Honda MUV700 big red Service Manual Download Page 581

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Summary of Contents for MUV700 big red

Page 1: ......

Page 2: ...w the procedures and precautions in thiS manual and other service materials carefully AWARNING Failure to property Iollow Instructions and precautIOns can cause you to be seriously hurt or killed Foll...

Page 3: ...on sel lice ifllormatlon Ind lroubles hootlrlg lor the section The SI Ibseqll6nl pages give deta1led pl oeedure t you r not lamMiar WIlli thiS vehICle read Tac mlca Features III seetiorI2 II you don k...

Page 4: ...lybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Example Molykole BR 2 plus manufactured by Dow Corning U S A Mutti purpose M 2 manulactured by Mitsubishi Oil...

Page 5: ...SPECIFICATIONS 9 DRIVETRAIN SYSTEM SPECIFICATIONS 9 FRONT WHEEL SUSPENSION SPECIFICATIONS 9 STEERING SYSTEM SPECIFICATIONS 9 REAR WHEEL SUSPENSION SPECIFICATIONS 9 BRAKE SYSTEM SPECIFICATIONS 0 FRONT...

Page 6: ...operation 8 Route all electrical wires as show in the Cable and Harness Routing page 1 21 ABBREVIATION Throughout this manual the following abbreviations are used to identify the respective parts or...

Page 7: ...SERIAL NUMBERS The Vehicle Identification Number VIN is stamped on the right front side of the frame the instrument panel The engine serial number is stamped on the right side of the rear crankcase GE...

Page 8: ...front side of the frame behind the instrument panel The color label is attached on the left front side of the frame behind the instrument panel When ordering color coded parts always specify the desig...

Page 9: ...lift Exhaust valve opens at 1 mm 0 04 in lift Exhaust valve closes at 1 mm 0 04 in lift Lubrication system Oil pump type Cooling system Air filtration i iicv E ngine dry weight FUEL DELIVERY Type GENE...

Page 10: ...ing system d 3 d Reverse Sub transmission o R system and e e Multi plate wet hydraulic clutch with electric controlled 1 333 64148 2 562 41f16 3 153 41 13 3 461 45 13 3 461 45 13 2 053 39 19 1 417 341...

Page 11: ...ECIFICATIONS Throttle body identification number GQ6AA Idle speed 1 400 100 rpm Accelerator pedal freeplay 5 10 mm 1 5 215 in ECT sensor resistance 20 C 68 F 2 3 2 6 ill Fuel injector resistance at 20...

Page 12: ...4 7335 1 36746 Cam follower 0 0 I 22 467 22 482 0 8845 0 8851 22 46 0 884 Follower bore 1 0 I N _ 2 510 22 526 0 8862 0 8868 22 54 0 887 Follower to bore clear IN EX 0 028 0 059 O OOll 0 0023 0 07 0 0...

Page 13: ...e at line 785 kPa 8 0 kgf cm 114 psi 5 000 rpm 1st 2nd and 3rd clutch 785 kPa 8 0 kgf cm 114 psO Shift clutch Initial clearance 0 7 0 9 0 03 0 04 1st 2nd and Disc thickness 1 88 2 00 0 074 0 079 worn...

Page 14: ...sh 0 05 0 25 0 002 0 010 0 4 0 02 r acklashdifference 0 2 0 01 REAR DRIVING MECHANISM SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE UMIT Rear final Oil capacity At draining 465 em 15 7 US 02 16 4 Im...

Page 15: ...TE M STANDARD Starter motor brush length _____ lhl 22 O 0 lIOO 477j1 _ __ 5 Un it mm in _ S ER iV ICE LIMIT 6 5 0 26 LIGHTS METERS SWITCHES SPECIFICATIONS ITEM SPECIFICATIONS Headlight 12V 30 30Wx2 Br...

Page 16: ...AD DIA mm 1 6 1 36 1 12 1 20 a TV THREAD I DIA mm 1 a TV THREAD DIA mm 1 5 Insulator band screw throttle body s do e l r Insulator band screw engine side 5 ECT sensor 10 COOLING SYSTEM a TV THREAD DIA...

Page 17: ...ap Oil passage sealing cap EDT sensor O TY 1 O TY 1 1 1 THREAD DIA mmJ 6 THREAD DIA mmJ 16 10 22 2 20 10 GENERAL INFORMATION TORQUE N m kgf m IbHt 12 1 2 9 TORQUE N m kgf m Ibf ft 108 11 0 80 14 1 4 1...

Page 18: ...ting bolt lock nut plate torx bolt out Q TY 8 4 4 2 2 4 4 2 2 13 18 2 4 4 6 8 14 4 10 4 6 2 5 Q TY 1 1 1 1 1 1 1 2 THREAD OIA lmmJ 10 10 10 10 10 12 7 1 6 7116 7 16 6 6 6 6 6 6 6 6 12 6 8 8 8 THREAD D...

Page 19: ...ighten until its grooves aligns with the cot ter pin hole ALOC bolt replace with a new one ALOe bolt replace with a new one ALOe bolt replace with a new one ALOC bolt replace with a new one Lock nut r...

Page 20: ...mounting bolt 8 27 2 8 20 ALOC bolt replace with a new one Stabilizer link nut 10 46 4 7 34 Lock nut replace with a new one BRAKE SYSTEM r ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m Ibf ftJ Bra...

Page 21: ...fferential lock clutch housing bolt 4 8 25 2 6 19 Drive mode selector lever pivot nut 1 8 26 2 7 20 Front differential lock cable nut 4 14 26 t2 7 20 REAR DRIVING MECHANISM ITEM O TY THREAD TORQUE REM...

Page 22: ...ransmission gear teeth and sliding surfaces Mainshaft countershaft and output shaft journals Primary driven gear lock nul threads and seating surface Torque converter sprag clutch Torque converter loc...

Page 23: ...final gear oil filler cap O ring Universal joint bearing Rear final gear case propeller shaft oil seal lips Rear final gear case drive shaft oil seal lips Rear final gear case cover O ring Rear diffe...

Page 24: ...e caliper cam bearing Rear brake caliper cam seal grocve reave Rear brake caliper cam dust seal 9 Rear brake caliper rod ends Rear brake caliper cup Brake master cylinder pistons and cups als i Brake...

Page 25: ...BLE HARNESS ROUTING HEADLIGHT 3P Black CONNECTOR Right Headlight RADIATOR SHROUD i 1 GENERAL INFORMATION FRONT HOOD FRAME Front ____ I FRONT HOOD 2 places c _ J LlGHT FRAME 2 places Left Headlight 1 2...

Page 26: ...GENERAL INFORMATION N b i7 t HEADLlGHT3P Black CONNECTOR GUIDE y c 1 ______ 0 1 22...

Page 27: ...WIRE RADIATOR RESERVE TANK tIlv I l 111 SIPHON HOSE ji d RADIATOR r I P 1 FRONT FINAL GEAR CASE UL jl BREATHER HOSE I COOLING FAN MOTOA BREATHER HOSE Pink GENERAL INFORMATION iii L III FOOT BRAKE SWIT...

Page 28: ...GENERAL INFORMATION WATER HOSE Iii FAN MOTOR WIRE _ lr f r i 06L1N ANMOTOR N Y S m COOLING FAN MOTOR BREATHER HOSE Pink GUIDES 0 1 24 FRONT FINAL GEAR CASE BREATHER HOSE SIPHON HOSE 11 GUIDES II...

Page 29: ...ENTIAL LOCK SWITCH WIRE F 0 1 D GENERAL INFORMATION STARTER MOTOR CABLE 1 ttjL GROUND I POINT J r DATA LINK CONNECTOR olC BATTERY H CABLE MODULE PCM BATTERY POWERTRAINCONTROl FAN MOTOR WIRE 0 FOOT BRA...

Page 30: ...33P Gray CONNECTOR PCM 33P Black CONNECTOR _ _ GROUNO __ 7 POINT 1 26 MAIN WIRE HARNESS l 4WD SELECT SWITCHI DIFFERENTIAL LOCK SWITCH WIRE HEADLIGHT WIRE _ J BATTERY 1 CABLE STARTER MOTOR _ y CABLE F...

Page 31: ...NESS SElECTOR LEVER if INDICATORS IGNITION SWITCH ___ LIGHTING DIMMER SWITCH GEAR REGULATOR RECTIFIER DIODE _ _ _ _ _ _ _ 3P Gray CONNECTOR m 3P Black CONNECTOR 1 FRONT DIFFERENTIAL 1 LOCK CABLE I REA...

Page 32: ......

Page 33: ...LOCK CABLE GEAR SELECTOR CABLE THROTILE CABLE _ o a o FRAME __ FRONT DIFFERENTIAL LOCK CABLE ___ FRONT FINAL GEAR CASE FRONTDIFFERENTIAL V F __ LOCK CABLE GEAR SELECTOR ___ CABLE REAR DIFFERENTIAL LO...

Page 34: ...R CABLE GROMMET 1 30 Inside of floor panel REAR DIFFERENTIAL FRONT DIFFERENTIAL LOCK CABLE ___ WATER HOSE GEAR e enR CABLE REAR DIFFERENTIAL LOCK CABLE o f4 f __ MAIN WIRE HARNESS STARTER MOTOR CABLE...

Page 35: ...E Clip Position THROTILE CABLE r REAR DIFFERENTIAL I LOCK CABLE MAIN WIRE f HARNESS MAIN WIRE HARNESS i 0 c E __ 1i B Clip Position GEAR SELECTOR CABLE 0 0 f 0 REAR DIFFERENTIAL LOCK CABLE STAR ER MOT...

Page 36: ...ack CONNECTOR ALTERNATORfCRANKSHAFT POSITION CKP SENSOR 5P Black CONNECTOR THROTIlE CABLE STARTER MOTOR CAB 4 J 4iWlP n 11 SHifT SOLENOID A e 2P Black CONNECTOR BATIERY CABLE i t 41 REAR DIFFEREN IA L...

Page 37: ...Front Up ft I Front GENERAL INFORMATION WATER HOSE I STARTER MOTOA CABLE 1fT Fronl BATTERY CABLE I STARTER MOTOR STARTER MOTOR CABLE GUIDE BATTERY H CABLE WATER HOSE THERMOSTAT u 9ht Q Green orange If...

Page 38: ...STAT FUEL PUMP 5P Gray CONNECTOR 1 34 STARTER MOTOR CABLE 2P Black CONNECTOR THROTTLE CABLE CLIP Clamp at marking position of thronle cable PARKING BRAKE 7 t tl ft JC c Y PARKING BRAKE LEVER CABLE Fro...

Page 39: ...LLER4 I GEAR POSITION D S TCH r r EDT SENSOR GENERAL INFORMATION ACCESSORY SOCKET 2P Green CONNECTOR k o L BAND 11 L __ If Gear position switch wire Alternator CKP sensor wire GROUND CABLE Frame ta En...

Page 40: ...SWITCH Around the throttle body Viewed from right rear side Around the fuel tank ACCESSORY SOCKET 2P Green CONNECTOR iCA 1 Viewed from right side j J AIR INTAKE DUCT e _____ FUEL TANK BREATHER HOSE J...

Page 41: ...se Viewed from right front side GENERAL INFORMATION _ ___ REARDIFFEAENTIAL LOCK CABLE r l ___ I _ REAR DIFFERE TIAL LOCK CABLE lfr UNDERBODY Up p _ 1 o REAR FINAL GEAR _ ii CASE BREATHER HOSE I L ____...

Page 42: ...NERAL INFORMATION e 1 38 Under side of cargo bed Viewed from left side CONNECTOR BOOT TAILLIGHT 6P Black CONNECTOR To taillights Viewed from right front side J CL 4 Ii fJ r i j I no l o o VS SENSOR WI...

Page 43: ...GENERAL INFORMATION Ii LEFT TAILLIGHT TAILLIGHT TAIL GA TAILLIGHT WIRE Front FRAME 1 39...

Page 44: ...GENERAL INFORMATION Front brake hose routing MASTER CYLINDER BRAKE HOSE CLAMP l KNUCKLE BRAKE HOSE 1 40 BRAKE CALIPER Left side CLAMP UPPER ARM...

Page 45: ...Front frame bake piping PIPE JOINT Right Front GENERAL INFORMATION Master cylinder B BR AKE PIPE Right Rear RETAINING PLATE o Outside 2 places left and right 1 41...

Page 46: ...GENERAL INFORMATION Underbody bake piping PIPE GUIDE BRAKE PIPE Right Rear Q BRAKE PIPE left Rear 1 42 BRAKE PIPE left Rear PIPE CUPS 5 places MASTER CYLINDER Front...

Page 47: ...ping BRAKE PIPE BRAKE PIPE Right Rear PIPE GUIDES 2 places aBRAKE PIPE Left Rear BRAKE PIPE left Rear r a BRAKE PIPE Right Rear i BRAKE PIPE left Rear o o Front J 1jc 2 5 mm minimum o BRAKE PIPE RighI...

Page 48: ...GENERAL INFORMATION lEFTPARKING BRAKE CABLE A I 1 44 Paring brake cable routing RIGHT PARKING BRAKE CABLE LEFTPARKING BRAKE CABLE lPARKING BRAKE LEVER...

Page 49: ...Rear brake hose and paring brake cable routing __ STOPPER CLAMP PARING BRAKE CABLE RETAINING PLATE 2 places left and right RETAINING PLATE STOPPER STOPPER CALIPER BRAKE CALIPER Left side CABLE HOLDER...

Page 50: ...ssion control system is composed of the PGM FI system and no adjustments should be made The exhaust emission control system is separate from the crankcase emission control system CRANKCASE EMISSION CO...

Page 51: ...parts other then those specified by the manufacturer FUEL PERMEATION EMISSION CONTROL SYSTEM This MUV complies with the Fuel Permeation Emission Control regulations of the U S Environmental Protectio...

Page 52: ...brake Position the floor jack under the center of the front frame crosspipe behind the under guard plate or the center of the rear end frame crosspipe IA or BI as shown and jack up the vehicle high e...

Page 53: ...2 TECHNICAL FEATURES MUV OVERViEW 2 2 AUTOMATIC TRANSMISSION SySTEM 2 7 PGM FI SySTEM 2 4 SELECTABLE 4WD AND DIFFERENTIAL LOCK SYSTEM 2 14 2 1...

Page 54: ...seals with retractable three points seat belt Tilting cargo bed Selectable 4WD and differential lock systems Front and rear independent double wishbone suspension OCCUPANT PROTECTEVE STRUCTURE OPS DOO...

Page 55: ...LUMN UNIVERSAL JOINTS J STEERING SHAFT STEERING GEAR BOX Rack and Pinion TIE RODS ELR Emergency Locking Retractor SEAT BELT The MUV is equipped with three point seat belts with ELR _ KNUCKlE The three...

Page 56: ...ntegrates the following sensors and device This throttle body has a compact design with simplified inspection capabilities MAP Manifold Absolute Pressure sensor detects the intake air pressure TP Thro...

Page 57: ...detects the following Throttle valve open Gear position switch is in gear position except neutral During engine idling and warm up from the time the ignition switch is turned ON the PCM controls the...

Page 58: ...es input signals that indicate the completion of engine warm up it operates the step motor to move the slide valve downward This results in a reduced amount of bypassed air compared to the amount duri...

Page 59: ...that detects the signal from each sensor and switch The hydraulic oil for this system is the engine oil which is supplied from the engine lubrication oil pump page 5 2 The valve body which incorporat...

Page 60: ...OR SHAFT PRIMARY DRIVE GEAR STOPPER PIN OPERATION PRINCIPLE Oil Flow The oil in the torque convener flows in this order from the pump to the turbine and then to the stator The oil is sup plied from th...

Page 61: ...en clutch fluid pressure rises during shifting It releases the pressure to reduce shift shock Emergency Valve The emergency valve is used when the hydraulic pressure is shut off by a faulty clutch PC...

Page 62: ...of the respective solenoid valves opera tion Gear in Neutral sition Clutch PC Solenoid Gear po NeuIral r ON Shift Solenoid A B OFF OFF Shift Clutch 2nd I 3 d The hydraulic passage is the same as the...

Page 63: ...valve AI idling the AfT clutch PC solenoid valve is on valve closed to eliminate vehicle creep At start up the AIT clutch PC solenoid valve controls the clutch hydraulic pressure to the linear valve a...

Page 64: ...ontrol valve 3rd Shift clutch q 2 3 Shift valve When shifting from 1st to 2nd pOSition the draining volume of the 1st clutch hydraulic oil is controlled by the ordinary orifice and the 2nd orifice con...

Page 65: ...rained by way of 1st Shift dutch 1 2 Shift valve 2nd Orifice control valve 2nd Shift clu tch 2 3 Shih valve q 3rd Orifice control valve When shifting from 2nd to 3rd position the draining volume of th...

