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Yamaha YFM45FAR User Manual

Yamaha YFM45FAR
405 pages
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YFM45FAR
YFM450FAR
5ND2-AE1
SERVICE MANUAL

Table of Contents

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Yamaha YFM45FAR Specifications

General IconGeneral
BrandYamaha
ModelYFM45FAR
CategoryOffroad Vehicle
LanguageEnglish

Summary

How to Use This Manual

Manual Organization

Explains the structure of the service manual, including chapter titles, section titles, and sub-sections.

Illustrated Symbols

Defines the meaning of various symbols used throughout the manual for chapters, specifications, and lubrication points.

Chapter 1. General Information

Machine Identification

Details on identifying the vehicle's serial number and model label for parts ordering and reference.

Features

Highlights key features of the vehicle, such as the liquid-cooled engine, park position, and front differential.

Important Information

Provides crucial guidance on preparation for removal, replacement parts, and handling of specific components like gaskets and circlips.

Checking of Connections

Instructions on how to inspect and ensure proper continuity and connections of electrical connectors.

Special Tools

Lists and illustrates specific tools required for tune-up and assembly to prevent damage from incorrect tools.

Chapter 2. Specifications

General Specifications

Provides overall vehicle dimensions, weight, engine type, displacement, bore/stroke, and starting system details.

Maintenance Specifications

Details on engine, chassis, and electrical specifications, including limits and standard measurements for various components.

General Torque Specifications

Specifies standard torque values for common fasteners with ISO pitch threads.

Lubrication Points and Lubricant Types

Identifies specific lubrication points on the engine and the recommended lubricant types for each.

Coolant Flow Diagrams

Illustrates the flow of coolant through the system, showing the path from the radiator to other components.

Oil Flow Diagrams

Diagrams showing the path of oil circulation through the engine, including the camshaft, crankshaft, and drive axle.

Cable Routing

Diagrams illustrating the correct routing of various cables and hoses throughout the vehicle.

Chapter 3. Periodic Checks and Adjustments

Periodic Maintenance/Lubrication

Outlines recommended maintenance intervals and lubrication schedules for various vehicle components.

Seat, Carriers, Fenders and Fuel Tank

Procedures for removing and installing seat, side panels, front carrier, bumper, fender, and fuel tank.

Footrest Boards

Instructions for removing and installing the left and right footrest boards and brackets.

Engine

Covers checks and adjustments for engine components like valve clearance, idling speed, and spark plug.

Chassis

Procedures for adjusting brakes, checking fluid levels, and inspecting chassis components like tires and wheels.

Electrical

Guidance on checking and maintaining electrical components such as the battery, fuses, switches, and lights.

Chapter 4. Engine

Engine Removal

Step-by-step instructions for removing the engine, including air ducts, muffler, and exhaust pipe.

Cylinder Head

Procedures for removing, checking, and installing the cylinder head, tappet covers, and timing chain components.

Camshaft, Rocker Arms and Valves

Instructions for removing, checking, and installing camshaft, rocker arms, valves, and related components.

Cylinder and Piston

Procedures for removing, checking, and installing the cylinder, piston, piston rings, and related parts.

Recoil Starter and A.C. Magneto

Details on removing, disassembling, and checking the recoil starter, A.C. magneto, CDI, and starter clutch.

Primary and Secondary Sheaves

Instructions for removing, disassembling, checking, and assembling the primary and secondary sheaves.

Clutch

Procedures for removing, checking, and installing the clutch assembly, including the one-way clutch bearing.

Crankcase

Steps for removing starter motor, timing chain, oil filter, separating crankcase, and checking bearings.

Crankshaft and Oil Pump

Procedures for removing the crankshaft, checking the oil pump, and installing the crankshaft and balancer.

Transmission

Details on checking shift forks, shift cam, transmission, and installing the transmission assembly.

Middle Gear

Procedures for removing and installing middle drive/driven shafts, checking pinion gears, and measuring backlash.

