Yamaha YFM45FAR, YFM450FAR. Service Manual

8 - 42

CHAS

FRONT ARMS AND FRONT SHOCK ABSORBER

Order

Job name/Part name

Q’ty

Remarks

Removing the front arms and front
shock absorber

Remove the parts in the order below.

Engine skid plate

Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK” in CHAPTER 3.

Front fender
Front wheel/brake disc

Refer to “FRONT AND REAR WHEELS”.

Air duct

Brake disc guard

Protector

8 - 43

CHAS

FRONT ARMS AND FRONT SHOCK ABSORBER

Order

Job name/Part name

Q’ty

Remarks

Nut

Refer to “REMOVING THE FRONT
ARMS” and “INSTALLING THE FRONT
ARMS AND FRONT SHOCK
ABSORBER”.

Nut

Bolt/nut

2/2

Front lower arm/bushing

1/2

Nut/bolt

2/2

Front shock absorber

Bolt/nut

2/2

Front upper arm/bushing

1/2

Circlip

Ball joint

For installation, reverse the removal
procedure.

8 - 44

CHAS

FRONT ARMS AND FRONT SHOCK ABSORBER

REMOVING THE FRONT ARMS

1.Check:

●

Front arm free play

*****************************************************

Checking steps:

●

Check the front arm side play

by moving it

from side to side.
If side play is noticeable, check the bushings.

●

Check the front arm vertical movement

moving it up and down.
If the vertical movement is tight or rough, or if
there is binding, check the bushings.

*****************************************************
2.Remove:

●

Front arms

CHECKING THE FRONT ARM

1.Check:

●

Front arms
Bends/damage

→

Replace.

2.Check:

●

Bushings
Wear/damage

→

Replace.

3.Check:

●

Ball joint
Damage/pitting

→

Replace the ball joint.

Free play

→

Replace the ball joint.

Turns roughly

→

Replace the ball joint.

8 - 45

CHAS

*****************************************************

Replacement steps:

●

Clean the outside of the front lower arm.

●

Remove the circlip

and rubber boot

Use the ball joint remover and installer set.

●

Install the body

, long bolt

, remover

washer

and remover spacer

onto ball

joint.

NOTE:

Remover washer

must be aligned with the

projection on the head of the ball joint.

●

Hold the body

in place while turning in the

long bolt

to remove the ball joint

from

the front lower arm.

●

Remove the ball joint remover/installer.

Ball joint remover/installer set:

P/N. YM-01474/90890-01474

Ball joint remover/installer
attachment set:

P/N. YM-01477

Body

YM-01474
90890-01474

Long bolt

YM-01474
90890-01474

Remover washer

YM-01477

Remover spacer

YM-01477

Installer attachment

YM-01477

Installer spacer

YM-01477

Installer guide

YM-01477

●

Install the long bolt

, installer spacer

and installer guide

onto the body

FRONT ARMS AND FRONT SHOCK ABSORBER

8 - 46

CHAS

FRONT ARMS AND FRONT SHOCK ABSORBER

●

Attach the assembled ball joint remover/
installer, new ball joint

and installer

attachment

to the front lower arm

NOTE:

Do not tap or damage the top of the ball joint.

●

Hold the body

in place while turning in the

long bolt

to install the new ball joint

into

the front lower arm

●

Remove the ball joint remover/installer.

●

Apply lithium-soap base grease to the new
ball joint

●

Install a new rubber boot and new circlip.

NOTE:

Always use a new ball joint set.

*****************************************************

CHECKING THE FRONT SHOCK
ABSORBER

1.Check:

●

Shock absorber rod
Bends/damage

→

Replace the shock

absorber assembly.

●

Shock absorber assembly
Oil leaks

→

Replace the shock absorber

assembly.

●

Spring
Fatigue

→

Replace the shock absorber

assembly.
Move the spring up and down.

8 - 47

CHAS

FRONT ARMS AND FRONT SHOCK ABSORBER

INSTALLING THE FRONT ARMS AND
FRONT SHOCK ABSORBER

1.Install:

●

Front arms

●

Front shock absorber

*****************************************************

Installation steps:

●

Install the front upper arm

and front lower

arm

NOTE:

●

Lubricate the bolts

with lithium-soap-

based grease.

●

Be sure to position the bolts

so that the

bolt head faces outward.

●

Temporarily tighten the nuts

●

Install the front shock absorber

●

Install the ball joints.

●

Install the new cotter pins.

