Yamaha YFM45FAR, YFM450FAR. Service Manual

3 - 23

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CHECKING THE ENGINE OIL LEVEL

1.Place the machine on a level surface.
2.Remove:

●

Engine side panel
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.

3.Check:

●

Engine oil level
Oil level should be between the maximum
level mark

and minimum level mark

Oil level low

→

Add oil to the proper level.

NOTE:

Do not screw the dipstick

in when checking

the oil level.

Recommended oil:

Follow the left chart.

NOTE:

Recommended oil classification:
API Service “SE”, “SF” type or equivalent (e.g.
“SF–SE–CC”, “SF–SE–SD” etc.)

CAUTION:

Do not allow foreign material to enter the
crankcase.

4.Start the engine and let it warm up for

several minutes.

5.Stop the engine and check the oil level

again.

NOTE:

Wait a few minutes until the oil settles before
checking the oil level.

WARNING

Never remove the dipstick just after high
speed operation because the heated oil
could spurt out. Wait until the oil cools
down before removing the dipstick.

6.Install:

●

Engine side panel

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CHANGING THE ENGINE OIL

1.Start the engine and let it warm up for

several minutes.

2.Stop the engine and place an oil pan under

the engine.

3.Remove:

●

Seat

●

Fuel tank side panel (left)

●

Engine side cover
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.

4.Remove:

●

Engine oil filler plug (dipstick)

5.Remove:

●

Engine oil drain bolt

Drain the engine oil.

●

Oil strainer cover

●

Compression spring

●

Oil strainer

6.Clean:

●

Oil strainer

7.If the oil filter cartridge is also to be replaced,

perform the following procedure.

*****************************************************

Replacement steps:

●

Remove the oil filter cartridge

with an oil

filter wrench

Oil filter wrench:

P/N. YU-38411, 90890-01426

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●

Lubricate the O-ring

of the new oil filter

cartridge with a thin coat of engine oil.

CAUTION:

Make sure that the O-ring

is positioned

correctly in the groove of the oil filter
cartridge.

●

Tighten the new oil filter cartridge to
specification with an oil filter wrench.

*****************************************************

Oil filter cartridge:

17 Nm (1.7 m • kg, 12 ft • lb)

8.Install:

●

Oil strainer

●

Compression spring

●

Oil strainer cover

●

Engine oil drain bolt

9.Fill:

●

Crankcase
Refer to “CHECKING THE ENGINE OIL
LEVEL”.

10.Install:

●

Engine oil filler plug

11.Warm up the engine for a few minutes, then

stop the engine.

12.Check:

●

Engine
(for engine oil leaks)

●

Oil level

●

Refer to “CHECKING THE ENGINE OIL
LEVEL”.

Oil quantity:

Periodic oil change:

2.3 L (2.0 Imp qt, 2.4 US qt)

With oil filter replacement:

2.4 L (2.1 Imp qt, 2.5 US qt)

Total amount:

2.6 L (2.3 Imp qt, 2.7 US qt)

32 Nm (3.2 m • kg, 23 ft • lb)

23 Nm (2.3 m • kg, 17 ft • lb)

CHANGING THE ENGINE OIL

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CHANGING THE ENGINE OIL/

CLEANING THE AIR FILTER

13.Check:

●

Engine oil pressure

*****************************************************

●

Slightly loosen the oil gallery bolt

●

Start the engine and keep it idling until
engine oil starts to seep from the oil gallery
bolt. If no engine oil comes out after one
minute, turn the engine off so that it will not
seize.

●

Check the engine oil passages, the oil filter
cartridge and the oil pump for damage or
leakage. Refer to “CRANKCASE” in
CHAPTER 4.

●

Start the engine after solving the problem(-s)
and check the engine oil pressure again.

●

Tighten the oil gallery bolt to specification.

*****************************************************
14.Install:

●

Engine side cover

●

Fuel tank side panel (left)

●

Seat
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.

Oil gallery bolt:

7 Nm (0.7 m • kg, 5.1 ft • lb)

CLEANING THE AIR FILTER

NOTE:

There is a check hose

at the bottom of the

air filter case. If dust and/or water collects in
this hose, clean the air filter element and air
filter case.

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CLEANING THE AIR FILTER

1.Remove:

●

Seat

2.Remove:

●

Air filter case cover

3.Remove:

●

Air filter element assembly

●

Air filter element cap

●

Air filter element

Air filter element cap

Air filter element

CAUTION:

Never operate the engine with the air filter
element removed. This will allow unfiltered
air to enter, causing rapid wear and
possible engine damage. Additionally,
operation without the filter element will
affect carburetor tuning with subsequent
poor performance and possible engine
overheating.

4.Check:

●

Air filter element
Damaged

→

Replace.

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CLEANING THE AIR FILTER

5.Clean:

●

Air filter element

*****************************************************

Cleaning steps:

●

Wash the element gently, but thoroughly in
solvent.

