Yamaha YFM45FAR, YFM450FAR. Service Manual - part 3

2 - 13

SPEC

Middle driven shaft drive pinion gear

Nut

M22

1

130

13

94

Stake

Middle drive shaft bearing housing

Bolt

M8

6

32

3.2

23

Middle driven gear bearing retainer

Nut

M65

1

110

11

80

LT

Left-hand threads

Yoke (middle driven gear)

Nut

M14

1

97

9.7

70

LT

Middle driven gear bearing housing

Bolt

M8

4

25

2.5

18

Middle driven shaft bearing retainer

Nut

M55

1

80

8.0

58

LT

Left-hand threads

Shift arm

Bolt

M6

1

14

1.4

10

Shift rod

Nut

M8

2

15

1.5

11

Primary sheave assembly

Nut

M16

1

100

10.0

72

Secondary sheave assembly

Nut

M16

1

100

10.0

72

Secondary sheave spring retainer

Nut

M36

1

90

9.0

65

Shift lever 2

Bolt

M6

1

14

1.4

10

Shift control cable

—

M12

1

6

0.6

4.3

Select lever unit

Bolt

M8

3

15

1.5

11

Shift cam ball holding bolt

—

M14

1

18

1.8

13

CDI unit

Screw

M6

1

2

0.2

1.4

Neutral switch

—

M10

1

20

2.0

14

Reverse switch

—

M10

1

20

2.0

14

Stator assembly

Screw

M6

3

7

0.7

5.1

LT

Pickup coil

Bolt

M5

2

7

0.7

5.1

LT

Ignition coil

Bolt

M6

2

7

0.7

5.1

Thermo switch (cylinder head)

—

PT1/8

1

8

0.8

5.8

LT

Speed sensor

Bolt

M6

1

10

1.0

7.2

LT

Thermo switch (radiator)

—

M18

1

28

2.8

20

Tappet covers

Bolt

M6

4

10

1.0

7.2

Coolant drain bolt (water pump)

Bolt

M6

1

10

1.0

7.2

Coolant inlet joint 

Bolt

M6

2

10

1.0

7.2

Bearing housing

Bolt

M6

1

10

1.0

7.2

Primary pulley sheave cap

Screw

M4

4

3

0.3

2.2

Clutch housing assembly

Bolt

M6

8

10

1.0

7.2

Clutch housing assembly cover

Bolt

M6

5

10

1.0

7.2

Starter motor 

Bolt 

M6

2

10

1.0

7.2

Shift lever cover 

Bolt 

M6

4

10

1.0

7.2

Crankcase (right)

Bolt

M6

3

10

1.0

7.2

Stopper lever 

Bolt

M6

1

10

1.0

7.2

Yoke (middle driven shaft)

Nut

M14

1

97

9.7

70

LT

Thermostat cover

Bolt

M6

2

10

1.0

7.2

Water pump outlet pipe

Bolt

M6

1

10

1.0

7.2

Water pump assembly

Bolt

M6

2

10

1.0

7.2

Low-range switch

—

M10

1

20

2.0

14

High-range switch

—

M10

1

20

2.0

14

Part to be tightened

Part 

name

Thread 

size

Q’ty

Tightening torque

Remarks

Nm

m·kg

ft·lb

MAINTENANCE SPECIFICATIONS

2 - 14

SPEC

CHASSIS

Item

Standard

Limit

Steering system:

Steering bearing type

Ball and race bearing

----

Front suspension:

Shock absorber travel

99 mm (3.90 in)

----

Fork spring free length

265 mm (10.43 in)

----

Spring fitting length

215.8 mm (8.50 in)

----

Spring rate

(K1)

15 N/mm (1.53 kg/mm, 85.68 lb/in) ----

Stroke

(K1)

0 ~ 99 mm (0 ~ 3.90 in)

----

Optional spring

No

----

Rear suspension:

Shock absorber travel

126 mm (4.96 in)

