Yamaha 2004 YXR660 Service Manual Download

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CHAS

FRONT AND REAR BRAKES

INSTALLING THE BRAKE MASTER
CYLINDER

1. Install:

• brake master cylinder

2. Install:

• brake pipe
• copper washers
• brake hose
• union bolt

NOTE:

Tighten the union bolt while holding the brake
hose as shown.

WARNING

Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING” in chapter 2.

3. Fill:

• brake fluid reservoir

CAUTION:

Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.

WARNING

• Use only the designated quality brake

fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.

• Refill with the same type of brake fluid:

mixing brake fluids may result in a harm-
ful chemical reaction and lead to poor
brake performance.

• Be careful that water does not enter the

brake master cylinder when refilling.
Water will significantly lower the boiling
point of the brake fluid and may result in
vapor lock.

Recommended brake fluid

DOT 4

~65˚

16 Nm (1.6 m · kg, 11 ft · lb)

19 Nm (1.9 m · kg, 13 ft · lb)

New

27 Nm (2.7 m · kg, 19 ft · lb)

www.midwestmanuals.com

Summary of Contents for 2004 YXR660

Page 1: ...arify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to read way by the ...

Page 2: ...t clearance G Engine speed H Electrical data Ω V A Symbols I to N in the exploded diagrams indicate the types of lubricants and lubrication points I Apply engine oil J Apply gear oil K Apply molybdenum disulfide oil L Apply wheel bearing grease M Apply lithium soap based grease N Apply molybdenum disulfide grease Symbols O to P in the exploded diagrams indicate where to apply a locking agent O and...

Page 3: ...RMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 ENGINE ENG 4 COOLING SYSTEM COOL 5 FUEL SYSTEM FUEL 6 DRIVE TRAIN DRIV 7 CHASSIS CHAS 8 ELECTRICAL ELEC 9 TROUBLESHOOTING TRBL SHTG 10 www midwestmanuals com ...

Page 4: ...ALS AND O RINGS 1 5 LOCK WASHERS PLATES AND COTTER PINS 1 6 BEARINGS AND OIL SEALS 1 6 CIRCLIPS 1 6 CHECKING OF CONNECTIONS 1 7 SPECIAL TOOLS 1 8 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 4 CHASSIS SPECIFICATIONS 2 12 ELECTRICAL SPECIFICATIONS 2 14 TIGHTENING TORQUES 2 16 ENGINE TIGHTENING TORQUES 2 16 CHASSIS TIGHTENING TORQUES 2 19 HOW TO USE THE CONVERSION TABL...

Page 5: ...LEVEL 3 13 CHANGING THE ENGINE OIL 3 14 CLEANING THE AIR FILTER 3 16 CHECKING THE COOLANT LEVEL 3 18 CHANGING THE COOLANT 3 19 CHECKING THE COOLANT TEMPERATURE WARNING LIGHT 3 23 CHECKING THE V BELT 3 23 CLEANING THE SPARK ARRESTER 3 25 CHASSIS 3 26 ADJUSTING THE BRAKE PEDAL 3 26 ADJUSTING THE PARKING BRAKE 3 27 CHECKING THE BRAKE FLUID LEVEL 3 28 CHECKING THE FRONT BRAKE PADS 3 29 CHECKING THE RE...

Page 6: ...LER AND EXHAUST PIPE 4 1 SELECT LEVER UNIT AND COOLANT RESERVOIR 4 3 HOSES AND LEADS 4 4 ENGINE MOUNTING BOLTS 4 6 INSTALLING THE ENGINE 4 8 CYLINDER HEAD COVER 4 9 REMOVING THE CYLINDER HEAD COVER 4 11 CHECKING THE CYLINDER HEAD COVER 4 11 CHECKING THE TAPPET COVERS 4 11 INSTALLING THE CYLINDER HEAD COVER 4 12 ROCKER ARMS 4 13 REMOVING THE ROCKER ARMS 4 15 CHECKING THE ROCKER ARMS 4 15 INSTALLING...

Page 7: ...4 45 BALANCER GEARS AND OIL PUMP GEARS 4 48 REMOVING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 4 50 CHECKING THE OIL PUMP DRIVE GEAR AND OIL PUMP DRIVEN GEAR 4 50 CHECKING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 4 50 INSTALLING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 4 51 PRIMARY AND SECONDARY SHEAVES 4 52 PRIMARY SHEAVE 4 54 SECONDARY SHEAVE 4 55 REMOVING THE PRIMARY AND ...

Page 8: ...NSTALLING THE CRANKSHAFT AND BALANCER 4 78 TRANSMISSION 4 79 DRIVE AXLE ASSEMBLY 4 80 REMOVING THE TRANSMISSION 4 81 CHECKING THE SHIFT FORKS 4 81 CHECKING THE SHIFT DRUM 4 82 CHECKING THE DRIVE AXLE 4 82 CHECKING THE HIGH WHEEL GEAR AND MIDDLE DRIVE GEAR 4 82 CHECKING THE SECONDARY SHAFT AND DRIVEN SPROCKET 4 83 CHECKING THE CHAIN 4 83 ASSEMBLING THE SHIFT FORK ASSEMBLY 4 84 INSTALLING THE TRANSM...

Page 9: ...ETOR 6 8 ASSEMBLING THE CARBURETOR 6 10 ADJUSTING THE FUEL LEVEL 6 11 CHAPTER 7 DRIVE TRAIN TROUBLESHOOTING 7 1 FRONT CONSTANT VELOCITY JOINTS DIFFERENTIAL GEAR AND DRIVE SHAFT 7 4 DISASSEMBLING THE UNIVERSAL JOINT 7 9 REMOVING THE DIFFERENTIAL GEAR ASSEMBLY 7 9 CHECKING THE CONSTANT VELOCITY JOINTS 7 10 CHECKING THE DIFFERENTIAL GEAR 7 10 CHECKING THE GEAR MOTOR 7 11 ASSEMBLING THE FRONT CONSTANT...

Page 10: ...BED 8 6 SKID PLATES 8 8 ENCLOSURE AND SEAT BELTS 8 9 FRONT WHEELS AND BRAKE DISCS 8 10 CHECKING THE FRONT WHEEL 8 12 CHECKING THE FRONT WHEEL HUB 8 12 CHECKING THE FRONT BRAKE DISC 8 13 INSTALLING THE FRONT WHEEL HUB 8 13 INSTALLING THE FRONT WHEEL 8 13 REAR WHEELS AND BRAKE DISC 8 14 REAR WHEELS 8 14 REAR BRAKE DISC 8 15 CHECKING THE REAR WHEEL 8 16 CHECKING THE REAR WHEEL HUB 8 16 CHECKING THE R...

Page 11: ...M 8 50 TIE ROD AND STEERING KNUCKLE 8 51 REMOVING THE STEERING KNUCKLES 8 52 CHECKING THE TIE RODS 8 52 CHECKING THE STEERING KNUCKLES 8 52 FRONT ARMS AND FRONT SHOCK ABSORBER 8 56 REMOVING THE FRONT ARMS 8 58 CHECKING THE FRONT ARMS 8 58 CHECKING THE FRONT SHOCK ABSORBER 8 60 INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 8 61 REAR KNUCKLE AND STABILIZER 8 62 CHECKING THE REAR KNUCKLE 8 63 CH...

Page 12: ...HE STARTER MOTOR 9 21 ASSEMBLING THE STARTER MOTOR 9 22 CHARGING SYSTEM 9 23 CIRCUIT DIAGRAM 9 23 TROUBLESHOOTING 9 24 LIGHTING SYSTEM 9 26 CIRCUIT DIAGRAM 9 26 TROUBLESHOOTING 9 27 CHECKING THE LIGHTING SYSTEM 9 29 SIGNALING SYSTEM 9 32 CIRCUIT DIAGRAM 9 32 TROUBLESHOOTING 9 34 CHECKING THE SIGNAL SYSTEM 9 36 COOLING SYSTEM 9 46 CIRCUIT DIAGRAM 9 46 TROUBLESHOOTING 9 47 2WD 4WD SELECTING SYSTEM 9...

Page 13: ...AR SHIFTING 10 4 HARD SHIFTING 10 4 SHIFT LEVER DOES NOT MOVE 10 4 JUMPS OUT OF GEAR 10 4 FAULTY CLUTCH PERFORMANCE 10 4 ENGINE OPERATES BUT VEHICLE WILL NOT MOVE 10 4 CLUTCH SLIPPING 10 4 POOR STARTING PERFORMANCE 10 4 POOR SPEED PERFORMANCE 10 5 OVERHEATING 10 5 OVERHEATING 10 5 FAULTY BRAKE 10 5 POOR BRAKING EFFECT 10 5 SHOCK ABSORBER MALFUNCTION 10 5 MALFUNCTION 10 5 UNSTABLE HANDLING 10 6 UNS...

Page 14: ...HICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts VEHICLE IDENTIFICATION www midwestmanuals com ...

Page 15: ... brake caliper piston and the adjusting bolt This adjustment procedure is unnecessary for vehicles equipped with a self adjusting parking brake mechanism The proper clearance is automatically maintained at all times ensuring stable braking performance when parking the vehicle 1 Parking brake arm 2 Parking brake arm shaft 3 Set bolt 4 Adjusting bolt sleeve 5 Adjusting bolt 6 Nut 7 Brake caliper pis...

Page 16: ...ft 2 and the set bolt 3 is pushed against the adjusting bolt sleeve 4 When the adjusting bolt sleeve receives the force the dark shaded area in the above illustration is pushed together and the brake pad 6 is pushed against the brake disc When the brake pad wears the clearance between the brake caliper piston 5 and the brake pad becomes larger and the force applied to the brake pad becomes weaker ...

Page 17: ...akes no adjustment The adjustment operation is as follows 1 When the brake pedal is operated the brake fluid pressure increases and the brake caliper pis ton and the nut move 2 When the movement of the brake caliper piston and the nut is greater than the backlash of the threads of the nut and the adjusting bolt the force È will be required to pull the adjusting bolt The force to pull the adjusting...

Page 18: ...ll parts and place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EB101010 REPLACEMENT PARTS 1 Use only genuine Yamaha parts for all replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferi...

Page 19: ...hen installing oil seals apply a light coating of lithium soap based grease to the seal lips Oil bearings liberally when install ing if appropriate 1 Oil seal CAUTION Do not use compressed air to spin the bearings dry This will damage the bearing surfaces 1 Bearing EB101050 CIRCLIPS 1 Check all circlips carefully before reassem bly Always replace piston pin clips after one use Replace distorted ci...

Page 20: ...veral times 3 Check connector leads Looseness Bend up the pin 1 and con nect the terminals 4 Connect connector terminals NOTE The two terminals click together 5 Check continuity using a pocket tester NOTE If there is no continuity clean the terminals When checking the wire harness be sure to perform steps 1 to 3 As a quick remedy use a contact revitalizer available at most part stores Check the co...

Page 21: ...S and CDN P N 90890 Tool No Tool name Function Illustration Bolt 90890 01083 Weight 90890 01084 Set YU 01083 A Slide hammer bolt M6 weight set These tools are used to remove the rocker arm shaft 90890 01135 YU 01135 A Crankcase separating tool This tool is used to separate the crank case 90890 01229 YM 01229 Coupling gear middle shaft tool This tool is needed when removing or installing the coupli...

Page 22: ...h This tool is needed when removing or installing the secondary sheave spring 90890 01352 YU 33984 Radiator cap tester adapter This tool is used to check the cooling sys tem Adapter 90890 01383 YM 01383 Spacer 90890 04081 YM 91044 Adapter Spacer crankshaft installer These tools are used to install the crank shaft 90890 01404 YM 01404 Flywheel puller These tools are needed to remove the rotor 90890...

Page 23: ... Primary sheave holder This tool is needed to hold the primary sheave when removing or installing the sheave bolts Set 90890 03081 YU 33223 Adapter 90890 04082 YU 33223 4 Compression gauge Adapter compression gauge These tools are needed to measure engine compression 90890 03112 YU 03112 C Pocket tester This instrument is needed for checking the electrical system 90890 03113 Engine tachometer This...

Page 24: ...nt holder This tool is needed when removing or installing the universal joint yoke nut 90890 04064 YM 04064 A Valve guide remover ø 6 This tool is needed to remove and install the valve guide 90890 04065 YM 04065 A Valve guide installer ø 6 This tool is needed to install the valve guide 90890 04066 YM 04066 Valve guide reamer ø 6 This tool is needed to rebore the new valve guide 90890 04086 YM 910...

Page 25: ...rument is necessary for checking the ignition system components Bond 90890 85505 Sealant ACC 11001 05 01 Yamaha bond No 1215 Sealant Quick Gasket This sealant bond is used on crankcase mating surfaces etc YM 01477 Ball joint remover installer attachment set This tool is used to remove and install the ball joints YU 8036 C Digital engine test tachometer This tool is needed for observing engine rpm ...

Page 26: ...ard compression pressure at sea level 1 324 kPa 13 24 kg cm2 188 31 psi at 850 r min Starting system Electric starter Lubrication system Wet sump Oil type or grade Engine oil API service SE SF SG type or higher Final gear oil SAE 80API GL 4 Hypoid Gear Oil Differential gear oil SAE 80API GL 4 Hypoid Gear Oil Oil capacity Engine oil Periodic oil change 1 90 L 1 67 Imp qt 2 01 US qt With oil filter ...

Page 27: ... V belt Secondary reduction system Shaft drive Secondary reduction ratio 41 21 24 18 33 9 9 544 Transmission type V belt automatic Operation Right hand operation Single speed automatic 2 37 0 91 1 Sub transmission ratio low 35 17 2 058 high 28 19 1 473 Reverse gear 25 17 1 471 Chassis Frame type Steel tube frame Caster angle 5 0 Camber angle 0 Kingpin angle 12 Kingpin offset 0 mm 0 in Trail 26 mm ...

Page 28: ...ouble wishbone Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 185 mm 7 28 in Rear wheel travel 185 mm 7 28 in Electrical Ignition system DC C D I Generator system A C magneto Battery type U1L 11 Battery capacity 12 V 28 AH Headlight type Krypton bulb Bulb wattage quantity Headlight 12 V 30 W 30 W 2 Tail brake li...

Page 29: ...9410 in Measuring point 50 mm 1 97 in Camshaft Drive method Chain drive Left Cam dimensions Intake A 35 69 35 79 mm 1 4051 1 4091 in 35 59 mm 1 4012 in B 30 06 30 16 mm 1 1835 1 1874 in 29 96 mm 1 1795 in Exhaust A 36 50 36 60 mm 1 4370 1 4409 in 36 40 mm 1 4331 in B 30 11 30 21 mm 1 1854 1 1894 in 30 01 mm 1 1815 in Camshaft runout limit 0 03 mm 0 0012 in A B www midwestmanuals com ...

Page 30: ...29 9 30 1 mm 1 1772 1 1850 in EX 31 9 32 1 mm 1 2559 1 2638 in B face width IN 2 25 mm 0 0900 in EX 2 26 mm 0 0890 in C seat width IN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 0 85 1 15 mm 0 0335 0 0453 in EX 0 85 1 15 mm 0 0335 0 0453 in Stem outside diameter IN 5 975 5 990 mm 0 2352 0 2358 in 5 945 mm 0 2341 in EX 5 960 5 9...

Page 31: ... 0433 in Valve spring Inner spring Free length IN 32 63 mm 1 28 in 31 0 mm 1 22 in EX 36 46 mm 1 44 in 34 6 mm 1 36 in Set length valve closed IN 27 5 mm 1 08 in EX 31 0 mm 1 22 in Compressed pressure installed IN 100 0 115 7 N 10 20 11 80 kg 22 49 26 01 lb EX 120 6 138 3 N 12 30 14 10 kg 27 12 31 09 lb Tilt limit IN 2 5 1 4 mm 2 5 0 055 in EX 2 5 1 6 mm 2 5 0 063 in Direction of winding top view ...

Page 32: ...n Piston pin outside diameter 21 991 22 000 mm 0 8658 0 8661 in 21 971 mm 0 8650 in Piston rings Top ring Type Barrel Dimensions B T 1 2 3 8 mm 0 0472 0 1496 in End gap installed 0 30 0 45 mm 0 0118 0 0177 in 0 70 mm 0 0276 in Side clearance installed 0 04 0 08 mm 0 0016 0 0031 in 0 13 mm 0 0051 in 2nd ring Type Taper Dimensions B T 1 2 4 0 mm 0 0472 0 1575 in End gap installed 0 30 0 45 mm 0 0118...

Page 33: ...ut limit C1 0 03 mm 0 0012 in C2 0 03 mm 0 0012 in Big end side clearance D 0 35 0 65 mm 0 0138 0 0256 in 1 0 mm 0 0394 in Big end radial clearance E 0 010 0 025 mm 0 0004 0 0010 in Balancer Balancer drive method Gear Automatic centrifugal clutch Clutch shoe thickness 1 5 mm 0 06 in 1 0 mm 0 04 in Clutch in revolution 1 900 2 300 r min Clutch stall revolution 3 350 3 850 r min Item Standard Limit ...

Page 34: ...3 B P 3 0 8 Valve seat size V S 2 3 Starter jet G S 1 55 Starter jet G S 2 0 8 Throttle valve size Th V 105 Float height F H 13 mm 0 51 in Fuel level F L 4 0 5 0 mm 0 16 0 20 in Engine idle speed 1 450 1 550 r min Intake vacuum 28 0 30 7 kPa 210 230 mmHg 8 27 9 06 inHg Oil pump Oil filter type Foam Oil pump type Trochoid Tip clearance 0 15 mm 0 0059 in 0 23 mm 0 0091 in Side clearance 0 03 0 10 mm...

Page 35: ...low to full level 0 20 L 0 15 Imp qt 0 21 US qt Water pump Type Single suction centrifugal pump Reduction ratio 32 31 1 032 Shaft drive Middle gear backlash 0 1 0 3 mm 0 004 0 012 in Final gear backlash 0 1 0 3 mm 0 004 0 012 in Differential gear backlash 0 05 0 25 mm 0 002 0 010 in Lubrication chart Item Standard Limit Oil pan Oil strainer Oil pump Oil cooler Drive axle Crankshaft and related par...

Page 36: ...2 11 SPEC ENGINE SPECIFICATIONS Cylinder head tightening sequence www midwestmanuals com ...

Page 37: ...n Shock absorber travel 81 mm 3 19 in Spring free length 328 mm 12 91 in Spring fitting length 273 2 mm 10 76 in Spring rate K1 44 1 N mm 4 41 kg mm 246 95 lb in K2 117 7 N mm 11 77 kg mm 659 08 lb in Stroke K1 0 60 mm 0 2 36 in K2 60 81 mm 2 36 3 15 in Optional spring No Front wheel Type Panel wheel Rim size 12 6 0 AT Rim material Steel Rim runout limit radial 2 0 mm 0 08 in lateral 2 0 mm 0 08 i...

Page 38: ... fluid type DOT 4 Rear disc brake Type Single Disc outside diameter thickness 165 0 5 0 mm 6 50 0 20 in Pad thickness inner 5 6 mm 0 22 in 1 5 mm 0 06 in Pad thickness outer 5 6 mm 0 22 in 1 5 mm 0 06 in Master cylinder inside diameter 17 4 mm 0 69 in Caliper cylinder inside diameter 32 0 mm 1 26 in Brake fluid type DOT 4 Brake lever and brake pedal Accelerator pedal free play 0 mm 0 0 in Brake pe...

Page 39: ...ition coil Model manufacturer 2JN YAMAHA Minimum spark gap 6 mm 0 24 in Primary winding resistance 0 18 0 28 Ω at 20 C 68 F Secondary winding resistance 6 32 9 48 kΩ at 20 C 68 F Spark plug cap Type Resin type Resistance 10 kΩ Charging system Type A C magneto generator Model manufacturer F4T46972 MITSUBISHI Nominal output 14 V 23 A at 5 000 r min Charging coil resistance color 0 32 0 43 Ω at 20 C ...

Page 40: ...ng 180 A Coil winding resistance 4 18 4 62 Ω at 20 C 68 F Radiator fan Running rpm 2 950 r min Thermo switch Thermo switch 1 Model manufacturer 4BA DENSO Thermo switch 2 Model manufacturer 5FU NIPPON THERMOSTAT Thermo switch 3 Model manufacturer 5GM NIPPON THERMOSTAT Circuit breaker Type Fuse Amperage for individual circuit Main fuse 30 A 1 Lighting system fuse 15 A 1 Ignition fuse 10 A 1 Auxiliar...

Page 41: ... 0 14 Rocker arm shaft stopper Bolt M6 2 10 1 0 7 2 Valve adjusting locknut M6 5 14 1 4 10 Engine oil drain bolt M14 1 30 3 0 22 Oil filter cartridge union bolt M20 1 63 6 3 46 Oil filter cartridge M20 1 17 1 7 12 E Oil pipe assembly Bolt M6 4 7 0 7 5 1 Oil delivery pipe 1 Union bolt M8 2 18 1 8 13 Oil delivery pipe 2 Union bolt M14 1 35 3 5 25 Oil delivery pipe 3 Union bolt M10 1 20 2 0 14 Oil de...

Page 42: ... LT Stator lead holder Bolt M6 2 10 1 0 7 2 A C magneto cover Bolt M6 12 10 1 0 7 2 1 10 1 0 7 2 Sealant Quick Gasket Yamaha bond No 1215 Starter clutch Bolt M8 3 30 3 0 22 LT Clutch carrier assembly Nut M22 1 160 16 0 115 Stake Clutch housing assembly Bolt M6 9 10 1 0 7 2 Bearing retainer middle drive shaft Screw M8 4 29 2 9 21 Middle drive pinion gear Nut M22 1 145 14 5 105 Stake Middle drive sh...

Page 43: ...et joint M6 1 9 0 9 6 5 Coolant reservoir Bolt M6 2 7 0 7 5 1 Radiator bracket and frame Bolt M6 4 7 0 7 5 1 Fuel pump Bolt M6 2 7 0 7 5 1 Fuel tank Bolt M8 2 30 3 0 22 Muffler stay Bolt M6 2 11 1 1 8 0 Muffler and exhaust pipe Bolt M8 1 20 2 0 14 Muffler bracket and muffler Bolt M8 1 20 2 0 14 Muffler bracket and frame Bolt M8 2 20 2 0 14 Muffler damper and muffler Bolt M6 1 10 1 0 7 2 Muffler da...

Page 44: ...e pinion gear M14 62 6 2 45 LT Gear motor and differential gear case cover M8 13 1 3 9 4 Differential gear case cover and differential gear case M8 25 2 5 18 Final drive gear case and frame M10 70 7 0 51 Final drive gear case filler plug M20 23 2 3 17 Final drive gear case drain plug M10 20 2 0 14 Ring gear bearing housing and final drive gear case M8 23 2 3 17 M10 40 4 0 29 Ring gear stopper nut ...

Page 45: ...d constant velocity joint M20 260 26 0 190 Stake Rear brake hose and frame M6 7 0 7 5 1 Brake pipe and brake master cylinder M10 19 1 9 13 Brake pipe and rear brake hose M10 19 1 9 13 Pedal assembly and frame M8 16 1 6 11 Brake master cylinder and pedal assembly M8 16 1 6 11 Secondary brake master cylinder kit stopper bolt M6 9 0 9 6 5 Brake rod locknut M8 17 1 7 12 Rear brake disc and brake disc ...

Page 46: ...frame M10 64 6 4 46 Left support frame enclosure and right support frame enclosure M10 64 6 4 46 Support frame enclosure and side frame enclo sure M10 64 6 4 46 Top frame enclosure and side frame enclosure M10 64 6 4 46 Seat support and frame M8 16 1 6 11 Select lever bracket and seat support M10 32 3 2 23 Skid plate and frame M6 7 0 7 5 1 Part to be tightened Thread size Tightening torque Remarks...

Page 47: ...ise specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERIAL Torque Metric unit Multiplier Imperial unit m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz S...

Page 48: ...rter idle gear shaft M Starter wheel gear E Clutch housing assembly shaft end LS Clutch carrier assembly E One way clutch bearing M Middle driven shaft splines M Drive axle driven sprocket high wheel gear and low wheel gear M Middle drive gear and clutch dog shift fork groove M Timing chain sprocket E Shift drum E Shift fork guide bar E Shift drum stopper ball E Shift lever 2 assembly LS Shift lev...

Page 49: ...EC COOLANT FLOW DIAGRAMS COOLANT FLOW DIAGRAMS 1 Radiator 2 Thermo switch 3 3 Radiator outlet hose 4 Radiator inlet hose 5 Radiator outlet pipe 6 Radiator inlet pipe 6 5 A A 4 3 1 2 A A www midwestmanuals com ...

Page 50: ...Coolant breather hose 2 Coolant breather pipe 3 Radiator outlet pipe 4 Water pump inlet hose 5 Water pump outlet pipe 6 Water pump outlet hose 7 Coolant outlet hose 8 Radiator inlet pipe 8 3 A A 7 1 2 3 4 5 6 A A www midwestmanuals com ...

Page 51: ...2 26 SPEC COOLANT FLOW DIAGRAMS 1 Coolant outlet hose 2 Radiator inlet pipe 2 1 www midwestmanuals com ...

Page 52: ...2 27 SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 Camshaft 2 Oil delivery pipe 2 3 Oil delivery pipe 3 4 Crankshaft 4 1 2 3 www midwestmanuals com ...

Page 53: ...2 28 SPEC OIL FLOW DIAGRAMS 1 Oil delivery pipe 1 2 Oil delivery pipe 2 3 Oil delivery pipe 3 4 Oil pump 5 Oil strainer 4 5 3 2 1 www midwestmanuals com ...

