Yamaha YFM45FAR, YFM450FAR. Service Manual - part 11

4 - 34

ENG

RECOIL STARTER AND A.C. MAGNETO

RECOIL STARTER AND A.C. MAGNETO 

Order

Job name/Part name

Q’ty

Remarks

Removing the CDI magneto 

Remove the parts in the order below.

Engine oil

Drain.
Refer to “CHANGING THE ENGINE OIL” 
in CHAPTER 3.

Seat and side panels

Refer to “SEAT AND SIDE PANELS” in 
CHAPTER 3.

Left footrest board

Refer to “FOOTREST BOARDS” in 
CHAPTER 3.

1

Recoil starter assembly

1

2

A.C. magneto coupler

2

Disconnect.

3

Starter pulley

1

Refer to “REMOVING/INSTALLING THE 
A.C. MAGNETO”.

4

Crankcase cover (left)/gasket

1/1

5

Dowel pin

2

6

Lead holder

1

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ENG

RECOIL STARTER AND A.C. MAGNETO

Order

Job name/Part name

Q’ty

Remarks

7

Pickup coil

1

8

Stator assembly

1

9

Rotor

1

Refer to “REMOVING/INSTALLING THE 
A.C. MAGNETO”.

10

Starter wheel gear

1

11

Woodruff key

1

12

Washer

1

13

Starter idle gear shaft

1

14

Washer/bearing

1/1

15

Starter idle gear

1

For installation, reverse the removal 
procedure.

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ENG

RECOIL STARTER AND A.C. MAGNETO

Order

Job name/Part name

Q’ty

Remarks

Disassembling the recoil starter 

Remove the parts in the order below.

1

Cap

1

Refer to “DISASSEMBLING/
ASSEMBLING THE RECOIL 
STARTER”.

2

Starter handle

1

3

Friction plate

1

4

Pawl spring

1

5

Drive pawl

1

6

Spring

1

7

Sheave drum

1

8

Rope

1

9

Coil spring

1

For assembly, reverse the disassembly 
procedure.

4 - 37

ENG

RECOIL STARTER AND A.C. MAGNETO

REMOVING THE A.C. MAGNETO 

1.Remove:

●

Starter pulley 

1

 

NOTE:

Use the rotor holding tool 

2

 to hold the starter

pulley.

2.Remove:

●

Crankcase cover (left)

●

Gasket

●

Dowel pins

NOTE:

Working in a crisscross pattern, loosen each
bolt 1/4 of a turn. Remove them after all of
them are loosened.

Rotor holding tool:

P/N. YU-01235, 90890-01235

3.Remove:

●

Rotor 

1

 

NOTE:

Use the flywheel puller 

2

.

Flywheel puller:

P/N. YM-01404, 90890-01404

DISASSEMBLING THE RECOIL STARTER 

1.Remove:

●

Cap 

1

 

●

Starter handle 

2

 

NOTE:

Before untying the knot 

3

 above the starter

handle, make a knot 

4

 in the rope so that the

rope is not pulled into the case.

CHECKING THE CDI MAGNETO 

1.Check:

●

Stator assembly

●

Pickup coil
Damage 

→

 Replace.

4 - 38

ENG

RECOIL STARTER AND A.C. MAGNETO

CHECKING THE STARTER CLUTCH 

1.Check:

●

Starter one-way clutch 

1

 

Cracks/damage 

→

 Replace.

●

Bolts 

2

 (starter clutch)

Loose 

→

 Replace with a new one, and clinch

the end of the bolt.

NOTE:

The arrow mark on the starter clutch must face
inward, away from the rotor.

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

Checking steps:

●

Install the starter wheel gear to the starter
clutch, and hold the starter clutch.

●

When turning the starter wheel gear
counterclockwise 

È

, the starter clutch and

the wheel gear should be engaged.
If not, the starter clutch is faulty. Replace it.

●

When turning the starter wheel gear
clockwise 

É

, the starter wheel gear should

turn freely.
If not, the starter clutch is faulty. Replace it.

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

T

 

R

.

.

Bolts (starter clutch):

30 Nm (3.0 m • kg, 22 ft • lb)
LOCTITE

®

 

2.Check:

●

Gear teeth (starter idle) 

1

 

●

Gear teeth (starter wheel) 

2

 

Burrs/chips/roughness/wear 

→

 Replace.

3.Check:

●

Starter wheel gear
(contacting surface)
Damage/pitting/wear 

→

 Replace.

4 - 39

ENG

RECOIL STARTER AND A.C. MAGNETO

CHECKING THE STARTER PULLEY 

1.Check: 

●

Starter pulley 
Cracks/pitting 

→

 Deburr or replace.

CHECKING THE RECOIL STARTER 

1.Check:

●

Rope 

1

 

●

Sheave drum 

2

 

●

Drive pawl 

3

 

Wear/damage 

→

 Replace.

●

Coil spring 

4

 

●

Pawl spring 

5

 

●

Spring 

6

 

Fatigue 

→

 Replace.

