Yamaha YFM450FAR 2005 Manuals

Manuals and User Guides for Yamaha YFM450FAR 2005. We have 1 Yamaha YFM450FAR 2005 manual available for free PDF download: Service Manual

Yamaha YFM450FAR 2005 Service Manual

Yamaha YFM450FAR 2005 Service Manual (405 pages)

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Brand: Yamaha | Category: Offroad Vehicle | Size: 20.08 MB

Table of Contents

Table of Contents

7
- Important Information
  4
- How to Use this Manual
  5
- Carburetion
  6
- Chassis
  6
- Cooling System
  6
- Drive Train
  6
- Electrical
  6
- Engine
  6
- Periodic Checks and Adjustments
  6
- Troubleshooting
  6
  - Table of Contents
    7
- Chapter 1
  12
- General Information
  12
- Machine Identification
  12
  - Vehicle Identification Number
    12
  - Model Label
    12
- Features
  13
  - Liquid Cooling Engine
    13
  - Park Position
    13
  - Front Differential
    14
- Important Information
  19
  - Preparation for Removal Procedures
    19
  - Replacement Parts
    19
  - Gaskets, Oil Seals and O-Rings
    19
  - Lock Washers/Plates and Cotter Pins
    20
  - Bearings and Oil Seals
    20
  - Circlips
    20
- Checking of Connections
  21
- Special Tools
  22
- Spec
  28
2 Spec

29
- Chapter 2. Specifications
  31
- General Specifications
  31
- Maintenance Specifications
  34
  - Engine
    34
  - Chassis
    44
  - Electrical
    48
- General Torque Specifications
  50
- How to Use the Conversion Table
  50
- Lubrication Points and Lubricant Types
  51
  - Engine
    51
- Coolant Flow Diagrams
  52
- Oil Flow Diagrams
  54
- Cable Routing
  57
- Chk Adj
  67
Chapter 3. Periodic Checks and Adjustments

68
- Introduction
  70
- Periodic Checks and Adjustments
  70
- Periodic Maintenance/Lubrication
  70
- Seat, Carriers, Fenders and Fuel Tank
  72
  - Seat and Side Panels
    72
  - Front Carrier, Front Bumper and Front Fender
    73
  - Rear Carrier and Rear Fender
    75
  - Fuel Tank
    77
- Footrest Boards
  78
- Engine
  79
  - Adjusting the Valve Clearance
    79
  - Adjusting the Idling Speed
    82
  - Adjusting the Throttle Lever Free Play
    83
  - Adjusting the Speed Limiter
    85
  - Adjusting the Starter Cable
    86
  - Checking the Spark Plug
    88
  - Checking the Ignition Timing
    89
  - Measuring the Compression Pressure
    90
  - Checking the Engine Oil Level
    92
  - Changing the Engine Oil
    93
  - Cleaning the Air Filter
    95
  - Checking the Coolant Level
    98
  - Changing the Coolant
    99
  - Checking the V-Belt
    102
  - Cleaning the Spark Arrester
    103
- Chassis
  105
  - Adjusting the Rear Brake
    105
  - Checking the Brake Fluid Level
    107
  - Checking the Front Brake Pad
    108
  - Checking the Rear Brake Pad
    108
  - Checking the Brake Hose
    109
  - Bleeding the Hydraulic Brake System
    110
  - Adjusting the Select Lever Control Cable and Shift Rod
    111
  - Adjusting the Rear Brake Light Switch
    113
  - Checking the Final Gear Oil Level
    113
  - Changing the Final Gear Oil
    114
  - Checking the Differential Gear Oil
    115
  - Changing the Differential Gear Oil
    115
  - Checking the Constant Velocity Joint Dust Boot
    116
  - Checking the Steering System
    117
  - Adjusting the Toe-In
    117
  - Adjusting the Front Shock Absorber
    119
  - Adjusting the Rear Shock Absorber
    119
  - Checking the Tire
    120
  - Checking the Wheel
    122
  - Checking and Lubricating the Cable
    122
  - Lubricating the Levers, Pedal, Etc
    123
- Electrical
  124
  - Checking the Battery
    124
  - Checking the Fuse
    129
  - Adjusting the Headlight Beam
    131
  - Changing the Headlight Bulb
    132
- Eng
  134
Chapter 4. Engine