Page 66: ...TOR LEVER ____ 3 mode Whettl REAR DIFFERENTIAL LOCK CLUTCH Rea Differential Engine f77 DRIVE __ I SHAFTS __ _ U v PROPELLER SHAFT _ ____ DRtVE 2WD 4WD SHAFTS FINAL CLUTCH Wheel DRIVE MODE SELECTOR LEV...

Page 67: ...of the clutch lock spring 4WDto 2WD Pulling the selector lever to 2WD returns the clutch arm shaft In lost motion state the clutch arm shaft SELECTOR stays in the 4WO position with the clutch sleeve...

Page 68: ...s ditferentiallock with the selector lever the shift fork slides the clutch sleeve to engage the differ ential gear housing in the final gear case with the half shaft connected to the right drive shaf...

Page 69: ...g differential lock by the ten sion of the fork spring Differential lock to Normal Operation Setting the selector lever to lock free returns the lock arm shaft to secure it with the stopper spring and...

Page 70: ...MEMO...

Page 71: ...D 3 14 SEAT CENTER COVER 3 5 FRONT GRILLE 3 15 SEAT UNDER COVER 3 6 FRONT BUMPER 3 16 ENGINE FRONT COVER 3 6 MAINTENANCE LID 3 16 PARKING BRAKE LEVER BRACKET 3 7 CARGO BED 3 16 CENTER FRAME COVER 3 7...

Page 72: ...rame bolt Side panel screw 6 x 13 mml Parking brake bracket socket bolt Floor cross plate socket bolt Muffler band bolt Exhaust pipe cover band screw TOOLS pinpliers I 07AAC SJAA100 U S A only TROUBLE...

Page 73: ...T HOOD page 3 14 16 FRONT GRILLE page 3 15 17 FRONT BUMPER page 3 16 1S MAINTENANCE LID page 3 16 19 CARGO BED page 3 16 20 SIDE NET page 3 21 21 OCCUPANT PROTECTIVE STRUCTURE page 3 21 22 SEAT BELT p...

Page 74: ...seat cushion by aligning the prongs onto the frame pipe then press down to lock it SEAT FRAME Remove the seat cushion page 3 4 Remove the following three bolts mounting rubbers and collars seat frame...

Page 75: ...or lower prongs onto the frame pipe Carefully align the bolt holes and install the bolts and tighten them SEAT CENTER COVER Remove the driver and passenger seal cush ions page 3 4 Raise the parking b...

Page 76: ...er cover Installation is in the reverse order of removal ENGINE FRONT COVER 3 6 Remove the seat under covers page 3 6 Remove the following three bolts and sub frame to get the space for front cover re...

Page 77: ...cket bolt 38 N m 3 9 kgf m 28 Ibf ft After installation adjust the parking brake lever page 4 21 CENTER FRAME COVER Unlock the cargo bed by pulling up on the release lever and then raise the bed Remov...

Page 78: ...ttle cable clip ignition coil wire and throttle body wire untie the wire band and release the ignition coil wire from the wire clip accessory socket 2P green connector Remove the four 10 mm nuts and b...

Page 79: ...g excessive force and opens smoothlv If necessary loosen the cap nuts and adjust the door panel position DOOR HINGE Remove the door panel page 3 9 Remove the following two socket boils and washers doo...

Page 80: ...s latch Release the spring end off of the bracket Remove the following lock pin locating pin collar spring handle collar rod Installation is in the reverse order of removal COLLAR LOCK PIN I LATCH LOC...

Page 81: ...e three 6 x 20 mm floor side two 6 x 18 mm seat side Remove the fuel fill cap right side only Release the side panel from the seat under cover carefully to remove it then install the fuel fill cap rig...

Page 82: ...Remove the following driver and passenger seat cushions page 3 4 side panels page 3 1 1 Remove the 23 setting screws four 6 x 18 mm seat side nineteen 6 x 18 mm floor bottom Release the floor panel fr...

Page 83: ...ase the retaining straps hood and open the front Remove the wire bands from the indicator cover and disconnect the following connectors lighting dimmer switch 4P green indicator lOP black indicator 6P...

Page 84: ...erse order of removal FRONT HOOD REMOVALIINSTAlLATION Release the retaining straps and open the front hood Remove the wire band from the frame and discon nect the headlight 3P black connector While su...

Page 85: ...bolts 6 x 14 mm long step four nuts and bolts 6 x 14 mm short step hood frame headlights page 24 4 Assembly is in the reverse order of disassembly FRONT GRILLE Release the retaining straps and open t...

Page 86: ...allation is in the reverse order of removal CARGO BED 3 16 BED DAMPER Unlock the cargo bed by pulling up on the release lever and then raise the bed Securely support the cargo bed with wooden blocks o...

Page 87: ...eing careful not to damage the brake taillights and release lever remove the cargo bed Set the cargo bed down on its bed frame Make sure rhe Installation is in the reverse order of removal rubber moun...

Page 88: ...g screws six trim clips bed base panel Installation is in the reverse order of removal TORQUE Screw 8 N m 0 8 kgf m 5 9 IbUt TRIM CUPS HOOKS f V o 7 _ e i c _ Qn I BOLTS _ _ NUTS i I 0 o o 0 1i SCREWS...

Page 89: ...and pivot pipe cap nut socket bolt washer and support cables socket bolts cable stay and lock lever Installation is in the reverse order of removal TORQUE Lock lever socket bolt 12 N m 1 2 kgf m 9Ibf...

Page 90: ...s from side face of the inner brackets nuts inside bolts outside release lever assembly from the cargo bed frame Remove the following from the release lever outer brackets separate them return springs...

Page 91: ...net retainers net Installation is in the reverse order of removal OCCUPANT PROTECTIVE STRUCTURE OPS TOPOPS BOLTS Remove the following side nets page 3 21 eight nut caps TOP eight nuts and bolts top OP...

Page 92: ...hen storing the vehicle outdoors cover the cabin area and keep the seat belt assemblies away from sunlight and rain Do not apply grease to the seat belt components To do so wilt cause dirt or sand to...

Page 93: ...24 Ibf ft After installing check the following the belt does not lock when pulled slowly and it will retract automatically when released The seat belt is designed to lock only during a sudden stop eac...

Page 94: ...e buckle bolt properly if it was disassembled TORQUE 32 N m 3 3 kgf m 24 Ibl ftl FUEL TANK PLATE COVER Remove the fuel tank page 6 40 Remove the following two trim clips and four bolts fuel tank plate...

Page 95: ...ter page 4 23 When the exhaust system will be separated loosen the muffler band bolts Remove the following two joint nuts two mounting nuts and bolts exhaust pipe muffler assembly gasket Separate the...

Page 96: ......

Page 97: ...ASSEMBLY ASSEMBLY NOTE For service of the spark arrester in the muffler see Maintenance section page 4 23 TORQUE Band screw 2 5 N m O 25 kgf m 1 8 IbHt FRONT EXHAUST PIPE COVER FRONT EXHAUST PIPE COVE...

Page 98: ...MEMO...

Page 99: ...SYSTEM 4 20 AIR CLEANER 4 6 UNDERBODY 4 22 AIR CLEANER HOUSING DRAIN TUBE 4 8 SUSPENSION 4 23 SPARK PLUG 4 8 SPARK ARRESTER 4 23 BATTERY 4 9 EXHAUST SYSTEM 4 24 VALVE CLEARANCE 4 10 WHEELS TIRES 4 24...

Page 100: ...e oil Engine oil capacity After draining EX 0 33 0 02mm 0 013 O OOl in i Pro Honda GN4 4 stroke 011 U S A and Canada or an equivalent motor oil API service classification SG or higher JASO T 903 stand...

Page 101: ...e torx bolt Wheel nut Rack guide screw Rack guide screw lock nut Tie rod end lock nut TOOL I Lock not w ench 07MAA SL00100 or 07916 SA50QOl U S A only 22 N m 2 2 kgf m 16Ibf ft 17 N m 1 7 kgf m 12 Ibf...

Page 102: ...I I and pi ots Ipage 4 291 Ithe I I Item components page 4 23 Wheels page 4 24 Drive shaft boots page 4 16 Accelerator throttle operation page 4 5 and brake pedals page 4 21 Foot brake switch page 4...

Page 103: ...ther end of the throttle cable Minor adjustments are made with the pedal side adjuster Release the retaining straps and open the front hood Slide the boot off the adjuster Loosen the lock nut turn the...

Page 104: ...ips and two lid springs from the air cleaner housing cover and remove the air cleaner cover Loosen the air cleaner element band screw and remove the air cleaner element assembly from the housing Remov...

Page 105: ...ver is in position and in good condition Install the element band onto the air cleaner ele ment and the element assembly over the connect ing tube flange of the housing securely Tighten the band screw...

Page 106: ...lower the cargo bed SPARK PLUG Clean with compressed air before removmg the plug and be sure that no debns Is allowed to enter Info the combustion chamber 4 8 Remove the seat center cover page 3 5 Dis...

Page 107: ...de carefully Thread the spark plug in by hand to prevent cross threading and tighten it with a spark plug wrench TORQUE 22 N m 2 2 kgf m 16 Ibf ft U H Connect the spark plug cap Install the seat cente...

Page 108: ...the crankcase cover index mark rotare Make sure the piston is at TDC Top Dead Center on the cranksnaft only the compression stroke clockwise again and This position can be obtained by confirming that...

Page 109: ...th oil and install them into the groove in each valve adjusting hole cap Install the valve adjusting hole caps and lighten the bolts securely Coat new O rings with oil and install them into the timing...

Page 110: ...l of 10 minutes Stop the engine and wait for 2 3 minutes Remove the driver seat cushion page 3 4 and release the rubber sheet from the tabs Remove the dipstick and wipe it clean Check the oil level by...

Page 111: ...nance lid page 3 16 driver seat cushion page 3 4 Start the engine and let it idle for a few minutes Stop the engine Remove the drain bolt and the filler cap release the rubber sheet from the tabs to d...

Page 112: ...page 4 13 Remove the engine front cover page 3 6 Place a oil pan Remove the following under the engme filter center bolt Ta e care not to filter cover lose the washer setting spring and spnng washer...

Page 113: ...er may cause engine damage Check to see if there are any coolant leaks when the coolant level decreases very rapidly If the reserve tank becomes completely empty there is a possibility of air getting...

Page 114: ...e the vehicle on a level surface Remove the oil fi ller cap and check that the oil level is up to the lower edge of the oil filler hole Check for leaks if the oil level is low Pour the oil through the...

Page 115: ...tiller hole Check for leaks if the oil level is low Pour the oil through the filler hole until it reaches the lower edge of the hole RECOMMENDED Oil Hypoid gear oil SAE 80 Coat a new O ring with grea...

Page 116: ...the caliper piston is pushed out and this causes a low reservoir level If the brake pads are not worn and the fluid level is low check entire system for leaks page 4 20 Release the retaining straps an...

Page 117: ...r Replace the brake pads if the wear limit groove of either pad is worn Qut Brake pad replacement page 18 8 FOOT BRAKE SWITCH Check that the brake light comes on just prior to the brake actually being...

Page 118: ...when oper ated bleed the system Bleeding procedure page 18 7 Release the retaining straps and open the front hood Unlock the cargo bed by pulling up on the release lever and then raise the bed Inspect...

Page 119: ...If the freeplay is not within standard value loosen pedal Pivot WI houl the lock nut and turn the adjusting bolt until the preSSing the master freeplay is within 1 5 mm cylmder lad Recheck the pedal...

Page 120: ...r brake caliper contacts the stopper pin The brake arm will contact the pin when the adjust ing nut is loosened Pull the parking brake lever 1 click 65 85 mm Tighten the adjusting nut until the brakes...

Page 121: ...d components that cannot be repaired Tighten all nuts and bolts SPARK ARRESTER Unlock the cargo bed by pulling up on the release lever and then raise the bed Remove the three bolts and the spark arres...

Page 122: ...mbedded nails or other damage Measure the tread depth at the center of the tires Replace the tires when the tread depth reaches the following limit MINIMUM TREAD DEPTH Front Rear 4 mm 0 2 in Raise the...

Page 123: ...owing tie rod page 16 14 and ball joint page 16 8 knuckle bearing page 15 10 STEERING SYSTEM GEAR BOX BOOT AND OPERATION CHECK Raise the front wheels off the ground page 1 48 Check the gear box boots...

Page 124: ...ale as shown and read it as soon as the front tires begin to turn INITIAL TURNING LOAD 13 7 N 1 4 kgf 3 1 Ibf If the scale reads more than the specification inspect the steering linkage and steering g...

Page 125: ...easure the toe on the rear part of the tires at the same points with no load on the vehicle TOE IN 0 10 mm 0 215 in NOTE The front and rear measurements are the same for this vehicle I Front Rear MAIN...

Page 126: ...dius gauge under the rear wheels then lower the vehicle Apply the parking brake Set the drive mode selector lever to the 2WD posi tion to free the differential lock Turn the wheels left and right with...

Page 127: ...go bed strikers 0 tailgate pivots page 3 19 E door ratches F brake pedal pivot page 18 28 G accelerator pedal pivot page 6 43 H parking brake lever pivot page 3 5 I drive mode selector lever pivots pa...

Page 128: ...MEMO...

Page 129: ...5 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 5 2 OIL PRESSURE CHECK 5 5 SERVICE INFORMATION 5 3 OIL PUMP 5 6 TROUBLESHOOTING 5 4 OIL COOLER 5 13 5 1...

Page 130: ...N SYSTEM LUBRICATION SYSTEM DIAGRAM CYLINDER HEAD COVER CAMSHAFT TORQUE COIWERTE R I BODY ROCKER ARMS REUEFVALVE OIL OIL COOLER CRANKSHAFT _ FLYWHEEU STARTER CLUTCH 2nd13rd SHIFT CLUTCH OIL STRAINER S...

Page 131: ...beyond the specified service limits replace the oil pump as an assembly After oil pump oil cooler andlor oil hoses have been installed check for oil leaks For oil level check oil change and filler re...

Page 132: ...oil leak Incorrect oil being used No oil pressure Oil level too low Oil pressure relief valve stuck open Broken oil pump drive chain Broken oil pump drive or driven sprocket Damaged oil pump Internal...

Page 133: ...e sure that no dirt enters the oit gallery Connect the oil pressure gauge and adapter to the oil gallery hole TOOLS Pressure gauge set 07406 0020005 U S A TOOLS Oil pressure 9auge 0 160 psi 07ZMJ HN2A...

Page 134: ...he oil pump will be disassembled loosen the two assembly bolts Remove the following three mounting bolts oit pump from the crankcase and release the driver chain three O rings strainer joint pipe rubb...

Page 135: ...lled In che inner rotor Oflgmal oC i1Ions drive pin two dowel pins pump body C outer rotor inner rotor drive pin pump body B pressure relief valve bolt driven sprocket LUBRICATION SYSTEM BODY 0 DOWEL...

Page 136: ...ing from the relief valve Check the operation of the valve by pushing on the piston Temporarily assemble each inner rotor outer rotor and drive pin on the pump shaft and install them into each pump bo...

Page 137: ...DRIVEN SPROCKET DRIVE PINS o Qi v DOWEl PINS I Y e PUMP BODY A P PUMP BODY B OUTER ROTORS PUMP BODye Coat all parts with clean engine oil Install the outer and inner rotors into the pump body A Inser...

Page 138: ...w O ring with engine oil and install it into the relief valve groove Install the relief valve into the pump body B Install the oil pump body B onto the pump body A Insert the drive pin into the pump s...

Page 139: ...Make sure that there is no clearance at the mating surfaces of the pump bodies Install the two assembly bolts INSTALLATION Coat a new O ring with engine oit and install it onlo the oil return pipe In...

Page 140: ...mp Place the driven sprocket on the oil pump onto the oil drive chain and install the pump onto the crank case by aligning the joint pipes with the joint holes properly Install the three mounting bolt...

Page 141: ...om the stay Remove the two joint bolts from each oit pipe ends Disconnect the oil pipes from the engine and oil cooler and remove them out of the frame Remove the O rings from the oil pipe Disconnect...

Page 142: ...ings ASSEMBLY Clean the ccoler housing cover and core fins with compressed air thoroughly Coat new O rings with engine oil and install them onto the joint collars Install the collars into the cooler h...

Page 143: ...ooler with the two bolts and tighten them securely Connect the water hoses to the oil cooler Coat new D rings with engine oil and install them into the grooves in each pipe ends Install the pipe A Ins...

Page 144: ...securely Install the hose clip and wire band into the stay Fill the engine with recommended oil page 4 14 Fill and bleed the cooling system page 7 5 Check the engine oil level page 4 12 Install the fo...

