Yamaha YFM45FXV Supplementary Service Manual
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Yamaha YFM45FXV Supplementary Service Manual

Yamaha YFM45FXV Supplementary Service Manual

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YFM45FXV
SUPPLEMENTARY
SERVICE MANUAL
3C2-F8197-E0

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Summary of Contents for Yamaha YFM45FXV

  • Page 1 YFM45FXV SUPPLEMENTARY SERVICE MANUAL 3C2-F8197-E0...
  • Page 2 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YFM45FXV. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. YFM45FAR/YFM450FAR SERVICE MANUAL: 5ND2-AE1...

  • Page 3: Important Information

    EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle repair.
  • Page 4 EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section.
  • Page 5 EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 0 are printed on the SPEC INFO top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetion COOL CARB...

  • Page 6: Table Of Contents

    CONTENTS GENERAL INFORMATION ................1 VEHICLE IDENTIFICATION................. 1 VEHICLE IDENTIFICATION NUMBER..........1 MODEL LABEL ..................1 SPECIFICATIONS ....................2 GENERAL SPECIFICATIONS ..............2 MAINTENANCE SPECIFICATIONS ............4 ENGINE ....................4 CHASSIS ....................5 ELECTRICAL ..................6 COOLANT FLOW DIAGRAMS..............7 CABLE ROUTING ..................
  • Page 7 ELECTRIC STARTING SYSTEM............... 92 CIRCUIT DIAGRAM................92 LIGHTING SYSTEM................... 93 CIRCUIT DIAGRAM................93 TROUBLESHOOTING ................. 94 SIGNALING SYSTEM ................96 CIRCUIT DIAGRAM................96 CHECKING THE SIGNALING SYSTEM..........98 2WD/4WD SELECTING SYSTEM ............. 99 CIRCUIT DIAGRAM................99 TROUBLESHOOTING ............... 100 YFM45FXV 2006 WIRING DIAGRAM...

  • Page 8: General Information

    VEHICLE IDENTIFICATION INFO GENERAL INFORMATION VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame. MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.

  • Page 9: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: 3C21 (for USA) 3C22 (for CDN) 3C23 (for Europe) Dimensions: Overall length 1,978 mm (77.9 in) Overall width 1,063 mm (41.9 in) Overall height 1,095 mm (43.1 in) Seat height 840 mm (33.1 in) Wheelbase 1,233 mm (48.5 in)
  • Page 10 SPEC GENERAL SPECIFICATIONS Item Standard Transmission: Primary reduction system V-belt Secondary reduction system Shaft drive 39/24 × 24/18 × 33/9 (7.944) Secondary reduction ratio Transmission type V-belt automatic Operation Left hand operation Single speed automatic 2.55 ~ 0.75 : 1 Sub transmission ratio 38/23 (1.652) Reverse gear...

  • Page 11: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Air filter oil grade: Yamaha foam air filter oil or other ---- quality foam air filter oil Carburetor: I. D. mark 5NDC 00 ---- Main jet (M.J) #131.3 ---- Main air jet (M.A.J)

  • Page 12: Chassis

    SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part Thread Part to be tightened Q’ty Remarks name size m·kg ft·lb Oil seal retainer Screw Access cover Bolt Thermo switch — Stopper lever shaft Bolt Park switch — CHASSIS Item Standard Limit Front suspension: Shock absorber travel 99 mm (3.90 in)

  • Page 13: Electrical

    SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Brake lever and brake pedal: Rear brake lever free play (pivot) 0.5 ~ 2 mm (0.02 ~ 0.08 in) ---- Brake pedal height 67 ~ 77 mm (2.64 ~ 3.03 in) ---- Throttle lever free play 3 ~ 5 mm (0.12 ~ 0.20 in) ---- Tightening torques...

  • Page 14: Coolant Flow Diagrams

    SPEC COOLANT FLOW DIAGRAMS COOLANT FLOW DIAGRAMS 1 Radiator 2 Thermo switch 2 3 Fan motor È To coolant reservoir – 7 –...
  • Page 15 SPEC COOLANT FLOW DIAGRAMS 1 Radiator 2 Thermostat – 8 –...