●

Tighten the nuts

NOTE:

Before tightening the nuts

, adjust the length

to 310 mm (12.2 in).

*****************************************************

Nut

45 Nm (4.5 m • kg, 32 ft • lb)

Nut

30 Nm (3.0 m • kg, 22 ft • lb)

Nut

45 Nm (4.5 m • kg, 32 ft • lb)

8 - 48

CHAS

REAR SHOCK ABSORBER AND SWINGARM

Order

Job name/Part name

Q’ty

Remarks

Removing the rear shock absorber
and swingarm

Remove the parts in the order below.

Rear wheel hubs/brake disc

Refer to “FRONT AND REAR WHEELS”.

Rear brake caliper/brake hose

Refer to “FRONT AND REAR BRAKES”.

Final drive gear assembly

Refer to “REAR AXLE/FINAL DRIVE GEAR
AND DRIVE SHAFT” in CHAPTER 7.

Clip/washer/pin

1/1/1

Nut/bolt

1/1

Rear shock absorber

Collar

Trailer hitch bracket

Final drive gear case breather hose

Metal clamp

8 - 49

CHAS

REAR SHOCK ABSORBER AND SWINGARM

Order

Job name/Part name

Q’ty

Remarks

Rear axle housing

Refer to “INSTALLING THE REAR AXLE
HOUSING”.

Nut/bolt

2/2

Refer to “REMOVING THE
SWINGARM”.

Swingarm/bushing

1/2

Spring/rubber boot

1/1

For installation, reverse the removal
procedure.

8 - 50

CHAS

REAR SHOCK ABSORBER AND SWINGARM

REMOVING THE SWINGARM

1.Check:

●

Swingarm free play

*****************************************************

Checking steps:

●

Check the tightening torque of the nuts
(swingarm).

●

Check the swingarm side play

by moving

it from side to side.
If side play is noticeable, check the bushing
and frame pivot.

●

Check the swingarm vertical movement

by moving it up and down.
If vertical movement is tight or rough, or if
there is binding, check the bushing and
frame pivot.

*****************************************************
2.Remove:

●

Nuts

●

Bolts

●

Swingarm

Nut (swingarm):

82 Nm (8.2 m • kg, 59 ft • lb)

CHECKING THE REAR SHOCK ABSORBER

1.Check:

●

Shock absorber
Oil leaks

→

Replace the shock absorber

assembly.

●

Shock absorber rod
Bends/damage

→

Replace the shock

absorber assembly.

●

Spring
Fatigue

→

Replace the shock absorber

assembly.
Move the spring up and down.

8 - 51

CHAS

REAR SHOCK ABSORBER AND SWINGARM

CHECKING THE SWINGARM

1.Check:

●

Swingarm

●

Rear axle housing

Bends/cracks/damage

→

Replace.

2.Check:

●

Bushings

Wear/damage

→

Replace.

CHECKING THE RUBBER BOOT

1.Check:

●

Rubber boot

Damage

→

Replace.

INSTALLING THE RUBBER BOOT

1.Apply:

●

Adhesive (for rubber)
(to the engine

)

2.Install:

●

Rubber boot

NOTE:

Be sure to position the rubber boot so that the
tang

faces towards the left.

8 - 52

CHAS

REAR SHOCK ABSORBER AND SWINGARM

INSTALLING THE REAR AXLE HOUSING

1.Install:

●

Rear axle housing

●

Final gear case assembly

●

Rear axle
(with dust seal)

*****************************************************

Installation steps:

●

Install the drive shaft.
Refer to “REAR AXLE/FINAL DRIVE GEAR
AND DRIVE SHAFT” in CHAPTER 7.

●

Apply sealant (Quick Gasket

) to the mating

surfaces of the swingarm and the final gear
case.

●

Temporarily install the rear axle housing

and final gear case assembly

on the

swingarm. The bolts and nuts

should

be temporarily tightened.

●

Install the rear axle (with dust seal)

from

the left side of the machine.
Refer to “REAR AXLE/FINAL DRIVE GEAR
AND DRIVE SHAFT” in CHAPTER 7.

●

Tighten the bolts and nuts

in the

specified order.

Nut (

Bolt (

Bolt/nut (

*****************************************************

Nut

63 Nm (6.3 m • kg, 45 ft • lb)
LOCTITE

Bolt

63 Nm (6.3 m • kg, 45 ft • lb)
LOCTITE

Nut

63 Nm (6.3 m • kg, 45 ft • lb)

–

ELEC

CHAPTER 9.

