Yamaha YFM45FAT Supplementary Service Manual Download

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YAMAHA MOTOR CO., LTD.

2500 SHINGAI IWATA SHIZUOKA JAPAN

Summary of Contents for YFM45FAT

Page 1: ...YFM45FAT YFM450FAT 5ND2 AE3 SUPPLEMENTARY SERVICE MANUAL ...

Page 2: ......

Page 3: ...upplementary Service Manual together with the following manual YFM45FAR YFM450FAR SERVICE MANUAL 5ND2 AE1 YFM45FAS YFM450FAS SUPPLEMENTARY SERVICE MANUAL 5ND2 AE2 YFM45FAT YFM450FAT SUPPLEMENTARY SERVICE MANUAL 2004 by Yamaha Motor Co Ltd First edition June 2004 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...ifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ...

Page 5: ...tify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to...

Page 6: ...cant D Special tool E Torque F Wear limit clearance G Engine speed H Ω V A Illustrated symbols I to N in the exploded diagrams indicate the types of lubricants and lubrication points I Apply engine oil J Apply gear oil K Apply molybdenum disulfide oil L Apply wheel bearing grease M Apply lithium soap based grease N Apply molybdenum disulfide grease Illustrated symbols O to P in the exploded diagra...

Page 7: ...RBERS 25 ENGINE 26 MIDDLE GEAR 26 MIDDLE DRIVEN SHAFT 26 DRIVE TRAIN 28 TROUBLESHOOTING 28 FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR 31 MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH 31 REAR CONSTANT VELOCITY JOINTS FINAL DRIVE GEAR AND DRIVE SHAFT 33 ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS 38 DISASSEMBLING THE FINAL DRIVE GEAR 39 CHECKING THE DRIVE SHAFT UNIVERSAL JOINT YOKE 3...

Page 8: ...RAKE PADS 52 REAR BRAKE CALIPER 53 INSTALLING THE REAR BRAKE CALIPER 55 FRONT ARMS AND FRONT SHOCK ABSORBERS 57 REAR KNUCKLES AND STABILIZER 59 CHECKING THE REAR KNUCKLES 60 CHECKING THE STABILIZER 60 REAR ARMS AND REAR SHOCK ABSORBERS 61 CHECKING THE REAR ARMS 62 INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBERS 62 YFM45FAT YFM450FAT WIRING DIAGRAM ...

Page 9: ...ity Engine oil Periodic oil change 2 30 L 2 02 Imp qt 2 43 US qt With oil filter replacement 2 40 L 2 11 Imp qt 2 54 US qt Total amount 2 60 L 2 29 Imp qt 2 75 US qt Final gear case oil Periodic oil change 0 16 L 0 14 Imp qt 0 17 US qt Total amount 0 18 L 0 16 Imp qt 0 19 US qt Differential gear case oil Periodic 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 R...

Page 10: ...MAXXIS for USA CDN and Europe CHENG SHIN for Oceania rear MAXXIS for USA CDN and Europe CHENG SHIN for Oceania Model front M911Y for USA CDN and Europe C828 for Oceania rear M912Y for USA CDN and Europe C828 for Oceania Suspension Front suspension Double wishbone Rear suspension Double wishbone Item Standard ...

Page 11: ...t P J 17 5 Bypass 1 B P 1 0 8 Bypass 2 B P 2 0 8 Bypass 3 B P 3 0 8 Pilot screw P S 2 1 2 turns out Valve seat size V S 2 0 Starter jet G S 1 70 Starter jet G S 2 0 9 Throttle valve size Th V 90 Float height F H 13 mm 0 51 in Fuel level F L 4 0 5 0 mm 0 16 0 20 in Engine idle speed 1 450 1 550 r min Intake vacuum 33 3 kPa 250 mmHg 9 84 inHg Part to be tightened Part name Thread size Q ty Tightenin...

