Yamaha YFM45FAR, YFM450FAR. Service Manual

8 - 26

CHAS

FRONT AND REAR BRAKES

DISASSEMBLING THE FRONT AND REAR
BRAKE CALIPER

1.Remove:

●

Brake caliper piston

●

Dust seal

●

Caliper piston seal

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

Removal steps:

●

Blow compressed air into the hose joint
opening to force out the caliper piston from
the brake caliper body.

WARNING

●

Never try to pry out the caliper piston.

●

Cover the caliper piston with a rag. Be
careful not to get injured when the piston
is expelled from the master cylinder.

●

Remove the caliper piston seals.

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

EB702040

CHECKING THE FRONT AND REAR BRAKE
CALIPER

WARNING

All internal brake components should be
cleaned in new brake fluid only. Do not use
solvents as they will cause seals to swell
and distort.

Recommended brake component

replacement schedule:

Brake pads

As required

Piston seal, dust seal Every two years

Brake hoses

Every two years

Brake fluid

Replace when
brakes are
disassembled.

1.Check:

●

Brake caliper piston

Scratches/rust/wear

→

Replace the brake

caliper assembly.

●

Brake caliper cylinder

Wear/scratches

→

Replace the brake caliper

assembly.

●

Brake caliper body

Cracks/damage

→

Replace.

8 - 27

CHAS

FRONT AND REAR BRAKES

●

Brake fluid delivery passage (brake caliper
body)
Blockage

→

Blow out with compressed air.

WARNING

Replace the caliper piston seal and dust
seal whenever the brake caliper is
disassembled.

Front

Rear

ASSEMBLING THE FRONT AND REAR
BRAKE CALIPER

WARNING

●

All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.

●

Replace the caliper piston seal whenever
a brake caliper is disassembled.

1.Install:

●

Caliper piston seal

●

Dust seal

Recommended brake fluid:

DOT 4

New

2.Install:

●

Brake caliper piston

INSTALLING THE FRONT BRAKE CALIPER

1.Install:

●

Brake caliper assembly

●

Brake caliper mounting bolt

●

Brake hose

●

Copper washers

●

Union bolt

30 Nm (3.0 m • kg, 22 ft • lb)

New

27 Nm (2.7 m • kg, 19 ft • lb)

8 - 28

CHAS

FRONT AND REAR BRAKES

CAUTION:

When installing the brake hose on the
brake caliper, make sure that the brake
pipe touches the projection

on the brake

caliper.

WARNING

Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING” in CHAPTER 2.

2.Fill:

●

Brake reservoir

CAUTION:

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

WARNING

●

Use only the designated quality brake
fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.

●

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

●

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

3.Air bleed

●

Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3.

4.Check:

●

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

→

Fill up.

Refer to “CHECKING THE BRAKE FLUID
LEVEL” in CHAPTER 3.

Recommended brake fluid:

DOT 4

8 - 29

CHAS

FRONT AND REAR BRAKES

INSTALLING THE REAR BRAKE CALIPER

1.Install:

●

Brake caliper assembly

●

Brake caliper mounting bolt

●

Brake hose

●

Copper washers

●

Union bolt

30 Nm (3.0 m • kg, 22 ft • lb)

New

30 Nm (3.0 m • kg, 22 ft • lb)

2.Fill:

●

Brake reservoir

CAUTION:

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

WARNING

●

Use only the designated quality brake
fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.

●

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

●

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

3.Air bleed

●

Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3.

4.Check:

●

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

→

Fill up.

Refer to “CHECKING THE BRAKE FLUID
LEVEL” in CHAPTER 3.

Recommended brake fluid:

DOT 4

8 - 30

CHAS

STEERING SYSTEM

HANDLEBAR

Order

Job name/Part name

Q’ty

Remarks

Removing the handlebar

Remove the parts in the order below.

Handlebar cover

Band

On-command four-wheel drive switch
and differential gear lock switch

Refer to “INSTALLING THE MASTER
CYLINDER ASSEMBLY”.

Master cylinder assembly/bracket

1/1

Throttle lever assembly/bracket

1/1

Rear brake switch

Refer to “REMOVING THE REAR
BRAKE SWITCH”.