135
- Engine
  139
- Engine Removal
  139
  - Air Ducts, Muffler and Exhaust Pipe
    139
  - Select Lever Unit and Coolant Reservoir
    141
  - Hoses and Leads
    142
  - Engine Mounting Bolts
    143
  - Installing the Engine
    145
- Cylinder Head
  146
  - Removing the Cylinder Head
    148
  - Checking the Tappet Cover
    149
  - Checking the Timing Chain Tensioner
    149
  - Checking the Camshaft Sprocket
    149
  - Checking the Cylinder Head
    150
  - Installing the Cylinder Head
    151
- Camshaft, Rocker Arms and Valves
  154
- Cylinder and Piston
  165
  - Removing the Piston
    166
  - Checking the Cylinder and Piston
    166
  - Checking the Piston Ring
    168
  - Checking the Piston Pin
    169
  - Installing the Piston
    170
  - Installing the Cylinder
    171
- Recoil Starter and A.C. Magneto
  172
  - Removing the A.C. Magneto
    175
  - Disassembling the Recoil Starter
    175
  - Checking the CDI Magneto
    175
  - Checking the Starter Clutch
    176
  - Checking the Starter Pulley
    177
  - Checking the Recoil Starter
    177
  - Assembling the Recoil Starter
    177
  - Installing the A.C. Magneto
    178
- Primary and Secondary Sheaves
  180
  - Secondary Sheave
    183
  - Disassembling the Secondary Sheave
    184
  - Checking the Primary Sheave
    185
  - Checking the Secondary Sheave
    185
  - Assembling the Primary Sheave
    186
  - Assembling the Secondary Sheave
    186
  - Installing the Primary and Secondary Sheaves
    188
- Clutch
  189
  - Removing the Clutch
    191
  - Checking the Clutch
    191
  - Installing the Clutch
    192
- Crankcase
  194
  - Starter Motor, Timing Chain and Oil Filter
    194
  - Crankcase
    195
  - Crankcase Bearing
    197
  - Removing the Oil Pump Drive Gear
    198
  - Separating the Crankcase
    198
  - Checking the Oil Strainer and Oil Delivery Pipe
    199
  - Checking the Crankcase
    200
  - Checking the Bearings
    200
  - Assembling the Crankcase
    200
  - Installing the Shift Lever
    201
  - Installing the Oil Pump Drive Gear
    202
- Crankshaft and Oil Pump
  203
  - Oil Pump
    204
  - Removing the Crankshaft
    205
  - Checking the Oil Pump
    205
  - Checking the Crankshaft
    206
  - Installing the Crankshaft and Balancer
    207
- Transmission
  208
  - Checking the Shift Fork
    210
  - Checking the Shift Cam
    210
  - Checking the Transmission
    211
  - Checking the Secondary Shaft and Driven Sprocket
    211
  - Checking the Chain
    212
  - Checking the Stopper Lever and Stopper Wheel
    212
  - Installing the Transmission
    212
- Middle Gear
  214
  - Middle Drive Shaft
    214
  - Middle Driven Shaft
    215
  - Removing the Middle Drive Shaft
    217
  - Removing the Middle Driven Shaft
    217
  - Checking the Pinion Gear
    219
  - Selecting the Middle Drive and Driven Gear Shim
    220
  - Installing the Middle Driven Shaft
    223
  - Installing the Middle Drive Shaft
    225
  - Measuring the Middle Gear Backlash
    225
- Cool
  227
5 Cool

228
- Chapter 5. Cooling System
  230
- Radiator
  230
  - Checking the Radiator
    232
  - Installing the Radiator
    233
- Thermostat
  234
  - Checking the Thermostat
    235
  - Installing the Thermostat
    235
- Water Pump
  236
  - Disassembling the Water Pump
    238
  - Checking the Water Pump
    238
  - Assembling the Water Pump
    239
- Carb
  242
6 Carb

243
- Carburetor
  245
  - Checking the Carburetor
    248
  - Assembling the Carburetor
    250
  - Adjusting the Fuel Level
    251
- Chapter 6. Carburetion
  245
- Driv
  253
7 Driv

254
- Chapter 7. Drive Train
  256
- Troubleshooting
  256
- Front Constant Velocity Joints and Differential Gear
  259
- Rear Axle/Final Drive Gear and Drive Shaft
  272
- Chas
  288
Chapter 8. Chassis

