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Yamaha 2016 Grizzly yf700gg, Service Manual, Page: 433 / 474

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Yamaha 2016 Grizzly yf700gg Service Manual Download Page 433

ELECTRICAL COMPONENTS

9-78

1. Four-wheel-drive motor relay 1
2. Four-wheel-drive motor relay 2
3. Headlight relay 1
4. Fuel injection system fuse
5. Starter relay
6. EPS fuse (for EPS models)
7. Main fuse
8. Fuse box (ignition, headlights, four-wheel-

drive motor, radiator fan motor, signaling 
system, auxiliary DC jack)

9. Radiator fan motor circuit breaker
10. Rectifier/regulator
11. Reverse switch
12. Gear position switch
13. Auxiliary DC jack
14. Main switch
15. Differential motor
16. EPS torque sensor (for EPS models)
17. EPS motor (for EPS models)
18. Horn (except for CDN)
19. Radiator fan motor

Summary of Contents for 2016 Grizzly yf700gg

Page 1: ...2016 SERVICE MANUAL YF70GG YF70GPG YF70GPSG YF70GPLG YFM70GDXG YFM70GDHG YFM70GPXG YFM70GPHG YFM70GPSG YFM70GPLG YFM700FWAD 2UD F8197 E0 ...

Page 2: ...0GDHG YFM70GPXG YFM70GPHG YFM70GPSG YFM70GPLG YFM700FWAD SERVICE MANUAL 2015 by Yamaha Motor Co Ltd First edition July 2015 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ...apply to this model This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future edi...

Page 4: ...on title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction chart 6 accompanies the exploded diagram providing the order...

Page 5: ...ITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOCTITE Engine oil Replace the part with a new one G M BF B T R LS M S LT E New ...

Page 6: ......

Page 7: ...EBS10003 TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 DRIVE TRAIN 8 ELECTRICAL SYSTEM 9 TROUBLESHOOTING 10 ...

Page 8: ......

Page 9: ...or EPS models 1 3 INSTRUMENT FUNCTIONS 1 5 IMPORTANT INFORMATION 1 7 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 7 REPLACEMENT PARTS 1 7 GASKETS OIL SEALS AND O RINGS 1 7 LOCK WASHERS PLATES AND COTTER PINS 1 7 BEARINGS AND OIL SEALS 1 8 CIRCLIPS 1 8 RUBBER PARTS 1 8 BASIC SERVICE INFORMATION 1 9 QUICK FASTENERS 1 9 ELECTRICAL SYSTEM 1 10 SPECIAL TOOLS 1 14 ...

Page 10: ...N EBS30003 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame EBS30004 MODEL LABEL The model label 1 is affixed at the location in the illustration This information will be needed to order spare parts 1 ...

Page 11: ...IDENTIFICATION 1 2 ...

Page 12: ...FEATURES 1 3 EBS20010 FEATURES EBS30007 OUTLINE OF THE EPS ELECTRIC POWER STEERING SYSTEM for EPS models 4 5 7 6 1 2 3 d c e a b f ...

Page 13: ...rmation from speed sensor 2 Engine RPM information from ECU 3 Battery 4 EPS control unit 5 EPS motor 6 Torque sensor 7 EPS unit a Operates steering b Twists torsion bar c Sends the torque sensor signal d EPS control unit calculates assist power e Electricity output switched by EPS control unit f Activates EPS motor ...

Page 14: ...e clock mode CLOCK and the hour meter mode HOUR in the following order CLOCK HOUR CLOCK To set the clock 1 Set the display to the clock mode 2 Push the SELECT button and RESET but ton together for at least three seconds 3 When the hour digits start flashing push the RESET button to set the hours 4 Push the SELECT button and the minute digits will start flashing 5 Push the RESET button to set the m...

Page 15: ...le warning light will come on or flash and the multi function display will indicate an fault code If the multi function display indicates an fault code note the code number and check the ve hicle NOTICE ECB02030 If the display indicates a fault code the vehi cle should be checked as soon as possible in order to avoid engine damage 1 Fault code display 2 Engine trouble warning light 1 2 ...

Page 16: ... correct installation of all parts 5 Keep all parts away from any source of fire EBS30010 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EBS30011 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

Page 17: ...d air because this will damage the bearing surfac es EBS30014 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives EBS30015 RUBBER PARTS Check rubber parts for deterioration during in...

Page 18: ...tener push its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin in with a screwdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fastene...

Page 19: ...f a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECB01520 Be sure to connect the battery leads to the correct battery terminals Reversing the bat tery lead connections could damage the electrical components NOTICE ECB01530 When connecting the battery leads to the battery be sure to connect the positive bat tery lead first then ...

Page 20: ... 5 seconds before turning the main switch back to ON Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECB01440 Never insert the tester probes into the cou pler terminal slots Always insert the probes from the opposite end a of the coupler tak ing care not to loosen or damage the leads NOTICE ECB01500 For waterproof ...

Page 21: ...erefore be sure to check the type of cou pler lock before disconnecting the coupler NOTICE ECB01550 When disconnecting a connector do not pull the leads Hold both sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler Connector Moisture Dry with an air blower Rust stains Connect and disconnect sev eral times 3 Connect Lead Coupler Connector TIP When connecting ...

Page 22: ...most part stores 5 Check Resistance TIP The resistance values shown were obtained at the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring conditions will be shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Pocket tester 90890 03112 Analog pocket tester YU 03112 C Intake air temperature sensor re sistance 5 40 6 60 kΩ a...

Page 23: ... mistakes TIP For U S A and Canada use part number starting with YM YU YS YK or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 13 1 13 9 82 9 83 9 84 9 84 9 88 9 90 9 91 9 91 9 91 9 92 9 92 9 93 9 93 9 94 9 94 9 95 9 95 9 96 9 96 9 96 9 97 9 97 9 98 9 98 Thickness gauge 90890 03180 Feeler...

Page 24: ...older 30 mm 90890 01327 Damper rod holder 30 mm YM 01327 4 57 4 57 Ball joint remover 90890 01474 Ball joint remover YM 01474 4 63 4 68 Ball joint remover attachment set 90890 01480 Ball joint adapter set YM 01480 4 63 4 68 Ball joint installer attachment 38mm 90890 01583 Ball joint installer attachment 38mm YM 01583 4 63 Ball joint remover short shaft set 90890 01514 Ball joint remover short shaf...

Page 25: ...YU 01304 5 22 Valve spring compressor 90890 04019 Valve spring compressor YM 04019 5 29 5 33 Valve spring compressor attachment 90890 01243 Valve spring compressor adapter 26 mm YM 01253 1 5 29 5 33 Valve guide remover installer set ø5 5 90890 04016 Valve guide remover 5 5 mm YM 01122 5 31 Tool name Tool No Illustration Reference pages 90890 03081 YU 33223 YU 01304 ...

