2011-2013 Yamaha Grizzly 450 4x4 Including EPS ATV Service Repair Manual - PDF Download

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Use Genuine

YAMAHA Parts And Accessories

GRIZZLY 450 4WD 2011

PROTECT YOUR INVESTMENT

1.125

Fo. 7

GRIZZLY 450 4WD 2011 Service Manual

For a list of Genuine YAMAHA Parts Go to www.yamaha-motor.com/sport/parts/home.aspx

LIT-11616-KD-49 YAMAHA MOTOR CORPORATION, U.S.A. PRINTED IN U.S.A. BY CRESTEC USA

Service Manual

*LIT11616KD49*

LIT-11616-KD-49

eVAMAHA

2011

SUPPLEMENTARY SERVICE MANUAL

YFM45FGA YFM45FGHA YFM45FGPA YFM45FGPHA

LIT-11616-24-39

1 CT-F8197-1 0

FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YFM45FGANFM45FGHANFM45FGPANFM45FGPHA. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.

YFM450FAR SERVICE MANUAL: LIT-11616-16-01 (5ND-F8197-10) YFM450FAS SUPPLEMENTARY SERVICE MANUAL: LIT-11616-17-25 (5ND-F8197-11) YFM450FAT SUPPLEMENTARY SERVICE MANUAL: LIT-11616-18-35 (5ND-F8197-12) YFM45FGX SUPPLEMENTARY SERVICE MANUAL: LIT-11616-21-46 (5ND-F8197-13) YFM45FGY SUPPLEMENTARY SERVICE MANUAL: LIT-11616-22-47 (5ND-F8197-14)

YFM45FGANFM45FGHAI YFM45FGPANFM45FGPHA SUPPLEMENTARY SERVICE MANUAL ©201 0 by Yamaha Motor Corporation, U.S.A. First edition, August 2010 All rights reserved.

Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited.

Printed in U.S.A. LIT-11616-24-39

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EBS00002

IMPORTANT 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. Repairs attempted by anyone without this knowledge are likely to render the vehicle unsafe and unfit for use.

This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications 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.

TIP ------------------------------------------------------------• This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully. • Designs and specifications are subject to change without notice.

IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

& A

WARNING

A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property.

A TIP provides key information to make procedures easier or clearer.

EBS00004

HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See "symbols") 1st title CD: This is the title of the chapter with its symbol in the upper right corner of each page.

2nd title ®: This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page.

3rd title @: This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations.

EXPLODED DIAGRAMS To help identify 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 @ is provided for removal and disassembly jobs.

2. Numbers ® 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-read way by the use of symbol marks @. The meanings of the symbol marks are given on the next page.

4. A job instruction chart (J) accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements ® are given in addition to the exploded diagram and the job instruction chart.

3

2

REAR KNUCKLE AND STABILIZER

REAR KNUCKLE AND TABILIZER

ICHASiftl

REAR KNUCKLE AND STABILIZER

d. Install the new beanng.

!!!!. ..~,=.....=,..=..-:-.,..:-::,.--:.,c:-.,. bearing. COntact ahoulc:l be mada only with

the outer race. e. lnstallanewcirclip.

CHECKING THE STABILIZER 1. Check:

•stabilizer Bends/cracks/damage ---) Replace.

Refer to 'FRONT AND REAR WHEELS".

Rear knuckle Spacer cover Spacer Stabilizer joint Stabilizer holder Bushing Stabilizer

Forinstallation,reverselheremovalprocedure.

-83-

-84-

EBS00006

CD

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ENG

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CD General information ® Specifications ® Periodic checks and adjustments @Engine @ Cooling system ® Carburetion (j) Drive train ®Chassis ® Electrical ®> Troubleshooting

® to @) indicate the following

Symbols

@

Can be serviced with engine mounted @) Filling fluid @Lubricant @ Special tool @Torque @Wear limit, clearance @ Engine speed @ Electrical data (Q, V, A)

~ B ~ ~~

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[g]@[ij]

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The following symbols are not relevant to every vehicle.

Symbols G) to @) indicate the subject of each chapter.