Page 12: ... 247 9 mm 9 76 in Spring rate K1 27 N mm 2 75 kg mm 153 99 lb in Stroke K1 0 95 mm 0 3 74 in Optional spring No Rear disc brake Type Single Disc outside diameter thickness 220 0 3 5 mm 8 66 0 14 in Pad thickness inner 5 0 mm 0 20 in 1 mm 0 04 in Pad thickness outer 5 0 mm 0 20 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 flui...

Page 13: ...protector M6 7 0 7 5 1 Fuel tank and frame M6 10 1 0 7 2 Front wheel and wheel hub M10 55 5 5 40 Rear axle and wheel hub M20 260 26 0 190 Stake Rear knuckle and brake caliper M8 30 3 0 22 Brake disc guard and rear knuckle M6 7 0 7 5 1 Rear brake disc and wheel hub M8 30 3 0 22 LT Front brake pipe joint and frame M6 7 0 7 5 1 Rear brake master cylinder M8 23 2 3 17 Rear brake master cylinder bracke...

Page 14: ...rer F4T464 MITSUBISHI Pickup coil resistance color 459 561 Ω at 20 C 68 F White Red White Green Rotor rotation direction sensing coil resis tance color 0 086 0 105 Ω at 20 C 68 F Red White Blue C D I unit model manufacturer F8T40373 MITSUBISHI MAINTENANCE SPECIFICATIONS ...

Page 15: ...er ential gear lock switch 6 Throttle cable 7 Horn switch for Europe and Oceania 8 Handlebar switch 9 Handlebar switch lead 0 Main switch lead A Fan motor lead B Fan motor breather hose C Differential gear case breather hose D Sub wire harness E Horn switch lead for Europe and Oceania F On command four wheel drive switch and differ ential gear lock switch lead ...

Page 16: ...ead rear brake switch lead and horn switch lead for Europe and Oceania behind the handlebar with a plastic band Ê Fasten the handlebar switch lead rear brake switch lead and horn switch lead for Europe and Oceania behind the handlebar with a plas tic band Ë Fasten the handlebar switch lead rear brake switch lead and on command four wheel drive switch and differential gear lock switch lead and horn...

Page 17: ... 9 SPEC CABLE ROUTING Ì To wire harness Í Loop the horn switch lead for Europe and Oce ania around the plastic band as shown ...

Page 18: ...ead 4 Four wheel drive relay 3 5 Fan motor breather hose 6 Differential gear case breather hose 7 Coolant reservoir breather hose 8 Meter assembly couplers È Fasten the wire harness with a plastic band É Fasten the auxiliary DC jack lead with a plastic holder Ê 50 60 mm 1 97 2 36 in ...

Page 19: ...ther hose A Thermo switch 2 B Horn for Europe and Oceania È Insert the fuel tank breather hose into the hole of the handlebar cover É Fasten the sub wire harness and differential gear case breather hose with a plastic band Ê Fasten the sub wire harness differential gear case breather hose coolant reservoir hose coolant reservoir breather hose fan motor lead and fan motor breather hose with a plast...

Page 20: ...e 7 Rectifier regulator 8 Air filter case check hose 9 Water pump breather hose 0 Speed sensor lead A Radiator outlet hose B Starter cable C Float chamber air vent hose D Cylinder head breather hose E Fuel hose F A C magneto lead G Low range switch high range switch neutral switch reverse switch leads H Rectifier regulator lead I Low range switch J High range switch ...

Page 21: ...ge switch high range switch neutral switch reverse switch leads speed sensor lead and A C magneto lead with a plastic band Ê Fasten the wire harness and starter motor lead with a plastic band Ë Fasten the low range switch high range switch neutral switch reverse switch leads speed sen sor lead A C magneto lead rectifier regulator lead negative battery lead and final drive gear case breather hose w...

Page 22: ... brake cable 0 Rear brake hose A Rear brake pipe È Fasten the radiator inlet hose and spark plug lead with a plastic band É Fasten the select lever control cable with a plas tic holder Ê Fasten the radiator inlet hose with a plastic holder Ë Fasten the select lever control cable and rear brake light switch lead with the plastic bands Ì Fasten the rear brake hose with a plastic holder Í 15 45 mm 0 ...