ASSEMBLING THE RECOIL STARTER 

1.Install:

●

Sheave drum 

1

 

●

Rope 

2

 

●

Pawl spring 

3

 

●

Drive pawl 

4

 

NOTE:

Wind the rope 4-1/2 turns clockwise around
the sheave drum. Then insert the rope into the
drum slit 

a

.

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ENG

RECOIL STARTER AND A.C. MAGNETO

2.Install:

●

Starter spring 

1

 

●

Sheave drum assembly 

2

 

NOTE:

●

Mesh the spring hook 

3

 with the case slit,

then wind the spring clockwise into the case
from the larger to smaller diameter.

●

Mesh the sheave drum hook 

4

 with the

spring hook 

5

.

3.Install:

●

Spring 

1

 

●

Friction plate 

2

 

●

Nut

NOTE:

Insert the spring hooks into the pawl side
holes.

4.Turn the sheave drum 3-turn clockwise to

give preload to the spring.

5.Install:

●

Starter handle 

1

 

●

Cap 

2

 

NOTE:

●

Pass the rope through the case hole and
make a knot 

3

 on the rope so that the rope

is not pulled into the case.

●

Untie the knot 

3

 after making a knot 

4

above the handle.

INSTALLING THE A.C. MAGNETO 

1.Apply:

●

Sealant (Quick Gasket

®

) 

1

 

(into the slit)

Sealant (Quick Gasket

®

):

P/N. ACC-11001-05-01

Yamaha bond No. 1215:

P/N. 90890-85505

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ENG

RECOIL STARTER AND A.C. MAGNETO

2.Install:

●

Woodruff key

●

Rotor

NOTE:

●

Before installing the rotor, clean the outside
of the crankshaft and the inside of the rotor.

●

After installing the rotor, check that the rotor
rotates smoothly. If not, reinstall the key and
rotor.

3.Install:

●

Dowel pins

●

Gasket 

●

Crankcase cover (left)

NOTE:

●

When installing the crankcase cover (left),
use a long rod to hold the rotor in position
from the outside. This will make assembly
easier. Be careful not to damage the oil seal.

●

Tighten the bolts in stages, using a
crisscross pattern.

New

T

 

R

.

.

10 Nm (1.0 m • kg, 7.2 ft • lb)

4.Install:

●

Starter pulley 

1

 

NOTE:

Use a rotor holding tool 

2

 to hold the starter

pulley.

NOTE:

Before installing the starter pulley, do not
forget to install the O-ring.

Rotor holding tool:

P/N. YU-01235, 90890-01235

T

 

R

.

.

50 Nm (5.0 m • kg, 36 ft • lb)

4 - 42

ENG

PRIMARY AND SECONDARY SHEAVES

PRIMARY AND SECONDARY SHEAVES

Order

Job name/Part name

Q’ty

Remarks

Removing the primary and 
secondary sheave

Remove the parts in the order below.

Front fender

Refer to “SEAT, CARRIERS, FENDERS 
AND FUEL TANK” in CHAPTER 3.

Rear fender
Right footrest board

1

Exhaust pipe bracket

1

2

Drive belt cover

1

3

Rubber gasket

1

4

Bearing housing

1

5

Dowel pin

2

6

Primary sliding sheave assembly

1

Refer to “REMOVING/INSTALLING THE 
PRIMARY AND SECONDARY 
SHEAVES”.

7

V-belt

1

4 - 43

ENG

PRIMARY AND SECONDARY SHEAVES

Order

Job name/Part name

Q’ty

Remarks

8

Primary fixed sheave

1

Refer to “REMOVING/INSTALLING THE 
PRIMARY AND SECONDARY 
SHEAVES”.

9

Secondary sheave assembly

1

For installation, reverse the removal 
procedure.

4 - 44

ENG

PRIMARY AND SECONDARY SHEAVES

PRIMARY SLIDING SHEAVE

Order

Job name/Part name

Q’ty

Remarks

Disassembling the primary sliding 
sheave 

Remove the parts in the order below.

1

Primary pulley sheave cap

1

Refer to “ASSEMBLING THE PRIMARY 
SHEAVE”.

2

Primary pulley slider

4

3

Spacer

4

4

Primary pulley cam

1

5

Primary pulley weight

8

6

Collar

1

7

Oil seal

2

8

Primary sliding sheave

1

9

O-ring

1

For assembly, reverse the disassembly 
procedure.

4 - 45

ENG

PRIMARY AND SECONDARY SHEAVES

SECONDARY SHEAVE

Order

Job name/Part name

Q’ty

Remarks

Disassembling the secondary 
sheave 

Remove the parts in the order below.

1

 Nut

1

Refer to “DISASSEMBLING/
ASSEMBLING THE SECONDARY 
SHEAVE”.

2

 Spring 

seat

1

3

 Compression 

spring

1

4

 Spring 

seat

1

5

 Guide 

pin

4

6

 

Secondary sliding sheave

1

7

 O-ring

2

8

 

Secondary fixed sheave

1

9

 Oil 

seal

1

0

 Oil 

seal

1

For assembly, reverse the disassembly 
procedure.