@

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SYMBOLS

®

a ®

~~ ®

llr:wJI

Symbols @) to ® in the exploded diagrams indicate the types of lubricants and lubrication points. @) Apply engine oil

® Apply gear oil @Apply molybdenum disulfide oil @ Apply brake fluid ® Apply wheel bearing grease ®Apply lithium-soap-based grease ®Apply molybdenum disulfide grease ®Apply silicone grease

Symbols ® to ® in the exploded diagrams indicate where to apply a locking agent ® and when to install a new part @. @ Apply the locking agent (LOCTIT~) ®Replace

CONTENTS GENERAL INFORMATION ................................................................................ 1 FEATURES .................................................................................................. 1 OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM ............................................................................................... 1 EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM ............................................................................................. 2 SPECIAL TOOLS ......................................................................................... 3 SPECIFICATIONS .............................................................................................. 4 GENERAL SPECIFICATIONS ..................................................................... 4 MAINTENANCE SPECIFICATIONS ............................................................ 6 ENGINE ................................................................................................. 6 Tightening torques ................................................................................. 7 CHASSIS ............................................................................................... 8 Tightening torques ............................................................................... 10 ELECTRICAL ....................................................................................... 11 CABLE ROUTING (YFM45FGANFM45FGHA) ......................................... 14 CABLE ROUTING (YFM45FGPANFM45FGPHA) .................................... 26 PERIODIC CHECKS AND ADJUSTMENTS .................................................... 39 INTRODUCTION ........................................................................................ 39 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ................................................................................. 39 GENERAL MAINTENANCE AND LUBRICATION CHART ........................ 40 SEAT, CARRIERS, FENDERS AND FUEL TANK ..................................... 42 REAR CARRIER AND REAR FENDER (YFM45FGPANFM45FGPHA) ........................................................... 42 CHASSIS .................................................................................................... 44 ADJUSTING THE REAR BRAKE ........................................................ 44 CHECKING THE REAR BRAKE FRICTION PLATES ......................... 47 CHECKING THE FINAL GEAR OIL LEVEL. ........................................ 48 CHANGING THE FINAL GEAR OIL .................................................... 48 CHECKING THE STEERING SYSTEM (YFM45FGPANFM45FGPHA) ........................................................... 49

DRIVE TRAIN ................................................................................................... 52 TROUBLESHOOTING ............................................................................... 52 CHECKING NOISES ............................................................................ 52 TROUBLESHOOTING CHART ............................................................ 54 REAR CONSTANT VELOCITY JOINTS AND FINAL GEAR CASE ASSEMBLY .................................................................................... 55 DISASSEMBLING THE REAR CONSTANT VELOCITY JOINTS ............................................................................. 61 ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS ............. 62 REMOVING THE FINAL DRIVE PINION GEAR AND BEARING ................................................................................... 64 INSTALLING THE FINAL DRIVE PINION GEAR AND BEARING ................................................................................... 65 POSITIONING THE FINAL DRIVE PINION GEAR .............................. 65 FINAL DRIVE PINION GEAR SHIM SELECTION ............................... 65 MEASURING THE FINAL GEAR BACKLASH ..................................... 68 ADJUSTING THE FINAL GEAR BACKLASH ...................................... 69 ADJUSTING THE RING GEAR THRUST CLEARANCE ..................... 70 ADJUSTING THE RING GEAR STOPPER ......................................... 71 ASSEMBLING THE FINAL GEAR CASE ............................................ 71 INSTALLING THE FINAL GEAR CASE ............................................... 73 CHASSIS .......................................................................................................... 74 FRONT AND REAR BRAKES .................................................................... 74 BRAKE PEDAL .................................................................................... 74 FINAL GEAR CASE (REAR BRAKE) .................................................. 75 DISASSEMBLING THE FINAL GEAR CASE (REAR BRAKE) ............ 77 CHECKING THE FRICTION PLATES ................................................. 77 CHECKING THE REAR BRAKE PLATES ........................................... 77 CHECKING THE REAR BRAKE SPRINGS ......................................... 78 CHECKING THE SPLINED COLLAR .................................................. 78 ASSEMBLING THE FINAL GEAR CASE (REAR BRAKE) .................. 78 STEERING SYSTEM ................................................................................. 79 STEERING STEM (YFM45FGANFM45FGHA) ................................... 79 STEERING STEM (YFM45FGPANFM45FGPHA) .............................. 81 INSTALLING THE STEERING STEM (YFM45FGANFM45FGHA) ................................................................ 83 INSTALLING THE STEERING STEM (YFM45FGPANFM45FGPHA) ........................................................... 84 INSTALLING THE PITMAN ARM (YFM45FGPANFM45FGPHA) ........................................................... 85

