2008

SUPPLEMENTARY

SERVICE MANUAL

LIT-11616-21-46

5ND-F8197-13

YFM45FGX

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

YFM45FGX. For complete service information procedures it is necessary to use this Supplementary

Service Manual together with the following manual.

YFM450FAR SERVICE MANUAL: LIT-11616-16-01 (5ND-F8197-10)

YFM450FAS SUPPLEMENTARY SERVICE MANUAL: LIT-11616-17-25 (5ND-F8197-11)

YFM450FAT SUPPLEMENTARY SERVICE MANUAL: LIT-11616-18-35 (5ND-F8197-12)

YFM45FGX

SUPPLEMENTARY

SERVICE MANUAL

©2007 by Yamaha Motor Corporation, U.S.A.

First edition, July 2007

All rights reserved.

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

LIT-11616-21-46

EBS00002

NOTICE

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers

and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one

manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on

Yamaha vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle

repair. Repairs attempted by anyone without this knowledge are likely to render the vehicle unsafe

and unfit for use.

This model has been designed and manufactured to perform within certain specifications in regard

to performance and emissions. Proper service with the correct tools is necessary to ensure that the

vehicle will operate as designed. If there is any question about a service procedure, it is imperative

that you contact a Yamaha dealer for any service information changes that apply to this model. This

policy is intended to provide the customer with the most satisfaction from his vehicle and to conform

to federal environmental quality objectives.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers

and will appear in future editions of this manual where applicable.

NOTE:

_

• This Service Manual contains information regarding periodic maintenance to the emission control

system. Please read this material carefully.

• Designs and specifications are subject to change without notice.

EBS00003

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

the vehicle operator, a bystander or a person checking or repairing the vehicle.

A CAUTION indicates special precautions that must be taken to avoid damage

to the vehicle.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

EBS00004

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “symbols”)

1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.

2nd title 2: This title indicates the section of the chapter and only appears on the first page of each

section. It is located in the upper left corner of the page.

3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa-

nied by corresponding illustrations.

EXPLODED DIAGRAMS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.

2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed

by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

6. The meanings of the symbol marks are given on the next page.

4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition

to the exploded diagram and the job instruction chart.

EBS00006

SYMBOLS

The following symbols are not relevant to

every vehicle.

Symbols 1 to 0 indicate the subject of each

chapter.

1 General information

2 Specifications

3 Periodic checks and adjustments

4 Engine

5 Cooling system

6 Carburetion

7 Drive train

8 Chassis

9 Electrical

0 Troubleshooting

Symbols A to H indicate the following

A Can be serviced with engine mounted

B Filling fluid

C Lubricant

D Special tool

E Torque

F Wear limit, clearance

G Engine speed

H Electrical data (Ω, V, A)

Symbols I to P in the exploded diagrams

indicate the types of lubricants and lubrication

points.

I Apply engine oil

J Apply gear oil

K Apply molybdenum disulfide oil

L Apply brake fluid

M Apply wheel bearing grease

N Apply lithium-soap-based grease

O Apply molybdenum disulfide grease

P Apply silicone grease

Symbols Q to R in the exploded diagrams

indicate where to apply a locking agent Q and

when to install a new part R.

Q Apply the locking agent (LOCTITE^®)

R Replace

1

2

3

4

5

6

7

8

9

0

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

GEN

INFO

SPEC

CHK

ADJ

ENG

COOL

CARB

DRIV

CHAS

–

+

ELEC

TRBL

SHTG

T R

.

.