Page 145: ...6 42 LOCATION 6 7 ACCELERATOR PEDAL 6 42 PGM FI SYSTEM DIAGRAM 6 8 THROTTLE BODy 6 45 PGM FI CONNECTOR LOCATION 6 9 IACV 6 48 PGM FI TROUBLESHOOTING INFORMATION 6 11 FUEL INJECTOR 6 49 PGM FI DTC IND...

Page 146: ...FUEL SYSTEM PGM FI SYSTEM COMPONENTS 6 2...

Page 147: ...FUEL SYSTEM PGM FI 6 3...

Page 148: ...ter the throttle body has been removed Do not damage the throttle body It may cause incorrect throttle valve operation Prevent dirt and debris from entering the throttle bore IACV sensor hole and fuel...

Page 149: ...1 U S A Only Pressure gauge manifold 07ZAJ S5A0111 Not available in U S A Hose attachment B joint 07ZAJ S5A0150 Not available in U S A Adaptor female 07AAJ SSMA400 U S A only Test probe 2 pack 07ZAJ R...

Page 150: ...t the fuel supply system page 6 31 Check the ignition system 1 Inspect the fuel supply system page 6 31 2 Check the air cleaner for clog ging page 4 6 1 Check the idle speed page 6 55 2 Check the IACV...

Page 151: ...EL SYSTEM PGM FI PGM FI SYSTEM COMPONENT LOCATION IAT SENSOR VS SENSOF FUEL INJECTOR MAP SENSOR TP SENSOR FUEL CKP SENSOF GEAR pn tT N IGNITION SWITCH ECT SENSOR MAIN RELAY FUEL PUMP RELAY FUSE BOX 6...

Page 152: ...R ll l IAT SENSOR 91 ECT SENSOR 71 I EtE G E G 8 G BI Bl vee 814 TH 82 SG itr i j G m r G 813 LG 0 Bnro 0 8 0 PG2 PCM C l MIL Blink PCM C 3 BI Black 0 Orange 6 cb Br Brown R Red 9 Bu Blue V Violel G G...

Page 153: ...he connector must be removed to disconnect the connector OLC PCM 5P BU CKCONNECTQA PCM 33P BLACK CONNECTOR PCM 33P GRAY CONNECTOR PCM connectorsJDLC banery box cover page 21 6 Alternator 5P black conn...

Page 154: ...TOR SENSOR UNIT 5P BLACK CONNECTOR Injector 2P gray connector center frame cover page 3 7 EeT sensor 2P connector raise the cargo bed Sensor unit 5P black connector tAT sensor 2P black connector raise...

Page 155: ...is maintained by pre programed value in the simulated program map When any abnormality is detected in the fuel injector and crankshaft posi tion CKP sensor the fail safe function stops the engine to p...

Page 156: ...n and the MIL will start to blink as its oTC It is pos sible to readout the MIL blink pauern as the current OTC In case the PCM does not detect any problem at present but has a problem stored in its m...

Page 157: ...al tool TOOL SCS connector 070PZ ZV30100 CONNECTION Brown red Green 3 Turn the ignition switch to ON I 4 Remove the special tool from the OLC 5 The MIL will light for approximately 5 seconds While the...

Page 158: ...4 93 V IAT sensor connector of the fuel injector connector malfunction Symptom Fail safe function value Fail safe value 0 AfT shift function and anti creep function does not work 2nd gear I Fail safe...

Page 159: ...wn green wire for continuity between the wire harness side 5P black connec tor and 33P gray connector terminals TOOL Test probe 2 pack 07ZAJ RDJA110 Connection Brown green 83 Brow n green Is there con...

Page 160: ...P black connector 2 MAP Sensor System Inspection 2 Turn the ignition switch 10 OFF 0 Disconnect the sensor unit 5P black connector Connect the wire harness side 5P black connec tor terminals with a ju...

Page 161: ...tester Is about 0 V indicated YES GO TO STEP 2 NO Interminent failure 2 ECT Sensor Inspection Turn the ignition switch to OFF 0 Disconnect the ECT sensor 2P connector Turn the ignition switch to ON I...

Page 162: ...ction Turn the ignition switch to ON I Check the EeT sensor with the HDS pocket tester Is about 5 V indicated YES GO TO STEP 2 ND _ Intermittent failure Loose or poor contact on the ECT sensor 2P conn...

Page 163: ...se or poor contacts and recheck the OTC 1 TP Sensor System Inspection Turn the ignition switch to ON I Check the TP sensor with the HOS pocket tester with the throttle fully closed Is about 0 V indica...

Page 164: ...YES GO TO STEP 6 NO Open circuit in the Yellow gray wire 6 TP Sensor Output Une Short Circuit Inspection Brown green 83 IJJ PCM 33PGRAY CONNECTOR Brown green SENSOR UNIT 5P BLACK CONNECTOR Terminal si...

Page 165: ...n Turn the ignition switch to OFF 0 Disconnect the sensor unit 5P black connector Measure the TP sensor resistance between the sensor unit side 5P connector terminals Is the resistance within 1 0 3 0...

Page 166: ...n Turn the ignition switch OFF 0 Measure the resistance between the IAT sensor side connector terminals Standard 2 2 2 7 kO 20 C 68 F Is the resistance within standard value YES Replace the PCM with a...

Page 167: ...ith the HOS pocket tester Is about 0 V indicated YES Faulty IAT sensor NO GO TO STEP 3 3 IAT Sensor Open Circuit Inspection Turn the ignition switch to OFF 0 Remove the jumper wire Disconnect the PCM...

Page 168: ...3P black connector terminal and ground Connection Black ground H Is there battery voltage YES GO TO STEP 3 NO Open circuit in the Black wire 3 VS Sensor Ground Line Inspection Measure the voltage bet...

Page 169: ...d NO _ Intermittent failure Loose or poor contact on the fuel injector 2P gray connector YES GO TO STEP 2 2 Fuel Injector Resistance Inspection Turn the ignition switch to OFF 0 Disconnect the fuel in...

Page 170: ...here continuity YES Short circuit in the Green brown wire NO Replace the peM with a known good one and recheck DTC 29 lACV Before starting the troubleshooting check the IACV 4P black connector for loo...

Page 171: ...esistance Inspection Measure the resistance between the IACV side 4P connector terminals Connection 1A 1B 2A 2B Standard 120 140 n 20 C 68 F Is the resistance within the standard values YES GO TO STEP...

Page 172: ...TEP 2 NO Intermittent failure 2 Drive Power Input line Inspection Turn the ignition switch to OFF 0 Disconnect the PCM 5P black connector Turn the ignition switch to ON I Measure the voltage between t...

Page 173: ...il Ground line Short Circuit Inspection Disconnect the peM 33P gray connector Check for continuity between the Violet wire ter minal of the main relay relay box connector and ground 15 there continuit...

Page 174: ...e wire 619 terminal of the wire harness side connector with a jumper wire TOOL Test probe 2 pack 07ZAJ RDJA110 Turn the ignition switch to ON 1 and check the MIL Does the MIL come on YES Replace the P...

Page 175: ...e clamp and remove the screw and the hose clamp from the throttle body and feed hose FUEL SYSTEM PGM FI 4 Hold the connector with one hand squeeze the 1II1II1II III III g IIIIII retainer tabs with the...

Page 176: ...ase the I locking pawls from the connector and pull the connector off the fuel pipe 6 32 Prevent the remaining fuel in the fuel feed hose from flowing out with a shop towel Be careful not to damage th...

Page 177: ...nnector 2 Install a new joint rubber onto the fuel pipe 3 Install the connector on the fuel pipe straight and align the retainer grooves with the joint rubber tabs as shown Then press the connector on...

Page 178: ...Install the following center frame cover page 3 7 passenger seat under cover page 3 6 FUEL TANK SIDE 1 Insert a new retainer into the connector 2 Install a new rubber cover onto the fuel pipe as shown...

Page 179: ...ZAJ S5A0130 Attachment joint 6 mm 9 mm 07ZAJ S5A0150 U S A TOOLS Fuel pressure gauge 100 psi 07406 0040008 Pressure manifold hose 07AMJ HW3A100 Adapter male 07AAJ S6MA200 Adapter female 07AAJ S6MA400...

Page 180: ...ds at 12 V If the fuel flow is less than specified volume inspect the following fuel pump page 6 36 pinched or clogged fuel feed hose Connect the quick connect fitting to the fuel injector page 6 33 R...

Page 181: ...SYSTEM PGM FI FUEL PUMP 5P CONNECTOR Terminal side of the wire harness Brown Green H pump and ground terminal L _________________ J fuel pump relay and its circuits page 6 381 REMOVAL Remove the fuel...

Page 182: ...e the main relay and fuel pump relay from the relay box Installation is in the reverse order of removal RELAY INSPECTION FUEL SENDER WRENCH LOCK NUT Remove the main relay and fuel pump relay page 6 38...

Page 183: ...FUEL PUMP RELAY CIRCUIT INSPECTION 1 Power Input line Inspection Remove the fuel pump relay page 6 38 Turn the ignition switch to ON I Measure the voltage between the Black yellow wire terminals of th...

Page 184: ...uick connect fitting from the fuel injector page 6 31 Remove the following mudguard page 3 12 right side panel page 3 1 1 right rear wheel page 17 5 Release the breather hose from the clips Remove the...

Page 185: ...In cleaner housing and remove it from the connecting removal tube Remove the two duct mounting bolts and trim clip to loosen the intake air duct Loosen the connecting tube band screws Remove the thre...

Page 186: ...take air duct When Iflsraliing the Installation is in the reverse order of removal duct cap align the index lines CLIPS ACCELERATOR PEDAL REMOVAL INSTALLATION CAP Release the cable retainer Yellow by...

Page 187: ...oner pin and washer pivot shaft accelerator pedal return spring collar dust seals ASSEMBLY Coat the lips of new dust seals with grease Install the dust seals into the brake pedal with the flat side fa...

Page 188: ...ease to the groove in the pivot shaft Install the pedal into the bracket so the lower spring end is rest on the bracket by inserting the pivot shaft from the right side and align the flat surfaces of...

Page 189: ...ng injector 2P gray connector IACV 4P black connector sensor unit 5P black connector Remove the wire clip from the hose guide bracket Disconnect the quick connect fitting from the fuel injector page 6...

Page 190: ...l installation page 6 48 Fuel injector replacement page 6 49 TP sensor MAP sensor sensor unit replacement page 6 51 INSTALLATION WHITE PAIINT D SCREWS INJECTOR lACY TP SENSOR MAP SENSOR Align the pin...

Page 191: ...the groove Tighten the insulator band screw so that the dis tance between the band tabs is as shown Connect the throttle cable end to the throttle drum Install the throttle cable adjuster into the th...

Page 192: ...nition switch is turned ON I the IACV operates for a few seconds Remove the center frame cover page 3 n TheJACVoperaflOfl Turn the ignition switch to ON I and check the can be chedr ed IACV visually b...

Page 193: ...the IACV 4P black connector Install the center frame cover page 3 7 FUEL INJECTOR REPLACEMENT Relieve the fuel pressure page 6 31 1 Disconnect the quick connect fitting from the fuel injector page 6...

Page 194: ...ing on the injector Install the injector joint onto the injector being care ful not to damage the a ring Install the fuel injector assembly into the throttle body being careful not to damage the seal...

Page 195: ...tor Remove the three torx screws and the sensor unit from the throttle body Install a new D ring into the groove of the throttle body Install the a new sensor unit onto the throttle body by aligning t...

Page 196: ...ignition switch to ON I The MIL stars blinking reset receiving pattern Within 10 seconds after turning the ignition switch to ON I disconnect the jumper wire from the 2P connector 4 When the reset pro...

Page 197: ...ctor to the EeT sensor lower the cargo bed Fill the cooling system with the recommended cool ant page 7 5 VS SENSOR REMOVAL INSTALLATION Slide the connector cover off the VS sensor 3P black connector...

Page 198: ...be continuity at all times If there is no continuity check for an open circuit in the green wires POWER INPUT UNE Turn the ignition switch to ON Ul Measure the voltage between the wire harness side 3...

Page 199: ...e must be warm for accurate idle speed inspection This system eliminates the need for manual idle speed adjustment compared to previous designs Use a tachometer with graduations of 50 rpm or smaller t...

Page 200: ...MEMO...

Page 201: ...W PATTERN 7 2 SERVICE INFORMATION 7 3 TROUBLESHOOTING 7 3 SYSTEM TESTING 7 4 COOLANT REPLACEMENT 7 5 7 COOLING SYSTEM THERMOSTAT 7 7 WATER PUMP 7 9 COOLING FAN 7 11 RADIATOR 7 13 RADIATOR RESERVE TANK...

Page 202: ...COOLING SYSTEM SYSTEM FLOW PATTERN RADIATOR t I RES RVE TANK THERMOSTAT WATER PUMP 7 2...

Page 203: ...EM C oO o laCnCtCcC aC pcac cc ty Radiator and engine Reserve tank Radiator cap relief press u ___ ___ Thermostat Begin to open I open Valve lift Recommended antifreeze I SPECIACATIONS 3 3 liters 3 5...

Page 204: ...d open the front hood The engme must be Remove the radiator cap cool before removmg rhe radlBtor cap 7 4 Test the coolant gravity using a hydrometer STANDARD COOLANT CONCENTRATION 1 1 mixture of disti...

Page 205: ...pecified pressure for at least 6 seconds Remove the tester and install the radiator cap Close the front hood and secure it with the straps COOLANT REPLACEMENT PREPARATION I NOTICE I Using coolant with...

Page 206: ...serve tank and rinse the inside of the tank with water Install the reserve tank with the bolt by inserting the boss and rib into the frame Remove the bleed bolt and sealing washer from the thermostat...

Page 207: ...er page 3 6 Remove the following two bolts thermostat cover thermostat INSPECTION Visually inspect the thermostat for damage Replace the thermostat if the valve Slays open al room temperature Heat a c...

Page 208: ...is in good condition Apply coolant to the rubber seal and install the ther mostat into the housing aligning the bleed hole with the lug Install the thermostat and tighten the two bolts securely Fill...

Page 209: ...system page 7 6 Release the hose clip from the stay on the oil cooler Remove the bolt securing the water pipes Take care nor to Disconnect the front water hose from the water damage the water pump an...

Page 210: ...rning the impeller to engage the pump shafts Align the mounting bolt holes in the pump body and crankcase cover and be sure the water pump is fully seated Install a new D ring into the pump body groov...

Page 211: ...stay on the oil cooler Fill and bleed the cooling system page 7 5 Install the following engine front cover page 3 6 floor panel page 3 12 COOLING FAN REMOVAL INSTALLATION Remove the banery box cover...

Page 212: ...nd coltars Be careful not to Release the two mounting bosses of the shroud bot damage the radla or tom from the frame and remove the cooling fan fins assembly so the battery box is not interfered Rout...

Page 213: ...sur faces of the fan and shaft Apply locking agent to the motor shaft threads RADIATOR REMOVALIINSTALLATION NOTE Take care not to damage the radiator fins while servicing the radiator Drain the coola...

Page 214: ...l the fan motor page 7 11 Fill and bleed the cooling system page 7 5 RADIATOR RESERVE TANK REMOVAL INSTALLATION 7 14 Aelease the retaining straps and open the front hood Remove the reserve tank cap Re...

Page 215: ...8 ENGINE REMOVAL INSTALLATION SYSTEM COMPONENTS 8 2 ENGINE REMOVAL 8 4 SERVICE INFORMATION 8 3 ENGINE INSTALLATION 8 9 8 1...

Page 216: ...ENGINE REMOVALlINSTAlLATION SYSTEM COMPONENTS 32 N m 3 3 241bf ft 16 N m 1 6 12Ibf ft 8 2...

Page 217: ...ters 2 9 US qt 2 4 Imp qt ___ _ After draining filter I r ange 1 2 9 liters 3 1 US qt 2 6 Imp qt h After disassembly I Coolant capacity radiator and engine 4 1 titers 4 3 US qt 3 6 Imp qt 3 3 liters 3...

Page 218: ...page 5 13 exhaust system page 3 25 cargo bed page 3 17 throttle body page 6 45 Disconnect the negative H cable from the battery page 21 6 Remove the following from the engine EeT sensor 2P black conne...

Page 219: ...llernalor CKP sensor 5P black connector wire band release to free the gear position switch and alternalor CKP sensor wires mOlor cable clip release to free the cable rubber cap release from the termin...

Page 220: ...breather hose wire band from the cable holder VS sensor 3P black connector differential lock cable from the two cable clips Remove the two bolts and damper stay Support the gear case with wooden block...

Page 221: ...r differential lock switch connector breather hose loosen the two bracket bolts PO mm and remove the lower mounting nut and bolt 12 mm Remove the bracket bolts and mounting bracket Support the gear ca...

Page 222: ...following from each engine lower damage the brake mount pipeS of the left engine hanger nut and bolt engme mounting two hanger bracket bolts area hanger bracket mounting rubbers Make sure the engine w...