ELECTRICAL ................................................................................................... 86 ELECTRICAL COMPONENTS (YFM45FGPANFM45FGPHA) ................. 86 EPS (ELECTRIC POWER STEERING) SYSTEM (YFM45FGPANFM45FGPHA) .................................................................. 88 CIRCUIT DIAGRAM ............................................................................. 88 EPS CONTROL UNIT'S SELF-DIAGNOSTIC FUNCTION .................. 89 EPS WARNING LIGHT DURING NORMAL OPERATION .................. 90 DIAGNOSTIC MODE ........................................................................... 91 SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM) .................. 94 TROUBLESHOOTING DETAILS (EPS SYSTEM) ............................... 95 CHECKING THE EPS MOTOR ........................................................... 99 CHECKING THE EPS TORQUE SENSOR ......................................... 99 YFM45FGANFM45FGHA 2011 WIRING DIAGRAM YFM45FGPANFM45FGPHA 2011 WIRING DIAGRAM

FEATURES

---------------------------------------------------GENERAL INFORMATION

~~~~~~--~

FEATURES OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM

Speed information from speed sensor

1. Operates steering Battery

I

4. EPS control unit calculates assist power

5. Electricity output switched by EPS control unit

3. Sends the torque sensor signal

I 6. Activates EPS motor I

I

2. Twists torsion bar

EPS control unit

Torque sensor

EPS motor

EPS unit

To prevent accidental damage to the EPS unit, it must not be disassembled.

-1-

I

FEATURES

------------------------------------------------------EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM

l~~~~l6iel

Meter assembly Multifunction display Odometer!Tripmeter A/Tripmeter B/Ciock/Gear position EPS UNIT

Torque sensor

Indicator and warning lights Coolant temperature warning/Reverse indicator/ Neutral indicator/Park indicator/High-range indicator/Low-range indicator/On-command differential gear lock indicator

I EPS motor

----1

Speed sensor signal

~,

~

EPS control unit ~------~.~~----~~

1

Battery

I

...

CDI unit

~ Engine revolution

f---

EPS self-diagnostic error codes

L----------~

EPS warning light

-2-

Ignition coil

I

SPECIAL TOOLS

-------------------------------------------------------

l~~~~l6iel

EBS00021

SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country. In such a case, two types are provided.

When placing an order, refer to the list provided below to avoid any mistakes.

For US and CON P/N. YM-, YU-, YS-, YK-, ACeExcept for US and CON P/N. 90890Tool No.

Tool name/How to use Boots band installation tool

90890-01526 YM-01526

This tool is used to remove or install the boot band.

Bearing retainer wrench 90890-01561

This tool is needed to removing and installing the final gear case bearing retainer.

Shim setting tool

90890-01562

This tool is used to measure the pinion gear backlash.

90890-03170 YM-03170

Belt tension gauge Rear drive belt tension gauge This tool is used to measure the steering tension.

-3-

Illustration

l s PECI a-1 ---------------------------------------------------GENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS Item

Standard

Model code

1CU1 (YFM45FGA), 1CU5 (YFM45FGHA), 1CT1 (YFM45FGPA), 1CT5 (YFM45FGPHA), 1CT8 (YFM45FGPA (Cast wheel model))

Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Basic weight With oil and full fuel tank

1 ,993 mm (78.5 in) 1,093 mm (43.0 in) 1,120mm(44.1 in) 840 mm (33.1 in) 1,233 mm (48.5 in) 245 mm (9.6 in) 3,000 mm (118 in) YFM45FGA 275.0 kg (606 lb) YFM45FGHA 275.0 kg (6061b) YFM45FGPANFM45FGPHA 281.0 kg (6191b) YFM45FGPA (Cast wheel model) 284.0 kg (6261b)