  • Page 16: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 On-command four-wheel drive switch 0 Front brake light switch lead 2 On-command four-wheel drive switch lead A Main switch lead 3 Throttle cable B Coolant reservoir hose 4 Handlebar switch lead C Coolant reservoir breather hose 5 Handlebar switch D Differential gear case breather hose 6 Rear brake switch lead...
  • Page 17 SPEC CABLE ROUTING È Fasten the on-command four-wheel drive switch Ë Pass the rear brake cable through the cable lead and front brake light switch lead behind the guide, making sure that it is routed on the right handlebar with the plastic bands. side of the steering stem.
  • Page 18 SPEC CABLE ROUTING 1 Auxiliary DC jack (optional) 2 Headlight lead 3 Headlight coupler – 11 –...
  • Page 19 SPEC CABLE ROUTING È Insert the fuel tank breather hose into the hole of 1 Starter cable 2 Fuel tank breather hose the handlebar cover. É Fasten the starter cable with a plastic band. 3 Fuel hose Ê Fasten the radiator outlet hose with a plastic 4 Cylinder head breather hose 5 Carburetor drain hose band.
  • Page 20 SPEC CABLE ROUTING Í Fasten the sub-wire harness 1 and differential gear case breather hose with a plastic band. Î Fasten the sub-wire harness 1, differential gear case breather hose, coolant reservoir hose, and coolant reservoir breather hose with a plastic band.
  • Page 21 SPEC CABLE ROUTING 1 Fuel hose B Radiator outlet hose 2 Cylinder head breather hose C Starter cable 3 Final drive gear case breather hose D Float chamber air vent hose 4 Negative battery lead E Neutral switch lead 5 Starter motor lead F Park switch 6 Wire harness G Reverse switch lead...
  • Page 22 SPEC CABLE ROUTING È Fasten the final drive gear case breather hose Ì Fasten the wire harness, negative battery lead, and wire harness with a plastic band. sub-wire harness 2, A.C. magneto lead, speed É Fasten the starter motor lead, final drive gear sensor lead, and final drive gear case breather case breather hose, and wire harness with a hose with a plastic band.
  • Page 23 SPEC CABLE ROUTING 1 Wire harness B Sub-wire harness 3 2 Throttle cable È Fasten the select lever control cable with the 3 Spark plug lead 4 Radiator inlet hose plastic holder. É Fasten the select lever control cable and rear 5 Main switch 6 Rear brake fluid reservoir hose brake light switch lead with the plastic bands.
  • Page 24 SPEC CABLE ROUTING 1 Auxiliary DC jack connectors (optional) B Sub-wire harness 3 coupler 2 Front brake hose C Main switch coupler 3 Throttle cable D Handlebar switch couplers 4 Float chamber air vent hose E Rear brake switch coupler 5 Wire harness F Coolant reservoir breather hose 6 Final drive gear case breather hose...
  • Page 25 SPEC CABLE ROUTING È Fasten the wire harness with the plastic bands. É Fasten the float chamber air vent hose with the plastic holders. Ê Route the headlight lead under the couplers. Ë Pass the hoses through the holes in the air duct bracket.
  • Page 26 SPEC CABLE ROUTING È Fasten the positive battery lead with the plastic 1 Battery 2 Positive battery lead holders. É Route the starter relay lead under the fuse box. 3 Tail/brake light lead 4 Headlight relay 5 CDI unit 6 Fuse box 7 Starter relay 8 Starter motor lead 9 Negative battery lead...
  • Page 27 SPEC CABLE ROUTING È Fasten the final drive gear case breather hose 1 Final drive gear case breather hose 2 Rear brake hose with the plastic holder. É Fasten the rear brake hose with the plastic hold- 3 Air filter case check hose ers.

  • Page 28: Periodic Checks And Adjustments

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

  • Page 29: General Maintenance And Lubrication Chart (For Cdn)

    GENERAL MAINTENANCE AND LUBRICATION CHART (For CDN) GENERAL MAINTENANCE AND LUBRICATION CHART (For CDN) INITIAL EVERY month Whichever ITEM ROUTINE comes first 1,300 2,500 2,500 5,000 (mi) (200) (800) (1,600) (1,600) (3,200) hours • Check coolant leakage. Cooling system • Repair if necessary. •...

