Yamaha YFM45FAT Supplementary Service Manual
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Yamaha YFM45FAT Supplementary Service Manual

Yamaha YFM45FAT Supplementary Service Manual

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YFM45FAT
YFM450FAT
5ND2-AE3
SUPPLEMENTARY
SERVICE MANUAL

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Summary of Contents for Yamaha YFM45FAT

  • Page 1 YFM45FAT YFM450FAT 5ND2-AE3 SUPPLEMENTARY SERVICE MANUAL...
  • Page 3 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YFM45FAT/YFM450FAT. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. YFM45FAR/YFM450FAR SERVICE MANUAL: 5ND2-AE1...
  • Page 4 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.
  • Page 5 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.
  • Page 6 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 0 are printed on the SPEC INFO 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 COOL...

  • Page 7: Table Of Contents

    CONTENTS SPECIFICATIONS ....................1 GENERAL SPECIFICATIONS ..............1 MAINTENANCE SPECIFICATIONS ............3 ENGINE ....................3 CHASSIS ....................4 ELECTRICAL ..................6 CABLE ROUTING ..................7 PERIODIC CHECKS AND ADJUSTMENTS ..........18 INTRODUCTION ..................18 PERIODIC MAINTENANCE/LUBRICATION ...........18 SEAT, CARRIERS, FENDERS AND FUEL TANK ........20 FRONT CARRIER, FRONT BUMPER AND FRONT FENDER ..20 CHASSIS ....................22 ADJUSTING THE REAR BRAKE ............22 CHECKING THE FINAL GEAR OIL LEVEL ........24...
  • Page 8 FRONT ARMS AND FRONT SHOCK ABSORBERS ......57 REAR KNUCKLES AND STABILIZER ............59 CHECKING THE REAR KNUCKLES ..........60 CHECKING THE STABILIZER ............60 REAR ARMS AND REAR SHOCK ABSORBERS ........61 CHECKING THE REAR ARMS ............62 INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBERS ..62 YFM45FAT/YFM450FAT WIRING DIAGRAM...

  • Page 9: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: 1D91, 1D95 (for USA) 1D92, 1D96 (for CDN) 1D93, 1D97 (for Europe) 1D94 (for Oceania) Dimensions: Overall length 1,993 mm (78.5 in) Overall width 1,093 mm (43.0 in) Overall height 1,120 mm (44.1 in) Seat height 830 mm (32.7 in)
  • Page 10 SPEC GENERAL SPECIFICATIONS Item Standard Tires: Type Tubeless AT25 × 8–12 Size front AT25 × 10–12 rear Manufacturer front MAXXIS (for USA, CDN, and Europe) CHENG SHIN (for Oceania) rear MAXXIS (for USA, CDN, and Europe) CHENG SHIN (for Oceania) Model front M911Y (for USA, CDN, and Europe)

  • Page 11: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Carburetor: I. D. mark 5NDC 00 ---- Main jet (M.J) #131.3 ---- Main air jet (M.A.J) ---- Jet needle (J.N) 5EP13-55-3 ---- Needle jet (N.J) P-0M ---- Pilot air jet (P.A.J.1) ---- Pilot air jet (P.A.J.2)

  • Page 12: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Front suspension: Shock absorber travel 99 mm (3.90 in) ---- Fork spring free length 285 mm (11.22 in) ---- Spring fitting length 231.9 mm (9.13 in) ---- Spring rate (K1) 15 N/mm ---- (1.53 kg/mm, 85.68 lb/in) Stroke (K1)
  • Page 13 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Thread Part to be tightened Remarks size Nm m · kg ft · lb Rear shock absorber and sub-frame Rear shock absorber and rear lower arm Rear upper arm and sub-frame Rear lower arm and sub-frame Rear upper arm and rear knuckle Rear lower arm and rear knuckle Stabilizer and sub-frame...

  • Page 14: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit C.D.I.: Magneto model/manufacturer F4T464/MITSUBISHI ---- 459 ~ 561 Ω at 20 °C (68 °F)/ Pickup coil resistance/color ---- White/Red – White/Green 0.086 ~ 0.105 Ω at 20 °C (68 °F)/ Rotor rotation direction sensing coil resis- ---- tance/color Red –...

