2008

SUPPLEMENTARYSERVICE MANUAL

YXR45FX

LIT-11616-21-21 2P5-F8197-12

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for theYXR45FX. For complete service information procedures it is necessary to use this SupplementaryService Manual together with the following manual.

YXR45FAV SERVICE MANUAL: LIT-11616-19-43 (2P5-F8197-10)YXR45FW SUPPLEMENTARY SERVICE MANUAL: LIT-11616-20-50 (2P5-F8197-11)

YXR45FXSUPPLEMENTARY SERVICE MANUAL

©2007 by Yamaha Motor Corporation, U.S.A.First edition, August 2007

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-11616-21-21

EBS00002

NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealersand their qualified mechanics. It is not possible to include all the knowledge of a mechanic in onemanual, so it is assumed that anyone who uses this book to perform maintenance and repairs onYamaha vehicle has a basic understanding of the mechanical ideas and the procedures of vehiclerepair. Repairs attempted by anyone without this knowledge are likely to render the vehicle unsafeand unfit for use.

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

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 dealersand will appear in future editions of this manual where applicable.

TIP:_

• This Service Manual contains information regarding periodic maintenance to the emission controlsystem. Please read this material carefully.

• Designs and specifications are subject to change without notice.

EBS00003

IMPORTANT INFORMATIONParticularly 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 injuryhazards. Obey all safety messages that follow this symbol to avoid possibleinjury or death.

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

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

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

WARNING

NOTICE

TIP:

EBS00004

HOW TO USE THIS MANUALMANUAL ORGANIZATIONThis 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 eachsection. 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 DIAGRAMSTo help identify parts and clarify procedure steps, there are exploded diagrams at the start of eachremoval 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-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 7 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 8 are given in addition

to the exploded diagram and the job instruction chart.

EBS00006

SYMBOLSThe following symbols are not relevant toevery vehicle. Symbols 1 to 0 indicate the subject of eachchapter.1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetion7 Drive train 8 Chassis 9 Electrical 0 Troubleshooting

Symbols A to H indicate the followingA Can be serviced with engine mounted B Filling fluid C Lubricant D Special tool E Torque F Wear limit, clearance G Engine speed H Electrical data (Ω, V, A)

Symbols I to P in the exploded diagramsindicate the types of lubricants and lubricationpoints.I Apply engine oil J Apply gear oil K Apply molybdenum disulfide oil L Apply brake fluidM Apply wheel bearing grease N Apply lithium-soap-based grease O Apply molybdenum disulfide greaseP Apply silicone grease

Symbols Q to R in the exploded diagramsindicate where to apply a locking agent Q andwhen to install a new part R.Q Apply the locking agent (LOCTITE®) R Replace

1 2

3 4

5 6

7 8

9 0

A B C

D E F

G H

I J K L

M N O P

Q R

GENINFO SPEC

CHKADJ ENG

COOL CARB

DRIV CHAS

– +ELEC TRBLSHTG

T R..

E G M BF

B LS M S

LT New

CONTENTS

SPECIFICATIONS .............................................................................................. 1GENERAL SPECIFICATIONS ..................................................................... 1TIGHTENING TORQUES............................................................................. 1

CHASSIS TIGHTENING TORQUES ..................................................... 1

CHASSIS ............................................................................................................ 2SEATS, ENCLOSURE, HOOD AND CARGO BED ..................................... 2

SEATS, CONSOLE AND INSTRUMENT PANELS ............................... 2SIDE DOORS......................................................................................... 4

– 1 –

SPEC

SPECIFICATIONSGENERAL SPECIFICATIONS

TIGHTENING TORQUESCHASSIS TIGHTENING TORQUES

Item Standard

Model code 2P5A, 2P5C, 2P5D

Part to be tightened Thread sizeTightening torque

RemarksNm m · kg ft · lb

Passenger seat and passenger handhold bracket M6 8 0.8 5.8 LT

Passenger handhold strap and passenger hand-hold bracket

M6 7 0.7 5.1 LT

Handle latch and side door M5 5 0.5 3.6Side door bracket and side door M6 7 0.7 5.1Frame and hinge M8 23 2.3 17 LT

Frame and latch M6 8 0.8 5.8 LT

GENERAL SPECIFICATIONS/TIGHTENING TORQUES

CHASSEATS, ENCLOSURE, HOOD AND CARGO BED

CHASSISSEATS, ENCLOSURE, HOOD AND CARGO BEDSEATS, CONSOLE AND INSTRUMENT PANELS

(16)

(5)

(8)

(4)

(4)LT

LT

14

5

6

7

2

16

17

1815

14

13

13

1011

9 8

12

3

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

35 Nm (3.5 m • kg, 25 ft • Ib)

T R..

8 Nm (0.8 m • kg, 5.8 ft • Ib)

Order Job/Part Q’ty RemarksRemoving the seats, console and instrument panels

Remove the parts in the order listed.

1 Driver seat 12 Passenger seat 13 Air intake duct 14 Console 15 Steering wheel cover 16 Steering wheel 17 Pedal cover 18 Light switch coupler 1 Disconnect.9 Main switch coupler 1 Disconnect.

10 On-Command four-wheel drive switch and differential gear lock switch

2 Disconnect.

11 Indicator/warning light coupler 2 Disconnect.

– 2 –

CHASSEATS, ENCLOSURE, HOOD AND CARGO BED

(16)

(5)

(8)

(4)

(4)LT

LT

14

5

6

7

2

16

17

1815

14

13

13

1011

9 8

12

3

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

7 Nm (0.7 m • kg, 5.1 ft • Ib)

T R..

35 Nm (3.5 m • kg, 25 ft • Ib)

T R..

8 Nm (0.8 m • kg, 5.8 ft • Ib)

Order Job/Part Q’ty Remarks12 Auxiliary DC jack connector 2 Disconnect.13 Nut/starter cable 1/114 Upper instrument panel 115 Lower instrument panel 116 Passenger handhold strap 117 Passenger handhold grip 118 Passenger handhold bracket 1

For installation, reverse the removal pro-cedure.

– 3 –

CHASSEATS, ENCLOSURE, HOOD AND CARGO BED

SIDE DOORS

LT

T R..

8 Nm (0.8 m • kg, 5.8 ft • Ib)

T R..

23 Nm (2.3 m • kg, 17 ft • Ib)

2

3

(4)

(4)

5

1

6

T R..

5 Nm (0.5 m • kg, 3.6 ft • Ib)T R.

.

7 Nm (0.7 m • kg, 5.1 ft • Ib)

New

1

4

New

4

1

LT

Order Job/Part Q’ty RemarksRemoving the side doors Remove the parts in order listed.

The following procedure applies to bothof the side doors.

1 Rubber protector 22 Side door 13 Handle latch 14 Side door bracket 25 Hinge 16 Latch 1

For installation, reverse the removal pro-cedure.

– 4 –

YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPAN

PRINTED IN U.S.A.