Engine Engine type Liquid-cooled 4-stroke, SOHC Cylinder arrangement Forward-inclined single cylinder Displacement 421 cm 3 Bore x stroke 84.5 x 75.0 mm (3.33 x 2.95 in) Compression ratio 10: 1 Standard compression pressure (at sea level) 1,270 kPa (12.7 kg/cm 2 , 181 psi) at 700 r/min Starting system Electric starter Oil type or grade Engine oil YAMALUBE Recommended brand SAE 5W-30, 1OW-30, 1OW-40, 15W-40, Type 20W-40 or 20W-50 Recommended oil grade API service SG type or higher, JASO standard 0 10 30 50 70 MA I I I I I SAE5W-30 SAE 10W-30

: SAE 1~W-40 : SAE 20W-4o

~AE 20~-50

I

i

-20

-10

i 0

10

Final gear oil Differential gear oil

i

20

i

30

40

so·c Yamaha Friction Modified Shaft Drive Gear Oil (Part No.: ACC-SHAFT-LU-00) Yamaha Friction Modified Shaft Drive Gear Oil (Part No.: ACC-SHAFT-LU-00) or SAE 80 API GL-4 Hypoid gear oil

-4-

lsPEcl a-1 ---------------------------------------------------GENERAL SPECIFICATIONS

Item

Standard

Oil capacity Engine oil Periodic oil change With oil filter cartridge replacement Total amount Final gear case oil Periodic oil change Total amount Differential gear case oil Periodic oil change Total amount Radiator capacity (including all routes) Tire Type Size front rear Manufacturer front rear Type front rear Bulb wattage x quantity Headlight Tail/brake light Meter lighting Indicator lights Neutral indicator light Reverse indicator light Coolant temperature warning light Park indicator light On-command four-wheel-drive/differential gear lock indicator High-range indicator light Low-range indicator light On-command differential gear lock indicator light EPS warning light

2.30 L (2.02 Imp qt, 2.43 US qt) 2.40 L (2.11 Imp qt, 2.54 US qt) 2.60 L (2.29 Imp qt, 2.75 US qt) 0.38 L (0.33 Imp qt, 0.40 US qt) 0.40 L (0.35 Imp qt, 0.42 US qt) 0.23 L (0.20 Imp qt, 0.24 US qt) 0.25 L (0.22 Imp qt, 0.26 US qt) 1.32 L (1.16 Imp qt, 1.40 US qt) Tubeless AT25 x 8-12 AT25 x 10-12 MAXXIS MAXXIS MU13 MU14 12 V 30.0/30.0 W X 2 12 v 5.0/21.0 w EL (Electroluminescent) LED X LED x LED x LED X LCD X

1 1 1 1 1

LED x 1 LED X 1 LED X 1 12 v 1.7 w X 1 (YFM45FGPA/YFM45FGPHA)

-5-

l s PECI a-1 ---------------------------------------------MAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

ENGINE Standard

Item Timing chain Model/No. of links Tensioning system

DID SCR-0409 SV/116 Automatic

-6-

Limit

----

----

lsPEcl a-1 ---------------------------------------------------MAINTENANCE SPECIFICATIONS

Tightening torques

Part to be tightened Crankcase end cover Stator rotor boss Neutral switch Reverse switch Low-range switch High-range switch

Tightening torque

Part name

Thread size

Q'ty

Bolt Bolt -

M6 M10 M10 M10 M10 M10

4 1 1 1 1 1

-7-

Remarks Nm

m-kg

ft·lb

10 50 17 17 17 17

1.0 5.0 1.7 1.7 1.7 1.7

7.2 36 12 12 12 12

lsPEcl a-1 -------------------------------------------------MAINTENANCE SPECIFICATIONS

CHASSIS

Item Front suspension Shock absorber travel Fork spring free length Installed length Spring rate

Spring stroke Optional spring available Rear suspension Shock absorber travel Spring free length Installed length Spring rate Spring stroke Optional spring available Front wheel Type

Standard 100.6 mm (3.96 in) 286.6 mm (11.28 in) 233.5 mm (9.19 in) 15.00 N/mm (1.53 kg/mm, 85.65 lb/in) 0 - 100.6 mm (0 - 3.96 in) No

-------

95.0 mm (3.74 in) 258.5 mm (1 0.18 in) 228.5 mm (9.00 in) 27.00 N/mm (2. 75 kg/mm, 154.17 lb/in) 0- 95.0 mm (0- 3.74 in) No

-------

Panel wheel (YFM45FGANFM45FG HAl YFM45FGPANFM45FGPHA) Cast wheel (YFM45FGPA (Cast wheel model)) 12x6.0AT Steel (YFM45FGANFM45FG HAl YFM45FGPANFM45FGPHA) Aluminum (YFM45FGPA (Cast wheel model))

