Yamaha YFM450FAR Service Manual

LIT-11616-16-01 5ND-F8197-10YFM450FARSERVICE MANUALNot For Resale www.SmallEngineDiscount.com

CAMSHAFT, ROCKER ARMS AND VALVES ...4-16REMOVING THE CAMSHAFT AND ROCKER ARM ...4-18REM

3 - 33CHKADJCOOLANT TEMPERATURE WARNING LIGHT CHECK/CHECKING THE V-BELTCOOLANT TEMPERATURE WARNING LIGHT CHECK1 Coolant temperature warning lightTurn

3 - 34CHKADJCHECKING THE V-BELT/CLEANING THE SPARK ARRESTER4.Replace:●V-belt*****************************************************Replacing steps:●Inst

3 - 35CHKADJCLEANING THE SPARK ARRESTER●Remove the bolt 1.●Remove the tailpipe 2 by pulling it out of themuffler.●Tap the tailpipe lightly with a soft

3 - 36CHKADJADJUSTING THE REAR BRAKECHASSISADJUSTING THE REAR BRAKEWARNINGAlways adjust both the brake pedal and therear brake lever whenever adjustin

3 - 37CHKADJADJUSTING THE REAR BRAKE●Loosen the locknut 4.●Turn the adjusting bolt 5 until the brakepedal height is within the specified limits.●Tight

3 - 38CHKADJCHECKING THE BRAKE FLUID LEVEL 1.Place the machine on a level surface.NOTE:When checking the brake fluid level, makesure that the top of t

3 - 39CHKADJCHECKING THE FRONT BRAKE PAD/CHECKING THE REAR BRAKE PADCHECKING THE FRONT BRAKE PAD 1.Remove:●Front wheels2.Check:●Brake padWear indicato

3 - 40CHKADJCHECKING THE BRAKE HOSECHECKING THE BRAKE HOSE 1.Remove:●Seat●Front carrier●Front fender Refer to “SEAT, CARRIERS, FENDERSAND FUEL TANK”.

3 - 41CHKADJBLEEDING THE HYDRAULIC BRAKE SYSTEMBLEEDING THE HYDRAULIC BRAKE SYSTEMWARNINGBleed the brake system if:●The system has been disassembled.●

3 - 42CHKADJBLEEDING THE HYDRAULIC BRAKE SYSTEM/ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT RODk.Add brake fluid to the proper level.Refer to “

CRANKCASE ...4-56STARTER MOTOR, TIMING CHAIN AND OIL FILTER

3 - 43CHKADJADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD/ADJUSTING THE REAR BRAKE LIGHT SWITCH●When the brake begins to work “a = 20 ~30 mm

3 - 44CHKADJADJUSTING THE REAR BRAKE LIGHT SWITCH/CHECKING THE FINAL GEAR OIL LEVEL2.Adjust:●Rear brake light switch operation timing*****************

3 - 45CHKADJCHANGING THE FINAL GEAR OILCHANGING THE FINAL GEAR OIL1.Place the machine on a level surface.2.Remove:●Final gear case protector 1 3.Place

3 - 46CHKADJCHECKING THE DIFFERENTIAL GEAR OIL/CHANGING THE DIFFERENTIAL GEAR OILCHECKING THE DIFFERENTIAL GEAR OIL1.Place the machine on a level surf

3 - 47CHKADJCHANGING THE DIFFERENTIAL GEAR OIL/CHECKINGTHE CONSTANT VELOCITY JOINT DUST BOOT4.Drain:●Differential gear oil 5.Install:●Drain plug NOTE:

3 - 48CHKADJCHECKING THE STEERING SYSTEM 1.Place the machine on a level surface.2.Check:●Steering assembly bushingsMove the handlebar up and down, and

3 - 49CHKADJ●Measure the width È between the marks.●Rotate the front tires 180° until the marks areexactly opposite one another.●Measure the width É b

3 - 50CHKADJADJUSTING THE FRONT SHOCK ABSORBER/ADJUSTING THE REARSHOCK ABSORBER/CHECKING THE TIREADJUSTING THE FRONT SHOCK ABSORBER WARNINGAlways adju

3 - 51CHKADJCHECKING THE TIRE●TIRE CHARACTERISTICS1)Tire characteristics influence thehandling of ATV’s. The tires listed belowhave been approved by Y

3 - 52CHKADJCHECKING THE TIRE1.Measure:●Tire pressure (cold tire pressure)Out of specification → Adjust.NOTE:●The low-pressure tire gauge 1 is include

CHAPTER 5.COOLING SYSTEMRADIATOR ...5-1CHECKING THE R

3 - 53CHKADJCHECKING THE WHEEL/CHECKING AND LUBRICATING THE CABLECHECKING THE WHEEL 1.Check:●Wheels 1 Damage/bends → Replace.NOTE:Always balance the w

3 - 54CHKADJLUBRICATING THE LEVERS, PEDAL, ETC.LUBRICATING THE LEVERS, PEDAL, ETC. 1.Lubricate the pivoting parts.Recommended lubricant:Yamaha chain a

3 - 55CHKADJCHECKING THE BATTERYEB305000ELECTRICALCHECKING THE BATTERYNOTE:Since the MF battery is a sealed type battery, itis not possible to measure

3 - 56CHKADJBatteries generate explosive hydrogen gas.Always follow these preventive measures:●Charge batteries in a well-ventilated area.●Keep batter

3 - 57CHKADJCHECKING THE BATTERY●Check the condition of the battery using thefollowing charts.Example:●Open-circuit voltage = 12.0 V●Charging time = 6

3 - 58CHKADJCHECKING THE BATTERYCharging method using a variable voltage chargerMeasure the open-circuitvoltage prior to charging.Connect a charger an

3 - 59CHKADJCHECKING THE BATTERYCharging method using a constant voltage chargerMeasure the open-circuitvoltage prior to charging.Connect a charger an

3 - 60CHKADJCHECKING THE BATTERY/CHECKING THE FUSE5.Check:●Battery terminalsDirty → Clean with a wire brush.Poor connection → Correct.NOTE:After clean

3 - 61CHKADJCHECKING THE FUSENOTE:Set the tester to the “Ω × 1” position.●If the tester indicates ∞, replace the fuse.********************************

3 - 62CHKADJCHECKING THE FUSE/ADJUSTING THE HEADLIGHTBEAM/CHANGING THE HEADLIGHT BULB4.Install:●SeatRefer to “SEAT, CARRIERS, FENDERSAND FUEL TANK”.AD

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT ...7-17REMOVING THE REAR AXLE ...

3 - 63CHKADJCHANGING THE HEADLIGHT BULB3.Install:●Bulb Secure the new bulb with the headlight unit.CAUTION:Avoid touching the glass part of the bulb.K

4 - 1ENGENGINE REMOVALENGINEENGINE REMOVALAIR DUCTS, MUFFLER AND EXHAUST PIPEOrder Job name/Part name Q’ty RemarksRemoving the air ducts, muffler and

4 - 2ENGENGINE REMOVALOrder Job name/Part name Q’ty Remarks6 Final drive gear case breather hose 17 Cylinder head breather hose 18 Vacuum chamber brea

4 - 3ENGENGINE REMOVALSELECT LEVER UNIT AND COOLANT RESERVOIROrder Job name/Part name Q’ty RemarksRemoving the select lever unit and coolant reservoir

4 - 4ENGENGINE REMOVALHOSES AND LEADSOrder Job name/Part name Q’ty RemarksRemoving the hoses and leads Remove the parts in the order below.Water pump

4 - 5ENGENGINE REMOVALENGINE MOUNTING BOLTSOrder Job name/Part name Q’ty RemarksRemoving the engine mounting bolts Remove the parts in the order below

4 - 6ENGENGINE REMOVALOrder Job name/Part name Q’ty Remarks9 Engine assembly 1NOTE:Remove the engine assembly from theleft side of the machine.For ins

4 - 7ENGINSTALLING THE ENGINE1.Install:●Engine bracket (front upper) 1●Engine mount bolt (front upper)/nut 2●Engine bracket bolt (front upper) 3●Engin

4 - 8ENGCYLINDER HEADCYLINDER HEADOrder Job name/Part name Q’ty RemarksRemoving the cylinder head Remove the parts in the order below.Fuel tank/rubber

4 - 9ENGCYLINDER HEADOrder Job name/Part name Q’ty Remarks5 Cylinder head breather hose 16 Camshaft sprocket cover/O-ring 1/17 Tappet cover/O-ring 2/2

STEERING SYSTEM ...8-30HANDLEBAR ...