Page 223: ...ks damage Ihe frame end engine NOTICE Do not hold or s rike the solenoid valves on the shih valve body during engine removal Holding the solenoid valve or excessive shock may damage the solenoid valvB...

Page 224: ...olt TORQUE 54 N m 5 5 kgf m 40 Ibf ft engine side upper engine hanger bolts TORQUE 32 N m 3 2 kgf m 24 Ibf ft Coat a new O ring with molybdenum disulfide grease and install it into the output shaft gr...

Page 225: ...ENGINE REMOVAL INSTALLATION Connect the breather hose Connect the differential lock switch connector Connect the 4WO select switch connector 8 11...

Page 226: ......

Page 227: ...ipe hose securely Install the bolt to secure the water pipes Connect the water hose to the cylinder head ENGINE REMOVAL INSTALLATION Connect the ground cable to the engine with the r bolt and tighten...

Page 228: ...CTOR 6P CONNECTOR 5P CONNECTOR Connect the ground cable to the engine with the iiiiiiiii iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii bolt and tighten it 8 14 Install the gear selector arm by aligning the slit wi...

Page 229: ...smooth operation and adjust the selector cable jf necessary page 12 16 Install the following throttle body page 6 46 oil cooter page 5 15 exhaust system page 3 26 cargo bed page 3 17 front bumper page...

Page 230: ...MEMO...

Page 231: ...PLACEMENT 9 12 TROUBLESHOOTING 9 5 VALVE SEAT INSPECTION REFACING 9 13 CYLINDER COMPRESSiON 9 6 CAMSHAFT 9 16 CYLINDER HEAD COVER REMOVAL DISASSEMBLY 9 6 CYLINDER HEAD ASSEMBLy 9 19 CYLINDER HEAD REMO...

Page 232: ...CYLINDER HEADIVALVE CAMSHAFT SYSTEM COMPONENTS 22 N m 2 2 kgf m 16Ibf ft 12 N m 1 2 kgf m 9Ibf ft 32 N m 3 3 kgf m 24 Ibf ft 9 2...

Page 233: ...r head caver and cylinder head SPECIFICATIONS Uo mm On ITEM I L1MIl 05k 510 g ifi BO Valve I IN EX 33 0 02 0 013 001 Valve Valve stem 0 0 IN _5 475 5 490 p 2156 0 2161 5 45 215 valve guide I Valve gui...

Page 234: ...A 9 4 Valve guide driver 5 5 mm 07742 0010100 Flat cutter 38 5 mm 320 IN 07780 0012400 or equivalent commercially available in U S A Cutter holder 5 5 mm 07781 0010101 or equivalent commercially avail...

Page 235: ...inder head Leaking or damaged cylinder head gasket Loose spark plug Warped or cracked cylinder head Cylinder piston problem page 10 3 Compression too high overheating or knocking Excessive carbon buil...

Page 236: ...4 7 seconds COMPRESSION PRESSURE 550 kPa 5 6 kgflcm 80 psi at 350 rpm min Check that there is no leakage at the gauge connec tion low compression can be caused by blown cylinder head gasket improper...

Page 237: ...puSh rods gasket Marl the push rods so they C ln be placed back In rhell onglna locatlons dowel pins cam followers DISASSEMBLY Remove the two bolts and sealing washers Push the rocker arm shaft with t...

Page 238: ...shaft 0 0 SERVICE LIMIT 11 92 mm 0 469 in Measure each rocker arm 1 0 SERVICE LIMIT 12 05 mm 0 474 in Subtract each rocker arm shaft 0 0 from the corre sponding rocker arm 1 0 to obtain the rocker arr...

Page 239: ...03 in CYLINDER HEAD REMOVAL Remove the following cylinder head cover page 9 6 thermostat page 7 7 Disconnect the ECT sensor 2P black connector Remove the following ECT sensor and O ring bypass hose fr...

Page 240: ...all rhe parIS so they can be placed back In tflelr ongma locatlons Remove the following spring retainer inner and outer valve springs valve stem seal spring seat CYLINDER HEAD INSPECTION CYLINDER HEAD...

Page 241: ...hly in the guide Check the valve for bending burning or abnormal wear Measure each valve stem 0 0 and record it SERVICE LIMITS IN 5 45 mm 0 215 in EX 5 43 mm 0 214 in Ream the valve guide to remove an...

Page 242: ...w valve guides in a freezer for about an hour Heat the cylinder head to 130 C 140 C 275 F 290a F with a hOI plate or oven Do not heat the cyl inder head beyond 150 C 300 F Use temperature indicator st...

Page 243: ...ontact Remove the valve and inspect the valve seat face The valve seat contact should be within the speci fied width and even all around the circumference STANDARD 1 0 1 1 mm 0 039 0 043 in SERVICE LI...

Page 244: ...ter Using a 45 seat cutter remove any roughness or irregularities from the seat TOOLS Seat cutter 35 mm UN EX 07780 0010400 Cutter holder 5 5 mm 07781 0010101 or equivalent commercially available in U...

Page 245: ...LVE CAMSHAFT OLD SEAT WIDTH l 60 0 L Using a 45 seat cutter cuI the seat to the proper width VALVE SEAT WIDTH 1 0 1 1 mm O 039 0 043 in Make sure all pitting and irregularities are removed After cutti...

Page 246: ...h the special tool TOOL Tensioner holder B 070MG 0010100 or 07AMG 001A100 or U S A only 07AMG MFJA100 U S A only Refer to CylinderlPiston section for tensioner lifter service page 10 4 Remove the four...

Page 247: ...the decompressor cam should lock above the base of the exhaust cam lobe As you press on other side the decompressor cam lobe should extend below the base of the exhaust cam lobe INSTALLATION Careful...

Page 248: ...es with the dowel pins Place the camshaft assembly onto the cylinder and I install the cam chain over the sprocket while align ing the timing marks index lines on the sprocket with the cylinder top su...

Page 249: ...ith compressed air Install the valve spring seats and new stem seals Lubricate the valve stem sliding surface with molyb denum disulfide grease Insert the valve into the guide while turning it slowly...

Page 250: ...stems gently with two plastic ham ey mdor head so mers to seat the cotters firmly the valve heads will not COntBct anylhmg thaI cause damage CYLINDER HEAD INSTALLATION Ttghten rile cylmder head bolts...

Page 251: ...tat page 7 8 cylinder head cover page 9 22 CYLINDER HEAD COVER ASSEMBLY INSTALLATION ASSEMBLY EXHAUST ROCKER ARM SEALING WASHERS 8 SETITING BOLTS Coat new D rings with engine oil and install them Appl...

Page 252: ...olts securely INSTALLATION WAVE WASHERS ROCKER ARMS It SEALING WASHER ROCKER ARM SHAFT Turn the crankshaft using the recoil stater knob and 9 22 align the uT mark with the index notch then check the c...

Page 253: ...rod end Apply engine oil to the cap nut threads and seating surfaces and install the following fasteners four washers and cap nuts three new washers and seven bolts Tighten the nuts and bolts includi...

Page 254: ...VALVE CAMSHAFT 9 24 Connect the EeT sensor 2P black connector Connect the spark plug cap Install the following throttle body page 6 46 exhaust system page 3 26 crossbar page 3 8 parking brake lever br...

Page 255: ...SYSTEM COMPONENTS 10 2 SERVICE INFORMATION 10 3 TROUBLESHOOTING 10 3 10 CYLINDER PISTON CYLINDER PISTON REMOVAL 10 4 CYLINOER PISTON INSPECTION 10 5 CYLINDER PISTON INSTALLATION 10 8 10 1...

Page 256: ...CYLINDER PISTON SYSTEM COMPONENTS 10 2...

Page 257: ...oi 4 9 9 o o gap Second 0 40 0 5 5 1 0 0 6 0 022 0 7 0 03 Piston ring end Top 0 25 0 35 0 010 Oil side rail 0 20 0 70 0 008 0 028 0 9 O 04 Piston ring to ring 1 c Co p 0 045 0 080 0 0018 0 0 0 3 I___...

Page 258: ...the four bolts and clip stay cylmder head too cylinder hard and do not damage the mating surface WIth a screwdrIVer 10 4 cam chain guide gasket dowel pins PISTON REMOVAL Place a clean shop towel over...

Page 259: ...re for scratch or wear Measure the cylinder I D at three levels in an X and Y axis Take the maximum reading to determine the cylinder wear SERVICE LIMIT 102 05 mm 4 018 in Calculate the cylinder ta pi...

Page 260: ...the piston and measure the ring le ring groove clearance SERVICE LIMITS Top 0 095 mm 0 0037 in Second 0 075 mm 0 0030 in Insert the piston ring into the bottom of the cylinder squarely using the pist...

Page 261: ...not go into the lifter body when it is pushed When the shaft inside of the body is turned clock wise with a screwdriver the lifter shaft should be pulled into the lifter body The shaft should spring o...

Page 262: ...r the side rail end gaps as shown SECOND RING wa Oil RING f W PISTON INSTALLATION Place a clean shop towel over the crankcase to pre 1 _ vent the piston pin clip from falling into the crank case Apply...

Page 263: ...he cylinder wall piston outer surface and piston rings Be careful not 10 Route the cam chain through the cylinder and install damage the piston the cylinder over the piston while compressing the rmgs...

Page 264: ...the cam chain tensioner lifter with a new gas ket and tighten the two mounting bolts Coat a new O ring with coolant and install it on the waler pipe Connect the water pipe and secure it with the bolt...

Page 265: ...11 ALTERNATORISTARTER CLUTCH SYSTEM COMPONENTS 11 2 ALTERNATOR STATOR STARTER REDUCTION GEARS 11 5 SERVICE INFORMATION 11 3 FLYWHEEL STARTER CLUTCH 11 10 TROUBLESHOOTING 11 4 11 1...

Page 266: ...ALTERNATORISTARTER CLUTCH SYSTEM COMPONENTS 16 N m 1 6 kgf m 12Ibf ft 108 N m 11 0 kgf m 80 Ibf ft 11 2...

Page 267: ...IMIT r starter driven gear boss 0 0 51 705 51 718 2 0356 2 0361 51 6t 2 032 Torque limiter slip torque 53 84 N m 5 4 8 6 kgf m 39 62 Ibf ft TORQUE VALUES 30 N m 3 1 kgf m 22 Ibf ft Apply locking agent...

Page 268: ...200 not available in U S A TROUBLESHOOTING Attachment 24 x 26 mm 07746 0010700 Torque limiter attachment 0 070MJ HN80100 not available in U S A Starter motor turns but engine does not turn Faulty star...

Page 269: ...page 4 12 Disconnect the alternator CKP sensor 5P black con nector and release the wire from the two clips ALTERNATOR STARTER CLUTCH 5P CONNECTOR Disconnect the EOT sensor 2P black connector and ___...

Page 270: ...moval 11 6 dowel pins gasket starter torque limiter reduction gear gear shah INSPECTION Check the bearings in the alternator and rear crank case covers Turn the inner race of each bearing with your fi...

Page 271: ...ttl STATOR CKP SENSOR REMOVAL INSTALLATION Remove the CKP sensor socket bolts Release the wire grommet off the alternator cover Remove the four bolts and alternator stator CKP sensor assembly Install...

Page 272: ...936 3710200 Drive new Torque limiter bearings in with the marks facing up TOOLS Driver Attachment 24 x 26 mm Pilot 10 mm 01749 0010000 07746 0010700 07746 0040100 ALTERNATOR COVER INSTALLATION NOTE Ro...

Page 273: ...em in a crisscross pattern in several steps NOTE The location for the bolt with sealing washer is marked 6 on the cover Install the gear selector arm by aligning the slil with the index line of the sp...

Page 274: ...over page 3 6 Fill the engine with recommended oil page 4 12 FLYWHEEL STARTER CLUTCH REMOVAL 11 10 Remove the rear crankcase cover page 12 5 Hold the flywheel with the special tool and remove the bolt...

Page 275: ...gear while turning it clockwise Hold the flywheel with the special tool and remove the starter clutch bolts TOOL Flywheel holder on25 0040001 or equivalent commer cially available in U S A Remove the...

Page 276: ...to the clutch outer with the flanged side facing the flywheel side Apply locking agent to the starter clutch bolt threads Install the flywheel onto the clutch outer and the clutch bolts Hold the flywh...

Page 277: ...Install the flywheel staner driven gear by aligning the key way with the key on the crankshaft Apply engine oil to the flywheel boll threads and seating surface then install the washer and bolt Hold t...

Page 278: ...MEMO...

Page 279: ...SION GEARSHIFT LINKAGE SYSTEM COMPONENTS 12 2 SERVICE INFORMATION 12 3 TROUBLESHOOTING 12 4 REAR CRANKCASE COVER 12 5 SUB TRANSMISSION 12 9 GEAR SELECTOR LEVER LINKAGE 12 15 GEAR SELECTOR CABLE ADJUST...

Page 280: ...SUB TRANSMISSION GEARSHIFT LINKAGE SYSTEM COMPONENTS 12 N m 1 2 kgf m 9 Ibf ft 181bHt 12 2...

Page 281: ...93 5 00 0 194 0 197 Shaft D D G 0 9 SSi 10 984 0 4317 0 4324 I Reverse idle Collar 1 0 13 000 13 034 0 5118 0 5131 gear Shaft 0 0 12 966 12 984 0 5105 0 5112 L ____ __L C o r to sha ft I n e _____ _...

Page 282: ...n Drive position with the brake applied Wait several seconds Release the brake and check the vehicle condition Does the vehicle creep YES Perform the inspection Vehicle creeps when idling page 14 6 wh...

Page 283: ...switch 3P black con nector Remove the following EOT sensor and sealing washer oil filler hose from the pipe two bolts oil filler pipe and D ring Release the gear position switch wire from the wire cl...

Page 284: ...ngs replacement page 13 10 OUTPUT SHAFT BEARING Press the needle bearing out of the crankcase cover TOOLS Driver Attachment 28 x 30 mm Pilot 25 mm 07749 0010000 07946 870100 01146 0040600 Press in a n...

Page 285: ...urfaces Apply engine oil to the lips of new oil seals and install them into the crankcase cover until they are fully seated Coat new O rings with engine oil and install them into the joint collar groo...

Page 286: ...f ttl Temporarily install the gear selector arm and make sure the sub transmission is into neutral page 12 17 Coat a new O ring with engine oil and install it into the groove in the gear position swit...

Page 287: ...t TORQUE 12 N m 1 2 kgf m 9 Ibf ft Install the reduction gears and alternator cover page 11 8 Connect the gear position switch 3P black connec tor Connect the front propeller shaft page 8 10 Install t...

Page 288: ...T LINKAGE 12 10 shih fork shaft shift fork countershaft assembly washer output shaft output driven gear Remove the oil seal from the front crankcase cover Remove the shift drum while lifting the stopp...

Page 289: ...aft INSPECTION COUNTERSHAFT Check the gear dogs and teeth for abnormal wear or damage Check the gear shifter for smooth operation Check the gear shifter groove dogs and splines for abnormal wear or da...

Page 290: ...e gear la shaft clearance SERVICE LIMIT 0 10 mm 0 004 in SHIFT FORK AND SHAFT Check shift fork guide pin for abnormal wear or damage Measure each shift fork claw thickness SERVICE LIMIT 4 5 mm 0 18 in...

Page 291: ...nde line facing the snap ring aligning the wide groove with the wide tooth Install the gearshift spindle and rest it onto the stop per on the crankcase Install the washer onto the spindle Apply engine...

Page 292: ...PUT DAIVE GEAR BEARING 20 x 24 x 1 3 WASHER BEARI NG 20 x 24 x11 Install the countershaft assembly by engaging the r splines Apply engine oil to the fork shaft outer surface Before Installation Instal...

Page 293: ...SELECTOR LEVER LINKAGE DISASSEMBLY Remove the gear selector lever grip Loosen the cable nuts Remove the following cotter pin and washer gear selector cable collar Loosen the lever pivot nut Be carefu...

Page 294: ...arm pivot bolt washer bolt Install the selector lever assembly and the bolt w hile hold the lever Tighten the arm pivot bolt washer bolt Tighten the lever pivot nut TORQUE 26 N m 2 7 kgf m 20 Ibf ft I...

Page 295: ...m will be vertical neutral mdlcator comes on at this r me Do not move the Without applying force to move the cables gradu selector lever from ally screw the cable nuts together by hand until they the...

Page 296: ...MEMO...

Page 297: ...ANKCASE CRANKSHAFT BALANCER SYSTEM COMPONENTS 13 2 CRANKSHAFT 13 7 SERVICE INFORMATION 13 3 CRANKCASE BEARING REPLACEMENT 13 10 TROUBLESHOOTING 13 5 CRANKCASE ASSEMBLy 13 12 CRANKCASE SEPARATION 13 6...

