LUBRICATING THE LEVERS, PEDAL, ETC. ..................................... 3-54

ELECTRICAL 

............................................................................................. 3-55

CHECKING THE BATTERY ................................................................ 3-55
CHECKING THE FUSE ....................................................................... 3-60
ADJUSTING THE HEADLIGHT BEAM  ............................................... 3-62
CHANGING THE HEADLIGHT BULB ................................................. 3-62

3 - 1

CHK

ADJ

INTRODUCTION/

PERIODIC MAINTENANCE/LUBRICATION

EB300000

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 vehicle operation
and a longer service life. The need for costly overhaul work will be greatly reduced. This information
applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All
service technicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE/LUBRICATION

ITEM

ROUTINE

INITIAL

EVERY

Whichever 

comes first

km

(mile)

320

(200)

1,200

(750)

2,400

(1,500)

2,400

(1,500)

4,800

(3,000)

hours

20

75

150

150

300

Valves*

• Check valve clearance.
• Adjust if necessary.

Cooling system

• Check coolant leakage.
• Repair if necessary.
• Replace coolant every 24 months.

Spark plug

• Check condition. 
• Adjust gap and clean.
• Replace if necessary.

Air filter element

• Clean. 
• Replace if necessary.

Every 20–40 hours

(More often in wet or dusty areas.)

Carburetor*

• Check and adjust idle speed/starter operation.
• Adjust if necessary.

Crankcase breather 
system*

• Check breather hose for cracks or damage.
• Replace if necessary.

Exhaust system*

• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.

Fuel line*

• Check fuel hose for cracks or damage.
• Replace if necessary.

Engine oil

• Replace. (Warm engine before draining.)

Engine oil filter 
cartridge

• Replace.

Engine oil strainer*

• Clean.

Final gear oil

• Check oil level/oil leakage. 
• Replace every 12 months.

Differential gear oil

Front brake*

• Check operation/fluid leakage. (See NOTE page 3-2.)
• Correct if necessary.

Rear brake*

• Check operation/fluid leakage. (See NOTE page 3-2.)
• Correct if necessary.

V-belt*

• Check operation. 
• Check for cracks or damage.

Wheels*

• Check balance/damage/runout. 
• Repair if necessary.

Wheel bearing*

• Check bearing assemblies for looseness/damage.
• Replace if damaged.

3 - 2

CHK

ADJ

PERIODIC MAINTENANCE/LUBRICATION

*

It is recommended that these items be serviced by a Yamaha dealer.

** Lithium-soap-based grease

NOTE:

●

Recommended brake fluid: DOT 4

●

Brake fluid replacement:

1.When disassembling the master cylinder or caliper, replace the brake fluid. Normally check the

brake fluid level and add fluid as required.

2.On the inner parts of the master cylinder and caliper, replace the oil seals every two years.
3.Replace the brake hoses every four years, or if cracked or damaged.

WARNING

Indicates a potential hazard that could result in serious injury or death.

Front and rear 
suspension*

• Check operation.
• Correct if necessary.

Steering system*

• Check operation./Replace if damaged.
• Check toe-in./Adjust if necessary.

Drive shaft universal 
joint*

• Lubricate.**

Engine mount*

• Check for cracks or damage.

Front axle boots*

• Check operation.
• Replace if damaged.

Fittings and 
fasteners*

• Check all chassis fittings and fasteners.
• Correct if necessary.

ITEM

ROUTINE

INITIAL

EVERY

Whichever 

comes first

km

(mile)

320

(200)

1,200

(750)

2,400

(1,500)

2,400

(1,500)

4,800

(3,000)

hours

20

75

150

150

300

3 - 3

CHK

ADJ

SEAT, CARRIERS, FENDERS AND FUEL TANK

SEAT, CARRIERS, FENDERS AND FUEL TANK

SEAT AND SIDE PANELS

Order

Job name/Part name

Q’ty

Remarks

Removing the seat and side panels

Remove the parts in the order below.

1

Seat

1

NOTE:

Pull up the seat lock lever, then pull up on
the rear of the seat.

2

Fuel tank side panel (left)

1

3

Fuel tank side panel (right)

1

4

Engine side panel

1

5

Engine side cover

1

For installation, reverse the removal 
procedure.

3 - 4

CHK

ADJ

SEAT, CARRIERS, FENDERS AND FUEL TANK

FRONT CARRIER, FRONT BUMPER AND FRONT FENDER

Order

Job name/Part name

Q’ty

Remarks

Removing the front carrier, front 
bumper and front fender

Remove the parts in the order below.

Seat and fuel tank side panels

Refer to “SEAT AND SIDE PANELS”.

1

Front carrier

1

2

Front fender panel

1

3

Engine skid plate

1

4

Front bumper cover

1

5

Front bumper

1

6

Headlight coupler

2

Disconnect.

7

Front grill

1

8

Main switch coupler

1

Disconnect.

9

Handlebar cover

1

10

Fuel tank cover

1

3 - 5

CHK

ADJ

SEAT, CARRIERS, FENDERS AND FUEL TANK

Order

Job name/Part name

Q’ty

Remarks

11

Meter assembly coupler

3

Disconnect.

12

Four-wheel drive relay 3 coupler

1

Disconnect.

13

Auxiliary DC jack connector

2

Disconnect.

14

Coolant reservoir breather hose

1

15

Fan motor breather hose

1

16

Differential gear case breather hose

1

17

Front fender

1

For installation, reverse the removal 
procedure.

3 - 6

CHK

ADJ

SEAT, CARRIERS, FENDERS AND FUEL TANK

REAR CARRIER AND REAR FENDER

Order

Job name/Part name

Q’ty

Remarks

Removing the rear carrier and rear 
fender

Remove the parts in the order below.

Seat and fuel tank side panels 

Refer to “SEAT AND SIDE PANELS”.

Fuel tank

Refer to “FUEL TANK”.

1

Rear carrier 

1

2

Battery holding bracket

1

3

Battery lead cover

1

4

Battery lead

2

Disconnect.

CAUTION:

First disconnect the negative lead,
then disconnect the positive lead.

5

Battery

6

Starter relay ground lead

1

Disconnect.

7

Tail/brake light connector

3

Disconnect.

 

 

 

 

 

 

 

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