Yamaha YFM45FAR, YFM450FAR. Service Manual

3 - 39

CHK

ADJ

CHECKING THE FRONT BRAKE PAD/

CHECKING THE REAR BRAKE PAD

CHECKING THE FRONT BRAKE PAD

1.Remove:

●

Front wheels

2.Check:

●

Brake pad
Wear indicators groove

almost touch the

brake disc

→

Replace the brake pads as a

set.
Refer to “FRONT AND REAR BRAKES” in
CHAPTER 8.

3.Operate the brake lever.
4.Install:

●

Front wheels

Brake pad wear limit

1 mm (0.04 in)

CHECKING THE REAR BRAKE PAD

1.Remove:

●

Rear wheel (left)

2.Check:

●

Brake pad
Wear indicator groove

almost

disappeared

→

Replace the brake pads as a

set.
Refer to “FRONT AND REAR BRAKES” in
CHAPTER 8.

3.Operate the brake lever or brake pedal.
4.Install:

●

Rear wheel (left)

Brake pad wear limit

1 mm (0.04 in)

3 - 40

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ADJ

CHECKING THE BRAKE HOSE

1.Remove:

●

Seat

●

Front carrier

●

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

●

Right footrest board
Refer to “FOOTREST BOARDS”.

2.Check:

●

Front brake hoses

●

Rear brake hoses

Cracks/wear/damage

→

Replace.

Fluid leakage

→

Replace the hose.

Refer to “FRONT AND REAR BRAKES” in
CHAPTER 8.

NOTE:

Hold the machine in an upright position and
apply the front or rear brake.

3.Check:

●

Brake hose clamp
Loosen

→

Tighten.

4.Install:

●

Right footrest board
Refer to “FOOTREST BOARDS”.

●

Front fender

●

Front carrier

●

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

3 - 41

CHK

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BLEEDING THE HYDRAULIC BRAKE SYSTEM

BLEEDING THE HYDRAULIC BRAKE
SYSTEM

WARNING

Bleed the brake system if:

●

The system has been disassembled.

●

A brake hose or brake pipe have been
loosened or removed.

●

The brake fluid has been very low.

●

The brake operation has been faulty.

A loss of braking performance may occur if
the brake system is not properly bled.

1.Bleed:

●

Brake system

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

Air bleeding steps:

a.Add the proper brake fluid to the reservoir.

b.Install the diaphragm. Be careful not to spill

any fluid or allow the reservoir to overflow.

c.Connect the clear plastic hose

tightly to

the caliper bleed screw

Front

Rear

d.Place the other end of the hose into a

container.

e.Slowly apply the brake lever or pedal several

times.

f. Pull the lever in or push down on the pedal

and hold it.

g.Loosen the bleed screw and allow the lever

or pedal to travel towards its limit.

h.Tighten the bleed screw when the lever or

pedal limit has been reached, then release
the lever or pedal.

i. Repeat steps (e) to (h) until all the air

bubbles have disappeared from the fluid.

j. Tighten the bleed screw.

NOTE:

If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the system have disappeared.

Bleed screw:

6 Nm (0.6 m • kg, 4.3 ft • lb)

3 - 42

CHK

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BLEEDING THE HYDRAULIC BRAKE SYSTEM/

ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD

k.Add brake fluid to the proper level.

Refer to “CHECKING THE BRAKE FLUID
LEVEL”.

WARNING

Check the operation of the brake after
bleeding the brake system.

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

ADJUSTING THE SELECT LEVER
CONTROL CABLE AND SHIFT ROD

NEUTRAL

HIGH

LOW

REVERSE

PARK

Control cable

Select lever shift rod

WARNING

Before moving the select lever, bring the
machine to a complete stop and return the
throttle lever to its closed position.
Otherwise the transmission may be
damaged.

1.Adjust:

●

Rear brake pedal free play
Refer to “ADJUSTING THE REAR BRAKE”.

2.Adjust:

●

Select lever control cable

●

Select lever shift rod

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

Adjustment steps:
Control cable:

●

Make sure the select lever is in NEUTRAL.

●

Adjust the control cable so there is zero free
play in the cable. When the adjustment is
correct, slack in the return spring

will be

taken up.

NOTE:

In some cases it will be necessary to further
adjust the cable with the locknuts

arrangement that holds the cable to its mount.

