Yamaha Rhino 450 YXR45FAV User manual

LIT-11616-19-43 2P5-F8197-10
YXR45FAV
SERVICE MANUAL

EBS00001
YXR45FAV
SERVICE MANUAL
©2005 by Yamaha Motor Corporation, U.S.A.
First Edition, August 2005
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-11616-19-43

EBS00002
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. Repairs attempted by anyone without this knowledge are likely to render the vehicle unsafe
and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig-
nificant 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.
EBS00003
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death
to the vehicle operator, passenger, a bystander, or a person checking or
repairing the vehicle.
A CAUTION indicates special precautions that must be taken to avoid dam-
age to the vehicle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:

EBS00004
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “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. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa-
nied 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 4is provided for removal and disassembly jobs.
2. Numbers 5are 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
6. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7accompanies 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 8are given in addition
to the exploded diagram and the job instruction chart.

EBS00006
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1to 0indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Engine
5Cooling system
6Fuel system
7Drive train
8Chassis
9Electrical
0Troubleshooting
Symbols Ato Hindicate the following.
ACan be serviced with engine mounted
BFilling fluid
CLubricant
DSpecial tool
ETorque
FWear limit, clearance
GEngine speed
HElectrical data (Ω, V, A)
Symbols Ito Nin the exploded diagrams
indicate the types of lubricants and lubrication
points.
IApply engine oil
JApply gear oil
KApply molybdenum disulfide oil
LApply wheel bearing grease
MApply lithium-soap-based grease
NApply molybdenum disulfide grease
Symbols Oto Pin the exploded diagrams
indicate where to apply a locking agent Oand
when to install a new part P.
OApply the locking agent (LOCTITE®)
PReplace
12
34
56
78
90
AB
CD
EF
GH
IJK
LMN
OP
GEN
INFO SPEC
CHK
ADJ ENG
COOL
FUEL
DRIV
CHAS
–+
ELEC TRBL
SHTG
T
R
.
.
EGM
BLS M
LT
New

EBS00008
TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC 2
PERIODIC CHECKS AND
ADJUSTMENTS CHK
ADJ 3
ENGINE ENG 4
COOLING SYSTEM COOL 5
FUEL SYSTEM FUEL 6
DRIVE TRAIN DRIV 7
CHASSIS CHAS 8
ELECTRICAL ELEC 9
TROUBLESHOOTING TRBL
SHTG
10
–+

CONTENTS
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION............................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL..........................................................................................1-1
IMPORTANT INFORMATION .........................................................................1-2
PREPARATION FOR REMOVAL PROCEDURES ...................................1-2
REPLACEMENT PARTS...........................................................................1-2
GASKETS, OIL SEALS AND O-RINGS ....................................................1-2
LOCK WASHERS/PLATES AND COTTER PINS .....................................1-3
BEARINGS AND OIL SEALS ....................................................................1-3
CIRCLIPS ..................................................................................................1-3
CHECKING OF CONNECTIONS ....................................................................1-4
SPECIAL TOOLS ............................................................................................1-5
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................2-1
ENGINE SPECIFICATIONS ............................................................................2-5
CHASSIS SPECIFICATIONS ........................................................................2-13
ELECTRICAL SPECIFICATIONS .................................................................2-15
TIGHTENING TORQUES ..............................................................................2-18
ENGINE TIGHTENING TORQUES.........................................................2-18
CHASSIS TIGHTENING TORQUES.......................................................2-21
LUBRICATION POINTS AND LUBRICANT TYPES ....................................2-24
ENGINE...................................................................................................2-24
HOW TO USE THE CONVERSION TABLE..................................................2-25
GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-25