Page 26: ... YM 01196 5 31 Rotor holding tool 90890 04166 YM 04166 5 37 5 37 5 38 5 39 5 45 5 46 5 52 5 57 Flywheel puller M38 X P1 5 90890 04178 Flywheel puller M38 X P1 5 YM 04178 5 37 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 5 42 7 8 Sheave fixed block 90890 04135 Sheave fixed bracket YM 04135 5 52 5 56 Tool name Tool No Illustration Reference pages M38 P1 5 ...

Page 27: ...eave spring compressor 90890 04134 Sheave spring compressor YM 04134 5 52 5 56 Universal clutch holder 90890 04086 Universal clutch holder YM 91042 5 61 5 62 Crankcase separating tool 90890 01135 Crankcase separator YU 01135 B 5 67 5 72 Tool name Tool No Illustration Reference pages ...

Page 28: ...75 Bolt YU 90060 5 74 Adapter M16 90890 04130 Adapter 13 YM 04059 5 74 Spacer crankshaft installer 90890 04081 Pot spacer YM 91044 5 74 Coupling gear middle shaft tool 90890 01229 Gear holder YM 01229 5 84 5 84 5 87 5 87 Bearing retainer wrench 90890 04128 Middle gear bearing retainer YM 04128 5 85 5 86 Tool name Tool No Illustration Reference pages YU 90058 YU 90059 YM 91044 ...

Page 29: ...r kit YU 24460 A 6 6 Radiator cap tester adapter 90890 01352 Pressure tester adapter YU 33984 6 6 Mechanical seal installer 90890 01581 Mechanical seal installer YM 01581 6 12 Middle driven shaft bearing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 6 12 Fuel pressure adapter 90890 03176 Fuel pressure adapter YM 03176 7 7 Tool name Tool No Illustration Reference pages YU 2446...

Page 30: ...stallation tool YM 01526 8 9 8 11 8 21 8 21 8 23 Ring gear fix bolt M10 90890 01527 Ring gear fix bolt M10 YM 01527 8 13 Gear lash measurement tool 90890 01475 Middle drive gear lash tool YM 01475 8 13 Ring gear fix bolt M14 90890 01524 Ring gear fix bolt M14 YM 01524 8 29 Tool name Tool No Illustration Reference pages M10 P1 25 M14 P1 5 ...

Page 31: ...ENING TORQUES 2 12 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 12 ENGINE TIGHTENING TORQUES 2 13 CHASSIS TIGHTENING TORQUES 2 18 LUBRICATION POINTS AND LUBRICANT TYPES 2 23 ENGINE 2 23 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 ENGINE OIL LUBRICATION CHART 2 25 LUBRICATION DIAGRAMS 2 27 COOLING SYSTEM DIAGRAMS 2 31 CABLE ROUTING 2 33 ...

Page 32: ...height 1253 mm 49 3 in Seat height 918 mm 36 1 in Wheelbase 1250 mm 49 2 in Ground clearance 288 mm 11 3 in Minimum turning radius 3500 mm 138 in Maximum water depth 35 cm 14 in Weight Curb weight 308 0 kg 679 lb YF70GG YFM70GDHG YFM70GDXG 314 0 kg 692 lb YF70GPG YFM700FWAD YFM70GPHG YFM70GPXG 320 0 kg 705 lb YF70GPLG YF70GPSG YFM70GPLG YFM70GPSG Maximum loading limit 240 0 kg 530 lb Total weight ...

Page 33: ...gine oil Lubrication system Wet sump Recommended brand YAMALUBE Type SAE 0W 30 10W 30 10W 40 15W 40 20W 40 or 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Without oil filter cartridge replacement 2 00 L 2 11 US qt 1 76 Imp qt With oil filter cartridge replacement 2 10 L 2 22 US qt 1 85 Imp qt Quantity disassembled 2 60 L 2 75 US qt 2 29 Imp...

Page 34: ...it 0 15 mm 0 006 in Spark plug s Manufacturer model NGK CPR7EA 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Cylinder head Warpage limit 0 03 mm 0 0012 in Camshaft Drive system Chain drive left Camshaft journal diameter 21 946 21 963 mm 0 8640 0 8647 in Camshaft lobe dimensions Lobe height Intake limit 33 800 mm 1 3307 in Base circle diameter Intake limit 24 850 mm 0 9783 in Lobe height Exhaust limit...

Page 35: ...ound limit 0 050 mm 0 0020 in Piston Piston to cylinder clearance 0 040 0 075 mm 0 0016 0 0030 in Diameter 102 960 102 975 mm 4 0535 4 0541 in Measuring point from piston skirt bottom 11 0 mm 0 43 in Piston pin bore inside diameter limit 23 035 mm 0 9069 in Piston pin outside diameter limit 22 974 mm 0 9045 in Piston ring Top ring Ring type Barrel End gap installed limit 0 50 mm 0 0197 in Ring sid...

Page 36: ...backlash 0 05 0 25 mm 0 002 0 010 in Shifting mechanism Shift fork thickness 5 76 5 89 mm 0 2268 0 2319 in Decompression device Device type Auto decomp Air filter Air filter element Wet element Air filter oil grade Foam air filter oil Fuel pump Pump type Electrical Throttle body Type quantity 44EIS 1 ID mark B161 00 Throttle valve size 100 Fuel injector Model quantity E270103 1 Resistance 12 0 Ω T...

Page 37: ...ENGINE SPECIFICATIONS 2 6 Air induction system Solenoid resistance 18 22 Ω ...

Page 38: ...l Steel Radial wheel runout limit 1 2 mm 0 05 in Lateral wheel runout limit 1 2 mm 0 05 in Rear wheel Wheel type Cast wheel YF70GPLG YF70GPSG YFM70GPLG YFM70GPSG Panel wheel YF70GG YF70GPG YFM700FWAD YFM70GDHG YFM70GDXG YFM70GPHG YFM70GPXG Rim size 12 7 5AT Wheel material Steel Radial wheel runout limit 1 2 mm 0 05 in Lateral wheel runout limit 1 2 mm 0 05 in Front tire Type Tubeless Size AT26 8 1...

Page 39: ...ness 205 0 3 5 mm 8 07 0 14 in Brake disc thickness limit 3 0 mm 0 12 in Brake disc deflection limit 0 10 mm 0 0039 in Brake pad lining thickness limit 1 0 mm 0 04 in Master cylinder inside diameter 12 70 mm 0 50 in Caliper cylinder inside diameter 33 96 mm 1 34 in Specified brake fluid DOT 4 Brake pedal free play 1 0 6 0 mm 0 04 0 24 in Front suspension Type Double wishbone Spring shock absorber ...

Page 40: ...e 2 16 2 64 Ω Secondary coil resistance 8 64 12 96 kΩ Spark plug cap Resistance 10 0 kΩ Charging system Charging system AC magneto Standard output 14 0 V 35 0 A at 5000 r min Stator coil resistance 0 15 0 22 Ω Rectifier regulator Regulator type Semi conductor short circuit Regulated voltage DC 14 3 14 7 V Rectifier capacity DC 50 0 A Battery Model YTX20L BS Voltage capacity 12 V 18 0 Ah Handle mou...