E

G

M

BF

B

LS

M

S

LT

New

CONTENTS

GENERAL INFORMATION ................................................................................ 1

SPECIAL TOOLS ......................................................................................... 1

SPECIFICATIONS.............................................................................................. 3

GENERAL SPECIFICATIONS ..................................................................... 3

ENGINE SPECIFICATIONS......................................................................... 6

CHASSIS SPECIFICATIONS....................................................................... 7

ELECTRICAL SPECIFICATIONS ................................................................ 8

TIGHTENING TORQUES............................................................................. 9

CHASSIS TIGHTENING TORQUES ..................................................... 9

CABLE ROUTING ...................................................................................... 10

PERIODIC CHECKS AND ADJUSTMENTS.................................................... 19

INTRODUCTION........................................................................................ 19

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL

SYSTEM.................................................................................................... 19

GENERAL MAINTENANCE AND LUBRICATION CHART ....................... 20

CHASSIS.................................................................................................... 22

ADJUSTING THE BRAKE PEDAL HEIGHT........................................ 22

ADJUSTING THE REAR BRAKE ........................................................ 23

CHECKING THE REAR BRAKE FRICTION PLATES......................... 24

ADJUSTING THE SELECT LEVER CONTROL CABLE AND

SHIFT ROD......................................................................................... 25

ADJUSTING THE BRAKE PEDAL LIGHT SWITCH............................ 26

CHECKING THE FINAL GEAR OIL LEVEL......................................... 27

CHANGING THE FINAL GEAR OIL .................................................... 28

CHECKING THE DIFFERENTIAL GEAR OIL LEVEL ......................... 29

CHANGING THE DIFFERENTIAL GEAR OIL..................................... 29

DRIVE TRAIN ................................................................................................... 31

FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR ... 31

CHECKING THE DIFFERENTIAL GEAR MOTOR.............................. 35

ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS........... 35

ASSEMBLING THE DIFFERENTIAL GEAR........................................ 36

MEASURING THE DIFFERENTIAL GEAR LASH............................... 38

ADJUSTING THE DIFFERENTIAL GEAR LASH ................................ 39

REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR

AND DRIVE SHAFT .................................................................................. 40

CHECKING THE FINAL DRIVE GEAR................................................ 45

DISASSEMBLING THE FINAL DRIVE PINION GEAR AND

BEARING............................................................................................ 45

INSTALLING THE FINAL DRIVE PINION GEAR AND BEARING ...... 45

POSITIONING THE FINAL DRIVE PINION GEAR AND

RING GEAR........................................................................................ 46

MEASURING THE RING GEAR THRUST CLEARANCE ................... 46

MEASUREMENT THE FINAL GEAR LASH ........................................ 47

ADJUSTING THE FINAL GEAR LASH................................................ 48

ASSEMBLING THE FINAL DRIVE GEAR ........................................... 49

INSTALLING THE FINAL GEAR CASE............................................... 51

CHASSIS .......................................................................................................... 52

FRONT AND REAR WHEELS ................................................................... 52

FRONT WHEELS................................................................................. 52

INSTALLING THE WHEEL HUBS ....................................................... 54

FRONT AND REAR BRAKES.................................................................... 55

BRAKE PEDAL .................................................................................... 55

FINAL GEAR CASE (REAR BRAKE) .................................................. 56

CHECKING THE FRICTION PLATES ................................................. 58

CHECKING THE REAR BRAKE PLATES........................................... 58

CHECKING THE REAR BRAKE SPRINGS......................................... 59

CHECKING THE PRESSURE PLATE................................................. 59

CHECKING THE RING GEAR............................................................. 59

STEERING SYSTEM ................................................................................. 60

TIE ROD AND STEERING KNUCKLE................................................. 60

REAR KNUCKLES AND STABILIZER....................................................... 62

ELECTRICAL ................................................................................................... 63

ELECTRICAL COMPONENTS................................................................... 63

CHECKING THE SWITCHES .................................................................... 66

CHECKING THE SWITCH CONTINUITY............................................ 66

LIGHTING SYSTEM................................................................................... 68

CIRCUIT DIAGRAM............................................................................. 68

TROUBLESHOOTING......................................................................... 69

CHECKING THE LIGHTING SYSTEM ................................................ 70

YFM45FGX 2008 WIRING DIAGRAM

– 1 –

GEN

INFO

GENERAL INFORMATION

EBS00021

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use

only the appropriate special tools; this will help prevent damage caused by the use of inappropriate

tools or improvised techniques. Special tools may differ by shape and part number from country to

country. In such a case, two types are provided.

When placing an order, refer to the list provided below to avoid any mistakes.

For US and CDN

P/N. YM-, YU-, YS-, YK-, ACC-

Except for US and CDN

P/N. 90890-

Tool No.