Page 54: ...29 SPEC OIL FLOW DIAGRAMS 1 Oil filter cartridge 2 Oil pipe adapter 3 Oil delivery pipe 2 4 Oil delivery pipe 1 5 Drive axle 6 Relief valve 7 Oil pump 8 Oil strainer 1 3 4 5 6 7 8 2 www midwestmanuals com ...

Page 55: ...2 30 SPEC OIL FLOW DIAGRAMS 1 Oil outlet pipe 2 Oil inlet pipe 3 Oil outlet hose 4 Oil inlet hose 5 Oil cooler inlet pipe 2 6 Oil cooler outlet pipe 2 5 6 A A 1 2 4 3 A A www midwestmanuals com ...

Page 56: ...MS 1 Oil cooler 2 Oil cooler inlet pipe 2 3 Oil cooler outlet pipe 2 4 Oil cooler inlet hose 5 Oil cooler outlet hose 6 Oil cooler inlet pipe 1 7 Oil cooler outlet pipe 1 2 3 2 4 3 5 A A B C 1 6 7 B C A A www midwestmanuals com ...

Page 57: ...ob 8 Light switch 9 Coolant reservoir breather hose 0 Parking brake switch lead A Parking brake cable B Crankcase breather hose C Gear position switch D Reverse switch lead E Front brake hoses F Differential gear case breather hose G Reverse switch terminal H Gear position switch lead Ñ Ñ Ê È É Ï Ë Ð Î Í Ì C B A A B C 2 7 8 5 F 9 3 0 A B 1 5 3 4 6 C D E G H D 9 Ë www midwestmanuals com ...

Page 58: ... the hoses Ì Fasten the throttle cable parking brake switch lead and parking brake cable to the air duct assembly 1 with the plastic band Í Fasten the throttle cable to the air duct assembly 1 with the plastic band Î Fasten the radiator inlet hose and throttle cable with the plastic bands Ï 20 mm 0 79 in or less Ð 5 mm 0 20 in or less Ñ 15 Ñ Ñ Ê È É Ï Ë Ð Î Í Ì C B A A B C 2 7 8 5 F 9 3 0 A B 1 5 ...

Page 59: ...buretor heater È Fasten the parking brake switch lead and park ing brake cable to the air duct assembly 1 with the plastic band É 55 65 mm 2 17 2 56 in Ê Fasten the wire harness to the frame with the plastic bands Ë Pass the tail brake light lead through the grom met Ì Pass the wire harness through the loop in the guide C C A B E C C D D D D C C B A E É Ï Ì Í Î È 1 2 3 4 5 6 Ê Ë 7 8 Ò Ñ Ò Ó Ñ Ñ Ð ...

Page 60: ... lead gear position switch lead thermo switch 1 lead carburetor heater lead and parking brake switch lead with the plastic band Ñ Fasten the wire harness with the plastic holders Ò Fasten the tail brake light lead with the plastic holders Ó Push the excess tail brake light lead into the rear fender so that there is no slack in the lead C C A B E C C D D D D C C B A E É Ï Ì Í Î È 1 2 3 4 5 6 Ê Ë 7 ...

Page 61: ...Thermo switch 3 B Gear motor couplers C Coolant reservoir hose D Speed sensor coupler E A C magneto couplers F Parking brake switch lead G Parking brake cable H Throttle cable I Radiator inlet pipe J Rear brake pipe K Radiator outlet pipe L Gear motor lead M Brake light switch lead N Indicator light assembly leads O Auxiliary DC jack lead A B D D C Ó Õ Ö Ô Ø Ù É É Ê Ê Ë Ì Î Ï Ð È Ñ Ò B A C D D 3 5...

Page 62: ... Î 12 22 mm 0 47 0 87 in Ï Fasten the wire harness starter motor lead ground lead and starter choke cable to the frame with the plastic band Ð Fasten the wire harness starter motor lead and ground lead to the frame with the plas tic band Ñ Fasten the wire harness speed sensor lead starter choke cable starter motor lead and ground lead with the plastic band A B D D C Ó Õ Ö Ô Ø Ù É É Ê Ê Ë Ì Î Ï Ð È...

Page 63: ...r outlet pipe with the plastic band Fasten the wire harness starter choke cable starter motor lead and ground lead with the plastic bands Ø Fasten the gear motor lead with the plastic band Ù Fasten the wire harness brake light switch lead and starter choke cable with the plastic band A B D D C Ó Õ Ö Ô Ø Ù É É Ê Ê Ë Ì Î Ï Ð È Ñ Ò B A C D D 3 5 L K I H J L 3 M 4 O N 1 2 3 4 5 6 7 F C D E G 9 0 A B Í...

Page 64: ...se 9 Ground lead 0 Rear brake hose A Parking brake cable B Ignition coil C Rear brake pipe D Wire harness E Fuel tank breather hose F Rollover valve G Fuel return hose H Fuel suction hose H H H H G G G G E E F F D D D D Ï Î É Ë Ë È Ê Ì Í Ð Ñ Ò Ó Ô Õ Ö Ø Ù Ú Û Ø Ù Í A 0 5 B 3 5 5 3 A 3 0 A 3 0 C D A B I D D C F F E E G G H H A C B I 1 2 3 4 5 7 8 9 0 A 6 H G F E www midwestmanuals com ...

Page 65: ...the metal holder Í Fasten the A C magneto leads reverse switch lead gear position switch lead thermo switch 1 lead carburetor heater lead and parking brake switch lead with the plastic bands Î 195 205 mm 7 68 8 07 in Ï 15 25 mm 0 59 0 98 in Ð Fasten the wire harness with the plastic band Ñ Fasten the parking brake cable and wire har ness with the plastic clip H H H H G G G G E E F F D D D D Ï Î É ...

Page 66: ...plastic holders Fasten the final gear case breather hose with the plastic holders Ø Fasten the parking brake cable and final gear case breather hose with the plastic holders Ù Fasten the rear brake hose with the plastic bands Ú Fasten the rear brake pipe with the plastic bands Û Fasten the wire harness with the plastic bands H H H H G G G G E E F F D D D D Ï Î É Ë Ë È Ê Ì Í Ð Ñ Ò Ó Ô Õ Ö Ø Ù Ú Û Ø...

Page 67: ...he throttle cable through the cable guide É Fasten the speed sensor lead starter choke cable starter motor lead and ground lead with the plastic band Ê Fasten the wire harness and A C magneto lead with the plastic band Ë Fasten the wire harness with the plastic band Ì Fasten the fuel hose with the metal holder A B B A B B É Ê Ò Ð Ô Õ Ó Ð Ï Ñ 1 2 3 4 9 8 2 È Ë Ì Í Î 5 6 7 8 www midwestmanuals com ...

Page 68: ...e harness with the plastic bands Ò The end of the spark plug cap boot must face towards the passenger side of the vehicle Ó Pass the spark plug lead through the cutout in the protective cover as shown Ô Fasten the rear brake pipe with the plastic band Õ Fasten the wire harness speed sensor lead starter choke cable starter motor lead and ground lead with the plastic band A B B A B B É Ê Ò Ð Ô Õ Ó Ð...

Page 69: ...k switch 8 Main switch 9 Starter choke knob 0 Light switch A Differential gear case breather hose B Radiator fan motor breather hose C Left headlight lead D Throttle cable E Right headlight lead F Starter motor lead G Starter relay lead H Four wheel drive relay 1 I Four wheel drive relay 2 J Starter relay N R P LOCK DIFF D D E E C C B A A B D D C C E E P Q R S T U S Q P R T U V D Ð Ñ Ò A B 1 2 3 4...

Page 70: ... indicator light V C D I unit È Fasten the wire harness with the plastic bands É Pass the radiator fan motor breather hose dif ferential gear case breather hose coolant reser voir breather hose and brake light switch lead through the guide Ê Pass the radiator fan motor breather hose dif ferential gear case breather hose throttle cable and brake light switch lead through the guide N R P LOCK DIFF D...

Page 71: ...holder Î Fasten the starter motor lead and starter relay lead with the plastic holder Ï Fasten the positive battery lead with the plastic holder Ð 60 mm 2 36 in Ñ 4 mm 0 16 in of clearance or more is required around the boot Ò Make sure that the washer is installed on the side of the pedal assembly bracket towards the boot N R P LOCK DIFF D D E E C C B A A B D D C C E E P Q R S T U S Q P R T U V D...

Page 72: ...e cable 8 Wire harness 9 Front brake hoses 0 Coolant reservoir hose A Ground lead B Starter relay lead È Fasten the coolant reservoir breather hose with the plastic band É Fasten the front brake hose with the plastic band Ê Fasten the front brake hose with the plastic band Ë Fasten the radiator outlet hose with the plastic band A C B B B C B A Ì Í È É Ê Ë A B 1 2 3 4 5 6 7 8 9 9 0 3 È www midwestm...

Page 73: ...ound lead with the plastic band Í Fasten the differential gear case breather hose coolant reservoir hose radiator fan motor lead and thermo switch 3 lead with the plastic holder A C B B B C B A Ì Í È É Ê Ë A B 1 2 3 4 5 6 7 8 9 9 0 3 È www midwestmanuals com ...

Page 74: ...1 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 300 Valves Check valve clearance Adjust if necessary Cooling system Check coolant leakage Repair if necessary Replace coolant every 24 months Spark plug Check condition Adjust gap and clean Replace if necessary Air filter element Clean Replace if necessary Every 5 to 8 hours more often in heavy dust or sand 12 maximum if very low dust Carburetor Ch...

Page 75: ...r if necessary Wheel bearings Check bearing assemblies for looseness damage Replace if damaged Front and rear suspension Check operation and for leakage Correct if necessary Steering system Check operation and for looseness Replace if damaged Check toe in Adjust if necessary Rear upper and lower knuckle piv ots Lubricate with lithium soap based grease Drive shaft universal joint Lubricate with lit...

Page 76: ...e valve clearance when the piston is at the Top Dead Center TDC on the com pression stroke 1 Remove driver seat passenger seat console Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 2 Lift the cargo bed up 3 Remove tappet cover intake 1 tappet covers exhaust 2 4 Disconnect spark plug cap 3 5 Remove spark plug 6 Remove air shroud 1 1 1 www midwestmanuals com ...

Page 77: ...aligned with the stationary pointer the piston is at the Top Dead Center TDC NOTE When the piston is at the Top Dead Center TDC on the compression stroke there should be clearance between the valve stem tips and their respective rocker arm adjusting screws If there is no clearance rotate the crankshaft counterclockwise one turn c Measure the valve clearance using a thick ness gauge 3 Valve clearan...

Page 78: ...the proper clearance is obtained 11 Install all removed parts NOTE Install all removed parts in the reverse order of their disassembly Note the following points 12 Install engine cooling fan 13 Install air shroud 1 14 Install spark plug tappet covers exhaust tappet cover intake 15 Lower the cargo bed 16 Install console passenger seat driver seat Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapt...

Page 79: ...achometer to the spark plug lead Digital engine test tachometer P N YU 8036 C Engine tachometer P N 90890 03113 5 Check engine idling speed Out of specification Adjust 6 Adjust engine idling speed a Turn the throttle stop screw 1 in or out until the specified idling speed is obtained Engine idling speed 1 450 1 550 r min Turning in Idling speed becomes higher Turning out Idling speed becomes lower...

Page 80: ... idling speed 1 Remove driver seat passenger seat console 2 Remove throttle valve cover 1 3 Check throttle cable a Slack Remove the slack a 4 Adjust throttle cable a Loosen the locknut 1 b Turn the adjuster 2 in or out until there is no slack c Tighten the locknut NOTE _ After adjusting the throttle cable depress the accelerator pedal a few times and make sure that the throttle valve 3 closes comp...

Page 81: ...er 2 from the starter cable b Measure the starter plunger stroke distance a of the starter choke knob 3 fully close to fully open position If the distance is out of specification adjust it as described below È Fully closed position É Fully open position c Pull back the boot 4 d Loosen the locknut 5 e Turn the adjuster 6 in or out until the cor rect distance is obtained f Tighten the locknut 5 g Pu...

Page 82: ...Wear damage Replace insulator 2 Abnormal color Replace Normal color is a medium to light tan color 5 Clean the spark plug with a spark plug cleaner or wire brush Standard spark plug DPR8EA 9 NGK 6 Measure spark plug gap a Use a wire gauge or thickness gauge Out of specification Regap 7 Install spark plug NOTE Before installing a spark plug clean the gasket surface and plug surface 8 Lower the carg...

Page 83: ...iver seat passenger seat console Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 2 Lift the cargo bed up 3 Attach tachometer timing light to the spark plug lead Digital engine test tachometer P N YU 8036 C Engine tachometer P N 90890 03113 Timing light P N 90890 03141 Battery powered timing light P N YM 33277 A 4 Remove air shroud 1 1 1 5 Remove engine cooling fan 1 1 www midwestmanuals c...

Page 84: ...g fan 8 Install air shroud 1 9 Detach timing light tachometer 10 Lower the cargo bed 11 Install console passenger seat driver seat Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 MEASURING THE COMPRESSION PRESSURE NOTE Insufficient compression pressure will result in a loss of performance 1 Check valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE 2 Start th...

Page 85: ...ric starter be sure the battery is fully charged with the throttle wide open until the com pression reading on the gauge stabilizes Compression gauge P N YU 33223 90890 03081 Adapter P N YU 33223 4 90890 04082 Compression pressure with oil introduced into cylinder Reading Diagnosis Higher than without oil Worn or damaged pis tons Same as with out oil Defective ring s valves cylinder head gasket or...

Page 86: ...8 3 Check engine oil level Oil level should be between the maximum 1 and minimum 2 marks Oil level low Add oil to the proper level NOTE Do not screw the dipstick 3 in when checking the oil level NOTE Recommended oil classification API Service SE SF SG type or equiva lent e g SF SE CC SF SE SD etc CAUTION Do not allow foreign material to enter the crankcase 4 Start the engine and let it warm up for...

Page 87: ... SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 CHANGING THE ENGINE OIL 1 Start the engine and let it warm up for sev eral minutes 2 Stop the engine and place an oil pan under the engine 3 Remove driver seat passenger seat console Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 4 Remove engine oil filler plug dipstick 1 engine oil drain bolt 2 Drain the engine oil from the crankcase 5 If...

Page 88: ... Nm 1 7 m kg 12 ft lb 6 Install engine oil drain bolt 1 7 Fill crankcase with sufficient oil to reach the specified level Refer to CHECKING THE ENGINE OIL LEVEL 8 Install engine oil filler plug 9 Warm up the engine for a few minutes then stop the engine 10 Check engine for engine oil leaks oil level Refer to CHECKING THE ENGINE OIL LEVEL Oil quantity Periodic oil change 1 90 L 1 67 Imp qt 2 01 US ...

Page 89: ...RANKSHAFT AND OIL PUMP in chapter 4 d Start the engine after solving the problem s and check the engine oil pressure again e Tighten the oil gallery bolt to specification 12 Install console passenger seat driver seat Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 T R Oil gallery bolt 7 Nm 0 7 m kg 5 1 ft lb CLEANING THE AIR FILTER NOTE There is a check hose 1 at the bottom of the air fil...

Page 90: ...tion without the filter element will affect carbu retor tuning with subsequent poor perfor mance and possible engine overheating 4 Check air filter element Damaged Replace 5 Clean air filter element a Wash the element gently but thoroughly in solvent WARNING Use a cleaning solvent which is designed to clean parts only Never use gasoline or low flash point solvents as they may cause a fire or explo...

Page 91: ... to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 CHECKING THE COOLANT LEVEL 1 Place the vehicle on a level surface 2 Lift the hood up 3 Check coolant level The coolant level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended coolant to the proper level CAUTION Adding water instead of coolant lowers the antifreeze content of the c...

Page 92: ...the coolant has settled 6 Close the hood CHANGING THE COOLANT 1 Remove driver seat passenger seat console Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 2 Lift the hood up 3 Remove coolant reservoir cap 1 4 Disconnect coolant reservoir hose 2 5 Drain coolant from the coolant reservoir 6 Connect coolant reservoir hose 7 Remove coolant drain bolt water pump 1 along with the copper washer w...

Page 93: ...ck rag or a towel over the radia tor cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped turn the radiator cap counterclockwise while pressing down on it and then remove it 9 Drain coolant 10 Disconnect coolant outlet hose 1 water pump inlet hose 2 11 Drain coolant 12 Check copper washer 1 coolant drain...

Page 94: ...harmful and should be handled with special care WARNING If coolant splashes in your eyes thor oughly wash them with water and consult a doctor If coolant splashes on your clothes quickly wash it away with water and then with soap and water If coolant is swallowed induce vomiting and get immediate medical attention Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion ...

Page 95: ...ater Do not mix different types of antifreeze 17 Install air bleed bolt 18 Install radiator cap T R 9 Nm 0 9 m kg 6 5 ft lb 19 Fill coolant reservoir with the recommended coolant to the maxi mum level mark a 20 Install coolant reservoir cap 21 Start the engine warm it up for several min utes and then turn it off 22 Check coolant level Refer to CHECKING THE COOLANT LEVEL NOTE Before checking the co...

Page 96: ...to START with the transmission in neutral posi tion Coolant temperature warning light comes on momentarily Coolant temperature and electrical circuit are OK Go ahead with riding Coolant temperature warning light does not come on Coolant temperature warning light comes on Check the electrical circuit CHECKING THE V BELT 1 Remove driver seat passenger seat console Refer to SEATS ENCLOSURE HOOD AND C...

Page 97: ...Replace V belt a Install the bolts 1 90101 06016 into the secondary fixed sheave hold NOTE Tightening the bolts 1 will push the secondary sliding sheave away causing the gap between the secondary fixed and sliding sheaves to widen b Remove the V belt 1 from the primary sheave and secondary sheave c Install the V belt NOTE Install the V belt so that its arrow faces the direction shown in the illust...

Page 98: ...ailpipe from the muffler a Remove the bolts 1 b Remove the tailpipe 2 by pulling it out of the muffler c Tap the tailpipe lightly with a soft face ham mer or suitable tool then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the muffler d Insert the tailpipe 2 into the muffler and align the bolt holes e Insert the bol...

Page 99: ... cylinder 2 Brake pedal free play 0 mm 0 0 in 2 Adjust brake pedal free play a Loosen the locknut 1 b Turn brake rod 2 in or out until the correct free play is obtained c Tighten the locknut to specification NOTE _ Make sure that there is no brake drag on the front or rear wheels Turning in Free play is increased Turning out Free play is decreased T R Locknut 17 Nm 1 7 m kg 12 ft lb www midwestman...

Page 100: ...rking brake cable free play 2 3 mm 0 079 0 118 in 4 Adjust parking brake cable free play a Pull back the adjuster cover 1 b Loosen the locknut 2 c Turn the adjuster 3 in or out until the cor rect free play is obtained d Tighten the locknut 2 e Slide the adjuster cover 1 to its original position 5 Install console passenger seat driver seat Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Tu...

Page 101: ...es or plastic parts Always clean up spilled fluid immediately WARNING Use only the designed quality brake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor perfor mance Be careful that water does not enter the master cylinder when refilling W...

Page 102: ... chapter 8 3 Operate the brake pedal 4 Install front wheels Brake pad wear limit a 1 5 mm 0 06 in CHECKING THE REAR BRAKE PADS 1 Check brake pads Wear indicator groove 1 almost disap peared Replace the brake pads as a set Refer to FRONT AND REAR BRAKES in chapter 8 2 Operate the brake pedal Brake pad wear limit a 1 5 mm 0 06 in CHECKING THE BRAKE HOSES AND BRAKE PIPES 1 Remove driver seat passenge...

Page 103: ...ion and apply the brake pedal 5 Check brake hose clamps Loosen Tighten 6 Lower the cargo bed 7 Close the hood 8 Install console passenger seat driver seat Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 3 2 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the brake system if The system has been disassembled A brake hose or brake pipe have been loosened or removed The brake fluid has been...

Page 104: ...l towards its limit h Tighten the bleed screw when the pedal limit has been reached then release the pedal i Repeat steps e to h until all the air bub bles have disappeared from the fluid j Tighten the bleed screw NOTE If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the system have disappeared k Add b...

Page 105: ...ake sure the select lever is in NEUTRAL b Loosen both locknuts 1 CAUTION The select lever shift rod locknut select lever side has left handed threads To loosen the locknut turn it clockwise c Adjust the shift rod length for smooth and correct shifting d Tighten the locknuts 1 T R Locknut 15 Nm 1 5 m kg 11 ft lb ADJUSTING THE BRAKE LIGHT SWITCH NOTE The brake light switch is operated by move ment o...

Page 106: ...ght comes on at the proper time Direction a Brake light comes on sooner Direction b Brake light comes on later CHECKING THE FINAL GEAR OIL LEVEL 1 Place the vehicle on a level surface 2 Remove oil filler plug 1 3 Check oil level Oil level should be up to the brim of the hole Oil level low Add oil to the proper level CAUTION Take care not allow foreign material to enter the final gear case 4 Instal...

Page 107: ...he drain plug gasket If it is damaged replace it with a new one 6 Fill final gear case CAUTION Take care not to allow foreign material to enter the final gear case 7 Install oil filler plug Periodic oil change 0 25 L 0 22 Imp qt 0 26 US qt Total amount 0 28 L 0 25 Imp qt 0 30 US qt Recommended oil SAE 80 API GL 4 Hypoid gear oil T R 20 Nm 2 0 m kg 14 ft lb T R 23 Nm 2 3 m kg 17 ft lb CHECKING THE ...

Page 108: ...ear case 4 Install oil filler plug Recommended oil SAE 80 API GL 4 Hypoid gear oil T R 23 Nm 2 3 m kg 17 ft lb CHANGING THE DIFFERENTIAL GEAR OIL 1 Place the vehicle on a level surface 2 Place a receptacle under the differential gear case 3 Remove oil filler plug 1 drain plug 2 4 Drain differential gear oil 5 Install drain plug NOTE Check the gasket drain plug If it is damaged replace it with new ...

Page 109: ...its level CAUTION Take care not to allow foreign material to enter the differential gear case 7 Install oil filler plug Periodic oil change 0 32 L 0 28 Imp qt 0 34 US qt Total amount 0 33 L 0 29 Imp qt 0 35 US qt Recommended oil SAE 80 API GL 4 Hypoid gear oil T R 23 Nm 2 3 m kg 17 ft lb CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS 1 Check dust boots 1 Damage Replace Refer to FRONT CONSTANT VEL...

Page 110: ...rod end s have vertical play Replace the tie rod end s 4 Raise the front end of the vehicle so that there is no weight on the front wheels 5 Check ball joints and or wheel bearings Move the wheels laterally back and forth Excessive free play Replace the front arms upper and lower and or wheel bear ings ADJUSTING THE TOE IN 1 Place the vehicle on a level surface 2 Measure toe in Out of specificatio...

Page 111: ...accident After setting the toe in to specification run the vehicle slowly for some distance with both hands lightly holding the steer ing wheel and check that the steering wheel responds correctly If not turn either the right or left tie rod within the toe in specification a Mark both tie rods ends This reference point will be needed during adjustment b Loosen the locknut tie rod end 1 on each tie...

Page 112: ... Turn the adjuster 1 to increase or decrease the spring preload ADJUSTING THE REAR SHOCK ABSORBERS WARNING Always adjust both shock absorber spring preload to the same setting Uneven adjust ment can cause poor handling and loss of stability NOTE The spring preload of the shock absorbers can be adjusted to suit the operator s preference weight and the operating conditions 1 Adjust spring preload Tu...

Page 113: ...llowing are minimums Front 63 kPa 0 63 kg cm2 9 psi Rear 91 kPa 0 91 kg cm2 13 psi 3 Use no more than Front 250 kPa 2 5 kg cm2 36 psi Rear 250 kPa 2 5 kg cm2 36 psi when seating the tire beads Higher pressures may cause the tire to burst Inflate the tires slowly and carefully Fast inflation could cause the tire to burst MAXIMUM LOADING LIMIT 1 Vehicle loading limit total weight of cargo operator p...

Page 114: ...and may cause loss of control Maintain proper tire pressures Set tire pressures when the tires are cold Tire pressures must be equal in both front tires and equal in both rear tires 2 Check tire surfaces Wear damage Replace WARNING It is dangerous to ride with a worn out tire When tire wear is out of specification replace the tire immediately Cold tire pressure Front Rear Standard 70 kPa 0 70 kg c...

Page 115: ...ly on the rim CHECKING AND LUBRICATING THE CABLES WARNING A damaged cable sheath may cause corro sion and interfere with the cable move ment An unsafe condition may result so replace a damaged cable as soon as possi ble 1 Check cable sheath Damage Replace 2 Check cable operation Unsmooth operation Lubricate or replace NOTE Hold the cable end up and apply several drops of lubricant to the cable 3 A...

Page 116: ...3 43 CHK ADJ LUBRICATING THE PEDAL ETC LUBRICATING THE PEDAL ETC 1 Lubricate the pivoting parts Recommended lubricant Lithium soap based grease ______ I www midwestmanuals com ...

Page 117: ...ause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention CAUTION _ This is a sealed battery Never remove the sealing caps because the b...

Page 118: ...ls NOTE _ The charge state of an MF battery can be checked by measuring its open circuit volt age i e the voltage when the positive termi nal is disconnected No charging is necessary when the open cir cuit voltage equals or exceeds 12 8 V b Check the charge of the battery as shown in the charts and the following example Example c Open circuit voltage 12 0 V d Charging time 6 5 hours e Charge of th...

Page 119: ...tery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery termi nal and that they are not shorted A cor roded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging pro...