----

radial

----

lateral

----

2.0mm (0.08 in) 2.0mm (0.08 in)

(K1) (K1)

(K1) (K1)

Rim size Rim material

Rim runout limit

Rear wheel Type

Rim size

Limit

Panel wheel (YFM45FGANFM45FG HAl YFM45FGPANFM45FGPHA) Cast wheel (YFM45FGPA (Cast wheel model)) 12x7.5AT

-8-

-------

-------

-------

-------

----------

----

----------

lsPEcl a-1 ---------------------------------------------------MAINTENANCE SPECIFICATIONS

Item

Standard

Steel (YFM45FGANFM45FG HAl YFM45FGPANFM45FGPHA) Aluminum (YFM45FGPA (Cast wheel model))

----

radial

----

lateral

----

2.0mm (0.08 in) 2.0mm (0.08 in)

Rim material

Rim runout limit

Rear disc brake Type Friction disc diameter x thickness Rear brake plate thickness Brake lever and brake pedal Rear brake lever free play (pivot) Brake pedal free play Throttle lever free play

Limit

----

Wet multiple disc brake ---105.0 x 3.4 mm (4.134 x 0.133 in) 3.26 mm (0.128 in) 2.58 mm 2.66 mm (0.1 05 in) (0.1 02 in) 10.0 mm (0.39 in) 20.0 mm (0.79 in) 3.0 - 5.0 mm (0.12 - 0.20 in)

-9-

----------

lsPEcl a-1 ---------------------------------------------------MAINTENANCE SPECIFICATIONS

Tightening torques

Part to be tightened

Thread size

Engine mounting nut (front-upper) Engine mounting bolt (front-lower) Engine mounting nut (rear-lower) Engine mounting nut (rear-upper) Final gear case nut Final gear case bolt Pitman arm nut (for YFM45FG PANFM45FG PHA) EPS unit bolt (for YFM45FGPANFM45FGPHA) EPS motor cover bolt (for YFM45FG PANFM45FG PHA) Steering stem bolt (for YFM45FG PANFM45FG PHA) Steering stem bracket bolt EPS unit protector bolt (for YFM45FG PANFM45FG PHA) Final gear oil filler bolt Final gear oil drain bolt Ring gear bearing housing bolt Final gear case front cover bolt Rear brake plate holding bolt Universal joint yoke nut (final drive pinion gear) Trailer hitch bolt Rear brake camshaft lever bolt Bearing retainer (final drive pinion gear) Ring gear stopper nut

-10-

Tightening torque Nm

m-kg

ft¡lb

M10 M10 M10 M10 M10 M10

42 42 42 42 55 55

4.2 4.2 4.2 4.2 5.5 5.5

30 30 30 30 40 40

M16

205

20.5

148

M8

34

3.4

25

M6

7

0.7

5.1

M8

34

3.4

25

M8

33

33

24

M6

7

0.7

5.1

M10 M10 M8 M8 M8 M14 M10 M8

22 22 27 27 28 97 55 28

2.2 2.2 2.7 2.7 2.8 9.7 5.5 2.8

16 16 20 20 20 70 40 20

M75

115

11.5

83

M8

16

1.6

12

Remarks

-CJ -CJ

-CJ -CJ -CJ -CJ -CJ Left-hand threads

-CJ

lsPEcl a-1 -------------------------------------------------MAINTENANCE SPECIFICATIONS

ELECTRICAL

Item

CDI Magneto model/manufacturer

Pickup coil resistance/color

Rotor rotation direction sensing coil resistance/color

CDI unit model/manufacturer

Charging system Type Model/manufacturer Nominal output

Charging coil resistance/color

Standard

Limit

F4T46472/MITSUBISHI (YFM45FGA/YFM45FG HA) F4T46474/MITSUBISHI (YFM45FG PA/YFM45FG PHA) 459- 561 nat 20 oc (68 °F)/ white/red -white/green (YFM45FGA/YFM45FG HA) 408 - 612 nat 20 oc (68 °F)/ white/red -white/green (YFM45FG PA/YFM45FG PHA) 0.086 - 0.1 05 n at 20 oc (68 °F)/ red- white/blue (YFM45FGA/YFM45FG HA) 0.080 - 0.120 n at 20 oc (68 °F)/ red- white/blue (YFM45FGPA/YFM45FGPHA) F8T40381/MITSUBISHI (YFM45FGA/YFM45FGHA) F8T42071/MITSUBISHI (YFM45FG PA/YFM45FG PHA)

----

AC magneto generator F4T464/MITSUBISHI 14.0 V 17.5 A at 5,000 r/min (YFM45FGA/YFM45FG HA) 14.0 V 22.5 A at 5,000 r/min (YFM45FGPA/YFM45FGPHA) 0.46 - 0.56 n at 20 oc (68 °F)/ white -white 0.50 - 0.62 n at 20 oc (68 °F)/ white -white (YFM45FGA/YFM45FGHA) 0.16 - 0.24 n at 20 oc (68 °F)/ white -white 0.18 - 0.26 n at 20 oc (68 °F)/ white -white (YFM45FG PA/YFM45FG PHA)

----

-11-

----------

-------

-------

----------------

-------