3 - 43

CHK

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ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD/

ADJUSTING THE REAR BRAKE LIGHT SWITCH

●

When the brake begins to work “

= 20 ~

30 mm (0.8 ~ 1.2 in)”, verify that the select
lever can be shifted to REVERSE from
NEUTRAL, to PARK from REVERSE and to
NEUTRAL from REVERSE.

●

Before the brake begins to work “

= 0 ~

20 mm (0 ~ 0.8 in)”, verify that the select
lever cannot be shifted to REVERSE from
NEUTRAL, to REVERSE from PARK and to
NEUTRAL from REVERSE.

●

Check that locknuts

are tightened

correctly.

●

If the operation of the select lever is
incorrect, adjust the select lever control cable

with the adjuster

Select lever shift rod:

●

Make sure the select lever is in NEUTRAL.

●

Loosen both locknuts

●

Adjust the shift rod length for smooth and
correct shifting.

●

Tighten the locknuts

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

ADJUSTING THE REAR BRAKE LIGHT
SWITCH

NOTE:

The rear brake light switch is operated by
movement of the brake pedal.
The rear brake light switch is properly adjusted
when the brake light comes on just before the
braking effect starts.

1.Check:

●

Brake light operation timing
Incorrect

→

Adjust.

3 - 44

CHK

ADJ

ADJUSTING THE REAR BRAKE LIGHT SWITCH/

CHECKING THE FINAL GEAR OIL LEVEL

2.Adjust:

●

Rear brake light switch operation timing

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

●

Hold the main body

of the rear brake light

switch so that it does not rotate and turn the
adjusting nut

in direction

until the

rear brake light comes on at the proper time.

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

Direction

Brake light comes on
sooner.

Direction

Brake light comes on
later.

CHECKING THE FINAL GEAR OIL LEVEL

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

●

Oil filler bolt

3.Check:

●

Oil level
Oil level should be up to the brim of the hole.
Oil level low

→

Add oil to the proper level.

CAUTION:

Take care not allow foreign material to
enter the final gear case.

Recommended oil:

SAE 80 API “GL-4” Hypoid gear
oil

4.Install:

●

Oil filler bolt

23 Nm (2.3 m • kg, 17 ft • lb)

3 - 45

CHK

ADJ

CHANGING THE FINAL GEAR OIL

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

●

Final gear case protector

3.Place a receptacle under the final gear case.

4.Remove:

●

Oil filler bolt

●

Drain plug

5.Drain:

●

Final gear oil

6.Install:

●

Drain plug

NOTE:

Check the gasket (drain plug). If it is damaged,
replace it with a new one.

7.Fill:

●

Final gear case

CAUTION:

Take care not to allow foreign material to
enter the final gear case.

8.Check:

●

Oil level
Refer to “CHECKING THE FINAL GEAR OIL
LEVEL”.

9.Install:

●

Oil filler bolt

●

Final gear case protector

Periodic oil change:

0.23 L (0.20 Imp qt, 0.24 US qt)

Total amount:

0.25 L (0.22 Imp qt, 0.26 US qt)

Recommended oil:

SAE 80 API “GL-4” Hypoid gear
oil

23 Nm (2.3 m • kg, 17 ft • lb)

16 Nm (1.6 m • kg, 11 ft • lb)

3 - 46

CHK

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CHECKING THE DIFFERENTIAL GEAR OIL/

CHANGING THE DIFFERENTIAL GEAR OIL

CHECKING THE DIFFERENTIAL GEAR OIL

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

●

Oil filler bolt

3.Check:

●

Oil level
Oil level should be up to the brim of hole.
Oil level low

→

Add oil to proper level.

CAUTION:

Take care not allow foreign material to
enter the gear case.

4.Install:

●

Oil filler bolt

Recommended oil:

SAE 80 API “GL-4” Hypoid gear
oil

Oil quantity (periodic oil change):

0.23 L (0.20 Imp qt, 0.24 US qt)

23 Nm (2.3 m • kg, 17 ft • lb)

CHANGING THE DIFFERENTIAL GEAR OIL

1.Place the machine on a level surface.
2.Place a receptacle under the differential gear

case.

3.Remove:

●

Oil filler bolt

●

Drain plug

3 - 47

CHK

ADJ

CHANGING THE DIFFERENTIAL GEAR OIL/CHECKING

THE CONSTANT VELOCITY JOINT DUST BOOT

4.Drain:

●

Differential gear oil

5.Install:

●

Drain plug

NOTE:

Check the gasket (drain plug). If it is damaged,
replace it with new one.