Page 23: ...ctifier regulator lead 3 Rear brake hose 4 Rear brake pipe È Fasten the final drive gear case breather hose rectifier regulator lead and rear brake hose with a plastic band É Fasten the brake pipe with the plastic bands Ê Fasten the brake hose with the plastic bands ...

Page 24: ... 16 SPEC CABLE ROUTING 1 Front brake hose 2 Float chamber air vent hose 3 Throttle cable 4 Wire harness 5 Final drive gear case breather hose 6 Starter cable 7 Rear brake cable ...

Page 25: ... 17 SPEC CABLE ROUTING 1 Battery 2 Positive battery lead 3 Tail brake light lead 4 CDI unit 5 Negative battery lead È Fasten the positive battery lead with the plastic holders ...

Page 26: ...i 320 200 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 300 Valves Check valve clearance Adjust if necessary Cooling system Check coolant leakage Repair if necessary Replace coolant every 24 months Spark plug Check condition Adjust gap and clean Replace if necessary Air filter element Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Carburetor Check...

Page 27: ...eck balance damage runout Repair if necessary Wheel bearing Check bearing assemblies for looseness damage Replace if damaged Front and rear suspension Check operation Correct if necessary Steering system Check operation Replace if damaged Check toe in Adjust if necessary Rear upper and lower knuckle piv ots Lubricate with lithium soap based grease Drive shaft universal joint Lubricate with lithium...

Page 28: ...carrier front bumper and front fender Remove the parts in the order below Seat and fuel tank side panels Refer to SEAT AND SIDE PANELS in chapter 3 Manual No 5ND2 AE1 1 Front carrier 1 2 Front fender panel 1 3 Engine skid plate 1 4 Front bumper 1 5 Front bumper cover 2 6 Headlight coupler 2 Disconnect 7 Main switch coupler 1 Disconnect 8 Handlebar cover 1 9 Fuel tank cover 1 ...

Page 29: ...s 1 coupler 1 Disconnect 12 Sub wire harness 2 coupler 1 Disconnect 13 Four wheel drive relay 3 coupler 1 Disconnect 14 Auxiliary DC jack connector 2 Disconnect 15 Coolant reservoir breather hose 1 16 Differential gear case breather hose 1 17 Fan motor breather hose 1 18 Front fender 1 For installation reverse the removal pro cedure ...

Page 30: ... specification Adjust Rear brake lever free play 0 5 2 0 mm 0 02 0 08 in 2 Check rear brake pedal height a Out of specification Adjust 1 Brake pedal 2 Footrest bracket Rear brake pedal height 67 77 mm 2 64 3 03 in 3 Adjust rear brake lever free play rear brake pedal height a Loosen the locknut handlebar 1 and fully screw in the brake lever cable adjuster han dlebar 2 b Remove the rear brake master...

Page 31: ...ing nut 7 and tighten the locknut 6 i Turn the brake lever cable adjuster handle bar 2 until the rear brake lever free play c is within the specified limits Tighten the locknut handlebar 1 j Adjust the select lever control cable Refer to ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD in chapter 3 Manual No 5ND2 AE1 k Install the rear brake master cylinder cover WARNING After this adjustmen...

Page 32: ...not allow foreign material to enter the final gear case 4 Install oil filler plug Recommended oil SAE 80 API GL 4 Hypoid gear oil T R 23 Nm 2 3 m kg 17 ft lb CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS 1 Check dust boots 1 Damage Replace Refer to FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR in chapter 7 Manual No 5ND2 AE1 for the front constant velocity joint dust boots or REAR CONSTAN...

Page 33: ...ng Uneven adjust ment can cause poor handling and loss of stability NOTE The spring preload of the shock absorbers can be adjusted to suit the operator s preference weight and the operating conditions 1 Adjust spring preload Turn the adjuster 1 to increase or decrease the spring preload Standard position 2 Minimum Soft position 1 Maximum Hard position 5 1 ...

