Yamaha WOLVERINE YFM45FXV Manual

YFM45FXV
SUPPLEMENTARY
SERVICE MANUAL
3C2-F8197-E0

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
YFM45FXV
SUPPLEMENTARY
SERVICE MANUAL
©2005 by Yamaha Motor Co., Ltd.
First edition, July 2005
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

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. 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
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.
N
OTE:
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 ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death
to the vehicle operator, a bystander or a person inspecting or repairing the
vehicle.
A CAUTION indicates special precautions that must be taken to avoid
damage to the vehicle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:

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. 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
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 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.

EB003000
ILLUSTRATED SYMBOLS
Illustrated symbols 1to 0are printed on the
top right of each page and indicate the subject
of each chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Engine
5Cooling system
6Carburetion
7Drive train
8Chassis
9Electrical
0Troubleshooting
Illustrated symbols Ato Hare used to identify
the specifications appearing in the text.
ACan be serviced with engine mounted
BFilling fluid
CLubricant
DSpecial tool
ETorque
FWear limit, clearance
GEngine speed
HΩ, V, A
Illustrated 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
Illustrated 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 CARB
DRIV
CHAS
–+
ELEC TRBL
SHTG
T
R
.
.
EGM
BLS M
LT
New

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 ........................................................................................ 9
PERIODIC CHECKS AND ADJUSTMENTS.................................................... 21
INTRODUCTION ........................................................................................ 21
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM (For CDN) .................................................................................. 21
GENERAL MAINTENANCE AND LUBRICATION CHART (For CDN) ...... 22
PERIODIC MAINTENANCE AND LUBRICATION CHART (For Europe) ... 23
SEAT, FENDERS AND FUEL TANK.......................................................... 25
SEAT.................................................................................................... 25
FRONT GUARD AND FRONT FENDER ............................................. 26
REAR GUARD AND REAR FENDER.................................................. 27
FUEL TANK ......................................................................................... 29
FOOTREST BOARDS................................................................................ 31
CHASSIS.................................................................................................... 32
ADJUSTING THE REAR BRAKE ........................................................ 32
ADJUSTING THE SELECT LEVER CONTROL CABLE
AND SHIFT ROD ................................................................................ 34
ELECTRICAL ............................................................................................. 36
ADJUSTING THE HEADLIGHT BEAMS ............................................. 36
CHANGING THE HEADLIGHT BULBS ............................................... 36
ENGINE ............................................................................................................ 38
ENGINE REMOVAL ................................................................................... 38
SELECT LEVER UNIT AND COOLANT RESERVOIR........................ 38
AIR DUCTS, MUFFLER AND EXHAUST PIPE................................... 40
HOSES AND LEADS ........................................................................... 41
INSTALLING THE MUFFLER AND EXHAUST PIPE .......................... 42
CYLINDER HEAD ...................................................................................... 43
REMOVING THE CYLINDER HEAD ................................................... 45
INSTALLING THE CYLINDER HEAD.................................................. 46
A.C. MAGNETO ......................................................................................... 49
REMOVING THE A.C. MAGNETO ...................................................... 51
INSTALLING THE A.C. MAGNETO..................................................... 51
CRANKCASE ............................................................................................. 53
STARTER MOTOR, TIMING CHAIN AND OIL FILTER ...................... 53
TRANSMISSION ........................................................................................ 56