WARNING

Use a cleaning solvent which is designed
to clean parts only. Never use gasoline or
low flash point solvents as they may cause
a fire or explosion.

●

Squeeze the excess solvent out of the
element and let it dry.

CAUTION:

Do not twist or wring out the element. This
could damage the foam material.

●

Apply engine oil to the element.

●

Squeeze out the excess oil.

NOTE:

The element should be wet but not dripping.

*****************************************************

6.Install:

●

Air filter element

●

Air filter case cover

NOTE:

To prevent air leaks make sure that the sealing
surface of the element matches the sealing
surface of the case.

●

Seat
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.

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CHECKING THE COOLANT LEVEL

1.Place the machine on a level surface.
2.Remove:

●

Seat

●

Fuel tank side panel (left)

3.Check:

●

Coolant level
The coolant level should be between the
minimum level mark

and maximum level

mark

Below the minimum level mark

→

Add the

recommended coolant to the proper level.

CAUTION:

●

Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant, check
and if necessary, correct the antifreeze
concentration of the coolant.

●

Use only distilled water. However, soft
water may be used if distilled water is not
available.

4.Start the engine, warm it up for several

minutes, and then turn it off.

5.Check:

●

Coolant level

NOTE:

Before checking the coolant level, wait a few
minutes until the coolant has settled.

6.Install:

●

Fuel tank side panel (left)

●

Seat
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.

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CHANGING THE COOLANT

1.Remove:

●

Seat

●

Fuel tank side panel (left)

●

Engine side cover

●

Front carrier

●

Engine skid plate

●

Front fender
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.

●

Left footrest board
Refer to “FOOTREST BOARDS”.

2.Remove:

●

Plastic band

●

Coolant reservoir bolts

●

Coolant reservoir cap

3.Disconnect:

●

Coolant reservoir breather hose

4.Drain:

●

Coolant
(from the coolant reservoir)

5.Connect:

●

Coolant reservoir breather hose

6.Install:

●

Coolant reservoir bolts

●

Plastic band

7.Remove:

●

Radiator cap

WARNING

A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the
engine is hot. Scalding hot fluid and steam
may be blown out, which could cause
serious injury. When the engine has
cooled, open the radiator cap as follows:
Place a thick rag or a towel over the
radiator cap and slowly turn the radiator
cap counterclockwise toward the detent to
allow any residual pressure to escape.
When the hissing sound has stopped, turn
the radiator cap counterclockwise while
pressing down on it and then remove it.

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CHANGING THE COOLANT

8.Remove:

●

Coolant drain bolt (cylinder)

(along with the copper washer)

●

Coolant drain bolt (water pump)

(along with the copper washer)

9.Drain:

●

Coolant

10.Check:

●

Copper washer

●

Coolant drain bolt

Damage

→

Replace.

11.Install:

●

Coolant drain bolt (water pump)

●

Coolant drain bolt (cylinder)

10 Nm (1.0 m • kg, 7.2 ft • lb)

12.Fill:

●

Cooling system
(with the specified amount of the
recommended coolant)

Handling notes for coolant

Coolant is potentially harmful and should be
handled with special care.

WARNING

●

If coolant splashes in your eyes,
thoroughly wash them with water and
consult a doctor.

●

If coolant splashes on your clothes,
quickly wash it away with water and then
with soap and water.

●

If coolant is swallowed, induce vomiting
and get immediate medical attention.

Recommended antifreeze

High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines

Mixing ratio

1:1 (antifreeze:water)

Quantity

Total amount

1.32 L (1.16 Imp qt, 1.40 US qt)

Coolant reservoir capacity

0.39 L (0.34 Imp qt, 0.41 US qt)

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CHANGING THE COOLANT

CAUTION:

●

Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant, check,
and if necessary, correct the antifreeze
concentration of the coolant.

●

Use only distilled water. However, soft
water may be used if distilled water is not
available.

●

If coolant comes into contact with painted
surfaces, immediately wash them with
water.

●

Do not mix different types of antifreeze.

13.Install:

●

Radiator cap

14.Fill:

●

Coolant reservoir
(with the recommended coolant to the
maximum level mark

)

15.Install:

●

Coolant reservoir cap

16.Start the engine, warm it up for several

minutes, and then turn it off.

17.Check:

●

Coolant level
Refer to “CHECKING THE COOLANT
LEVEL”.

NOTE:

Before checking the coolant level, wait a few
minutes until the coolant has settled.

18.Install:

●

Left footrest board
Refer to “FOOTREST BOARDS”.

●

Front fender

●

Engine skid plate

●

Front carrier

●

Engine side cover

●

Fuel tank side panel (left)

●

Seat
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.

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CHECKING THE V-BELT

1.Remove:

●

Right footrest board

●

Crankcase cover (right)
Refer to “PRIMARY AND SECONDARY
SHEAVES” in CHAPTER 4.

2.Check:

●

V-belt

Cracks/wear/scaling/chipping

→

Replace.