lsPEcl a-1 -------------------------------------------------MAINTENANCE SPECIFICATIONS

Item

Rectifier/regulator Regulator type No load regulated voltage (DC) Model/manufacturer

Capacity

Withstand voltage Electric starter system Type Starter motor Model/manufacturer Output Armature coil resistance Brush overall length Spring force Starter relay Model/manufacturer Amperage rating Coil resistance Four-wheel drive relay 3 Model/manufacturer

Coil resistance

EPS relay (YFM45FGPANFM45FGPHA) Model/manufacturer Coil resistance Auxiliary DC jack relay (YFM45FGPANFM45FGPHA) Model/manufacturer Coil resistance

Standard

Limit

Semi conductor-short circuit 14.1 - 14.9 v SH640E-11/SHINDENGEN (YFM45FGA/YFM45FG HA) SH678-11/SHINDENGEN (YFM45FGPA/YFM45FGPHA) 25.0A (YFM45FGA/YFM45FG HA) 35.0A (YFM45FG PA/YFM45FG PHA) 200V

-------

Constant mesh type

----

SM-18/MITSUBA 0.7kW 0.010 - 0.020 n at 20 12.0 mm (0.47 in)

----------

oc (68 °F)

-------------

----

6.50 mm (0.26 in)

6.025- 6.515 N (614 - 664 g, 21.69 - 23.45 oz)

----

RC19-015/MITSUBA 180 A 4.18-4.62 nat 20 oc (68 °F)

----

ACA12115-1/MATSUSHITA (YFM45FGA/YFM45FG HA) ACM33211/MATSUSHITA (YFM45FG PA/YFM45FG PHA) 72- 88 nat 20 oc (68 °F) (YFM45FGA/YFM45FG HA) 96 nat 20 oc (68 °F) (YFM45FGPA/YFM45FGPHA)

----

G8H N-1 C4T-OJ/OM RON 94.5 - 115.5 n at 20 oc (68 °F)

-------

ACM33211/MATSUSHITA 96 nat 20 oc (68 °F)

----

-12-

-------

----------

----

lsPEcl a-1 -------------------------------------------------MAINTENANCE SPECIFICATIONS

Item

Circuit breaker Type Amperage for individual circuit Main fuse Headlight fuse Signaling system fuse Ignition fuse Auxiliary DC jack fuse Backup fuse

Four-wheel drive motor fuse EPS fuse Reserve Reserve Reserve Reserve

Standard

Limit

Fuse

----

30 Ax 1 15 A X 1 10 A X 1 10 A X 1 10 A X 1 10 A X 1 (YFM45FGANFM45FGHA) 5 Ax 1 (YFM45FGPANFM45FGPHA) 10 A X 1 40 Ax 1 (YFM45FG PANFM45FG PHA) 30 Ax 1 15 A X 1 10 A X 1 5 Ax 1 (YFM45FG PANFM45FG PHA)

----

-13-

-------

-------------

-------------

-------

l s PECI a-1 ------------------------------------------------------CABLE ROUTING (YFM45FGANFM45FGHA)

CABLE ROUTING (YFM45FGAIYFM45FGHA) CD Rear brake lever light switch lead ® Handlebar switch lead ® Starter cable ®> Wire harness @ Rear brake lever cable ® Coolant reservoir breather hose @ Auxiliary DC jack ® Thermo switch 2 lead @ Differential gear case breather hose ® Front brake hose @ Differential gear motor lead ® On-command four-wheel-drive switch and differ-

ential gear lock switch (j) Throttle cable ® Handlebar switch

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

-14-

lsPEcl a-1 ------------------------------------------------------CABLE ROUTING (VFM45FGANFM45FGHA)

@ @ @) @

Main switch lead Coolant reservoir hose Fan motor breather hose Fan motor lead

!AI Fasten the on-command four-wheel-drive switch and differential gear lock switch lead to the handlebar with the plastic bands, making sure to route the lead under the handlebar. [ill Fasten the starter cable, handlebar switch lead, and rear brake lever light switch lead to the handlebar with the plastic band, making sure to route the leads under the handlebar.

-15-

lsPEcl a-1 ------------------------------------------------------CABLE ROUTING (VFM45FGANFM45FGHA)

[g Fasten the handlebar switch lead and rear brake lever light switch lead to the handlebar with the plastic band, making sure to route the leads under the handlebar.

[QJ Fasten the handlebar switch lead, rear brake lever light switch lead, and on-command fourwheel-drive switch and differential gear lock switch lead with the plastic band.

[I] Route the rear brake lever cable through the guide.