Page 120: ...mperage exceeded If the amperage does not exceed the standard charging amperage after 5 minutes replace the battery If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging amperage Leave the battery unused for more than 30 minutes before measuring its open ...

Page 121: ... battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the battery This type of battery charger cannot charge an MF battery A variable voltage charger is recommended Charger Ammeter Voltmeter NOTE Leave the battery unused for more than 30 minutes before measuring its open circuit volt ag...

Page 122: ...ry terminals 11 Install battery case cover 12 Close the hood CHECKING THE FUSES CAUTION Always turn off the main switch when checking or replacing a fuse Otherwise a short circuit may occur 1 Lift the hood up 2 Remove battery case cover 3 Check fuses a Connect the pocket tester to the fuse and check it for continuity NOTE Set the tester to the Ω 1 position b If the tester indicates replace the fus...

Page 123: ...r materials in place of a fuse An improper fuse may cause extensive damage to the electrical system a malfunction of the lighting and ignition systems and could possibly cause a fire 5 Install battery case cover 6 Close the hood Description Current rating Quantity Main 30 A 1 Lighting system fuse 15 A 1 Ignition 10 A 1 Terminal Auxiliary DC jack 10 A 1 4WD Four wheel drive 3 A 1 Signaling system f...

Page 124: ...e the defective bulb by unhooking the headlight bulb holder tabs 2 WARNING Keep flammable products and your hands away from the bulb while it is on since it will be hot Do not touch the bulb until it cools down 4 Install bulb Secure the new bulb with the headlight bulb holder CAUTION Avoid touching the glass part of the bulb Keep it free from oil otherwise the trans parency of the glass life of th...

Page 125: ...he defective bulb WARNING Keep flammable products and your hands away from the bulb while it is on since it will be hot Do not touch the bulb until it cools down 3 Install bulb Secure the new bulb with the tail brake light bulb holder CAUTION Avoid touching the glass part of the bulb Keep it free from oil otherwise the trans parency of the glass life of the bulb and luminous flux will be adversely...

Page 126: ...3 53 CHK ADJ CHANGING THE TAIL BRAKE LIGHT BULB 4 Install tail brake light bulb holder with bulb 5 Install cargo bed panel T R 7 Nm 0 7 m kg 5 1 ft lb _______ I www midwestmanuals com ...

Page 127: ... air ducts muffler and exhaust pipe Remove the parts in the order listed Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Driver seat passenger seat console air duct end cover left protector Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Engine cooling fan air duct assembly Refer to ENGINE COOLING FAN AND A C MAGNETO ...

Page 128: ... 3 7 4 New T R 7 Nm 0 7 m kg 5 1 ft Ib 5 New 2 6 1 Order Job Part Q ty Remarks Fuel tank Refer to FUEL PUMP AND FUEL TANK in chapter 6 1 Heat protector 1 2 Muffler stay 1 3 Muffler damper 1 4 Muffler bracket 1 5 Muffler gasket 1 1 6 Exhaust pipe gasket 1 2 7 Air duct assembly 1 1 8 Air duct assembly 2 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 129: ...Ib Order Job Part Q ty Remarks Removing the select lever unit and coolant reservoir Remove the parts in the order listed 1 Shift arm 1 2 Select lever shift rod 1 CAUTION The select lever shift rod locknut select lever side has left handed threads To loosen the locknut turn it clockwise 3 Select lever unit 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 130: ...hose 1 Disconnect 2 Coolant outlet hose 1 Disconnect 3 Oil inlet hose 1 Disconnect 4 Oil outlet hose 1 Disconnect 5 Vacuum hose 1 Disconnect 6 Spark plug lead 1 7 Crankcase breather hose 1 8 Thermo switch 1 lead 1 Disconnect 9 Starter motor lead 1 Disconnect 10 A C magneto lead coupler 2 Disconnect 11 Speed sensor lead coupler 1 Disconnect 12 Gear position switch lead coupler 1 Disconnect www midw...

Page 131: ... 2 ft Ib 12 1 2 4 3 6 5 7 8 9 14 13 10 11 Order Job Part Q ty Remarks 13 Reverse switch lead 1 Green White 14 Engine ground lead 1 Disconnect For installation reverse the removal pro cedure ENGINE REMOVAL www midwestmanuals com ...

Page 132: ...s in the order listed Front skid plate center skid plate rear skid plate Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Rear wheels Refer to REAR WHEELS AND BRAKE DISC in chapter 8 Final drive gear assembly Refer to REAR CONSTANT VELOCITY JOINTS FINAL DRIVE GEAR AND DRIVE SHAFT in chapter 7 www midwestmanuals com ...

Page 133: ... them to full torque specifica tions Refer to INSTALLING THE ENGINE 2 Engine mounting bolt front upper 2 3 Engine mounting bolt front lower nut 1 1 4 Engine assembly 1 5 Rubber damper nut front 2 6 Rubber damper front 2 7 Rubber damper rear 2 8 Engine mounting bolt rear 4 9 Engine bracket left 1 10 Engine bracket right 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 134: ...t upper 6 rubber damper nut rear 7 NOTE Do not fully tighten the bolts and nuts 2 Tighten engine mounting bolt rear 1 rubber damper nut front 3 engine mounting bolt M10 front lower nut 5 engine mounting bolt M6 front upper 6 rubber damper nut rear 7 T R 33 Nm 3 3 m kg 24 ft lb T R 52 Nm 5 2 m kg 37 ft lb T R 56 Nm 5 6 m kg 40 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb T R 52 Nm 5 2 m kg 37 ft lb www midwe...

Page 135: ...er seat passenger seat console Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 air shroud 1 engine cooling fan timing plug Refer to ADJUSTING THE VALVE CLEARANCE in chapter 3 1 Union bolt 3 2 Copper washer 7 3 Oil delivery pipe 3 1 4 Oil delivery pipe 2 1 5 Spark plug 1 6 Tappet cover intake 1 7 Tappet cover exhaust 2 www midwestmanuals com ...

Page 136: ... COVER Order Job Part Q ty Remarks 8 Cylinder head cover 1 Refer to REMOVING THE CYLINDER HEAD COVER and INSTALLING THE CYLINDER HEAD COVER 9 Dowel pin 2 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 137: ...oke there should be clearance between the valve stem tips and their respective rocker arm adjusting screws If there is no clearance rotate the crankshaft counterclockwise one turn 2 Remove cylinder head cover NOTE Loosen each bolt 1 4 of a turn at a time in stages and in a crisscross pattern After all the bolts are loosened remove them 2 1 CHECKING THE CYLINDER HEAD COVER 1 Check cylinder head cov...

Page 138: ...der head cover 2 Install cylinder head cover washers 1 bolts 2 Bolt 25 mm 3 Bolt 40 mm 4 Bolt 55 mm 5 Bolt 55 mm 6 Bolt 115 mm 7 Bolt 130 mm NOTE Tighten the cylinder head cover bolts in stages using a crisscross pattern Sealant Quick Gasket P N ACC 11001 05 01 Yamaha bond No 1215 P N 90890 85505 T R 10 Nm 1 0 m kg 7 2 ft lb www midwestmanuals com ...

Page 139: ...r head cover Refer to CYLINDER HEAD COVER 1 Plug O ring 1 1 2 Rocker arm shaft stopper 2 3 Rocker arm shaft 2 1 Refer to REMOVING THE ROCKER ARMS and INSTALLING THE ROCKER ARMS 4 Rocker arm 3 1 5 Rocker arm shaft 3 O ring 1 1 6 Rocker arm 4 1 7 Rocker arm shaft 1 O ring 1 1 8 Rocker arm 1 1 9 Rocker arm 2 1 www midwestmanuals com ...

Page 140: ...4 14 ENG ROCKER ARMS Order Job Part Q ty Remarks 10 Wave washer 4 11 Locknut 5 12 Valve adjuster 5 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 141: ...e discoloration pitting scratches Replace 2 Check rocker arms rocker arm shafts Damage wear Replace a Check the two contact areas on the rocker arms for signs of abnormal wear 1 Rocker arm shaft hole 2 Camshaft lobe contact surface Excessive wear Replace b Check the surface of the rocker arm shafts Blue discoloration pitting scratches Replace check lubrication c Measure the inside diameter a of th...

Page 142: ...he defec tive part s Rocker arm shaft outside diame ter 11 976 11 991 mm 0 4715 0 4721 in Rocker arm to shaft standard clearance 0 009 0 042 mm 0 0004 0 0017 in INSTALLING THE ROCKER ARMS 1 Install rocker arms 1 rocker arm shafts 2 NOTE The thread hole a of the rocker arm shaft must face to the outside After installation make sure that the thread hole a of the rocker arm shaft is positioned correc...

Page 143: ...ose Refer to WATER PUMP in chapter 5 Muffler exhaust pipe thermo switch 1 lead Refer to ENGINE REMOVAL Cylinder head cover Refer to CYLINDER HEAD COVER 1 Timing chain tensioner cap bolt 1 Refer to REMOVING THE CAMSHAFT AND CYLINDER HEAD and INSTALL ING THE CAMSHAFT AND CYLINDER HEAD 2 Timing chain tensioner gasket 1 1 3 Timing chain guide exhaust side 1 4 Decompressor cam guide plate 2 5 Camshaft ...

Page 144: ... Order Job Part Q ty Remarks 7 Thermo switch 1 1 8 Cylinder head 1 9 Coolant outlet joint 1 10 Gasket 1 11 Cylinder head gasket 1 12 Dowel pin 2 13 Intake manifold 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 145: ... removing the camshaft sprocket it is not necessary to separate the timing chain 4 Remove cylinder head NOTE Loosen the bolts in the proper sequence Follow the numerical order shown in the illus tration Loosen each bolt 1 4 of a turn at a time until all of the bolts are loose CHECKING THE CAMSHAFT 1 Check cam lobes Pitting scratches blue discoloration Replace 2 Measure cam lobe dimensions a and b ...

Page 146: ... that the decompressor lever pin 1 projects from the camshaft b Check that the decompressor cam 2 moves smoothly CHECKING THE TIMING CHAIN GUIDE EXHAUST SIDE 1 Check timing chain guide exhaust side Wear damage Replace CHECKING THE TIMING CHAIN TENSIONER 1 Check timing chain tensioner Cracks damage rough movement Replace a Lightly press the timing chain tensioner rod into the timing chain tensioner...

Page 147: ...aper NOTE Do not use a sharp instrument to avoid damag ing or scratching spark plug threads valve seats 2 Check cylinder head Scratches damage Replace the cylinder head cover and cylinder head as a set cylinder head water jacket Mineral deposits rust Eliminate 3 Measure cylinder head warpage Out of specification Resurface a Place a straightedge and a thickness gauge across the cylinder head b Use ...

Page 148: ...he bolts in the proper sequence Follow the numerical order shown in the illus tration Tighten the bolts in two stages New T R 38 Nm 3 8 m kg 27 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 2 Install camshaft camshaft sprocket a Turn the crankshaft counterclockwise with a wrench b Align the I mark 1 on the rotor with the stationary pointer 2 on the A C magneto cover When the I mark is aligned with the statio...

Page 149: ...ll holes on camshaft sprocket 7 Punch mark on decompressor spring lever 8 Top front of cylinder head e Install the decompressor cam guide plates 9 and camshaft sprocket bolts 0 NOTE Insert a screwdriver into the timing chain ten sioner hole and push the timing chain guide intake side inward f Remove the retaining wire 3 Install timing chain guide exhaust side T R Camshaft sprocket bolt 20 Nm 2 0 m...

Page 150: ...que WARNING Always use a new gasket NOTE The UP mark on the timing chain tensioner should face up d Remove the screwdriver make sure that the timing chain tensioner rod releases and tighten the cap bolt to the specified torque 5 Check small holes on camshaft sprocket rotor I mark Out of alignment Adjust T R Timing chain tensioner bolt 10 Nm 1 0 m kg 7 2 ft lb T R Timing chain tensioner cap bolt 7 ...

Page 151: ...head Refer to CAMSHAFT AND CYLINDER HEAD 1 Valve cotter 10 Refer to REMOVING THE VALVES AND VALVE SPRINGS and INSTALL ING THE VALVES AND VALVE SPRINGS 2 Valve spring retainer 5 3 Intake valve spring 3 4 Exhaust valve spring 2 5 Intake valve 3 6 Exhaust valve 2 7 Valve stem seal 5 8 Valve spring seat 5 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 152: ...ke and exhaust ports b Check that the valve seals properly There should be no leakage at the valve seat 2 2 Remove valve cotters NOTE Attach a valve spring compressor 1 and valve spring compressor attachment 2 between the valve spring retainer and the cylinder head to remove the valve cotters Valve spring compressor set P N YM 04019 Valve spring compressor P N 90890 04019 Valve spring compressor a...

Page 153: ...ase guide removal installation and to maintain correct fit heat the cylinder head to 100 C 212 F in an oven a Remove the valve guide using a valve guide remover 1 b Install the new valve guide using a valve guide remover 1 and valve guide installer 2 c After installing the valve guide bore the valve guide using a valve guide reamer 3 to obtain proper stem to guide clearance NOTE After replacing th...

Page 154: ...ickness Intake 0 85 1 15 mm 0 0335 0 0453 in Exhaust 0 85 1 15 mm 0 0335 0 0453 in 5 Measure valve stem runout Out of specification Replace NOTE When installing a new valve always replace the guide If the valve is removed or replaced always replace the oil seal 6 Eliminate carbon deposits from the valve face and valve seat 7 Check valve seats Pitting wear Reface the valve seat Runout limit 0 01 mm...

Page 155: ...removed e If the valve seat is too wide too narrow or the seat is not centered the valve seat must be refaced Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in 9 Lap valve face valve seat NOTE After refacing the valve seat or replacing the valve and valve guide the valve seat and valve face should be lapped a Apply...

Page 156: ...ng operation be sure to clean off all of the compound from the valve face and valve seat f Apply Mechanic s blueing dye Dykem to the valve face g Install the valve into the cylinder head h Press the valve through the valve guide and onto the valve seat to make a clear pattern i Measure the valve seat width again If the valve seat width is out of specification reface and relap the valve seat 10 Mea...

Page 157: ...8 in Exhaust 120 6 138 3 N at 31 0 mm 12 30 14 10 kg 27 12 31 09 lb at 1 22 in Spring tilt limit Intake 2 5 1 4 mm 0 055 in Exhaust 2 5 1 6 mm 0 063 in INSTALLING THE VALVES AND VALVE SPRINGS 1 Apply molybdenum disulfide oil onto the valve stem and valve stem seal 2 Install valve spring seats valve stem seals valves valve springs valve spring retainers NOTE Install the valve springs with the large...

Page 158: ... spring compressor attachment 2 Valve spring compressor set P N YM 04019 Valve spring compressor P N 90890 04019 Valve spring compressor attach ment P N YM 01253 1 90890 01243 4 To secure the valve cotters onto the valve stem lightly tap the valve tip with a piece of wood CAUTION Hitting the valve tip with excessive force could damage the valve www midwestmanuals com ...

Page 159: ... WATER PUMP in chapter 5 Cylinder head Refer to CAMSHAFT AND CYLINDER HEAD 1 Coolant inlet joint 1 2 Cylinder O ring 1 1 Refer to INSTALLING THE CYLINDER 3 Cylinder gasket 1 4 Dowel pin 2 5 Piston pin clip 2 Refer to REMOVING THE PISTON and INSTALLING THE PISTON 6 Piston pin 1 7 Piston 1 8 Piston ring set 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 160: ...nd gaps apart while at the same time lifting the piston ring over the top of the piston crown Piston pin puller P N YU 01304 90890 01304 CHECKING THE CYLINDER AND PISTON 1 Check cylinder and piston walls Vertical scratches Rebore or replace the cylinder and the piston 2 Measure piston to cylinder clearance 1st step a Measure the cylinder bore C with a cylin der bore gauge 1 a 50 mm 2 0 in from the...

Page 161: ...the piston bottom edge b If out of specification replace the piston and piston rings as a set 3rd step a Find the piston to cylinder clearance with the following formula b If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set Piston skirt diameter P Standard 99 945 99 995 mm 3 9348 3 9368 in Piston to cylinder clearance Cylinder bore C Piston skirt...

Page 162: ... in cylinder NOTE Insert a ring into the cylinder and push it approximately 50 mm 2 0 in into the cylinder Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore a 50 mm 2 0 in 3 Measure ring end gap Out of specification Replace NOTE You cannot measure the end gap on the expander spacer of the oil control ring If the oil control ring rails show excessive...

Page 163: ...INSTALLING THE PISTON 1 Install piston rings onto the piston NOTE Be sure to install the piston rings so that the manufacturer s marks or numbers are located on the upper side of the rings Lubricate the piston and piston rings liberally with engine oil Piston pin outside diameter 21 991 22 000 mm 0 8658 0 8661 in Limit 21 971 mm 0 8650 in Piston pin bore inside diameter 22 004 22 015 mm 0 8663 0 8...

Page 164: ... piston 1 piston pin 2 piston pin clips 3 NOTE Apply engine oil onto the piston pin piston rings and piston Be sure that the arrow mark a on the piston points to the exhaust side of the engine Before installing the piston pin clip cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase 4 Lubricate piston piston rings cylinder NOTE Apply a liberal coating...

Page 165: ...Install the cylinder with one hand while com pressing the piston rings with the other hand CAUTION Be careful not to damage the timing chain guide during installation Pass the timing chain through the timing chain cavity New T R 42 Nm 4 2 m kg 30 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb www midwestmanuals com ...

Page 166: ...er seat passenger seat console Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Drive belt cover Refer to PRIMARY AND SECONDARY SHEAVES Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Water pump assembly Refer to WATER PUMP in chapter 5 1 Engine cooling fan air duct assembly 1 2 Air shroud 1 1 www midwestmanuals com ...

Page 167: ...1 Refer to REMOVING THE A C MAG NETO and INSTALLING THE A C MAGNETO 7 A C magneto cover gasket 1 1 8 Dowel pin 2 9 Stator lead holder 1 10 Pickup coil 1 11 Stator assembly 1 12 A C magneto rotor 1 Refer to REMOVING THE A C MAG NETO and INSTALLING THE A C MAGNETO 13 Woodruff key 1 14 Starter wheel gear 1 15 Washer 1 16 Starter idle gear shaft 1 17 Bearing 1 www midwestmanuals com ...

Page 168: ...4 42 ENG Order Job Part Q ty Remarks 18 Starter idle gear 1 For installation reverse the removal pro cedure ENGINE COOLING FAN AND A C MAGNETO www midwestmanuals com ...

Page 169: ...S 01880 A Sheave holder P N 90890 01701 2 Remove A C magneto cover gasket dowel pins NOTE Working in a crisscross pattern loosen each bolt 1 4 of a turn Remove them after all of them are loosened 3 Remove A C magneto rotor 1 NOTE Use the flywheel puller 2 Flywheel puller P N YM 01404 90890 01404 CHECKING THE A C MAGNETO 1 Check stator coil pickup coil Damage Replace www midwestmanuals com ...

Page 170: ...he groove a facing the A C magneto rotor b Turn the starter wheel gear counterclock wise È to check that the starter clutch and wheel gear engage If the starter clutch and wheel gear do not engage replace the starter clutch c Turn the starter wheel gear clockwise É to check the starter wheel gear for smooth operation If operation is not smooth replace the starter clutch T R Starter clutch bolts 30...

Page 171: ...the slit 2 Install woodruff key A C magneto rotor NOTE Before installing the rotor clean the outside of the crankshaft and the inside of the rotor After installing the rotor check that the rotor rotates smoothly If not reinstall the key and rotor Sealant Quick Gasket P N ACC 11001 05 01 Yamaha bond No 1215 P N 90890 85505 ENGINE COOLING FAN AND A C MAGNETO www midwestmanuals com ...

Page 172: ...hread of the bolt 2 shown in the illustration Tighten the bolts in stages using a criss cross pattern Sealant Quick Gasket P N ACC 11001 05 01 Yamaha bond No 1215 P N 90890 85505 2 1 New T R 10 Nm 1 0 m kg 7 2 ft lb 4 Install engine cooling fan pulley 1 NOTE Use a sheave holder 2 to hold the primary sheave NOTE Before installing the engine cooling fan pulley do not forget to install the O ring Pri...

Page 173: ...he collar of the engine cooling fan T R 7 Nm 0 7 m kg 5 1 ft lb 7 Install air shroud 1 engine cooling fan air duct assembly 1 NOTE Install the engine cooling fan air duct assembly with the arrow mark a towards the air shroud 1 T R 10 Nm 1 0 m kg 7 2 ft lb ENGINE COOLING FAN AND A C MAGNETO www midwestmanuals com ...

Page 174: ...listed Starter wheel gear Refer to ENGINE COOLING FAN AND A C MAGNETO 1 Nut lock washer 1 1 2 Balancer driven oil pump drive gear 1 Refer to REMOVING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR and INSTALLING THE BALANCER DRIVE GEAR AND BAL ANCER DRIVEN GEAR 3 Chain 1 4 Straight key 1 5 Oil pump driven gear 1 6 Plate 1 7 Balancer drive gear 1 8 Spring 8 www midwestmanuals com ...

Page 175: ...4 49 ENG Order Job Part Q ty Remarks 9 Pin 4 For installation reverse the removal pro cedure BALANCER GEARS AND OIL PUMP GEARS www midwestmanuals com ...

Page 176: ...late 1 balancer drive gear 2 springs 3 pins 4 CHECKING THE OIL PUMP DRIVE GEAR AND OIL PUMP DRIVEN GEAR 1 Check oil pump drive gear 1 oil pump driven gear 2 Cracks wear damage Replace CHECKING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 1 Check balancer drive gear 1 balancer driven gear 2 Damage wear Replace the balancer drive gear and balancer driven gear as a set Excessive noise during oper...

Page 177: ...nstall balancer driven gear NOTE Align the punch mark a on the balancer drive gear with the punch mark b on the balancer driven gear 3 Install lock washer balancer driven gear nut 1 NOTE Place an aluminum plate 2 between the teeth of the balancer drive gear 3 and bal ancer driven gear 4 Apply the molybdenum disulfide grease to the thread of axle and nut 4 Bend the lock washer tabs along the bal an...

Page 178: ... ft Ib T R 14 Nm 1 4 m kg 10 ft Ib LS Order Job Part Q ty Remarks Removing the primary and second ary sheaves Remove the parts in the order listed Engine assembly Refer to ENGINE REMOVAL 1 Drive belt cover 1 2 Rubber gasket 1 3 Bearing housing 1 4 Dowel pin 2 5 Primary sheave assembly 1 Refer to REMOVING THE PRIMARY AND SECONDARY SHEAVES and INSTALLING THE PRIMARY AND SECONDARY SHEAVES 6 V belt 1 ...

Page 179: ...8 5 4 3 2 1 12 7 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib LS Order Job Part Q ty Remarks 7 Primary fixed sheave 1 Refer to REMOVING THE PRIMARY AND SECONDARY SHEAVES and INSTALLING THE PRIMARY AND SECONDARY SHEAVES 8 Secondary sheave assembly 1 9 Drive belt case 1 10 Rubber gasket 2 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 180: ...ove the parts in the order listed 1 Primary pulley sheave cap 1 Refer to ASSEMBLING THE PRIMARY SHEAVE 2 Primary pulley slider 4 3 Spacer 4 4 Primary pulley cam 1 5 Primary pulley weight 8 6 Collar 1 7 Oil seal 2 8 Primary sliding sheave 1 9 O ring 1 For assembly reverse the disassembly procedure www midwestmanuals com ...

Page 181: ...n the order listed 1 Nut 1 Refer to DISASSEMBLING THE SEC ONDARY SHEAVE and ASSEMBLING THE SECONDARY SHEAVE 2 Spring seat 1 3 Compression spring 1 4 Spring seat 1 5 Guide pin 4 6 Secondary sliding sheave 1 7 O ring 2 8 Secondary fixed sheave 1 9 Oil seal 1 0 Oil seal 1 For assembly reverse the disassembly procedure www midwestmanuals com ...

Page 182: ...HE SECONDARY SHEAVE 1 Remove nut 1 a Attach the sheave fixed block 2 locknut wrench 3 and sheave spring compressor 4 to the secondary sheave assembly b Place the sheave fixed block in a vise and secure it c Tighten the sheave spring compressor nut 5 and compress the spring d Loosen the nut 1 with the locknut wrench 3 e Remove the nut 1 f Remove the sheave spring compressor and locknut wrench Sheav...

Page 183: ...heck primary sliding sheave primary fixed sheave Cracks damage Replace CHECKING THE SECONDARY SHEAVE 1 Check secondary fixed sheave smooth operation secondary sliding sheave smooth operation Scratches damage Replace as a set 2 Check torque cam grooves 1 Wear damage Replace 3 Check guide pins 2 Wear damage Replace 4 Check secondary sheave spring Damage Replace 5 Measure secondary sheave spring free...

Page 184: ... install Apply Yamaha Grizzly grease to the inner surface of the collar Apply Yamaha Grizzly grease to the inner surface of the primary sliding sheave 3 Install spacer sliders 1 primary pulley cam 2 primary sliding sheave cap T R 3 Nm 0 3 m kg 2 2 ft lb ASSEMBLING THE SECONDARY SHEAVE 1 Apply BEL RAY assembly lube to the secondary sliding sheave 1 inner surface and oil seals BEL RAY assembly lube ...

Page 185: ...ssembly b Place the sheave fixed block in a vise and secure it c Tighten the sheave spring compressor nut 1 and compress the spring d Install the nut 2 and tighten it to the speci fied torque using the locknut wrench e Remove the sheave spring compressor locknut wrench and sheave fixed block Sheave fixed block P N YM 04135 90890 04135 Locknut wrench P N YM 01348 90890 01348 Sheave spring compresso...

