YFM45FAR

YFM450FAR

5ND2-AE1

SERVICE MANUAL

YFM45FAR/YFM450FAR

SERVICE MANUAL

©2002 by Yamaha Motor Co., Ltd.

First edition, March 2002

All rights reserved.

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

EB001000

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 machine has a basic understanding of the mechanical ideas and the procedures of

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

machine unsafe and unfit for use.

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

significant 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:

Designs and specifications are subject to change without notice.

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 machine operator, a bystander or a person inspecting or repairing the

machine.

A CAUTION indicates special precautions that must be taken to avoid

damage to the machine.

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

WARNING

CAUTION:

NOTE:

EB002000

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “Illustrated 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

accompanied 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.

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1 to 0 are printed on the

top right of each page and 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

Illustrated symbols A to H are used to identify

the specifications appearing in the text.

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 Ω, V, A

Illustrated symbols I to N 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 wheel bearing grease

M Apply lithium-soap-based grease

N Apply molybdenum disulfide grease

Illustrated symbols O to P in the exploded

diagrams indicate where to apply a locking

agent O and when to install a new part P.

O Apply the locking agent (LOCTITE^®)

P 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

GEN

INFO

SPEC

CHK

ADJ

ENG

COOL

CARB

DRIV

CHAS

–

+

ELEC

TRBL

SHTG

T R

.

.

E

G

M

B

LS

M

LT

New

TABLE OF CONTENTS

GENERAL INFORMATION

GEN

INFO 1

SPECIFICATIONS

SPEC 2

PERIODIC CHECKS AND

ADJUSTMENTS

CHK

ADJ 3

ENGINE

ENG 4

COOLING SYSTEM

COOL 5

CARBURETION

CARB 6

DRIVE TRAIN

DRIV 7

CHASSIS

CHAS 8

ELECTRICAL

ELEC 9

TROUBLESHOOTING

TRBL

SHTG 10

–

+

GEN

INFO 1

GEN

INFO

CHAPTER 1.

GENERAL INFORMATION

MACHINE IDENTIFICATION ........................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER ................................................. 1-1

MODEL LABEL ..................................................................................... 1-1

FEATURES ................................................................................................... 1-2

LIQUID COOLING ENGINE .................................................................. 1-2

PARK POSITION .................................................................................. 1-2

FRONT DIFFERENTIAL ....................................................................... 1-3

IMPORTANT INFORMATION ...................................................................... 1-8

PREPARATION FOR REMOVAL PROCEDURES ............................... 1-8

REPLACEMENT PARTS ...................................................................... 1-8

GASKETS, OIL SEALS AND O-RINGS ................................................ 1-8

LOCK WASHERS/PLATES AND COTTER PINS ................................. 1-9

BEARINGS AND OIL SEALS ................................................................ 1-9

CIRCLIPS .............................................................................................. 1-9

CHECKING OF CONNECTIONS ............................................................... 1-10

SPECIAL TOOLS ....................................................................................... 1-11

GEN

INFO

1 - 1

GEN

INFO

MACHINE IDENTIFICATION

GENERAL INFORMATION

MACHINE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is

stamped into the left side of the frame.

MODEL LABEL

The model label 1 is affixed to the frame. This

information will be needed to order spare

parts.

1 - 2

GEN

INFO

FEATURES

LIQUID COOLING ENGINE

Compact liquid cooled 45° inclined engine. A

liquid cooling system has been incorporated

for stable power and engine endurance.

1 Radiator

2 Thermo switch

3 Fan motor

PARK POSITION

When the drive select lever is shifted into the

park position, a stopper lever is engaged into

the stopper gear preventing the drive select

lever and transmission from moving.

When the drive select lever is at the “L”, “H”,

“N”, or “R” positions, the stopper lever end 1

is moved away from the stopper gear 2 by the

return spring 3.

When the drive select lever is in the “P”

position, the lever cam 4 at the side of the

shift cam 5 lifts the stopper lever end 6 and

the stopper lever end locks the drive axle 7.

When the stopper lever end 1 is not

synchronized, a torsion spring 8 retains the

rotation force of the shift cam 5 until it is

synchronized.

FEATURES

GEN

INFO

1 - 3

FEATURES

FRONT DIFFERENTIAL

1 Adapter

2 Drive clutch

3 Differential side gear (left)

4 Differential pinion gear

5 Ring gear

6 Differential side gear (right)

7 Drive pinion gear

8 Gear motor

È To front wheel

É From the middle gear

GEN

INFO

1 - 4

FEATURES

2WD

Power is transmitted as follows: middle gear → front drive shaft → drive pinion gear 7 → ring gear

5 → differential pinion gear 4. In the 2WD mode, the left differential side gear 3 and the drive

clutch 2 are not engaged, therefore, the left side gear runs idle and does not transmit power to the

left front constant velocity joint.