4 - 10ENGCYLINDER HEADREMOVING THE CYLINDER HEAD1.Align:●“T” mark(with stationary pointer)*****************************************************Checkin

4 - 11ENGCYLINDER HEADNOTE:●Fasten a safety wire to the timing chain toprevent it from falling into the crankcase.●When removing the camshaft sprocket

4 - 12ENGCYLINDER HEADCHECKING THE CYLINDER HEAD1.Eliminate:●Carbon deposits (from the combustionchambers)Use a rounded scraper.NOTE:Do not use a shar

4 - 13ENGCYLINDER HEADINSTALLING THE CYLINDER HEAD1.Install:●Cylinder head●Bolt (M10)●Bolt (M6)NOTE:●Lubricate the washer with engine oil.●Tighten the

4 - 14ENGCYLINDER HEADNOTE:Be sure the “I” mark 5 on the camshaftsprocket is aligned with the match mark 2 onthe cylinder head.●Force the camshaft clo

4 - 15ENGCYLINDER HEAD4.Tighten:●Camshaft sprocket bolt 1 NOTE:Use the rotor holding tool 2 to hold the starterpulley.5.Check:●Camshaft sprocket “I” m

4 - 16ENGCAMSHAFT, ROCKER ARMS AND VALVESCAMSHAFT, ROCKER ARMS AND VALVES Order Job name/Part name Q’ty RemarksRemoving the camshaft, rocker arms and

4 - 17ENGCAMSHAFT, ROCKER ARMS AND VALVESOrder Job name/Part name Q’ty Remarks12 Valve spring (inner) 2Refer to “REMOVING/INSTALLING THEVALVE AND VALV

4 - 18ENGCAMSHAFT, ROCKER ARMS AND VALVESREMOVING THE CAMSHAFT AND ROCKER ARM1.Remove:●Camshaft 1 NOTE:Screw in a M10 bolt 2 into the thread hole onth

4 - 19ENGCAMSHAFT, ROCKER ARMS AND VALVES2.Remove:●Valve cottersNOTE:Attach a valve spring compressor 1 betweenthe valve spring retainer and the cylin

CHECKING THE BULBS AND BULB SOCKETS ...9-6TYPES OF BULBS ...

4 - 20ENGCAMSHAFT, ROCKER ARMS AND VALVES2.Check:●Rocker arms●Rocker arm shaftsDamage/wear → Replace.*************************************************

4 - 21ENGCAMSHAFT, ROCKER ARMS AND VALVESCHECKING THE VALVE AND VALVE SPRING 1.Measure:●Stem-to-guide clearanceOut of specification → Replace the valv

4 - 22ENGCAMSHAFT, ROCKER ARMS AND VALVES3.Check:●Valve facePitting/wear → Grind the face.●Valve stem endMushroom shape or diameter larger than thebod

4 - 23ENGCAMSHAFT, ROCKER ARMS AND VALVES*****************************************************Measurement steps:●Apply Mechanic’s blueing dye (Dykem)

4 - 24ENGCAMSHAFT, ROCKER ARMS AND VALVES●Apply a fine lapping compound to the valveface and repeat the above steps.NOTE:After every lapping operation

4 - 25ENGCAMSHAFT, ROCKER ARMS AND VALVES12.Measure:●Spring tilt a Out of specification → Replace.Spring tilt limit:Inner:2.5°/1.6 mm (0.06 in)Outer:2

4 - 26ENGCAMSHAFT, ROCKER ARMS AND VALVESINSTALLING THE CAMSHAFT AND ROCKER ARM 1.Apply:●Engine oil(onto the rocker arm shafts)2.Install:●Rocker arms

4 - 27ENGCYLINDER AND PISTONCYLINDER AND PISTONOrder Job name/Part name Q’ty RemarksRemoving the cylinder and piston Remove the parts in the order be

4 - 28ENGCYLINDER AND PISTONREMOVING THE PISTON 1.Remove:●Piston pin clips 1 ●Piston pin 2 ●Piston 3 NOTE:Before removing piston pin, deburr the clipg

4 - 29ENGCYLINDER AND PISTON2.Measure:●Piston-to-cylinder clearance*****************************************************Measurement steps:1st step:●Me

CHAPTER 10.TROUBLESHOOTINGSTARTING FAILURE/HARD STARTING ...10-1FUEL SYSTEM ...

4 - 30ENGCYLINDER AND PISTON3rd step:●Find the piston-to-cylinder clearance with thefollowing formula.●If out of specification, rebore or replace thec

4 - 31ENGCYLINDER AND PISTON3.Measure:●Ring end gap Out of specification → Replace.NOTE:You cannot measure the end gap on theexpander spacer of the oi

4 - 32ENGCYLINDER AND PISTON●If out of specification, replace the piston.*****************************************************Piston pin-to-piston cle

4 - 33ENGCYLINDER AND PISTON4.Lubricate:●Piston●Piston rings●CylinderNOTE:Apply a liberal coating of engine oil.INSTALLING THE CYLINDER 1.Install:●Cyl

4 - 34ENGRECOIL STARTER AND A.C. MAGNETORECOIL STARTER AND A.C. MAGNETO Order Job name/Part name Q’ty RemarksRemoving the CDI magneto Remove the part

4 - 35ENGRECOIL STARTER AND A.C. MAGNETOOrder Job name/Part name Q’ty Remarks7 Pickup coil 18 Stator assembly 19 Rotor 1Refer to “REMOVING/INSTALLING

4 - 36ENGRECOIL STARTER AND A.C. MAGNETOOrder Job name/Part name Q’ty RemarksDisassembling the recoil starter Remove the parts in the order below.1 C

4 - 37ENGRECOIL STARTER AND A.C. MAGNETOREMOVING THE A.C. MAGNETO 1.Remove:●Starter pulley 1 NOTE:Use the rotor holding tool 2 to hold the starterpull

4 - 38ENGRECOIL STARTER AND A.C. MAGNETOCHECKING THE STARTER CLUTCH 1.Check:●Starter one-way clutch 1 Cracks/damage → Replace.●Bolts 2 (starter clutch

4 - 39ENGRECOIL STARTER AND A.C. MAGNETOCHECKING THE STARTER PULLEY 1.Check: ●Starter pulley Cracks/pitting → Deburr or replace.CHECKING THE RECOIL ST

1 - 1GENINFOMACHINE IDENTIFICATIONGENERAL INFORMATIONMACHINE IDENTIFICATIONVEHICLE IDENTIFICATION NUMBERThe vehicle identification number 1 isstamped

4 - 40ENGRECOIL STARTER AND A.C. MAGNETO2.Install:●Starter spring 1 ●Sheave drum assembly 2 NOTE:●Mesh the spring hook 3 with the case slit,then wind

4 - 41ENGRECOIL STARTER AND A.C. MAGNETO2.Install:●Woodruff key●RotorNOTE:●Before installing the rotor, clean the outsideof the crankshaft and the ins

4 - 42ENGPRIMARY AND SECONDARY SHEAVESPRIMARY AND SECONDARY SHEAVESOrder Job name/Part name Q’ty RemarksRemoving the primary and secondary sheaveRemov

4 - 43ENGPRIMARY AND SECONDARY SHEAVESOrder Job name/Part name Q’ty Remarks8 Primary fixed sheave 1 Refer to “REMOVING/INSTALLING THE PRIMARY AND SECO

4 - 44ENGPRIMARY AND SECONDARY SHEAVESPRIMARY SLIDING SHEAVEOrder Job name/Part name Q’ty RemarksDisassembling the primary sliding sheave Remove the p

4 - 45ENGPRIMARY AND SECONDARY SHEAVESSECONDARY SHEAVEOrder Job name/Part name Q’ty RemarksDisassembling the secondary sheave Remove the parts in the

4 - 46ENGPRIMARY AND SECONDARY SHEAVESREMOVING THE PRIMARY AND SECONDARY SHEAVES 1.Loosen:●Nut (secondary sheave) 1 ●Nut (primary sheave) 2 NOTE:●Use

4 - 47ENGPRIMARY AND SECONDARY SHEAVESCHECKING THE PRIMARY SHEAVE 1.Check:●Weight outside diameter a Out of specification → Replace the weight.Weight

4 - 48ENGPRIMARY AND SECONDARY SHEAVESASSEMBLING THE PRIMARY SHEAVE 1.Clean:●Primary sliding sheave face 1 ●Primary fixed sheave face 2 ●Collar 3 ●Wei

4 - 49ENGPRIMARY AND SECONDARY SHEAVES3.Apply:●BEL-RAY assembly lube® (to the guide pin sliding groove 1, and O-ring2 )New4.Install:●Spring seat ●Comp

1 - 2GENINFOFEATURESLIQUID COOLING ENGINECompact liquid cooled 45° inclined engine. Aliquid cooling system has been incorporatedfor stable power and e

4 - 50ENGPRIMARY AND SECONDARY SHEAVESINSTALLING THE PRIMARY AND SECONDARY SHEAVES 1.Install:●Secondary sheave assembly●V-belt●Primary sheave assembly

4 - 51ENGCLUTCHCLUTCHOrder Job name/Part name Q’ty RemarksRemoving the clutch Remove the parts in the order below.Primary and secondary sheaves Refer

4 - 52ENGCLUTCHOrder Job name/Part name Q’ty RemarksDisassembling the clutch housing Remove the parts in the order below.1 Oil seal 12 Circlip 13 Bea

4 - 53ENGCLUTCHREMOVING THE CLUTCH 1.Remove:●Clutch housing assembly●Gasket●Dowel pinsNOTE:Working in crisscross pattern, loosen each bolt1/4 of a tur