Page 298: ...CRANKCASE CRANKSHAFT BALANCER SYSTEM COMPONENTS 13 2...

Page 299: ...ervicing SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Crankshaft Runout 0 05 0 002 0 15 0 059 Big end side ctearance 0 05 Big end radial clearance 0 006 TOOLS Remover weight 07741 0010201 or...

Page 300: ...l00 U S A only 13 4 Pilot 20 mm 07746 0040500 Pilot 40 mm 07746 0040900 Ball joint remover installer 07WMF HNOQ100 Threaded adaptor 07965 VM00300 or 07931 KF00200 U S A only f Pilot 28 mm 07746 004110...

Page 301: ...ngine noise Worn or damaged connecting rod bearing Worn crankshaft main journal bearing Worn connecting rod small end Worn balancer bearing Worn seized or chipped transmission gear Worn transmission b...

Page 302: ...oil pump drive chain pivot bolt cam chain tensioner and collar Tile crankcase bolts nine rear crankcase bolts are loosened In a Cflsscross palrem In several steps Do not orr the crankcase apart with 8...

Page 303: ...ershaft Refer to Drivetrain System section for mainshaft and countershaft page 14 47 Be careful nor 10 Remove the crankshaft and balancer from the rear damage the crankcase using a hydraulic press Be...

Page 304: ...ndicator SERVICE LIMIT 0 15 mm 0 059 in Measure the side clearance between the connecting rod big end and crank weight with a feeler gauge SERVICE LIMIT 0 8 mm 0 03 in Measure the radial clearance at...

Page 305: ...sides of the balancer drive and driven gears as shown and install them together into the rear crankcase Assemble the special tools onto the crankshaft Draw the crankshaft into the bearing inner race...

Page 306: ...ARING bearings with the special tools 13 10 TOOLS Balancer and Shift Drum Bearings Bearing remover 17 mm 07936 3710300 Remover handle 07936 3710100 Remover weight Mainshaft Bearing Bearing remover 20...

Page 307: ...8 mm Pilot 28 mm FRONT CRANKCASE 07749 0010000 07746 0010500 07746 0041100 Remove the balancer and countershaft bearings with the special tools TOOLS Balancer Bearing Bearing remover 17 mm Remover han...

Page 308: ...8 x 90 mm Balancer Bearing Driver Attachment 37 x 40 mm Pilot 17 mm 07749 0010000 07GAO SD40101 07149 0010000 07746 0010200 07746 0040400 CRANKCASE ASSEMBLY 13 12 Before installing the front crankcase...

Page 309: ...ApplV liquid sealant Three Bond 1215 or equiv8 II lent to the mating surface of the front crankcase I Install the front crankcase over the rear crankcase aligning the oil strainer pipe with the pipe...

Page 310: ...the flange side of the collar facing to the crankcase and tighten the bolt Install the oil pump drive and cam chains onto the crankshaft Install the following oil pump page 5 11 1st shift clutch and t...

Page 311: ...ETRAIN SYSTEM DIAGRAM 14 12 DRIVETRAIN CONNECTOR LOCATION 14 13 DRIVETRAIN TROUBLESHOOTING INFORMATION 14 15 DRIVETRAIN DTC INDEX 14 16 DRIVETRAIN DTC TROUBLESHOOTING 14 17 SHIFT VALVE BODY 14 28 FRON...

Page 312: ...DRIVETRAIN SYSTEM SYSTEM COMPONENTS 101bf ft 118 N m 12 0 kgf m 87Ibf ft 108 N m 11 0 kgf m 80 Ibf ft 21 N m 2 1 kgf m 15 Ibf ft 14 2...

Page 313: ...faulty Front final clutch and differential lock clutch service page 19 17 Rear differential lock clutch service page 20 15 Drive mode selector lever service page 19 42 Sub transmission Forward Neutral...

Page 314: ...01 or 07936 371020A or 07936 3710200 U S A only Pilot 25 mm 07746 0040600 Bearing remover handle 07936 3710100 Anachment 42 x 47 mrn 0774 0010300 Driver 07749 0010000 Bearing remover 17 mm 07936 37103...

Page 315: ...HDS pocket tester TDS 3557 0112 01 U S A only Test probe 2 pack 07ZAJ ROJA l 0 DRIVETRAIN SYSTEM 14 5...

Page 316: ...ck the 1st shift clutch system page 14 47 Driving power falls o ff Check the AfT clutch PC solenoid valve operation when starting insuffi page 14 6 cienl engine brake Check the 1st clutch oil pressure...

Page 317: ...tery to the solenoid valve cannec tor terminals as shown The AfT clutch PC solenoid valve should operate sound when the battery is connected SHIFT SOLENOID VALVE OPERATION INSPECTION Remove the valve...

Page 318: ...and oil leaks will cause low oil pressure readings Check the oil level and add the recommended engine oil if necessary page 4 12 Warm the engine to normal operating temperature and check for external...

Page 319: ...all the sealing bolt with a new sealing washer and tighten it Install the engine front cover page 3 6 SHIFT CLUTCH Oil PRESSURE Remove the left side panel page 3 1 Support the vehicle using a hoist or...

Page 320: ...oil pressure I 1st clutch o il pressure 2nd clutch oil pressure 3rd clutch oil pressure I AIT clutch PC solenoid valve 0 Emergency valve 0 2 shift valve 0 0 2 3 shift valve 0 0 Shift solenoid valve A...

Page 321: ...NT LOCATION TP SENSOR SHIFT SOLENOID VALVE A SHIFT SOLENOID VALVE 8 REAR VS SENSOR EOT SENSOR GEAR POSITION SWITCH peM AIT CLUTCH PC SOLENOID VALVE DRIVETRAIN SYSTEM BAITEAY MAIN RELAY FUSE BOX FOOT B...

Page 322: ...TCH BUG MAIN SlOPLAMPSW All GIV B BflBr V5I 116 G 3 LO aENYll At G G AEARVS G SENSOR 11 PCM c C 3 MIL Blink A A 11 e A 12 A 22 B 12 8 22 BI Blad 0 Orange P Pink c OODODO B l1 Sr Brown Bu Blue G Green...

Page 323: ...below the connector must be removed to disconnect the connector peM 5P BUICK CONNECTOR peM 33P o c CONNECTOR peM 33P GRAY CONNECTOR peM connectorsIDLC battery box cover page 21 6 pLJ I J EDT SENSOR C...

Page 324: ...ID VALVE 2P BLACK CONNECTOR Gear position switch 3P black connector engine front cover page 3 6 AfT clutch PC solenoid valve 2P black connector left side panel page 3 Shift solenoid valve 2P connector...

Page 325: ...em opera tion of both systems The drivetrain system is equipped with the self diagnostic system When any abnormality occurs in the AfT system the peM turns on the MIL and stores a DTe in its erasable...

Page 326: ...r does not work 2nd gear only connector Rear VS sensor or its circuit malfunction 15 1 15 Shift solenoid valve A short AfT shift function and anti creep function 14 19 Shift solenoid valve A or its ci...

Page 327: ...1 or 4 3 indicated YES GO TO STEP 2 NO Intermittent failure 2 AfT Clutch PC Solenoid Valve Inspection Turn the ignition switch to OFF 0 Disconnect the AIT clutch PC solenoid valve 2P black connector M...

Page 328: ...C with the HOS pocket tester Is OTC 4 1 or 4 3 indicated YES Replace the PCM with a new one and recheck NO Interminent failure DTC 4 2 IAIT CLUTCH PC SOLENOID VALVE HIGH INPUT Recheck OTC Test drive t...

Page 329: ...YES Replace the PCM with a new one and recheck NO Intermittent failure DTe 15 1 SHIFT SOLENOID VALVE A SHORT Recheck DTC Test drive the vehicle and stop the engine Recheck the current DTC with the HDS...

Page 330: ...ck NO Intermittent failure DTC 15 2 SHIFT SOLENOID VALVE A OPEN Before starting the troubleshooting check the shift solenoid valve A 2P black connector for loose or poor contacts and recheck the DTC 1...

Page 331: ...ck the OTC with the HDS pocket tester Is OTC 15 2 indicated YES Replace the PCM with a new one and recheck NO Intermittent failure DTe 16 1 SHIFT SOLENOID VALVE B SHORT 1 Recheck OTe Test drive the ve...

Page 332: ...inent failure DTC 16 2 SHIFT SOLENOID VALVE B OPEN Before starting the troubleshooting check the shift solenoid valve B 2P brown connector for loose or poor contacts and recheck the DTC 1 Recheck OTe...

Page 333: ...e B 2P brown con nector and PCM 33P black connector Erase the OTC page 6 13 Test drive the vehicle and stop the engine Recheck the DTC with the HDS pocket tester Is DTe 16 2 indicated 7 YES Replace th...

Page 334: ...he DTG w ith the HDS pocket tester Is OTC 3 1 1 indicated 7 YES Replace the PCM with a new one and recheck NO Intermittent failure DTC 32 1 FAIL SAFE RELAY CIRCUIT 1 Recheck OTe Erase the OTe page 6 1...

Page 335: ...ch 3P black connector GEAR POSITION SWITCH 3P BLACK Check for continuity between the switch side 3P CONNECTOR Terminal side of the switch black connector terminals and ground There should be continuit...

Page 336: ...or Resistance Inspection Turn the ignition switch to OFF 0 Measure the resistance between the sensor side 2P connector terminals Standard 2 5 2 8 kO 20 C 68 Fl 15 th8 resistance within standard value...

Page 337: ...the EOT sensor with the HDS pocket tester Is about 0 V indicated7 YES Faulty EDT sensor NO GO TO STEP 3 3 EOT Sensor Line Open Circuit Inspection Turn the ignition switch to OFF 0 Remove the jumper wi...

Page 338: ...e vehicle creeps dur ing idling The stopper bolt that operates the emergency vallis is secured with the lock plate When trou ble occurs remove the lock plate and turn the stopper bolt all the way in t...

Page 339: ...embly gasket fou r oil joint collars O rings DISASSEMBLYIINSPECTION NOTE Keep dust and dirt away from all the parts Take care not to damage the mating surfaces of the valve bodies SOLENOID AND EMERGEN...

Page 340: ...ENOID VALVE B CONNECTOR 12VBATIERY EB 8 12 V BATIERY Terminal side of the solenoid valve Air should not flow the pressure should be main tained while the battery is connected and should flow out of th...

Page 341: ...and lock plate valve stopper bolt LOCK PLATE emergency valve valve spring Wash aU the parts with a high flash point or non fl ammable solvent and blow dry them with com pressed air to clean completel...

Page 342: ...shih valves 1 2 and 2 3 81owthrougha lrhe Wash all the parts with a high flash point or non oil passages flammable solvent and blow dry them with com thoroughly pressed air to clean completely 14 32...

Page 343: ...BODY SHIFT VALVE 12 3 X SHIFT VALVE 1 2 __ SEPARATOR PLATE SPRING SEAT _ _ _ _ VALVE SPRING J VALVE SPRING IV 1l0 J r ORIFICE CONTROL SPRINGSEAT V VALVEI2nd ORIFICE CONTROL ORIFICE CONTROL VALVE 3rd...

Page 344: ...with the spring seats the shift valve body page 14 33 14 34 Install the four sealing bolts into the solenoid valve body with new sealing washers Install the following two dowel pins separator plate s...

Page 345: ...ith the valve body surface Secure the stopper bolt with the lock plate as shown and tighten the screw O RING II SPRING 1 EMERGENCY VALVE Coat a new rubber seal with engine oil and install it Aff C L U...

Page 346: ...damage them Coat new O rings with engine oil and install them into the grooves in the oil joint collars Install the four joint collars and a new gasket Install the shift valve body assembly with the...

Page 347: ...at under cover page 3 6 FRONT CRANKCASE COVER REMOVAL Remove the following exhaust system page 3 25 oil cooler page 5 13 water pump page 7 9 front propeller shaft page 19 12 shift valve body page 14 2...

Page 348: ...air to clean them thoroughly INSPECTION Check feed pipes A Band C for abnormal wear or damage NOTE The operating engine oil of each shift clutch is supplied through the following feed pipe A for the...

Page 349: ...to the cover surface of the groove properly collaf Drive new bearings in with the marked side facing up TOOLS Crankshaft bearing Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 Pilot 17 mm 07...

Page 350: ...and install it into the crankcase cover until it is fully seated Coat new O rings with engine oil and install them onlo the joint pipes Inslallthe joint pipes into the oil pump SEALING BOLTS WASHERS...

Page 351: ...g surfaces Install the fourteen bolts and tighten them in a criss touch evenly There cross pattern in several steps should be no clearance between rfle cover and crankcase Coat a new O ring with engin...

Page 352: ...nstall the setting cap and tighten it TORQUE 21 N m 2 1 kgf m 15Ibf ft Install the following shift valve body page 14 36 front propeller shaft page 19 39 water pump page 7 10 oil cooler page 5 15 exha...

Page 353: ...r damage Hold the torque converter and turn the drive gear to check the one way clutch in the torque converter The gear should turn counterclockwise smoothly and should not turn clockwise Check the ne...

Page 354: ...age Assemble the stator shaft and inner collar Hold the inner collar and turn the stator shaft The shaft should turn counterclockwise smoothly and should not turn clockwise TORQUE CONVERTER INSTALLATI...

Page 355: ...facing in Install the washers Install the two needle bearings into the stator shaft from both sides Install the needle bearing onto the stator shaft Install the stator shaft onto the crankshaft and th...

Page 356: ...oil to the threads of a new lock nut Install the lock nut and tighten it while holding the converter boss with an open end wrench width across flats 32 mm TORQUE 118 N m 12 0 kgf m 87 rbl ttl Stake t...

Page 357: ...n end wrench width across flals 29mm Remove the following lock nut washer lsI shift clutch assembly washer Ml gear guide a rings Remove the primary driven gear by prying it Remove the O rings from the...

Page 358: ...2ndJ3rd shift clutch assemblv O rings SHIFT CLUTCH DISASSEMBLY NOTE The following procedures are for the 1st clutch The procedures for the 2nd and 3rd clutches are the same as for the 1st clutch Remov...

Page 359: ...than necessary The MI gear bearing has one roller miSSing from each cage by deSign Loosen the nut and remove the special tools snap ring spring retainer and return spring Wrap a shop lowel around the...

Page 360: ...the clutch plates Check the oil holes in the drum boss and check valve in the piston for clogs CLUTCH DISC AND PLATE Check the linings of the clutch discs for wear disc groove disappearance Check the...

Page 361: ...G WAVE SPRING SPRING RETAINER r jVA SNAP RING RETURN SPRING 2nd 3rd SHIFT CLUTCH DRIVETRAIN SYSTEM CLUTCH PLATES 3 pes I PRIMARY DRIVEN GEAR O RINGS CLUTCH PISTON CLUTCH PISTON DRUM CLUTCH PLATES 3 pe...

Page 362: ...facing in Be careful nor tD Install the piston while turning it to ensure proper ponel the O rings seating wnh too much I Place the return spring spring retainer and snap ring into the clutch drum Ins...

Page 363: ...d plate up against the stopper ring and read the clearance and record it Perform this inspection at the three points in 120Q apart STANDARD 0 7 0 9 mm 0 03 0 04 in If the clearance is not within the s...

Page 364: ...mm 1 9mm 13 2 75 mm 2 2 0mm 1 3 05 mm 3 35 mm 16 3 65 mm Install the end plate into the drum Install the stopper ring into the drum grooves prop erly COUNTERSHAFT ASSEMBLY STOPPER RING END PLATE LOCK...

Page 365: ...needle bear ing and install the following needle bearing C2 gear thrust washer C1 gear end washer Install the countershaft assembly page 13 10 MAINSHAFT ASSEMBLY Blow through the oil passages in the...

Page 366: ...into the grooves in the driven gear boss Install the driven gear into the 1st shift clutch until it is fully seated Apply engine oil to the gear teeth and install the Ml gear guide and washer onto the...

Page 367: ...ge 3 6 Disconnect the gear position switch 3P black con nector Release the gear position switch wire from the clamps Shift the sub transmission into neutral Remove the two bolts and the gear position...

Page 368: ...ge 4 13 Remove the maintenance lid page 3 16 Disconnect the 2P black connector from the EDT sensor Remove the EDT sensor and sealing washer Install a new EOT sensor with a new sealing washer and tight...

Page 369: ...WHEEL SUSPENSION SYSTEM COMPONENTS 15 2 SERVICE INFORMATION 15 3 TROUBLESHOOTING 15 5 FRONT WHEEL 15 6 TIRES 15 6 FRONT WHEEL HUB AND KNUCKLE 15 10 FRONT SUSPENSION ARM 15 17 FRONT SHOCK ABSORBER 15...