Page 186: ...ary fixed and sliding sheaves to widen Install the V belt so that its arrow faces the direction show in the illustration 2 Tighten primary sheave nut 1 secondary sheave nut 2 NOTE Use the sheave holder 3 to hold the primary sheave First tighten the primary sheave nut 1 then tighten the secondary sheave nut 2 Primary sheave holder P N YS 01880 A Sheave holder P N 90890 01701 T R 120 Nm 12 0 m kg 85...

Page 187: ... Primary and secondary sheaves Refer to PRIMARY AND SECONDARY SHEAVES 1 Clutch housing assembly 1 Refer to REMOVING THE CLUTCH and INSTALLING THE CLUTCH 2 Gasket dowel pin 1 2 3 One way clutch bearing 1 4 Nut 1 5 Clutch carrier assembly 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 188: ...assembling the clutch housing Remove the parts in the order listed 1 Oil seal 1 2 Circlip 1 3 Bearing housing 1 4 Circlip 1 5 Bearing 1 6 Circlip 1 7 Bearing 1 8 Clutch housing 1 For assembly reverse the disassembly procedure www midwestmanuals com ...

Page 189: ...the clutch carrier assembly Universal clutch holder P N YM 91042 90890 04086 CHECKING THE CLUTCH 1 Check clutch housing 1 Heat damage wear damage Replace one way clutch bearing 2 Chafing wear damage Replace NOTE Replace the one way clutch assembly and clutch housing as a set The one way clutch bearing must be installed with the flange side facing in a Install the one way clutch bearing and clutch ...

Page 190: ...h assembly is faulty Replace it 2 Check clutch shoe Heat damage Replace 3 Measure clutch shoe thickness Out of specification Replace Clutch shoe thickness 1 5 mm 0 06 in Clutch shoe wear limit a 1 0 mm 0 04 in INSTALLING THE CLUTCH 1 Install clutch carrier assembly nut 1 NOTE Use a universal clutch holder 2 to hold the clutch carrier assembly 2 Lock the threads with a drift punch Universal clutch ...

Page 191: ...ly with the arrow mark a facing toward the clutch hous ing 4 Install dowel pins gasket clutch housing assembly NOTE Tighten the bolts in stages using a criss cross pattern After tightening the bolts check that the clutch housing assembly to counterclockwise rotates smoothly New T R 10 Nm 1 0 m kg 7 2 ft lb www midwestmanuals com ...

Page 192: ...NGINE REMOVAL Cylinder head Refer to CAMSHAFT AND CYLINDER HEAD Cylinder and piston Refer to CYLINDER AND PISTON A C magneto rotor Refer to ENGINE COOLING FAN AND A C MAGNETO Primary and secondary sheaves Refer to PRIMARY AND SECONDARY SHEAVES Clutch carrier assembly Refer to CLUTCH 1 Timing chain guide intake side 1 2 Timing chain 1 3 Starter motor O ring 1 1 4 Oil filter cartridge O ring 1 www m...

Page 193: ... 2 6 Oil pipe adapter O ring 1 1 7 Relief valve assembly 1 8 Speed sensor 1 9 Shift drum stopper 1 10 Gear position switch 1 11 Reverse switch 1 12 Oil filler cap 1 13 Oil delivery pipe 1 1 14 Drain plug 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 194: ...r cover gasket 1 1 Refer to INSTALLING THE SHIFT LEVERS 2 Dowel pin 1 3 Shift lever 1 1 4 Shift lever 2 assembly 1 5 Right crankcase 1 Refer to SEPARATING THE CRANK CASE and ASSEMBLING THE CRANKCASE 6 Dowel pin 2 7 Left crankcase 1 8 Spacer 1 9 Crankshaft seal 2 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 195: ...moving the crankcase bearings Remove the parts in the order listed Crankshaft and oil pump Refer to CRANKSHAFT AND OIL PUMP Transmission Refer to TRANSMISSION Middle drive driven shaft Refer to MIDDLE GEAR 1 O ring collar 1 1 2 Oil seal 1 3 Bearing retainer 1 4 Bearing 9 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 196: ...er to tap on one side of the crankcase Tap only on reinforced portions of the crankcase Do not tap on the crank case mating surfaces Work slowly and carefully Make sure that the crankcase halves separate evenly c Remove the dowel pins È É CHECKING THE TIMING CHAIN AND GUIDES 1 Check timing chain Cracks stiff Replace the timing chain and camshaft sprocket as a set 2 Check timing chain guides Wear d...

Page 197: ...rfaces thoroughly 3 Check crankcase Cracks damage Replace oil delivery passages Clogged Blow out with compressed air CHECKING THE BEARINGS 1 Check bearings Clean and lubricate then rotate the inner race with a finger Roughness Replace ASSEMBLING THE CRANKCASE 1 Apply sealant Quick Gasket 1 to the mating surfaces of both case halves 2 Install dowel pins 2 Sealant Quick Gasket P N ACC 11001 05 01 Ya...

Page 198: ...stages using a criss cross pattern Apply sealant Quick Gasket 4 to the thread of the bolt 2 shown in the illustration 5 Apply 4 stroke engine oil to the crank pin bearing and oil delivery hole 6 Check crankshaft and transmission operation Unsmooth operation Repair INSTALLING THE SHIFT LEVERS 1 Install shift lever 2 assembly 1 shift lever 1 2 NOTE When installing the shift lever 1 align the punch m...

Page 199: ...parts in the order listed Crankcase separation Refer to CRANKCASE 1 Oil strainer O ring 1 1 2 Oil pump assembly gasket 1 1 3 Balancer 1 Refer to REMOVING THE CRANK SHAFT and INSTALLING THE CRANKSHAFT AND BALANCER 4 Plate 1 5 Relief valve assembly 1 6 Crankshaft 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 200: ...Job Part Q ty Remarks Disassembling the oil pump Remove the parts in the order listed 1 Rotor cover 1 2 Pin 2 3 Shaft 1 4 Pin 1 5 Inner rotor 1 6 Outer rotor 1 7 Oil pump housing 1 For assembly reverse the disassembly procedure www midwestmanuals com ...

Page 201: ...he outer rotor 2 side clearance b between the outer rotor 2 and the pump housing 3 body clearance c between the outer rotor 2 and the pump housing 3 Out of specification Replace the oil pump 3 Check oil pump operation Unsmooth Repeat steps 1 and 2 or replace the defective parts Tip clearance less than 0 15 mm 0 0059 in Limit 0 23 mm 0 0091 in Side clearance 0 03 0 10 mm 0 0012 0 0039 in Limit 0 17...

Page 202: ...ring 4 Damage wear Replace the defective part s CHECKING THE OIL STRAINER 1 Check oil strainer 1 O ring 2 Damage Replace Contaminants Clean with engine oil ASSEMBLING THE OIL PUMP 1 Install inner rotor outer rotor oil pump shaft with the recommended lubricant Recommended lubricant Engine oil www midwestmanuals com ...

Page 203: ... crank shaft The crankshaft 1 and the crank pin 2 oil pas sages must be properly interconnected with a tolerance of less than 1 mm 0 04 in CAUTION The buffer boss and woodruff key should be replaced when removed from the crank shaft Crank width 74 95 75 00 mm 2 9508 2 9528 in Big end side clearance 0 35 0 65 mm 0 0138 0 0256 in Limit 1 0 mm 0 0394 in Runout limit C1 0 03 mm 0 0012 in C2 0 03 mm 0 ...

Page 204: ...alling tool until the crankshaft bottoms against the bearing CAUTION Apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier Crankshaft installer pot 1 P N 90890 01274 Crankshaft installer bolt 2 P N 90890 01275 Crankshaft installer set 3 P N YU 90050 Adapter 4 P N YM 01383 90890 01383 Spacer crankshaft installer 5 P N YM 91044 90890 04081 Space...

Page 205: ...ven gear Refer to MIDDLE GEAR 1 Low wheel gear 1 Refer to REMOVING THE TRANSMISSION and INSTALLING THE TRANSMISSION 2 Shift drum 1 3 Shift fork assembly 1 4 Short spring 1 White painting 5 Shift fork 1 1 6 Long spring 1 7 Shift fork 2 1 8 Guide bar 1 9 Secondary shaft 1 10 Drive axle assembly 1 11 Chain 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 206: ...Part Q ty Remarks Disassembling the drive axle assembly Remove the parts in the order listed 1 Clutch dog 1 2 High wheel gear 1 3 Middle drive gear 1 4 Driven sprocket 1 5 Drive axle 1 For assembly reverse the disassembly procedure www midwestmanuals com ...

Page 207: ...s c Remove the shift drum d Remove the shift fork assembly 2 Remove secondary shaft 1 drive axle assembly 2 chain 3 NOTE Remove the secondary shaft drive axle assembly and chain as a set CHECKING THE SHIFT FORKS 1 Check shift fork follower 1 shift fork pawl 2 Scoring bends wear damage Replace 2 Check guide bar Roll the guide bar on a flat surface Bends Replace WARNING Do not attempt to straighten ...

Page 208: ... drum grooves Scratches wear damage Replace CHECKING THE DRIVE AXLE 1 Measure axle runout Use a centering device and a dial gauge Out of specification Replace the bent axle Drive axle runout limit 0 06 mm 0 0024 in CHECKING THE HIGH WHEEL GEAR AND MIDDLE DRIVE GEAR 1 Check gear teeth Blue discoloration pitting wear Replace mated dogs Rounded edges cracks missing portions Replace www midwestmanuals...

Page 209: ... THE SECONDARY SHAFT AND DRIVEN SPROCKET 1 Check gear teeth Blue discoloration pitting wear Replace 2 Check gear movement Unsmooth Repeat steps 1 or replace the defective parts 3 Check circlip Bends looseness damage Replace CHECKING THE CHAIN 1 Check chain Cracks shift Replace the chain second ary shaft and driven sprocket as a set www midwestmanuals com ...

Page 210: ...G THE TRANSMISSION 1 Install chain 1 drive axle assembly 2 secondary shaft 3 shift fork assembly 4 shift drum 5 low wheel gear 2 Check shift operation Unsmooth operation Repair NOTE Oil each gear and bearing thoroughly Before assembling the crankcase be sure that the transmission is in neutral and that the gears turn freely www midwestmanuals com ...

Page 211: ...ration Refer to CRANKCASE 1 Bearing housing 1 2 Middle driven gear 1 3 Nut 1 Refer to REMOVING THE MIDDLE DRIVE SHAFT and INSTALLING THE MIDDLE DRIVE SHAFT 4 Middle drive pinion gear 1 5 Shim Refer to SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS 6 Middle drive shaft 1 7 Bearing retainer 2 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 212: ...g 1 Refer to REMOVING THE MIDDLE DRIVEN SHAFT and INSTALLING THE MIDDLE DRIVEN SHAFT 2 Circlip 2 3 Bearing 2 4 Universal joint 1 5 Universal joint yoke 1 6 Bearing housing O ring 1 1 7 Shim Refer to SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS 8 Middle driven pinion gear 1 Refer to REMOVING THE MIDDLE DRIVEN SHAFT and INSTALLING THE MIDDLE DRIVEN SHAFT 9 Bearing retainer 1 www midwestmanuals c...

Page 213: ...4 87 ENG MIDDLE GEAR Order Job Part Q ty Remarks 10 Bearing retainer 1 11 Middle driven shaft 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 214: ...cure the middle drive shaft in the vise with a clean rag 3 Remove middle drive pinion gear nut middle drive pinion gear shim s REMOVING THE MIDDLE DRIVEN SHAFT 1 Remove nut 1 washer drive shaft coupling NOTE Use the coupling gear middle shaft tool 2 to hold the drive shaft coupling Coupling gear middle shaft tool P N YM 01229 90890 01229 1 2 www midwestmanuals com ...

Page 215: ...shown NOTE It may be necessary to lightly tap the yoke with a punch d Repeat the steps for the opposite bearing e Remove the yoke NOTE It may be necessary to lightly tap the yoke with a punch 3 Remove nut 1 washer universal joint yoke NOTE Use the universal joint holder 2 to hold the universal joint yoke Universal joint holder P N YM 04062 90890 04062 MIDDLE GEAR www midwestmanuals com ...

Page 216: ...uitable socket 2 on the mid dle driven pinion gear end to protect the thread from damage c Press the middle driven pinion gear end and remove the bearing housing 5 Remove bearing retainer bearing a Place a rag 1 in the vise b Secure the bearing housing edge in the vise c Attach the bearing retainer wrench 2 CAUTION The middle driven shaft bearing retainer has left handed threads To loosen the reta...

Page 217: ...loosen the retainer turn it clockwise Ring nut wrench P N YM 38404 90890 01430 7 Remove middle driven shaft 1 with bearing CHECKING THE PINION GEARS 1 Check gear teeth drive pinion gear 1 gear teeth driven pinion gear 2 Pitting galling wear Replace 2 Check O ring Damage Replace bearings Pitting damage Replace 3 Check universal joint movement Roughness Replace universal joint www midwestmanuals com...

Page 218: ...e thickness calculated from information marked on crankcase bearing housing and drive gear end 1 Shim thickness A 2 Shim thickness B b To find shim thickness A use following for mula Middle drive pinion gear shim thickness A a d b c Where a a numeral usually a decimal number on the bearing housing is either added to or subtracted from 7 5 b 17 0 c drive pinion gear to driven pinion gear center dis...

Page 219: ...s you however to round off 0 to 0 Shims are supplied in the following thickness Hundredths Round value 0 1 2 0 3 4 5 6 7 5 8 9 10 Middle drive pinion gear shim Thickness mm 0 10 0 30 0 15 0 40 0 20 0 50 c To find shim thickness B use the following formula Where e a numeral usually a decimal number on the bearing housing is either added to or subtracted from 76 f a numeral usually a decimal number ...

Page 220: ...is 60 00 3 If the driven pinion gear is marked 13 g is 80 37 4 If the crankcase right is marked 97 29 h is 97 29 5 If the crankcase left is marked 1 67 i is 1 67 6 Therefore the shim thickness is 0 64 mm B 75 94 60 00 80 37 97 29 1 67 0 05 0 64 7 Round off hundredths digit and select appropriate shim s In the example above the calculated shim thickness is 0 64 mm The chart instructs you however to...

Page 221: ...58 ft lb LOCTITE Ring nut wrench P N YM 38404 90890 01430 2 Install bearing retainer 1 a Place a rag 2 in the vise b Secure the bearing housing edge in the vise c Attach the bearing retainer wrench 3 d Tighten the bearing retainer CAUTION The middle driven shaft bearing retainer has left handed threads To tighten the retainer turn it counterclockwise Bearing retainer wrench P N YM 04128 90890 0412...

Page 222: ...t 150 Nm 15 0 m kg 110 ft lb LOCTITE Universal joint holder P N YM 04062 90890 04062 5 Install universal joint a Install the opposite yoke into the universal joint b Apply wheel bearing grease to the bearings c Install the bearing 1 onto the yoke CAUTION Check each bearing The needles can eas ily fall out of their races Slide the yoke back and forth on the bearings the yoke will not go all the way...

Page 223: ...ring 6 Install drive shaft coupling washer nut 1 NOTE Use the coupling gear middle shaft tool 2 to hold the drive shaft coupling Coupling gear middle shaft tool P N YM 01229 90890 01229 1 2 T R 97 Nm 9 7 m kg 70 ft lb INSTALLING THE MIDDLE DRIVE SHAFT 1 Tighten middle drive pinion gear nut 1 NOTE Secure the middle drive shaft in the vise with a clean rag 2 Lock the threads with a drift punch New T...

Page 224: ...h the gear lash measurement tool 4 and dial gauge 5 a 6 7 mm 0 26 in d Measure the gear lash while rotating the middle driven shaft back and forth NOTE Measure the gear lash at 4 positions Rotate the middle driven gear 90 each time e If the gear lash is incorrect adjust the gear lash by middle driven pinion gear shims and or middle drive pinion gear shim s Middle gear lash 0 1 0 3 mm 0 004 0 012 i...

Page 225: ...listed Oil cooler Refer to OIL COOLER Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Thermo switch 3 coupler 1 Disconnect 2 Coolant reservoir hose 1 Disconnect 3 Radiator fan breather hose 1 Disconnect 4 Radiator inlet hose 1 5 Radiator outlet hose 1 6 Water pump inlet hose 1 7 Coolant outlet hose 1 8 Radiator 1 9 Radiator fan 1 10 Thermo switch 3 1 RADIATOR AND COOLANT RESERVOIR 5 www...

Page 226: ...kg 5 1 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib 12 11 Order Job Part Q ty Remarks 11 Coolant reservoir 1 12 Coolant reservoir breather hose 1 Disconnect For installation reverse the removal pro cedure RADIATOR AND COOLANT RESERVOIR www midwestmanuals com ...

Page 227: ... Below the specified pressure Replace the radiator cap a Install the radiator cap tester 1 and adapter 2 onto the radiator cap 3 b Apply the specified pressure for ten sec onds and make sure that there is no drop in pressure 4 Check radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM in chapter 9 Radiator cap opening pressure 107 9 137 3 kPa 1 079 1 373 kg cm2 15 35 19...

Page 228: ...ERVOIR INSTALLING THE RADIATOR 1 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check cooling system Leaks Repair or replace any faulty part www midwestmanuals com ...

Page 229: ... order listed Driver seat passenger seat console Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 1 Coolant outlet joint breather hose 1 2 Water pump inlet hose 1 3 Water pump outlet hose 1 4 Water pump outlet pipe 1 5 O ring 1 6 Water pump assembly 1 7 O ring 1 8 Water pump breather hose 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 230: ...move the parts in the order listed 1 Water pump housing cover 1 2 Gasket 1 3 Circlip 1 4 Impeller 1 5 Rubber damper holder 1 6 Rubber damper 1 7 Water pump seal 1 8 Oil seal 1 9 Bearing 1 0 Water pump housing 1 For assembly reverse the disassembly procedure www midwestmanuals com ...

Page 231: ...he water pump housing 2 Water pump housing 3 Remove bearing 1 oil seal 2 NOTE Tap out the bearing and oil seal from the out side of the water pump housing 3 Water pump housing CHECKING THE WATER PUMP 1 Check water pump housing cover 1 water pump housing 2 impeller 3 rubber damper 4 rubber damper holder 5 Cracks damage wear Replace 2 Check water pump seal oil seal water pump outlet pipe Cracks dama...

Page 232: ...coolant onto its outer surface Install the oil seal with a socket 3 that matches its outside diameter 2 Install water pump seal 1 into the water pump housing 2 CAUTION Never lubricate the water pump seal sur face with oil or grease NOTE Install the water pump seal with the special tools È Push down Water pump seal installer 3 P N YM 33221 Mechanical seal installer 3 P N 90890 04078 Middle driven s...

Page 233: ...r 1 rubber damper holder 2 NOTE Before installing the rubber damper apply tap water or coolant onto its outer surface CAUTION Make sure that the rubber damper and rub ber damper holder are flush with the impel ler New New www midwestmanuals com ...

Page 234: ...ver seat passenger seat console left support side panel right support side panel footrest cover Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Oil cooler inlet pipe 1 oil cooler outlet pipe 1 1 1 2 O ring 2 3 Oil cooler 1 4 Oil cooler inlet hose 1 5 Oil cooler outlet hose 1 6 Oil outlet hose 1 7 Oil inlet hose 1 www midwest...

Page 235: ...w New R 7 Nm 0 7 m kg 5 1 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib 1 2 2 3 4 7 6 8 4 5 Order Job Part Q ty Remarks 8 Oil cooler inlet pipe 2 oil cooler outlet pipe 2 1 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 236: ...k oil cooler Obstruction Clean Apply compressed air to the rear of the oil cooler Damage Repair or replace the oil cooler NOTE Straighten any flattened fins with a thin flat head screwdriver 2 Check oil hoses Cracks damage Replace www midwestmanuals com ...

Page 237: ... in the order listed Driver seat passenger seat console right side panel right support side panel right protector passenger seat support Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 1 Vacuum hose 1 2 Fuel hose 2 3 Fuel filter 1 4 Fuel suction hose 1 5 Fuel return hose 1 6 Fuel pump 1 7 Fuel tank breather hose 2 8 Rollover valve 1 9 Fuel tank stay 2 FUEL PUMP AND FUEL TANK 6 www midwest...

Page 238: ...1 T R 30 Nm 3 0 m kg 22 ft Ib 7 8 7 10 2 T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks 10 Fuel tank cap 1 11 Fuel tank 1 For installation reverse the removal pro cedure FUEL PUMP AND FUEL TANK www midwestmanuals com ...

Page 239: ...pter 8 2 Place a container under the end of the fuel hose 1 1 3 Check fuel pump operation a Suck on the end of the vacuum hose 1 4 Install right protector console passenger seat driver seat Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Fuel flows Fuel pump is OK Fuel does not flow Replace the fuel pump 1 FUEL PUMP AND FUEL TANK www midwestmanuals com ...

Page 240: ...Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 1 Crankcase breather hose 1 Disconnect 2 Air filter case 1 3 Carburetor joint air filter case 1 4 Vacuum chamber breather hose 1 5 Air vent hose 1 6 Starter cable starter plunger 1 1 7 Fuel hose 1 Disconnect 8 Carburetor heater lead 2 Disconnect 9 Carburetor assembly 1 10 Drain hose 1 11 Throttle valve cover 1 www midwestmanuals com ...

Page 241: ...12 11 8 13 6 2 9 1 7 10 5 Order Job Part Q ty Remarks 12 Throttle cable end 1 13 Throttle cable 1 14 Carburetor joint intake manifold 1 For installation reverse the removal pro cedure CARBURETOR www midwestmanuals com ...

Page 242: ... disassembling the carburetor make sure to note the number of times the pilot screw is turned out from the seated position to its set position 1 Throttle stop screw 1 2 Vacuum chamber cover 1 3 Spring 1 4 Jet needle holder 1 5 Spring 1 6 Jet needle set 1 7 Piston valve 1 8 Coasting enricher diaphragm 1 www midwestmanuals com ...

Page 243: ...crew 1 A Float chamber 1 B Float 1 Refer to ASSEMBLING THE CARBURE TOR C Needle valve set 1 D Main jet 1 E Needle jet 1 Refer to ASSEMBLING THE CARBURE TOR F Pilot jet 1 G Starter jet 1 H Carburetor heater 1 For assembly reverse the disassembly procedure www midwestmanuals com ...

Page 244: ...e Replace fuel passage Contamination Clean as indicated fuel chamber body Contamination Clean a Wash the carburetor in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compressed air 2 Check float 1 float tang 2 Damage Replace 3 Check needle valve seat 1 needle valve 2 O ring 3 Contamination wear damage Replace as a set NOTE...

Page 245: ...r cover 1 spring 2 Cracks damage Replace 6 Check diaphragm coasting enricher 1 spring 2 cover 3 Tears diaphragm damage Replace 7 Check jet needle 1 main jet 2 needle jet 3 pilot air jet 4 pilot jet 5 starter jet 6 starter plunger 7 Bends wear damage Replace Blockage Blow out the jets with com pressed air www midwestmanuals com ...

Page 246: ... assembling wash all of the parts in a clean petroleum based solvent 1 Measure float height a Out of specification Adjust a Hold the carburetor in an upside down posi tion b Measure the distance from the front mating surface of the float chamber gasket removed to the top of the float NOTE The float arm should be resting on the needle valve but not compressing it c If the float height is not within...

Page 247: ...ine e Measure the fuel level a with the gauge f If the fuel level is incorrect adjust the fuel level g Remove the carburetor h Check the valve seat and needle valve i If either is worn replace them both j If both are fine adjust the float level by bending the float tang 4 slightly k Install the carburetor l Recheck the fuel level Fuel level 4 0 5 0 mm 0 16 0 20 in Above the float chamber mating su...

Page 248: ...shaft drive component or area 3 A locked up condition of the shaft drive train mechanism no power transmitted from the engine to the front and or rear wheel A Bearing damage B Improper gear lash C Gear tooth damage D Broken drive shaft E Broken gear teeth F Seizure due to lack of lubrication G Small foreign objects lodged between the moving parts Check notes 1 Investigate any unusual noises The fo...

Page 249: ...ble injury to the rider 2 Check drained oil Drained oil shows large amounts of metal particles Check the bearing for seizure NOTE A small amount of metal particles in the oil is normal 3 Check oil leakage a Clean the entire vehicle thoroughly then dry it b Apply a leak localizing compound or dry powder spray to the shaft drive c Road test the vehicle for the distance nec essary to locate the leak ...

Page 250: ... in chapter 8 YES Check the front constant velocity joints Feel for bearing damage NO Constant velocity joint bearings and differen tial gear bearings are probably not damaged Repeat the test or remove the individual components YES NO Check the parking brake adjustment Adjust per instructions Refer to ADJUSTING THE PARKING BRAKE in chapter 3 YES Check the rear constant velocity joints Feel for bea...

Page 251: ... gear and drive shaft Remove the parts in the order listed Front skid plate Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Differential gear oil Drain Steering knuckle Refer to STEERING SYSTEM in chap ter 8 Front lower arms Refer to FRONT ARMS AND FRONT SHOCK ABSORBER in chapter 8 1 Constant velocity joint 2 2 Gear motor coupler On Command four wheel drive switch and differential gear lo...