  • Page 15: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Rear brake switch lead 9 Handlebar switch lead 2 Starter cable 0 Main switch lead 3 Rear brake cable A Fan motor lead 4 Front brake hose B Fan motor breather hose 5 On-command four-wheel drive switch and differ- C Differential gear case breather hose D Sub-wire harness ential gear lock switch...
  • Page 16 SPEC CABLE ROUTING G Coolant reservoir hose Ê Fasten the handlebar switch lead, rear brake H Coolant reservoir breather hose switch lead, and horn switch lead (for Europe and Oceania) behind the handlebar with a plas- È Fasten the on-command four-wheel drive switch tic band.
  • Page 17 SPEC CABLE ROUTING Ì To wire harness Í Loop the horn switch lead (for Europe and Oce- ania) around the plastic band as shown. – 9 –...
  • Page 18 SPEC CABLE ROUTING 1 Sub-wire harness È Fasten the wire harness with a plastic band. 2 Headlight leads É Fasten the auxiliary DC jack lead with a plastic 3 Auxiliary DC jack lead holder. 4 Four-wheel drive relay 3 Ê 50 ~ 60 mm (1.97 ~ 2.36 in) 5 Fan motor breather hose 6 Differential gear case breather hose 7 Coolant reservoir breather hose...
  • Page 19 SPEC CABLE ROUTING 1 Starter cable B Horn (for Europe and Oceania) 2 Fuel tank breather hose È Insert the fuel tank breather hose into the hole of 3 Cylinder head breather hose the handlebar cover. 4 Fuel hose É Fasten the sub-wire harness and differential 5 Carburetor drain hose gear case breather hose with a plastic band.
  • Page 20 SPEC CABLE ROUTING 1 Cylinder head breather hose B Starter cable 2 Final drive gear case breather hose C Float chamber air vent hose 3 Wire harness D Cylinder head breather hose 4 Starter motor lead E Fuel hose 5 Negative battery lead F A.C.
  • Page 21 SPEC CABLE ROUTING K Neutral switch Ê Fasten the wire harness and starter motor lead L Reverse switch with a plastic band. Ë Fasten the low-range switch/high-range switch/ È Fasten the wire harness with a plastic band. neutral switch/reverse switch leads, speed sen- É...
  • Page 22 SPEC CABLE ROUTING 1 Throttle cable È Fasten the radiator inlet hose and spark plug 2 Radiator inlet hose lead with a plastic band. 3 Spark plug lead É Fasten the select lever control cable with a plas- 4 Main switch tic holder.
  • Page 23 SPEC CABLE ROUTING 1 Final drive gear case breather hose È Fasten the final drive gear case breather hose, 2 Rectifier/regulator lead rectifier/regulator lead, and rear brake hose with 3 Rear brake hose a plastic band. 4 Rear brake pipe É...
  • Page 24 SPEC CABLE ROUTING 1 Front brake hose 2 Float chamber air vent hose 3 Throttle cable 4 Wire harness 5 Final drive gear case breather hose 6 Starter cable 7 Rear brake cable – 16 –...
  • Page 25 SPEC CABLE ROUTING 1 Battery È Fasten the positive battery lead with the plastic 2 Positive battery lead holders. 3 Tail/brake light lead 4 CDI unit 5 Negative battery lead – 17 –...

  • Page 26: Periodic Checks And Adjustments

    INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 27 • Correct if necessary. • Check operation. Lights and switches* • Adjust headlight beams. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the ser- vice. NOTE: • Recommended brake fluid: DOT 4 •...

  • Page 28: Seat, Carriers, Fenders And Fuel Tank

    SEAT, CARRIERS, FENDERS AND FUEL TANK SEAT, CARRIERS, FENDERS AND FUEL TANK FRONT CARRIER, FRONT BUMPER AND FRONT FENDER Order Job/Part Q’ty Remarks Removing the front carrier, front Remove the parts in the order below. bumper and front fender Seat and fuel tank side panels Refer to “SEAT AND SIDE PANELS”...
  • Page 29 SEAT, CARRIERS, FENDERS AND FUEL TANK Order Job/Part Q’ty Remarks Meter assembly coupler Disconnect. Sub-wire harness 1 coupler Disconnect. Sub-wire harness 2 coupler Disconnect. Four-wheel drive relay 3 coupler Disconnect. Auxiliary DC jack connector Disconnect. Coolant reservoir breather hose Differential gear case breather hose Fan motor breather hose Front fender For installation, reverse the removal pro-...