Chapter 5. Cooling System

Radiator

Instructions for removing, checking radiator fins, hoses, and cap pressure, and installing the radiator.

Thermostat

Procedures for checking thermostat operation and installing the thermostat and cover.

Water Pump

Steps for removing, disassembling, checking, and assembling the water pump.

Chapter 6. Carburetion

Carburetor

Procedures for removing, checking, and assembling the carburetor, including float height adjustment.

Chapter 7. Drive Train

Troubleshooting

Diagnoses common drive train problems, symptoms, and possible causes like bearing damage or gear lash.

Front Constant Velocity Joints and Differential Gear

Procedures for removing, disassembling, checking, and assembling CV joints and the differential gear.

Rear Axle/Final Drive Gear and Drive Shaft

Instructions for removing, disassembling, replacing bearings, and checking/adjusting final drive gear lash.

Chapter 8. Chassis

Front and Rear Wheels

Procedures for removing, checking, and installing front and rear wheels, hubs, and brake discs.

Front and Rear Brakes

Instructions for replacing brake pads, checking master cylinders, calipers, and bleeding the brake system.

Steering System

Procedures for removing/installing handlebars, steering stem, tie rods, and checking steering knuckle.

Front Arms and Front Shock Absorber

Steps for removing, checking, and installing front arms, ball joints, and front shock absorbers.

Rear Shock Absorber and Swingarm

Procedures for removing, checking, and installing rear shock absorber, swingarm, and axle housing.

Chapter 9. Electrical

Electrical Components

Overview of major electrical components with identification numbers and locations.

Checking the Switch

Guidance on testing switch continuity and checking switch positions using a pocket tester.

Checking the Bulbs and Bulb Sockets

Procedures for checking bulb and socket condition, continuity, and types of bulbs used.

Ignition System

Troubleshooting steps for ignition system failures, including checks for fuses, battery, spark plug, and coil resistance.

Electric Starting System

Troubleshooting steps for starter motor failure, covering fuses, battery, starter motor, relay, and wiring connections.

Charging System

Troubleshooting steps for battery not charging, including checks for fuses, battery, charging voltage, and coil resistance.

Lighting System

Troubleshooting procedures for headlights and taillights failing to come on, checking bulbs, voltage, and wiring.

Signal System

Troubleshooting for indicator lights, horn, and coolant temperature warning light failures.

Cooling System

Troubleshooting steps for fan motor failure, covering fuses, battery, main switch, and wiring connections.

2WD/4WD Selecting System

Troubleshooting for gear motor failure, including checks for fuses, battery, switches, relays, and wiring.

Chapter 10. Troubleshooting

Starting Failure/Hard Starting

Covers potential causes and checks for engine starting issues related to fuel, electrical, compression, and carburetor systems.

Poor Idle Speed Performance

Identifies causes for unstable or incorrect engine idle speed, including carburetor and electrical system issues.

Poor Medium and High-Speed Performance

Addresses issues affecting engine performance at medium and high speeds, focusing on fuel and air filter systems.

Faulty Drive Train

Diagnoses problems related to the shaft drive train, such as hesitation, noises, or locked-up conditions.

Faulty Gear Shifting

Covers issues like hard shifting, stuck shift levers, and gears jumping out, related to shift components and transmission.

Faulty Clutch Performance

Addresses problems like engine operating but machine not moving, clutch slipping, poor starting, and poor speed performance.

Overheating

Lists causes for engine overheating, including ignition, fuel, compression, oil, and cooling system issues.

Faulty Brake

Covers poor braking effect due to worn pads, discs, fluid issues, or master cylinder/caliper problems.

Shock Absorber Malfunction

Identifies malfunctions related to damper rod, oil seals, or shock absorber springs.

Unstable Handling

Discusses causes of unstable handling related to handlebars, steering, tires, wheels, and frame issues.

Lighting System

Troubleshooting for headlights being dark, possibly due to bulb issues, electrical problems, or incorrect connections.

Bulb Burnt Out

Potential causes for burnt-out bulbs, including battery, rectifier, switches, and bulb life.

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