4 - 54ENGCLUTCH2.Check:●Clutch shoeHeat damage → Replace.3.Measure:●Clutch shoe thicknessOut of specification → Replace.Clutch shoe thickness:1.5 mm (

4 - 55ENGCLUTCH4.Install:●Dowel pins●Gasket ●Clutch housing assemblyNOTE:●Tighten the bolts in stages, using acrisscross pattern.●After tightening the

4 - 56ENGCRANKCASECRANKCASESTARTER MOTOR, TIMING CHAIN AND OIL FILTEROrder Job name/Part name Q’ty RemarksRemoving the starter motor, timing chain and

4 - 57ENGCRANKCASEOrder Job name/Part name Q’ty Remarks6 Oil filter cartridge 17 Speed sensor 18 Shift cam stopper 19 Low-range switch 110 High-range

4 - 58ENGCRANKCASECRANKCASEOrder Job name/Part name Q’ty RemarksSeparating the crankcase Remove the parts in the order below.1 Shift lever cover/gaske

4 - 59ENGCRANKCASECRANKCASE BEARINGOrder Job name/Part name Q’ty RemarksRemoving the crankcase bearing Remove the parts in the order below.Crankshaft

GENINFO1 - 3FEATURESFRONT DIFFERENTIAL1 Adapter2 Drive clutch3 Differential side gear (left)4 Differential pinion gear5 Ring gear6 Differential side g

4 - 60ENGCRANKCASEREMOVING THE OIL PUMP DRIVE GEAR 1.Straighten:●Lock washer tab2.Remove:●Oil pump drive gear nut*************************************

4 - 61ENGCRANKCASE●Remove the left crankcase.CAUTION:Use a soft hammer to tap on one side of thecrankcase. Tap only on reinforced portionsof the crank

4 - 62ENGCRANKCASECHECKING THE CRANKCASE1.Thoroughly wash the case halves in a mildsolvent. 2.Clean all the gasket mating surfaces andcrankcase mating

4 - 63ENGCRANKCASE4.Tighten:●Crankcase bolts(follow the proper tightening sequence)È Right crankcaseÉLeft crankcaseNOTE:Tighten the bolts in stages, u

4 - 64ENGCRANKCASEINSTALLING THE OIL PUMP DRIVE GEAR 1.Install:●Straight key●Oil pump drive gear●Lock washer ●Oil pump drive gear nutNew2.Tighten:●Oil

4 - 65ENGCRANKSHAFT AND OIL PUMPCRANKSHAFT AND OIL PUMPOrder Job name/Part name Q’ty RemarksRemoving the crankshaft and oil pump Remove the parts in t

4 - 66ENGCRANKSHAFT AND OIL PUMPOIL PUMPOrder Job name/Part name Q’ty RemarksDisassembling the oil pump Remove the parts in the order below.1 Rotor c

4 - 67ENGCRANKSHAFT AND OIL PUMPREMOVING THE CRANKSHAFT 1.Remove:●Crankshaft seal 1 NOTE:Mark a note of the position of each crankshaftseal so that th

4 - 68ENGCRANKSHAFT AND OIL PUMP3.Check:●Oil pump operationUnsmooth → Repeat steps #1 and #2 orreplace the defective parts.CHECKING THE CRANKSHAFT 1.

4 - 69ENGCRANKSHAFT AND OIL PUMPINSTALLING THE CRANKSHAFT AND BALANCER 1.Install:●CrankshaftNOTE:Hold the connecting rod at the Top DeadCenter (T.D.C.

YFM450FARSERVICE MANUAL©2002 by Yamaha Motor Corporation, U.S.A.First Edition, March 2002All rights reserved. Any reproduction orunauthorized use with

GENINFO1 - 4FEATURES2WDPower is transmitted as follows: middle gear → front drive shaft → drive pinion gear 7 → ring gear5 → differential pinion gear

4 - 70ENGTRANSMISSIONTRANSMISSIONOrder Job name/Part name Q’ty RemarksRemoving the transmission Remove the parts in the order below.Crankcase separat

4 - 71ENGTRANSMISSIONOrder Job name/Part name Q’ty Remarks11 Shift fork “R” 112 Spring 113 Shift cam 114 Stopper wheel 115 Clutch dog 1 116 High wheel

4 - 72ENGTRANSMISSIONCHECKING THE SHIFT FORK 1.Check:●Shift fork cam follower 1 ●Shift fork pawl 2 Scoring/bends/wear/damage → Replace.2.Check:●Guide

4 - 73ENGTRANSMISSIONCHECKING THE TRANSMISSION 1.Measure:●Axle runoutUse a centering device and a dial gauge.Out of specification → Replace the bent a

4 - 74ENGTRANSMISSIONCHECKING THE CHAIN1.Check:●ChainCracks/shift → Replace the chain, secondaryshaft and driven sprocket as a set.CHECKING THE STOPPE

4 - 75ENGTRANSMISSION2.Check:●Shift operationUnsmooth operation → Repair.NOTE:●Oil each gear and bearing thoroughly.●Before assembling the crankcase,

4 - 76ENGMIDDLE GEARMIDDLE GEARMIDDLE DRIVE SHAFTOrder Job name/Part name Q’ty RemarksRemoving the middle drive shaft Remove the parts in the order b

4 - 77ENGMIDDLE GEARMIDDLE DRIVEN SHAFTOrder Job name/Part name Q’ty RemarksRemoving the middle driven shaft Remove the parts in the order below.Cran

4 - 78ENGMIDDLE GEAROrder Job name/Part name Q’ty Remarks12 Bearing retainer 113 Middle driven shaft 1For installation, reverse the removal procedure.

4 - 79ENGMIDDLE GEARREMOVING THE MIDDLE DRIVE SHAFT 1.Straighten:●Punched portion of the nut (middle drivepinion gear)2.Loosen:●Nut (middle drive pini

GENINFO1 - 5FEATURES4WDWhen the 4WD mode is selected, the gear motor is operated, and the drive clutch 2 moves to theright and engages with the left d

4 - 80ENGMIDDLE GEAR2.Remove:●Nut 1 ●Washer●Universal joint yokeNOTE:Use the universal joint holder 2 to hold theuniversal joint yoke.3.Remove:●Bearin

4 - 81ENGMIDDLE GEAR5.Remove:●Front drive shaft coupling●Bearing retainer 1 ●Bearing NOTE:Attach the ring nut wrench 2.CAUTION:The middle driven shaft

4 - 82ENGMIDDLE GEAR4.Check:●O-ringDamage → Replace.●BearingsPitting/damage → Replace.5.Check:●U-joint movementRoughness → Replace U-joint.SELECTING T

4 - 83ENGMIDDLE GEARExample:1) If the bearing housing is marked “+04”,... a is 10.54.2) b is 553) If the crankcase (right) is marked “66.03”,...

4 - 84ENGMIDDLE GEARWhere:d = a numeral (usually a decimal number)on the bearing housing is either addedto or subtracted from “76”.e = a numeral (usua

4 - 85ENGMIDDLE GEARShims are supplied in the following thickness.*****************************************************Middle drive pinion gear shimTh

4 - 86ENGMIDDLE GEAR●Tighten the bearing retainer.CAUTION:The middle driven shaft bearing retainerhas left-handed threads. To tighten theretainer turn

4 - 87ENGMIDDLE GEAR●Install the bearing 1 onto the yoke.CAUTION:Check each bearing. The needles caneasily fall out of their races. Slide the yokeback

4 - 88ENGMIDDLE GEAR●Attach the gear lash measurement tool 3and dial gauge 4.a8.12 mm (0.32 in)●Measure the gear lash while rotating themiddle driven

5 - 1COOLRADIATORCOOLING SYSTEMRADIATOROrder Job name/Part name Q’ty RemarksRemoving the radiator Remove the parts in the order below.Seat and fuel ta

GENINFO1 - 6FEATURES4WD (Diff-Lock)When the 4WD (Diff-Lock) mode is selected, the gear motor moves the drive clutch 2 further to theright, which cause

5 - 2COOLRADIATOROrder Job name/Part name Q’ty Remarks5 Radiator inlet hose 1 Disconnect.6 Radiator outlet hose 1 Disconnect.7Radiator 18 Radiator fan

5 - 3COOLRADIATORCHECKING THE RADIATOR1.Check:●Radiator finsObstruction → Clean.Apply compressed air to the rear of theradiator.Damage → Repair or rep

5 - 4COOLRADIATORINSTALLING THE RADIATOR1.Fill:●Cooling system(with the specified amount of therecommended coolant)Refer to “CHANGING THE COOLANT” inC

5 - 5COOLTHERMOSTATTHERMOSTATOrder Job name/Part name Q’ty RemarksRemoving the thermostat Remove the parts in the order below.Seat and fuel tank side

5 - 6COOLTHERMOSTATCHECKING THE THERMOSTAT1.Check:●Thermostat 1 Does not open at 63.5 ~ 66.5 °C (146.3 ~151.7 °F) → Replace.**************************