10 Nm (1.0 m • kg, 7.2 ft • lb)

6.Fill:

●

Differential gear case

NOTE:

If gear oil is filled to the brim of the oil filler
hole, oil may start leaking from the differential
gear case breather hose. Therefore, check the
quantity of the oil, not its level.

CAUTION:

Take care not to allow foreign material to
enter the differential gear case.

7.Install:

●

Oil filler bolt

Periodic oil change:

0.23 L (0.20 Imp qt, 0.24 US qt)

Total amount:

0.28 L (0.25 Imp qt, 0.30 US qt)

Recommended oil:

SAE 80 API “GL-4” Hypoid gear
oil

23 Nm (2.3 m • kg, 17 ft • lb)

CHECKING THE CONSTANT VELOCITY
JOINT DUST BOOT

1.Check:

●

Dust boots

Damage

→

Replace.

Refer to “FRONT CONSTANT VELOCITY
JOINTS AND DIFFERENTIAL GEAR” in
CHAPTER 7.

3 - 48

CHK

ADJ

CHECKING THE STEERING SYSTEM

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

●

Steering assembly bushings
Move the handlebar up and down, and/or
back and forth.
Excessive play

→

Replace the steering stem

bushings.

3.Check:

●

Tie-rod ends
Turn the handlebar to the left and/or right
until it stops completely, then move the
handlebar from the left to the right slightly.
Tie-rod end has any vertical play

→

Replace

the tie-rod end(s).

4.Raise the front end of the machine so that

there is no weight on the front wheels.

5.Check:

●

Ball joints and/or wheel bearings
Move the wheels laterally back and forth.
Excessive free play

→

Replace the front

arms (upper and lower) and/or wheel
bearings.

ADJUSTING THE TOE-IN

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

●

Toe-in
Out of specification

→

Adjust.

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

Measurement steps:

NOTE:

Before measuring the toe-in, make sure that
the tire pressure is correct.

●

Mark both front tire tread centers.

●

Face the handlebar straight ahead.

Toe-in:

0 ~ 10 mm (0 ~ 0.39 in)
(with tire touching the ground)

CHECKING THE STEERING SYSTEM/

ADJUSTING THE TOE-IN

3 - 49

CHK

ADJ

●

Measure the width

between the marks.

●

Rotate the front tires 180° until the marks are
exactly opposite one another.

●

Measure the width

between the marks.

●

Calculate the toe-in using the formula given
below.

●

If the toe-in is incorrect, adjust it.

*****************************************************
3.Adjust:

●

Toe-in

WARNING

●

Be sure that both tie-rods are turned the
same amount. If not, the machine will drift
right or left even though the handlebar is
positioned straight. This may lead to
mishandling and an accident.

●

After setting the toe-in to specification,
run the machine slowly for some distance
with both hands lightly holding the
handlebar and check that the handlebar
responds correctly. If not, turn either the
right or left tie-rod within the toe-in
specification.

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

Adjustment steps:

●

Mark both tie-rods ends.
This reference point will be needed during
adjustment.

●

Loosen the locknuts (tie-rod end)

of both

tie-rods.

●

The same number of turns should be given
to both the right and left tie-rods

until the

specified toe-in is obtained. This is to keep
the length of the rods the same.

●

Tighten the rod end locknuts of both tie rods.

NOTE:

Adjust the rod ends so that A and B are equal.

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

Toe-in =

–

Locknut (rod end):

40 Nm (4.0 m • kg, 29 ft • lb)

ADJUSTING THE TOE-IN

3 - 50

CHK

ADJ

ADJUSTING THE FRONT SHOCK ABSORBER/ADJUSTING THE REAR

SHOCK ABSORBER/CHECKING THE TIRE

ADJUSTING THE FRONT SHOCK
ABSORBER

WARNING

Always adjust both front shock absorber
spring preload to the same setting. Uneven
adjustment can cause poor handling and
loss of stability.

1.Adjust:

●

Spring preload
Turn the adjuster

to increase or decrease

the spring preload.

Standard position: 2
Minimum (Soft) position: 1
Maximum (Hard) position: 5

ADJUSTING THE REAR SHOCK
ABSORBER

1.Adjust:

●

Spring preload
Turn the adjuster

to increase or decrease

the spring preload.

NOTE:

The spring preload of the rear shock absorber
can be adjusted to suit the rider’s preference,
weight, and the riding conditions.

Standard position: 2
Minimum (Soft) position: 1
Maximum (Hard) position: 5

CHECKING THE TIRE

WARNING

This model is equipped with low pressure
tires. It is important that they be inflated
correctly and maintained at the proper
pressures.