289
- Front and Rear Wheels
  291
  - Front Wheels
    291
  - Rear Wheels
    292
  - Checking the Wheel
    293
  - Checking the Wheel Hub
    293
  - Checking the Brake Disc
    294
  - Installing the Wheel Hub
    294
  - Installing the Wheel
    294
- Front and Rear Brakes
  296
  - Front Brake Pads
    296
  - Rear Brake Pads
    297
  - Replacing the Front Brake Pad
    298
  - Replacing the Rear Brake Pad
    300
  - Front Brake Master Cylinder
    302
  - Rear Brake Master Cylinder
    304
  - Checking the Master Cylinder
    307
  - Assembling the Front Brake Master Cylinder
    308
  - Assembling the Rear Brake Master Cylinder
    308
  - Installing the Front Brake Master Cylinder
    309
  - Installing the Rear Brake Master Cylinder
    310
  - Front Brake Caliper
    312
  - Rear Brake Caliper
    314
  - Disassembling the Front and Rear Brake Caliper
    316
  - Checking the Front and Rear Brake Caliper
    316
  - Assembling the Front and Rear Brake Caliper
    317
  - Installing the Front Brake Caliper
    317
  - Installing the Rear Brake Caliper
    319
- Steering System
  320
  - Handlebar
    320
  - Removing the Rear Brake Switch
    321
  - Checking the Handlebar
    321
  - Installing the Handlebar
    321
  - Installing the Rear Brake Lever
    321
  - Installing the Master Cylinder Assembly
    322
  - Steering Stem
    323
  - Removing the Bearing Retainer
    325
  - Checking the Steering Stem
    325
  - Installing the Bearing Retainer
    325
  - Installing the Cable Guide
    325
  - Tie Rod and Steering Knuckle
    326
  - Removing the Steering Knuckle
    328
  - Checking the Tie Rod
    328
  - Checking the Steering Knuckle
    328
  - Installing the Tie Rod
    331
- Front Arms and Front Shock Absorber
  332
- Rear Shock Absorber and Swingarm
  338
  - Removing the Swingarm
    340
  - Checking the Rear Shock Absorber
    340
  - Checking the Swingarm
    341
  - Checking the Rubber Boot
    341
  - Installing the Rubber Boot
    341
  - Installing the Rear Axle Housing
    342
- Elec
  343
Chapter 9. Electrical

344
- Electrical Components
  346
- Checking the Switch
  347
  - Checking a Switch Shown in the Manual
    347
  - Checking the Switch Continuity
    349
- Checking the Bulbs and Bulb Sockets
  351
- Ignition System
  354
  - Circuit Diagram
    354
  - Troubleshooting
    355
- Electric Starting System
  360
  - Circuit Diagram
    360
  - Troubleshooting
    361
  - Starter Motor
    364
  - Checking the Starter Motor
    365
  - Assembling the Starter Motor
    366
- Charging System
  367
  - Circuit Diagram
    367
  - Troubleshooting
    368
- Lighting System
  370
  - Circuit Diagram
    370
  - Troubleshooting
    371
  - Checking the Lighting System
    373
- Signal System
  375
  - Circuit Diagram
    375
  - Troubleshooting
    377
  - Checking the Signal System
    379
- Cooling System
  383
  - Circuit Diagram
    383
  - Troubleshooting
    384
- 2Wd/4Wd Selecting System
  388
  - Circuit Diagram
    388
  - Troubleshooting
    389
- Trbl Shtg
  394
Trbl Shtg

395
- Chapter 10. Troubleshooting
  397
- Starting Failure/Hard Starting
  397
  - Fuel System
    397
  - Electrical System
    397
  - Compression System
    398
- Poor Idle Speed Performance
  398
- Poor Medium and High-Speed Performance
  398
- Faulty Drive Train
  399
- Faulty Clutch Performance
  400
  - Engine Operates but Machine will Not Move
    400
  - Clutch Slipping
    400
  - Poor Starting Performance
    400
  - Poor Speed Performance
    401
- Faulty Gear Shifting
  400
  - Hard Shifting
    400
  - Shift Lever Does Not Move
    400
  - Jumps out of Gear
    400
- Faulty Brake
  401
  - Poor Braking Effect
    401
- Overheating
  401
- Lighting System
  402
  - Headlight Dark
    402
  - Bulb Burnt out
    402
- Shock Absorber Malfunction
  402
  - Malfunction
    402
- Unstable Handling
  402

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