MIDDLE GEAR........................................................................................... 58
MIDDLE DRIVEN SHAFT .................................................................... 58
COOLING SYSTEM.......................................................................................... 60
RADIATOR ................................................................................................. 60
DRIVE TRAIN ................................................................................................... 62
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR ... 62
DISASSEMBLING THE DIFFERENTIAL GEAR.................................. 67
CHECKING THE CONSTANT VELOCITY JOINTS............................. 67
CHECKING THE DIFFERENTIAL GEAR ............................................ 68
ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS........... 68
ASSEMBLING THE DIFFERENTIAL GEAR........................................ 69
MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR
LASH................................................................................................... 70
CHECKING THE DIFFERENTIAL OPERATION ................................. 72
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT............................ 73
CHASSIS .......................................................................................................... 74
FRONT AND REAR WHEELS ................................................................... 74
FRONT WHEELS................................................................................. 74
REAR WHEELS................................................................................... 76
INSTALLING THE REAR BRAKE DISC .............................................. 78
FRONT AND REAR BRAKES .................................................................... 79
REAR BRAKE MASTER CYLINDER................................................... 79
STEERING SYSTEM ................................................................................. 81
STEERING STEM................................................................................ 81
TIE ROD AND STEERING KNUCKLE................................................. 83
FRONT ARMS AND FRONT SHOCK ABSORBERS................................. 85
REAR SHOCK ABSORBER AND SWINGARM ......................................... 87
ELECTRICAL ................................................................................................... 89
ELECTRICAL COMPONENTS................................................................... 89
CHECKING THE SWITCH ......................................................................... 90
CHECKING THE SWITCH CONTINUITY............................................ 90
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

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

–2 –
SPEC
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)
Minimum ground clearance 220 mm (8.7 in)
Minimum turning radius 3,000 mm (118.1 in)
Basic weight:
With oil and full fuel tank 250 kg (551 lb)
Engine:
Engine type Liquid-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 421 cm3
Bore ×stroke 84.5 ×75.0 mm (3.33 ×2.95 in)
Compression ratio 10 : 1
Standard compression pressure (at sea level) 1,270 kPa (12.7 kg/cm2, 181 psi) at 700 r/min
Starting system Electric starter
Oil capacity:
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 0.23 L (0.20 Imp qt, 0.24 US qt)
Total amount 0.25 L (0.22 Imp qt, 0.26 US qt)
Differential gear case oil
Periodic oil change 0.35 L (0.31 Imp qt, 0.37 US qt)
Total amount 0.40 L (0.35 Imp qt, 0.42 US qt)
Radiator capacity (including all routes) 1.32 L (1.16 Imp qt, 1.40 US qt)
Fuel:
Type Unleaded gasoline only (for USA)
Regular unleaded gasoline only (for CDN and
Europe)
Fuel tank capacity 14.5 L (3.19 Imp gal, 3.83 US gal)
Fuel reserve amount 4.5 L (0.99 Imp gal, 1.19 US gal)
GENERAL SPECIFICATIONS

–3 –
SPEC
GENERAL SPECIFICATIONS
Transmission:
Primary reduction system V-belt
Secondary reduction system Shaft drive
Secondary reduction ratio 39/24 ×24/18 ×33/9 (7.944)
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 29/17 (1.706)
Chassis:
Frame type Steel tube frame
Caster angle 4°
Camber angle 1°
Kingpin angle 11°
Kingpin offset 0 mm (0 in)
Trail 19.3 mm (0.76 in)
Tread (STD) front 820 mm (32.28 in)
rear 850 mm (33.46 in)
Toe-in 0 ~ 10 mm (0 ~ 0.39 in)
Tire:
Type Tubeless
Size front AT23 ×8R12
rear AT23 ×10R12
Manufacturer front MAXXIS
rear MAXXIS
Type front M937
rear M938
Tire pressure (cold tire):
Maximum load* 100 kg (220 lbs)
Off-road riding front 37 ~ 43 kPa (0.37 ~ 0.43 kgf/cm2, 5.3 ~ 6.1 psi)
rear 37 ~ 43 kPa (0.37 ~ 0.43 kgf/cm2, 5.3 ~ 6.1 psi)
*Load is total weight of rider, cargo and acces-
sories
Bulb wattage ×quantity:
Headlight 12 V 30 W/30 W ×2
Tail/brake light 12 V 5 W/21 W ×1
Indicator lights
Neutral indicator light LED ×1
Reverse indicator light LED ×1
Coolant temperature warning light LED ×1
Park indicator light LED ×1
Item Standard