Page 41: ...HG YFM70GPLG YFM70GPSG YFM70GPXG Quantity 1 pcs YFM700FWAD YFM70GDHG YFM70GDXG YFM70GPHG YFM70GPLG YFM70GPSG YFM70GPXG Maximum amperage 1 0 A YFM700FWAD YFM70GDHG YFM70GDXG YFM70GPHG YFM70GPLG YFM70GPSG YFM70GPXG Fuel sender unit Sender unit resistance full 19 00 21 00 Ω Sender unit resistance empty 138 50 141 50 Ω EPS torque sensor Coil resistance 1 00 1 50 kΩ YF70GPG YF70GPLG YF70GPSG YFM700FWAD...

Page 42: ...n fuse 10 0 A Radiator fan motor fuse 20 0 A Auxiliary DC jack fuse 10 0 A Fuel injection system fuse 15 0 A Four wheel drive motor fuse 10 0 A EPS fuse 40 0 A YF70GPG YF70GPLG YF70GPSG YFM700FWAD YFM70GPHG YFM70GPLG YFM70GPSG YFM70GPXG Spare fuse 20 0 A Spare fuse 15 0 A Spare fuse 10 0 A ...

Page 43: ... To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kgf ft lbf 10 mm 6 mm 6 0 ...

Page 44: ...f Timing chain stopper guide bolt low er M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Timing chain guide bolt intake side M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Air cut off valve bracket bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Reed valve cover bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf AC magneto cover bolt M6 11 See TIP Crankshaft end accessing screw M32 1 11 Nm 1 1 m kgf 8 0 ft lbf Timing mark accessing screw M14 1 4 0 Nm 0...

Page 45: ...2 ft lbf Bearing retainer bolt bearing hous ing M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Primary sheave assembly nut M16 1 140 Nm 14 m kgf 100 ft lbf Primary sheave cap screw M4 8 3 0 Nm 0 30 m kgf 2 2 ft lbf Secondary sheave assembly nut M16 1 100 Nm 10 m kgf 72 ft lbf Secondary sheave spring retaining nut M36 1 90 Nm 9 0 m kgf 65 ft lbf Clutch housing assembly bolt M6 9 10 Nm 1 0 m kgf 7 2 ft lbf Clutch ...

Page 46: ...drive shaft coupling gear nut middle gear side M16 1 115 Nm 11 5 m kgf 83 ft lbf Starter motor bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Starter motor cover bolt M5 2 5 Nm 0 5 m kgf 3 6 ft lbf Starter motor lead nut M6 1 11 Nm 1 1 m kgf 8 0 ft lbf Starter motor lead terminal nut M6 1 11 Nm 1 1 m kgf 8 0 ft lbf Spark plug new M10 1 11 Nm 1 1 m kgf 8 0 ft lbf Stator coil assembly bolt M6 3 10 Nm 1 0 m kg...

Page 47: ...n the cylinder head bolts M11 to 30 Nm 3 0 m kgf 22 ft lbf in the proper tightening se quence 6 Tighten the cylinder head bolts M11 to the specified angle 85 90 in the proper tightening se quence 7 Tighten the cylinder head bolts M11 to the specified angle 85 90 in the proper tightening se quence again 8 Tighten the cylinder head bolts M6 and cylinder bolts M6 to 10 Nm 1 0 m kgf 7 2 ft lbf in the ...

Page 48: ...TIGHTENING TORQUES 2 17 TIP Oil pump bolt Tighten the oil pump bolts to 10 Nm 1 0 m kgf 7 2 ft lbf in the proper tightening sequence 10 6 1 2 9 11 5 7 3 8 4 3 1 2 ...

Page 49: ... 5 8 ft lbf Brake pedal free play adjusting nut M8 1 7 Nm 0 7 m kgf 5 1 ft lbf Brake pedal height adjuster locknut M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Radiator bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Coolant reservoir bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Fuel pump nut M6 6 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank breather hose joint bolt M6 1 3 5 Nm 0 35 m kgf 2 5 ft...

Page 50: ... 5 1 ft lbf Rear carrier bracket bolt M10 2 60 Nm 6 0 m kgf 43 ft lbf License plate bracket nut for CDN M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Rear fender bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Rear fender bolt M6 2 4 0 Nm 0 40 m kgf 2 9 ft lbf Rear fender bracket bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Rear storage compartment bracket screw M5 2 4 0 Nm 0 40 m kgf 2 9 ft lbf Tail brake light unit nut M5 2 2 8 N...

Page 51: ...lt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Rear arm protector bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Rear arm protector nut M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Stabilizer joint nut M10 4 56 Nm 5 6 m kgf 41 ft lbf Stabilizer holder bolt M8 4 30 Nm 3 0 m kgf 22 ft lbf Handlebar cover bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Meter cover nut M5 3 4 0 Nm 0 40 m kgf 2 9 ft lbf Handle mounted light screw M5 2 1 3 Nm 0 13 m kg...

Page 52: ...ial assembly bolt M10 2 55 Nm 5 5 m kgf 40 ft lbf Differential gear oil filler bolt M14 1 23 Nm 2 3 m kgf 17 ft lbf Differential gear oil drain bolt M10 1 10 Nm 1 0 m kgf 7 2 ft lbf Differential case cover bolt M8 5 24 Nm 2 4 m kgf 17 ft lbf Differential motor bolt M6 3 11 Nm 1 1 m kgf 8 0 ft lbf Front drive shaft yoke nut differen tial case side M14 1 62 Nm 6 2 m kgf 45 ft lbf Final drive assembl...

Page 53: ...sensor screw M5 1 1 5 Nm 0 15 m kgf 1 1 ft lbf Rectifier regulator bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Ignition coil bolt M6 2 9 Nm 0 9 m kgf 6 5 ft lbf Horn bracket bolt except for CDN M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Frame ground bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Item Thread size Q ty Tightening torque Remarks ...

Page 54: ...ter cartridge union bolt Dipstick mating surface Starter idler gear inner surface Starter idler gear shafts Starter wheel gear Starter clutch Clutch housing shaft end Clutch carrier assembly One way clutch bearing Reverse idle gear shaft Reverse idle gear Secondary shaft Middle driven pinion gear inner surface Middle driven shaft splines Shift drum Shift forks and shift fork guide bar Shift fork a...

Page 55: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 24 Crankcase mating surface Yamaha bond No 1215 Three Bond No 1215 Lubrication point Lubricant Sealant ...

Page 56: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EBS20020 LUBRICATION SYSTEM CHART AND DIAGRAMS EBS30022 ENGINE OIL LUBRICATION CHART 11 10 9 8 7 1 6 4 5 2 3 ...

Page 57: ...CHART AND DIAGRAMS 2 26 1 Oil pan 2 Oil strainer 3 Oil pump 4 Relief valve 5 Oil filter cartridge 6 Drive axle 7 Reverse idle gear shaft 8 Oil pipe crankcase 9 Oil hose crankcase to cylinder 10 Crankshaft 11 Cylinder head ...