----

Spring free length

317 mm (12.48 in)

----

Spring fitting length

283 mm (11.14 in)

----

Spring rate

(K1)

30.4 N/mm
(3.10 kg/mm, 173.60 lb/in)

----

Stroke

(K1)

0 ~ 126 mm (0 ~ 4.96 in)

----

Optional spring

No

----

Swingarm:

Free play limit

end

----

1 mm 
(0.04 in)

side

----

1 mm 
(0.04 in)

Front wheel:

Type

Panel wheel

----

Rim size

12 

×

 6.0 AT

----

Rim material

Steel

----

Rim runout limit

radial

----

2 mm 
(0.08 in)

lateral

----

2 mm 
(0.08 in)

Rear wheel:

Type

Panel wheel

----

Rim size

12 

×

 7.5 AT

----

Rim material

Steel

----

Rim runout limit

radial

----

2 mm 
(0.08 in)

lateral

----

2 mm 
(0.08 in)

MAINTENANCE SPECIFICATIONS

2 - 15

SPEC

Front 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 mm 
(0.04 in)

Pad thickness

outer

4.5 mm (0.18 in)

1 mm 
(0.04 in)

Master cylinder inside diameter

14 mm (0.55 in)

----

Caliper cylinder inside diameter

32 mm (1.26 in)

----

Brake fluid type

DOT 4

----

Rear disc brake:

Type

Single

----

Disc outside diameter

 

×

 

thickness

220.0 

×

 3.5 mm (8.66 ~ 0.14 in)

----

Pad thickness

inner

5.6 mm (0.22 in)

1 mm 
(0.04 in)

Pad thickness

outer

5.6 mm (0.22 in)

1 mm 
(0.04 in)

Master cylinder inside diameter

14 mm (0.55 in)

----

Caliper cylinder inside diameter

32.03 mm (1.26 in)

----

Brake fluid type

DOT 4

----

Brake lever and brake pedal:

Brake lever free play (pivot)

front

0 mm (0 in)

----

rear

0.5 ~ 2 mm (0.02 ~ 0.08 in)

----

Brake pedal position

70 ~ 80 mm (2.76 ~ 3.15 in)

----

Throttle lever free play

3 ~ 5 mm (0.12 ~ 0.20 in)

----

Item

Standard

Limit

MAINTENANCE SPECIFICATIONS

2 - 16

SPEC

Tightening torques

Part to be tightened

Thread size

Tightening torque

Remarks

Nm

m·kg

ft·lb

Engine bracket (front-upper) and frame

M8

33

3.3

24

Engine bracket (front-lower) and frame

M8

33

3.3

24

Engine bracket (front-upper) and engine

M10

42

4.2

30

Engine bracket (front-lower) and engine

M10

42

4.2

30

Engine and frame

M10

56

5.6

40

Frame and bearing retainer (steering stem holder 
bearing)