–4 –
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) #50 ----
Jet needle (J.N) 5EP13-55-3 ----
Needle jet (N.J) P-0M ----
Pilot air jet (P.A.J.1) #80 ----
Pilot air jet (P.A.J.2) 1.3 ----
Pilot outlet (P.O) 0.95 ----
Pilot jet (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 ----
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 ----
Pilot screw (P.S.) 2-1/2 turns out ----
Float height (F.H) 13 mm (0.51 in) ----
Fuel level (F.L) 4.0 ~ 5.0 mm (0.16 ~ 0.20 in)
Above the float chamber mating
surface
----
Engine idle speed 1,450 ~ 1,550 r/min ----
Intake vacuum 32 kPa (240 mmHg, 9.47 inHg) ----
Cooling system:
Radiator core
Width 208 mm (8.19 in) ----
Height 300 mm (11.81 in) ----
Thickness 24 mm (0.94 in) ----
Radiator cap opening pressure 107.8 ~ 137.2 kPa (1.078 ~
1.372 kg/cm2, 15.33 ~ 19.51 psi)
----
Radiator capacity 0.68 L (0.60 Imp qt, 0.72 US qt) ----
Coolant reservoir capacity
Up to the maximum level mark 0.25 L (0.22 Imp qt, 0.26 US qt) ----
From low to full level 0.15 L (0.13 Imp qt, 0.16 US qt) ----
Shaft drive:
Middle gear backlash 0.1 ~ 0.3 mm (0.004 ~ 0.012 in) ----
Final gear backlash 0.1 ~ 0.2 mm (0.004 ~ 0.008 in) ----
Differential gear backlash 0.10 ~ 0.50 mm
(0.004 ~ 0.020 in)
----

–5 –
SPEC
MAINTENANCE SPECIFICATIONS
Tightening torques
CHASSIS
Part to be tightened Part
name
Thread
size Q’ty Tightening torque Remarks
Nm m·kg ft·lb
Oil seal retainer Screw M5 2 7 0.7 5.1 LT
Access cover Bolt M6 4 10 1.0 7.2
Thermo switch —M18 1 7 0.7 5.1
Stopper lever shaft Bolt M6 1 10 1.0 7.2
Park switch —M10 1 20 2.0 14
Item Standard Limit
Front suspension:
Shock absorber travel 99 mm (3.90 in) ----
Fork spring free length 285 mm (11.22 in) ----
Spring fitting length 231.9 mm (9.13 in) ----
Spring rate (K1) 16.5 N/mm
(1.68 kg/mm, 94.07 lb/in)
----
Stroke (K1) 0 ~ 99 mm (0 ~ 3.90 in) ----
Optional spring No ----
Rear suspension:
Shock absorber travel 126 mm (4.96 in) ----
Spring free length 317 mm (12.48 in) ----
Spring fitting length 283.1 mm (11.15 in) ----
Spring rate (K1) 31.6 N/mm
(3.22 kg/mm, 180.43 lb/in)
----
Stroke (K1) 0 ~ 126 mm (0 ~ 4.96 in) ----
Optional spring No ----
Front wheel:
Type Panel wheel ----
Rim size 12 ×6.0 AT ----
Rim material Aluminum ----
Rim runout limit radial ---- 2 mm
(0.08 in)
lateral ---- 2 mm
(0.08 in)
Rear wheel:
Type Panel wheel ----
Rim size 12 ×7.5 AT ----
Rim material Aluminum ----
Rim runout limit radial ---- 2 mm
(0.08 in)
lateral ---- 2 mm
(0.08 in)

–6 –
SPEC
MAINTENANCE SPECIFICATIONS
Tightening torques
ELECTRICAL
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) ----
Part to be tightened Thread size Tightening torque Remarks
Nm m·kg ft·lb
Steering stem, pitman arm and frame M14 190 19.0 140
Fuel tank and frame M6 10 1.0 7.2
Front wheel and wheel hub M10 55 5.5 40
Front brake hose holder bolt M6 7 0.7 5.1
Front guard and frame M8 34 3.4 24
Rear guard and frame M8 34 3.4 24
Four-wheel drive switch M10 20 2.0 14
Engine side cover M6 7 0.7 5.1
Headlight and headlight bracket M6 7 0.7 5.1
Front grill and headlight bracket M6 7 0.7 5.1
Fan motor M6 8 0.8 5.8
Item Standard Limit
CDI:
Magneto model/manufacturer F4T46472/MITSUBISHI ----
Pickup coil resistance/color 459 ~ 561 Ωat 20 °C (68 °F)/
White/Red –White/Green
----
Rotor rotation direction sensing coil resis-
tance/color
0.086 ~ 0.105 Ωat 20 °C (68 °F)/
Red –White/Blue
----
CDI unit model/manufacturer F8T40377/MITSUBISHI ----
Headlight relay:
Model/manufacturer G8HN-1C4T-DJ-Y52/OMRON ----
Coil winding resistance 94.5 ~ 115.5 Ωat 20 °C (68 °F) ----
Item Standard Limit