Page 34: ...r to REMOVING THE MIDDLE DRIVEN SHAFT and INSTALLING THE MIDDLE DRIVEN SHAFT in chap ter 4 Manual No 5ND2 AE1 2 Bearing 4 3 Universal joint 2 4 Universal joint yoke 2 5 Bearing housing 1 6 Shim Refer to SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIM in chapter 4 Manual No 5ND2 AE1 7 Middle drive pinion gear 1 Refer to REMOVING THE MIDDLE DRIVEN SHAFT and INSTALLING THE MIDDLE DRIVEN SHAFT in chap...

Page 35: ... 27 ENG MIDDLE GEAR Order Job Part Q ty Remarks 9 Damper cam 1 10 Spring 1 11 Gear coupling 1 12 Bearing retainer 1 13 Middle driven shaft 1 For installation reverse the removal pro cedure ...

Page 36: ...d whine a clunk from a shaft drive component or area 3 A locked up condition of the shaft drive train mechanism no power transmitted from the engine to the front and or rear wheel A Bearing damage B Improper gear lash C Gear tooth damage D Broken drive shaft E Broken gear teeth F Seizure due to lack of lubrication G Small foreign objects lodged between the moving parts 1 Check unusual noises The f...

Page 37: ...ne and possible injury to the rider 2 Check drained oil Drained oil shows large amounts of metal particles Check the bearings for seizure NOTE A small amount of metal particles in the oil is normal 3 Check oil leakage a Clean the entire machine thoroughly then dry it b Apply a leak localizing compound or dry powder spray to the shaft drive c Road test the machine for the distance nec essary to loc...

Page 38: ...5ND2 AE1 for the front wheel nuts and hub nuts or FRONT AND REAR WHEELS for the rear wheel nuts and hub nuts YES Check the front constant velocity joints Feel for bearing damage NO Constant velocity joint bearings and differential gear bearings are probably not damaged Repeat the test or remove the individual components YES Check the rear brake adjustment NO Adjust per instructions Refer to ADJUST...

Page 39: ...the ring gear Otherwise the ring gear will be dam aged 4 Attach gear lash measurement tool 1 dial gauge 2 a Measuring point is 32 mm 1 26 in 5 Measure gear lash Gently rotate the gear coupling from engagement to engagement NOTE Measure the gear lash at four positions Rotate the shaft 90 each time Adjusting differential gear lash 1 Remove shim s left 1 differential gear assembly 2 shim s right 3 Ge...

Page 40: ...1 mm 0 004 in of left shim increase 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 decreased Left only Too little gear lash Reduce shim thickness Too large gear lash Increase shim thickness Ring gear shim left and right Thickness mm 0 1 0 2 0 3 0 4 0 5 1 0 1 5 FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL...

Page 41: ...4 6 7 8 2 1 Order Job Part Q ty Remarks Removing the rear constant velocity joints final drive gear assembly and drive shaft Remove the parts in the order below Engine skid plate Refer to SEAT CARRIERS FENDERS AND FUEL TANK Rear fender Refer to SEAT CARRIERS FENDERS AND FUEL TANK in chapter 3 Manual No 5ND2 AE1 Footrest boards Refer to FOOTREST BOARDS in chap ter 3 Manual No 5ND2 AE1 Final gear oi...

Page 42: ...4 5 m kg 32 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib LS 5 3 4 4 6 7 8 2 1 Order Job Part Q ty Remarks 1 Final gear case skid plate 1 2 Rectifier regulator 1 3 Air duct assembly 2 1 4 Rear constant velocity joint 2 5 Final drive gear case breather hose 1 Disconnect 6 Final drive gear assembly 1 7 Trailer hitch 1 8 Sub frame 1 For installation reverse the removal pro cedure ...

Page 43: ... constant velocity joint Remove the parts in the order below 1 Dust cover 1 2 Circlip 1 3 Boot band 2 Refer to ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS 4 Boot band 2 5 Dust boot 2 6 Circlip 1 7 Double off set joint 1 8 Snap ring 1 9 Ball bearing 1 0 Joint shaft assembly 1 For assembly reverse the disassembly procedure ...