Tool name/How to use

Illustration

90890-01467

YM-01467

Gear lash measurement tool

This tool is used to measure the gear

lash.

90890-01475

YM-01475

Gear lash measurement tool

Middle drive gear lash tool

This tool is used to measure the gear

lash.

90890-01527

YM-01527

Ring gear fix bolt (M10)

This tool is used to measure the gear

lash.

90890-01530

YM-01530

Ring gear fix bolt (M12)

This tool is used to measure the gear

lash.

90890-04062

YM-04062

Universal joint holder

This tool is needed when removing or

installing the universal joint yoke nut.

M10×P1.25

M12×P1.5

SPECIAL TOOLS

– 2 –

GEN

INFO

SPECIAL TOOLS

90890-85505

Yamaha bond No. 1215

(Three bond No.1215^®)

This bond is used on crankcase mating

surfaces, etc.

Tool No.

Tool name/How to use

Illustration

– 3 –

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item

Standard

Model code

17S1, 17S5 (for USA) (for panel wheel models)

17S2, 17S6 (for CDN) (for panel wheel models)

17S3, 17S7 (for Europe) (for panel wheel mod-

els)

17S4 (for Oceania)

17SA (for USA) (for cast wheel models)

17SB (for CDN) (for cast wheel models)

17SC (for Europe) (for cast wheel models)

Basic weight

With oil and full fuel tank

285 kg (628 lb) (for USA and CDN) (for panel

wheel models)

284 kg (626 lb) (for Europe) (for panel wheel

models)

288 kg (635 lb) (for Oceania)

Oil type or grade

Engine oil

For USA and CDN

For Europe and Oceania

API service SG type or higher, JASO standard

MA

Final gear oil

Yamaha Friction Modified Shaft Drive Gear Oil

(Part No.: ACC-SHAFT-LU-00) (for USA and

Oceania)

Yamaha Friction Modified Shaft Drive Gear Oil

(for CDN and Europe)

0

10

30

50

70

90

110

130 ˚F

YAMALUBE 4 (10W-30) or SAE 10W-30

-20

-10

0

10

20

30

40

50 ˚C

YAMALUBE 4 (20W-40) or SAE 20W-40

YAMALUBE 4-CW (5W-30) or SAE 5W-30

-20

-10

0

10

20

30

40

50 ˚C

SAE 15W-40

SAE 20W-40

SAE 20W-50

SAE 10W-40

SAE 5W-30

SAE 10W-30

GENERAL SPECIFICATIONS

– 4 –

SPEC

GENERAL SPECIFICATIONS

Differential gear oil

Yamaha Friction Modified Shaft Drive Gear Oil

(Part No.: ACC-SHAFT-LU-00) or SAE 80 API

GL-4 Hypoid gear oil (for USA and Oceania)

Yamaha Friction Modified Shaft Drive Gear Oil

or SAE 80 API GL-4 Hypoid gear oil (for CDN

and Europe)

Oil capacity

Engine oil

Periodic oil change

2.30 L (2.02 Imp qt, 2.43 US qt)

With oil filter replacement

2.40 L (2.11 Imp qt, 2.54 US qt)

Total amount

2.60 L (2.29 Imp qt, 2.75 US qt)

Final gear case oil

Periodic oil change

0.50 L (0.44 Imp qt, 0.53 US qt)

Total amount

0.53 L (0.47 Imp qt, 0.56 US qt)

Differential gear case oil

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)

Radiator capacity (including all routes)

1.32 L (1.16 Imp qt, 1.40 US qt)

Chassis

Frame type

Steel tube frame

Caster angle

2.5°

Camber angle

1°

Kingpin angle

11°

Kingpin offset

–5.0 mm (–0.20 in)

Trail

8.5 mm (0.33 in)

Tread (STD)

front

850 mm (33.46 in)

rear

839 mm (33.03 in)

Toe-in

0 ~ 10 mm (0 ~ 0.39 in)