Page 252: ... DRIVE SHAFT LS LS 6 5 3 2 4 T R 55 Nm 5 5 m kg 40 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib 1 1 LS LS Order Job Part Q ty Remarks 4 Differential gear assembly 1 5 Drive shaft 1 6 Compression spring 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 253: ...tant velocity joint Remove the parts in the order listed 1 Circlip 1 2 Boot band 2 Refer to ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS 3 Boot band 2 4 Dust boot 2 5 Circlip 1 6 Double off set joint 1 7 Circlip 1 8 Ball bearing 1 9 Joint shaft assembly 1 For assembly reverse the disassembly procedure www midwestmanuals com ...

Page 254: ...E Do not disassemble the gear motor or remove the pinion gear 2 Circlip 2 Refer to DISASSEMBLING THE UNI VERSAL JOINT and ASSEMBLING THE UNIVERSAL JOINT 3 Bearing 2 4 Universal joint 1 5 Universal joint yoke O ring 1 1 6 Stopper bolt shaft 1 1 7 Shift fork with shift fork sliding gear 1 8 Differential gear case cover O ring 1 1 9 Drive clutch 1 0 Circlip bearing 1 1 A Adapter 1 www midwestmanuals ...

Page 255: ...E SHAFT Order Job Part Q ty Remarks B Shim right C Differential gear assembly 1 D Shim left E Bearing 1 F Bearing 1 G Circlip bearing 1 1 H Drive pinion gear 1 I Differential gear case 1 J Bearing 1 For assembly reverse the disassembly procedure www midwestmanuals com ...

Page 256: ...he opposite bearing e Remove the yoke 2 Remove universal joint yoke Use a universal joint holder 1 Universal joint holder P N YM 04062 90890 04062 REMOVING THE DIFFERENTIAL GEAR ASSEMBLY 1 Remove differential gear assembly 1 NOTE The ring gear and the differential gear should be fastened together Do not disassemble the differential gear assembly CAUTION The differential gears are assembled into a ...

Page 257: ... a new boot band 3 Check balls and ball races inner surface of double off set joint Pitting wear damage Replace CHECKING THE DIFFERENTIAL GEAR 1 Check gear teeth Pitting galling wear Replace drive pinion gear and ring gear as a set bearings Pitting damage Replace oil seals O rings Damage Replace 2 Check drive shaft splines universal joints drive pinion gear splines Wear damage Replace spring Fatig...

Page 258: ...ons CAUTION Do not use a 12 V battery to operate the pinion gear Do not connect the batteries to the gear motor when it is installed in the gear case The gear motor should be checked when it is removed from the gear case È Check that the pinion gear 2 turns counter clockwise É Check that the pinion gear 2 turns clockwise NOTE Do not disassemble the gear motor or remove the pinion gear È É ASSEMBLI...

Page 259: ...t bands 3 at the grooves in the joint shaft 3 Check free play thrust movement Excessive play Replace the joint assem bly Molybdenum disulfide grease 40 g 1 4 oz per dust boot front wheel side 45 g 1 6 oz per dust boot dif ferential gear case side New ASSEMBLING THE DIFFERENTIAL GEAR 1 Measure gear lash Refer to MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH 2 Install gear motor a Slide the shi...

Page 260: ...ferential gear assembly 8 so that the shift fork sliding gear 9 does not move CAUTION If the position of the shift fork sliding gear is moved the position of the differential gear and the indicator light display may dif fer and the 2WD or differential lock mode may not be activated d Remove the 8 mm bolts and then install the motor with the gear motor bolts T R Gear motor bolts 13 Nm 1 3 m kg 9 4 ...

Page 261: ...onto the yoke CAUTION Check each bearing The needles can eas ily fall out of their races Slide the yoke back and forth on the bearings the yoke will not go all the way onto a bearing if a needle is out of plate d Press each bearing into the universal joint using a suitable socket NOTE The bearing must be inserted far enough into the universal joint so that the circlip can be installed e Install th...

Page 262: ...lash measurement tool 1 dial gauge 2 a Measuring point is 21 mm 0 83 in 5 Measure gear lash Gently rotate the gear coupling from engagement to engagement NOTE Measure the gear lash at four positions Rotate the shaft 90 each time Gear lash measurement tool P N YM 01467 90890 01467 Differential gear lash 0 05 0 25 mm 0 002 0 010 in Adjusting the differential gear lash 1 Remove shim s left 1 differen...

Page 263: ...sh exceeds the specifi cation increase the thickness of the right shim s by 0 1 mm 0 004 in and decrease the thickness of the left shim s by 0 1 mm 0 004 in b Measure the differential gear lash again Too little gear lash Reduce right shim thickness Too large gear lash Increase right shim thickness Ring gear shim left and right Thickness mm 0 1 0 5 0 2 1 0 0 3 1 5 0 4 CHECKING THE DIFFERENTIAL GEAR...

Page 264: ...er front wheel will turn in the opposite direction 4 Out of specification Replace the differen tial gear assembly 5 Within specification Install the new cotter pin and wheel cap T R Front wheel starting torque differential gear preload New unit 17 25 Nm 1 7 2 5 m kg 12 18 ft lb Minimum 10 Nm 1 0 m kg 7 2 ft lb FRONT CONSTANT VELOCITY JOINTS DIFFERENTIAL GEAR AND DRIVE SHAFT www midwestmanuals com ...

Page 265: ...oints final drive gear and drive shaft Remove the parts in the order listed Rear skid plate Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Muffler exhaust pipe Refer to ENGINE REMOVAL in chapter 4 Final gear oil Drain Rear knuckle Refer to REAR KNUCKLE AND STABI LIZER in chapter 8 Rear lower arm Refer to REAR ARMS AND REAR SHOCK ABSORBER in chapter 8 Brake caliper assembly Refer to FRONT...

Page 266: ...ate the final gear assembly slightly so that the con stant velocity joint on the left side clears the frame and then remove it 2 Final drive gear case breather hose 1 Disconnect 3 Final drive gear assembly 1 4 Compression spring 1 5 Coupling gear 1 6 Drive shaft 1 For installation reverse the removal pro cedure REAR CONSTANT VELOCITY JOINTS FINAL DRIVE GEAR AND DRIVE SHAFT www midwestmanuals com ...

Page 267: ...nstant velocity joint Remove the parts in the order listed 1 Circlip 1 2 Boot band 2 Refer to ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS 3 Boot band 2 4 Dust boot 2 5 Circlip 1 6 Double off set joint 1 7 Circlip 1 8 Ball bearing 1 9 Joint shaft assembly 1 For assembly reverse the disassembly procedure www midwestmanuals com ...

Page 268: ...isc Refer to REAR WHEELS AND BRAKE DISC in chapter 8 1 Bolt 4 2 Final drive pinion gear shim 3 Drive shaft coupling 1 Refer to DISASSEMBLING THE FINAL GEAR CASE and ASSEM BLING THE FINAL GEAR CASE 4 Final drive pinion gear 1 5 Inner race 1 6 Oil seal 1 7 Bearing retainer 1 8 Bearing 1 9 O ring 1 0 Final drive pinion gear bearing housing 1 A Ring gear stopper 1 www midwestmanuals com ...

Page 269: ... B Bolt 2 NOTE Working in a crisscross pattern loosen each bolt 1 4 of a turn After all the bolts are loosened remove them C Bolt 6 D Oil seal 1 E Bearing 1 F O ring 1 G Ring gear bearing housing 1 H Ring gear shim I Ring gear 1 J Thrust washer 1 K Oil seal 1 L Final gear case 1 www midwestmanuals com ...

Page 270: ... DRIVE GEAR AND DRIVE SHAFT Order Job Part Q ty Remarks M Bearing 1 Refer to REMOVING THE FINAL DRIVE ROLLER BEARINGS and INSTALLING THE FINAL DRIVE ROLLER BEARINGS N Bearing 1 For assembly reverse the disassembly procedure www midwestmanuals com ...

Page 271: ... new boot bands may differ from the orig inal ones The dust boots should be fastened with the boot bands 3 at the grooves in the joint shaft Molybdenum disulfide grease 40 g 1 8 oz per dust boot rear wheel side 60 g 2 3 oz per dust boot final gear case side New 3 Check free play thrust movement Excessive play Replace the joint assem bly DISASSEMBLING THE FINAL GEAR CASE 1 Remove drive shaft coupli...

Page 272: ...end to protect the thread from damage c Press the gear end and remove the bearing housing assembly 3 Remove bearing retainer a Place a folded rag 1 b Secure the final drive pinion gear bearing housing edge in the vise c Attach the bearing retainer wrench 2 d Remove the bearing retainer CAUTION The bearing retainer has left handed threads To loosen the retainer turn it clockwise Bearing retainer wr...

Page 273: ...at the main housing only to 150 C 302 F b Install the roller bearing outer race using the proper adapter c Install the inner race onto the drive pinion gear 2 Install roller bearing ring gear 1 Use a suitable press tool 2 and a press to install the above components into the main housing New POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR When the final drive pinion gear ring gear final gear ...

Page 274: ... from 112 Example 1 a 92 5 2 If 98 is stamped on the final drive pinion gear bearing housing b 34 0 98 34 98 3 If 48 is stamped on the final drive pinion gear bearing housing c 55 0 48 55 48 4 If 03 is stamped on the final gear case d 112 0 03 112 03 5 Therefore A is 0 97 A 92 5 55 48 34 98 112 03 0 97 6 Round off the hundredth digit and select the appropriate shim s In the example above the calcu...

Page 275: ... a numeral usually a decimal number on the outside of the ring gear bearing hous ing and added to 1 g a numeral usually a decimal number on the inside of the ring gear either added to or subtracted from 35 00 h bearing thickness considered constant Example 1 If 98 is stamped on the final gear case e 50 0 98 50 98 2 If 55 is stamped on the ring gear bearing housing f 1 0 55 1 55 3 If 05 is stamped ...

Page 276: ...er 1 Measure ring gear thrust clearance C a Place four pieces of Plastigauge between the originally fitted thrust washer and the ring gear b Install the final gear assembly and tighten the bolts to specification NOTE Do not turn the drive pinion gear and ring gear when measuring the clearance with Plasti gauge Hundredths Rounded value 0 1 2 0 3 4 5 6 7 5 8 9 10 Ring gear shim Thickness mm 0 25 0 3...

Page 277: ... measurement steps until the ring gear thrust clearance is within the specified limits Ring gear thrust clearance 0 1 0 2 mm 0 004 0 008 in Thrust washer Thickness mm 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 Adjusting the ring gear stopper 1 Install ring gear stopper nut 2 Adjust ring gear stopper clearance a Finger tighten the ring gear stopper 1 until it contacts the ring gear 2 b Turn th...

Page 278: ...bearing housing are replaced be sure to adjust the shim of the final drive pinion gear and or ring gear 2 Check gear teeth Pitting galling wear Replace the drive pinion gear and ring gear as a set oil seals O rings Damage Replace 3 Check bearings Damage Replace NOTE Reusing roller bearings is acceptable but Yamaha recommends installing new ones Do not reuse the oil seal When the final drive pinion...

Page 279: ...the drain plug hole CAUTION Finger tighten the bolt until it holds the ring gear Otherwise the ring gear will be dam aged 4 Attach gear lash measurement tool 1 dial gauge 2 a Measuring point is 31 1 mm 1 22 in Gear lash measurement tool P N YM 01467 90890 01467 5 Measure gear lash Gently rotate the gear coupling from engagement to engagement NOTE Measure the gear lash at four positions Rotate the ...

Page 280: ...0 2 mm 0 008 in for every 0 2 mm of ring gear shim increase c If reduced by more than 0 2 mm 0 008 in Increase the thrust washer thickness by 0 2 mm 0 008 in for every 0 2 mm that the ring gear shim is decreased Too little gear lash Reduce shim thickness Too large gear lash Increase shim thickness Ring gear shim Thickness mm 0 25 0 30 0 35 0 40 0 45 0 50 Thrust washer Thickness mm 1 0 1 1 1 2 1 3 ...

Page 281: ...t lb 3 Install bearing retainer a Place a folded rag 1 b Secure the final drive pinion gear bearing housing edge in the vise NOTE Apply locking agent LOCTITE to the threads of bearing retainer c Attach the bearing retainer wrench 2 d Tighten the bearing retainer CAUTION The bearing retainer has left hand threads Turn the retainer counterclockwise to tighten it Bearing retainer wrench P N YM 04128 ...

Page 282: ... the drive shaft coupling edge in the vise c Tighten the drive shaft coupling nut 5 Check final drive gear operation Unsmooth operation Replace the final drive gear assembly Insert the double off set joint into the final drive gear and turn the gear back and forth T R Drive shaft coupling nut 80 Nm 8 0 m kg 58 ft lb www midwestmanuals com ...

Page 283: ...m 0 7 m kg 5 1 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib Order Job Part Q ty Remarks Removing the front bumper and the hood Remove the parts in the order listed 1 Front bumper protector 1 2 Front bumper 1 3 Headlight coupler 2 Disconnect 4 Hood 1 For installation reverse the removal pro cedure SEATS ENCLOSURE HOOD AND CARGO BED 8 www midwestmanuals com ...

Page 284: ...ving the seats console and instrument panels Remove the parts in the order listed 1 Driver seat 1 2 Passenger seat 1 3 Console 1 4 Steering wheel cover 1 5 Steering wheel 1 6 Pedal cover 1 7 Light switch coupler 1 Disconnect 8 Main switch coupler 1 Disconnect 9 On Command four wheel drive switch and differential gear lock switch 2 Disconnect 10 Indicator warning light coupler 2 Disconnect www midw...

Page 285: ... R 35 Nm 3 5 m kg 25 ft Ib Order Job Part Q ty Remarks 11 Auxiliary DC jack connector 2 Disconnect 12 Nut starter cable 1 1 13 Upper instrument panel 1 14 Lower instrument panel 1 For installation reverse the removal pro cedure SEATS ENCLOSURE HOOD AND CARGO BED www midwestmanuals com ...

Page 286: ...g 23 ft Ib Order Job Part Q ty Remarks Removing the panels and footrest cover Remove the parts in the order listed 1 Left side panel 1 2 Right side panel 1 3 Left corner panel 1 4 Right corner panel 1 5 Air duct end cover 1 6 Protector cap 2 7 Left protector 2 1 8 Right protector 2 1 9 Left protector 1 1 10 Right protector 1 1 11 Footrest cover 1 12 Driver seat support 1 www midwestmanuals com ...

Page 287: ...4 6 7 9 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib Order Job Part Q ty Remarks 13 Passenger seat support 1 For installation reverse the removal pro cedure SEATS ENCLOSURE HOOD AND CARGO BED www midwestmanuals com ...

Page 288: ...1 6 m kg 11 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib Order Job Part Q ty Remarks Removing the cargo bed Remove the parts in the order listed 1 Tail brake light connector 6 Disconnect 2 Damper 2 3 Pin 2 4 Cargo bed assembly 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 289: ...6 Nm 2 6 m kg 19 ft Ib Order Job Part Q ty Remarks Disassembling the cargo bed Remove the parts in the order listed 1 Hinge cover 2 2 Tailgate 1 3 Cargo bed panel 2 4 Tail brake light bulb holder 2 5 Mud guard 2 6 Cargo bed release lever 1 7 Cargo bed 1 For assembly reverse the disassembly procedure SEATS ENCLOSURE HOOD AND CARGO BED www midwestmanuals com ...

Page 290: ... T R 7 Nm 0 7 m kg 5 1 ft Ib 3 1 2 11 7 4 4 7 11 11 11 Order Job Part Q ty Remarks Removing the engine skid plates Remove the parts in the order listed 1 Front skid plate 1 2 Center skid plate 1 3 Rear skid plate 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 291: ...Ib T R 59 Nm 5 9 m kg 43 ft Ib 6 1 2 3 5 7 4 8 4 8 4 8 Order Job Part Q ty Remarks Removing the enclosure and seat belts Remove the parts in the order listed 1 Front top frame 1 2 Rear top frame 1 3 Left support frame 1 4 Right support frame 1 5 Left side frame 1 6 Right side frame 1 7 Seat belt 2 8 Buckle 2 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 292: ... R 260 Nm 26 0 m kg 190 ft lb Order Job Part Q ty Remarks Removing the front wheel Remove the parts in the order listed Place the vehicle on a level surface WARNING Securely support the vehicle so there is no danger of it falling over 1 Front wheel 1 Refer to INSTALLING THE FRONT WHEEL 2 Center cap 1 3 Axle nut 1 Refer to INSTALLING THE FRONT WHEEL HUB www midwestmanuals com ...

Page 293: ... 5 m kg 40 ft Ib T R 260 Nm 26 0 m kg 190 ft lb Order Job Part Q ty Remarks 4 Brake caliper assembly 1 NOTE Do not depress the brake pedal when the brake caliper is off of the brake disc as the brake pads will be forced shut 5 Front wheel hub 1 6 Brake disc 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 294: ...alance Adjust WARNING After replacing the tire ride conservatively to allow the tire to be properly seated in the rim Failure to do so may cause an accident resulting in vehicle damage and possible injury Wheel runout limit Radial 2 2 0 mm 0 08 in Lateral 3 2 0 mm 0 08 in CHECKING THE FRONT WHEEL HUB 1 Check wheel hub 1 Cracks damage Replace splines wheel hub 2 Wear damage Replace 1 2 www midwestm...

Page 295: ...isc minimum thickness 3 0 mm 0 12 in INSTALLING THE FRONT WHEEL HUB 1 Install axle nut NOTE Do not apply oil to the seat of the nut After tightening the nut stake the collar of the nut into the notch of the shaft New T R 260 Nm 26 0 m kg 190 ft lb INSTALLING THE FRONT WHEEL 1 Install wheel NOTE The arrow mark 1 on the tire must point in the direction of rotation È of the wheel 2 Tighten wheel nuts...

Page 296: ...oving the rear wheel Remove the parts in the order listed Place the vehicle on a level surface WARNING Securely support the vehicle so there is no danger of it falling over 1 Rear wheel 1 Refer to INSTALLING THE REAR WHEEL 2 Center cap 1 3 Axle nut 1 Refer to INSTALLING THE REAR WHEEL HUB 4 Rear wheel hub 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 297: ...s Removing the rear brake disc Remove the parts in the order listed Brake caliper assembly Refer to FRONT AND REAR BRAKES Final drive gear Refer to REAR CONSTANT VELOCITY JOINTS FINAL DRIVE GEAR AND DRIVE SHAFT in chapter 7 1 Rear brake disc 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 298: ... Wheel runout limit Radial 2 0 mm 0 08 in Lateral 2 0 mm 0 08 in CHECKING THE REAR WHEEL HUB 1 Check wheel hub 1 Cracks damage Replace splines wheel hub 2 Wear damage Replace 1 2 CHECKING THE REAR BRAKE DISC 1 Check brake disc Galling damage Replace 2 Measure brake disc deflection Out of specification Replace brake disc thickness a Out of specification Replace Brake disc maximum deflection 0 10 mm...

Page 299: ...LING THE REAR WHEEL HUB 1 Install axle nut Refer to INSTALLING THE FRONT WHEEL HUB New INSTALLING THE REAR WHEEL 1 Install wheel Refer to INSTALLING THE FRONT WHEEL 2 Tighten wheel nuts Refer to INSTALLING THE FRONT WHEEL www midwestmanuals com ...

Page 300: ...er Job Part Q ty Remarks Removing the front brake pads Remove the parts in the order listed Front wheel Refer to FRONT WHEELS AND BRAKE DISCS 1 Brake caliper mounting bolt 2 Refer to REPLACING THE FRONT BRAKE PADS 2 Brake pad holding bolt 2 3 Brake pad 2 4 Pad spring 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 301: ...Remove the parts in the order listed Rear skid plate Refer to SEATS ENCLOSURE HOOD AND CARGO BED 1 Spring 1 Refer to REPLACING THE REAR BRAKE PADS 2 Parking brake cable 1 3 Brake caliper mounting bolt 2 4 Brake pad holding bolt 2 5 Brake pad piston side 1 6 Brake pad 1 7 Insulator pad shim 2 2 8 Pad spring 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 302: ...e injury splash brake fluid onto painted surfaces or plastic parts as this may cause dam age disconnect any hydraulic connection as this would require the entire brake sys tem to be disassembled drained cleaned properly filled and bled after reassembly REPLACING THE FRONT BRAKE PADS NOTE It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads 1 Measure brake p...

Page 303: ...iper bleed screw d Install the retaining bolts and brake caliper 3 Check brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 4 Check brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 T R Brake caliper bleed screw 6 Nm 0 6 m kg 4 3 ft lb T R Brake pad holding bolt 18 Nm 1 8 m kg 13 ft lb Brake caliper mou...

Page 304: ... Loosen the brake caliper bleed screw and then turn the brake caliper piston 3 clock wise until section a of the brake caliper pis ton is level with the surface of the brake caliper body NOTE Align an end b of the groove in the brake cali per piston with the punch mark c on the brake caliper body c Tighten the brake caliper bleed screw d Install new brake pads new insulators new brake pad shims an...

Page 305: ...fer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 4 Check brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 T R Brake pad holding bolt 17 Nm 1 7 m kg 12 ft lb Brake caliper mounting bolt 40 Nm 4 0 m kg 29 ft lb FRONT AND REAR BRAKES www midwestmanuals com ...

Page 306: ...e brake master cylinder Remove the parts in the order listed Brake fluid Drain 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm 1 3 Brake fluid reservoir float 1 4 Union bolt 1 Refer to INSTALLING THE BRAKE MASTER CYLINDER 5 Copper washer 2 6 Brake hose 1 Disconnect 7 Brake pipe 1 Disconnect 8 Brake master cylinder 1 For installation reverse the removal pro cedure www midwestmanuals...

Page 307: ...ke master cyl inder Remove the parts in the order listed 1 Dust boot 1 Refer to ASSEMBLING THE BRAKE MASTER CYLINDER 2 Circlip 1 3 Primary brake master cylinder kit 1 4 Secondary brake master cylinder kit stopper 1 5 Gasket 1 6 Secondary brake master cylinder kit 1 For assembly reverse the disassembly procedure www midwestmanuals com ...

Page 308: ...inder kit Scratches wear damage Replace as a set È Primary brake master cylinder kit É Secondary brake master cylinder kit 1 È É 3 Check brake fluid reservoir 1 brake fluid reservoir diaphragm 2 Cracks damage Replace 2 1 EB702060 ASSEMBLING THE BRAKE MASTER CYLINDER WARNING All internal brake components should be cleaned and lubricated with new brake fluid only before installation Whenever a maste...

Page 309: ...ean up spilled brake fluid immediately WARNING Use only the designated quality brake fluid other brake fluids may deteriorate the rubber seals causing leakage and poor brake performance Refill with the same type of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor brake performance Be careful that water does not enter the brake master cylinder when refilli...

Page 310: ... THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level Brake fluid level is under the MIN level line Fill up Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 6 Adjust brake pedal free play Refer to ADJUSTING THE BRAKE PEDAL in chapter 3 www midwestmanuals com ...

Page 311: ... listed Brake fluid Drain Front wheel Refer to FRONT WHEELS AND BRAKE DISCS 1 Union bolt 1 Refer to INSTALLING THE FRONT BRAKE CALIPERS 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Brake pad holding bolt 2 Loosen 5 Brake caliper mounting bolt 2 6 Brake caliper assembly 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 312: ...nt brake cali per Remove the parts in the order listed 1 Brake pad holding bolt 2 2 Brake pad 2 3 Pad spring 1 4 Caliper bracket 1 5 Brake caliper piston 2 Refer to DISASSEMBLING THE FRONT BRAKE CALIPERS and ASSEMBLING THE FRONT BRAKE CALIPERS 6 Dust seal 2 7 Caliper piston seal 2 8 Bleed screw 1 For assembly reverse the disassembly procedure www midwestmanuals com ...

Page 313: ...w Order Job Part Q ty Remarks Removing the rear brake caliper Remove the parts in the order listed Rear skid plate Refer to SEATS ENCLOSURE HOOD AND CARGO BED Brake fluid Drain 1 Parking brake switch coupler 1 Disconnect 2 Spring 1 3 Parking brake cable 1 4 Parking brake lever assembly mount ing bolt 1 5 Parking brake lever assembly 1 www midwestmanuals com ...

Page 314: ... 5 6 7 8 9 10 New Order Job Part Q ty Remarks 6 Union bolt 1 Refer to INSTALLING THE REAR BRAKE CALI PER 7 Copper washer 2 8 Brake hose 1 Disconnect 9 Brake caliper mounting bolt 2 10 Brake caliper assembly 1 For installation reverse the removal pro cedure FRONT AND REAR BRAKES www midwestmanuals com ...

Page 315: ...rear brake cali per Remove the parts in the order listed 1 Brake pad holding bolt 1 Refer to ASSEMBLING THE REAR BRAKE CALIPER 2 Brake pad piston side 1 3 Brake pad 1 4 Insulator pad shim 2 2 5 Pad spring 1 6 Brake caliper bracket 1 7 Parking brake arm nut 1 Refer to ASSEMBLING THE REAR BRAKE CALIPER 8 Parking brake arm 1 9 Set bolt 1 0 Parking brake arm shaft 1 A Parking brake case bolt 2 www mid...

Page 316: ...ob Part Q ty Remarks B Parking brake case 1 Refer to ASSEMBLING THE REAR BRAKE CALIPER C Gasket 1 D Brake caliper piston 1 Refer to DISASSEMBLING THE FRONT BRAKE CALIPERS and ASSEMBLING THE REAR BRAKE CALIPER E Dust seal 1 F Caliper piston seal 1 G Bleed screw 1 For assembly reverse the disassembly procedure FRONT AND REAR BRAKES www midwestmanuals com ...