Page 58: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EBS30023 LUBRICATION DIAGRAMS 6 7 8 9 3 4 3 2 1 5 ...

Page 59: ...YSTEM CHART AND DIAGRAMS 2 28 1 Oil hose crankcase to cylinder 2 Oil pipe crankcase 3 Oil filter cartridge 4 Oil strainer 5 Oil pump 6 Oil pipe AC magneto cover 7 Reverse idle gear shaft 8 Drive axle 9 Relief valve ...

Page 60: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 1 2 3 4 5 ...

Page 61: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Camshaft 2 Crankshaft 3 Oil strainer 4 Oil pump 5 Oil pump driven sprocket ...

Page 62: ...COOLING SYSTEM DIAGRAMS 2 31 EBS20021 COOLING SYSTEM DIAGRAMS 1 2 3 10 9 8 6 7 5 4 ...

Page 63: ...AMS 2 32 1 Coolant reservoir hose 2 Radiator inlet hose 3 Coolant reservoir 4 Water pump 5 Water pump inlet hose 6 Water pump outlet pipe 7 Oil cooler inlet hose 8 Water pump outlet hose 9 Radiator outlet hose 10 Radiator ...

Page 64: ...CABLE ROUTING 2 33 EBS20022 CABLE ROUTING Handlebar front view 1 D 1 2 A B C D E 1 2 3 4 5 B 3 4 5 F G 1 2 3 4 5 3 4 5 9 10 1 2 6 7 8 1 2 3 4 5 6 7 8 9 10 H I 11 ...

Page 65: ...brake hose so that the slack in the hoses and cable is positioned below the handle mounted light cover and to the front of the steering stem B Pass the rear brake hose through the guide C Pass the rear brake cable and shift control cable through the guide D Pass the front brake hose and throttle cable through the guide E Route the leads on top of where the cables cross F Pass the leads through the...

Page 66: ...CABLE ROUTING 2 35 Handlebar front view 2 1 2 3 4 B 3 4 11 C D 5 6 1 2 3 4 E F G H 5 6 6 I J K 7 8 9 10 A 1 2 L 11 12 11 11 ...

Page 67: ... portion of the handlebar where the handlebar begins to bend C Pass the differential case breather hose through the hole on the battery cover D Pass the radiator fan motor breather hose through the hole on the battery cover E Route the radiator fan motor breather hose differential case breather hose and horn lead except for CDN in front of the frame F Fasten the differential case breather hose to ...

Page 68: ...CABLE ROUTING 2 37 Engine left side view J 1 13 16 J K 1 13 15 J L 1 13 M N O P 9 10 11 17 18 19 20 21 22 O 11 A 1 2 3 4 5 2 3 6 7 8 9 10 11 B 12 C 13 D 14 15 E F G H I 23 ...

Page 69: ...ad and EPS torque sensor lead for EPS models in the holder and then insert the ends of the holder into the hole in the stay on the frame E Route the differential case breather hose to the inside of the frame F Fasten the differential case breather hose to the frame with the plastic band making sure to face the end of the band inward G Connect the air induction system solenoid coupler to the air cu...

Page 70: ...ABLE ROUTING 2 39 Engine right side view 1 A B 1 2 3 4 5 6 7 8 9 C 3 6 10 11 12 13 14 15 D 16 17 E 13 14 15 F 18 19 20 G 21 22 23 J 13 14 15 J I 7 18 3 4 5 7 9 1 3 4 5 9 H H K L 13 14 15 H 14 20 M 19 20 ...

Page 71: ...he throttle cable C Pass the final drive case breather hose and throttle body breather hose through the hole on the battery cover D Route the radiator fan motor lead between the electrical components tray and the radiator inlet hose E Fasten the radiator fan motor lead and radiator fan motor breather hose to the frame with the plastic band making sure to face the end of the band inward Be sure to ...

Page 72: ...CABLE ROUTING 2 41 Engine right side view 2 C E 1 9 10 E 1 9 10 E 5 6 9 A B C D 1 2 3 4 5 6 7 8 ...

Page 73: ...nsor lead 8 Final drive case breather hose 9 Fuel hose 10 Fuel pump lead A To tail brake light B Fasten the tail brake light lead to the frame with a plastic locking tie making sure to face the end of the tie downward C Route the tail brake light lead to the outside of the frame D Install the plastic band near the split in the wire harness E Face the end of the plastic band downward ...

Page 74: ...Electrical components tray top view A B B C D E F G H I I J K L M N O P Q R S 1 1 2 3 4 5 5 6 7 6 7 7 8 9 10 10 11 12 13 13 13 14 15 16 17 18 18 19 20 21 22 22 23 23 23 24 25 25 26 27 28 29 30 31 32 33 33 34 34 K T 35 35 ...

Page 75: ...y F To main switch and auxiliary DC jack G Route the final drive case breather hose above the leads in the electrical components tray H Route the starter motor lead above the leads in the electrical components tray I Fasten the EPS control unit leads with the holder for EPS models J Fasten the meter assembly lead and EPS control unit lead with the twist tie for EPS models K Fasten the handlebar sw...

Page 76: ...CABLE ROUTING 2 45 Engine top view B 5 6 7 8 9 10 11 12 13 14 15 16 17 A 1 2 3 4 19 20 21 22 C 18 11 17 17 ...

Page 77: ...ss 12 ISC unit lead 13 Rectifier regulator lead 14 AC magneto lead 15 Fuel hose 16 Circuit breaker 17 Tail brake light lead 18 Fuel pump lead 19 Intake air temperature sensor lead 20 TPS lead 21 Intake air pressure sensor lead 22 Fuel injector lead A Route the throttle cable between the air duct and the frame B Fasten the throttle body breather hose with the holder C Make sure that the fuel hose a...

Page 78: ...CABLE ROUTING 2 47 Front and rear brake hoses F 3 F 3 F 3 3 I G H 4 4 B C D 2 E D 2 A 1 ...

Page 79: ...the holder D Fasten the front brake hose with the holder E Connect the end of the front brake hose that is identified by the green paint mark to the left front brake caliper F Pass the rear brake pipe through the holder G Fasten the rear brake hose with the holder H Route the rear brake hose above the frame I Connect the end of the rear brake hose that is identified by the green paint mark to the ...

Page 80: ...CABLE ROUTING 2 49 ...

Page 81: ...G THE WHEELS 3 15 CHECKING THE TIRES 3 16 CHECKING THE V BELT 3 17 REPLACING THE V BELT 3 17 CHECKING THE FASTENER 3 18 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES 3 18 ADJUSTING THE FRONT SHOCK ABSORBER ASSEMBLIES 3 18 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES 3 19 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 19 CHECKING THE STABILIZER BUSHING 3 19 LUBRICATING THE REAR KNUCKLE PIVOTS 3 19 LUBR...