5 - 7COOLWATER PUMPWATER PUMPOrder Job name/Part name Q’ty RemarksRemoving the water pump Remove the parts in the order below.Seat, fuel tank side pan

5 - 8COOLWATER PUMPOrder Job name/Part name Q’ty RemarksDisassembling the water pump Remove the parts in the order below.1 Water pump housing cover 12

5 - 9COOLWATER PUMPDISASSEMBLING THE WATER PUMP1.Remove:●Rubber damper holder 1 ●Rubber damper 2 (from the impeller, with a thin, flatheadscrewdriver)

5 - 10COOLWATER PUMP3.Measure:●Impeller shaft tiltOut of specification → Replace.1Straightedge2ImpellerMax. impeller shaft tilt:0.15 mm (0.006 in)ASSE

5 - 11COOLWATER PUMP3.Install:●Rubber damper 1 ●Rubber damper holder 2 NOTE:Before installing the rubber damper, apply tapwater or coolant onto its ou

GENINFO1 - 7FEATURESIn addition, the 4WD (Diff-Lock) mode can be engaged only when the ATV is stopped. Even if anattempt is made to select this mode w

6 - 1CARBCARBURETORCARBURETIONCARBURETOROrder Job name/Part name Q’ty RemarksRemoving the carburetor Remove the parts in the order below.Seat/fuel tan

6 - 2CARBCARBURETOROrder Job name/Part name Q’ty RemarksDisassembling the carburetor Remove the parts in the order below.1 Float chamber air vent hos

6 - 3CARBCARBURETOROrder Job name/Part name Q’ty RemarksD Pilot jet 1 NOTE:Before disassembling the carburetor,make sure to note the number of timesth

6 - 4CARBCARBURETORDISASSEMBLING THE CARBURETORNOTE:Before disassembling the carburetor, makesure to note the number of times the pilotscrew is turned

6 - 5CARBCARBURETOR4.Check:●Piston valve 1 Scratches/wear/damage → Replace.●Rubber diaphragm 2 Tears → Replace.5.Check:●Vacuum chamber cover 1 ●Spring

6 - 6CARBCARBURETOR8.Check:●Free movement (piston valve)Sticks → Replace the piston valve guide andthe piston valve.Insert the piston valve into the c

6 - 7CARBCARBURETORADJUSTING THE FUEL LEVEL1.Measure:●Fuel level a Out of specification → Adjust. ****************************************************

7 - 1DRIVTROUBLESHOOTINGDRIVE TRAINTROUBLESHOOTINGThe following conditions may indicate damaged shaft drive components:NOTE:Areas A, B, and C above ma

7 - 2DRIVTROUBLESHOOTINGCAUTION:Too little gear lash is extremely destructive tothe gear teeth. If a test ride followingreassembly indicates this cond

7 - 3DRIVTROUBLESHOOTINGTroubleshooting chart When basic condition “a” and “b” exist, check the following points: Elevate and spin both wheels. Feel f

1 - 8GENINFOEB101000IMPORTANT INFORMATIONPREPARATION FOR REMOVAL PROCEDURES1.Remove all dirt, mud, dust and foreignmaterial before removal and disasse

7 - 4DRIVFRONT CONSTANT VELOCITY JOINTS ANDDIFFERENTIAL GEARFRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAROrder Job name/Part name Q’ty RemarksR

7 - 5DRIVFRONT CONSTANT VELOCITY JOINTS ANDDIFFERENTIAL GEAROrder Job name/Part name Q’ty Remarks4 Differential gear 15 Drive shaft 16 Compression spr

7 - 6DRIVFRONT CONSTANT VELOCITY JOINTS ANDDIFFERENTIAL GEAROrder Job name/Part name Q’ty RemarksDisassembling the constant velocity jointRemove the p

7 - 7DRIVFRONT CONSTANT VELOCITY JOINTS ANDDIFFERENTIAL GEAROrder Job name/Part name Q’ty RemarksDisassembling the differential gear Remove the parts

7 - 8DRIVFRONT CONSTANT VELOCITY JOINTS ANDDIFFERENTIAL GEAROrder Job name/Part name Q’ty RemarksB Differential gear assembly 1C Shim (right) 1D Circl

7 - 9DRIVREMOVING THE UNIVERSAL JOINT1.Remove:●Universal joint*****************************************************Removal steps:●Remove the circlips

7 - 10DRIVFRONT CONSTANT VELOCITY JOINTS ANDDIFFERENTIAL GEARCHECKING THE CONSTANT VELOCITY JOINT1.Check:●Double off-set joint spline●Ball joint splin

7 - 11DRIVFRONT CONSTANT VELOCITY JOINTS ANDDIFFERENTIAL GEARCHECKING THE GEAR MOTOR1.Check:●Gear motor***********************************************

7 - 12DRIVFRONT CONSTANT VELOCITY JOINTS ANDDIFFERENTIAL GEAR3.Check:●Free play (thrust movement)Excessive play → Replace the joint assembly.ASSEMBLIN

7 - 13DRIVFRONT CONSTANT VELOCITY JOINTS ANDDIFFERENTIAL GEAR3.Install:●Universal joint yoke●O-ring●Washer●NutUse a universal joint holder 1.Universal

1 - 9GENINFOEB101030LOCK WASHERS/PLATES AND COTTER PINS1.Replace all lock washers/plates 1 and cotterpins after removal. Bend lock tabs along thebolt

7 - 14DRIVMEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASHMeasuring the differential gear lash1.Secure the gear case in a vise or anothersupporting

7 - 15DRIVAdjusting differential gear lash1.Remove:●Shim(s) (left) 1 ●Differential gear assembly 2 ●Shim(s) (right) 3 2.Adjust:●Gear lash*************

7 - 16DRIVCHECKING THE DIFFERENTIAL GEAR OPERATION 1.Block the rear wheels, and elevate the frontwheels by placing a suitable stand under theframe.2.R

7 - 17DRIVREAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFTREAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFTOrder Job name/Part name Q’ty RemarksRemoving the rear a

7 - 18DRIVREAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFTOrder Job name/Part name Q’ty RemarksDisassembling the final drive gear Remove the parts in the o

7 - 19DRIVREAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFTOrder Job name/Part name Q’ty RemarksA Bearing retainer/O-ring 1/1Refer to “DISASSEMBLING/ASSEMBLI

7 - 20DRIVREAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFTREMOVING THE REAR AXLE 1.Remove:●Rear axle 1 (with dust seal)●O-ringCAUTION:●Never directly tap th

7 - 21DRIVREAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFTREPLACING THE FINAL DRIVE ROLLER BEARING 1.Remove:●Roller bearing (ring gear) 1 Use a suitable pre

7 - 22DRIVREAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFTPOSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR When the final drive pinion gear, ring gear,

7 - 23DRIVREAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFTShims are supplied in the followingthicknesses.***************************************************

1 - 10GENINFOCHECKING OF CONNECTIONSEB801000CHECKING OF CONNECTIONSCheck the connectors for stains, rust,moisture, etc.1.Disconnect:●Connector2.Check:

7 - 24DRIVREAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT5) Therefore, shim thickness “B” is 0.63.“B”= 45.53 + 1.05 – (34.95 + 11.00)= 46.58 – 45.95= 0.636

7 - 25DRIVREAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT●Remove the ring gear assembly.●Measure the thrust clearance. Calculate thewidth of the flattened

7 - 26DRIVREAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFTRing gear stopper clearance adjustment1.Remove:●Ring gear 1 ●Ring gear stopper 2 ●Shim(s) 3 4Beari

7 - 27DRIVREAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFTCHECKING THE DRIVE SHAFT 1.Check:●Drive shaft (splines)Wear/damage → Replace.CHECKING THE FINAL DR

7 - 28DRIVREAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFTMEASUREMENT AND ADJUSTING THE FINAL GEAR LASH Final gear lash measurement1.Secure the gear case in

7 - 29DRIVREAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFTFinal gear lash adjustment1.Remove:●Bearing housing 1 ●Ring gear shim(s) 2 ●Ring gear 3 ●Thrust wa

7 - 30DRIVREAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFTASSEMBLING THE FINAL DRIVE GEAR 1.Install:●Drive pinion gear (with shim(s) and bearing)(proper shi

7 - 31DRIVREAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT3.Apply:●Sealant (Quick Gasket®)(to the mating surfaces of the swingarm andthe final drive gear ca

8 - 1CHASFRONT AND REAR WHEELSCHASSISFRONT AND REAR WHEELSFRONT WHEELSOrder Job name/Part name Q’ty RemarksRemoving the front wheel Remove the parts i

8 - 2CHASFRONT AND REAR WHEELSREAR WHEELSOrder Job name/Part name Q’ty RemarksRemoving the rear wheel Remove the parts in the order below.Place the ma

GENINFO1 - 11SPECIAL TOOLSEB102001SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Useonly the a

8 - 3CHASFRONT AND REAR WHEELSCHECKING THE WHEEL1.Check:●Wheel2.Measure:●Wheel runoutOver the specified limit → Replace the wheelor check the wheel be

