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Rhino 450 YXR45FAV
Yamaha Rhino 450 YXR45FAV User Manual
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LIT-11616-19-43
2P5-F8197-10
YXR45FAV
SERVICE MANUAL
2
Table of Contents
Default Chapter
3
Specifications
3
Periodic Checks and
5
Table of Contents
8
Chapter 1 General Information
18
Vehicle Identification
18
Vehicle Identification Number
18
Model Label
18
Important Information
19
Preparation for Removal Procedures
19
Replacement Parts
19
Gaskets, Oil Seals and O-Rings
19
Lock Washers/Plates and Cotter Pins
20
Bearings and Oil Seals
20
Circlips
20
Checking of Connections
21
Special Tools
22
Chapter 2 Specifications
27
General Specifications
27
Engine Specifications
31
Cooling System
37
Chassis Specifications
39
Electrical Specifications
41
Tightening Torques
44
Engine Tightening Torques
44
Chassis Tightening Torques
47
Lubrication Points and Lubricant Types
50
Engine
50
How to Use the Conversion Table
51
General Tightening Torque Specifications
51
Coolant Flow Diagrams
52
Oil Flow Diagrams
55
Cable Routing
60
Chapter 3 Periodic Checks and Adjustments
77
Introduction
77
Periodic Maintenance/Lubrication
77
Brake Fluid Replacement
78
Engine
79
Adjusting the Valve Clearance
79
Adjusting the Idling Speed
81
Adjusting the Throttle Cable
83
Adjusting the Starter Cable
84
Checking the Spark Plug
85
Checking the Ignition Timing
86
Measuring the Compression Pressure
87
Checking the Engine Oil Level
89
Changing the Engine Oil
90
Cleaning the Air Filter Elements
92
Checking the Coolant Level
95
Changing the Coolant
96
Checking the Coolant Temperature Warning Light
101
Checking the V-Belt
102
Cleaning the Spark Arrester
103
Chassis
104
Adjusting the Brake Pedal
104
Adjusting the Parking Brake
105
Checking the Brake Fluid Level
106
Checking the Front Brake Pads
107
Checking the Rear Brake Pads
107
Checking the Brake Hoses and Brake Pipes
108
Bleeding the Hydraulic Brake System
108
Adjusting the Select Lever Shift Rod
110
Adjusting the Brake Light Switch
110
Checking the Final Gear Oil Level
111
Changing the Final Gear Oil
112
Checking the Differential Gear Oil
112
Changing the Differential Gear Oil
113
Checking the Constant Velocity Joint Dust Boots
114
Checking the Steering System
115
Adjusting the Toe-In
115
Adjusting the Front Shock Absorbers
117
Adjusting the Rear Shock Absorbers
117
Checking the Tires
118
Checking the Wheels
120
Checking and Lubricating the Cables
120
Lubricating the Pedals, Etc
121
Electrical
122
Checking and Charging the Battery
122
Checking the Fuses
127
Adjusting the Headlight Beams
129
Changing the Headlight Bulbs
129
Changing the Tail/Brake Light Bulbs
130
Chapter 4 Engine
132
Engine Removal
132
Air Ducts, Muffler and Exhaust Pipe
132
Select Lever Unit and Coolant Reservoir
134
Hoses and Leads
135
Engine Mounting Bolts
137
Installing the Engine
139
Cylinder Head
140
Removing the Cylinder Head
142
Checking the Tappet Covers
143
Checking the Timing Chain Tensioner
143
Checking the Camshaft Sprocket
143
Checking the Cylinder Head
144
Installing the Cylinder Head
145
Camshaft, Rocker Arms and Valves
148
Removing the Camshaft and Rocker Arms
150
Removing the Valves and Valve Springs
150
Checking the Camshaft
151
Checking the Rocker Arms and Camshaft
151
Checking the Valves and Valve Springs
153
Installing the Valves and Valve Springs
157
Installing the Camshaft and Rocker Arms
158
Cylinder and Piston
159
Removing the Piston
160
Checking the Timing Chain Guide
160
Checking the Cylinder and Piston
160
Checking the Piston Rings
162
Checking the Piston Pin
163