Page 317: ... out a caliper piston Cover the caliper piston with a rag Be careful not to get injured when the piston is expelled from the caliper cylinder b Remove the dust seals and caliper piston seals 1 2 DISASSEMBLING THE REAR BRAKE CALIPER 1 Remove brake caliper piston 1 dust seal 2 caliper piston seal 3 a Turn the brake caliper piston counterclock wise to remove it WARNING Never try to pry out the calipe...

Page 318: ...inders 2 Wear scratches Replace the brake cali per assembly brake caliper body 3 Cracks damage Replace brake fluid delivery passage brake caliper body Blockage Blow out with compressed air WARNING Replace the caliper piston seals and dust seals whenever the brake caliper is disas sembled È Front É Rear Recommended brake component replacement schedule Brake pads As required Piston seals dust seals ...

Page 319: ..._ All internal brake components should be cleaned and lubricated with new brake fluid only before installation Replace the caliper piston seals and dust seal whenever a brake caliper is disas sembled Recommended brake fluid DOT 4 1 Install caliper piston seals 1 dust seals 2 1 2 New New New New 2 Install brake caliper pistons 1 1 www midwestmanuals com ...

Page 320: ... 2 Recommended brake fluid DOT 4 New New 1 2 New New 2 Install brake caliper piston 1 Turn the brake caliper piston clockwise until section a of the brake caliper piston is level with the surface of the brake caliper body NOTE Align an end b of the groove in the brake cali per piston with the punch mark c on the brake caliper body 1 a b c 1 1 3 Install gasket 1 parking brake case 2 parking brake c...

Page 321: ...en the parking brake arm shaft is screwed in completely remove the parking brake arm shaft and screw it in from a different starting position b Turn the parking brake arm shaft approxi mately 60 clockwise c Install the parking brake arm to the parking brake arm shaft so that the punch mark c on the parking brake arm is aligned with the punch mark a on the parking brake arm shaft d Turn the parking...

Page 322: ...UTION _ When installing the brake hose on the brake caliper make sure that the brake pipe touches the projection a on the brake caliper WARNING _ Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING in chapter 2 2 Fill brake reservoir CAUTION _ Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately Recommen...

Page 323: ...ock 3 Air bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 4 Check brake fluid level Brake fluid level is below the MIN level line Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 EBS00436 INSTALLING THE REAR BRAKE CALIPER 1 Install brake caliper assembly brake caliper mounting bolts brake hose 1 copper washers uni...

Page 324: ...poor brake performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 3 Air bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 4 Check brake fluid level Brake fluid level is below the MIN level line Add the recommended brake fluid to the proper level R...

Page 325: ...r instrument panel lower instrument panel Refer to SEATS ENCLOSURE HOOD AND CARGO BED Steering joint Refer to STEERING SYSTEM Brake master cylinder Refer to FRONT AND REAR BRAKES 1 Splash plate 1 2 Brake light switch coupler 1 Disconnect 3 Brake switch 1 4 Throttle cable 1 Disconnect 5 Pin 1 6 Brake pedal rod 1 7 Pedal assembly 1 For installation reverse the removal pro cedure PEDAL ASSEMBLY www m...

Page 326: ...ng the pedal assembly Remove the parts in the order listed 1 Spring 1 2 Circlip 1 3 Washer 2 4 Brake pedal 1 5 Spring 1 6 Circlip 1 7 Washer 2 8 Accelerator pedal 1 9 Pedal assembly bracket 1 For assembly reverse the disassembly procedure PEDAL ASSEMBLY www midwestmanuals com ...

Page 327: ... kg 28 ft Ib Order Job Part Q ty Remarks Removing the steering column and steering assembly Remove the parts in the order listed Steering wheel cover steering wheel upper instrument panel lower instru ment panel Refer to SEATS ENCLOSURE HOOD AND CARGO BED 1 Steering shaft 1 2 Steering joint 1 3 Steering assembly 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 328: ...emove the parts in the order listed 1 Tie rod end locknut 2 Refer to ASSEMBLING THE STEER ING ASSEMBLY 2 Tie rod end 2 3 Plastic locking tie 2 4 Dust boot 2 5 Adjuster 1 6 Spring 1 7 Pressure pad 1 8 Oil seal 1 9 Circlip 1 0 Pinion gear 1 Refer to DISASSEMBLING THE STEERING ASSEMBLY and ASSEM BLING THE STEERING ASSEMBLY A Circlip 1 B Bearing 1 www midwestmanuals com ...

Page 329: ...5 C 2 4 1 3 New New New T R 40 Nm 4 0 m kg 29 ft Ib 0 Order Job Part Q ty Remarks C Steering assembly 1 Refer to ASSEMBLING THE STEERING ASSEMBLY For assembly reverse the disassembly procedure STEERING SYSTEM www midwestmanuals com ...

Page 330: ...eering joint Rough movement Replace CHECKING THE STEERING ASSEMBLY 1 Check pinion gear bearing Check the bearing movement on the pinion gear by rotating with the fingers Roughness Replace 2 Check pinion needle bearing 1 Damage Replace NOTE When replacing the pinion needle bearing it is recommended to replace the steering assem bly The steering housing may be subject to damage during removal of the...

Page 331: ...mproper adjustment or lack of lubrication 1 2 4 Check pressure pad 1 Wear damage Replace dust boots 2 Damage Replace 1 2 5 Check tie rod free play and movement Free play Replace the tie rod end Turns roughly Replace the tie rod end 6 Check tie rods Bends damage Replace ASSEMBLING THE STEERING ASSEMBLY 1 Lubricate bearings rack gear pinion gear oil seal Recommended lubricant Molybdenum disulfide gr...

Page 332: ...ium soap based grease to the gear surface of the rack gear Lithium soap based grease 5 10 g 0 2 0 4 oz New a 4 Adjust rack gear pinion gear backlash a Install the force pressure pad spring and adjuster b Tighten the adjuster 1 c Loosen the adjuster 15 25 5 Install dust boots plastic locking tie tie rod end tie rod end locknut T R Adjuster 3 9 Nm 0 39 m kg 2 8 ft lb LOCTITE 15 25 1 New T R 40 Nm 4 ...

Page 333: ... Part Q ty Remarks Removing the tie rod and steering knuckle Remove the parts in the order listed Front wheel brake disc Refer to FRONT WHEELS AND BRAKE DISCS 1 Tie rod 1 2 Brake disc guard 1 3 Nut 2 4 O ring 1 5 Brake hose holder bolt 1 6 Steering knuckle 1 Refer to REMOVING THE STEERING KNUCKLES 7 Circlip 1 8 Ball joint 1 9 Rubber boot 1 For installation reverse the removal pro cedure www midwes...

Page 334: ...rod end Turns roughly Replace the tie rod end 2 Check tie rods Bends damage Replace CHECKING THE STEERING KNUCKLES 1 Check steering knuckles Damage pitting Replace 2 Check ball joints Damage pitting Replace the ball joint Free play Replace the ball joint Turns roughly Replace the ball joint a Clean the outside of the steering knuckle b Remove the steering knuckle oil seal c Remove the circlip 1 an...

Page 335: ... remove the ball joint A from the steering knuckle f Remove the ball joint remover installer Ball joint remover installer set P N 90890 01474 Ball joint adapter set P N YM 01474 Ball joint remover installer attach ment set P N YM 01477 3 Body YM 01474 90890 01474 4 Long bolt YM 01474 90890 01474 5 Short bolt YM 01477 6 Remover washer YM 01477 7 Remover spacer YM 01477 8 Installer attachment YM 014...

Page 336: ...e a new ball joint set m Install a steering knuckle oil seal 3 Check front wheel bearings Bearings allow play in the wheel hubs or the wheel turns roughly Replace oil seals Damage Replace a Clean the outside of the steering knuckle b Remove the oil seals 1 c Drive out the bearings 2 WARNING Eye protection is recommended when using striking tools d Remove the spacer 3 e Apply lithium base grease to...

Page 337: ...8 55 CHAS STEERING SYSTEM h Install the new oil seals NOTE When installing the oil seals the seal side of the oil seal faces out www midwestmanuals com ...

Page 338: ...3 2 LS LS 8 Order Job Part Q ty Remarks Removing the front arms and front shock absorber Remove the parts in the order listed Front wheel brake disc Refer to FRONT WHEELS AND BRAKE DISCS 1 Brake disc guard 1 2 Front arm protector 1 3 Nut 2 Refer to REMOVING THE FRONT ARMS and INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 4 Bolt nut 2 2 5 Front lower arm bushing 1 2 6 Nut bolt 2 2 7 Front shoc...

Page 339: ... Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib 3 2 LS LS 8 Order Job Part Q ty Remarks 10 Circlip 1 11 Ball joint 1 For installation reverse the removal pro cedure FRONT ARMS AND FRONT SHOCK ABSORBER www midwestmanuals com ...

Page 340: ...the vertical movement is tight or rough or if there is binding check the bushings 2 Remove front arms CHECKING THE FRONT ARMS 1 Check front arms Bends damage Replace 2 Check bushings Wear damage Replace 3 Check ball joint Damage pitting Replace the ball joint Free play Replace the ball joint Turns roughly Replace the ball joint a Clean the outside of the front lower arm b Remove the circlip 1 and ...

Page 341: ...ed ball joint remover installer new ball joint A and installer attachment 7 to the front lower arm B NOTE Do not tap or damage the top of the ball joint h Hold the body 3 in place while turning in the long bolt 4 to install the new ball joint A into the front lower arm B i Remove the ball joint remover installer Ball joint remover installer set P N 90890 01474 Ball joint adapter set P N YM 01474 B...

Page 342: ...nd new circlip NOTE Always use a new ball joint set CHECKING THE FRONT SHOCK ABSORBER 1 Check shock absorber rod Bends damage Replace the shock absorber assembly shock absorber assembly Oil leaks Replace the shock absorber assembly spring Fatigue Replace the shock absorber assembly Move the spring up and down www midwestmanuals com ...

Page 343: ...cate the bolts 3 with lithium soap based grease Be sure to position the bolts 3 so that the bolt head faces outward Temporarily tighten the nuts 4 b Install the front shock absorber 5 c Install the ball joints d Install the new cotter pins e Tighten the nuts 4 T R Nut 6 45 Nm 4 5 m kg 32 ft lb T R Nut 7 30 Nm 3 0 m kg 22 ft lb T R Nut 4 45 Nm 4 5 m kg 32 ft lb 6 5 34 34 2 7 7 1 6 www midwestmanual...

Page 344: ...T R 32 Nm 3 2m kg 23 ft Ib LS Order Job Part Q ty Remarks Removing the rear knuckle and stabilizer Remove the parts in the order listed Rear wheel hubs Refer to REAR WHEELS AND BRAKE DISC 1 O ring 1 2 Rear knuckle 1 3 Spacer cover 4 4 Spacer 2 5 Stabilizer joint 2 6 Stabilizer holder 2 7 Bushing 2 8 Stabilizer 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 345: ...ction is recommended when using striking tools d Remove the spacer 3 e Apply lithium base grease to the bearings and oil seals f Install the spacer to the rear knuckle g Install the new bearings NOTE Install the outside bearing first CAUTION Do not strike the center race or balls of the bearing Contact should be made only with the outer race h Install a new oil seal NOTE When installing the oil se...

Page 346: ... Order Job Part Q ty Remarks Removing the rear arms and rear shock absorber Remove the parts in the order listed Rear knuckle stabilizer Refer to REAR KNUCKLE AND STABI LIZER 1 Nut bolt 2 2 Refer to INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER 2 Rear upper arm bushing 1 2 3 Nut bolt 2 2 4 Rear shock absorber 1 5 Nut bolt 2 2 6 Rear lower arm bushing 1 2 For installation reverse the removal pro...

Page 347: ...bushings 2 Wear damage Replace 1 2 2 CHECKING THE REAR SHOCK ABSORBER 1 Check shock absorber rod Bends damage Replace the shock absorber assembly shock absorber assembly Oil leaks Replace the shock absorber assembly spring Move the spring up and down Fatigue Replace the shock absorber assembly www midwestmanuals com ...

Page 348: ... 2 NOTE Lubricate the bolts 3 with lithium soap based grease Be sure to position the bolts 3 so that the bolt head faces inward Temporarily tighten the nuts 4 b Install the rear shock absorber 5 c Install the rear knuckle d Tighten the nuts 4 T R Nut 6 45 Nm 4 5 m kg 32 ft lb T R Nut 7 45 Nm 4 5 m kg 32 ft lb T R Nut 4 45 Nm 4 5 m kg 32 ft lb 5 1 7 7 2 6 34 6 www midwestmanuals com ...

Page 349: ...fan motor 5 Carburetor heater 6 Thermo switch 1 7 Ignition coil 8 Gear position switch 9 Reverse switch 0 Brake light switch A Parking brake switch B Pickup coil stator assembly C Speed sensor D Gear motor E Radiator fan F Thermo switch 3 5 6 7 4 8 9 A 0 1 B C D E F 2 3 ELECTRICAL COMPONENTS 9 www midwestmanuals com ...

Page 350: ...e switch and differ ential gear lock switch 6 Main switch 7 Light switch 8 Four wheel drive relay 1 9 Four wheel drive relay 2 0 Starter relay A Main fuse B Four wheel drive relay 3 C Differential gear lock indicator light relay D Four wheel drive indicator light relay E Fuse box F C D I unit G Battery G E F D A 0 C B 1 2 3 4 5 6 7 8 9 www midwestmanuals com ...

Page 351: ...ew times when checking it Pocket tester P N YU 03112 C 90890 03112 CHECKING A SWITCH SHOWN IN THE MANUAL The terminal connections for switches main switch light switch etc are shown in a chart similar to the one on the left This chart shows the switch positions in the column and the switch lead colors in the top row For each switch position indicates the terminals with continuity The example chart...

Page 352: ...r continuity between lead terminals Poor connection no continuity Correct or replace The coupler locations are circled 4 3 1 2 R B L B L G L R Sb Br Gy G R B 2WD 4WD LOCK L G L B L B R Y L R Br L Sb Gy Br G R B BLACK GRAY P L Gy W Br Y BLACK 7 9 8 6 L R B 5 L Y G OFF ON START OFF www midwestmanuals com ...

Page 353: ...se 2 Brake light switch 3 On Command four wheel drive switch and differential gear lock switch 4 Main switch 5 Light switch 6 Parking brake switch 7 Gear position switch 8 Reverse switch 9 Four wheel drive switch www midwestmanuals com ...

Page 354: ... illustration on the left Bulbs A and B are used for headlights and usually use a bulb holder which must be detached before removing the bulb The majority of these bulbs can be removed from their respective socket by turning them coun terclockwise Bulb C is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counter clockwise Bulbs D and E ...

Page 355: ...of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bulb for continuity with the pocket tester No continuity Replace NOTE Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the tester lead to terminal 1 and the tester lead to terminal 2...

Page 356: ...eplace NOTE Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket Pocket tester P N YU 03112 C 90890 03112 ...

Page 357: ... V R W R W G W G W W 2 R R 5 C G L W L L B W L L B Y B B L B Sb Br S T X Y BROWN L R B Br R Br R Br R B L G U Br R Br R B Y Br B B L R G R Gy Gy L G Br B Br R Br R L G B BLACK B Y Br R Br R L R B BLACK Y B L R Br R Gy BLACK GRAY GRAY BLACK B B B L R L B Sb Br W q q R Y R Y r R L B W L L R B W L Y B R Y B G L R W L W W R R O W G B W W 1 B Y L W Y L B Y L W Y L BLACK BLACK Y L r B Y k Br L P P B i B...

Page 358: ... Remove the following part s before trouble shooting 1 Console 2 Footrest cover Use the following special tool s for trouble shooting Pulse ignition spark checker P N YM 34487 Ignition checker P N 90890 06754 Pocket tester P N YU 03112 C 90890 03112 EB802011 CONTINUITY 1 Fuses main ignition Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse s EB802012 CORRECT 2 Battery Check the battery c...

Page 359: ...e the spark plug OUT OF SPECIFICATION OR NO SPARK 4 Ignition spark gap Disconnect the spark plug cap from the spark plug Connect the pulse ignition spark checker or ignition checker 1 as shown 2 Spark plug cap Turn the main switch to ON Check the ignition spark gap a Crank the engine by pushing the starter switch and increase the spark gap until a misfiring occurs Minimum spark gap 6 0 mm 0 24 in ...

Page 360: ...ct the pocket tester Ω 1k to the ignition coil Tester lead Orange lead terminal Tester lead Spark plug lead Check that the secondary coil has the specified resistance Secondary coil resistance 6 32 9 48 kΩ at 20 C 68 F OUT OF SPECIFICATION Replace the ignition coil 5 Spark plug cap resistance Remove the spark plug cap Connect the pocket tester Ω 1k to the spark plug cap MEETS SPECIFICATION Check t...

Page 361: ...assembly MEETS SPECIFICATION 9 Rotor rotation direction detection coil resistance Disconnect the A C magneto coupler from the wire harness Connect the pocket tester Ω 1 to the rotor rotation direction detection coil termi nal Tester lead Red terminal 1 Tester lead White Blue terminal 2 Check the rotor rotation direction detection coil for the specified resistance Rotor rotation direction detec tio...

Page 362: ...ION SYSTEM CORRECT 10 Wiring connection Check the connections of the entire igni tion system Refer to CIRCUIT DIAGRAM Replace the C D I unit POOR CONNECTION Properly connect the ignition system www midwestmanuals com ...

Page 363: ...R R 5Br C G L W L L B W L L B Y B B L B Sb Br S T X Y BROWN L R B Br R Br R Br R B L G U Br R Br R B Y Br B B L R G R Gy Gy L G Br B Br R Br R L G B BLACK B Y Br R Br R L R B BLACK Y B L R Br R Gy BLACK GRAY GRAY BLACK B B B L R L B Sb Br W q q R Y R Y r R L B W L L R B W L Y B R Y B G L R W L W W R R O W G B W W 1 B Y L W Y L B Y L W Y L BLACK BLACK Y L r B Y k Br L P P B i Br L R W h Br L Br l o...

Page 364: ...e starter motor can be operated only if 1 Main fuse 2 Battery 3 Starter relay 4 Starter motor 5 Diode 1 6 Signaling system fuse 7 Brake light switch 8 Ignition fuse 9 C D I unit 0 Gear position switch È TO MAIN SWITCH É FROM MAIN SWITCH The transmission is in neutral the gear position switch is in the neutral gear posi tion or The brake pedal is pressed the brake light switch is closed Y L 5 6 7 8...

Page 365: ... the following part s before trouble shooting 1 Console Use the following special tool s for trouble shooting Pocket tester P N YU 03112 C 90890 03112 EB802011 CONTINUITY 1 Fuses main ignition signaling system Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse s EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit volt...

Page 366: ...that no flammable gas or fluid is in the vicinity DOES NOT TURN Repair or replace the starter motor CONTINUITY 4 Starter relay Remove the starter relay from the wire harness Connect the pocket tester Ω 1 and the battery 12 V to the starter relay termi nals Battery terminal Yellow Blue terminal 1 Battery terminal Blue Black terminal 2 Tester lead Red terminal 3 Tester lead Black terminal 4 Check th...

Page 367: ...minal 1 Tester lead Black Yellow terminal 2 Continu ity Tester lead Yellow Blue terminal 1 Tester lead Blue White terminal 3 Tester lead Black Yellow terminal 2 Tester lead Yellow Blue terminal 1 No conti nuity Tester lead Blue White terminal 3 Tester lead Yellow Blue terminal 1 NOTE When you switch the tester s positive and neg ative probes the readings in the left chart will be reversed L W B Y ...

Page 368: ...1 2 Starter motor O ring 1 1 For installation reverse the removal pro cedure Disassembling the starter motor Remove the parts in the order listed 1 Bracket 1 1 Refer to ASSEMBLING THE STARTER MOTOR 2 Washer kit 1 3 Bracket 2 1 4 Shims 5 Brush seat 1 brush seat 2 1 1 6 Armature coil 1 7 Yoke 1 For assembly reverse the disassembly procedure www midwestmanuals com ...

Page 369: ...ng a hacksaw blade which has been grounded to fit the commutator Outside diameter 28 mm 1 10 in Wear limit 27 mm 1 06 in Mica undercut 0 7 mm 0 03 in 4 Check armature coil insulation continuity Defects Replace the starter motor a Connect the pocket tester for the continuity check 1 and insulation check 2 b Measure the armature resistances c If the resistance is incorrect replace the starter motor ...

Page 370: ...hing O rings Wear damage Replace Brush length 12 5 mm 0 49 in Wear limit 5 mm 0 20 in Brush spring force 7 65 10 01 Nm 780 1 021 g 27 5 36 0 oz ASSEMBLING THE STARTER MOTOR 1 Install brush seat 1 1 NOTE Align the projection a on the brush seat 1 with the slot b on the yoke 2 Install yoke brackets NOTE Align the match marks a on the yoke with the match marks b on the brackets www midwestmanuals com...

Page 371: ... L M N O P Q R j 3 Br L m V R W R W G W G W W 2 R R 5 C G L W L L B W L L B Y B B L B Sb Br S T X Y BROWN L R B Br R Br R Br R B L G U Br R Br R B Y Br B B L R G R Gy Gy L G Br B Br R Br R L G B BLACK B Y Br R Br R L R B BLACK Y B L R Br R Gy BLACK GRAY GRAY BLACK B B B L R L B Sb Br W q q R Y R Y r R L B W L L R B W L Y B R Y B G L R W L W W R R O W G B W W 1 B Y L W Y L B Y L W Y L BLACK BLACK Y...

Page 372: ...e tachometer P N 90890 03113 Pocket tester P N YU 03112 C 90890 03112 EB802011 CONTINUITY 1 Fuse main Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the battery terminals Recharge or replace the battery EB804011...

Page 373: ...Connect the pocket tester Ω 1 to the charging coils Tester lead White terminal 1 Tester lead White terminal 2 Tester lead White terminal 1 Tester lead White terminal 3 Measure the charging coil resistance Charging coil resistance 0 32 0 43 Ω at 20 C 68 F OUT OF SPECIFICATION Replace the pickup coil stator assembly EB804015 CORRECT 5 Wiring connections Check the connections of the entire charg ing ...

Page 374: ... L m V R W R W G W G W W 2 R R 5 C G L W L L B W L L B Y B B L B Sb Br S T X Y BROWN L R B Br R Br R Br R B L G U Br R Br R B Y Br B B L R G R Gy Gy L G Br B Br R Br R L G B BLACK B Y Br R Br R L R B BLACK Y B L R Br R Gy BLACK GRAY GRAY BLACK B B B L R L B Sb Br W q q R Y R Y r R L B W L L R B W L Y B R Y B G L R W L W W R R O W G B W W 1 B Y L W Y L B Y L W Y L BLACK BLACK Y L r B Y k Br L P P B...

Page 375: ...cial tool s for trouble shooting Pocket tester P N YU 03112 C 90890 03112 EB802011 CONTINUITY 1 Fuses main lighting system Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse s EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the battery terminals Recharge or repla...

Page 376: ...ight switch EB805013 CORRECT 5 Wiring connection Check the connections of the entire light ing system Refer to CIRCUIT DIAGRAM Check the condition of each of the lighting system s circuits Refer to CHECKING THE LIGHTING SYS TEM POOR CONNECTION Properly connect the lighting system www midwestmanuals com ...

Page 377: ...er DC 20 V to the headlight couplers Tester lead Green terminal 1 or Yellow terminal 2 Tester lead Black terminal 3 È When the light switch is on É When the light switch is on Turn the main switch to ON Turn the light switch to or Check the voltage 12 V of the Green and Yellow leads on the bulb socket con nector This circuit is not faulty È É L H L H OUT OF SPECIFICATION The wiring circuit from th...

Page 378: ...ket tester DC 20 V to the tail brake light connectors Tester lead Blue lead terminal 1 Tester lead Black lead terminal 2 MEETS SPECIFICATION Turn the main switch to ON Turn the light switch to or Check the voltage 12 V of the Blue lead on the bulb socket connector This circuit is not faulty L H OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty repa...

Page 379: ... A A 9 4 6 7 8 A 0 B E D F G I J K L M N O P Q R j 3 Br L m V R W R W G W G W W 2 R R 5 C G L W L L B W L L B Y B B L B Sb Br S T X Y BROWN L R B Br R Br R Br R B L G U Br R Br R B Y Br B B L R G R Gy Gy L G Br B Br R Br R L G B BLACK B Y Br R Br R L R B BLACK Y B L R Br R Gy BLACK GRAY GRAY BLACK B B B L R L B Sb Br W q q R Y R Y r R L B W L L R B W L Y B R Y B G L R W L W W R R O W G B W W 1 B Y...

Page 380: ...tch 1 Z Gear motor Diode 2 Four wheel drive indicator light _ Differential gear lock indicator light a Coolant temperature warning light b Four wheel drive indicator light relay c Differential gear lock indicator light relay e Neutral indicator light f Reverse indicator light g Parking brake indicator light h Signaling system fuse r Tail brake light www midwestmanuals com ...

Page 381: ... special tool s for trouble shooting Pocket tester P N YU 03112 C 90890 03112 EB802011 CONTINUITY 1 Fuses main signaling system Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse s EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the battery terminals Recharge or ...

Page 382: ...nnections Check the connections of the entire signal system Refer to CIRCUIT DIAGRAM Check the condition of each of the signal sys tem s circuits Refer to CHECKING THE SIGNAL SYS TEM POOR CONNECTION Properly connect the signal system www midwestmanuals com ...

Page 383: ...NO CONTINUITY Replace the brake light switch 3 Voltage Connect the pocket tester DC 20 V to the bulb socket connector Tester lead Yellow terminal 1 Tester lead Black terminal 2 MEETS SPECIFICATION Turn the main switch to ON Turn the light switch to or Check the voltage 12 V of the Yellow lead on the bulb socket connector This circuit is not faulty L H OUT OF SPECIFICATION The wiring circuit from t...