8 - 4CHASFRONT AND REAR WHEELSCHECKING THE BRAKE DISC1.Check:●Brake discGalling/damage → Replace.2.Measure:●Brake disc deflectionOut of specification

8 - 5CHASFRONT AND REAR WHEELS2.Install:●Nuts (wheel) 1 WARNINGTapered wheel nuts 1 are used for both thefront and rear wheels. Install each nut withi

8 - 6CHASFRONT AND REAR BRAKESFRONT AND REAR BRAKESFRONT BRAKE PADSOrder Job name/Part name Q’ty RemarksRemoving the front brake pads Remove the parts

8 - 7CHASFRONT AND REAR BRAKESREAR BRAKE PADSOrder Job name/Part name Q’ty RemarksRemoving the rear brake pads Remove the parts in the order below.Re

8 - 8CHASFRONT AND REAR BRAKESCAUTION:Disc brake components rarely requiredisassembly. DO NOT:●disassemble components unlessabsolutely necessary;●use

8 - 9CHASFRONT AND REAR BRAKES*****************************************************Installation steps:●Connect a suitable hose 1 tightly to thebrake c

8 - 10CHASFRONT AND REAR BRAKESREPLACING THE REAR BRAKE PADNOTE:It is not necessary to disassemble the brakecaliper and brake hose to replace the brak

8 - 11CHASFRONT AND REAR BRAKES3.Check:●Brake fluid levelRefer to “CHECKING THE BRAKE FLUIDLEVEL” in CHAPTER 3.4.Check:●Brake lever or brake pedal ope

8 - 12CHASFRONT AND REAR BRAKESFRONT BRAKE MASTER CYLINDEROrder Job name/Part name Q’ty RemarksRemoving the front brake master cylinder Remove the par

GENINFO1 - 12SPECIAL TOOLSYU-90050Crankshaft installer setThese tools are used to install the crankshaft.AdapterYM-33279Spacer90890-04060YM-90070-AAda

8 - 13CHASFRONT AND REAR BRAKESOrder Job name/Part name Q’ty RemarksDisassembling the front brake master cylinderRemove the parts in the order below.1

8 - 14CHASFRONT AND REAR BRAKESREAR BRAKE MASTER CYLINDEROrder Job name/Part name Q’ty RemarksRemoving the rear brake master cylinderRemove the parts

8 - 15CHASFRONT AND REAR BRAKESOrder Job name/Part name Q’ty Remarks10 Brake cable 1 Disconnect.11 Bracket 112 Brake master cylinder 113 Hose joint 11

8 - 16CHASFRONT AND REAR BRAKESOrder Job name/Part name Q’ty RemarksDisassembling the rear brake master cylinderRemove the parts in the order below.1

8 - 17CHASFRONT AND REAR BRAKESCHECKING THE MASTER CYLINDER1.Check:●Brake master cylinder 1 Wear/scratches → Replace the brake mastercylinder assembly

8 - 18CHASFRONT AND REAR BRAKESEB702060ASSEMBLING THE FRONT BRAKE MASTER CYLINDERWARNING●All internal brake components should becleaned and lubricated

8 - 19CHASFRONT AND REAR BRAKESINSTALLING THE FRONT BRAKE MASTER CYLINDER 1.Install:●Brake master cylinder 1 ●Brake master cylinder bracket 2 NOTE:The

8 - 20CHASFRONT AND REAR BRAKES●Be careful that water does not enter thebrake master cylinder when refilling.Water will significantly lower the boilin

8 - 21CHASFRONT AND REAR BRAKES2.Fill:●Brake fluid reservoirCAUTION:Brake fluid may damage painted surfacesor plastic parts. Always clean up spilledbr

8 - 22CHASFRONT AND REAR BRAKESFRONT BRAKE CALIPEROrder Job name/Part name Q’ty RemarksRemoving the front brake caliper Remove the parts in the order

GENINFO1 - 13SPECIAL TOOLS90890-04135YM-04135Sheave fixed blockThis tool is needed when removing or installing the secondary sheave spring.90890-01404

8 - 23CHASFRONT AND REAR BRAKESOrder Job name/Part name Q’ty RemarksDisassembling the front brake caliperRemove the parts in the order below.1 Brake

8 - 24CHASFRONT AND REAR BRAKESREAR BRAKE CALIPEROrder Job name/Part name Q’ty RemarksRemoving the rear brake caliper Remove the parts in the order be

8 - 25CHASFRONT AND REAR BRAKESOrder Job name/Part name Q’ty RemarksDisassembling the rear brake caliper Remove the parts in the order below.1 Brake

8 - 26CHASFRONT AND REAR BRAKESDISASSEMBLING THE FRONT AND REAR BRAKE CALIPER1.Remove:●Brake caliper piston●Dust seal 1 ●Caliper piston seal 2 *******

8 - 27CHASFRONT AND REAR BRAKES●Brake fluid delivery passage (brake caliperbody)Blockage → Blow out with compressed air.WARNINGReplace the caliper pis

8 - 28CHASFRONT AND REAR BRAKESCAUTION:When installing the brake hose on thebrake caliper, make sure that the brakepipe touches the projection a on th

8 - 29CHASFRONT AND REAR BRAKESINSTALLING THE REAR BRAKE CALIPER1.Install:●Brake caliper assembly●Brake caliper mounting bolt 1 ●Brake hose 2 ●Copper

8 - 30CHASSTEERING SYSTEMSTEERING SYSTEMHANDLEBAROrder Job name/Part name Q’ty RemarksRemoving the handlebar Remove the parts in the order below.1 Han

8 - 31CHASSTEERING SYSTEMREMOVING THE REAR BRAKE SWITCH1.Remove:●Rear brake switch 1 NOTE:Push the fastener when removing the rearbrake switch out of

8 - 32CHASSTEERING SYSTEMINSTALLING THE MASTER CYLINDER ASSEMBLY1.Install:●Throttle lever assembly●Master cylinder assembly NOTE:The “UP” mark on the

EB001000NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealersand their qualified mechanics. It is not possibl

GENINFO1 - 14SPECIAL TOOLSCompression gauge90890-03081YU-33223Adapter90890-04082YU-33223-3Compression gaugeAdapterThese tools are needed to measure en

8 - 33CHASSTEERING SYSTEMSTEERING STEMOrder Job name/Part name Q’ty RemarksRemoving the steering stem Remove the parts in the order below.Handlebar Re

8 - 34CHASSTEERING SYSTEMOrder Job name/Part name Q’ty Remarks11 Oil seal 112 Bearing retainer 1 Refer to “REMOVING/INSTALLING THE BEARING RETAINER”.1

8 - 35CHASSTEERING SYSTEMREMOVING THE BEARING RETAINER1.Remove:●Bearing retainer (steering stem)Damper rod holder:P/N. YM-01327, 90890-01327CHECKING T

8 - 36CHASSTEERING SYSTEMTIE ROD AND STEERING KNUCKLEOrder Job name/Part name Q’ty RemarksRemoving the tie rod and steering knuckleRemove the parts in

8 - 37CHASSTEERING SYSTEMOrder Job name/Part name Q’ty Remarks9Oil seal 110 Oil seal 111 Bearing 212 Spacer 113 Circlip 114 Rubber boot 115 Ball joint

8 - 38CHASSTEERING SYSTEMREMOVING THE STEERING KNUCKLE1.Remove:●Steering knuckle 1 NOTE:Use a general puller to separate the ball joint2 and steering

8 - 39CHASSTEERING SYSTEM●Install the body 3, short bolt 5, removerwasher 6 and remover spacer 7 onto balljoint.NOTE:●Remover washer 6 must be aligned

8 - 40CHAS●Attach the assembled ball joint remover/installer, new ball joint B and installerattachment 8 to the steering knuckle C.NOTE:Do not tap or

8 - 41CHAS●Install the new bearings.NOTE:Install the outside bearing first.CAUTION:Do not strike the center race or balls of thebearing. Contact shoul

8 - 42CHASFRONT ARMS AND FRONT SHOCK ABSORBERFRONT ARMS AND FRONT SHOCK ABSORBEROrder Job name/Part name Q’ty RemarksRemoving the front arms and front

GENINFO1 - 15SPECIAL TOOLS90890-04086YM-91042Clutch holding toolThis tool is needed to hold the clutch carrier when removing or installing the carrier

8 - 43CHASFRONT ARMS AND FRONT SHOCK ABSORBEROrder Job name/Part name Q’ty Remarks4Nut 1Refer to “REMOVING THE FRONT ARMS” and “INSTALLING THE FRONT A

8 - 44CHASFRONT ARMS AND FRONT SHOCK ABSORBERREMOVING THE FRONT ARMS 1.Check:●Front arm free play*****************************************************

8 - 45CHAS*****************************************************Replacement steps:●Clean the outside of the front lower arm.●Remove the circlip 1 and r

8 - 46CHASFRONT ARMS AND FRONT SHOCK ABSORBER●Attach the assembled ball joint remover/installer, new ball joint A and installerattachment 7 to the fro

8 - 47CHASFRONT ARMS AND FRONT SHOCK ABSORBERINSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER1.Install:●Front arms●Front shock absorber*************