  • Page 30: Chassis

    ADJUSTING THE REAR BRAKE CHASSIS ADJUSTING THE REAR BRAKE WARNING Always adjust both the brake pedal and the rear brake lever whenever adjusting the rear brake. 1. Check: • rear brake lever free play a Out of specification → Adjust. Rear brake lever free play 0.5 ~ 2.0 mm (0.02 ~ 0.08 in) 2.
  • Page 31 ADJUSTING THE REAR BRAKE c. Loosen the locknut 4. d. Turn the adjusting bolt 5 until the brake pedal height is within the specified limits. Brake pedal height 67 ~ 77 mm (2.64 ~ 3.03 in) e. Tighten the locknut 4. NOTE: When adjusting the brake pedal height make sure the locknut-to-adjusting bolt clearance a...

  • Page 32: Checking The Final Gear Oil Level

    CHECKING THE FINAL GEAR OIL LEVEL/CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS CHECKING THE FINAL GEAR OIL LEVEL 1. Place the vehicle on a level surface. 2. Remove: • oil filler plug 1 3. Check: • oil level Oil level should be up to the brim of the hole.

  • Page 33: Adjusting The Rear Shock Absorbers

    ADJUSTING THE REAR SHOCK ABSORBERS ADJUSTING THE REAR SHOCK ABSORBERS WARNING Always adjust both shock absorber spring preload to the same setting. Uneven adjust- ment can cause poor handling and loss of stability. NOTE: The spring preload of the shock absorbers can be adjusted to suit the operator’s preference, weight, and the operating conditions.

  • Page 34: Engine

    MIDDLE GEAR ENGINE MIDDLE GEAR MIDDLE DRIVEN SHAFT Order Job/Part Q’ty Remarks Removing the middle driven shaft Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE” in chapter 4. (Manual No.: 5ND2-AE1) Circlip Refer to “REMOVING THE MIDDLE Bearing DRIVEN SHAFT”...
  • Page 35 MIDDLE GEAR Order Job/Part Q’ty Remarks Damper cam Spring Gear coupling Bearing retainer Middle driven shaft For installation, reverse the removal pro- cedure. – 27 –...

  • Page 36: Drive Train

    DRIV TROUBLESHOOTING DRIVE TRAIN TROUBLESHOOTING The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1. A pronounced hesitation or “jerky” movement A. Bearing damage. during acceleration, deceleration, or sus- B. Improper gear lash. tained speed. (This must not be confused C.
  • Page 37 DRIV TROUBLESHOOTING CAUTION: Too little gear lash is extremely destructive to the gear teeth. If a test ride following reassembly indicates this condition, stop riding immediately to minimize gear dam- age. c. A slight “thunk” evident at low speed opera- tion.
  • Page 38 DRIV TROUBLESHOOTING Troubleshooting chart When basic condition “a” and “b” exist, check the following points: YES Replace the wheel bearings. Elevate and spin both wheels. Feel for wheel bearing damage. (Refer to “STEERING SYSTEM” (Manual No.: 5ND2-AE2) for the front wheel bearings or “REAR KNUCKLES AND STABILIZER”...

  • Page 39: Front Constant Velocity Joints And Differential Gear

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH Measuring the differential gear lash 1. Secure the gear case in a vise or another supporting device. 2. Remove: •...
  • Page 40 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR 2. Adjust: • gear lash M MMM M MMM M MMM M MMM M MMM a. Select the suitable shims using the following chart. Too little gear Reduce shim lash thickness. Too large gear Increase shim lash thickness.

