2004

YFM45FAS
YFM450FAS
5ND2-SE2

SERVICE
INFORMATION

Yamaha Motor Co., Ltd.

 FOREWORD

This service information has been prepared to introduce new service and data for the
YFM45FAS/YFM450FAS 2004. For complete service information procedures, it is
necessary to use this Supplementary Service Information together with the following
manual.

YFM45FAS/YFM450FAS 2004 SERVICE MANUAL: 5ND2-ME2

YFM45FAR/YFM450FAR 2003 SERVICE INFORMATION: 5ND2-SE1

Yamaha Motor Co., Ltd.

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 machine has a basic understanding of the mechanical ideas and the procedures of
machine repair. Repairs attempted by anyone without this knowledge are likely to render the
machine 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.

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 ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING Failure to follow WARNING instructions could result in severe injury or death
to the machine operator, a bystander or a person inspecting or repairing the
machine.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid
damage to the machine.
NOTE: A NOTE provides key information to make procedures easier or clearer.
 EB003000
1 2 ILLUSTRATED SYMBOLS
GEN Illustrated symbols 1 to 0 are printed on the
INFO SPEC top right of each page and indicate the subject
of each chapter.
3 4
1 General information
CHK ENG 2 Specifications
ADJ 3 Periodic checks and adjustments
4 Engine
5 6 5 Cooling system
6 Carburetion
COOL CARB 7 Drive train
8 Chassis
9 Electrical
7 8
0 Troubleshooting

DRIV CHAS
9 0

– + TRBL
ELEC SHTG
A B Illustrated symbols A to H are used to identify
the specifications appearing in the text.
A Can be serviced with engine mounted
B Filling fluid
C D C Lubricant
D Special tool
E Torque
F Wear limit, clearance
G Engine speed
E F H Ω, V, A
T.
R.

G H

I J K Illustrated symbols I to N in the exploded

diagrams indicate the types of lubricants and
lubrication points.
E G M I Apply engine oil
L M N J Apply gear oil
K Apply molybdenum disulfide oil
L Apply wheel bearing grease
B LS M
M Apply lithium-soap-based grease
N Apply molybdenum disulfide grease
O P Illustrated symbols O to P in the exploded
diagrams indicate where to apply a locking
LT
New agent O and when to install a new part P.
O Apply the locking agent (LOCTITE®)
P Replace
 CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

YFM45FAS/YFM450FAS WIRING DIAGRAM

 1

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard
Model code: 5ND7/5ND9: (for CDN)
5NDA: (for Europe)
5NDB: (for Oceania)
Chassis:
Frame type Steel tube frame
Caster angle 4°
Camber angle 1°
Kingpin angle 11°
Kingpin offset 0 mm (0 in)
Trail 21 mm (0.83 in)
Tread (STD) front 850 mm (33.46 in)
rear 825 mm (32.48 in)
Toe-in 0 ~ 10 mm (0 ~ 0.39 in)

–3–
 2

MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
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 ----
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) 3.0 ~ 4.0 mm (0.12 ~ 0.16 in) ----
Engine idle speed 1,450 ~ 1,550 r/min ----
Intake vacuum 32 kPa (240 mmHg, 9.45 inHg) ----
Cooling system:
Radiator core
Width 300 mm (11.8 in) ----
Height 208 mm (8.19 in) ----
Thickness 26 mm (1.02 in) ----
Radiator cap opening pressure 93.7 ~ 122.6 kPa (0.937 ~ ----
1.226 kg/cm2, 13.32 ~ 17.43 psi)
Radiator capacity 0.70 L (0.62 Imp qt, 0.74 US qt) ----
Coolant reservoir
Capacity 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) ----

CHASSIS
Tightening torques

Tightening torque
Part to be tightened Thread size Remarks
Nm m·kg ft·lb
Steering stem, pitman arm and frame M14 190 19.0 140 LS

Brake hose holder and steering knuckle M6 7 0.7 5.1

Brake hose holder and upper front arm M6 7 0.7 5.1

–4–
 3

MAINTENANCE SPECIFICATIONS SPEC

ELECTRICAL

Item Standard Limit

Ignition coil:
Model/manufacturer 2JN/YAMAHA ----
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.18 ~ 0.28 Ω at 20 °C (68 °F) ----
Secondary winding resistance 6.32 ~ 9.48 kΩ at 20 °C (68 °F) ----
Four-wheel drive relay 1:
Model/manufacturer G8HN-1C4T-DJ-Y52/OMRON ----
Coil winding resistance 94.5 ~ 115.5 Ω at 20 °C (68 °F) ----
Four-wheel drive relay 2:
Model/manufacturer G8HN-1C4T-DJ-Y52/OMRON ----
Coil winding resistance 94.5 ~ 115.5 Ω at 20 °C (68 °F) ----
Four-wheel drive relay 3:
Model/manufacturer ACA12115-1/MATSUSHITA ----
Coil winding resistance 72 ~ 88 Ω at 20 °C (68 °F) ----