8 - 48CHASREAR SHOCK ABSORBER AND SWINGARMREAR SHOCK ABSORBER AND SWINGARMOrder Job name/Part name Q’ty RemarksRemoving the rear shock absorber and sw

8 - 49CHASREAR SHOCK ABSORBER AND SWINGARMOrder Job name/Part name Q’ty Remarks8 Rear axle housing 1 Refer to “INSTALLING THE REAR AXLE HOUSING”.9 Nut

8 - 50CHASREAR SHOCK ABSORBER AND SWINGARMREMOVING THE SWINGARM 1.Check: ●Swingarm free play*****************************************************Check

8 - 51CHASREAR SHOCK ABSORBER AND SWINGARMCHECKING THE SWINGARM1.Check: ●Swingarm 1 ●Rear axle housing 2 Bends/cracks/damage → Replace.2.Check:●Bushin

8 - 52CHASREAR SHOCK ABSORBER AND SWINGARMINSTALLING THE REAR AXLE HOUSING1.Install:●Rear axle housing●Final gear case assembly●Rear axle(with dust se

2 - 1SPECSPECIFICATIONSGENERAL SPECIFICATIONSItem StandardModel code: 5ND1, 5ND5 Dimensions:Overall length 1,984 mm (78.1 in)Overall width 1,085 mm (4

9 - 1– +ELECELECTRICAL COMPONENTSEB800000ELECTRICALELECTRICAL COMPONENTS1Main switch2Front brake light switch3Rear brake switch4Thermo switch 15Batter

9 - 2– +ELECCHECKING THE SWITCHCHECKING THE SWITCHCHECKING THE SWITCHUse a pocket tester to check the terminals forcontinuity. If the continuity is fa

9 - 3– +ELECCHECKING THE SWITCHNot For Resale www.SmallEngineDiscount.com

9 - 4– +ELECCHECKING THE SWITCHCHECKING THE SWITCH CONTINUITYRefer to “CHECKING THE SWITCH” and check for continuity between lead terminals.Poor conne

9 - 5– +ELECCHECKING THE SWITCH1 Light switch2 Engine stop switch3 Start switch4 On-command four-wheel drive switch and differential gear lock switch5

9 - 6– +ELECCHECKING THE BULBS AND BULB SOCKETSEB801020CHECKING THE BULBS AND BULB SOCKETSCheck each bulb and bulb socket for damageor wear, proper co

9 - 7– +ELECCHECKING THE BULBS AND BULB SOCKETSWARNINGSince the headlight bulb gets extremelyhot, keep flammable products and yourhands away from the

9 - 8– +ELECCHECKING THE CONDITION OF THE BULB SOCKETSThe following procedure applies to all of thebulb sockets.1.Check:●Bulb socket (for continuity)(

9 - 9– +ELECIGNITION SYSTEMEB802000IGNITION SYSTEMCIRCUIT DIAGRAMW/BBB/R B/RBW/BCDOB BOLBBLYBrBBB/YBBB(GRAY) (GRAY)DWIRE HARNESSSUB-WIRE HARNESS 4Br S

9 - 10– +ELECIGNITION SYSTEMEB802010TROUBLESHOOTINGProcedureCheck:1.Fuse (main, ignition)2.Battery3.Spark plug4.Ignition spark gap5.Spark plug cap res

2 - 2SPECDifferential gear case oilPeriodic oil change 0.23 L (0.20 Imp qt, 0.24 US qt)Total amount 0.28 L (0.25 Imp qt, 0.30 US qt)Radiator capacity

9 - 11– +ELECIGNITION SYSTEMCORRECTSpark plug gap:0.6 ~ 0.7 mm (0.024 ~ 0.028 in)INCORRECT Repair or replace the spark plug.OUT OFSPECIFICATION OR NO

9 - 12– +ELECIGNITION SYSTEMC0NTINUITY6.Ignition coil resistance●Disconnect the ignition coil connector fromthe wire harness.●Connect the pocket teste

9 - 13– +ELECIGNITION SYSTEMC0NTINUITYCORRECT8.Main switchRefer to “CHECKING THE SWITCH”.*INCORRECTReplace the main switch.9.Pickup coil resistance●Di

9 - 14– +ELECIGNITION SYSTEMC0NTINUITYCORRECT11.Wiring connection●Check the connections of the entire ignitionsystem.Refer to “CIRCUIT DIAGRAM”.Replac

9 - 15– +ELECELECTRIC STARTING SYSTEMEB803000ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAMW/BBB/R B/RBW/BCDOB BOLBBLYBrBBB/YBBB(GRAY) (GRAY)DWIRE HARNESSSUB

9 - 16– +ELECELECTRIC STARTING SYSTEMEB803020TROUBLESHOOTINGProcedureCheck:1.Fuse (main, ignition)2.Battery3.Starter motor4.Starter relay5.Main switch

9 - 17– +ELECELECTRIC STARTING SYSTEMC0NTINUITY TURNS3.Starter motor●Connect the battery positive terminal 1and starter motor cable 2 using a jumperle

9 - 18– +ELECELECTRIC STARTING SYSTEMC0NTINUITYCORRECT5.Main switchRefer to “CHECKING THE SWITCH”.*INCORRECT Replace the main switch.CORRECT6.Engine s

9 - 19– +ELECELECTRIC STARTING SYSTEMSTARTER MOTOROrder Job name/Part name Q’ty RemarksRemoving the starter motor Remove the parts in the order below.

9 - 20– +ELECELECTRIC STARTING SYSTEMCHECKING THE STARTER MOTOR1.Check:●CommutatorDirty → Clean it with #600 grit sandpaper.2.Measure:●Commutator diam

2 - 3SPECTire pressure (cold tire):Maximum load* 210 kg (463 lb)Off-road riding front 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm2, 3.2 ~ 4.0 psi)rear 22 ~ 28 kPa

9 - 21– +ELECELECTRIC STARTING SYSTEM5.Measure:●Brush length a (each)Out of specification → Replace the brushholder set. Brush length:12.5 mm (0.49 in

9 - 22– +ELECCHARGING SYSTEMEB804000CHARGING SYSTEMCIRCUIT DIAGRAM W/BBB/R B/RBW/BCDOB BOLBBLYBrBBB/YBBB(GRAY) (GRAY)DWIRE HARNESSSUB-WIRE HARNESS 4Br

9 - 23– +ELECCHARGING SYSTEMEB804010TROUBLESHOOTINGProcedureCheck:1.Fuse (main)2.Battery3.Charging voltageIF THE BATTERY IS NOT CHARGED:4.Charging coi

9 - 24– +ELECCHARGING SYSTEMOUT OFSPECIFICATION ●Start the engine and accelerate to about3,000 r/min.Charging voltage:14 V at 3,000 r/minNOTE:Use a fu

9 - 25– +ELECLIGHTING SYSTEMEB805000LIGHTING SYSTEMCIRCUIT DIAGRAMOFFW/BBB/R B/RBW/BCDOB BOLBBLYBrBBB/YBBB(GRAY) (GRAY)DWIRE HARNESSSUB-WIRE HARNESS 4

9 - 26– +ELECLIGHTING SYSTEMEB805010TROUBLESHOOTINGProcedureCheck:1.Fuse (main, headlight)2.Battery3.Main switchIF THE HEADLIGHT AND/OR TAILLIGHT FAIL

9 - 27– +ELECLIGHTING SYSTEMC0NTINUITYCORRECT3.Main switchRefer to “CHECKING THE SWITCH”.*INCORRECT Replace the main switch.CORRECT4.Light switchRefer

9 - 28– +ELECLIGHTING SYSTEMEB805020CHECKING THE LIGHTING SYSTEM1.If the headlights fail to come on:CONTINUITY1.Bulb and bulb socket●Check the bulb an

9 - 29– +ELECLIGHTING SYSTEMEB8050212.If the taillight fails to come on:CONTINUITY1.Bulb and bulb socket●Check the bulb and bulb socket forcontinuity.

9 - 30– +ELECSIGNAL SYSTEMEB806000SIGNAL SYSTEMCIRCUIT DIAGRAM2WD4WDLOCKW/BBB/R B/RBW/BCDOB BOLBBLYBrBBB/YBBB(GRAY) (GRAY)DWIRE HARNESSSUB-WIRE HARNES

2 - 4SPECMAINTENANCE SPECIFICATIONSENGINEItem Standard LimitCylinder head:Warp limit ---- 0.03 mm (0.0012 in)Cylinder:Bore size 84.500 ~ 84.510 mm (3.