Rear brake lever/bracket

1/1

Refer to “INSTALLING THE REAR
BRAKE LEVER”.

Handlebar switch

Handlebar grip

Handlebar holder

Refer to “INSTALLING THE
HANDLEBAR”.

Handlebar

For installation, reverse the removal
procedure.

8 - 31

CHAS

STEERING SYSTEM

REMOVING THE REAR BRAKE SWITCH

1.Remove:

●

Rear brake switch

NOTE:

Push the fastener when removing the rear
brake switch out of the rear brake lever holder.

CHECKING THE HANDLEBAR

1.Check:

●

Handlebar
Bends/cracks/damage

→

Replace.

WARNING

Do not attempt to straighten a bent
handlebar as this may dangerously weaken
the handlebar.

INSTALLING THE HANDLEBAR

1.Install:

●

Handlebar

●

Handlebar holders

NOTE:

The upper handlebar holder should be
installed with the punched mark

forward

CAUTION:

First tighten the bolts

on the front side of

the handlebar holder, and then tighten the
bolts

on the rear side.

23 Nm (2.3 m • kg, 17 ft • lb)

INSTALLING THE REAR BRAKE LEVER

1.Install:

●

Handlebar switch

●

Rear brake lever

●

Lever bracket

NOTE:

Install the lever bracket as shown.

80 mm (3.1 in)

8 - 32

CHAS

STEERING SYSTEM

INSTALLING THE MASTER CYLINDER
ASSEMBLY

1.Install:

●

Throttle lever assembly

●

Master cylinder assembly

NOTE:

The “UP” mark on the master cylinder bracket
should face up.

7 Nm (0.7 m • kg, 5.1 ft • lb)

8 - 33

CHAS

STEERING SYSTEM

STEERING STEM

Order

Job name/Part name

Q’ty

Remarks

Removing the steering stem

Remove the parts in the order below.

Handlebar

Refer to “HANDLEBAR”.

Seat

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

Front fender

Lock washer

Refer to “INSTALLING THE CABLE
GUIDE”.

Cable guide

Steering stem bushing

Collar

Oil seal

Tie rod end nut

Tie rod

Disconnect.

Steering stem nut

Pitman arm

Steering stem

8 - 34

CHAS

STEERING SYSTEM

Order

Job name/Part name

Q’ty

Remarks

Oil seal

Bearing retainer

Refer to “REMOVING/INSTALLING THE
BEARING RETAINER”.

Bearing

Oil seal

For installation, reverse the removal
procedure.

8 - 35

CHAS

STEERING SYSTEM

REMOVING THE BEARING RETAINER

1.Remove:

●

Bearing retainer (steering stem)

Damper rod holder:

P/N. YM-01327, 90890-01327

CHECKING THE STEERING STEM

1.Check:

●

Steering stem
Bends

→

Replace.

WARNING

Do not attempt to straighten a bent stem;
this may dangerously weaken the stem.

2.Check:

●

Oil seals

●

Steering stem bushings

Wear/damage

→

Replace.

INSTALLING THE BEARING RETAINER

1.Install:

●

Bearing retainer (steering stem)

INSTALLING THE CABLE GUIDE

1.Install

●

Cable guide

●

Lock washer

●

Bolts

2.Bend the lock washer tab along a flat side of

the bolt.

NOTE:

Pass the cables and hoses through the cable
guide. Refer to “CABLE ROUTING” in
CHAPTER 2.

Damper rod holder:

P/N. YM-01327, 90890-01327

40 Nm (4.0 m • kg, 29 ft • lb)

New

23 Nm (2.3 m • kg, 17 ft • lb)

8 - 36

CHAS

STEERING SYSTEM

TIE ROD AND STEERING KNUCKLE

Order

Job name/Part name

Q’ty

Remarks

Removing the tie rod and steering
knuckle

Remove the parts in the order below.

Front fender

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

Front wheel/brake disc

Refer to “FRONT AND REAR WHEELS”.

Tie rod

Refer to “INSTALLING THE TIE ROD”.