  • Page 41: Rear Constant Velocity Joints, Final Drive Gear And Drive Shaft

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT 48 Nm (4.8 m kg, 35 ft • • 82Nm (8.2 m kg, 59 ft • • 45 Nm (4.5 m kg, 32 ft •...
  • Page 42 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT 48 Nm (4.8 m kg, 35 ft • • 82Nm (8.2 m kg, 59 ft • • 45 Nm (4.5 m kg, 32 ft • • 40 Nm (4.0 m kg, 29 ft •...
  • Page 43 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT Order Job/Part Q’ty Remarks Disassembling the rear constant Remove the parts in the order below. velocity joint Dust cover Circlip Boot band Boot band Dust boot Circlip Refer to “ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS”.
  • Page 44 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT Order Job/Part Q’ty Remarks Disassembling the final drive gear Remove the parts in the order below. Circlip Refer to “DISASSEMBLING THE FINAL Bearing DRIVE GEAR” and “ASSEMBLING THE Drive shaft/universal joint yoke FINAL DRIVE GEAR”.
  • Page 45 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT Order Job/Part Q’ty Remarks Ring gear shim Ring gear Thrust washer Bearing retainer Oil seal Refer to “REPLACING THE FINAL Final drive pinion gear DRIVE PINION GEAR AND BEARING”. Bearing Final drive pinion gear shim Final drive gear case...

  • Page 46: Assembling The Rear Constant Velocity Joints

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS 1. Apply: • lithium-soap base grease (into the ball joint assembly) 2. Install: • dust boots 1 • boot bands 2, 3 M MMM M MMM M MMM M MMM...

  • Page 47: Disassembling The Final Drive Gear

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT DISASSEMBLING THE FINAL DRIVE GEAR 1. Remove: • drive shaft assembly M MMM M MMM M MMM M MMM M MMM a. Remove the circlips 1. b. Place the U-joint in a press. c.

  • Page 48: Checking The Final Drive Gear

    • bearings Damage → Replace. NOTE: • Reusing roller bearing is acceptable, but Yamaha recommends installing new ones. Do not reuse oil seals. • When the final drive pinion gear and/or ring gear are replaced, be sure to adjust the shim of the final drive pinion gear and/or ring gear.

  • Page 49: Replacing The Final Drive Pinion Gear And Bearing

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT 2. Install: • roller bearing 1 Use a suitable press tool 2 and a press to install the above component into the main housing. REPLACING THE FINAL DRIVE PINION GEAR AND BEARING 1.
  • Page 50 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT 4. Install: • final drive pinion gear bearing 1 • final drive pinion gear 2 Use a suitable press tool 3 and a press to install the final drive pinion gear bearing into the final drive pinion gear.

  • Page 51: Positioning The Final Drive Pinion Gear

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT POSITIONING THE FINAL DRIVE PINION GEAR When the final drive pinion gear, ring gear, final drive gear case and/or ring gear bearing housing are replaced, be sure to adjust the positions of the final drive pinion gear using shim.

  • Page 52: Measurement And Adjusting The Final Gear Lash

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT Shims are supplied in the following thick- nesses. Final drive pinion gear shim 0.15 0.30 0.40 Thickness (mm) 0.45 0.50 L LLL L LLL L LLL L LLL L LLL MEASUREMENT AND ADJUSTING THE FINAL GEAR LASH Final gear lash measurement...
  • Page 53 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT 4. Measure: • gear lash Gently rotate the gear coupling from engagement to engagement Final gear lash 0.1 ~ 0.2 mm (0.004 ~ 0.008 in) NOTE: • Secure the gear case with the ring gear bear- ing housing side facing down.
  • Page 54 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT Ring gear thrust clearance adjustment 1. Measure/adjust: • ring gear thrust clearance “C” M MMM M MMM M MMM M MMM M MMM ® a. Place four pieces of Plastigauge between the thrust washer and the ring gear.

  • Page 55: Assembling The Final Drive Gear

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT Ring gear stopper adjustment 1. Install: • ring gear stopper • nut 2. Adjust: • ring gear stopper clearance M MMM M MMM M MMM M MMM M MMM a.
  • Page 56 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT 3. Install: • universal joint yoke • washer • nut 1 97 Nm (9.7 m · kg, 70 ft · lb) NOTE: Use the universal joint holder 2 to hold the yoke.

  • Page 57: Chassis

    CHAS FRONT AND REAR WHEELS CHASSIS FRONT AND REAR WHEELS REAR WHEELS 260 Nm (26.0 m kg, 190 ft • • 260 Nm (26.0 m kg, 190 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft •...
  • Page 58 CHAS FRONT AND REAR WHEELS 260 Nm (26.0 m kg, 190 ft • • 260 Nm (26.0 m kg, 190 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • •...