Page 44: ...1 Circlip 2 Refer to DISASSEMBLING THE FINAL DRIVE GEAR and ASSEMBLING THE FINAL DRIVE GEAR 2 Bearing 2 3 Drive shaft universal joint yoke 1 4 Universal joint yoke 1 5 Ring gear stopper 1 6 Bolt 2 7 Bolt 4 NOTE Working in a crisscross pattern loosen each bolt 1 4 of a turn After all the bolts are loosened remove them 8 Ring gear bearing housing 1 9 Oil seal 1 0 Bearing 1 ...

Page 45: ...1 C Thrust washer 1 D Bearing retainer 1 Refer to REPLACING THE FINAL DRIVE PINION GEAR AND BEARING E Oil seal 1 F Final drive pinion gear 1 G Bearing 1 H Final drive pinion gear shim 1 I Final drive gear case 1 J Oil seal 1 K Bearing 1 Refer to REPLACING THE FINAL DRIVE ROLLER BEARING For assembly reverse the disassembly procedure ...

Page 46: ...soap base grease into the dust boots 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 boot bands 3 at the grooves in the joint shaft Lithium soap base grease 40 g 1 4 oz per dust boot rear wheel side 60 g 2 1 oz per dust boot final gear case side New 3 Check free play thrust movement Excessi...

Page 47: ...pe as shown NOTE It may be necessary to lightly tap the yoke with a punch d Repeat the steps for the opposite bearing e Remove the yoke NOTE It may be necessary to lightly tap the yoke with a punch 2 Remove nut 1 washer universal joint yoke NOTE Use the universal joint holder 2 to hold the universal joint yoke Universal joint holder P N YM 04062 90890 04062 1 2 CHECKING THE DRIVE SHAFT UNIVERSAL J...

Page 48: ... Replace the drive pinion gear and ring gear as a set Refer to REPLACING THE FINAL DRIVE PINION GEAR AND BEARING oil seals O rings Damage Replace 3 Check bearings Damage Replace NOTE Reusing roller bearing is acceptable but Yamaha recommends installing new ones Do not reuse oil seals When the final drive pinion gear and or ring gear are replaced be sure to adjust the shim of the final drive pinion...

Page 49: ...etainer CAUTION The bearing retainer has left handed threads To loosen the retainer turn it clockwise 2 Remove final drive pinion gear 1 final drive pinion gear bearing 2 a Heat the main housing only to 150 C 302 F b Remove the final drive pinion gear assem bly with an appropriately shaped punch 3 c Remove the final drive pinion gear bearing 2 from the final drive pinion gear 1 NOTE The removal of...

Page 50: ... shim final drive pinion gear assembly 1 Use a suitable press tool 2 and a press to install the above components into the final drive gear case 1 2 6 Install bearing retainer a Place a folded rag 1 b Secure the final drive gear case edge in the vise c Attach the bearing retainer wrench 2 d Tighten the bearing retainer CAUTION The bearing retainer has left hand threads Turn the retainer countercloc...

Page 51: ...on gear shim thick ness A use the following formula a 76 0 mm b a numeral usually a decimal number on the final drive gear case either added to or subtracted from 75 Example 1 a 76 2 If 51 is stamped on the final drive gear case b 75 0 51 75 51 3 Therefore A is 0 49 A 76 75 51 0 49 4 Round off the hundredth digit and select the appropriate shim In the example above the calculated num ber is 0 49 T...

Page 52: ...D ADJUSTING THE FINAL GEAR LASH Final gear lash measurement 1 Remove drain plug gasket 2 Install a bolt of the specified size 1 into the drain plug hole CAUTION Finger tighten the bolt until it holds the ring gear Otherwise the ring gear will be dam aged 1 3 Attach gear lash measurement tool 1 dial gauge 2 a Measuring point is 34 15 mm 1 34 in Gear lash measurement tool P N YM 01467 90890 01467 a ...