Page 370: ...COMPONENTS 12 N m 1 2 Ibf ft 11 N m 1 1 kgf m 8Ibf ft 108 N m 11 0 kgf m l N m 1 1 kgf m 8Ibf ft 49 N m 5 0 kgf m 36 Ibf ftl 15 2 49 N m 5 0 137 N m 14 0 kgf m 101 IbUt Ibf ft 1 N m 1 1 kgf m B Ibf ft...

Page 371: ...shaft outboard guard at caliper Drive shaft guard bolt at lower arm Shock absorber mounting nut Brake hose damp bolt Upper and lower arm pivot nut Upper and lower arm ball joint nut Tie rod joint nut...

Page 372: ...joint remover 28 mm 07MAC Sl00200 15 4 Attachment 62 x 64 mm 07947 6340400 or 07AMO HLlA100 U S A only Installer attachment 07LAD PW50601 Ball joint remover installer 07JMF HC501 O ATV Bead Buster KlS...

Page 373: ...aulty shock absorber pivot bushings Improperly installed suspension arms Faulty suspension arm bushings Front suspension noise Faulty front shock absorber Loose front suspension fasteners Worn suspens...

Page 374: ...he lire from the rim side opposite the valve stem Remove the core from the valve stem Use a pneumatic tire changer or equivalent to remove the tire from the rim If a tire changer is not available rim...

Page 375: ...k two turns to allow the shoe to clear the rim s bead which may cause lock rhe re 0 leak Push down on the leverage bar to push the tire bead over the bead lock Use only short strokes on the handle Whi...

Page 376: ...Do this three times Do not let the cement dry Insert and center a rubber plug through the eye of the inserting needle Apply cement to rubber plug Push the inserting needle with plug into the injury u...

Page 377: ...irty or greasy hands Remove the lining from the patch and center over the injury Press the patch against the injury using a special roller ASSEMBLY Install the tire onto the rim where the rim shoulder...

Page 378: ...the cal per Remove the following so thallI does no two setting bolts and outboard guard hang from the brake two mounting bolts and brake caliper hose Do not tWIst or bend the brake hose cotter pin hub...

Page 379: ...Ball joint remover 28 mm 07MAC SL00200 Apply grease 10 the ball joint remover at Ihe point shown This will ease installation of the tool and prevent damage to the pressure bolt threads Insert Ihe jaw...

Page 380: ...ghten the pressure bolt with a wrench until the ball joint stud pops loose Remove the ball joint nuts and the knuckle INSPECTION Remove the dust seals from the knuckle Turn the inner race of the beari...

Page 381: ...64 mm Driver attachment 07749 0010000 07947 6340400 or 07AMD HllAl00 U S A only Install the snap ring into the knuckle groove with the chamfered side facing in BALL JOINT REPLACEMENT Remove the snap r...

Page 382: ...mover installer of the tool so that the ball joint can go into the remover installer and try again Install the snap ring with the chamfered edge facing in INSTALLATION Install rhe mner seal Coat the t...

Page 383: ...the joint nut Tighten the joint nut to the specified torque and fur ther tighten until its grooves align wi th the cotter pin hole TORQUE 49 N m 5 0 kgf m 36 IbHt Install a new cotter pins Install th...

Page 384: ...install the wheel hub threads 15 16 Install the hub nut and tighten it to the specified torque and further tighten until its grooves align with the cotter pin hole TORQUE 137 N m 14 0 kgf m 101 IbUt...

Page 385: ...m yet Loosen the pivot nuts and shock absorber mounting nuts To prevent the wheel hub knuckle assembly from falling hang it with a strap Release the ball joints using the special tool accord ing to th...

Page 386: ...PECTION Check the pivot bushings for wear or damage For ball jOint Inspect the ball joint boot on the upper arm for tears repl8cemenl page or other damage by moving the ball joint stud 15 IB It should...

Page 387: ...over installer Ball joint base I NOTICE I 01JMF HC50110 01JAF SH20200 If you feel strong resistance when lowering the press stop Reset the jOint base of the tool so the ball joint head can go into the...

Page 388: ...20 porting the lower arm so that the distance between the centers of the shock absorber mounting bolt holes is 394 mm 15 5 in After adjusting the angle tighten all the upper and lower arm pivot faste...

Page 389: ...e the shock absorber assembly if necessary INSTALLATION Install new dust seals into the lower pivot with the lips side facing out until they are fully seated Apply molybdenum disulfide grease to the l...

Page 390: ...MEMO...

Page 391: ...SYSTEM COMPONENTS 16 2 SERVICE INFORMATION 16 3 TROUBLESHOOTING 16 4 STEERING WHEEL 16 5 16 STEERING SYSTEM STEERING COLUMN AND SHAFT 16 5 TIE ROD BALL JOINT 16 7 STEERING GEAR BOX 16 9 16 1...

Page 392: ...STEERING SYSTEM SYSTEM COMPONENTS 39 N m 4 0 49 N m 5 0 kgf m 36Ibf ft 16 2 29Ibf ft 27 N m 2 8 kgf m 20 Ibf ft 36Ibf ft 27 N m 2 8 kgf m 20 Ibf ft 49 N m 5 0 kgf m 36 Ibf ft...

Page 393: ...Outward 33 reference Toe Toe in 0 10 mm 0 2 5 in TORQUE VALUES Steering whee nut Steering column mounting bolt Steering shaft pinch bolt Tie rod joint nut Rack end joint Steering gear box mounting nut...

Page 394: ...ear box or column components Incorrect wheel alignment page 4 27 Faulty suspension or wheel components page 15 5 and 17 4 Steering wheel wobbles loose steering wheel or column fasteners Worn steering...

Page 395: ...ING COLUMN AND SHAFT REMOVAL Remove the steering wheel page 16 5 WASHER J Y SHAFT Raise the front wheels off the ground page 48 Release the retaining straps and open the front hood Remove the followin...

Page 396: ...the they are damaged check the steering wheel and steering shaft splines also Check that the universal joint moves smoothly with out binding or noise Check the steering shaft for deformation or other...

Page 397: ...RQUE Mounting bolt 27 N m 2 8 kgf m 20 Ibf ft Pinch bolt 27 N m 2 8 kgf m 20 Ibf hj Install the steering wheel page 16 5 Check that the steering wheel rotates smoothly from lock to Iock without bindin...

Page 398: ...he strap on the brake hose brake pipe rubber boot and other parts that can be damaged easily Once the tool is in place turn the adjusting bolt as necessary to make the jaws parallel Then hand tighten...

Page 399: ...ur ther lighten until its grooves align with the cotter pin hole TORQUE 49 N m 5 0 kgf m 36 Ibf ft Install new cotter pin Install the fran wheel page 15 6 Adjust the wheel alignment page 4 27 STEERING...

Page 400: ...over bolt clutch arm cover by releasing the two tabs adjusting nut cable retaining plate 2WDf4WD selector cable remove from the cable holder and joint pin cable spri ng joint pin base boils arm cover...

Page 401: ...ith wooden blocks and remove the upper mounting nul and bolt 12 mm Move the gear case assembly forward for maximum clearance between the propeller shaft joint and engine Pull the shaft joint out of th...

Page 402: ...ve damage the tle od the four mounting nuts and bolts then disconnect boots and shaft in9 the steering shaft splines Remove the gear box assembly out of the frame to the left 16 12 Remove the mounting...

Page 403: ...t clip and the tie rod boot loosen the rack end joint of the tie rod while hold ing the steering rack to remove the tie rod Remove the lock washer Remove the following lock nut rack guide screw cone w...

Page 404: ...s shown arrows evenly to remove the steering pinion bearing assembly Do not reuse the pinion and or bearing Remove the following steering rack end bushing Clean the disassembled pans with a high flash...

Page 405: ...out binding or noise ASSEMBLY NOTE Keep dust and dirt out of the gear box housing GUIDE SPRING CONE WASHER RACK GUIDE SCREW LOCK NUT _ li lml LOCK WASHER TIE ROD STEERING SYSTEM TIE ROD DUSTCOVER DUST...

Page 406: ...the gear box housing slowly in damage the the direction as shown busfHng by rhe rack end edge 5 10 g Apply grease to the needle bearing in the gear box 16 16 housing and the ball bearing on the steeri...

Page 407: ...PG20120 Pack 2 5 9 of grease in between the dust seal and cover shadowed area Be sure the dust Install the dust cover and fit it into the pinion cover does not groove comact the gear box housing STEE...

Page 408: ...aligned from the center of the lock washer it will cause the tool to pop our Set the components in a hydraulic press properly and hold the special tool and gear box securely TOOL l ock w asher clinch...

Page 409: ...ailable pincher Oetiker 1098 or equiva PINCHER lent until the pinched area clearance is 1 3 5 mm as shown to secure tie rod boot Install the other side boot in the same procedure as above Slide the ra...

Page 410: ...louch each bracket onto the frame and lighten all the fasteners TORQUE 39 N m 4 0 kgf m 29 Ibf ft 16 20 Install the pinch bolt with the lock washer and tighten it TORQUE 27 N m 2 8 kgf m 20 Ibf ft Co...

Page 411: ...t Install the holder bracket and cover base with the two bolts and tighten them TORQUE 10 N m 1 0 kgf m 7 Ibf ft STEERING SYSTEM 10mm BOLTS Sel the drive mode selector lever to the 2WD posi r __ tion...

Page 412: ...ING SYSTEM 16 22 Connect the breather hose Connect the differential lock switch connector Connect the 4WD select switch connector Install the following tie rod ball joints page 16 9 front bumper page...

Page 413: ...17 REAR WHEEL SUSPENSION SYSTEM COMPONENTS 17 2 REAR WHEEL HUB KNUCKLE 17 5 SERVICE INFORMATION 17 3 REAR SUSPENSION ARM 17 11 TROUBLESHOOTING 17 4 REAR SHOCK ABSORBER 17 16 REAR WHEEL 17 5 17 1...

Page 414: ...m 6 5 kgf m 47 Ibf ft ___ ____64 N m 6 5 kgf m _ 47 I 12N m 1 2kgf m ___ 9lbf hl lJ Il 49 N m 5 0 kgf m _ _ 36 Ibf ft 137 N m 14 0 c 44 N m 4 5 kgf m 33 Ibf ft I 27 N m 2 8 kgf m 20 Ibf ft J j 46 N m...

Page 415: ...ose clamp bolt Upper arm pivot nut lower arm pivot nut frame side lower arm pivot nut knuckle side Stabilizer arm mounting bolt Stabilizer link nut Rear brake caliper mounting bolt TOOLS Driver 07749...

Page 416: ...pension Damaged shock absorber damper Faulty shock absorber pivot bushings Improperly installed suspension arms Faulty suspension arm bushings Rear suspension noise Faulty rear shock absorber Loose re...

Page 417: ...surfaces of the wheel and hub thoroughly Install the wheel and the nuts with the tapered side facing inward and tighten them TORQUE 108 N m 111 0 kgf m 80 IbUt REAR WHEEL HUB KNUCKLE REMOVAL Remove t...

Page 418: ...ket bolts splash guard lower arm pivot nut and bolt upper arm pivot nut and bolt knuckle from the drive shaft INSPECTION Remove the seal caps and pivot collar Check the pivot collar and bushings for w...

Page 419: ...ON wheel hub DISC Install a new brake disc with the stamp mark faCing the hub Install new disc bolts and tighten them TORQUE 42 N m 4 3 kgf m 31 IbUt BEARING REPLACEMENT Remove the snap ring Press the...

Page 420: ...340201 or 07AMO HllAl00 U S A only Apply molybdenum disulfide grease to the sliding surfaces of the lower bushings and install them into the knuckle until they afe fully seated Install new dust seals...

Page 421: ...pivot bolts Install new pivot nuts and tighten them TORQUE Upper ann 64 N m 6 5 kgf m 47 IbUt Lower ann 44 N m 4 5 kgf m 33 Ibf ft Install the splash guard with new bolts and tighten them TORQUE 11 N...

Page 422: ...ith molybde on the drl l6shafr nurn disulfide grease and install the wheel hub threads Install the hub nut and tighten it to the specified torque and further lighten until its grooves align with the c...

Page 423: ...he rear wheel page 17 5 REAR SUSPENSION ARM REMOVAL Remove the rear wheel page 17 5 Support the wheel hub knuckle assembly securely LOWER ARM Remove the following lower arm pivot nut and bolt to disco...

Page 424: ...holding the stud bolt end rear shock absorber page 17 16 upper arm pivot nuts and bolts upper arm while disconnecting the stabilizer link STABILIZER ARM AND LINK Remove the following link nuts while...

Page 425: ...or other damage by moving the ball joint stud INSTALLATION NOTE The upper and lower arm pivot fastener tighten ing is performed after adjusting the suspension arm angle page 17 15 STABILIZER ARM AND...

Page 426: ...ts while inserting the stabilizer link from the outside of into the upper arm Ihearm Insert the knuckle Side Pivot bolt from the rear Side 17 14 Connect the upper arm to the knuckle with the pivot bol...

Page 427: ...5 SUSPENSION ARM FASTENER TIGHTENING REAR WHEEL SUSPENSION Adjust the suspension arm angle with a jack sup 1 porting the lower arm so that the distance between the centers of the shock absorber mounti...

Page 428: ...r INSPECTION Check the pivot bushings for wear or damage Check the damper unit for leaks or other damage Replace the shock absorber assembly if necessary INSTALLATION Insert the bolts Install the shoc...

Page 429: ...18 2 MASTER CYLINDER 18 11 SERVICE INFORMATION 18 4 FRONT BRAKE CALIPER 18 15 TROUBLESHOOTING 18 5 REAR BRAKE CALIPER 18 19 BRAKE FLUID REPLACEMENT BRAKE PEDAL 18 27 AIR BLEEDING 18 6 PARKING BRAKE LE...

Page 430: ...BRAKE SYSTEM SYSTEM COMPONENTS I Front Rear 49 N m 5 0 kgf m 36 Ibf ft 108 N m 11 0 kgf m 80 Ibf ft 34 N m 3 5 kgf m 25 Ibf h 11 N m 1 1 kgf m 8 Ibf ft 18 2...

Page 431: ...BRAKE SYSTEM o i Cl C 0 C C t C 18 3...

Page 432: ...height from accelerator pedal Parking brake lever locked clicks TORQUE VALUES Brake hose oil bolt Caliper bleed valve Brake pipe joint nut Master cylinder brake pedal bracket mounting nut Master cylin...

Page 433: ...deformed brake disc Sticking worn caliper piston Sticking worn master cylinder piston Snap ring pliers 07914 SA50001 Incorrect pedal height adjustment page 4 21 Brake pedal hard Clogged restricted br...

Page 434: ...ve the rubber cap out of the reservoir tank Remove the reservoir cap by turning it counter clockwise Remove the bleed valve cap Connect the bleed hose to the caliper bleed valve loosen the bleed valve...

Page 435: ...valve has been closed Install the valve cap Perform the above procedure at each remaining bleed valve 3 places After bleeding air operate the brake pedal If it still feels spongy bleed the system aga...

Page 436: ...ylmder reservoir as thiS operation causes the fluid level to flS8 FRONT BRAKE PAD REPLACEMENT Remove the front wheel page 15 6 Push the caliper piston all the way in by pushing the caliper body agains...

Page 437: ...om the caliper bracket Remove the brake pads from the caliper bracket Always replace rhe Install new pads onto the caliper bracket properly so brake pads mp8IfS the wear indicator on the inner pad is...

Page 438: ...lly inspect the brake disc for damage or crack Measure the brake disc thickness at several points SERVICE LIMIT 6 0 mm 0 24 in Replace the brake disc if the smallest measurement is less than service l...

Page 439: ...fluid page 1S 6 Remove the cotter pin and joint pin to disconnect the push rod Loosen the joint nuts to disconnect the brake pipes Remove the two mounting nuts bolts and master cylinder from the fram...

Page 440: ...ngs for damage Check the master cylinder and piston for scoring scratches or damage ASSEMBLY RESERVOIR SECONDARY PISTON PRIMARY PISTON t 1AP RING CUPS SPRING SNAP RING 1 sHROO SECONDARY PISTON ASSEMBL...

Page 441: ...f the joint pin hole and rod end is 91 1 mm After adjustment tighten the lock nut TORQUE 17 2 N m 1 8 kgf m 13 Ibf ft Apply 0 1 g of silicone grease to the boot groove in the push rod Install the boot...

Page 442: ...der with the mounting bolts and the nut aligning the push rod slit with the brake pedal Connect the brake pipes to the master cylinder with the joint nuts Tighten the mounting nuts then tighten the jo...

Page 443: ...nd outboard guard Disconnect the brake hose by removing the oil bolt and sealing washers loosen the two slide pin bolts Remove the two mounting bolts and brake caliper Remove the two slide pin bolts a...

Page 444: ...he pad retainers Place a shop towel over the piston Position the caliper body with the piston down and apply small squirts of air pressure to the fluid inlet to remove the piston Remove the piston boo...