ELECTRICAL

ELECTRICAL COMPONENTS

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

CHECKING THE SWITCH

............................................................................ 9-2

CHECKING THE SWITCH  .................................................................... 9-2
CHECKING A SWITCH SHOWN IN THE MANUAL  ............................. 9-2
CHECKING THE SWITCH CONTINUITY  ............................................. 9-4

CHECKING THE BULBS AND BULB SOCKETS

....................................... 9-6

TYPES OF BULBS ................................................................................ 9-6
CHECKING THE CONDITION OF THE BULBS ................................... 9-6
CHECKING THE CONDITION OF THE BULB SOCKETS ................... 9-8

IGNITION SYSTEM

...................................................................................... 9-9

CIRCUIT DIAGRAM .............................................................................. 9-9
TROUBLESHOOTING ........................................................................ 9-10

ELECTRIC STARTING SYSTEM

............................................................... 9-15

CIRCUIT DIAGRAM  ............................................................................ 9-15
TROUBLESHOOTING ........................................................................ 9-16
STARTER MOTOR  ............................................................................. 9-19
CHECKING THE STARTER MOTOR  ................................................. 9-20
ASSEMBLING THE STARTER MOTOR ............................................. 9-21

CHARGING SYSTEM

................................................................................. 9-22

CIRCUIT DIAGRAM ............................................................................ 9-22
TROUBLESHOOTING ........................................................................ 9-23

LIGHTING SYSTEM

................................................................................... 9-25

CIRCUIT DIAGRAM ............................................................................ 9-25
TROUBLESHOOTING ........................................................................ 9-26
CHECKING THE LIGHTING SYSTEM ............................................... 9-28

SIGNAL SYSTEM

....................................................................................... 9-30

CIRCUIT DIAGRAM ............................................................................ 9-30
TROUBLESHOOTING ........................................................................ 9-32
CHECKING THE SIGNAL SYSTEM ................................................... 9-34

COOLING SYSTEM

.................................................................................... 9-38

CIRCUIT DIAGRAM ............................................................................ 9-38
TROUBLESHOOTING ....................................................................... 9-39

2WD/4WD SELECTING SYSTEM

.............................................................. 9-43

CIRCUIT DIAGRAM ............................................................................ 9-43
TROUBLESHOOTING ........................................................................ 9-44

9 - 1

–

ELEC

ELECTRICAL COMPONENTS

EB800000

ELECTRICAL

ELECTRICAL COMPONENTS

Main switch

Front brake light
switch

Rear brake switch

Thermo switch 1

Battery

Tail/brake light

Fuse box

Four-wheel drive
relay 2

Four-wheel drive
relay 1

Main fuse

Starter relay

CDI unit

Rectifier/regulator

Reverse switch

Neutral switch

High-range switch

Low-range switch

Speed sensor

Rear brake light switch

Gear motor

Thermo switch 2

Fan

Headlight

Circuit breaker (fan)

Four-wheel drive relay 3

Ignition coil

9 - 2

–

ELEC

CHECKING THE SWITCH

Use a pocket tester to check the terminals for
continuity. If the continuity is faulty at any
point, replace the switch.

NOTE:

●

Set the pocket tester to “0” before starting
the test.

●

The pocket tester should be set to the

“

Ω ×

1”

range when testing the switch for continuity.

●

Turn the switch on and off a few times when
checking it.

Pocket tester:

P/N. YU-03112, 90890-03112

CHECKING A SWITCH SHOWN IN THE
MANUAL

The terminal connections for switches (main
switch, handlebar switch, engine stop switch,
light switch, etc.) are shown in a chart similar
to the one on the left.
This chart shows the switch positions in the
column and the switch lead colors in the top
row.
For each switch position, “

” indicates

the terminals with continuity.

The example chart shows that:

There is continuity between red and brown/
blue, and between red and brown when the
switch is set to “ON”.

OFF

9 - 4

–

ELEC

CHECKING THE SWITCH

CHECKING THE SWITCH CONTINUITY

Refer to “CHECKING THE SWITCH” and check for continuity between lead terminals.
Poor connection, no continuity

→

Correct or replace.

The coupler locations are circled.

(BLACK)

B R

PUSH

Br L Y G

B L

L Br

R Sb Br Gy G

R B

2WD

4WD

LOCK

(BLACK)

(GRAY)

OFF

P Br

(BLACK)

OFF

PUSH

OFF

Yamaha YFM45FAR, YFM450FAR. Service Manual - part 21