Page 53: ... Measure the gear lash at four positions Rotate the shaft 90 each time Final gear lash 0 1 0 2 mm 0 004 0 008 in Final gear lash adjustment 1 Remove bearing housing 1 ring gear shim 2 ring gear 3 1 2 3 2 Adjust gear lash a Select suitable shim and thrust washer using the following chart Too little gear lash Reduce shim thick ness Too large gear lash Increase shim thick ness Ring gear shim Thicknes...

Page 54: ...drive pinion gear and ring gear when measuring the clearance with Plas tigauge c Remove the ring gear assembly d Measure the thrust clearance Calculate the width of the flattened Plastigauge 1 e If out of specification repeat the measure ment steps with a slightly thicker thrust washer until the ring gear thrust clearance is within the specified limits Thrust washer Thickness mm 1 0 1 1 1 2 1 3 1 ...

Page 55: ...per 120 counter clockwise c Tighten the ring gear stopper nut 3 NOTE Apply Quick Gasket to the ring gear stopper threads T R Ring gear stopper nut 16 Nm 1 6 m kg 11 ft lb 1 2 3 ASSEMBLING THE FINAL DRIVE GEAR 1 Adjust final gear lash Refer to MEASUREMENT AND ADJUST ING THE FINAL GEAR LASH 2 Check final drive gear operation Unsmooth operation Replace the final drive gear assembly Insert the double ...

Page 56: ...gs 1 onto the yoke CAUTION Check each bearing The needles can eas ily fall out of their races Slide the yoke back and forth on the bearings the yoke will not go all the way onto a bearing if a needle is out of place d Press the bearings into the U joint using a suitable socket NOTE The bearing must be inserted far enough into the U joint so that the circlip can be installed e Install the circlips ...

Page 57: ...LT 1 1 3 5 6 5 7 2 3 4 2 Order Job Part Q ty Remarks Removing the rear wheel Remove the parts in the order below Place the machine on a level surface WARNING Securely support the machine so there is no danger of it falling over 1 Rear wheel 2 Refer to INSTALLING THE WHEELS in chapter 8 Manual No 5ND2 AE1 2 Wheel cap 2 3 Axle nut 2 Refer to INSTALLING THE REAR WHEEL HUBS 4 Brake caliper mounting bo...

Page 58: ...g 22 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib T R 260 Nm 26 0 m kg 190 ft lb T R 260 Nm 26 0 m kg 190 ft lb LT 1 1 3 5 6 5 7 2 3 4 2 Order Job Part Q ty Remarks 7 Brake disc guard 1 For installation reverse the removal pro cedure ...

Page 59: ... to the rear wheel hub with the IN mark facing away from the wheel hub IN T R 30 Nm 3 0 m kg 22 ft lb INSTALLING THE REAR WHEEL HUBS 1 Install axle nut NOTE Do not apply oil to the seat of the nut After tightening the nut stake the collar of the nut into the notch of the shaft New T R 260 Nm 26 0 m kg 190 ft lb ...

Page 60: ... Q ty Remarks Removing the rear brake pads Remove the parts in the order below Rear wheel left Refer to FRONT AND REAR WHEELS 1 Brake caliper mounting bolt 2 Refer to REPLACING THE REAR BRAKE PAD in chapter 8 Manual No 5ND2 AE1 2 Brake pad holding bolt 2 3 Brake pad insulator pad shim 2 2 2 4 Pad spring 1 For installation reverse the removal pro cedure ...

Page 61: ...marks Removing the rear brake caliper Remove the parts in the order below Brake fluid Drain Rear wheel Refer to FRONT AND REAR WHEELS 1 Union bolt 1 Refer to INSTALLING THE REAR BRAKE CALI PER 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Brake pad holding bolt 2 Loosen 5 Brake caliper mounting bolt 2 6 Brake caliper assembly 1 For installation reverse the removal pro cedure ...