[f] Fasten the differential gear case breather hose and differential gear motor lead with the plastic band, making sure not to pinch the hose.

[Q] Route the throttle cable through the lower portion of the guide.

[8] Make sure not to pinch the hoses.

-16-

lsPEcl a-1 -----------------------------------------------------CABLE ROUTING (VFM45FGANFM45FGHA)

!AI Connect the meter assembly couplers,

CD Headlight relay

速 Headlight leads @ Four-wheel-drive motor relay 3 @ Fan motor breather hose 速 Differential gear case breather hose 速 Coolant reservoir breather hose (J) Differential gear motor lead 速 Meter assembly couplers

and then fasten the wire harness with the plastic band. [ill50-60 mm (1.97-2.36 in)

A

-17-

lsPEcl a-1 ------------------------------------------------------CABLE ROUTING (VFM45FGANFM45FGHA)

CD Starter cable

® Fuel tank breather hose @ Cylinder head breather hose @Fuel hose ® Carburetor overflow hose ® Radiator outlet hose (f) Coolant reservoir hose ® Coolant reservoir breather hose

® Differential gear motor lead @ Differential gear case breather hose ® Fan motor breather hose @) Four-wheel-drive motor relay 3 @ Headlight relay @ Brake pedal cable @ Rear brake lever cable @ Coolant reservoir

A

[1]7

a[I]

6

B-8

D-D

-18-

lsPEcl a-1 -----------------------------------------------------CABLE ROUTING (VFM45FGANFM45FGHA)

[A] Pass the fuel tank breather hose through the hole in the handlebar cover. [ill Fasten the starter cable, rear brake lever cable, and brake pedal cable with the plastic band. [g Fasten the radiator outlet hose with the plastic band, making sure that the hose does not contact the edge of the frame.

[Q] 7.0-17.0 mm (0.28-0.67 in) [1] Make sure not to pinch the hose.

A

[1]7

a[I]

6

B-8

D-D

-19-

lsPEcl a-1 -----------------------------------------------------CABLE ROUTING (VFM45FGANFM45FGHA)

CD Cylinder head breather hose

® Final drive gear case breather hose @ Wire harness @ Starter motor lead ® Negative battery lead ® Rectifier/regulator (f) Air filter case check hose ® Water pump breather hose ® Speed sensor lead @)Sub-wire harness 2 lead ® Radiator outlet hose

@) Starter cable @ Float chamber air vent hose @ Brake pedal cable @ Rear brake lever cable @Fuel hose @ AC magneto lead @ Low-range switch @) High-range switch ® Neutral switch @ Reverse switch

-20-

lsPEcl a-1 ------------------------------------------------------CABLE ROUTING (VFM45FGANFM45FGHA)

[A] Fasten the rear brake lever cable and brake pedal cable with the plastic band. llil55.0-75.0 mm (2.17-2.95 in) [g Fasten the sub-wire harness 2 lead, speed sensor lead, AC magneto lead, rectifier/regulator lead, negative battery lead, rear brake lever cable, and brake pedal cable with the plastic band.

[QJ Fasten the rectifier/regulator lead and final drive gear case breather hose with the plastic band, making sure not to pinch the hose.

[1] Fasten the rectifier/regulator lead with the plastic band. [f] Make sure not to pinch the final drive gear case breather hose.

[Q] Do not fasten the sub-wire harness 2 lead, AC magneto lead, and speed sensor lead with the plastic band.

[8] To wire harness ITJ To battery QJ 35-45°

-21-

lsPEcl a-1 -----------------------------------------------------CABLE ROUTING (VFM45FGANFM45FGHA)

CD Throttle cable

(f) Drive select lever control cable ® Brake pedal light switch lead ® Rear brake lever cable @ Ignition coil ® Sub-wire harness 1 lead @) Fuel tank breather hose

®

Spark plug lead @ Radiator inlet hose @ Main switch lead ® Wire harness ® Brake pedal cable

B-B

A

-22-

lsPEcl a-1 ------------------------------------------------------CABLE ROUTING (VFM45FGANFM45FGHA)