COOLANT FLOW DIAGRAMS .....................................................................2-26
OIL FLOW DIAGRAMS.................................................................................2-29
CABLE ROUTING .........................................................................................2-34
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION..............................................................................................3-1
PERIODIC MAINTENANCE/LUBRICATION ..................................................3-1
ENGINE ...........................................................................................................3-3
ADJUSTING THE VALVE CLEARANCE ..................................................3-3
ADJUSTING THE IDLING SPEED............................................................3-5
ADJUSTING THE THROTTLE CABLE .....................................................3-7
ADJUSTING THE STARTER CABLE .......................................................3-8
CHECKING THE SPARK PLUG ...............................................................3-9
CHECKING THE IGNITION TIMING.......................................................3-10
MEASURING THE COMPRESSION PRESSURE..................................3-11
CHECKING THE ENGINE OIL LEVEL....................................................3-13
CHANGING THE ENGINE OIL ...............................................................3-14
CLEANING THE AIR FILTER ELEMENTS .............................................3-16
CHECKING THE COOLANT LEVEL.......................................................3-19
CHANGING THE COOLANT...................................................................3-20
CHECKING THE COOLANT TEMPERATURE WARNING LIGHT.........3-25
CHECKING THE V-BELT........................................................................3-25
CLEANING THE SPARK ARRESTER ....................................................3-27
CHASSIS .......................................................................................................3-28
ADJUSTING THE BRAKE PEDAL ..........................................................3-28
ADJUSTING THE PARKING BRAKE......................................................3-29
CHECKING THE BRAKE FLUID LEVEL.................................................3-30
CHECKING THE FRONT BRAKE PADS ................................................3-31
CHECKING THE REAR BRAKE PADS ..................................................3-31
CHECKING THE BRAKE HOSES AND BRAKE PIPES .........................3-31
BLEEDING THE HYDRAULIC BRAKE SYSTEM ...................................3-32
ADJUSTING THE SELECT LEVER SHIFT ROD....................................3-34
ADJUSTING THE BRAKE LIGHT SWITCH ............................................3-34
CHECKING THE FINAL GEAR OIL LEVEL ............................................3-35
CHANGING THE FINAL GEAR OIL........................................................3-36
CHECKING THE DIFFERENTIAL GEAR OIL.........................................3-36
CHANGING THE DIFFERENTIAL GEAR OIL ........................................3-37
CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS ..........3-38
CHECKING THE STEERING SYSTEM ..................................................3-39
ADJUSTING THE TOE-IN.......................................................................3-39
ADJUSTING THE FRONT SHOCK ABSORBERS .................................3-41

ADJUSTING THE REAR SHOCK ABSORBERS....................................3-41
CHECKING THE TIRES..........................................................................3-42
CHECKING THE WHEELS .....................................................................3-44
CHECKING AND LUBRICATING THE CABLES ....................................3-44
LUBRICATING THE PEDALS, ETC........................................................3-45
ELECTRICAL ................................................................................................3-46
CHECKING AND CHARGING THE BATTERY.......................................3-46
CHECKING THE FUSES ........................................................................3-51
ADJUSTING THE HEADLIGHT BEAMS.................................................3-53
CHANGING THE HEADLIGHT BULBS...................................................3-53
CHANGING THE TAIL/BRAKE LIGHT BULBS.......................................3-54
CHAPTER 4
ENGINE
ENGINE REMOVAL ........................................................................................4-1
AIR DUCTS, MUFFLER AND EXHAUST PIPE ........................................4-1
SELECT LEVER UNIT AND COOLANT RESERVOIR .............................4-3
HOSES AND LEADS.................................................................................4-4
ENGINE MOUNTING BOLTS ...................................................................4-6
INSTALLING THE ENGINE.......................................................................4-8
CYLINDER HEAD............................................................................................4-9
REMOVING THE CYLINDER HEAD.......................................................4-11
CHECKING THE TAPPET COVERS ......................................................4-12
CHECKING THE TIMING CHAIN TENSIONER......................................4-12
CHECKING THE CAMSHAFT SPROCKET............................................4-12
CHECKING THE CYLINDER HEAD .......................................................4-13
INSTALLING THE CYLINDER HEAD .....................................................4-14
CAMSHAFT, ROCKER ARMS AND VALVES..............................................4-17
REMOVING THE CAMSHAFT AND ROCKER ARMS............................4-19
REMOVING THE VALVES AND VALVE SPRINGS ...............................4-19
CHECKING THE CAMSHAFT.................................................................4-20
CHECKING THE ROCKER ARMS AND CAMSHAFT ............................4-20
CHECKING THE VALVES AND VALVE SPRINGS ................................4-22
INSTALLING THE VALVES AND VALVE SPRINGS ..............................4-26
INSTALLING THE CAMSHAFT AND ROCKER ARMS ..........................4-27
CYLINDER AND PISTON..............................................................................4-28
REMOVING THE PISTON ......................................................................4-29
CHECKING THE TIMING CHAIN GUIDE ...............................................4-29
CHECKING THE CYLINDER AND PISTON ...........................................4-29
CHECKING THE PISTON RINGS...........................................................4-31
CHECKING THE PISTON PIN ................................................................4-32
INSTALLING THE PISTON .....................................................................4-33
INSTALLING THE CYLINDER ................................................................4-34