–7 –
SPEC
COOLANT FLOW DIAGRAMS
COOLANT FLOW DIAGRAMS
1Radiator
2Thermo switch 2
3Fan motor
ÈTo coolant reservoir

–8 –
SPEC
COOLANT FLOW DIAGRAMS
1Radiator
2Thermostat

–9 –
SPEC
CABLE ROUTING
CABLE ROUTING
1On-command four-wheel drive switch
2On-command four-wheel drive switch lead
3Throttle cable
4Handlebar switch lead
5Handlebar switch
6Rear brake switch lead
7Starter cable
8Rear brake cable
9Front brake hose
0Front brake light switch lead
AMain switch lead
BCoolant reservoir hose
CCoolant reservoir breather hose
DDifferential gear case breather hose
ESub-wire harness 1
FFan motor breather hose
GFan motor lead
C
D
B
E
G
Í
123
A
A
D
F
0
E
2
ÉÊ45
6
7
8
0
9
È
87
6
4
A
B
C
93
Ì
Ë

–10 –
SPEC
CABLE ROUTING
ÈFasten the on-command four-wheel drive switch
lead and front brake light switch lead behind the
handlebar with the plastic bands.
ÉFasten the starter cable, handlebar switch lead,
and rear brake switch lead behind the handlebar
with a plastic band.
ÊFasten the handlebar switch lead and rear brake
switch lead behind the handlebar with a plastic
band.
ËPass the rear brake cable through the cable
guide, making sure that it is routed on the right
side of the steering stem.
ÌFasten the on-command four-wheel drive switch
lead, front brake light switch lead, handlebar
switch lead, and rear brake switch lead with a
plastic band.
ÍFasten the sub-wire harness 1, coolant reservoir
breather hose, coolant reservoir hose, differen-
tial gear case breather hose, and fan motor lead
with a plastic band.
C
D
B
E
G
Í
123
A
A
D
F
0
E
2
ÉÊ45
6
7
8
0
9
È
87
6
4
A
B
C
93
Ì
Ë

–11 –
SPEC
CABLE ROUTING
1Auxiliary DC jack (optional)
2Headlight lead
3Headlight coupler
A-A
A
A
1
22
3

–12 –
SPEC
CABLE ROUTING
1Starter cable
2Fuel tank breather hose
3Fuel hose
4Cylinder head breather hose
5Carburetor drain hose
6Radiator outlet hose
7Coolant reservoir breather hose
8Coolant reservoir hose
9Sub-wire harness 1
0Differential gear case breather hose
AThermo switch 2
ÈInsert the fuel tank breather hose into the hole of
the handlebar cover.
ÉFasten the starter cable with a plastic band.
ÊFasten the radiator outlet hose with a plastic
band.
ËFasten the coolant reservoir breather hose, cool-
ant reservoir hose, and radiator outlet hose with
the plastic bands.
ÌFasten the sub-wire harness 1 with the plastic
bands.
ÏÏ
1
2
34
9
0
A
C
B
C
A
Ì
Ë
ÌËÊ
B-B C-C
A
8
7
7
765
8
8
9
È
É
Í
Î
C
C
B

–13 –
SPEC
CABLE ROUTING
ÍFasten the sub-wire harness 1 and differential
gear case breather hose with a plastic band.
ÎFasten the sub-wire harness 1, differential gear
case breather hose, coolant reservoir hose, and
coolant reservoir breather hose with a plastic
band.
Ï7 ~ 17 mm (0.28 ~ 0.67 in)
ÏÏ
1
2
34
9
0
A
C
B
C
A
Ì
Ë
ÌËÊ
B-B C-C
A
8
7
7
765
8
8
9
È
É
Í
Î
C
C
B