M42

40

4.0

29

Select lever assembly and frame

M8

23

2.3

17

Swingarm

M12

82

8.2

60

Rear shock absorber and frame

M12

82

8.2

60

Final gear case and swingarm

M10

63

6.3

45

LT

Final gear case and rear axle housing

M10

63

6.3

46

Swingarm and rear axle housing

M10

63

6.3

46

Differential gear case and frame

M10

55

5.5

40

Front arm and frame

M10

45

4.5

32

LS

Front shock absorber and frame

M10

45

4.5

32

Front shock absorber and upper front arm

M10

45

4.5

32

Steering stem, pitman arm and frame

M14

130

13.0

94

LS

Steering stem holder and frame

M8

23

2.3

17

Use lock 
washer

Steering stem and handlebar holder

M8

23

2.3

17

Pitman arm and tie-rod end

M12

30

3.0

22

Tie-rod and locknut

M12

40

4.0

29

Steering knuckle and upper front arm

M12

30

3.0

22

Steering knuckle and lower front arm

M12

30

3.0

22

LS

Steering knuckle and tie-rod

M12

30

3.0

22

Fuel tank and fuel cock

M6

4

0.4

2.9

Front wheel and wheel hub

M10

64

6.4

46

Front axle and wheel hub

M16

150

15.0

110

Steering knuckle and brake caliper

M8

30

3.0

22

Front brake disc and wheel hub

M8

30

3.0

22

LT

Rear wheel and rear wheel hub

M10

55

5.5

40

Rear axle and nut

M16

150

15.0

110

Rear axle housing and rear brake caliper

M8

30

3.0

22

Rear brake disc and brake disc bracket

M8

28

2.8

20

LT

Front brake pipe nut

M10

19

1.9

13

Front brake hose union bolt

M10

27

2.7

19

Rear brake hose union bolt

M10

30

3.0

22

Bleed screw

M8

6

0.6

4.3

Master cylinder and handlebar

M6

7

0.7

5.1

Footrest and frame

M8

16

1.6

11

MAINTENANCE SPECIFICATIONS

2 - 17

SPEC

Front bumper and frame

M8

33

3.3

24

Front carrier and frame

M8

33

3.3

24

Front carrier and front bumper

M8

33

3.3

24

Rear carrier and frame

M8

33

3.3

24

Differential gear case filler bolt

M14

23

2.3

16

Differential gear case drain bolt

M10

10

1.0

7

Differential gear case and bearing housing

M8

25

2.5

18

Gear motor

M8

13

1.3

9.4

Final gear case oil filler bolt 

M14

23

2.3

16

Final gear case oil drain bolt

M14

23

2.3

16

Bearing retainer (drive pinion gear)

M65

100

10.0

72

Final gear case and bearing housing

M10

40

4.0

29

Final gear case and bearing housing

M8

23

2.3

17

Battery holding bracket

M6

7

0.7

5.1

Footrest board and footrest bracket

M6

7

0.7

5.1

Yoke (drive pinion gear)

M12

62

6.2

45

Trailer hitch bracket 

M10

32

3.2

23

Front brake pad holding bolt

M10

18

1.8

13

Rear brake pad holding bolt

M10

18

1.8

13

Rear brake master cylinder bracket

M8

23

2.3

17

Brake outer cable bracket

M8

23

2.3

17

Brake master cylinder cover 

M6

7

0.7

5.1

Front brake caliper retaining bolt

M8

30

3.0

22

Air duct (front)

M6

7

0.7

5.1

Part to be tightened

Thread size

Tightening torque

Remarks

Nm

m·kg

ft·lb

MAINTENANCE SPECIFICATIONS

2 - 18

SPEC

ELECTRICAL

Item

Standard

Limit

Voltage:

12 V

----

Ignition system:

Ignition timing (B.T.D.C.)

10°/ 1,500 r/min

----

C.D.I.:

Magneto model/manufacturer

F4T46471/MITSUBISHI

----

Pickup coil resistance/color

459 ~ 561 

Ω

 at 20 °C (68 °F)/

White/Red – White/Green

----

Rotor rotation direction sensing coil 
resistance/color

0.085 ~ 0.105 

Ω

 at 20 °C (68 °F)/

Red – White/Blue

----

C.D.I. unit model/manufacturer

F8T38678/MITSUBISHI

----

Ignition coil:

Model/manufacturer

2JN/MORIYAMA

----

Minimum spark gap

6 mm (0.24 in)

----

Primary winding resistance

0.18 ~ 0.28 

Ω

 at 20 °C (68 °F)

----

Secondary winding resistance

6.32 ~ 9.48 k

Ω

 at 20 °C (68 °F)

----

Spark plug cap:

Type

Resin type

----

Resistance

10 k

Ω

----

Charging system:

Type

A.C. magneto generator

----

Model/manufacturer

F4T464/MITSUBISHI

----

Nominal output

14 V 14 A at 3,000 r/min

----

Charging coil resistance/color

0.41 ~ 0.61 

Ω

 at 20 °C (68 °F)/

White – White

----

Rectifier/regulator:

Regulator type

Semi conductor-short circuit

----

No load regulated voltage (DC)

14.1 ~ 14.9 V

----

Model/manufacturer

SH640E-11/SHINDENGEN

----

Capacity

14 A

----

Withstand voltage

200 V

----

Electric starter system:

Type

Constantmesh type

----

Starter motor

Model/manufacturer

SM-13/MITSUBA

----

Output

0.8 kW

----

Armature coil resistance

0.025 ~ 0.035 

Ω

 at 20 °C (68 °F)

----

MAINTENANCE SPECIFICATIONS

2 - 19

SPEC

Brush 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 mm (1.10 in)

27 mm 
(1.06 in)

Mica undercut

0.7 mm (0.03 in)

----

Starter relay

Model/manufacturer

MS5F-561/JIDECO

----

Amperage rating

180 A

----

Coil winding resistance

4.18 ~ 4.62 

Ω

 at 20 °C (68 °F)

----

Four-wheel drive relay 1:

Model/manufacturer

5DM/OMRON

----

Coil winding resistance

94.5 ~ 115.5 

Ω

 at 20 °C (68 °F)

----

Four-wheel drive relay 2:

Model/manufacturer

5DM/OMRON

----

Coil winding resistance

94.5 ~ 115.5 

Ω

 at 20 °C (68 °F)

----

Four-wheel drive relay 3:

Model/manufacturer

29U/MATSUSHITA

----

Coil winding resistance

72 ~ 88 

Ω

 at 20 °C (68 °F)

----

Electric fan:

Running rpm

3,500 r/min

----

Thermostat switch:

Thermostat switch 1

Model/manufacturer

5KM/DENSO

----

Thermostat switch 2

Model/manufacturer

5ND/NIPPON THERMOSTAT

----

Circuit breaker:

Type

Fuse

----

Amperage for individual circuit

Main fuse

30 A 

×

 1

----

Headlight fuse

15 A 

×

 1

----

Ignition fuse

10 A 

×

 1

----

Auxiliary DC jack fuse

10 A 

×

 1

----

Four-wheel drive fuse

3 A 

×

 1

----

Signaling system fuse

10 A 

×

 1

----

Back up fuse (odometer)

10 A 

×

 1

----

Reserve

30 A 

×

 1

----

Reserve

15 A 

×

 1

----

Reserve

10 A 

×

 1

----

Reserve

3 A 

×

 1

----

Item

Standard

Limit

MAINTENANCE SPECIFICATIONS

2 - 20

SPEC

EB201000

HOW TO USE THE CONVERSION 
TABLE

All specification data in this manual are listed in
SI and METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.
Ex.

CONVERSION TABLE

EB202001

GENERAL TORQUE 
SPECIFICATIONS

This chart specifies torque for standard
fasteners with standard I.S.O. pitch threads.
Torque specifications for special components
or assemblies are provided for each chapter of
this manual. To avoid warpage, tighten multi-
fastener assemblies in a crisscross fashion, in
progressive stages, until the specified torque is
reached. Unless otherwise specified, torque
specifications require clean, dry threads.
Components should be at room temperature.

A: Distance between flats
B: Outside thread diameter

METRIC

MULTIPLIER

IMPERIAL

** mm

×

 0.03937

=

** 

in

2 mm

×

 0.03937

=

0.08 

in

METRIC TO IMPERIAL

Metric unit

Multiplier

Imperial unit

Torque

m·kg
m·kg
cm·kg
cm·kg

7.233
86.794
0.0723
0.8679

ft·lb
in·lb
ft·lb
in·lb

Weight

kg
g

2.205
0.03527

lb
oz

Speed

km/hr

0.6214

mph

Distance

km
m
m
cm
mm

0.6214
3.281
1.094
0.3937
0.03937

mi
ft
yd
in
in

Volume/Ca
pacity

cc (cm

3

)

cc (cm

3

)

lt (liter)
lt (liter)

0.03527
0.06102
0.8799
0.2199

oz (IMP liq.)
cu·in
qt (IMP liq.)
gal (IMP liq.)