Brakes

Front brake

type

Dual disc brake

operation

Right hand operation

Rear brake

type

Wet, multiple-plate brake

operation

Left hand and right foot operation

Item

Standard

– 5 –

SPEC

Tires

Type

Tubeless

Size

front

AT25 × 8-12

rear

AT25 × 10-12

Manufacturer

front

MAXXIS (for USA, CDN, and Europe) (for panel

wheel models)

CHENG SHIN (for Oceania)

ITP (for USA, CDN, and Europe) (for cast wheel

models)

rear

MAXXIS (for USA, CDN, and Europe) (for panel

wheel models)

CHENG SHIN (for Oceania)

ITP (for USA, CDN, and Europe) (for cast wheel

models)

Model

front

M979 (for USA, CDN, and Europe) (for panel

wheel models)

C-828 (for Oceania)

MUD LITE (for USA, CDN, and Europe) (for

cast wheel models)

rear

M980 (for USA, CDN, and Europe) (for panel

wheel models)

C-828 (for Oceania)

MUD LITE (for USA, CDN, and Europe) (for

cast wheel models)

Item

Standard

GENERAL SPECIFICATIONS

– 6 –

SPEC

ENGINE SPECIFICATIONS

ENGINE SPECIFICATIONS

Item

Standard

Limit

Carburetor

I. D. mark

1D9M 10 (for USA and CDN)

----

5ND6 00 (for Europe and Oce-

ania)

----

Main jet

(M.J)

#131.3

----

Main air jet

(M.A.J)

#50

----

Jet needle

(J.N)

5EP19-1 (for USA and CDN)

----

5EP13-55-3 (for Europe and Oce-

ania)

----

Needle jet

(N.J)

P-0M

----

Pilot air jet

(P.A.J.1)

#80

----

Pilot air jet

(P.A.J.2)

1.3

----

Pilot outlet

(P.O)

0.95

----

Pilot jet

(P.J)

#17.5

----

Bypass 1

(B.P.1)

0.8

----

Bypass 2

(B.P.2)

0.8

----

Bypass 3

(B.P.3)

0.8

----

Valve seat size

(V.S)

2.0

----

Starter jet

(G.S.1)

#70

----

Starter jet

(G.S.2)

0.9

----

Throttle valve size

(Th.V)

#90

----

Float height

(F.H)

13 mm (0.51 in)

----

Fuel level

(F.L)

4.0 ~ 5.0 mm (0.16 ~ 0.20 in)

----

Engine idle speed

1,450 ~ 1,550 r/min

----

Intake vacuum

33.3 kPa (250 mmHg, 9.84 inHg)

----

– 7 –

SPEC

CHASSIS SPECIFICATIONS

CHASSIS SPECIFICATIONS

Item

Standard

Limit

Front suspension

Shock absorber travel

99 mm (3.90 in)

----

Fork spring free length

286.6 mm (11.28 in)

----

Spring fitting length

233.5 mm (9.19 in)

----

Spring rate

(K1)

15 N/mm

(1.53 kg/mm, 85.65 lb/in)

----

Stroke

(K1)

0 ~ 99 mm (0 ~ 3.90 in)

----

Optional spring

No

----

Rear suspension

Shock absorber travel

95 mm (3.74 in)

----

Spring free length

279.5 mm (11.00 in)

----

Spring fitting length

249.5 mm (9.82 in)

----

Spring rate

(K1)

27 N/mm

(2.75 kg/mm, 154.17 lb/in)

----

Stroke

(K1)

0 ~ 95 mm (0 ~ 3.74 in)

----

Optional spring

No

----

Rear disc brake

Type

Wet, multiple-plate brake

----

Friction plate diameter

144.50 mm (5.69 in)

----

Friction plate thickness

2.45 mm (0.10 in)

2.22 mm

(0.09 in)

Rear brake plate thickness

2.29 mm (0.09 in)

2.14 mm

(0.08 in)

Front wheel

Type

Panel wheel (for panel wheel

models)

----

Cast wheel (for cast wheel mod-

els)

----

Rim size

12 × 6.0 AT

----

Rim material

Steel (for panel wheel models)

----

Aluminum (for cast wheel mod-

els)

----

Rim runout limit

radial

----

2 mm

(0.08 in)

lateral

----

2 mm

(0.08 in)