Installing the Piston
164
Installing the Cylinder
165
Engine Cooling Fan and A.C. Magneto
166
Removing the A.C. Magneto
169
Checking the A.C. Magneto
169
Checking the Starter Clutch
170
Checking the Engine Cooling Fan
171
Installing the A.C. Magneto
171
Primary and Secondary Sheaves
173
Primary Sliding Sheave
174
Secondary Sheave
175
Removing the Primary and Secondary Sheaves
176
Disassembling the Secondary Sheave
176
Checking the Primary Sheave
177
Checking the Secondary Sheave
177
Checking the V-Belt Case Cooling Fan
178
Assembling the Primary Sheave
178
Assembling the Secondary Sheave
178
Installing the Primary and Secondary Sheaves
180
Clutch
181
Removing the Clutch
183
Checking the Clutch
183
Installing the Clutch
184
Crankcase
186
Starter Motor, Timing Chain and Oil Filter
186
Crankcase
187
Crankcase Bearings
190
Removing the Oil Pump Drive Gear
191
Separating the Crankcase
191
Checking the Timing Chain and Guide
192
Checking the Oil Strainer and Oil Delivery Pipe
192
Checking the Relief Valve
193
Checking the Crankcase
193
Checking the Bearings
193
Installing the Bearing Retainer
193
Assembling the Crankcase
194
Installing the Shift Lever
195
Installing the Oil Pump Drive Gear
195
Crankshaft and Oil Pump
196
Oil Pump
197
Removing the Crankshaft
198
Checking the Oil Pump
198
Checking the Crankshaft
199
Installing the Crankshaft and Balancer
200
Transmission
201
Checking the Shift Forks
203
Checking the Shift Drum
203
Checking the Transmission
204
Checking the Secondary Shaft and Driven Sprocket
204
Checking the Chain
204
Installing the Transmission
205
Middle Gear
206
Middle Drive Pinion Gear Shaft
206
Middle Drive Shaft
207
Removing the Middle Drive Pinion Gear Shaft
209
Removing the Middle Drive Shaft
209
Checking the Pinion Gears
212
Selecting the Middle Drive and Driven Gear Shims
212
Installing the Middle Drive Shaft
215
Installing the Middle Drive Pinion Gear Shaft
218
Measuring the Middle Gear Backlash
218
Chapter 5 Cooling System
219
Radiator and Coolant Reservoir
219
Checking the Radiator
221
Water Pump
222
Disassembling the Water Pump
224
Checking the Water Pump
224
Assembling the Water Pump
225
Oil Cooler
227
Checking the Oil Cooler
229
Chapter 6 Fuel System
230
Fuel Pump and Fuel Tank
230
Checking the Fuel Pump Operation
232
Carburetor
233
Disassembling the Carburetor
237
Checking the Carburetor
237
Assembling the Carburetor
239
Adjusting the Fuel Level
240
Installing the Carburetor
241
Chapter 7 Drive Train
242
Troubleshooting
242
Front Constant Velocity Joints, Differential Gear and Front Drive Shaft
245
Disassembling the Universal Joint
250
Disassembling the Differential Gear
250
Checking the Constant Velocity Joints
251
Checking the Differential Gear
251
Checking the Gear Motor
252
Assembling the Front Constant Velocity Joints
252
Assembling the Differential Gear
253
Assembling the Universal Joint
255
Measuring and Adjusting the Differential Gear Lash
255
Checking the Differential Operation
257
Rear Constant Velocity Joints, Final Drive Gear and Rear Drive Shaft
259
Assembling the Rear Constant Velocity Joints
265
Disassembling the Final Drive Gear
265
Removing the Final Drive Roller Bearings
266
Installing the Final Drive Roller Bearings
267
Positioning the Final Drive Pinion Gear and Ring Gear
267
Checking the Rear Drive Shaft
272
Checking the Final Drive Gear Assembly
272
Measuring and Adjusting the Final Gear Lash
273
Assembling the Final Drive Gear Assembly
274
Chapter 8
277
Front Guard and Hood
277
Chassis
277
Seats, Console and Instrument Panels
278
Panels and Footrest Cover
280
Cargo Bed
281
Skid Plates
283