Page 384: ...eplace the gear position switch 3 Voltage Connect the pocket tester DC 20 V to the indicator light assembly 2 coupler Tester lead Brown terminal 1 Tester lead Sky blue terminal 2 Br B G Br W L Br W Y Br B G Br W Y Br W L R W G L R W L R R W Sb Br G L Br Sb Br L R 1 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V This circuit is not faulty OUT OF SPECIFICATION The wiring cir...

Page 385: ...lace the parking brake switch 3 Voltage Connect the pocket tester DC 20 V to the indicator light assembly 2 coupler Tester lead Brown terminal 1 Tester lead Blue Red terminal 2 Br B G Br W L Br W Y Br B G Br W Y Br W L R W G L R W L R R W Sb Br G L Br Sb Br L R 1 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V This circuit is not faulty OUT OF SPECIFICATION The wiring circu...

Page 386: ...ce the reverse switch 3 Voltage Connect the pocket tester DC 20 V to the indicator light assembly 2 coupler Tester lead Brown terminal 1 Tester lead Green Blue terminal 2 Br B G Br W L Br W Y Br B G Br W Y Br W L R W G L R W L R R W Sb Br G L Br Sb Br L R 1 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V Replace the C D I unit OUT OF SPECIFICATION The wiring circuit from th...

Page 387: ... for continuity While heating the coolant use a thermom eter 3 to record the temperatures È The thermo switch 1 circuit is open and the coolant temperature warning light is off É The thermo switch 1 circuit is closed and the coolant temperature warning light is on Test step Coolant temperature Continuity 1 Less than 120 3 C 248 5 4 F No 2 More than 120 3 C 248 5 4 F Yes 3 More than 113 C 235 4 F Y...

Page 388: ...ulb socket connector is faulty repair it 4 Diode 2 Remove the diode from the coupler Connect the pocket tester Ω 1 to the diode terminals as shown Check the diode for continuity as follows CORRECT Tester lead Blue Black terminal 1 Tester lead White Blue terminal 2 Continu ity Tester lead White Blue terminal 2 Tester lead Blue Black terminal 1 No conti nuity This circuit is not faulty NOTE When you...

Page 389: ...1 and the battery 12 V to the differential gear lock indicator light relay terminals Check the differential gear lock indicator light relay for continuity as follows Tester lead Black Green terminal 1 Tester lead Black terminal 2 Continu ity Battery terminal Brown terminal 3 Battery terminal Black Red terminal 4 No conti nuity Tester lead Black Green terminal 1 Tester lead Black terminal 2 NO CONT...

Page 390: ...Brown terminal 1 Tester lead Black Green terminal 2 Br B G Br W L Br W Y Br B G Br W Y Br W L 1 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty repair it www midwestmanuals com ...

Page 391: ...d the battery 12 V to the four wheel drive indi cator light relay terminals Check the four wheel drive indicator light relay for continuity as follows Tester lead White Yellow terminal 1 Tester lead Black terminal 2 Continu ity Battery terminal Brown terminal 3 Battery terminal White Black terminal 4 No conti nuity Tester lead White Yellow terminal 1 Tester lead Black terminal 2 NO CONTINUITY Repl...

Page 392: ...rown terminal 1 Tester lead White Yellow terminal 2 Br B G Br W L Br W Y Br B G Br W Y Br W L 1 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty repair it www midwestmanuals com ...

Page 393: ...R W R W G W G W W 2 R R 5 C G L W L L B W L L B Y B B L B Sb Br S T X Y BROWN L R B Br R Br R Br R B L G U Br R Br R B Y Br B B L R G R Gy Gy L G Br B Br R Br R L G B BLACK B Y Br R Br R L R B BLACK Y B L R Br R Gy BLACK GRAY GRAY BLACK B B B L R L B Sb Br W q q R Y R Y r R L B W L L R B W L Y B R Y B G L R W L W W R R O W G B W W 1 B Y L W Y L B Y L W Y L BLACK BLACK Y L r B Y k Br L P P B i Br L...

Page 394: ...he following special tool s for trouble shooting Pocket tester P N YU 03112 C 90890 03112 EB802011 CONTINUITY 1 Fuse main Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the battery terminals Recharge or replace ...

Page 395: ...erminal 2 Check the operation of the radiator fan motor DOES NOT TURN Replace the radiator fan motor MEETS SPECIFICATION 5 Circuit breaker radiator fan motor Remove the circuit breaker from the wire harness Connect the pocket tester Ω 1 to the circuit breaker Circuit breaker resistance Zero Ω at 20 C 68 F OUT OF SPECIFICATION Replace the circuit breaker www midwestmanuals com ...

Page 396: ...ircuit is closed É The thermo switch 3 circuit is open Test step Coolant temperature Continuity 1 Less than 75 3 C 167 5 4 F No 2 More than 75 3 C 167 5 4 F Yes 3 More than 68 C 154 4 F Yes 4 Less than 68 C 154 4 F No Test steps 1 2 Heating phase Test steps 3 4 Cooling phase WARNING Handle the thermo switch 3 with special care Never subject it to a strong shock or allow it to be dropped Should it ...

Page 397: ...YSTEM EB803028 CORRECT 7 Wiring connection Check the connections of the entire cool ing system Refer to CIRCUIT DIAGRAM This circuit is not faulty POOR CONNECTION Properly connect the cooling system www midwestmanuals com ...

Page 398: ... B Sb Br S T X Y BROWN L R B Br R Br R Br R B L G U Br R Br R B Y Br B B L R G R Gy Gy L G Br B Br R Br R L G B BLACK B Y Br R Br R L R B BLACK Y B L R Br R Gy BLACK GRAY GRAY BLACK B B B L R L B Sb Br W q q R Y R Y r R L B W L L R B W L Y B R Y B G L R W L W W R R O W G B W W 1 B Y L W Y L B Y L W Y L BLACK BLACK Y L r B Y k Br L P P B i Br L R W h Br L Br l o Br L R B R B L B L Br W L p n Br B G...

Page 399: ...E Remove the following part s before trouble shooting 1 Console Use the following special tool s for trouble shooting Pocket tester P N YU 03112 C 90890 03112 EB802011 CONTINUITY 1 Fuses main four wheel drive Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse s EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit volta...

Page 400: ...al 5 Check the four wheel drive relay 1 for con tinuity NO CONTINUITY Replace the four wheel drive relay 1 CONTINUITY 5 Four wheel drive relay 2 Remove the four wheel drive relay 2 from the wire harness Connect the pocket tester Ω 1 and the battery 12 V to the four wheel drive relay 2 terminals Tester lead Brown Black terminal 1 Tester lead Black terminal 2 Battery terminal Brown Red terminal 3 Ba...

Page 401: ...rown Red terminal 1 Battery terminal Yellow Black terminal 2 Tester lead Blue Red terminal 3 Tester lead Gray terminal 4 Check the four wheel drive relay 3 for continuity NO CONTINUITY Replace the four wheel drive relay 3 CORRECT 7 On Command four wheel drive switch and differential gear lock switch Refer to CHECKING THE SWITCH INCORRECT Replace the On Command four wheel drive switch and different...

Page 402: ...nter clockwise É Check that the pinion gear 2 turns clockwise Make sure that the drive gear shift fork sliding gear operates correctly NOTE When installing the differential gear case in the gear motor refer to FRONT CONSTANT VELOCITY JOINTS DIFFERENTIAL GEAR AND DRIVE SHAFT in chapter 7 INCORRECT Replace the gear motor È É EB803028 CORRECT 9 Wiring connection Check the connections of the entire 2W...

Page 403: ...Q R j 3 Br L m V R W R W G W G W W 2 R R 5 C G L W L L B W L L B Y B B L B Sb Br S T X Y BROWN L R B Br R Br R Br R B L G U Br R Br R B Y Br B B L R G R Gy Gy L G Br B Br R Br R L G B BLACK B Y Br R Br R L R B BLACK Y B L R Br R Gy BLACK GRAY GRAY BLACK B B B L R L B Sb Br W q q R Y R Y r R L B W L L R B W L Y B R Y B G L R W L W W R R O W G B W W 1 B Y L W Y L B Y L W Y L BLACK BLACK Y L r B Y k ...

Page 404: ...nsole Use the following special tool s for trouble shooting Pocket tester P N YU 03112 C 90890 03112 CORRECT 1 Fuses main carburetor heater Refer to CHECKING THE SWITCH NO CONTINUITY Replace the fuse s CORRECT 2 Battery Check the battery condition Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the battery terminals Recharge ...

Page 405: ...ified temperature as indicated in the table Check the thermo switch 2 for continuity at the temperatures indicated in the table È The thermo switch 2 circuit is closed É The thermo switch 2 circuit is open Test step Water temperature Continuity 1 Less than 16 3 C 60 8 37 4 F Yes 2 More than 16 3 C 60 8 37 4 F No 3 More than 11 3 C 51 8 37 4 F No 4 Less than 11 3 C 51 8 37 4 F Yes Test steps 1 2 He...

Page 406: ...inal 1 Tester lead Carburetor heater body 2 Measure the carburetor heater resistance Carburetor heater resistance 6 12 Ω at 20 C 68 F INCORRECT Replace the carburetor heater CORRECT 6 Wiring connection Check the connections on the entire car buretor heating system Refer to CIRCUIT DIAGRAM This circuit is not faulty POOR CONNECTION Properly connect the carburetor heating sys tem www midwestmanuals ...

Page 407: ...ir Deformed float Worn needle valve Improperly sealed valve seat Improperly adjusted fuel level Improperly set pilot jet Clogged starter jet Starter plunger malfunction Air filter Clogged air filter element ELECTRICAL SYSTEM Spark plug Improper plug gap Worn electrodes Wire between terminals broken Improper heat range Faulty spark plug cap Ignition coil Broken or shorted primary secondary Faulty s...

Page 408: ...arance Improperly adjusted valve timing EBS00538 POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE Carburetor Improperly returned starter plunger Loose pilot jet Clogged pilot jet Clogged pilot air jet Improperly adjusted idle speed throttle stop screw Improper throttle cable play Flooded carburetor Electrical system Faulty spark plug Faulty C D I unit Faulty pickup coil Faulty charging roto...

Page 409: ...A pronounced hesitation or jerky move ment during acceleration deceleration or sustained speed This must not be con fused with engine surging or transmission characteristics 2 A rolling rumble noticeable at low speed a high pitched whine a clunk from a shaft drive component or area 3 A locked up condition of the shaft drive mechanism no power transmitted from the engine to the front and or rear wh...

Page 410: ...ransmission Worn gear dog EBS00543 FAULTY CLUTCH PERFORMANCE ENGINE OPERATES BUT VEHICLE WILL NOT MOVE V belt Bent damaged or worn V belt V belt slips Primary pulley cam and primary pulley slider Damaged or worn primary pulley cam Damaged or worn primary pulley slider Transmission Damaged transmission gears CLUTCH SLIPPING Clutch spring Damaged loose or worn clutch shoe spring Clutch shoe Damaged ...

Page 411: ...er set ting Improper fuel level Clogged air filter element Compression system Heavy carbon deposit Engine oil Improper oil level Improper oil viscosity Inferior oil quality Brake Brake drag Cooling system Low coolant level Clogged or damaged radiator Damaged or faulty water pump Faulty fan motor Faulty thermo switch Oil cooling system Clogged or damaged oil cooler EBS00550 FAULTY BRAKE POOR BRAKIN...

Page 412: ...even tire wear Wheels Deformed wheel Loose bearing Bent or loose wheel axle Excessive wheel runout Frame Bent Damaged frame EBS00553 LIGHTING SYSTEM HEADLIGHT DOES NOT COME ON Improper bulb Too many electric accessories Hard charging broken stator coil and or faulty rectifier regulator Incorrect connection Improperly grounded Poor contacts main or lights switch Bulb life expired BULB BURNT OUT Imp...

Page 413: ... heater fuse 6 Battery 7 Main fuse 8 Starter relay 9 Starter motor 0 Brake light switch A Diode 1 B Reverse switch C C D I unit D Ignition coil E Spark plug F Speed sensor G Meter assembly H Multi function meter I Differential gear lock indicator light J Coolant temperature warning light K Reverse indicator light L Neutral indicator light M Parking brake indicator light N High range indicator ligh...

Page 414: ...arify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to read way by the ...

Page 415: ...t clearance G Engine speed H Electrical data Ω V A Symbols I to N in the exploded diagrams indicate the types of lubricants and lubrication points I Apply engine oil J Apply gear oil K Apply molybdenum disulfide oil L Apply wheel bearing grease M Apply lithium soap based grease N Apply molybdenum disulfide grease Symbols O to P in the exploded diagrams indicate where to apply a locking agent O and...

Page 416: ...N 20 PERIODIC MAINTENANCE LUBRICATION 20 ENGINE 22 CLEANING THE AIR FILTER ELEMENTS 22 CHASSIS 25 ADJUSTING THE PARKING BRAKE 25 ENGINE 26 ENGINE REMOVAL 26 AIR DUCTS MUFFLER AND EXHAUST PIPE 26 FUEL SYSTEM 28 CARBURETOR 28 INSTALLING THE AIR FILTER CASE JOINT 30 CHASSIS 31 SEATS ENCLOSURE HOOD AND CARGO BED 31 SEATS CONSOLE AND INSTRUMENT PANELS 31 PANELS AND FOOTREST COVER 33 CARGO BED 34 ENCLOS...

Page 417: ...9 544 Transmission type V belt automatic Operation Right hand operation Single speed automatic 2 450 0 834 1 Sub transmission ratio low 35 17 2 058 high 28 19 1 473 Reverse gear 25 17 1 471 Tire pressure cold tire Maximum load 398 kg 878 lb Off road riding front 63 77 kPa 0 63 0 77 kg cm2 9 11 psi rear 91 105 kPa 0 91 1 05 kg cm2 13 15 psi Load in total weight of cargo operator passenger accessori...

Page 418: ... 8 Throttle valve size Th V 105 Float height F H 13 mm 0 51 in Fuel level F L 4 0 5 0 mm 0 16 0 20 in Engine idle speed 1 450 1 550 r min Intake vacuum 28 0 30 7 kPa 210 230 mmHg 8 27 9 06 inHg Item Standard Limit Brake lever and brake pedal Accelerator pedal free play 0 mm 0 0 in Brake pedal free play 0 mm 0 0 in Parking brake lever free play 0 1 click of parking brake lever Item Standard Limit C...

Page 419: ... Tightening torque Remarks Nm m kg ft lb Engine cooling fan Bolt M6 2 9 0 9 6 5 Part to be tightened Thread size Tightening torque Remarks Nm m kg ft lb Rear wheel hub and constant velocity joint M20 260 26 0 190 LT Stake Cargo hook and cargo bed M6 7 0 7 5 1 Tailgate cable and cargo bed M6 7 0 7 5 1 Tailgate cable and tailgate M6 7 0 7 5 1 www midwestmanuals com ...

Page 420: ...b 8 Light switch 9 Coolant reservoir breather hose 0 Parking brake switch lead A Parking brake cable B Crankcase breather hose C Gear position switch D Reverse switch lead E Front brake hoses F Differential gear case breather hose G Reverse switch terminal H Gear position switch lead Ñ Ñ Ê È É Ï Ë Ð Î Í Ì C B A A B C 2 7 8 5 F 9 3 0 A B 1 5 3 4 6 C D E G H D 9 Ë www midwestmanuals com ...

Page 421: ...the hoses Ì Fasten the throttle cable parking brake switch lead and parking brake cable to the air duct assembly 1 with the plastic band Í Fasten the throttle cable to the air duct assembly 1 with the plastic band Î Fasten the radiator inlet hose and throttle cable with the plastic bands Ï 20 mm 0 79 in or less Ð 5 mm 0 20 in or less Ñ 15 Ñ Ñ Ê È É Ï Ë Ð Î Í Ì C B A A B C 2 7 8 5 F 9 3 0 A B 1 5 3...

Page 422: ...ds A Carburetor heater È Fasten the parking brake switch lead and park ing brake cable to the air duct assembly 1 with the plastic band É Fasten the wire harness to the frame with the plastic bands Ê Pass the tail brake light lead through the grom met Ë Fasten the parking brake cable to the air duct assembly 2 with the plastic band A B C B A C Ð Ì Ë È 1 2 3 4 5 6 É Ê 7 8 Ñ 9 0 A Î 8 Ï Ï Ï Î Í 7 Ò ...

Page 423: ...nto the rear fender so that there is no slack in the lead Ï Fasten the tail brake light lead with the plastic clamp Ð 20 40 Ñ Fasten the starter motor lead reverse switch lead gear position switch lead thermo switch 1 lead carburetor heater lead and parking brake switch lead with the plastic band Ò Fasten the wire harness with the plastic clamps A B C B A C Ð Ì Ë È 1 2 3 4 5 6 É Ê 7 8 Ñ 9 0 A Î 8 ...

Page 424: ...Thermo switch 3 B Gear motor couplers C Coolant reservoir hose D Speed sensor coupler E A C magneto couplers F Parking brake switch lead G Parking brake cable H Throttle cable I Radiator inlet pipe J Rear brake pipe K Radiator outlet pipe L Gear motor lead M Brake light switch lead N Indicator light assembly leads O Auxiliary DC jack lead A B D D C Ó Õ Ö Ô Ø Ù É Ê Ë Ì Î Ï Ð Ñ Ò B A C D D 3 5 L K I...

Page 425: ...nd coolant reservoir hose with the plastic clip Î 12 22 mm 0 47 0 87 in Ï Fasten the wire harness starter motor lead ground lead and starter choke cable to the frame with the plastic band Ð Fasten the wire harness starter motor lead and ground lead to the frame with the plas tic band Ñ Fasten the wire harness speed sensor lead starter choke cable starter motor lead and ground lead with the plastic...

Page 426: ...or outlet pipe with the plastic band Fasten the wire harness starter choke cable starter motor lead and ground lead with the plastic band Ø Fasten the gear motor lead with the plastic band Ù Fasten the wire harness brake light switch lead and starter choke cable with the plastic band A B D D C Ó Õ Ö Ô Ø Ù É Ê Ë Ì Î Ï Ð Ñ Ò B A C D D 3 5 L K I H J L 3 M 4 O N 1 2 3 4 5 6 7 F C D E G 9 0 A B Í 8 È È...

Page 427: ... 9 Ground lead 0 Rear brake hose A Parking brake cable B Ignition coil C Rear brake pipe D Wire harness E Fuel tank breather hose F Rollover valve G Fuel return hose H Fuel suction hose H H H H G G G G E E F F D D D D É Ë Ë È Ê Ì Í Ï Ð Ñ Ò Ó Ô Õ Ö Ö Ø Ú Ù Ø Í A 0 5 B 3 5 5 3 A 3 0 A 3 0 C D A B I D D C F F E E G G H H A C B I 1 2 3 4 5 7 8 9 0 A 6 H G F E Î D 1 www midwestmanuals com ...

Page 428: ...the A C magneto leads reverse switch lead gear position switch lead thermo switch 1 lead carburetor heater lead and parking brake switch lead with the plastic bands Î Pass the wire harness through the grommet Ï Fasten the wire harness with the plastic band Ð Fasten the parking brake cable and wire har ness with the plastic clip Ñ Fasten the parking brake cable with the metal holder H H H H G G G G...

Page 429: ...he final gear case breather hose with the plastic holders Fasten the parking brake cable and final gear case breather hose with the plastic holders Ø Fasten the rear brake hose with the plastic bands Ù Less than 1 mm 0 04 in Ú Fasten the rear brake pipe and wire harness with the plastic holder H H H H G G G G E E F F D D D D É Ë Ë È Ê Ì Í Ï Ð Ñ Ò Ó Ô Õ Ö Ö Ø Ú Ù Ø Í A 0 5 B 3 5 5 3 A 3 0 A 3 0 C D...

Page 430: ...e throttle cable through the cable guide É Fasten the speed sensor lead starter choke cable starter motor lead and ground lead with the plastic band Ê Fasten the wire harness and A C magneto lead with the plastic band Ë Fasten the wire harness with the plastic band Ì Fasten the fuel hose and vacuum hose with the metal holder A B B A B B É Ê Ô Õ Ó Ï Ñ 1 2 3 4 0 9 2 È Ë Ì Í Î 6 7 8 9 5 Ò Ð www midwe...

Page 431: ...e plastic holder Ñ Fasten the wire harness with the plastic band Ò Make sure that the plastic band is not fastened too tightly around the wire harness Ó Pass the spark plug lead through the cutout in the protective cover as shown Ô Fasten the rear brake pipe with the plastic band Õ Fasten the wire harness speed sensor lead starter choke cable starter motor lead and ground lead with the plastic ban...

Page 432: ... 8 Main switch 9 Starter choke knob 0 Light switch A Differential gear case breather hose B Radiator fan motor breather hose C Left headlight lead D Throttle cable E Right headlight lead F Starter motor lead G Starter relay lead H Four wheel drive relay 1 I Four wheel drive relay 2 J Starter relay N R P LOCK DIFF N R P TEMP DIFF LOCK 4WD D D C C B A A B D D C C P Q R S T U S Q P R T U V D Ñ Ò Ó 1 ...

Page 433: ...or light V C D I unit È Fasten the wire harness with the plastic bands É Pass the radiator fan motor breather hose dif ferential gear case breather hose coolant reser voir breather hose and brake light switch lead through the guide Ê Pass the radiator fan motor breather hose dif ferential gear case breather hose throttle cable and brake light switch lead through the guide N R P LOCK DIFF N R P TEM...

Page 434: ...ear case breather hose with the plastic holder Ï Fasten the starter motor lead and starter relay lead with the plastic holder Ð Fasten the positive battery lead with the plastic holder Ñ 59 61 mm 2 32 2 40 in Ò 4 mm 0 16 in of clearance or more is required around the boot Ó Make sure that the washer is installed on the side of the pedal assembly bracket towards the boot N R P LOCK DIFF N R P TEMP ...

Page 435: ...ant reservoir hose A Ground lead B Starter relay lead È Fasten the coolant reservoir breather hose with the plastic band É Fasten the front brake hose with the plastic band Ê Fasten the wire harness and ground lead with the plastic band Ë Fasten the differential gear case breather hose coolant reservoir hose radiator fan motor lead and thermo switch 3 lead with the plastic holder A B B B B A Ê Ë È...

Page 436: ...0 1 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 300 Valves Check valve clearance Adjust if necessary Cooling system Check coolant leakage Repair if necessary Replace coolant every 24 months Spark plug Check condition Adjust gap and clean Replace if necessary Air filter elements Engine and air intake duct Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Carburetor C...

Page 437: ...ir if necessary Wheel bearings Check bearing assemblies for looseness damage Replace if damaged Front and rear suspension Check operation and for leakage Correct if necessary Steering system Check operation and for looseness Replace if damaged Check toe in Adjust if necessary Rear upper and lower knuckle pivots Lubricate with lithium soap based grease Drive shaft universal joint Lubricate with lit...

Page 438: ...r filter element by hand tap the air filter element to remove most of the dust and dirt and then blow the remaining dirt out with compressed air 4 Check air filter element Damage Replace 5 Install air filter element into the air intake duct grill 6 Install air intake duct grill Cleaning the engine air filter element NOTE There is a check hose 1 at the bottom of the air filter case If dust and or w...

Page 439: ...filter element cap 2 air filter element 3 CAUTION Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid wear and possi ble engine damage Additionally operation without the filter element will affect carbu retor tuning with subsequent poor perfor mance and possible engine overheating 4 Check air filter element Damaged Replace www midwestm...

Page 440: ...et it dry CAUTION Do not twist or wring out the element This could damage the foam material c Apply Yamaha foam air filter oil or other quality foam air filter oil not spray type d Squeeze out the excess oil NOTE The element should be wet but not dripping 6 Install air filter element air filter case cover NOTE To prevent air leaks make sure that the sealing surface of the element matches the seali...

Page 441: ... play as follows NOTE The parking brake lever must be released when checking and adjusting the parking brake lever free play 4 Adjust parking brake lever free play a Pull back the adjuster cover b Loosen the locknut 1 c Turn the adjusting nut 2 in or out until the correct free play is obtained d Tighten the locknut 1 e Slide the adjuster cover to its original posi tion 5 Install console passenger ...

Page 442: ...e parts in the order listed Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Manual No 5UG F8197 10 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Manual No 5UG F8197 10 Driver seat passenger seat console air duct end cover left protector Refer to SEATS ENCLOSURE HOOD AND CARGO BED Engine cooling fan air duct assembly Refer to ENGINE COOLING FAN AND A C MAGNETO in chapter 4...

Page 443: ... R 7 Nm 0 7 m kg 5 1 ft Ib 5 New 2 6 1 Order Job Part Q ty Remarks Fuel tank Refer to FUEL PUMP AND FUEL TANK in chapter 6 Manual No 5UG F8197 10 1 Heat protector 1 2 Muffler stay 1 3 Muffler damper 1 4 Muffler bracket 1 5 Muffler gasket 1 1 6 Exhaust pipe gasket 1 2 7 Air duct assembly 1 1 8 Air duct assembly 2 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 444: ...fer to SEATS ENCLOSURE HOOD AND CARGO BED 1 Crankcase breather hose 1 Disconnect 2 Air filter case joint 1 3 Air filter case 1 4 Carburetor joint air filter case 1 5 Vacuum chamber breather hose 1 6 Air vent hose 1 7 Starter cable starter plunger 1 1 8 Fuel hose 1 Disconnect 9 Carburetor heater lead 2 Disconnect 10 Carburetor assembly 1 11 Drain hose 1 12 Throttle valve cover 1 CARBURETOR www midw...