  • Page 59: Installing The Rear Brake Disc

    CHAS FRONT AND REAR WHEELS INSTALLING THE REAR BRAKE DISC 1. Install: • brake disc 30 Nm (3.0 m · kg, 22 ft · lb) NOTE: Install the brake disc to the rear wheel hub with the “IN” mark facing away from the wheel hub. INSTALLING THE REAR WHEEL HUBS 1.

  • Page 60: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES FRONT AND REAR BRAKES REAR BRAKE PADS 17 Nm (1.7 m kg, 12 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order below. Rear wheel (left) Refer to “FRONT AND REAR WHEELS”.

  • Page 61: Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES REAR BRAKE CALIPER 17 Nm (1.7 m kg, 12 ft • • 30 Nm (3.0 m kg, 22 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order below.
  • Page 62 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Disassembling the rear brake cali- Remove the parts in the order below. Brake pad holding bolt Brake pad/insulator/pad shim 2/2/2 Pad spring Caliper bracket Brake caliper piston Refer to “DISASSEMBLING THE FRONT AND REAR BRAKE CALIPER”...

  • Page 63: Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EBS00436 INSTALLING THE REAR BRAKE CALIPER 1. Install: • brake caliper assembly 40~50˚ • brake caliper mounting bolts 30 Nm (3.0 m · kg, 22 ft · lb) • brake hose 1 • copper washers •...
  • Page 64 CHAS FRONT AND REAR BRAKES 3. Air bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. (Manual No.: 5ND2-AE1) 4. Check: • brake fluid level Brake fluid level is below the “MIN” level line → Add the recommended brake fluid to the proper level.

  • Page 65: Front Arms And Front Shock Absorbers

    CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS FRONT ARMS AND FRONT SHOCK ABSORBERS Order Job/Part Q’ty Remarks Removing the front arms and front Remove the parts in the order below. shock absorbers Engine skid plate Refer to “SEAT, CARRIERS, FEND- ERS AND FUEL TANK”.
  • Page 66 CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS Order Job/Part Q’ty Remarks Refer to “REMOVING THE FRONT Bolt/nut ARMS” and “INSTALLING THE FRONT Front lower arm/washer/bushing 1/1/2 ARMS AND FRONT SHOCK Nut/bolt ABSORBER” in chapter 8. Front shock absorber (Manual No.: 5ND2-AE1) Bolt/nut Front upper arm/washer/bushing 1/1/2...

  • Page 67: Rear Knuckles And Stabilizer

    CHAS REAR KNUCKLES AND STABILIZER REAR KNUCKLES AND STABILIZER 56 Nm (5.6 m kg, 40 ft • • 56 Nm (5.6 m kg, 40 ft • • 30 Nm (3.0 m kg, 22 ft • • 56 Nm (5.6 m kg, 40 ft •...

  • Page 68: Checking The Rear Knuckles

    CHAS REAR KNUCKLES AND STABILIZER CHECKING THE REAR KNUCKLES 1. Check: • rear knuckles Damage/pitting → Replace. 2. Check: • rear wheel bearings Bearings allow play in the wheel hubs or the wheel turns roughly → Replace. • oil seals Damage →...

  • Page 69: Rear Arms And Rear Shock Absorbers

    CHAS REAR ARMS AND REAR SHOCK ABSORBERS REAR ARMS AND REAR SHOCK ABSORBERS 45 Nm (4.5 m kg, 32 ft • • 45 Nm (4.5 m kg, 32 ft • • 45 Nm (4.5 m kg, 32 ft • • Order Job/Part Q’ty...

  • Page 70: Checking The Rear Arms

    CHAS REAR ARMS AND REAR SHOCK ABSORBERS CHECKING THE REAR ARMS 1. Check: • rear arms 1 Bends/damage → Replace. 2. Check: • bushings 2 Wear/damage → Replace. INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBERS 1. Install: • rear arms •...
  • Page 72 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...

  • Page 73: Yfm45Fat/Yfm450Fat Wiring Diagram

    YFM45FAT/YFM450FAT WIRING DIAGRAM 1 A.C. magneto 2 Rectifier/regulator 3 Main switch 4 Backup fuse Br Sb L/B L/B Sb Br W/R Sb Sb W/R W/B B B/R B/R B W/B L/W G/W G/W L/W R/BBr/B B/Y B/Y Br/B R/B (GRAY)

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