Yamaha Rhino 450 YXR45FAV Manuals

Manuals and User Guides for Yamaha Rhino 450 YXR45FAV. We have 1 Yamaha Rhino 450 YXR45FAV manual available for free PDF download: Service Manual

Yamaha Rhino 450 YXR45FAV Service Manual (413 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 21.81 MB

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
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
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
Rear Constant Velocity Joints, Final Drive Gear and Rear Drive Shaft

259
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
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
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
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

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Yamaha Rhino 450 YXR45FAV Manuals

Yamaha Rhino 450 YXR45FAV Service Manual (413 pages)

Table of Contents

Chapter 1 General Information

Vehicle Identification

Important Information

Checking of Connections

Special Tools

Chapter 2 Specifications

General Specifications

Engine Specifications

Chassis Specifications

Electrical Specifications

Tightening Torques

Lubrication Points and Lubricant Types

How to Use the Conversion Table

General Tightening Torque Specifications

Coolant Flow Diagrams

Oil Flow Diagrams

Cable Routing

Chapter 3 Periodic Checks and Adjustments

Introduction

Periodic Maintenance/Lubrication

Engine

Chassis

Electrical

Chapter 4 Engine

Engine Removal

Cylinder Head

Camshaft, Rocker Arms and Valves

Cylinder and Piston

Engine Cooling Fan and A.C. Magneto

Primary and Secondary Sheaves

Clutch

Crankcase

Crankshaft and Oil Pump

Transmission

Middle Gear

Chapter 5 Cooling System

Radiator and Coolant Reservoir

Water Pump

Oil Cooler

Chapter 6 Fuel System

Fuel Pump and Fuel Tank

Carburetor

Chapter 7 Drive Train

Troubleshooting

Front Constant Velocity Joints, Differential Gear and Front Drive Shaft

Rear Constant Velocity Joints, Final Drive Gear and Rear Drive Shaft

Chapter 8

Seats, Enclosure, Hood and Cargo Bed

Front Wheels and Brake Discs

Rear Wheels and Brake Disc

Front and Rear Brakes

Pedal Assembly

Steering System

Front Arms and Front Shock Absorbers

Rear Knuckles and Stabilizer

Rear Arms and Rear Shock Absorbers

Chapter 9 Electrical

Electrical Components

Checking the Switches

Checking the Bulbs and Bulb Sockets

Ignition System

Electric Starting System

Charging System

Signaling System

Cooling System

2Wd/4Wd Selecting System

Carburetor Heating System

Chapter 10

Starting Failure/Hard Starting

Poor Idle Speed Performance

Poor Medium and High-Speed Performance

Faulty Drive Train

Faulty Gear Shifting

Unstable Handling

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