9 - 31– +ELECSIGNAL SYSTEM3 Main switch4 Backup fuse5 Battery6 Main fuse9 Reverse switch0 CDI unitD Speed sensorE Thermo switch 1G Multi-function mete

9 - 32– +ELECSIGNAL SYSTEMEB806010TROUBLESHOOTINGProcedureCheck:1.Fuse (main, backup, ignition, signaling system)2.Battery3.Main switch4.Wiring connec

9 - 33– +ELECSIGNAL SYSTEMC0NTINUITY CORRECT3.Main switchRefer to “CHECKING THE SWITCH”.*INCORRECT Replace the main switch.EB806011CORRECT4.Wiring con

9 - 34– +ELECSIGNAL SYSTEMCHECKING THE SIGNAL SYSTEM1.If the brake light fails to come on:CONTINUITY1.Bulb and bulb socket●Check the bulb and bulb soc

9 - 35– +ELECSIGNAL SYSTEMEB8060242.If the indicator lights fails to come on:CONTINUITY1.Neutral switchRefer to “CHECKING THE SWITCH”.NO CONTINUITYRep

9 - 36– +ELECSIGNAL SYSTEM3.If the coolant temperature warning light does not come on:●Check that the light comes on when the main switch is set to “O

9 - 37– +ELECCOOLING SYSTEMCOOLING SYSTEMCIRCUIT DIAGRAMW/BBB/R B/RBW/BCDOB BOLBBLYBrBBB/YBBB(GRAY) (GRAY)DWIRE HARNESSSUB-WIRE HARNESS 4Br SbL/BR/BBr

9 - 38– +ELECCOOLING SYSTEMTROUBLESHOOTING ProcedureCheck:1.Fuse (main)2.Battery3.Main switch4.Fan motor5.Circuit breaker (fan motor)IF THE FAN MOTOR

9 - 39– +ELECCOOLING SYSTEMC0NTINUITYTURNS4.Fan motor●Disconnect the fan motor coupler.●Connect the battery (12 V) as shown.Battery (+) lead → Blue te

9 - 40– +ELECCOOLING SYSTEMC0NTINUITYGOODCONDITION6.Thermo switch 2●Remove the thermo switch 2 from theradiator.●Connect the pocket tester (Ω × 10) to

2 - 5SPECCam chain:Cam chain type/No. of links DID SCR-0409 SDH/116 ----Cam chain adjustment method Automatic ----Rocker arm/rocker arm shaft:Bearing

9 - 41– +ELECCOOLING SYSTEMC0NTINUITYEB803028CORRECT7.Wiring connection●Check the connections of the entire startingsystem.Refer to “CIRCUIT DIAGRAM”.

9 - 42– +ELEC2WD/4WD SELECTING SYSTEM2WD/4WD SELECTING SYSTEMCIRCUIT DIAGRAMW/BBB/R B/RBW/BCDOB BOLBBLYBrBBB/YBBB(GRAY) (GRAY)DWIRE HARNESSSUB-WIRE HA

9 - 43– +ELEC2WD/4WD SELECTING SYSTEMEB803020TROUBLESHOOTINGProcedureCheck:1.Fuse (main, four-wheel drive)2.Battery3.Main switch4.Four-wheel drive rel

9 - 44– +ELEC2WD/4WD SELECTING SYSTEMC0NTINUITYCONTINUITY4.Four-wheel drive relay 1●Remove the four-wheel drive relay 1 fromthe wire harness.●Connect

9 - 45– +ELEC2WD/4WD SELECTING SYSTEMC0NTINUITYCONTINUITY6.Four-wheel drive relay 3●Remove the four-wheel drive relay 3 fromthe wire harness.●Connect

9 - 46– +ELEC2WD/4WD SELECTING SYSTEMC0NTINUITYCORRECT8.Gear motor●Disconnect the gear motor coupler.●Remove the gear motor from thedifferential gear

10 - 1TRBLSHTGSTARTING FAILURE/HARD STARTINGTROUBLESHOOTINGNOTE:The following troubleshooting does not cover all the possible causes of trouble. It sh

10 - 2TRBLSHTGSTARTING FAILURE/HARD STARTING/POOR IDLE SPEEDPERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCECOMPRESSION SYSTEM Cylinder and cylinder

10 - 3TRBLSHTGFAULTY DRIVE TRAINFAULTY DRIVE TRAINThe following conditions may indicate damaged shaft drive components:NOTE:Areas A, B, and C above ma

10 - 4TRBLSHTGFAULTY GEAR SHIFTING/FAULTY CLUTCH PERFORMANCEFAULTY GEAR SHIFTINGHARD SHIFTINGRefer to “CLUTCH SLIPPING/DRAGGING-CLUTCH DRAGGING”.SHIFT

2 - 6SPECStem runout limit ---- 0.01 mm (0.0004 in)Valve seat width IN 1.2 ~ 1.4 mm (0.0472 ~ 0.0551 in)----EX 1.2 ~ 1.4 mm (0.0472 ~ 0.0551 in)----Va

10 - 5TRBLSHTGFAULTY CLUTCH PERFORMANCE/OVERHEATING/FAULTY BRAKEPOOR SPEED PERFORMANCEV-belt●Oil or grease on the V-beltPrimary pulley weight●Faulty o

10 - 6TRBLSHTGSHOCK ABSORBER MALFUNCTIONMALFUNCTION●Bent or damaged damper rod●Damaged oil seal lip●Fatigued shock absorber springSHOCK ABSORBER MALFU

YFM450FAR WIRING DIAGRAMW/BBB/R B/RBW/BCDOB BOLBBLYBrBBB/YBBB(GRAY) (GRAY)DWIRE HARNESSSUB-WIRE HARNESS 4Br SbL/BR/BBr/BB/YL/BSb BrB/YBr/BR/BBr Y LL/B

YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPANPRINTED IN U.S.A.Not For Resale www.SmallEngineDiscount.com

2 - 7SPECTilt limit IN 2.5°/1.6 mm (2.5°/0.06 in)EX 2.5°/1.6 mm (2.5°/0.06 in)Direction of winding(top view) IN Clockwise ----EX Clockwise ----Piston:

2 - 8SPEC2nd ringType Taper ----Dimensions (B × T) 1.0 × 3.6 mm(0.0394 × 0.1417 in)----End gap (installed) 0.40 ~ 0.60 mm(0.0157 ~ 0.0236 in)0.95 mm (

EB002000HOW TO USE THIS MANUALMANUAL ORGANIZATIONThis manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)1st

2 - 9SPECTransmission:Main axle deflection limit ---- 0.06 mm (0.0024 in)Drive axle deflection limit ---- 0.06 mm (0.0024 in)Shifter:Shifter type Shif

2 - 10SPECCooling system:Radiator coreWidth 300 mm (11.8 in) ----Height 208 mm (8.19 in) ----Thickness 26 mm (1.02 in) ----Radiator cap opening pressu

2 - 11SPECCylinder head tightening sequence:Item Standard LimitMAINTENANCE SPECIFICATIONSNot For Resale www.SmallEngineDiscount.com

2 - 12SPECTightening torquesPart to be tightenedPart nameThread sizeQ’tyTightening torqueRemarksNm m·kg ft·lbCylinder head oil passageUnion boltM6 1 7

2 - 13SPECMiddle driven shaft drive pinion gear Nut M22 1 130 13 94 StakeMiddle drive shaft bearing housing Bolt M8 6 32 3.2 23Middle driven gear bear

2 - 14SPECCHASSISItem Standard LimitSteering system:Steering bearing type Ball and race bearing ----Front suspension:Shock absorber travel 99 mm (3.90

2 - 15SPECFront disc brake:Type Dual ----Disc outside diameter × thickness 200.0 × 3.5 mm (7.87 ~ 0.14 in) ----Pad thickness inner 4.5 mm (0.18 in) 1

2 - 16SPECTightening torquesPart to be tightened Thread sizeTightening torqueRemarksNm m·kg ft·lbEngine bracket (front-upper) and frame M8 33 3.3 24En

2 - 17SPECFront bumper and frame M8 33 3.3 24Front carrier and frame M8 33 3.3 24Front carrier and front bumper M8 33 3.3 24Rear carrier and frame M8

2 - 18SPECELECTRICALItem Standard LimitVoltage: 12 V ----Ignition system:Ignition timing (B.T.D.C.) 10°/ 1,500 r/min ----C.D.I.:Magneto model/manufact

EB003000ILLUSTRATED SYMBOLSIllustrated symbols 1 to 0 are printed on thetop right of each page and indicate the subjectof each chapter.1General inform

2 - 19SPECBrush overall length 12.5 mm (0.49 in) 5 mm (0.20 in)Spring force 7.65 ~ 10.01 N (780 ~ 1,020 g, 27.54 ~ 36.03 oz)----Commutator diameter 28

2 - 20SPECEB201000HOW TO USE THE CONVERSION TABLEAll specification data in this manual are listed inSI and METRIC UNITS.Use this table to convert METR

2 - 21SPECLUBRICATION POINTS AND LUBRICANT TYPESENGINELubrication points Lubricant typeOil seal lips (all)LSO-ring (all)LSBearings (all)ECrank pinECon

2 - 22SPECCOOLANT FLOW DIAGRAMS1 Radiator 2 Thermo switch3 Fan motorÈ To coolant reservoirCOOLANT FLOW DIAGRAMSNot For Resale www.SmallEngineDiscount.