Page 62: ...olding bolt 2 2 Brake pad insulator pad shim 2 2 2 3 Pad spring 1 4 Caliper bracket 1 5 Brake caliper piston 1 Refer to DISASSEMBLING THE FRONT AND REAR BRAKE CALIPER and ASSEMBLING THE FRONT AND REAR BRAKE CALIPER in chapter 8 Manual No 5ND2 AE1 6 Dust seal 1 7 Caliper piston seal 1 8 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 63: ...s or plastic parts Always clean up spilled brake fluid immediately WARNING _ Use only the designated quality brake fluid other brake fluids may deteriorate the rubber seals causing leakage and poor brake performance Refill with the same type of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor brake performance Be careful that water does not enter the mast...

Page 64: ...o BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 Manual No 5ND2 AE1 4 Check brake fluid level Brake fluid level is below the MIN level line Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 Manual No 5ND2 AE1 ...

Page 65: ...ks Removing the front arms and front shock absorbers Remove the parts in the order below Engine skid plate Refer to SEAT CARRIERS FEND ERS AND FUEL TANK Front fender Front wheel brake disc Refer to FRONT AND REAR WHEELS in chapter 8 Manual No 5ND2 AE1 1 Air duct assembly 1 1 2 Brake disc guard 1 3 Protector 1 ...

Page 66: ...d INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER in chapter 8 Manual No 5ND2 AE1 5 Nut 1 6 Bolt nut 2 2 7 Front lower arm washer bushing 1 1 2 8 Nut bolt 2 2 9 Front shock absorber 1 10 Bolt nut 2 2 11 Front upper arm washer bushing 1 1 2 12 Circlip 1 13 Ball joint 1 For installation reverse the removal pro cedure ...

Page 67: ...kg 22 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib 3 3 2 2 2 2 1 5 5 4 4 Order Job Part Q ty Remarks Removing the rear knuckles and stabilizer Remove the parts in the order listed Rear wheel hubs Refer to FRONT AND REAR WHEELS 1 Rear knuckle 1 2 Spacer cover 4 3 Spacer 2 4 Stabilizer joint 2 5 Stabilizer holder 2 6 Bushing 2 7 Stabilizer 1 For installation reverse the removal pro cedure ...

Page 68: ... oil seals Damage Replace a Clean the outside of the rear knuckle b Remove the circlip 1 c Drive out the bearing 2 WARNING Eye protection is recommended when using striking tools d Install a new bearing CAUTION Do not strike the center race or balls of the bearing Contact should be made only with the outer race e Install a new circlip 1 2 CHECKING THE STABILIZER 1 Check stabilizer Bends cracks dam...

Page 69: ...d rear shock absorbers Remove the parts in the order listed Rear knuckle stabilizer Refer to REAR KNUCKLES AND STABI LIZER Rear brake caliper Refer to FRONT AND REAR BRAKES 1 Nut bolt 2 2 Refer to INSTALLING THE REAR ARMS AND REAR SHOCK ABSORB ERS 2 Rear shock absorber 1 3 Plastic holder 1 4 Plastic band 3 5 Nut bolt 2 2 6 Rear upper arm washer bushing 1 1 2 7 Nut bolt 2 2 8 Rear lower arm washer ...

Page 70: ... shock absorbers a Install the rear upper arm 1 and rear lower arm 2 NOTE Lubricate the bolts 3 with lithium soap based grease Be sure to position the bolts 3 so that the bolt head faces outward Temporarily tighten the nuts 4 b Install the rear shock absorber 5 c Install the rear knuckle d Tighten the nuts 4 T R Nut 6 45 Nm 4 5 m kg 32 ft lb T R Nut 7 45 Nm 4 5 m kg 32 ft lb T R Nut 4 45 Nm 4 5 m ...

Page 71: ......

Page 72: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 73: ...R S T U V W X Y Z a b f h i o m n f c d e g j Q A 0 9 È È É l k 1 A C magneto 2 Rectifier regulator 3 Main switch 4 Backup fuse 5 Battery 6 Main fuse 7 Starter relay 8 Starter motor 9 Carburetor heater fuse 0 Thermo switch carburetor heater A Carburetor heater B Reverse switch C CDI unit D Rear brake switch E Ignition coil F Spark plug G Speed sensor H Thermo switch cylinder head I Meter assembly ...

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