  • Page 30: Periodic Maintenance And Lubrication Chart (For Europe)

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 31 PERIODIC MAINTENANCE AND LUBRICATION CHART (For Europe) INITIAL EVERY month CHECK OR MAINTENANCE Whichever ITEM 1200 2400 2400 4800 comes first km (mi) (200) (750) (1500) (1500) (3000) hours • Check operation and repair or replace if damaged. √ √ √...

  • Page 32: Seat, Fenders And Fuel Tank

    SEAT, FENDERS AND FUEL TANK SEAT, FENDERS AND FUEL TANK SEAT 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the seat Remove the parts in the order below. Seat NOTE: Pull rearward on the seat lock lever,...

  • Page 33: Front Guard And Front Fender

    SEAT, FENDERS AND FUEL TANK FRONT GUARD AND FRONT FENDER 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 34 Nm (3.4 m kg, 24 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 34: Rear Guard And Rear Fender

    SEAT, FENDERS AND FUEL TANK REAR GUARD AND REAR FENDER 34 Nm (3.4 m kg, 24 ft • • Order Job/Part Q’ty Remarks Removing the rear fender Remove the parts in the order below. Seat Refer to “SEAT”. Fuel tank cover Refer to “FRONT GUARD AND FRONT FENDER”.
  • Page 35 SEAT, FENDERS AND FUEL TANK 34 Nm (3.4 m kg, 24 ft • • Order Job/Part Q’ty Remarks Wire harness Rear fender For installation, reverse the removal pro- cedure. – 28 –...

  • Page 36: Fuel Tank

    SEAT, FENDERS AND FUEL TANK FUEL TANK 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order below. Seat Refer to “SEAT”.
  • Page 37 SEAT, FENDERS AND FUEL TANK 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Plastic band Rubber cover For installation, reverse the removal pro- cedure. – 30 –...

  • Page 38: Footrest Boards

    FOOTREST BOARDS FOOTREST BOARDS Order Job/Part Q’ty Remarks Removing the footrest boards Remove the parts in the order below. Left footrest board Right footrest board Footrest board bracket For installation, reverse the removal pro- cedure. – 31 –...

  • Page 39: Chassis

    ADJUSTING THE REAR BRAKE CHASSIS ADJUSTING THE REAR BRAKE WARNING Always adjust both the brake pedal and the rear brake lever whenever adjusting the rear brake. 1. Check: • rear brake lever free play a Out of specification → Adjust. Rear brake lever free play 0.5 ~ 2.0 mm (0.02 ~ 0.08 in) 2.
  • Page 40 ADJUSTING THE REAR BRAKE c. Loosen the locknut 4. d. Turn the adjusting bolt 5 until the brake pedal height is within the specified limits. Brake pedal height 67 ~ 77 mm (2.64 ~ 3.03 in) e. Tighten the locknut 4. NOTE: When adjusting the brake pedal height make sure the locknut-to-adjusting bolt clearance a...

  • Page 41: Adjusting The Select Lever Control Cable And Shift Rod

    ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD 1 NEUTRAL 2 FORWARD 3 REVERSE 4 PARK 5 Control cable 6 Select lever shift rod WARNING Before moving the select lever, bring the vehicle to a complete stop and return the throttle lever to its closed position.
  • Page 42 ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD f. Check that locknuts 3 are tightened cor- rectly. g. If the operation of the select lever is incor- rect, adjust the select lever control cable 4 with the adjuster 5. Select lever shift rod: a.

  • Page 43: Electrical

    ADJUSTING THE HEADLIGHT BEAMS/ CHANGING THE HEADLIGHT BULBS ELECTRICAL EBS00122 ADJUSTING THE HEADLIGHT BEAMS 1. Adjust: • headlight beam (vertically) M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting bolt 1 in direction a or Headlight beam is Direction a raised.
  • Page 44 CHANGING THE HEADLIGHT BULBS 3. Install: • bulb Secure the new bulb with the headlight unit. CAUTION: Avoid touching the glass part of the bulb. Keep it free from oil; otherwise, the trans- parency of the glass, life of the bulb, and luminous flux will be adversely affected.