Page 445: ...ck the caliper cylinder and piston for scoring scratches or damage ASSEMBLY PIN BOLTS BRAKE PADS CALIPER BODY PISTON SEAL SLICE PIN A BOOT PAD RETAINERS PISTON BOOT CALIPER PISTON BRAKE SYSTEM CALIPER...

Page 446: ...then push the piston and set the out side boot rib into the boot groove in the piston to seat the piston Instatllhe pad retainers onto the bracket Install new pin boots into the grooves in the bracke...

Page 447: ...rake hose to the brake caliper with the oil bolt and new sealing washers and tighten it TORQUE 34 N m 3 5 kgf m 25 IbUt Install the outboard guard with new bolts and tighten them TORQUE 11 N m 1 1 kgf...

Page 448: ...move the washer bolt and cable holder Disconnect the brake hose by removing the oil bolt 18 20 and sealing washers Remove the two mounting bolts and the brake cali per Loosen the two slide pin bolts R...

Page 449: ...e caliper piston by turning it counter clockwise using the special tool or equivalent TOOL Lock nut wrench 07716 0020100 Remove the piston boot Be careful not to Push the piston seal in and lift it ou...

Page 450: ...ing return spring nut spring washer brake arm brake cam dust seat Clean the seal and boot grooves caliper cylinder and disassembled parts in clean brake fluid INSPECTION Check the caliper cvlinder and...

Page 451: ...ly 0 1 9 of silicone grease to the groove in a new dust seal and install it into the caliper body Apply 0 1 9 of silicone grease to the seal groove in the brake cam and install it with the rod hole fa...

Page 452: ...ed edge facing in TOOL Snap ring pliers 07914 SA50001 Coat a new piston seal with clean brake fluid and install it into the seal groove in the caliper cylinder Pack the inside of a new piston boot wit...

Page 453: ...racket so the wear indicator on the inner pad is facing the upper side Install the caliper body onto the caliper bracket with the slide pin bolts Install the brake caliper onto the knuckle with new mo...

Page 454: ...e parking brake cable into the holder by aligning the flat surfaces and connect it to the brake arm Secure the cable with the retaining plate Install the holder cover with new bolts and tighten them T...

Page 455: ...rake pedal assembly with the four bolts and two nuts aligning the pedal arm with the push rod slit Tighten the fasteners alternately TORQUE 27 N m 2 8 kgf m 20 Ibf ft Connect the push rod to the pedal...

Page 456: ...the brake pedal with the flat side facing out until they are fully seated Apply grease to the groove in the pivot shaft Install the brake pedal into the bracket by inserting the pivot shaft from the l...

Page 457: ...re from the two clips Remove the adjusting nut and the joint pin while moving the lever upward to disconnect the brake rod Remove the rod spring Remove the two bolts and parking brake lever Route the...

Page 458: ...MEMO...

Page 459: ...REMOVAL 19 12 FRONT PROPELLER SHAFT 19 15 FRONT FINAL CLUTCH 19 17 FRONT DIFFERENTIAL LOCK CLUTCH 19 23 FRONT FINAL GEAR OISASSEMBLY INSPECTION 19 28 CASE BEARING REPLACEMENT 19 34 FRONT FINAL GEAR AS...

Page 460: ...FRONT DRIVING MECHANISM SYSTEM COMPONENTS 54 N m 5 5 40Ibf ft 19 2...

Page 461: ...nal gear case cover 8 mm bolt Differential ring gear bolt Final dutch housing bolt Pinion bearing lock nut Final clutch shift fork bolt 4WO select switch Differential lock switch Final clutch arm cove...

Page 462: ...t 72 75 mm 07746 0010600 Pilot 12 mm 07746 0040200 19 4 Driver 07949 3710001 Attachment 52 x 55 mm 07746 0010400 Attachment 30 mm 1 0 07746 0030300 Pilot 15 mm 07746 0040300 Attachment 22 x 24 mm 0774...

Page 463: ...0 Bearing remover head 12 mm 07936 1660110 Bearing remover shaft 15 mm 07936 KC10100 or 07936 KC10500 lock nut wrench 30 x 64 mm 0791S MBOD002 FRONT DRIVING MECHANISM Fork seal driver weight 07747 001...

Page 464: ...ting gear oil Chipped or damaged gears Improper tooth contact between ring gear and pinion gear Gear noise while coasting Chipped or damaged gears Abnormal noises when turning Worn or damaged ring gea...

Page 465: ...TBOARD JOINT parts Check the boots for cuts or other damage Check the drive shaft joints for excessive play or noise by moving the joints in a circular direction If the outboard joint seems to be worn...

Page 466: ...inboard boot shaft boot band Rep ace rhese Check the following for wear or damage components as an bearing cage assembly race 19 8 steel balls inboard joint Remove the following shaft boot band outboa...

Page 467: ...RD JOINT j BAND OUTBOARD BOOT SHAFT BOOT BAND I 0 and the inboard boot 128 71L b 01 is large The outboard0 ot interchange them is small 1 0 0 134 71 ion of the boot bands the installation direct Note...

Page 468: ...ered side facing the bearing The shaft 0 0 of Pack the inboard joint with 60 809 of the specified the lefllnboardJOint grease IS larger than lhe fight inboardJomt Do not mterchange them 19 10 SPECIFIE...

Page 469: ...ear case Install the shaft boot band and a new inboard boot band onto the inboard boot Bend down each band end and secure it with the lock tabs Tap the lock tabs with a plastic hammer INSTALLATION Ins...

Page 470: ...front wheels page 15 6 left drive shaft page 19 7 Remove the following from the gear case 4WD select switch connector differential lock switch connector breather hose cotter pin and washer differenti...

Page 471: ...nt pin base bolts arm cover base holder bracket Loosen t he two bracket bol ts 10 mm and remove the lower mounting nut and bolt 12 mm Remove the bracket bolts and mounting bracket Support the gear cas...

Page 472: ...he gear case assembly Qut of the frame OPERATION CHECK Turn the pinion joint while the clutch arm is set to the upper side 4WD position and check that the gear turns smoothly and quietly without bindi...

Page 473: ...spring inner boot bands shaft boots Check the propeller shaft for deformation or dam age Check the splines of the propeller shaft and joint for wear or damage If they are damaged check the splines of...

Page 474: ...the seal lip 19 16 Install the inner boot bands into the each boot groove Install the joint spring into the propeller shaft securely Apply 5 8 9 of molybdenum disulfide grease to the propeller shaft j...

Page 475: ...loosenmg the bolt from the sleeve HOUSING clutch sleeve D ring dowel pins Check the splines of the pinion joint clutch sleeve and pinion gear shaft for wear or damage Check the needle bearing in the p...

Page 476: ...claws for wear or damage Check the arm shaft and stopper plate for deforma tion or damage Check the each spring for fatigue or damage PINION JOINT BALL BEARING REPLACEMENT Remove the snap ring and dri...

Page 477: ...e seal lips of a new oil seal with grease Install the oil seal so that its rubber area flush with the housing end Hold the bearing inner race and press the pinion joint into the bearing until it is fu...

Page 478: ...rk and housing contacting area Install the collar and the lock spring with the short end toward the collar and set the spring end into the hole in the collar Apply grease to the lips of a new oil seal...

Page 479: ...o the plate is attached onto the fork lug Install the clutch spring with the bended end toward the shift fork FRONT DRIVING MECHANISM Turn the arm shaft clockwise by holding the collar r with a open e...

Page 480: ...new O ring with grease and install it into the case groove Install the two dowel pins Aligning the fork claws with the sleeve groove install the final clutch housing while turning the clutch arm then...

Page 481: ...ing steel ball four bolts and cable holder differential lock clutch housing tby releasing the shift fork from the sleeve differential half shaft lock sleeve O ring two dowel pins Check the splines of...

Page 482: ...k spring from the spring pin on the stopper arm Remove the following arm bolt and washer stopper arm fork spring shift fork lock arm shaft oil seal Check the shift fork claws for wear or damage Check...

Page 483: ...it is fully seated Apply grease to the lock arm shaft outer surface fork and housing contacting surface Install the arm shaft being careful not to damage the oil seal then instal the shift fork with...

Page 484: ...een the spring ends Align the bolt hole in the fork with the groove in the shaft and install a new fork bol t Tighten the fork bolt TORQUE 10 N m 1 0 kgf m 7 Ibf ft Install a new oil seal so that it i...

Page 485: ...ease and install it into the case groove Install the two dowel pins Install the differential lock clutch housing by align ing the fork claws with the sleeve groove Install the four bolts with the cabl...

Page 486: ...final clutch housing page 19 17 diHerentiallock clutch housing page 19 23 BACKLASH INSPECTION Sel the final gear case into a jig or vise with soft jaws Remove the oil filler cap Cover the c urell Hol...

Page 487: ...the backlash is too small replace the ring gear left side shim with a thicker one The backlash is changed by about 0 06 mm 0 002 in when the thickness of the shim is changed by 0 10 mm 0 004 in NOTE...

Page 488: ...earings should turn smoothly and quietly Also check that the bear ing outer race fits tightly in the case or cover Differential bearing replacement page 19 34 GEAR TOOTH CONTACT PATTERN CHECK Apply th...

Page 489: ...ut slightly to the heel side and to the flank side If the patterns are not correct remove and change the pinion shim with one of an alternate thickness Replace the pinion shim with a thicker one if th...

Page 490: ...ly binding Check each gear for wear or damage RING GEAR REMOVAL Remove the ten bolts and the ring gear PINION GEAR REMOVAL Be carefulrhat Unstake the bearing lock nut with a drill or grinder metal par...

Page 491: ...3020A 070MF HP5Al00 Pull the pinion assembly out from the gear case PINION BALL BEARING AND SHIM REPLACEMENT Press the pinion gear out of the bearing Remove the pinion shim Replace the pinion jOint ne...

Page 492: ...eal the gear may cause warpage Remover weight Press a new bearing into the pinion gear with the marking facing up so that it is flush with the shaft end TOOLS Driver Attachment 22 II 24 mm Pilot 12 mm...

Page 493: ...using the special lools avoid burns when handling rhe heared gear case Using a torch ro hear the gear case may cause warpage TOOLS Remover head 15 mm Remover shaft 15 mm Bearing remover 5 mm Remover...

Page 494: ...If you strike it more than once the stopper ring may slip out of the groove If this happens remove the ring and bearing and install a new ring Make sure that the stopper ring is securely set in the g...

Page 495: ...tual 98 N m 10 0 kgf m 12 Ibf ft Information for Indicated 89 N m 9 1 kgf m 66 Ibf ft torque wrencfJ reading information page 19 3 Be careful not to Stake the lock nut into the case groove damage the...

Page 496: ...check the gear backlash page 19 28 Clean the mating surface of the gear case and cover being careful not to damage them Blow compressed air through the breather hole in the case cover Install the prop...

Page 497: ...kgf m 19 Ibf ft Make sure that the gear assembly rotates smoothly without binding Install the following final clutch housing page 19 22 differential lock clutch housing page 19 27 FRONT FINAL DRIVE I...

Page 498: ...into the output shaft groove Apply molybdenum disulfide grease to the propeller shaft joint splines Move the gear case assembly forward for maximum clearance between the shaft joint and output shaft E...

Page 499: ...perly Install the retaining plate onto the cable with the concave facing the cable holder to secure the cable Operate the differential lock arm to the upper side to set it to the lock free position Co...

Page 500: ...age 19 44 DRIVE MODE SELECTOR LEVER LINKAGE 19 42 REMOVAL Remove the battery box cover page 21 6 Set the drive mode selector lever to the 2WD posi tion Remove the following selector lever grip cable j...

Page 501: ...selector lever pivot bolt Install the lever spring onto the selector lever in the direction as shown Install the selector lever through the lever gale and onto the lever arm by setting the lower spri...

Page 502: ...the following right front wheel page 15 6 regulator rectifier page 21 8 battery box cover page 21 6 Set the drive mode selector lever to the 2WD posi tion Remove the bolt and the clutch arm cover by...

Page 503: ...ide switd to ON I and rear differential lock arm front side check that the all differential lock indicator does not come on this mdicator IS detected the only the front dlfferenual lock Do not move th...

Page 504: ...D marks Turn the adjusting nut on the 2WD 4WD selector cable clockwise until the joint pin just touches the clutch arm slot w ith the nut ends are contacted the joint pin cutout is not seated Then fur...

Page 505: ...LOCK CLUTCH 20 15 SERVICE INFORMATION 20 3 REAR FINAL GEAR DISASSEMBLYI INSPECTION 20 21 TROUBLESHOOTING 20 6 CASE BEARING REPLACEMENT 20 26 REAR DRIVE SHAFT 20 7 REAR FINAL GEAR ASSEMBLy 20 29 REAR...

Page 506: ...REAR DRIVING MECHANISM SYSTEM COMPONENTS 54 N m 5 5 kgf m 40 IbUt j II 20 2...

Page 507: ...de selector lever service and adjustment see Front Driving Mechanism section page 19 42 SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Rear final Oil capacity At draining 465cm 15 7 US OZ 16 4...

Page 508: ...07AMD HL1Al00 U S A only 20 4 Remover handle 07936 3710100 Driver 07749 0010000 Attachment 72 x 75 mm 07746 0010600 Pilot 17 mm 07746 0040400 or 07YMC GCS0100 not available in U S A Remover weight 07...

Page 509: ...k seal driver attachment 07947 KF00100 Puller shaft and nut 07965 VM00200 or 07931 ME4010B and 07931 H83020A U S A onlv Holding tool Snap on YA6010A or equivalent REAR DRIVING MECHANISM Bearing dip co...

Page 510: ...gears Improper tooth contact between ing gear and pinion gear Gear noise while coasting Chipped or damaged gears Abnormal noises when turning Worn or damaged ring gear bearing Damaged differential com...

Page 511: ...ve shaft joints for excessive play or noise by moving the joints in a circular direction If the outboard joint seems to be worn or damaged the drive shaft must be replaced NOTE To replace the outboard...

Page 512: ...ing inboard boot shaft boot band Rep ace their Check the following for wear or damage components as an _ bearing cage assembly _ race 20 8 steel balls inboard joint Remove the following shaft boot ban...

Page 513: ...identification mark shown below Do not interchange them RighI drive shaft Inboard 128 71 l Outboard 34 71 Left drive shaft Inboard 7 242NBJ75 Outboard 34 7 Note the installation direction of the boot...

Page 514: ...ive shaft Install the snap ring with the chamfered side facing the bearing Pack the specified grease to the each inboard joint shown below SPECIFIED GREASE NKG108 Kyodo Yushi Right inboard joint 60 80...

Page 515: ...e lock tabs with a plastic hammer INSTALLATION Install a new stopper ring into the groove in the inboard joint splines The fight dflve shaft Install the drive shaft by holding the inboard joint is lon...

Page 516: ...oil page 4 17 Remove the following drive shafts page 20 7 cargo bed damper page 3 16 two bolts and damper stay VS sensor page 6 53 wire band breather hose cotter pin and washer differential lock cabl...

Page 517: ...ve the propeller shaft aside and remove the gear case assembly out of the frame Remove the following propeller shaft universal joint joint spring from the propeller shaft O rings from the propeller sh...

Page 518: ...st be checked after disassembly replace them jf necessary Check the differential lock change over mechanism while turning the pinion gear both differential shafts in the gear case should turn each oth...

Page 519: ...lock tabs Tap the lock tabs with a plastic hammer REAR DIFFERENTIAL LOCK CLUTCH DISASSEMBLYIINSPECTION Remove the following stopper spring plug and sealing washer stopper spring steel ball four bolts...

Page 520: ...o dowel pins Check the splines of the lock sleeve and half shaft for wear or damage Check the steel ball and stopper spring for wear or damage Remove the oil seal Remove the fork boll Slide the shift...

Page 521: ...r arm for deforma tion or damage Check the spring for fatigue or damage HALF SHAFT BEARING REPLACEMENT Remove the bearing of the housing Drive a new bearing into the housing with the mak ing facing up...

Page 522: ...bolt hole facing up Install the fork spring and stopper arm and set the shaft end into the pivot hole in the housing so the spring end rest onto the spring pin on the stopper arm as shown Apply lockin...

Page 523: ...1 0 kgf m 7 Ibf ft Apply grease to the lips of a new oil seal and install it so that it is fl ush with the housing end TOOLS Driver Oil seal driver attachment 07749 0010000 07JAD PH80101 Install the...

Page 524: ...Install the four bolts with the cable holder and tighten them TORQUE 25 N m 2 6 kg m 19 Ibf ft Install the steel ball and stopper spring Install the spring plug with a new sealing washer and tighten i...

Page 525: ...he difference of the three measurements SERVICE LIMIT 0 2 mm 10 01 in If the difference in measurements exceeds the ser vice limit it indicates that the bearing is not installed squarely or the case i...