[A] Fasten the radiator inlet hose and spark plug lead with the plastic band. [ill Fasten the drive select lever control cable with the holder. [g Fasten the wire harness with the plastic band.

[QJ Fasten the drive select lever control cable and brake pedal light switch lead with the plastic band.

[1] Fasten the radiator inlet hose with the plastic band. [f] Fasten the brake pedal cable, brake pedal light switch lead, and drive select lever control cable with the plastic band.

[Q] 15-45 mm (0.59-1.77 in)

B-B

A

-23-

lsPEcl a-1 ---------------------------------------------------CABLE ROUTING (VFM45FGANFM45FGHA)

CD Front brake hose

®Throttle cable @ Wire harness @ Final drive gear case breather hose ®Battery ® Positive battery lead (J) Tail/brake light lead

® Four-wheel-drive motor relay 1 ® CDI unit

@ Starter relay ® Starter motor lead @) Negative battery lead @ Rear brake lever cable

A-A

-24-

lsPEcl a-1 ------------------------------------------------------CABLE ROUTING (VFM45FGANFM45FGHA)

[A] Route the throttle cable to the outside of the guide and above the plastic band that is holding the wire harness. [ill Fasten the wire harness with the plastic band.

Point the end of the plastic band upward. [g Fasten the wire harness with the plastic band.

[Q] 30-40 mm (1.18-1.57 in) [1] Fasten the positive battery lead with the holder. [f] Make sure that the sections of the leads that are not covered by the protective sleeves do not contact the edges of the metal holder.

A-A

-25-

l s PECI a-1 -----------------------------------------------------CABLE ROUTING (YFM45FGPANFM45FGPHA)

CABLE ROUTING (YFM45FGPAIYFM45FGPHA) CD Rear brake lever light switch lead ® Handlebar switch ® Starter cable ® Handlebar switch lead @ Rear brake lever cable ®> Main switch lead @ Auxiliary DC jack ® Wire harness ® Front brake hose ® Coolant reservoir breather hose @ Thermo switch 2 lead ® On-command four-wheel-drive switch and differ-

ential gear lock switch (j) Throttle cable

@ EPS torque sensor lead @ EPS motor lead

A

-26-

lsPEcl a-1 ------------------------------------------------------CABLE ROUTING (VFM45FGPANFM45FGPHA)

@ Differential gear case breather hose @ Differential gear motor lead @) On-command four-wheel-drive switch and differential gear lock switch lead @ EPS warning light lead ÂŽ Fan motor breather hose @ Fan motor lead @) Coolant reservoir hose

!AI Fasten the on-command four-wheel-drive switch and differential gear lock switch lead to the handlebar with the plastic bands, making sure to route the lead under the handlebar. [ill Fasten the starter cable, handlebar switch lead, and rear brake lever light switch lead to the handlebar with the plastic band, making sure to route the leads under the handlebar.

A

-27-

lsPEcl a-1 ------------------------------------------------------CABLE ROUTING (VFM45FGPANFM45FGPHA)

[g Fasten the handlebar switch lead and rear brake lever light switch lead to the handlebar with the plastic band, making sure to route the leads under the handlebar.

[QJ Cut off the excess end of the plastic locking tie.

[I] Fasten the handlebar switch lead, rear brake lever light switch lead, on-command four-wheeldrive switch and differential gear lock switch lead, and EPS warning light lead with the plastic band.

[f] Route the rear brake lever cable through the guide.

[Q] Fasten the differential gear case breather hose, differential gear motor lead, EPS motor lead and EPS torque sensor lead with the plastic band, making sure not to pinch the hose.

[8] Route the throttle cable through the lower portion of the guide.

ITJ Make sure not to pinch the hoses.

A

-28-

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