  • Page 45: Engine

    ENGINE REMOVAL ENGINE ENGINE REMOVAL SELECT LEVER UNIT AND COOLANT RESERVOIR Order Job/Part Q’ty Remarks Removing the select lever unit and Remove the parts in the order below. coolant reservoir Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. (Manual No.: 5ND2-AE1) Front fender/rear fender/fuel tank/rub- Refer to “SEAT, FENDERS AND FUEL ber cover...
  • Page 46 ENGINE REMOVAL Order Job/Part Q’ty Remarks Shift arm Select lever shift rod Select lever unit Coolant reservoir breather hose Coolant reservoir hose Coolant reservoir For installation, reverse the removal pro- cedure. – 39 –...

  • Page 47: Air Ducts, Muffler And Exhaust Pipe

    ENGINE REMOVAL AIR DUCTS, MUFFLER AND EXHAUST PIPE Order Job/Part Q’ty Remarks Removing the air ducts, muffler and Remove the parts in the order below. exhaust pipe Air duct assembly 1 (upper) Air duct assembly 1 (lower) Muffler Exhaust pipe stay Exhaust pipe/gasket Air duct assembly 2 Final drive gear case breather hose...

  • Page 48: Hoses And Leads

    ENGINE REMOVAL HOSES AND LEADS Order Job/Part Q’ty Remarks Removing the hoses and leads Remove the parts in the order below. Water pump inlet hose Refer to “WATER PUMP” in chapter 5. (Manual No.: 5ND2-AE1) Cylinder head breather hose Spark plug lead Thermo switch 1 lead Starter motor lead A.C.

  • Page 49: Installing The Muffler And Exhaust Pipe

    ENGINE REMOVAL INSTALLING THE MUFFLER AND EXHAUST PIPE 1. Install: • exhaust pipe 1 • exhaust pipe stay 2 • muffler 3 NOTE: Do not fully tighten the bolts and nuts. 2. Tighten: • exhaust pipe nut 4 20 Nm (2.0 m · kg, 14 ft · lb) •...

  • Page 50: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order below. Fuel tank/rubber cover/front fender/air Refer to “SEAT, FENDERS AND FUEL filter case TANK”. Air duct assembly 1 (upper and lower)/ Refer to “ENGINE REMOVAL”. exhaust pipe/muffler Carburetor assembly Refer to “CARBURETOR”...
  • Page 51 CYLINDER HEAD Order Job/Part Q’ty Remarks Cylinder head breather hose Camshaft sprocket cover/O-ring Tappet cover/O-ring Thermo switch 1 lead Disconnect. Timing chain tensioner cap bolt Refer to “REMOVING THE CYLINDER Timing chain tensioner/gasket HEAD” and “INSTALLING THE CYLIN- Camshaft sprocket DER HEAD”.

  • Page 52: Removing The Cylinder Head

    CYLINDER HEAD REMOVING THE CYLINDER HEAD 1. Align: • “T” mark 1 (with stationary pointer) M MMM M MMM M MMM M MMM M MMM a. Turn the crankshaft counterclockwise with a wrench. b. Align the “T” mark 1 on the rotor with the stationary pointer 2 on the A.C.

  • Page 53: Installing The Cylinder Head

    CYLINDER HEAD 5. Remove: • cylinder head NOTE: • Loosen the 6 mm bolts first. • Working in a crisscross pattern, loosen each 10-mm bolt 1/4 of a turn. After all the bolts are loosened, remove them. INSTALLING THE CYLINDER HEAD 1.
  • Page 54 CYLINDER HEAD NOTE: Be sure the “I” mark 5 on the camshaft sprocket is aligned with the match mark 2 on the cylinder head. f. Force the camshaft clockwise and counter- clockwise to remove timing chain slack. g. Insert a screwdriver into the timing chain tensioner hole and push the timing chain guide inward.
  • Page 55 CYLINDER HEAD 4. Tighten: • camshaft sprocket bolt 1 60 Nm (6.0 m · kg, 43 ft · lb) NOTE: When tightening the bolt, use a wrench 2 to hold the collar. 5. Check: • camshaft sprocket “I” mark • rotor “T” mark Out of alignment →...