2 - 23SPEC1 Radiator2 ThermostatÈ To coolant reservoirCOOLANT FLOW DIAGRAMSNot For Resale www.SmallEngineDiscount.com

2 - 24SPECOIL FLOW DIAGRAMS1 Camshaft2 Crankshaft3 Drive axleOIL FLOW DIAGRAMSNot For Resale www.SmallEngineDiscount.com

2 - 25SPEC1 Oil filterOIL FLOW DIAGRAMSNot For Resale www.SmallEngineDiscount.com

2 - 26SPEC1 Oil pump2 Oil strainerOIL FLOW DIAGRAMSNot For Resale www.SmallEngineDiscount.com

2 - 27SPECCABLE ROUTING1 Rear brake switch lead2 Starter cable3 Rear brake cable 4 Front brake hose5 On-command four-wheel drive switch and differenti

2 - 28SPECÈ Fasten the on-command four-wheel drive switch and differential gear lock switch lead behind thehandlebar with a plastic band.É Fasten the

TABLE OF CONTENTSGENERAL INFORMATIONGEN INFO1 SPECIFICATIONSSPEC2 PERIODIC CHECKS AND ADJUSTMENTSCHKADJ3 ENGINEENG4 COOLING SYSTEMCOOL5 CARBURETIONCAR

2 - 29SPEC1 Sub-wire harness2 Headlight lead3 Auxiliary DC jack lead4 Four-wheel drive relay 35 Fan motor breather hose6 Differential gear case breath

2 - 30SPEC1 Starter cable2 Cylinder head breather hose3 Fuel hose4 Carburetor drain hose5 Coolant reservoir breather hose6 Radiator outlet hose7 Coola

2 - 31SPEC1 Cylinder head breather hose2 Final drive gear case breather hose3 Wire harness4 Starter motor lead5 Negative battery lead6 Air filter case

2 - 32SPECÈ Fasten the wire harness with a plastic band.É Fasten the starter motor lead, wire harness, negative battery lead, final gear case breather

2 - 33SPEC1 Throttle cable2 Radiator inlet hose3 Spark plug lead4 Main switch5 Wire harness6 Rear brake light switch lead7 Rear brake fluid reservoir

2 - 34SPEC1 Front brake hose2 Float chamber air vent hose3 Throttle cable4 Wire harness5 Final drive gear case breather hose6 Starter cable7 Rear brak

2 - 35SPEC1 Battery2 Positive battery lead3 Tail/brake light lead4 CDI unit5 Negative battery leadCABLE ROUTINGNot For Resale www.SmallEngineDiscount.

2 - 36SPEC1 Final drive gear case breather hose2 Rear brake hose3 Air filter case check hoseCABLE ROUTINGNot For Resale www.SmallEngineDiscount.com

3 - 1CHKADJINTRODUCTION/PERIODIC MAINTENANCE/LUBRICATIONEB300000PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information neces

3 - 2CHKADJPERIODIC MAINTENANCE/LUBRICATION* It is recommended that these items be serviced by a Yamaha dealer.** Lithium-soap-based greaseNOTE:●Recom

CONTENTSCHAPTER 1.GENERAL INFORMATIONMACHINE IDENTIFICATION ...1-1VEHICLE IDENTIF

3 - 3CHKADJSEAT, CARRIERS, FENDERS AND FUEL TANKSEAT, CARRIERS, FENDERS AND FUEL TANKSEAT AND SIDE PANELSOrder Job name/Part name Q’ty RemarksRemoving

3 - 4CHKADJSEAT, CARRIERS, FENDERS AND FUEL TANKFRONT CARRIER, FRONT BUMPER AND FRONT FENDEROrder Job name/Part name Q’ty RemarksRemoving the front ca

3 - 5CHKADJSEAT, CARRIERS, FENDERS AND FUEL TANKOrder Job name/Part name Q’ty Remarks11 Meter assembly coupler 3 Disconnect.12 Four-wheel drive relay

3 - 6CHKADJSEAT, CARRIERS, FENDERS AND FUEL TANKREAR CARRIER AND REAR FENDEROrder Job name/Part name Q’ty RemarksRemoving the rear carrier and rear fe

3 - 7CHKADJSEAT, CARRIERS, FENDERS AND FUEL TANKOrder Job name/Part name Q’ty Remarks8CDI unit 19 Wire harness 110 Rear fender 1For installation, reve

3 - 8CHKADJSEAT, CARRIERS, FENDERS AND FUEL TANKFUEL TANKOrder Job name/Part name Q’ty RemarksRemoving the fuel tank Remove the parts in the order bel

3 - 9CHKADJFOOTREST BOARDSFOOTREST BOARDSOrder Job name/Part name Q’ty RemarksRemoving the footrest boards Remove the parts in the order below.Fuel ta

3 - 10CHKADJADJUSTING THE VALVE CLEARANCEENGINEADJUSTING THE VALVE CLEARANCE NOTE:●The valve clearance must be adjusted whenthe engine is cool to the

3 - 11CHKADJADJUSTING THE VALVE CLEARANCE7.Check:●Valve clearanceOut of specification → Adjust.*****************************************************Ch

3 - 12CHKADJADJUSTING THE VALVE CLEARANCE8.Adjust:●Valve clearance *****************************************************Adjustment steps:●Loosen the l

COOLANT FLOW DIAGRAMS ...2-22OIL FLOW DIAGRAMS ...

3 - 13CHKADJADJUSTING THE VALVE CLEARANCE/ADJUSTING THE IDLING SPEED11.Install:●Fuel tank●Front fender ●Front carrier●SeatRefer to “SEAT, CARRIERS, FE

3 - 14CHKADJADJUSTING THE IDLING SPEED/ADJUSTING THE THROTTLE LEVER FREE PLAY5.Adjust:●Engine idling speed********************************************

3 - 15CHKADJADJUSTING THE THROTTLE LEVER FREE PLAY1.Check:●Throttle lever free play a Out of specification → Adjust. Throttle lever free play:3 ~ 5 mm

3 - 16CHKADJADJUSTING THE THROTTLE LEVER FREE PLAY/ADJUSTING THE SPEED LIMITERSecond step:●Pull back the adjuster cover 4.●Loosen the locknut 5.●Turn

3 - 17CHKADJADJUSTING THE SPEED LIMITER/ADJUSTING THE STARTER CABLE2.Adjust:●Speed limiter length*****************************************************

3 - 18CHKADJADJUSTING THE STARTER CABLE2.Adjust:*****************************************************Adjustment steps:●Disconnect the starter cable 1

3 - 19CHKADJCHECKING THE SPARK PLUGCHECKING THE SPARK PLUG 1.Remove:●Seat●Fuel tank side panel (right)Refer to “SEAT, CARRIERS, FENDERSAND FUEL TANK”.

3 - 20CHKADJCHECKING THE IGNITION TIMINGCHECKING THE IGNITION TIMINGNOTE:Engine idling speed and throttle cable free playshould be adjusted properly b

3 - 21CHKADJ4.Detach:●Timing light●Inductive tachometer or engine tachometer5.Install:●Seat●Fuel tank side panel (right)Refer to “SEAT, CARRIERS, FEND

3 - 22CHKADJMEASURING THE COMPRESSION PRESSURE7.Measure:●Compression pressureAbove the maximum pressure:Check the cylinder head, valve surfaces, andpi

CHASSIS ...3-36ADJUSTING THE REAR BRAKE ...

3 - 23CHKADJCHECKING THE ENGINE OIL LEVELCHECKING THE ENGINE OIL LEVEL 1.Place the machine on a level surface.2.Remove:●Engine side panelRefer to “SEA

3 - 24CHKADJCHANGING THE ENGINE OILCHANGING THE ENGINE OIL1.Start the engine and let it warm up forseveral minutes.2.Stop the engine and place an oil

3 - 25CHKADJ●Lubricate the O-ring 3 of the new oil filtercartridge with a thin coat of engine oil.CAUTION:Make sure that the O-ring 3 is positionedcor

3 - 26CHKADJCHANGING THE ENGINE OIL/CLEANING THE AIR FILTER13.Check:●Engine oil pressure*****************************************************●Slightly

3 - 27CHKADJCLEANING THE AIR FILTER1.Remove:●Seat2.Remove:●Air filter case cover 1 3.Remove:●Air filter element assembly 1 ●Air filter element cap●Air

3 - 28CHKADJCLEANING THE AIR FILTER5.Clean:●Air filter element*****************************************************Cleaning steps:●Wash the element ge

3 - 29CHKADJCHECKING THE COOLANT LEVELCHECKING THE COOLANT LEVEL1.Place the machine on a level surface.2.Remove:●Seat●Fuel tank side panel (left)3.Che

3 - 30CHKADJCHANGING THE COOLANTCHANGING THE COOLANT 1.Remove:●Seat●Fuel tank side panel (left)●Engine side cover●Front carrier●Engine skid plate●Fron

3 - 31CHKADJCHANGING THE COOLANT8.Remove:●Coolant drain bolt (cylinder) 1 (along with the copper washer)●Coolant drain bolt (water pump) 2 (along with

3 - 32CHKADJCHANGING THE COOLANTCAUTION:●Adding water instead of coolant lowersthe antifreeze content of the coolant. Ifwater is used instead of coola