Oil/grease

→

Check primary sheave and

secondary sheave.

3.Measure:

●

V-belt width

Out of specification

→

Replace.

V-belt width:

30.7 mm (1.21 in)
<Limit:> 27.6 mm (10.9 in)

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CHECKING THE V-BELT/

CLEANING THE SPARK ARRESTER

4.Replace:

●

V-belt

*****************************************************

Replacing steps:

●

Install the bolts

(90101-06016) into the

secondary fixed sheave hold.

NOTE:

Tightening the bolts

will push the secondary

sliding sheave away, causing the gap between
the secondary fixed and sliding sheaves to
widen.

●

Remove the V-belt

from the primary

sheave and secondary sheave.

●

Install the V-belt.

NOTE:

Install the V-belt so that its arrow faces the
direction shown in the illustration.

●

Remove the bolts.

*****************************************************

CLEANING THE SPARK ARRESTER

1.Clean:

●

Spark arrester

*****************************************************

Cleaning steps:

WARNING

●

Select a well-ventilated area free of
combustible materials.

●

Always let the exhaust system cool
before performing this operation.

●

Do not start the engine when removing
the tailpipe from the muffler.

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CLEANING THE SPARK ARRESTER

●

Remove the bolt

●

Remove the tailpipe

by pulling it out of the

muffler.

●

Tap the tailpipe lightly with a soft-face
hammer or suitable tool, then use a wire
brush to remove any carbon deposits from
the spark arrester portion of the tailpipe and
the inner contact surfaces of the muffler.

●

Insert the tailpipe

into the muffler and

align the bolt holes.

●

Insert the bolt

and tighten it.

*****************************************************

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ADJUSTING THE REAR BRAKE

CHASSIS

ADJUSTING THE REAR BRAKE

WARNING

Always adjust both the brake pedal and the
rear brake lever whenever adjusting the
rear brake.

1.Check:

●

Rear brake lever free play

Out of specification

→

Adjust.

Rear brake lever free play:

0.5 ~ 2 mm (0.02 ~ 0.08 in)

2.Check:

●

Rear brake pedal height

Out of specification

→

Adjust.

Brake pedal

Footrest

Rear brake pedal height:

70 ~ 80 mm (2.76 ~ 3.15 in)

3.Adjust:

●

Rear brake lever free play

●

Rear brake pedal height

*****************************************************

Adjustment steps:

●

Loosen the locknut (handlebar)

and fully

screw in the brake lever cable adjuster
(handlebar)

●

Remove the rear brake master cylinder cover

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ADJUSTING THE REAR BRAKE

●

Loosen the locknut

●

Turn the adjusting bolt

until the brake

pedal height is within the specified limits.

●

Tighten the locknut

NOTE:

When adjusting the brake pedal height make
sure the locknut-to-adjusting bolt clearance

does not exceed 6 mm (0.24 in).

●

Loosen the locknut

●

Pull up the brake outer cable and turn the
brake cable adjusting (nut)

until the

clearance

is within the specified limits.

NOTE:

Make sure the pin

is all the way to the right

of the link plate hole.

●

Hold the adjusting nut

and tighten the

locknut

●

Turn the brake lever cable adjuster
(handlebar)

until the rear brake lever free

play

is within the specified limits.

Tighten the locknut (handlebar)

●

Adjust the select lever control cable.
Refer to “ADJUSTING THE SELECT LEVER
CONTROL CABLE AND SHIFT ROD”.

●

Install the rear brake master cylinder cover.

WARNING

After this adjustment is performed, lift the
front and rear wheels off the ground by
placing a block under the engine, and spin
the rear wheels to ensure there is no brake
drag. If any brake drag is noticed perform
the above steps again.

*****************************************************

Brake pedal height:

70 ~ 80 mm (2.76 ~ 3.15 in)

Clearance

Less than 1 mm (0.04 in)

Rear brake lever free play:

0.5 ~ 2 mm (0.02 ~ 0.08 in)

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CHECKING THE BRAKE FLUID LEVEL

1.Place the machine on a level surface.

NOTE:

When checking the brake fluid level, make
sure that the top of the brake fluid reservoir top
is horizontal.

2.Remove: (rear brake)

●

Front carrier

●

Front fender panel
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.

3.Check:

●

Brake fluid level
Fluid level is under “LOWER” level line

→

Fill up.

Front brake

Rear brake

CAUTION:

Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.

WARNING

●

Use only the designed quality brake fluid:
otherwise, the rubber seals may
deteriorate, causing leakage and poor
brake performance.

●

Refill with the same type of brake fluid;
mixing fluids may result in a harmful
chemical reaction and lead to poor
performance.

●

Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in a vapor lock.

4.Install: (rear brake)

●

Front fender panel

●

Front carrier
Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK”.

Recommended brake fluid:

DOT 4

CHECKING THE BRAKE FLUID LEVEL

Yamaha YFM45FAR, YFM450FAR. Service Manual - part 6