  • Page 56: A.c. Magneto

    A.C. MAGNETO A.C. MAGNETO Order Job/Part Q’ty Remarks Removing the A.C. magneto Remove the parts in the order below. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. (Manual No.: 5ND2-AE1) Seat Refer to “SEAT, FENDERS AND FUEL TANK”.
  • Page 57 A.C. MAGNETO Order Job/Part Q’ty Remarks Pickup coil Stator assembly Rotor Refer to “REMOVING THE A.C. MAG- Starter wheel gear NETO” and “INSTALLING THE A.C. MAGNETO”. Woodruff key Washer Starter idle gear shaft Washer/bearing Starter idle gear For installation, reverse the removal pro- cedure.

  • Page 58: Removing The A.c. Magneto

    Use the flywheel puller 2. Flywheel puller P/N. YM-01404, 90890-01404 INSTALLING THE A.C. MAGNETO 1. Apply: ® • sealant (Quick Gasket (into the slit) Yamaha bond No. 1215 ® (Three Bond No. 1215 P/N. 90890-85505 2. Install: • woodruff key • rotor NOTE: •...
  • Page 59 A.C. MAGNETO 3. Install: • dowel pins • gasket • A.C. magneto cover 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: • When installing the A.C. magneto cover, use a long rod to hold the rotor in position from the outside.

  • Page 60: Crankcase

    CRANKCASE CRANKCASE STARTER MOTOR, TIMING CHAIN AND OIL FILTER Order Job/Part Q’ty Remarks Removing the starter motor, timing Remove the parts in the order below. chain and oil filter Engine assembly Refer to “ENGINE REMOVAL” in chapter 4. (Manual No.: 5ND2-AE1) Cylinder head Refer to “CYLINDER HEAD”.
  • Page 61 CRANKCASE Order Job/Part Q’ty Remarks Oil pump drive gear/straight key Refer to “REMOVING THE OIL PUMP DRIVE GEAR” and “INSTALLING THE OIL PUMP DRIVE GEAR” in chapter 4. (Manual No.: 5ND2-AE1) Oil pump driven gear Timing chain guide Timing chain Starter motor/O-ring Oil filter cartridge Speed sensor...
  • Page 62 CRANKCASE Order Job/Part Q’ty Remarks Bearing cover/gasket Oil delivery pipe Oil strainer cover/O-ring Compression spring Oil strainer For installation, reverse the removal pro- cedure. – 55 –...

  • Page 63: Transmission

    TRANSMISSION TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE” in chapter 4. (Manual No.: 5ND2-AE1) Driven sprocket Chain Guide bar Shift fork Spring Clutch dog Low wheel gear Secondary shaft Middle driven gear Drive axle...
  • Page 64 TRANSMISSION Order Job/Part Q’ty Remarks Shift cam Middle drive gear Stopper wheel Stopper lever Stopper lever shaft Spacer For installation, reverse the removal pro- cedure. – 57 –...

  • Page 65: Middle Gear

    MIDDLE GEAR MIDDLE GEAR MIDDLE DRIVEN SHAFT Order Job/Part Q’ty Remarks Removing the middle driven shaft Remove the parts in the order below. Crankcase separation Refer to “CRANKCASE” in chapter 4. (Manual No.: 5ND2-AE1) Circlip Refer to “REMOVING THE MIDDLE Bearing DRIVEN SHAFT”...
  • Page 66 MIDDLE GEAR Order Job/Part Q’ty Remarks Damper cam Spring Gear coupling Front drive shaft coupling Bearing retainer Middle driven shaft For installation, reverse the removal pro- cedure. – 59 –...

  • Page 67: Cooling System

    COOL RADIATOR COOLING SYSTEM RADIATOR 8 Nm (0.8 m kg, 5.8 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order below. Front guard/front fender/headlights/ Refer to “SEAT, FENDERS AND FUEL front grill TANK”.
  • Page 68 COOL RADIATOR 8 Nm (0.8 m kg, 5.8 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Fan motor Thermo switch 2 For installation, reverse the removal pro- cedure. – 61 –...