Misc.

kg/mm
kg/cm

2

 

Centigrade
(°C)

55.997
14.2234
9/5+32 

lb/in
psi (lb/in

2

)

Fahrenheit (°F)

A

(nut)

B

(bolt)

General torque

specifications

Nm

m•kg

ft•lb

10 mm

6 mm

6

0.6

4.3

12 mm

8 mm

15

1.5

11

14 mm

10 mm

30

3.0

22

17 mm

12 mm

55

5.5

40

19 mm

14 mm

85

8.5

61

22 mm

16 mm

130

13.0

94

HOW TO USE THE CONVERSION TABLE/

GENERAL TORQUE SPECIFICATIONS

2 - 21

SPEC

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE

Lubrication points

Lubricant type

Oil seal lips (all)

LS

O-ring (all)

LS

Bearings (all)

E

Crank pin

E

Connecting rod (bearing)

E

Camshaft sprocket

M

Crankshaft

E

Piston surface/piston rings

E

Piston pin

E

Baffer boss

E

Valve stem/valve stem end

M

Rocker arm shaft

E

Rocker arm

M

Camshaft lobe/journal

M

Cylinder head bolt

E

Oil pump shaft, rotor, housing

E

Oil filter O-ring

E

Starter idle gear shaft

E

Transmission gear (wheel/pinion)

M

Axle (main/drive)

M

Shift fork/guide bar

E

Shift cam/shift shaft/shift cam stopper ball

E

Shift lever (select lever)/shift guide

LS

Shift cam lever

M

Stopper lever

E

Clutch housing

E

One-way bearing

M

Drive chain/sprocket

E

Driven cam

M

Front drive shaft collar

E

Crankcase mating surfaces

Sealant (Quick Gasket

®

)

Yamaha Bond No.1215

Stater lead grommet
(left side crankcase)

Sealant (Quick Gasket

®

)

Yamaha Bond No.1215

LUBRICATION POINTS AND LUBRICANT TYPES

2 - 22

SPEC

COOLANT FLOW DIAGRAMS

1

Radiator 

2

Thermo switch

3

Fan motor

È

To coolant reservoir

COOLANT FLOW DIAGRAMS

2 - 23

SPEC

1

Radiator

2

Thermostat

È

To coolant reservoir

COOLANT FLOW DIAGRAMS

2 - 24

SPEC

OIL FLOW DIAGRAMS

1

Camshaft

2

Crankshaft

3

Drive axle

OIL FLOW DIAGRAMS

2 - 25

SPEC

1

Oil filter

OIL FLOW DIAGRAMS

2 - 26

SPEC

1

Oil pump

2

Oil strainer

OIL FLOW DIAGRAMS

2 - 27

SPEC

CABLE ROUTING

1

Rear brake switch lead

2

Starter cable

3

Rear brake cable 

4

Front brake hose

5

On-command four-wheel drive switch and 
differential gear lock switch

6

Throttle cable

7

Handlebar switch

8

Handlebar switch lead

9

Main switch lead

0

Fan motor breather hose

A

Differential gear case breather hose 

B

Sub-wire harness (to gear motor)

C

On-command four-wheel drive switch and
differential gear lock switch lead

CABLE ROUTING

2 - 28

SPEC

È

Fasten the on-command four-wheel drive switch and differential gear lock switch lead behind the
handlebar with a plastic band.

É

Fasten the starter cable, handlebar switch lead and rear brake switch lead behind the handlebar with a
plastic band.

Ê

Fasten the handlebar switch lead and rear brake switch lead behind the handlebar with a plastic band.

CABLE ROUTING