Page 82: ...3 32 ADJUSTING THE DRIVE SELECT LEVER CONTROL CABLE AND SHIFT ROD 3 32 ADJUSTING THE THROTTLE LEVER FREE PLAY 3 33 ADJUSTING THE SPEED LIMITER 3 34 REPLACING THE HANDLE MOUNTED LIGHT BULB 3 34 ADJUSTING THE HEADLIGHT AND HANDLE MOUNTED LIGHT BEAMS 3 35 ...

Page 83: ......

Page 84: ...GENERAL MAINTENANCE AND LUBRICATION CHART TIP For vehicles not equipped with an odometer or an hour meter follow the month maintenance intervals For vehicles equipped with an odometer or an hour meter follow the km mi or hours maintenance intervals However keep in mind that if the vehicle isn t used for a long period of time the month main tenance intervals should be followed Items marked with an ...

Page 85: ... nec essary 9 V belt Check for wear cracks or other damage and replace if necessary 10 Chassis fasteners Make sure that all nuts bolts and screws are proper ly tightened 11 Shock absorber as semblies Check operation and correct if necessary Check for oil leakage and replace if necessary 12 Stabilizer bushes Check for cracks or other damage and replace if nec essary 13 Rear knuckle pivots Lubricate...

Page 86: ...and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 25 Throttle lever Check operation Check throttle lever free play and adjust if necessary Lubricate cable and lever housing 26 Front and rear brake switches Check operation and correct if necessary 27 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR MAINT...

Page 87: ...ug NOTICE ECB01270 Before removing the spark plug blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder 4 Check Spark plug type Incorrect Change 5 Check Electrodes 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 6 Clean Spark plug with a spark plug cleaner or ...

Page 88: ...age 5 12 3 Remove Spark plug Cylinder head cover 3 Refer to CAMSHAFTS on page 5 12 NOTICE ECB01270 Before removing the spark plug blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder 4 Remove Crankshaft end accessing screw 1 5 Measure Valve clearance Out of specification Adjust a Turn the crankshaft counterclockwise b Position the h...

Page 89: ...thickness of the current valve pad and then calculate the sum of the values ob tained to determine the required valve pad thickness and the valve pad number TIP The number a marked on the valve pad indi cate the valve pad thickness Refer to the following table for the available valve pads If there are no available valve pads with the same thickness as the calculated valve pad thickness select the ...

Page 90: ...g If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained 8 Install O ring Crankshaft end accessing screw 9 Install Cylinder head cover gasket Cylinder head cover Refer to CAMSHAFTS on page 5 12 Spark plug TIP Before installing the spark plug clean the spark plug and gasket surface 10 Connect Spark plug cap...

Page 91: ...ly 3 Install Air filter case Refer to GENERAL CHASSIS 5 on page 4 17 Side panel left Refer to GENERAL CHASSIS 1 on page 4 1 EBS30031 CHECKING THE EXHAUST SYSTEM 1 Check Exhaust pipe 1 Muffler 2 Exhaust pipe protector 3 Muffler bracket 4 Springs 5 Cracks damage Replace Gaskets 6 Exhaust gas leaks Replace 2 Check Tightening torque EBS30574 ADJUSTING THE EXHAUST GAS VOLUME TIP Be sure to set the CO d...

Page 92: ...e any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the muffler d Install a new gasket and then insert the tail pipe into the muffler and align the bolt holes e Install the bolts 1 and tighten them EBS30033 CHECKING THE AIR INDUCTION SYSTEM Refer to CHECKING THE AIR INDUCTION SYSTEM on page 7 13 EBS30037 CLEANING THE AIR FILTER ELEMENT 1 Check Ai...

Page 93: ...ow flash point solvents such as gasoline to clean the air filter element Such solvents may cause a fire or an explosion b After cleaning squeeze the air filter element to remove the excess solvent NOTICE ECB01290 Do not twist the air filter element when squeezing it c Properly dispose of the used solvent d Carefully wash the air filter element in soap water e Thoroughly rinse the air filter elemen...

Page 94: ...ake pads Wear indicator grooves a have almost dis appeared Replace the brake pads and brake pad spring as a set Refer to FRONT BRAKE on page 4 26 4 Install Front wheels Refer to FRONT WHEELS on page 4 20 EBS30050 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the rear brake pads 1 Remove Rear wheels Refer to REAR WHEELS on page 4 23 2 Operate the brake 3 Check Rear brake pa...

Page 95: ...e adjusting nut 1 and locknut 2 c Turn the adjusting nut 1 in direction a until the rear brake cable 3 is taut d Turn the adjusting nut 1 one turn in direction b and then tighten the locknut 2 e While holding the locknut 2 tighten the ad justing nut 1 f Check that there is a gap between the rear brake cable joint rear brake master cylinder side 4 and the pin 5 g Check that the brake pedal free pla...

Page 96: ...ront fender inner panel right Refer to GENERAL CHASSIS 3 on page 4 8 EBS30461 CHECKING THE FRONT BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps 1 Check Front brake hoses 1 Cracks damage wear Replace 2 Check Brake hose holders Loose Tighten the holder bolt 3 Apply the brake several times 4 Check Brake hoses Brake fluid leakage Replace the damaged hose Re...

Page 97: ...Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECB01320 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediate...

Page 98: ...ng the bleed screw will release the pres sure and cause the brake lever to touch the throttle grip h Tighten the bleed screw and then release the brake lever i Repeat steps e to h until all of the air bub bles have disappeared from the brake fluid in the plastic hose j Tighten the bleed screw to specification k Fill the brake fluid reservoir to the proper level with the specified brake fluid Refer...

Page 99: ...n the following pressures when seating the tire beads Front 250 kPa 2 5 kgf cm 36 psi Rear 250 kPa 2 5 kgf cm 36 psi Higher pressures and fast inflation may cause a tire to burst Inflate the tires very slowly and carefully Maximum loading limit WARNING EWB02990 Be extra careful of the vehicle balance and stability when towing a trailer 1 Measure Tire pressure Out of specification Adjust Front tire...

Page 100: ... dangerous to ride with a worn out tire When the tire tread reaches the wear limit re place the tire immediately TIP The arrow mark 1 on the tire must point in the direction of wheel rotation EBS30055 CHECKING THE V BELT 1 Remove Drive belt cover Refer to PRIMARY AND SECONDARY SHEAVES on page 5 49 2 Check V belt 1 Cracks damage wear Replace Grease oil Clean the primary and second ary sheaves Refer...

Page 101: ...ING THE FRONT SHOCK ABSORBER ASSEMBLIES The following procedure applies to both of the front shock absorber assemblies 1 Place the vehicle on a level place 2 Check Front shock absorber assembly Refer to CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES on page 4 67 3 Check Operation Pump the front shock absorber assembly up and down several times Unsmooth operation Replace front shock absorber assembly...

Page 102: ... absorber assemblies to the same setting Uneven adjustment can cause poor handling and loss of stability 1 Adjust Spring preload Turn the adjuster 1 in direction a or b EBS30064 CHECKING THE STABILIZER BUSHING 1 Check Stabilizer bushings Damage wear Replace Refer to REAR KNUCKLES AND STABILIZ ER on page 4 70 EBS30065 LUBRICATING THE REAR KNUCKLE PIVOTS 1 Lubricate Rear knuckle pivots Direction a S...