  • Page 69: Drive Train

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR DRIVE TRAIN FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR Order Job/Part Q’ty Remarks Removing the front constant veloc- Remove the parts in the order below. ity joints and differential gear Engine skid plate/front fender Refer to “SEAT, FENDERS AND FUEL TANK”.
  • Page 70 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Order Job/Part Q’ty Remarks Differential gear case breather hose Disconnect. Differential gear assembly Front drive shaft Compression spring Front drive shaft coupling For installation, reverse the removal pro- cedure. – 63 –...
  • Page 71 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Order Job/Part Q’ty Remarks Disassembling the constant velocity Remove the parts in the order below. joints Circlip Boot band Boot band Dust boot Circlip Refer to “ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS”. Double off-set joint Circlip Ball bearing...
  • Page 72 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Order Job/Part Q’ty Remarks Disassembling the differential gear Remove the parts in the order below. Gear motor/O-ring Four-wheel drive switch Dust seal Circlip Coupling gear/bearing/circlip 1/1/1 Stopper bolt/shaft Shift fork sliding gear Shift fork 2WD/4WD shift sleeve Differential gear case cover/O-ring...
  • Page 73 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Order Job/Part Q’ty Remarks Shim (right) Circlip/bearing Drive pinion gear Differential gear case For assembly, reverse the disassembly procedure. – 66 –...

  • Page 74: Disassembling The Differential Gear

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR DISASSEMBLING THE DIFFERENTIAL GEAR 1. Remove: • differential gear unit 1 CAUTION: The differential gear unit is assembled into a proper unit at the factory by means of specialized equipment. Do not attempt to disassemble this unit.

  • Page 75: Checking The Differential Gear

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR CHECKING THE DIFFERENTIAL GEAR 1. Check: • gear teeth Pitting/galling/wear → Replace drive pinion gear and differential gear unit as a set. • bearings Pitting/damage → Replace. • oil seal • O-ring Damage →...

  • Page 76: Assembling The Differential Gear

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR b. Install the dust boots. c. Install the dust boot bands. NOTE: • The new boot bands may differ from the orig- inal ones. • The dust boots should be fastened with the dust boot bands 3 at the grooves in the joint shaft.

  • Page 77: Measuring And Adjusting The Differential Gear Lash

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR 3. Check: • differential gear assembly operation Unsmooth operation → Replace the differ- ential gear assembly. Insert the double off-set joint into the differ- ential gear, and turn the gear back and forth.
  • Page 78 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR 5. Measure: • gear lash Gently rotate the gear coupling from engagement to engagement Differential gear lash 0.10 ~ 0.50 mm (0.004 ~ 0.020 in) NOTE: Measure the gear lash at four positions. Rotate the shaft 90°...

  • Page 79: Checking The Differential Operation

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR c. If it is necessary to reduce by more than 0.1 mm (0.004 in): Increase right shim thickness by 0.1 mm (0.004 in) for every 0.1 mm of left shim decrease. Ring gear shim (left and right) Thickness (mm) L LLL L LLL...

  • Page 80: Rear Axle/Final Drive Gear And Drive Shaft

    DRIV REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT Order Job/Part Q’ty Remarks Removing the rear axle, final drive Remove the parts in the order below. gear assembly and drive shaft Final gear oil Drain.

  • Page 81: Chassis

    CHAS FRONT AND REAR WHEELS CHASSIS FRONT AND REAR WHEELS FRONT WHEELS Order Job/Part Q’ty Remarks Removing the front wheels Remove the parts in the order below. Place the vehicle on a level surface. WARNING Securely support the vehicle so there is no danger of it falling over.
  • Page 82 CHAS FRONT AND REAR WHEELS Order Job/Part Q’ty Remarks Wheel hub Brake disc For installation, reverse the removal pro- cedure. – 75 –...

  • Page 83: Rear Wheels

    CHAS FRONT AND REAR WHEELS REAR WHEELS Order Job/Part Q’ty Remarks Removing the rear wheels Remove the parts in the order below. Place the vehicle on a level surface. WARNING Securely support the vehicle so there is no danger of it falling over. Rear wheel Refer to “INSTALLING THE WHEEL”...
  • Page 84 CHAS FRONT AND REAR WHEELS Order Job/Part Q’ty Remarks Brake disc Refer to “INSTALLING THE REAR BRAKE DISC”. Brake disc guard For installation, reverse the removal pro- cedure. – 77 –...

  • Page 85: Installing The Rear Brake Disc

    CHAS FRONT AND REAR WHEELS INSTALLING THE REAR BRAKE DISC 1. Install: • brake disc 1 28 Nm (2.8 m · kg, 20 ft · lb) NOTE: • Make sure that the “OUT” mark on the brake disc faces the brake disc bracket 2. ®...