Page 526: ...ck clutch page 20 15 Loosen the six cover bolts in a crisscross pattern in several steps and remove them Tap the cover with a soft mallet to rotate the cover slightly and then tap up to remover the co...

Page 527: ...pinion gear tighten the bolts to the specified torque in a crisscross pattern in several steps TORQUE 10 mm bolt 46 5 N m 14 7 kgf m 34Ibf ft 8 mm bott 25 N m 12 6 kgf m 19 Ibf ft Remove the oil fill...

Page 528: ...fferent thickness shims are available from the thinnest 1 26 mm thickness A shim to the thickest 11 B6 mm thickness K in intervals of 0 06 mm Pinion gear shims A thinnest 1 26 mm 0 050 in E standard 1...

Page 529: ...6010A or equiva lent Install the special tools onto the pinion gear shaft and gear case TOOLS Pinion puller base Puller shaft and nut Threaded adaptor U S A TOOLS Pinion puller base Puller shaft Speci...

Page 530: ...r set differential bearing differen tial andlor gear case has been replaced use a 1 50 mm 0 060 in thick shim for initial reference Press the pinion gear in a new bearing until it is fullv seated bv s...

Page 531: ...749 0010000 07JAD PH80101 PINION NEEDLE BEARING Rotate the stopper ring untit its end appears in the access hole Strike gently near the end of the ring with a punch to bend the end upward Grasp the en...

Page 532: ...m Puller attachment Pilot 17 mm 07949 3710001 07746 0010700 01VMC GCS0100 not available in U S A or 07746 0040400 Place the bearing and tool assembly into a freezer for at least 30 minutes Using a hea...

Page 533: ...PLUG _ I 1 LOCK SLEEVE BEARING 6009 RIGHT I GEAR SHIM PINION 1iO tJ i 1 GEAR RING LOCK NUT OIL SEAL PINION GEAR INSTALLATION STOP PIN BALL STCIPPIN SHIM DIFFER mA I I BEARING B008 GEAR CASE COVE R Dr...

Page 534: ...eal and install it so that it is flush with the gear case TOOLS Driver Driver attachment 07749 0010000 07LAD PW50500 or 07AMD HLlAl00 U S A only RING GEAR INSTALLATION Clean the mating surfaces of the...

Page 535: ...in specification heat the case cover to approximately 80 C 176 F and remove the slop pin by tapping the cover Instatl a stop pin shim to obtain the correct clear ance Stop pin shims A 0 10 mm 0 004 in...

Page 536: ...steps until the cover evenly touches the case Then white rotating the pinion gear tighten the bolts to the specified torque in a crisscross pattern in sev eral steps TORQUE 10 mm bolt 46 5 N m 4 7 kg...

Page 537: ...se to the splines of the propeller shaft Install the joint spring into the propeller shaft firmly Place the gear case assembly into the frame Connect the propeller shaft aligning the splines properly...

Page 538: ...ove drive mode selector both nuts to the cable holder side by your hands so ever 15 2WD that the cable does not forced until they are touched position and the to the cable holder dlffel8ntlilllock arm...

Page 539: ...HARGING SYSTEM COMPONENT LOCATION 21 2 SYSTEM DIAGRAM 21 2 SERVICE INFORMATION 21 3 TROUBLESHOOTING 21 5 BATIERY 21 6 CHARGING SYSTEM INSPECTION 21 7 ALTERNATOR CHARGING COIL 21 8 REGULATOR RECTIFIER...

Page 540: ...BATTERY CHARGING SYSTEM COMPONENT LOCATION ALTERNATOR SYSTEM DIAGRAM y ALTERNATOR REGULATOR RECTIFIER 21 2 MAIN f USE 30 A REGULATOR RECTIFIER BATTERY MAIN FUSE 30 A R G Green R Red Y Yeliow G BATTERY...

Page 541: ...this reason the charging system is often suspected as the problem Battery overcharge often results from problems in the battery itself which may appear to be an overcharging symptom If one of the bat...

Page 542: ...t eeds charging Charging cur Normal rent Quick Capacity I Alternator Charging coil resistance 20a C 68e F TOOLS Motorcycle battery analyzer Micro 404XL U S A only 21 4 Christie battery charger MC1Q12...

Page 543: ...tion switch 4 Alternator Charging Coil Inspection Check the alternator charging coil page 21 8 Is the alternator charging coif resistance within 0 1 1 0n 20CCI68 F YES GO TO STEP 5 NO Faulty charging...

Page 544: ...shown first and tIlen the negative H cable 21 6 VOLTAGE INSPECTION Remove the battery box cover page 21 6 Measure the battery voltage using a commercially available digital multimeter VOLTAGE 20C C 6...

Page 545: ...the specified value a shorted circuit is likely Locate the short by disconnecting connections one by one and measuring the current CHARGING VOLTAGE INSPECTION Remove the battery box cover page 21 6 B...

Page 546: ...INSPECTION Open the front hood Disconnect the regulator rectifier 3P black and gray connectors Check the connectors for loose contacts or corroded terminals Check the following at the wire harness sid...

Page 547: ...22 IGNITION SYSTEM COMPONENT LOCATION 22 2 IGNITION SYSTEM INSPECTION 22 5 SYSTEM DIAGRAM 22 2 IGNITION COIL 22 7 SERVICE INFORMATION 22 3 IGNITION TIMING 22 8 TROUBLESHOOTING 22 4 22 1...

Page 548: ...SYSTEM DIAGRAM peM MAIN RELAY BATIERY 61 Bla Bu Blue G Green R Red V Violet W While V Yel ow MAIN RELAY BOX I f I L____________ L _ _ _ _ _ _ _ _ _ _ _ _ _ _ 3 1 CKP SENSOR 22 2 IGNITION COIL I SPARK...

Page 549: ...e made to the ignition timing A faulty ignition system is often related to poor connections Check those connections before proceeding Make sure the battery is adequately charged Using the starter moto...

Page 550: ...case when the initial voltage is normal with the PCM 2 Battery is undercharged drops largely when the engine is started 3 No voltage at the Black green wire of the peM gray connector or loose or poorl...

Page 551: ...commercially available digital multimeter impedance 10 MlliOCV mini mum MTP07 0286 or 07HGJ 0020100 not available in U S A IGNITION COIL PRIMARY PEAK VOLTAGE NOTE Check all system connections before t...

Page 552: ...ion is normal and the spark plug is installed correctly in the cylinder head Remove the battery box cover page 21 6 Disconnect the 33P gray connector from the PCM NOTE When reconnecting the PCM 33P gr...

Page 553: ...ctor is abnormal and the one measured at the alternator connector is normal the Blue yellow or Greenlwhite wire has an open or short circuit or loose connection If both peak voltages are abnormal foll...

Page 554: ...ine let it idle and check the ignition timing The ignition timing is correct if the F mark on the c c c flywheel is visible from the timing hole in the rear TIMING HOLE crankcase cover at idle Increas...

Page 555: ...ELECTRIC STARTER COMPONENT LOCATION 23 2 STARTER MOTOR 23 6 SYSTEM DIAGRAM 23 2 STARTER RELAY SWiTCH 23 12 SERVICE INFORMATION 23 3 DIODE 23 13 TROUBLESHOOTING _ 23 4 BRAKE INHIBITOR RELAy 23 14 EI 23...

Page 556: ...ON SWITCH BATTERY FUSE 10A 8 BATTERY t Y MAIN FUSE 30A SWITCH 81 Black Sr Brown G Green 19 Ught green A Red Y Yeliow M VI IGNITION SWITCH 19lR L9IBI l9 BI VIR VIR VIR START FUSE lOA DIODE DIODE GEAR P...

Page 557: ...frame When checking the starter system always follow the steps in the troubleshooting page 23 4 A weak battery may be unable to turn the starter motor quickly enough or supply adequate ignition curre...

Page 558: ...tch to OFF 0 Apply battery voltage to the starter motor directly Does the starter motor turn YES _ Poorly connected starter motor cable Faulty starter relay switch page 23 13 NO Faulty starter motor p...

Page 559: ...rter relay switch connector terminal Starter motor turns engine slowly Low battery voltage Poorly connected battery cable Poorly connected starter motor cable Faulty starter motor Poorly connected gro...

Page 560: ...r motor cable ter minal and remove the terminal nut and starter molor cable Remove the two mounting bolts and hose guide TERMINAL NUT MOTOR CABLE Remove the starter motor from the rear crankcase Tr ca...

Page 561: ...e bushing in the rear cover for wear or damage Check the commutator bars of the armature for dis coloration NOTE Do not use emery or sand paper on the commu tator Check for continuity between pairs of...

Page 562: ...eck for continuity between the insulated brush and cable terminal There should be continuity Check for continuity between the insulated brush and motor case There should be no continuity Remove the fo...

Page 563: ...washer insulator terminal stopper D ring terminal bolt brush set A brush holder ASSEMBLY INSULATOR NUT SEAL RING MOTOA CASE ELECTRIC STARTER BRUSH SPRINGS D RING WASHER REAR COVEA BRUSH HOLDER BAUSH...

Page 564: ...r Install the armature in the motor case so the case groove is facing the rear cover side When installing the armature into the motor case hold the armature tightly to prevent the magnet of the case f...

Page 565: ...s in the front and rear covers by aligning the index lines on the front cover and motor case Install new O rings onto the motor case boils Install the bolts and tighten them INSTALLATION Coat a new O...

Page 566: ...hear the switch click inspect the relay switch circuits page 23 12 CIRCUIT INSPECTION Remove the battery box cover page 2 6 Disconnect the starter relay switch 2P green connec tor GROUND LINE Check fo...

Page 567: ...een red wire terminal of the starter relay switch side connector There should be continuity between t he cable termi nals while the battery is connected and no continu ity when the battery is disconne...

Page 568: ...e the relay box cover Remove the brake inhibitor relay from the relay box Installation is in the reverse order of removal RELAY INSPECTION Remove the brake inhibitor relay page 23 14 Check for continu...

Page 569: ...here battery voltage YES GO TO STEP 3 NO Open circuit in the Greenlyellow wire between the junction connector and brake inhibitor relay connector 3 Starter Relav Switch Line Inspection ELECTRIC STARTE...

Page 570: ...MEMO...

Page 571: ...N 24 3 HEADLIGHT 24 4 BRAKE TAILLIGHT 24 5 INDICATORS 24 5 ACCESSORY SOCKET 24 6 IGNITION SWiTCH 24 7 LIGHTING DIMMER SWITCH 24 8 ENGINE TEMPERATURE INDiCATOR 24 9 COOLING FAN MOTOR 24 11 LOW FUEL IND...

Page 572: ...LIGHTS METERS SWITCHES COMPONENT LOCATION INDICATORS LIGHTING or SWITCH ACCESSORY SOCKET PARKING SWITCH FUEL SENSOR IGNITION SWITCH 24 2...

Page 573: ...rical failure check the continuity of the electrical path through the part A continuity check can usually be made without removing the part from the vehicle Simply disconnect the connectors and connec...

Page 574: ...gn thB bulb tabs Install a new bulb in the reverse order of removal with the headlight grooves properly_ 24 4 REMOVALIINSTALLATION Open the front hood Remove the following wire band right headlight on...

Page 575: ...ree screws and the taillight cover TAILLIGHT COVER Remove the brake1taillight from the taillight cover BRAKEI by releasing the bosses from the grommets Disconnect the 3P connector from the brakeltail...

Page 576: ...en connector There should be battery voltage with the ignition switch turned to ON I If there is no voltage check for brown ACe fuse 10 A and an open circuit in the wire harness Remove the accessory s...

Page 577: ...switch position Continuity should exist between the color coded wires as follows I RIBI A AIW VIA Positien ST l1l C r o t O ON I t f O OFF e REPLACEMENT LIGHTS METERS SWITCHES Disconnect the ignition...

Page 578: ...REPLACEMENT Disconnect the lighting dimmer switch 4P green 24 8 connector page 24 8 Remove the screw and switch holder Remove the lighting dimmer switch from the instru ment panel by pushing in the t...

Page 579: ...O Open circuit in the Black yellow wire between the junction connector and indicator 10P connector 2 PCM Inspection Turn the ignition switch to OFF 0 Remove the battery box cover page 21 6 Disconnect...

Page 580: ...bulb Faulty indicator wire harness Temperature indicator stays on after the ignition switch is turned to ON I 1 OTe Inspection Check the current OTG page 6 2 Is DTe 7 1 7 or 44 1 44 indicated YES Perf...

Page 581: ...12 Is DTe 7 1 and or 7 2 indicated YES Perform the DIC 7 1 troubleshooting page 6 17 Perform the DIC 7 2 troubleshooting page 6 8 NO GO TO STEP 3 3 Ground line Inspection Disconnect the peM 5P black c...

Page 582: ...cted to the peM 5P connector check for continuity between the Green black wire terminal of the wire harness side 2P connector and ground Is there continuity YES GO TO STEP 6 NO Open circuit in the Gre...

Page 583: ...age 21 6 Disconnect the PCM 33P black connector Ground the Yellow wire A2l terminal of the wire harness side connector with a jumper wire TOOL Test probe 2 pack 01ZAJ ROJA110 Turn the ignition switch...

Page 584: ...re the voltage between the wire harness side 6P connector terminal and ground CONNECTION Black brown 1 ground H Is there battery voltage YES Open circuit in the Yellow wire between the peM and indicat...

Page 585: ...ection Remove the battery box cover page 21 6 Disconnect the peM 33P black connector Turn the ignition switch 10 ON I and check the low fuel indicator Does the indicator come on YES GO TO STEP 2 NO Re...

Page 586: ...ontinuity with the pedal released REPLACEMENT Unhook the brake switch springs from the brake r BRM e SY iiTiCHS Ni ii pedal and brake switch Disconnect the foot brake switch 2P gray connector page 24...

Page 587: ...t center cover page 3 5 Remove the parking brake switch 2P black connec tor from the lever bracket and remove it Release the switch wire from the two clamps LIGHTS METERS SWITCHES 2P BLACK CONNECTOR C...

Page 588: ...MEMO...

Page 589: ...25 WIRING DIAGRAM WIRING DIAGRAM 25 3 EI 25 1...

Page 590: ......

Page 591: ...26 TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD POOR PERFORMANCE AT LOW AND TO START 26 2 IDLE SPEED 26 5 ENGINE LACKS POWER 26 3 POOR PERFORMANCE AT HIGH SPEED 26 6 26 1...

Page 592: ...GO TO STEP 3 3 Fuel Pump Inspection Check for operation of the fuel pump and inspect the fuel flow Is the futl pump unit normal NO _ Faulty fuel pump unit YES GO TO STEP 4 4 PGM FI System Inspection C...

Page 593: ...her YES GO TO STEP 4 4 Engine Condition Inspection Accelerate or run at high speed Is there knocking YES Worn piston and cylinder Use of poor quality fuel Excessive carbon build up in combustion chamb...

Page 594: ...TO STEP 9 9 Fuel pump Inspection Inspect the fuel flow Is the fuel pump unit normal NO Faulty fuel pump unit page 6 36 YES GO TO STEP 10 10 PGM FI System Inspection Check the PGM FI system Is the PGM...

Page 595: ...pection Inspect the fuel flow Is the fuel pump unit normal NO Faulty fuel pump unit page 6 36 YES GO TO STEP 3 3 PGM FI System Inspection Check the PGM FI system Is the PGM FI system normal NO Faulty...

Page 596: ...FI system normal NO Faulty PGM FI system page 6 11 YES GO TO STEP 3 3 Ignition Timing Inspection Check ignition timing Is the ignition timing correct NO _ Faulty peM Faulty CKP sensor YES GO TO STEP...

Page 597: ...DEX 14 16 DRIVETRAIN DTC TROUBLESHOOTING 14 17 DRIVETRAIN SYSTEM DIAGRAM 1 4 12 DRIVETRAIN TROUBLESHOOTING INFORMATION 14 15 27 INDEX DTC TROUBLESHOOTING 6 15 ECT SENSOR 6 53 EMISSION CONTROL SySTEMS...

Page 598: ...47 SHIFT VALVE BODy 14 28 SIDE NET 3 21 SIDE PANEL 3 11 SPARK ARRESTER 4 23 SPARK PLUG 4 8 SPECIFICATIONS ALTERNATOR STARTER CLUTCH 1 8 27 2 SPECIFICATIONS BATIERY CHARGING SYSTEM 1 10 BRAKE SYSTEM 1...

Page 599: ...T SYSTEM 3 2 FRONT DRIVING MECHANISM 19 6 FRONT WHEEUSUSPENSION 15 5 IGNITION SYSTEM 22 4 LUBRICATION SYSTEM 5 4 INDEX POOR PERFORMANCE AT HIGH SPEED 26 6 POOR PERFORMANCE AT LOW AND IDLE SPEED 26 5 R...

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