Page 103: ...r left until it stops b Move the handlebar slightly to the right and left c Check for play in the tie rod ends d Turn the handlebar right until it stops e Move the handlebar slightly to the left and right f Check for play in the tie rod ends 4 Raise the front end of the vehicle so that there is no weight on the front wheels 5 Check Ball joints and wheel bearings Move the wheels laterally back and ...

Page 104: ...osening the bolts be sure to check that the steering stem moves smoothly on the serra tions of the shaft of the EPS unit c Tighten the steering stem bracket bolts to specification d Tighten the steering stem pinch bolt to speci fication e Measure the steering tension again f Repeat the above procedure until the steer ing tension is below specification g Install the electrical components tray Refer...

Page 105: ...to specification run the vehicle slowly for some distance with both hands lightly holding the handlebar and check that the handlebar responds cor rectly 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 tie rod end locknuts 1 of both tie rods c The same number of turns should be ...

Page 106: ...on a level surface 2 Check the engine oil level on a cold engine TIP If the engine was started before the oil level was checked be sure to warm up the engine suffi ciently and then wait at least 10 minutes until the oil settles for an accurate reading 3 Remove Dipstick accessing cover Refer to GENERAL CHASSIS 4 on page 4 11 4 Check Engine oil level The engine oil level should be between the minimu...

Page 107: ...off 2 Remove Dipstick accessing cover Refer to GENERAL CHASSIS 4 on page 4 11 3 Place a container under the engine oil drain bolt 4 Remove Dipstick 1 Engine oil drain bolt 2 along with the gasket 5 Drain Engine oil completely from the crankcase 6 If the oil filter cartridge is also to be replaced perform the following procedure a Remove the oil filter cartridge 1 with the oil filter wrench 2 b Lub...

Page 108: ... 4 1 Footrest board left Refer to GENERAL CHASSIS 4 on page 4 11 3 Start the engine warm it up for several min utes and then turn it off NOTICE ECB02550 When the engine is cold the engine oil will have a higher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine oil pressure after warming up the engine 4 Remove Main gallery bolt 1 WARNING EWB03630 The engi...

Page 109: ... bolt along with the gasket EBS30043 CHANGING THE DIFFERENTIAL GEAR OIL 1 Place the vehicle on a level surface 2 Place a container under the differential case 3 Remove Differential gear oil filler bolt along with the gasket Differential gear oil drain bolt 1 along with the gasket Completely drain the differential case of its oil 4 Install Differential gear oil drain bolt along with the gasket Oil ...

Page 110: ...e final drive case 4 Check Final gear oil level check bolt gasket Damage Replace 5 Install Final gear oil level check bolt along with the gasket EBS30041 CHANGING THE FINAL GEAR OIL 1 Place the vehicle on a level surface 2 Place a container under the final drive case 3 Remove Final gear oil filler bolt 1 along with the gasket 4 Remove Final gear oil level check bolt along with the gasket Final gea...

Page 111: ...iator outlet hose 5 Water jacket joint 6 Water pump outlet hose 7 Water pump outlet pipe 8 Water pump housing 9 Water pump inlet hose 10 Cooling water hose joint 11 Oil cooler inlet hose 12 Oil cooler outlet hose 13 Oil cooler 14 Cracks damage Replace Coolant leakage Replace any damaged hose and pipe Refer to RADIATOR on page 6 4 and WA TER PUMP on page 6 10 3 Install Footrest board left Refer to ...

Page 112: ...illed water However if dis tilled water is not available soft water may be used 3 If the coolant is at or below the minimum level mark remove the side panel left Refer to GENERAL CHASSIS 1 on page 4 1 4 Remove the reservoir cap 1 add coolant or distilled water to the maximum level mark a install the reservoir cap and then install the side panel left EBS30036 CHANGING THE COOLANT 1 Remove Side pane...

Page 113: ...s potentially harmful and should be handled with special care WARNING EWB02780 If coolant splashes in your eyes thorough ly wash them with water and consult a doc tor 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 NOTICE ECB01310 Adding water instead of coolant dilutes the ...

Page 114: ...ngine has cooled add sufficient coolant until it reaches the top of the radiator and then in stall the radiator cap 18 Check Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 29 19 Start the engine and then check for coolant leakage 20 Install Footrest board left Refer to GENERAL CHASSIS 4 on page 4 11 Upper panel Refer to GENERAL CHASSIS 2 on page 4 6 Side panel left Side panel right R...

Page 115: ... 1 Adjust Brake pedal free play Refer to ADJUSTING THE REAR DISC BRAKE on page 3 12 2 Remove Handle mounted light cover Refer to REPLACING THE HANDLE MOUNTED LIGHT BULB on page 3 34 Side panel left Refer to GENERAL CHASSIS 1 on page 4 1 3 Adjust Drive select lever shift control cable Drive select lever shift rod Drive select lever shift control cable a Make sure that the drive select lever is in N...

Page 116: ...ne Then with the drive select lever in the N neutral position and with out opening the throttle start the engine and check that the neutral indicator light comes on f Adjust the shift control cable again if neces sary EBS30446 ADJUSTING THE THROTTLE LEVER FREE PLAY 1 Check Throttle lever free play a Out of specification Adjust 2 Remove Storage compartment Refer to GENERAL CHASSIS 5 on page 4 17 3 ...

Page 117: ...djusting screw stops the engine speed from increasing 1 Measure Speed limiter length Out of specification Adjust 2 Adjust Speed limiter length a a Loosen the locknut 1 b Turn the adjuster 2 in direction b or c until the specified speed limiter length is obtained c Tighten the locknut WARNING EWB03830 Particularly for a beginner rider the speed limiter should be screwed in completely Screw it out l...

Page 118: ...rt of the handle mounted light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the handle mounted light bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lac quer thinner 5 Install Handle mounted light bulb holder TIP Install the handle mounted light bulb holder by pushing it in...

Page 119: ...PERIODIC MAINTENANCE 3 36 A Headlight left and right B Handle mounted light b a 1 A b a 1 B ...

Page 120: ...PERIODIC MAINTENANCE 3 37 ...

Page 121: ...FOOTREST BOARDS 4 16 GENERAL CHASSIS 5 4 17 INSTALLING THE AIR FILTER CASE 4 19 FRONT WHEELS 4 20 REMOVING THE FRONT WHEELS 4 21 REMOVING THE FRONT WHEEL HUBS 4 21 CHECKING THE FRONT WHEELS 4 21 CHECKING THE FRONT WHEEL HUBS 4 21 INSTALLING THE FRONT BRAKE DISCS 4 22 INSTALLING THE FRONT WHEEL HUBS 4 22 INSTALLING THE FRONT WHEELS 4 22 REAR WHEELS 4 23 REMOVING THE REAR WHEELS 4 24 REMOVING THE RE...