  • Page 86: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES FRONT AND REAR BRAKES REAR BRAKE MASTER CYLINDER Order Job/Part Q’ty Remarks Removing the rear brake master cyl- Remove the parts in the order below. inder Front fender Refer to “SEAT, FENDERS AND FUEL TANK”. Brake fluid Drain.
  • Page 87 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Brake cable Disconnect. Bracket Brake master cylinder Hose joint Brake pedal Select lever control cable Disconnect. Rear brake light switch Bracket Brake master cylinder bracket For installation, reverse the removal pro- cedure.

  • Page 88: Steering System

    CHAS STEERING SYSTEM STEERING SYSTEM STEERING STEM Order Job/Part Q’ty Remarks Removing the steering stem Remove the parts in the order below. Handlebar Refer to “HANDLEBAR” in chapter 8. (Manual No.: 5ND2-AE1) Seat/front fender Refer to “SEAT, FENDERS AND FUEL TANK”.
  • Page 89 CHAS STEERING SYSTEM Order Job/Part Q’ty Remarks Steering stem nut Pitman arm Steering stem Oil seal Bearing retainer Refer to “REMOVING THE BEARING RETAINER” and “INSTALLING THE BEARING RETAINER” in chapter 8. (Manual No.: 5ND2-AE1) Bearing Oil seal For installation, reverse the removal pro- cedure.

  • Page 90: Tie Rod And Steering Knuckle

    CHAS STEERING SYSTEM TIE ROD AND STEERING KNUCKLE Order Job/Part Q’ty Remarks Removing the tie rod and steering Remove the parts in the order below. knuckle Front fender Refer to “SEAT, FENDERS AND FUEL TANK”. Front wheel/brake disc Refer to “FRONT AND REAR WHEELS”. Tie rod Refer to “INSTALLING THE TIE ROD”...
  • Page 91 CHAS STEERING SYSTEM Order Job/Part Q’ty Remarks Steering knuckle Refer to “REMOVING THE STEERING KNUCKLE” in chapter 8. (Manual No.: 5ND2-AE1) Oil seal Oil seal Bearing Spacer Circlip Rubber boot Ball joint For installation, reverse the removal pro- cedure. – 84 –...

  • Page 92: Front Arms And Front Shock Absorbers

    CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS FRONT ARMS AND FRONT SHOCK ABSORBERS Order Job/Part Q’ty Remarks Removing the front arms and front Remove the parts in the order below. shock absorbers Engine skid plate/front fender Refer to “SEAT, FENDERS AND FUEL TANK”.
  • Page 93 CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS Order Job/Part Q’ty Remarks Refer to “REMOVING THE FRONT Bolt/nut ARMS” and “INSTALLING THE FRONT Front lower arm/bushing ARMS AND FRONT SHOCK Nut/bolt ABSORBER” in chapter 8. Front shock absorber (Manual No.: 5ND2-AE1) Bolt/nut Front upper arm/bushing Circlip...

  • Page 94: Rear Shock Absorber And Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order below. and swingarm Rear wheel hubs/brake disc Refer to “FRONT AND REAR WHEELS”. Rear brake caliper/brake hose Refer to “FRONT AND REAR BRAKES”...
  • Page 95 CHAS REAR SHOCK ABSORBER AND SWINGARM Order Job/Part Q’ty Remarks Rear axle housing Refer to “INSTALLING THE REAR AXLE HOUSING” in chapter 8. (Manual No.: 5ND2-AE1) Nut/bolt Refer to “REMOVING THE SWING- ARM” in chapter 8. Swingarm/bushing (Manual No.: 5ND2-AE1) Spring/rubber boot For installation, reverse the removal pro- cedure.

  • Page 96: Electrical

    – ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Main switch 8 Fuse box E Neutral switch L Headlight 2 Front brake light switch 9 Main fuse F Speed sensor M Circuit breaker (fan) 3 Rear brake switch 0 Starter relay G Diode N Ignition coil 4 Thermo switch 1...