Brake disc guard

Brake hose holder bolt

Protector

Nut

O-ring

Steering knuckle

Refer to “REMOVING THE STEERING
KNUCKLE”.

8 - 37

CHAS

STEERING SYSTEM

Order

Job name/Part name

Q’ty

Remarks

Oil seal

Bearing

Spacer

Circlip

Rubber boot

Ball joint

For installation, reverse the removal
procedure.

8 - 38

CHAS

STEERING SYSTEM

REMOVING THE STEERING KNUCKLE

1.Remove:

●

Steering knuckle

NOTE:

Use a general puller to separate the ball joint

and steering knuckle

or front lower arm

CHECKING THE TIE ROD

1.Check:

●

Tie rod free play and movement
Free play

→

Replace the tie rod end.

Turns roughly

→

Replace the tie rod end.

2.Check:

●

Tie rod

●

Bends/damage

→

Replace.

CHECKING THE STEERING KNUCKLE

1.Check:

●

Steering knuckle
Damage/pitting

→

Replace.

2.Check:

●

Ball joint
Damage/pitting

→

Replace the ball joint.

Free play

→

Replace the ball joint.

Turns roughly

→

Replace the ball joint.

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

Replacement steps:

●

Clean the outside of the steering knuckle.

●

Remove the steering knuckle oil seal.

●

Remove the circlip

and rubber boot

Use the ball joint remover and installer set.

8 - 39

CHAS

STEERING SYSTEM

●

Install the body

, short bolt

, remover

washer

and remover spacer

onto ball

joint.

NOTE:

●

Remover washer

must be aligned with the

projection on the head of the ball joint.

●

Surface

of the remover spacer

must be

aligned with surface

of the steering

knuckle.

●

Hold the body

in place while turning in the

short bolt

to remove the ball joint

from

the steering knuckle.

●

Remove the ball joint remover/installer.

Ball joint remover/installer set:

P/N. YM-01474/90890-01474

Ball joint remover/installer
attachment set:

P/N. YM-01477

Body

YM-01474
90890-01474

Long bolt

YM-01474
90890-01474

Short bolt

YM-01477

Remover washer

YM-01477

Remover spacer

YM-01477

Installer attachment

YM-01477

Installer spacer

YM-01477

Installer guide

YM-01477

●

Install the long bolt

, installer spacer

and installer guide

onto the body

8 - 40

CHAS

●

Attach the assembled ball joint remover/
installer, new ball joint

and installer

attachment

to the steering knuckle

NOTE:

Do not tap or damage the top of the ball joint.

●

Hold the body

in place while turning in the

long bolt

to install the new ball joint

into

the steering knuckle

●

Remove the ball joint remover/installer.

●

Apply lithium-soap base grease to the new
ball joint

●

Install a new rubber boot and new circlip.

NOTE:

Always use a new ball joint set.

●

Install a steering knuckle oil seal.

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

3.Check:

●

Front wheel bearings
Bearings allow play in the wheel hubs or the
wheel turns roughly

→

Replace.

●

Oil seals
Damage

→

Replace.

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

Replacement steps:

●

Clean the outside of the steering knuckle.

●

Remove the oil seals

●

Drive out the bearings

WARNING

Eye protection is recommended when
using striking tools.

●

Remove the spacer

●

Apply lithium base grease to the bearings
and oil seals.

●

Install the spacer to the steering knuckle.

STEERING SYSTEM

8 - 41

CHAS

●

Install the new bearings.

NOTE:

Install the outside bearing first.

CAUTION:

Do not strike the center race or balls of the
bearing. Contact should be made only with
the outer race.

●

Install a new oil seal.

NOTE:

When installing the oil seals, the “seal side” of
the oil seal faces out.

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

INSTALLING THE TIE ROD

1.Install:

●

Tie rods (left and right)

NOTE:

The tie rod which must be installed on the out
side has grooves

30 Nm (3.0 m • kg, 22 ft • lb)

2.Adjust:

●

Toe-in
Refer to “ADJUSTING THE TOE-IN” in
CHAPTER 3.

STEERING SYSTEM

Yamaha YFM45FAR, YFM450FAR. Service Manual - part 20