Page 122: ...ERS 4 45 INSTALLING THE REAR BRAKE CALIPERS 4 45 CHECKING THE REAR BRAKE MASTER CYLINDER 4 46 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 46 INSTALLING THE REAR BRAKE MASTER CYLINDER 4 46 HANDLEBAR 4 48 REMOVING THE HANDLEBAR 4 50 CHECKING THE HANDLEBAR 4 50 INSTALLING THE HANDLEBAR 4 50 STEERING STEM 4 53 REMOVING THE BEARING RETAINER except for EPS models 4 57 CHECKING THE STEERING STEM 4 57 INS...

Page 123: ...BSORBER ASSEMBLIES 4 68 INSTALLING THE FRONT ARM PROTECTORS 4 69 REAR KNUCKLES AND STABILIZER 4 70 CHECKING THE REAR KNUCKLES AND REAR WHEEL BEARINGS 4 71 CHECKING THE STABILIZER 4 71 INSTALLING THE REAR ARM PROTECTORS 4 71 REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES 4 72 CHECKING THE REAR ARMS 4 73 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES 4 73 INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER ...

Page 124: ...lates Order Job Parts to remove Q ty Remarks 1 Front skid plate 1 2 Center skid plate 1 3 Rear skid plate 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 1 2 3 ...

Page 125: ...l drive case breather hose 1 Disconnect 5 Differential case breather hose 1 Disconnect 6 Radiator fan motor breather hose 1 Disconnect 7 Top cover 1 8 Storage compartment lid 1 9 Side panel left 1 10 Side panel right 1 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 0 4 Nm 0 04 m kgf 0 29 ft Ibf T R 9 1 8 2 10 7 3 4 5 6 ...

Page 126: ...he holes b in the upper panel b Fit the projections c on the battery cover into the grommets d EBS30451 REMOVING THE TOP COVER 1 Remove Top cover 1 Storage compartment lid 2 a Remove the quick fasteners screws and bolts b Slide the top cover rearward and lift it up to unhook its projections a from the holes b in the side panels c Place the top cover upside down d Remove the storage compartment lid...

Page 127: ...p cover and then fit the storage compartment lid onto the left end of the hinge d Fit the projections a on the top cover into the holes b in the side panels and slide the cov er forward e Install the bolts screws and quick fasteners EBS30453 REMOVING THE SIDE PANELS The following procedure applies to both of the side panels The following procedure applies to both of the side panels 1 Remove Side p...

Page 128: ...e panel 1 a Fit the projections a on the side panel into the holes b in the front fender fit the projec tions c on the panel into the holes d in the footrest board and fit the projection e on the panel into the hole f in the rear fender b Install the bolt A Left side B Right side T R Side panel bolt 2 5 Nm 0 25 m kgf 1 8 ft lbf 1 A B A Right side B Left side 1 e f b a A b a d f e c B ...

Page 129: ...olding bracket 1 3 Battery lead 2 Disconnect 4 Battery 1 5 Upper panel 1 6 Front carrier bracket 2 7 Headlight coupler 2 Disconnect 8 Headlight unit 2 9 Front guard cover 2 10 Front guard 1 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 34 Nm 3 4 m kgf 25 ft Ibf T R 34 Nm 3 4 m kgf 25 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ib...

Page 130: ... quick fasteners b Slide the upper panel forward and lift it up to remove it EBS30456 INSTALLING THE UPPER PANEL 1 Install Upper panel 1 a Fit the projections a on the upper panel into the holes b in the front fender and then slide the panel rearward b Install the quick fasteners 1 1 a b b a ...

Page 131: ...t carrier Front guard Refer to GENERAL CHASSIS 2 on page 4 6 1 Front fender inner panel 2 2 Main switch coupler 1 Disconnect 3 Auxiliary DC jack coupler 1 Disconnect 4 Front fender 2 5 Front grill 1 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 8 Nm 0 8 ...

Page 132: ...4 Tail brake light coupler 1 Disconnect 5 Fuel tank breather hose 1 Disconnect 6 Fuel tank breather hose joint 1 7 Fuel tank cap 1 8 Rear fender 1 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 34 Nm 3 4 m kgf 25 ft Ibf T R 60 Nm 6 0 m kgf 43 ft Ibf T R 60 Nm 6 0 m kgf 43 ft Ibf T R 3 5 ...

Page 133: ...ER 1 Install Rear fender TIP The bolts may be tightened to the specified torque in any tightening sequence However in stall the front bolts 1 and tighten them tempo rarily before installing the rear bolts 2 T R Rear fender bolt 7 Nm 0 7 m kgf 5 1 ft lbf 2 1 ...

Page 134: ...t fenders Front grill Refer to GENERAL CHASSIS 3 on page 4 8 Air intake duct Storage compartment Refer to GENERAL CHASSIS 5 on page 4 17 V belt cooling exhaust duct V belt cooling intake duct Refer to ENGINE REMOVAL 1 on page 5 3 1 Battery holding bracket 1 2 Battery lead 2 Disconnect 3 Battery 1 4 Lean angle sensor coupler 1 Disconnect 5 Lean angle sensor 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 2 5 Nm 0 ...

Page 135: ...ht relay 1 1 9 EPS control unit coupler 5 Disconnect For EPS models 10 EPS electric power steering control unit 1 For EPS models 11 ECU coupler 2 Disconnect 12 ECU Engine Control Unit 1 13 Radiator fan motor coupler 1 Disconnect 7 Nm 0 7 m kgf 5 1 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 6 7 8 11 12 11 13 9 10 9 9 9 ...

Page 136: ...ect 2 Starter relay 1 3 Fuse box 1 4 EPS fuse 1 For EPS models 5 Main fuse 1 6 Radiator fan motor relay 1 7 Fuel injection system relay 1 8 Headlight relay 2 1 9 Frame ground terminal 1 10 Air cut off valve coupler 1 Disconnect 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 3 6 Nm 0 36 m kgf 2 6 ft Ibf T R 8 7 6 4 5 1 3 10 9 2 ...

Page 137: ...ector 2 Disconnect Except for CDN 14 Horn switch coupler 1 Disconnect Except for CDN 15 Coolant reservoir breather hose 1 Disconnect 16 Radiator fan motor breather hose 1 Disconnect 17 Differential case breather hose 1 Disconnect 18 Wire harness 1 19 Electrical components tray 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 3 6 Nm 0 36 m kgf 2 6 ft Ibf T R 14 13 19 12 18 17 16 15 11 ...

Page 138: ...s Refer to GENERAL CHASSIS 1 on page 4 1 1 Dipstick accessing cover 1 2 Footrest board 2 3 Footrest bracket 2 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 2 3 3 2 1 5 4 5 4 5 5 ...

Page 139: ...OARDS The following procedure applies to both of the footrest boards 1 Install Footrest board TIP Tighten the footrest board bolts to the specified torque in the proper tightening sequence as shown T R Footrest board bolt 8 Nm 0 8 m kgf 5 8 ft lbf 4 1 2 3 FWD ...