–5–
 YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
YFM45FAS/YFM450FAS WIRING DIAGRAM
A B C D 1 A.C. magneto
2 Rectifier/regulator
W/B B B/R B/R B W/B Br Sb L/B L/B Sb Br O B B O W/R Sb Sb W/R 3 Main switch
R/BBr/B B/Y B/Y Br/B R/B
(GRAY) (GRAY)
L/W G/W G/W L/W
4 Backup fuse
(BLACK) (BLACK)
5 Battery
WIRE HARNESS
SUB-WIRE
HARNESS 1
WIRE HARNESS
SUB-WIRE
HARNESS 2
WIRE HARNESS
SUB-WIRE
HARNESS 3
WIRE HARNESS
SUB-WIRE
HARNESS 4 R/B L/W O B W Y/B G/W W/B 6 Main fuse
B/Y R W/R W/G B/R Lg G/L Sb G/R
7 Starter relay
(BLACK) (BLACK) (BLACK)
8 Starter motor
R R O C O B 9 Reverse switch
W/G
W/R W/R 0 CDI unit
W/G R R W/G
W/G W/G
L/W
B C B
C A Rear brake switch
W/R W/G W/L W/R R/B
G/W
0 B Ignition coil
1 C
W W R Y/B L/Y
W W W W 2 G/W G/R W W D Spark plug
D
W W B Sb B
W W W W
4
R R R
D
G/L Speed sensor
R R/G
5R R R G/W
W/B
B/R
P O/R
B/W
E Thermo switch 1
B R 6 L/W L/B
Lg F Meter assembly
W W W
7
(BLACK)
B L/W
L/Y W
B G Multi-function meter
H
B/Y B
B B L/B 9 Differential gear lock indicator light
I
R R
B/Y Coolant temperature warning light
3
J
B
OFF Br R R Br A Reverse indicator light
ON Br/L R R Br/L B
B
8 B B W/L
K Neutral indicator light
L Park indicator light
È
Br/L Br
B
B/Y B E
M High-range indicator light
Br W Sb G/L L/Y W/B
W/R Br
R/G G/R N Low-range indicator light
k O
L/W B/R W/L B
Br Br L/Y W W/L F (GRAY)
(GRAY) Low-range switch
P
OFF
ON
B B Br
G/L Sb W G/R R/G
High-range switch
Q
Br/L Br/L Br/L Br/L Br/L W/B L/Y
P
B
W/L B/R L/W Br W/R B Neutral switch
g d [ Z X R Br/B B/Y
(GRAY)
(GRAY) R Four-wheel drive fuse
S
Br/R Br/R
P B B Br/R B L/G Br/R B L/R
H I J K L M N
Four-wheel drive relay 1
l Br R/Y R/W
(BLACK) (BLACK) R/G
Br T Four-wheel drive relay 2
U
Br/R Br/R Br/R
R/B
P
Br/R Br/R B/R
W/B Four-wheel drive relay 3
B L Y R/Y S T G/L
Sb
G V On-command four-wheel drive switch and
R/B \ R/Y
R/B
R/W L/B Lg
B G L/B Br/B
B/Y
G/R
differential gear lock switch
Br Br

i h ] ^ a b Br Y L Y L/G
B
L/R
B W Gear motor
e OFF OFF OFF
L/B G B
X Auxiliary DC jack fuse
Y
Y Br B B Y Br B B W/R B
(BLACK) (BLACK) (BLACK) (BLACK)
R/B L PUSH PUSH
R/B R/W
L/W Auxiliary DC jack
Y Y (DARK GRAY) L
Lg
B
Br/R
L/R
Y/B
Gy D
D
Z Ignition fuse
L Y G B Y/B Gy U L/R G/R [ Headlight fuse
\
Br/R L/R Sb
R/W R/B
Lg
L/G Gy
Handlebar switch (left)
]
D
Y L
L/G L/R L/R L/G
Light switch
L Y G Y G
L/B Sb Sb L/B V Sb L/W W/R
^ Engine stop switch
(BLACK) (BLACK) 2WD
j f c c Gy G/R G/R Gy
4WD
LOCK
a Start switch
Y G Y G Br B B Br
Q P O b Override switch
c
L B B B (GRAY) (GRAY)
L/B Br B
Br/B Headlight
d
B B B Sb B
B
B L G Y G Y Br/B Circuit breaker (fan motor)
B B B
B B/Y Br/B
B e Thermo switch 2
f
B W/B A W/B
L/B Br
Sb B/Y
W/B B/R A B/R Fan motor
g Signaling system fuse
L/B B Br Sb
h Front brake light switch
W B/Y Br/B W/B B/R B i Rear brake light switch
B B j Tail/brake light
B
k Horn switch
A
B
l Horn

È For Europe and Oceania

COLOR CODE
B ............Black Gy ..........Gray G/R ........Green/Red R/G ....... Red/Green
Br ...........Brown W ...........White G/W........Green/White R/W ....... Red/White
G............Green Y ............Yellow G/Y.........Green/Yellow R/Y ........ Red/Yellow
L.............Blue B/R.........Black/Red L/B .........Blue/Black W/B ....... White/Black
Lg...........Light green B/Y.........Black/Yellow L/G .........Blue/Green W/G....... White/Green
O............Orange Br/B........Brown/Black L/R .........Blue/Red W/L ....... White/Blue
P ............Pink Br/L ........Brown/Blue L/W ........Blue/White W/R ....... White/Red
R ............Red Br/R .......Brown/Red L/Y .........Blue/Yellow Y/B ........ Yellow/Black
Sb ..........Sky blue G/L.........Green/Blue R/B.........Red/Black