Page 445: ...OR 3 4 6 2 15 13 12 9 7 10 1 8 11 14 5 Order Job Part Q ty Remarks 13 Throttle cable end 1 14 Throttle cable 1 15 Carburetor joint intake manifold 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 446: ...30 FUEL CARBURETOR INSTALLING THE AIR FILTER CASE JOINT 1 Install air filter case joint NOTE Align the tab a on the air filter case joint with the slot b in the air filter case b a www midwestmanuals com ...

Page 447: ...nsole and instrument panels Remove the parts in the order listed 1 Driver seat 1 2 Passenger seat 1 3 Air intake duct 1 4 Console 1 5 Steering wheel cover 1 6 Steering wheel 1 7 Pedal cover 1 8 Light switch coupler 1 Disconnect 9 Main switch coupler 1 Disconnect 10 On Command four wheel drive switch and differential gear lock switch 2 Disconnect 11 Indicator warning light coupler 2 Disconnect SEAT...

Page 448: ...R 7 Nm 0 7 m kg 5 1 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib Order Job Part Q ty Remarks 12 Auxiliary DC jack connector 2 Disconnect 13 Nut starter cable 1 1 14 Upper instrument panel 1 15 Hinge 2 16 Glove box lid 1 17 Lower instrument panel 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 449: ... ty Remarks Removing the panels and footrest cover Remove the parts in the order listed 1 Left side panel 1 2 Right side panel 1 3 Left corner panel 1 4 Right corner panel 1 5 Air duct end cover 1 6 Left protector 1 1 7 Right protector 1 1 8 Footrest cover 1 9 Driver seat support 1 10 Passenger seat support 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 450: ...1 ft Ib T R 11 Nm 1 1 m kg 8 0 ft Ib T R 26 Nm 2 6 m kg 19 ft Ib Order Job Part Q ty Remarks Disassembling the cargo bed Remove the parts in the order listed 1 Tailgate cable 2 2 Hinge cover 2 3 Tailgate 1 4 Cargo bed panel 2 5 Tail brake light bulb holder 2 6 Mud guard 2 7 Cargo bed release lever 1 8 Cargo hook 4 9 Cargo bed 1 For assembly reverse the disassembly procedure www midwestmanuals com ...

Page 451: ...Ib T R 59 Nm 5 9 m kg 43 ft Ib 6 1 2 3 5 7 4 8 4 8 4 8 Order Job Part Q ty Remarks Removing the enclosure and seat belts Remove the parts in the order listed 1 Front top frame 1 2 Rear top frame 1 3 Left support frame 1 4 Right support frame 1 5 Left side frame 1 6 Right side frame 1 7 Seat belt 2 8 Buckle 2 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 452: ...ifier regulator 3 Main switch 4 Backup fuse 5 Carburetor heater fuse 6 Battery 7 Main fuse 8 Starter relay 9 Starter motor 0 Brake light switch A Diode 1 B Reverse switch C C D I unit D Ignition coil E Spark plug F Speed sensor G Meter assembly H Multi function meter I Differential gear lock indi cator light J Coolant temperature warning light K Reverse indicator light L Neutral indicator light M ...

Page 453: ...arify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to read way by the ...

Page 454: ...t clearance G Engine speed H Electrical data Ω V A Symbols I to N in the exploded diagrams indicate the types of lubricants and lubrication points I Apply engine oil J Apply gear oil K Apply molybdenum disulfide oil L Apply wheel bearing grease M Apply lithium soap based grease N Apply molybdenum disulfide grease Symbols O to P in the exploded diagrams indicate where to apply a locking agent O and...

Page 455: ...HOOD AND CARGO BED 28 FRONT GUARD AND HOOD 28 PANELS AND FOOTREST COVER 29 CARGO BED 30 SKID PLATES 32 INSTALLING THE REAR SKID PLATE 33 ENCLOSURE AND SEAT BELTS 34 FRONT WHEELS AND BRAKE DISCS 35 REAR WHEELS AND BRAKE DISC 37 REAR WHEELS 37 FRONT ARMS AND FRONT SHOCK ABSORBERS 38 REAR KNUCKLE AND STABILIZER 40 ELECTRICAL 41 ELECTRICAL COMPONENTS 41 LIGHTING SYSTEM 43 CIRCUIT DIAGRAM 43 TROUBLESHO...

Page 456: ...urope Chassis Frame type Steel tube frame Caster angle 5 0 Camber angle 0 Kingpin angle 12 Kingpin offset 0 mm 0 in Trail 26 mm 1 02 in Tread STD front 1 115 mm 43 90 in rear 1 105 mm 43 50 in Toe in 15 25 mm 0 59 0 98 in Tire Type Tubeless Size front 25 8 12NHS rear 25 10 12NHS Manufacturer front MAXXIS rear MAXXIS Type front M951Y rear M952Y Tire pressure cold tire Maximum load 401 kg 884 lb exc...

Page 457: ...ing light LED Parking brake indicator light LED High range indicator light LED Low range indicator light LED Differential gear lock indicator light LED Four wheel drive indicator LCD Item Standard Limit Front wheel Type Panel wheel except for special edition models Cast wheel for special edition models Rim size 12 6 0 AT Rim material Steel except for special edition models Aluminum for special edi...

Page 458: ...read size Tightening torque Remarks Nm m kg ft lb Seat belt buckle and support frame M10 59 5 9 43 Front wheel hub and constant velocity joint M24 350 35 0 255 Stake Rear wheel hub and constant velocity joint M24 350 35 0 255 Stake Cargo bed release lever M6 7 0 7 5 1 Gas spring assembly and gas spring assembly bracket M8 16 1 6 11 Cargo bed assembly and gas spring assembly bracket M6 7 0 7 5 1 Mu...

Page 459: ...choke knob 9 Light switch 0 Coolant reservoir breather hose A Parking brake switch lead B Parking brake cable C Crankcase breather hose D Gear position switch E Reverse switch lead F Front brake hoses G Differential gear case breather hose H Reverse switch terminal I Gear position switch lead Ò Ò Ñ È É Ï Ë Ð Î Í Ì C B A A B C 2 8 9 5 G 0 3 A B C 1 5 6 3 4 7 D E F H I E 0 Ë Ê www midwestmanuals com...

Page 460: ...ble parking brake switch lead and parking brake cable to the air duct assembly 1 with a plastic band Í Fasten the throttle cable to the air duct assembly 1 with a plastic band Î Fasten the radiator inlet hose and throttle cable with the plastic bands Ï 20 mm 0 79 in or less Ð 5 mm 0 20 in or less Ñ Route the throttle cable to the inside of the radia tor inlet hose Ò 15 Ò Ò Ñ È É Ï Ë Ð Î Í Ì C B A ...

Page 461: ...itch lead and park ing brake cable to the air duct assembly 1 with a plastic band É Fasten the wire harness to the frame with the plastic bands Ê Fasten the parking brake cable to the air duct assembly 2 with a plastic band Ë Fasten the parking brake cable and float cham ber breather hose with the plastic clip Ì Fasten the wire harness with the plastic holders A B C B A C Í Ë Ê È 1 2 3 4 5 6 É 7 8...

Page 462: ... tail brake light lead into the rear fender so that there is no slack in the lead Ð Fasten the unused coupler to the wire harness with tape Ñ Fasten the tail brake light lead with the plastic holders Ò Fasten the tail brake light lead with the plastic bands Ó Fasten the wire harness with the plastic bands A B C B A C Í Ë Ê È 1 2 3 4 5 6 É 7 8 Î 9 0 A Ì 7 Ì Ó D D Ñ Ò Ð Ó Ò Ñ 8 8 Ï E E 8 Ð Ì 7 D D w...

Page 463: ...Speed sensor coupler D A C magneto couplers E Parking brake switch lead F Parking brake cable G Throttle cable H Radiator inlet pipe I Rear brake pipe J Radiator outlet pipe K Gear motor lead L Brake light switch lead M Indicator light assembly leads except for special edition mod els N On Command four wheel drive switch and differential gear lock switch lead O Auxiliary DC jack lead A B D D C Ó Õ...

Page 464: ...coolant reservoir hose with the plastic clip Î 12 22 mm 0 47 0 87 in Ï Fasten the wire harness starter motor lead ground lead and starter choke cable to the frame with a plastic band Ð Fasten the wire harness starter motor lead and ground lead to the frame with a plastic band Ñ Fasten the wire harness speed sensor lead starter choke cable starter motor lead and ground lead with a plastic band A B ...

Page 465: ...tor outlet pipe with a plastic band Fasten the wire harness starter choke cable starter motor lead and ground lead with the plastic bands Ø Fasten the gear motor lead with a plastic band Ù Fasten the wire harness brake light switch lead and starter choke cable with a plastic band A B D D C Ó Õ Ö Ô Ø Ù É Ê Ë Ì Î Ï Ð Ñ Ò B A C D D 3 4 K J H G I K 3 L O M 1 2 3 4 5 6 E B C D F 8 9 0 A Í 7 N È È www m...

Page 466: ...nd lead 0 Rear brake hose A Parking brake cable B Ignition coil C Rear brake pipe D Wire harness E Fuel tank breather hose F Rollover valve G Fuel return hose H Fuel suction hose 1 Ü H H H H G G G G E E F F D D D D É Ë Ë È Ê Ì Í Ñ Ò Ó Ô Ï Õ Ö Ï Ø Ï Ù Û Ú Ø Ù Í A 0 5 B 3 5 3 A 3 0 A 3 0 C D A B I D D C F F E E G G H H A C B I 1 2 3 4 5 7 8 9 0 A 6 H G F E Ð D J J Î J J www midwestmanuals com ...

Page 467: ... reverse switch lead gear position switch lead thermo switch 1 lead carburetor heater lead and parking brake switch lead with the plastic bands Î 130 mm 5 12 in Ï Fasten the final gear case breather hose with the plastic holders Ð Pass the wire harness through the grommet Ñ Fasten the wire harness with a plastic band Ò Fasten the parking brake cable and wire har ness with the plastic clip 1 Ü H H ...

Page 468: ...ders Ø Fasten the parking brake cable and final gear case breather hose with the plastic holders Ù Fasten the rear brake hose with the plastic bands Ú Less than 1 mm 0 04 in Û Fasten the rear brake pipe and wire harness with the plastic holder Ü Fasten the ignition coil lead with a plastic band 1 Ü H H H H G G G G E E F F D D D D É Ë Ë È Ê Ì Í Ñ Ò Ó Ô Ï Õ Ö Ï Ø Ï Ù Û Ú Ø Ù Í A 0 5 B 3 5 3 A 3 0 A ...

Page 469: ...È Pass the throttle cable through the cable guide É Fasten the speed sensor lead starter choke cable starter motor lead and ground lead with a plastic band Ê Fasten the wire harness and A C magneto leads with a plastic band Ë Fasten the wire harness with a plastic band Ì Fasten the fuel hose and vacuum hose with the metal holder A B B A B B É Ê Ô Õ Ó Ð Ñ 1 2 3 4 0 Ï 9 2 È Ë Ì Í Î 6 7 8 9 5 Ò A www...

Page 470: ...he vehicle Ñ Fasten the wire harness with a plastic band Ò Make sure that a plastic band is not fastened too tightly around the wire harness Ó Pass the spark plug lead through the cutout in the protective cover as shown Ô Fasten the rear brake pipe with a plastic band Õ Fasten the wire harness speed sensor lead starter choke cable starter motor lead and ground lead with a plastic band A B B A B B ...

Page 471: ...wheel drive switch and differ ential gear lock switch 8 Main switch 9 Starter choke knob 0 Light switch A Rectifier regulator B Differential gear case breather hose C Radiator fan motor breather hose D Left headlight lead E Throttle cable F Right headlight lead G Starter motor lead H Starter relay lead N R P LOCK DIFF N R P TEMP DIFF LOCK 4WD D D C C B A A B D D C C R S T U V W U S R T V W X E Ò Ó...

Page 472: ...d R Neutral indicator light except for special edition models S Reverse indicator light except for special edition models T Parking brake indicator light except for special edition models U Four wheel drive indicator light except for spe cial edition models V Differential gear lock indicator light except for special edition models N R P LOCK DIFF N R P TEMP DIFF LOCK 4WD D D C C B A A B D D C C R ...

Page 473: ... breather hose coolant reser voir breather hose and brake light switch lead through the guide Ë Pass the radiator fan motor breather hose dif ferential gear case breather hose throttle cable and brake light switch lead through the guide Ì Pass the radiator fan motor breather hose and differential gear case breather hose through the guide N R P LOCK DIFF N R P TEMP DIFF LOCK 4WD D D C C B A A B D D...

Page 474: ... the starter motor lead and starter relay lead with the plastic holder Ñ Fasten the positive battery lead with the plastic holder Ò 59 61 mm 2 32 2 40 in Ó 4 mm 0 16 in of clearance or more is required around the boot Ô Make sure that the washer is installed on the side of the pedal assembly bracket on the boot side N R P LOCK DIFF N R P TEMP DIFF LOCK 4WD D D C C B A A B D D C C R S T U V W U S R...

Page 475: ...s A Coolant reservoir hose B Ground lead C Starter relay lead È Fasten the coolant reservoir breather hose with the plastic holders É Fasten the front brake hose with the plastic bands Ê Fasten the wire harness and ground lead with a plastic band Ë Fasten the differential gear case breather hose coolant reservoir hose radiator fan motor lead and thermo switch 3 lead with the plastic holder A B B B...

Page 476: ...ght bulb holder assembly WARNING Keep flammable products and your hands away from the bulb while it is on since it will be hot Do not touch the bulb until it cools down 5 Install headlight bulb holder assembly CAUTION Avoid touching the glass part of the bulb Keep it free from oil otherwise the trans parency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on ...

Page 477: ... 22 CHK ADJ CHANGING A HEADLIGHT BULB 6 Connect headlight coupler 7 Install headlight bulb holder cover 8 Close the hood ______ I www midwestmanuals com ...

Page 478: ... console Refer to SEATS ENCLOSURE HOOD AND CARGO BED Manual No 5UG F8197 11 Drive belt cover Refer to PRIMARY AND SECONDARY SHEAVES in chapter 4 Manual No 5UG F8197 10 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Manual No 5UG F8197 10 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Manual No 5UG F8197 10 ENGINE COOLING FAN AND A C MAGNETO www midwestmanuals com ...

Page 479: ...duct assembly 1 2 Air shroud 1 1 3 Engine cooling fan 1 4 Air shroud 2 1 5 A C magneto coupler 2 Disconnect 6 Engine cooling fan pulley base 1 Refer to REMOVING THE A C MAG NETO and INSTALLING THE A C MAGNETO in chapter 4 Manual No 5UG F8197 10 7 A C magneto cover gasket 1 1 8 Dowel pin 2 9 Stator lead holder 1 10 Pickup coil 1 11 Stator assembly 1 www midwestmanuals com ...

Page 480: ...1 Refer to REMOVING THE A C MAG NETO and INSTALLING THE A C MAGNETO in chapter 4 Manual No 5UG F8197 10 13 Woodruff key 1 14 Starter wheel gear 1 15 Washer 1 16 Starter idle gear shaft 1 17 Bearing 1 18 Starter idle gear 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 481: ...r seat console Refer to SEATS ENCLOSURE HOOD AND CARGO BED Manual No 5UG F8197 11 Left corner panel right corner panel footrest cover Refer to SEATS ENCLOSURE HOOD AND CARGO BED Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Manual No 5UG F8197 10 1 Oil cooler inlet pipe 1 oil cooler outlet pipe 1 1 1 2 O ring 2 3 Oil cooler 1 4 Oil cooler inlet hose 1 5 Oil cooler outlet hose 1 OI...

Page 482: ...g 5 1 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib 1 2 2 3 4 7 6 8 4 5 Order Job Part Q ty Remarks 6 Oil outlet hose 1 7 Oil inlet hose 1 8 Oil cooler inlet pipe 2 oil cooler outlet pipe 2 1 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 483: ...43 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the front guard and the hood Remove the parts in the order listed 1 Front guard protector 1 2 Front guard 1 3 Headlight coupler 2 Disconnect 4 Hood 1 For installation reverse the removal pro cedure SEATS ENCLOSURE HOOD AND CARGO BED www midwestmanuals com ...

Page 484: ...Job Part Q ty Remarks Removing the panels and footrest cover Remove the parts in the order listed 1 Left side panel 1 2 Right side panel 1 3 Left corner panel 1 4 Right corner panel 1 5 Left protector 1 1 6 Right protector 1 1 7 Footrest cover 1 8 Driver seat support 1 9 Passenger seat support 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 485: ...6 Nm 1 6 m kg 11 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the cargo bed Remove the parts in the order listed 1 Tail brake light connector 6 Disconnect 2 Gas spring assembly 2 3 Pin 2 4 Cargo bed assembly 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 486: ...6 Nm 2 6 m kg 19 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Disassembling the cargo bed Remove the parts in the order listed 1 Cargo bed mat 1 2 Tailgate cable 2 3 Hinge cover 2 4 Tailgate 1 5 Cargo bed panel 2 6 Tail brake light bulb holder 2 7 Cargo bed release lever 1 8 Cargo hook 4 9 Cargo bed 1 For assembly reverse the disassembly procedure www midwestmanuals com ...

Page 487: ...TES T R 7 Nm 0 7 m kg 5 1 ft Ib 2 1 7 7 7 7 4 Order Job Part Q ty Remarks Removing the engine skid plates Remove the parts in the order listed 1 Front skid plate 1 2 Rear skid plate 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 488: ...D CARGO BED INSTALLING THE REAR SKID PLATE 1 Install rear skid plate 1 NOTE Make sure that the hole a in the rear skid plate 1 is towards the left side of the vehicle È Forward É Left side Ê Right side È É Ê 1 a www midwestmanuals com ...

Page 489: ... 1 2 3 5 7 4 8 4 8 4 8 R 59 Nm 5 9 m kg 43 ft Ib 7 Order Job Part Q ty Remarks Removing the enclosure and seat belts Remove the parts in the order listed 1 Front top frame 1 2 Rear top frame 1 3 Left support frame 1 4 Right support frame 1 5 Left side frame 1 6 Right side frame 1 7 Seat belt 2 8 Buckle 2 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 490: ...ob Part Q ty Remarks Removing the front wheel Remove the parts in the order listed Place the vehicle on a level surface WARNING Securely support the vehicle so there is no danger of it falling over 1 Front wheel 1 Refer to INSTALLING THE FRONT WHEEL in chapter 8 Manual No 5UG F8197 10 2 Center cap 1 3 Axle nut 1 Refer to INSTALLING THE FRONT WHEEL HUB in chapter 8 Manual No 5UG F8197 10 www midwes...

Page 491: ...5 m kg 40 ft Ib T R 350 Nm 35 0 m kg 255 ft lb Order Job Part Q ty Remarks 4 Brake caliper assembly 1 NOTE Do not depress the brake pedal when the brake caliper is off of the brake disc as the brake pads will be forced shut 5 Front wheel hub 1 6 Brake disc 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 492: ...s in the order listed Place the vehicle on a level surface WARNING Securely support the vehicle so there is no danger of it falling over 1 Rear wheel 1 Refer to INSTALLING THE REAR WHEEL in chapter 8 Manual No 5UG F8197 10 2 Center cap 1 3 Axle nut 1 Refer to INSTALLING THE REAR WHEEL HUB in chapter 8 Manual No 5UG F8197 10 4 Rear wheel hub 1 For installation reverse the removal pro cedure www mid...

Page 493: ...Job Part Q ty Remarks Removing the front arms and front shock absorbers Remove the parts in the order listed Front wheel brake disc Refer to FRONT WHEELS AND BRAKE DISCS 1 Brake disc guard 1 2 Front arm protector 1 3 Nut 2 Refer to REMOVING THE FRONT ARMS and INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER in chapter 8 Manual No 5UG F8197 10 4 Bolt nut 2 2 5 Front lower arm bushing 1 2 6 Nut bo...

Page 494: ... New 4 LS 8 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib 3 2 LS LS 8 Order Job Part Q ty Remarks 10 Circlip 1 11 Ball joint 1 For installation reverse the removal pro cedure www midwestmanuals com ...

Page 495: ... Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the rear knuckle and sta bilizer Remove the parts in the order listed Rear wheel hubs Refer to REAR WHEELS AND BRAKE DISC 1 Mud guard for special edition models 1 2 O ring 1 3 Rear knuckle 1 4 Spacer cover 4 5 Spacer 2 6 Stabilizer joint 2 7 Stabilizer holder 2 8 Bushing 2 9 Stabilizer 1 For installation reverse the removal pro cedure www...

Page 496: ... fan motor 5 Carburetor heater 6 Thermo switch 1 7 Ignition coil 8 Gear position switch 9 Reverse switch 0 Brake light switch A Parking brake switch B Pickup coil stator assembly C Speed sensor D Gear motor E Radiator fan F Thermo switch 3 5 6 7 4 8 9 A 0 1 B C D E F 2 3 ELECTRICAL COMPONENTS www midwestmanuals com ...

Page 497: ... and differential gear lock switch 6 Main switch 7 Light switch 8 Four wheel drive relay 1 9 Four wheel drive relay 2 0 Starter relay A Main fuse B Four wheel drive relay 3 C Four wheel drive indicator light relay except for special edition models D Headlight relay E Differential gear lock indicator light relay except for special edition models F Fuse box G C D I unit H Battery H F G E A 0 C B 1 2...

Page 498: ...R Br R B Y Br B B G R Gy Gy L G Br B Br R Br R L G B BLACK B Y Br R Br R L R B BLACK Y B L R Br R Gy BLACK GRAY GRAY BLACK B B B L R L B Sb Br W R Y R Y R L B W L L R B W L Y B R Y B G L R W L W W R R O W G B W W B Y L W Y L B Y L W Y L BLACK BLACK Y L B Y Br L P P B Br L R W Br L Br Br L R B R B L B L Br W L Br B G Br W L Br W Y Br B G Br W Y Br W L W Y L R B L R B B L R B R Br B G B W B Br W Y B...

Page 499: ... tester P N YU 03112 C 90890 03112 EB802011 CONTINUITY 1 Fuses main lighting system Refer to CHECKING THE SWITCH in chap ter 9 Manual No 5UG F8197 10 NO CONTINUITY Replace the fuse s EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Manual No 5UG F8197 10 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the battery termin...

Page 500: ...Green terminal 2 Battery terminal Yellow terminal 3 Battery terminal Black terminal 4 Tester lead Blue terminal 1 Tester lead Yellow terminal 5 Check the headlight relay for continuity NO CONTINUITY Replace the headlight relay EB805013 CORRECT 6 Wiring connection Check the connections of the entire light ing system Refer to CIRCUIT DIAGRAM Check the condition of each of the lighting system s circu...

Page 501: ... W G W W R R Br L G L W L L B W L L B Y B B L B Sb Br BROWN L R B Br R Br R Br R B L G Br R Br R B Y Br B B Gy Gy L G Br B Br R Br R L G B BLACK B Y Br R Br R L R B BLACK Y B L R Br R Gy BLACK GRAY GRAY BLACK B B B L R L B Sb Br W R Y R Y R L B W L L R B W L Y B R Y B G L R W L W W R R O W G B W W B Y L W Y L B Y L W Y L BLACK BLACK Y L B Y Br L P P B Br L R W Br L Br Br L R B R B L B L Br W L Br ...

Page 502: ...ht J Coolant temperature warning light K Reverse indicator light L Neutral indicator light M Parking brake indicator light N High range indicator light O Low range indicator light P Gear position switch Q Parking brake switch R Thermo switch 1 Y On Command four wheel drive switch and differential gear lock switch Z Gear motor Diode 2 h Signaling system fuse i Ignition fuse s Tail brake light www m...

Page 503: ...ating the coolant use a thermom eter 3 to record the temperatures È The thermo switch 1 circuit is closed and the coolant temperature warning light is off É The thermo switch 1 circuit is open and the coolant temperature warning light is on Test step Coolant temperature Continuity 1 Less than 120 3 C 248 5 4 F Yes 2 More than 120 3 C 248 5 4 F No 3 More than 113 C 235 4 F No 4 Less than 113 C 235 ...

Page 504: ...ty as follows CORRECT Tester lead Blue Black terminal 1 Tester lead White Blue terminal 2 Continu ity Tester lead White Blue terminal 2 Tester lead Blue Black terminal 1 No conti nuity This circuit is not faulty NOTE When you switch the tester s positive and neg ative probes the readings in the left chart will be reversed 1 2 L B W L INCORRECT Replace the diode 2 www midwestmanuals com ...

Page 505: ... Sb Br BROWN L R B Br R Br R Br R B L G Br R Br R B Y Br B B G R Gy Gy L G Br B Br R Br R L G B BLACK B Y Br R Br R L R B BLACK Y B L R Br R Gy BLACK GRAY GRAY BLACK B B B L R L B Sb Br W R Y R Y R L B W L L R B W L Y B R Y B G L R W L W W R R O W G B W W B Y L W Y L B Y L W Y L BLACK BLACK Y L B Y Br L P P B Br L R W Br L Br Br L R B R B L B L Br W L Br B G Br W L Br W Y Br B G Br W Y Br W L W Y ...

Page 506: ...tor light a Coolant temperature warning light b Four wheel drive indicator light relay c Differential gear lock indicator light relay d Indicator light assembly 2 e Neutral indicator light f Reverse indicator light g Parking brake indicator light h Signaling system fuse i Ignition fuse j Lighting system fuse k Auxiliary DC jack fuse l Circuit breaker radiator fan motor m Light switch n Auxiliary D...

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Yamaha 2004 YXR660, Service Manual

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