  • Page 97: Checking The Switch

    – ELEC CHECKING THE SWITCH 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. Br L Y G R/B R/W PUSH (BLACK)
  • Page 98 – ELEC CHECKING THE SWITCH 1 Light switch 2 Engine stop switch 3 Start switch 4 On-command four-wheel drive switch 5 Main switch 6 Rear brake light switch 7 Front brake light switch 8 Rear brake switch 9 Four-wheel drive switch 0 Reverse switch A Park switch B Neutral switch...

  • Page 99: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM – 92 –...

  • Page 100: Lighting System

    – ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM – 93 –...

  • Page 101: Troubleshooting

    – ELEC LIGHTING SYSTEM EB805010 TROUBLESHOOTING IF THE HEADLIGHT AND/OR TAILLIGHT FAIL TO COME ON: Procedure Check: 1. Fuses (main, headlight) 4. Light switch 2. Battery 5. Headlight relay 3. Main switch 6. Wiring connections (the entire lighting system) NOTE: •...
  • Page 102 – ELEC LIGHTING SYSTEM INCORRECT 4. Light switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the handlebar switch (left). 5. Headlight relay • Remove the headlight relay from the wire harness. • Connect the pocket tester (Ω × 1) and the battery (12 V) to the headlight relay termi- nals.

  • Page 103: Signaling System

    – ELEC SIGNALING SYSTEM EB806000 SIGNALING SYSTEM CIRCUIT DIAGRAM – 96 –...
  • Page 104 – ELEC SIGNALING SYSTEM 3 Main switch 4 Backup fuse 5 Battery 6 Main fuse 0 CDI unit C Speed sensor E Multi-function meter F Neutral indicator light G Reverse indicator light H Park indicator light I Four-wheel drive indicator light J Coolant temperature warning light K Reverse switch L Neutral switch...

  • Page 105: Checking The Signaling System

    – ELEC SIGNALING SYSTEM CHECKING THE SIGNALING SYSTEM EB806024 1. If the indicator lights fail to come on: NO CONTINUITY 1. Neutral switch Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the neutral switch. NO CONTINUITY 2. Park switch Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the park switch.

  • Page 106: 2Wd/4Wd Selecting System

    – ELEC 2WD/4WD SELECTING SYSTEM 2WD/4WD SELECTING SYSTEM CIRCUIT DIAGRAM – 99 –...

  • Page 107: Troubleshooting

    – ELEC 2WD/4WD SELECTING SYSTEM EB803020 TROUBLESHOOTING IF THE GEAR MOTOR FAILS TO OPERATE: Procedure Check: 1. Fuses (main, four-wheel drive) 4. On-command four-wheel drive switch 2. Battery 5. Gear motor 3. Main switch 6. Wiring connections (the entire 2WD/4WD selecting system) NOTE: •...
  • Page 108 – ELEC 2WD/4WD SELECTING SYSTEM INCORRECT 4. On-command four-wheel drive switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the on-command four-wheel drive switch. 5. Gear motor • Check that the shift fork sliding gear is in the 2WD position. • Disconnect the gear motor coupler. •...
  • Page 109 – ELEC 2WD/4WD SELECTING SYSTEM EB803028 6. Wiring connections POOR CONNECTION • Check the connections of the entire 2WD/ 4WD selecting system. Refer to “CIRCUIT DIAGRAM”. Properly connect the 2WD/4WD selecting CORRECT system. This circuit is not faulty. – 102 –...
  • Page 110 YFM45FXV 2006 WIRING DIAGRAM 1 A.C. magneto COLOR CODE 2 Rectifier/regulator B ....Black 3 Main switch Br ...Brown 4 Backup fuse G....Green 5 Battery L.....Blue 6 Main fuse O....Orange 7 Starter relay P ....Pink 8 Starter motor R ....Red 9 Diode Sb ..Sky blue...
  • Page 111 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...

  • Page 112: Yfm45Fxv 2006 Wiring Diagram

    YFM45FXV 2006 YFM45FXV 2006 WIRING DIAGRAM SCHÉMA DE CÂBLAGE B/R L/B B B L/B B/R Sb L/R Br/W Sb R/B R/B Sb Br/W R/B L/W O B (BLACK) (BLACK) (BLACK) (BLACK) L/R R W/R W/G Sb B/Y SUB-WIRE SUB-WIRE SUB-WIRE...

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