4 - 46

ENG

PRIMARY AND SECONDARY SHEAVES

REMOVING THE PRIMARY AND 
SECONDARY SHEAVES 

1.Loosen:

●

Nut (secondary sheave) 

1

 

●

Nut (primary sheave) 

2

 

NOTE:

●

Use the sheave holder 

3

 to hold the primary

sheave.

●

First, loosen the nut (secondary sheave) 

2

,

then loosen the nut (primary sheave) 

1

.

Sheave holder:

P/N. YU-01880, 90890-01701

DISASSEMBLING THE SECONDARY 
SHEAVE 

1.Remove:

●

Nut 

1

 

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

Removing steps:

●

Attach the sheave fixed block 

2

, locknut

wrench 

3

 and sheave spring compressor 

4

to the secondary sheave assembly.

●

Place the sheave fixed block in a vise and
secure it.

●

Tighten the sheave spring compressor nut 

5

and compress the spring.

●

Loosen the nut 

1

 with the locknut wrench

3

.

●

Remove the nut 

1

.

●

Remove the sheave spring compressor and
locknut wrench.

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

Sheave fixed block:

P/N. YM-04135, 90890-04135

Locknut wrench:

P/N. 90890-01348

Sheave spring compressor:

P/N. YM-04134, 90890-04134

4 - 47

ENG

PRIMARY AND SECONDARY SHEAVES

CHECKING THE PRIMARY SHEAVE 

1.Check:

●

Weight outside diameter 

a

 

Out of specification 

→

 Replace the weight.

Weight outside diameter:

30 mm (1.18 in)
<Limit>: 29.5 mm (1.16 in)

2.Check:

●

Primary pulley slider

●

Primary sliding sheave splines
Wear/cracks/damage 

→

 Replace.

●

Spacer

●

Primary pulley cam
Cracks/damage 

→

 Replace.

3.Check:

●

Primary sliding sheave

●

Primary fixed sheave
Cracks/damage 

→

 Replace.

CHECKING THE SECONDARY SHEAVE 

1.Check:

●

Secondary fixed sheave smooth operation

●

Secondary sliding sheave smooth operation
Scratches/damage 

→

 Replace as a set.

2.Check:

●

Torque cam groove 

1

 

Wear/damage 

→

 Replace.

3.Check:

●

Guide pin 

2

 

Wear/damage 

→

 Replace.

4.Check:

●

Secondary sheave spring
Damage 

→

 Replace.

5.Measure:

●

Secondary sheave spring free length 

a

 

Out of specification 

→

 Replace the

secondary sheave spring.

Free length:

121.4 mm (4.78 in)
<Limit>: 115.33 mm (4.54 in)

4 - 48

ENG

PRIMARY AND SECONDARY SHEAVES

ASSEMBLING THE PRIMARY SHEAVE 

1.Clean:

●

Primary sliding sheave face 

1

 

●

Primary fixed sheave face 

2

 

●

Collar 

3

 

●

Weight 

4

 

●

Primary pulley cam face

NOTE:

Remove any excess grease.

2.Install:

●

Weight 

1

 

NOTE:

●

Apply Yamaha Grizzly grease (120 g) to the
whole outer surface of the weight and install.

●

Apply Yamaha Grizzly grease to the inner
surface of the collar.

●

Apply Yamaha Grizzly grease to the inner
surface of the primary sliding sheave.

3.Install:

●

Spacer

●

Slider 

1

 

●

Primary pulley cam 

2

 

●

Primary sliding sheave cap

T

 

R

.

.

3 Nm (0.3 m • kg, 2.2 ft • lb)

ASSEMBLING THE SECONDARY SHEAVE 

1.Apply:

●

BEL-RAY assembly lube

®

 

(to the secondary sliding sheave 

1

 inner

surface and oil seals)

●

BEL-RAY assembly lube

®

 

(to the bearings, oil seals and inner surface
of the secondary fixed sheave 

2

)

2.Install:

●

Guide pin 

1

 

4 - 49

ENG

PRIMARY AND SECONDARY SHEAVES

3.Apply:

●

BEL-RAY assembly lube

®

 

(to the guide pin sliding groove 

1

, and O-ring

2

 

)

New

4.Install:

●

Spring seat 

●

Compression spring

●

Spring seat 

●

Nut

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

Installing steps:

●

Attach the sheave fixed block, locknut
wrench and sheave spring compressor to the
secondary sheave assembly.

●

Place the sheave fixed block in a vise and
secure it.

●

Tighten the sheave spring compressor nut 

1

and compress the spring.

●

Install the nut 

2

 and tighten it to the

specified torque using the locknut wrench.

●

Remove the sheave spring compressor,
locknut wrench, and sheave fixed block.

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

Sheave fixed block:

P/N. YM-04135, 90890-04135

Locknut wrench:

P/N. 90890-01348

Sheave spring compressor:

P/N. YM-04134, 90890-04134

T

 

R

.

.

Nut:

90 Nm (9.0 m • kg, 65 ft • lb)