3 - 51

CHK

ADJ

CHECKING THE TIRE

●

TIRE CHARACTERISTICS

1)Tire characteristics influence the

handling of ATV’s. The tires listed below
have been approved by Yamaha Motor
Co., Ltd. for this model. If other tire
combinations are used, they can
adversely affect your machine’s handling
characteristics and are therefore not
recommended.

●

TIRE PRESSURE

1)Recommended tire pressure

Front 25 kPa (0.25 kg/cm

, 3.6 psi)

Rear 25 kPa (0.25 kg/cm

, 3.6 psi)

2)Tire pressure below the minimum

specification could cause the tire to
dislodge from the rim under severe riding
conditions.
The following are minimums:
Front 22 kPa (0.22 kg/cm

, 3.2 psi)

Rear 22 kPa (0.22 kg/cm

, 3.2 psi)

3)Use no more than

Front 250 kPa (2.5 kg/cm

, 36 psi)

Rear 250 kPa (2.5 kg/cm

, 36 psi)

when seating the tire beads. Higher
pressures may cause the tire to burst.
Inflate the tires slowly and carefully.
Fast inflation could cause the tire to
burst.

●

MAXIMUM LOADING LIMIT

1)Vehicle load limit (total weight of cargo,

rider and accessories, and tongue
weight): 210 kg (463 lb)

2)Front carrier: 40 kg (88 lb)
3)Rear carrier: 80 kg (176 lb)
4)Storage box: 2.0 kg (4.4 lb)
5)Trailer hitch:
Pulling load (total weight of trailer and
cargo): 500 kg (1,102 lb)
Tongue weight (vertical weight on trailer
hitch point): 15 kg (33 lb)
Be extra careful of the machine balance
and stability when towing a trailer.

Manufacturer

Size

Type

Front

CHENG SHIN AT25

8-12 M911Y

Rear

CHENG SHIN AT25

10-12 M912Y

3 - 52

CHK

ADJ

CHECKING THE TIRE

1.Measure:

●

Tire pressure (cold tire pressure)
Out of specification

→

Adjust.

NOTE:

●

The low-pressure tire gauge

is included

as standard equipment.

●

If dust or the like is stuck to this gauge, it will
not provide the correct readings. Therefore,
take two measurements of the tire’s pressure
and use the second reading.

WARNING

Uneven or improper tire pressure may
adversely affect the handling of this
machine and may cause loss of control.

●

Maintain proper tire pressures.

●

Set tire pressures when the tires are cold.

●

Tire pressures must be equal in both front
tires and equal in both rear tires.

2.Check:

●

Tire surfaces
Wear/damage

→

Replace.

WARNING

It is dangerous to ride with a worn-out tire.
When tire wear is out of specification,
replace the tire immediately.

Cold tire

pressure

Front

Rear

Standard

25 kPa

(0.25 kg/cm

3.6 psi)

25 kPa

(0.25 kg/cm

3.6 psi)

Minimum

22 kPa

(0.22 kg/cm

3.2 psi)

22 kPa

(0.22 kg/cm

3.2 psi)

Maximum

28 kPa

(0.28 kg/cm

4.0 psi)

28 kPa

(0.28 kg/cm

4.0 psi)

Tire wear limit

Front and rear: 3.0 mm (0.12 in)

3 - 53

CHK

ADJ

CHECKING THE WHEEL/

CHECKING AND LUBRICATING THE CABLE

CHECKING THE WHEEL

1.Check:

●

Wheels

Damage/bends

→

Replace.

NOTE:

Always balance the wheel when a tire or wheel
has been changed or replaced.

WARNING

●

Never attempt even small repairs to the
wheel.

●

Ride conservatively after installing a tire
to allow it to seat itself properly on the
rim.

CHECKING AND LUBRICATING THE
CABLE

WARNING

A damaged cable sheath may cause
corrosion and interfere with the cable
movement. An unsafe condition may result
so replace a damaged cable as soon as
possible.

1.Check:

●

Cable sheath
Damage

→

Replace.

2.Check:

●

Cable operation
Unsmooth operation

→

Lubricate or replace.

NOTE:

Hold the cable end up and apply several drops
of lubricant to the cable.

3.Apply:

●

Lithium-soap-based grease
(onto end of the cable)

Recommended lubricant:

Yamaha chain and cable lube or
Engine oil

Yamaha YFM45FAR, YFM450FAR. Service Manual - part 7