Installing the Rear Skid Plate
284
Enclosure and Seat Belts
285
Seats, Enclosure, Hood and Cargo Bed
277
Front Wheels and Brake Discs
286
Checking the Front Wheels
288
Checking the Front Wheel Hubs
288
Checking the Front Brake Discs
289
Installing the Front Wheel Hubs
289
Installing the Front Wheels
289
Rear Wheels and Brake Disc
290
Rear Wheels
290
Rear Brake Disc
291
Checking the Rear Wheels
292
Checking the Rear Wheel Hubs
292
Checking the Rear Brake Disc
292
Installing the Rear Wheel Hubs
293
Installing the Rear Wheels
293
Front and Rear Brakes
294
Front Brake Pads
294
Rear Brake Pads
295
Replacing the Front Brake Pads
296
Replacing the Rear Brake Pads
297
Brake Master Cylinder
300
Checking the Master Cylinder
302
Assembling the Brake Master Cylinder
302
Installing the Brake Master Cylinder
303
Front Brake Calipers
305
Rear Brake Caliper
307
Removing the Rear Brake Caliper
311
Disassembling the Front Brake Calipers
311
Disassembling the Rear Brake Caliper
311
Checking the Front and Rear Brake Calipers
312
Assembling the Front Brake Calipers
313
Assembling the Rear Brake Caliper
314
Installing the Front Brake Calipers
316
Installing the Rear Brake Caliper
317
Pedal Assembly
319
Steering System
321
Steering Column and Steering Assembly
321
Disassembling the Steering Assembly
324
Checking the Steering Joint
324
Checking the Steering Assembly
324
Assembling the Steering Assembly
325
Installing the Steering System
326
Tie-Rods and Steering Knuckles
327
Removing the Steering Knuckles
328
Checking the Tie-Rods
328
Checking the Steering Knuckles
328
Front Arms and Front Shock Absorbers
332
Removing the Front Arms
334
Checking the Front Arms
334
Checking the Front Shock Absorbers
336
Installing the Front Arms and Front Shock Absorbers
337
Rear Knuckles and Stabilizer
338
Checking the Rear Knuckles
339
Checking the Stabilizer
339
Installing the Stabilizer
340
Rear Arms and Rear Shock Absorbers
341
Checking the Rear Arms
342
Checking the Rear Shock Absorbers
342
Installing the Rear Arms and Rear Shock Absorbers
343
Chapter 9 Electrical
344
Electrical Components
345
Checking the Switches
346
Checking a Switch Shown in the Manual
346
Checking the Switch Continuity
348
Checking the Bulbs and Bulb Sockets
350
Types of Bulbs
350
Checking the Condition of the Bulbs
350
Checking the Condition of the Bulb Sockets
352
Ignition System
353
Circuit Diagram
353
Troubleshooting
354
Electric Starting System
359
Circuit Diagram
359
Starting Circuit Operation
360
Troubleshooting
361
Starter Motor
364
Checking the Starter Motor
365
Assembling the Starter Motor
366
Charging System
367
Circuit Diagram
367
Troubleshooting
368
Circuit Diagram
370
Troubleshooting
371
Checking the Lighting System
373
Signaling System
376
Circuit Diagram
376
Troubleshooting
378
Checking the Signal System
380
Cooling System
390
Circuit Diagram
390
Troubleshooting
391
2Wd/4Wd Selecting System
395
Circuit Diagram
395
Troubleshooting
396
Carburetor Heating System
400
Circuit Diagram
400
Troubleshooting
404
Chapter 10
404
Fuel System
404
Electrical System
404
Compression System
405
Starting Failure/Hard Starting
404
Poor Idle Speed Performance
405
Poor Medium and High-Speed Performance
405
Faulty Drive Train
406
Faulty Gear Shifting
407
Hard Shifting
407
Shift Lever Does Not Move
407
Jumps out of Gear
407
Poor Speed Performance
408
Unstable Handling
409
5
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Yamaha Rhino 450 YXR45FAV Specifications
General
Brand
Yamaha
Model
Rhino 450 YXR45FAV
Category
Offroad Vehicle
Language
English
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