Page 140: ... Air intake duct 1 4 Air filter element 1 5 Air filter element holder 1 6 Air filter element frame 1 7 Storage compartment 1 8 Intake air temperature sensor coupler 1 Disconnect 9 Air induction system hose air cut off valve assembly to air filter case 1 Disconnect New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 0 8 Nm 0 08 m kgf 0 58 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf ...

Page 141: ... case joint clamp screw 2 Loosen 12 Rectifier regulator coupler 2 Disconnect 13 Air filter case 1 14 Air filter case joint 1 15 Intake air temperature sensor 1 New New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 0 8 Nm 0 08 m kgf 0 58 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 13 10 12 11 11 14 15 ...

Page 142: ...r filter element assembly Air intake duct 1 to the air filter case cover Air filter case cover Storage compartment TIP Fit the projection a on the air intake duct be tween the projections b on the air filter case cover 2 T R Intake air temperature sensor screw 1 5 Nm 0 15 m kgf 1 1 ft lbf Air filter case bolt 10 Nm 1 0 m kgf 7 2 ft lbf Air filter case joint clamp screw throttle body side 3 5 Nm 0 ...

Page 143: ...surface 1 Front wheel 1 2 Wheel cap 1 3 Front wheel axle nut 1 4 Front brake caliper assembly 1 TIP Do not squeeze the front brake lever when the brake caliper is off of the brake disc as the brake pads will be forced shut 5 Front wheel hub 1 6 Front brake disc 1 260 Nm 26 m kgf 188 ft lbf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R LT LT LT 3 2 5 ...

Page 144: ...heel Refer to CHECKING THE TIRES on page 3 16 and CHECKING THE WHEELS on page 3 15 2 Measure Radial wheel runout 1 Lateral wheel runout 2 Over the specified limit Replace the wheel or check the wheel bearing play Refer to CHECKING THE STEERING KNUCKLES AND FRONT WHEEL BEAR INGS on page 4 62 3 Check Wheel balance Out of balance Adjust WARNING EWB03020 After replacing the tire ride conservatively to...

Page 145: ...ly oil to the threads of the nut After tightening the nut stake the collar of the nut into the notch of the shaft 2 Check Brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 31 EBS30364 INSTALLING THE FRONT WHEELS 1 Install Wheel TIP The arrow mark 1 on the tire must point in the direction of wheel rotation 2 Tighten Wheel nuts 1 WARNING EWB03130 Tapered wheel nuts are used for both the f...

Page 146: ...ce 1 Rear wheel 1 2 Wheel cap 1 3 Rear wheel axle nut 1 4 Rear brake caliper assembly 1 TIP Do not squeeze the rear brake lever and brake pedal when the brake caliper is off of the brake disc as the brake pads will be forced shut 5 Rear wheel hub 1 6 Rear brake disc 1 30 Nm 3 0 m kgf 22 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 260 Nm 26 m kgf 188 ft lbf T R LT LT 3 2 5 6 4 1 T R 30 Nm 3 0 m kg 22 ...

Page 147: ...CKING THE WHEELS on page 3 15 2 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEELS on page 4 21 Over the specified limit Replace the wheel or check the wheel bearing play Refer to REAR WHEELS on page 4 23 3 Check Wheel balance Refer to CHECKING THE FRONT WHEELS on page 4 21 EBS30368 CHECKING THE REAR WHEEL HUBS The following procedure applies to both of the rear wh...

Page 148: ... following procedure applies to both of the rear wheels 1 Install Wheel TIP The arrow mark 1 on the tire must point in the direction of wheel rotation 2 Tighten Wheel nuts 1 WARNING EWB03130 Tapered wheel nuts are used for both the front and rear wheels Install each nut with its tapered side towards the wheel T R Rear wheel axle nut 260 Nm 26 m kgf 188 ft lbf T R Rear wheel nut 55 Nm 5 5 m kgf 40 ...

Page 149: ...h of the front brake calipers Front wheel Refer to FRONT WHEELS on page 4 20 1 Front brake caliper bolt 2 2 Brake pad holding bolt plug 1 3 Brake pad holding bolt 1 4 Front brake pad 2 5 Brake pad spring 1 30 Nm 3 0 m kgf 22 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 1 2 3 4 5 FWD FWD ...

Page 150: ...d reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake lever 1 5 Union bolt 1 6 Copper washer 2 7 Front brake hose 1 Disconnect 8 Front brake light switch connector 2 Disconnect 9 Front brake light switch 1 10 Front brake master cylinder holder 1 11 Front brake master cylinder 1 6 Nm 0 6 m kgf 4 3 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 27 Nm 2 7 ...

Page 151: ...AKE 4 28 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder body 1 3 2 1 4 New New S FWD FWD BF ...

Page 152: ...AKE SYSTEM on page 3 14 Front wheel Refer to FRONT WHEELS on page 4 20 1 Union bolt 1 2 Copper washer 2 3 Front brake hose 1 Disconnect 4 Brake pad holding bolt plug 1 5 Brake pad holding bolt 1 Loosen 6 Front brake caliper bolt 2 7 Front brake caliper assembly 1 27 Nm 2 7 m kgf 20 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 6 1 3 2 7 4 5...

Page 153: ... 2 Brake pad 2 3 Brake pad spring 1 4 Brake caliper bracket 1 5 Brake caliper guide pin 1 6 Brake caliper retaining pin 1 7 Brake caliper piston 1 8 Brake caliper dust seal 1 9 Brake caliper piston seal 1 10 Bleed screw 1 BF S S S New New FWD FWD LT 5 Nm 0 5 m kgf 3 6 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 22 Nm 2 2 m kgf 16 ft Ibf T R 2 10 1 3 4 7 8 9 6 5 ...

Page 154: ...es and get im mediate medical attention EBS30373 CHECKING THE FRONT BRAKE DISCS The following procedure applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEELS on page 4 20 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Hold the dial gauge at a right angle against the brake ...

Page 155: ...o an open container b Loosen the bleed screw and push the brake caliper piston into the brake caliper with your finger c Tighten the bleed screw d Install new brake pads and a new brake pad spring 3 Install Brake pad holding bolt Brake pad holding bolt plug Brake caliper 4 Check Brake fluid level Below the minimum level mark Add the specified brake fluid to the proper level Refer to CHECKING THE B...

Page 156: ...dy Obstruction Blow out with compressed air WARNING EWB03140 Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and brake caliper piston seals EBS30376 ASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers WARNING EWB03150 Before installation all internal brake com ponents should be cleaned and lubricated with clean or n...

Page 157: ...the brake fluid and could cause vapor lock NOTICE ECB01320 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 14 4 Check Brake fluid level Below the minimum level mark Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL...

Page 158: ...t as shown Turn the handlebar to the left and right to make sure the brake hose does not touch other parts e g wire harness cables leads Correct if necessary 3 Fill Brake master cylinder reservoir with the specified amount of the specified brake fluid WARNING EWB02880 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake per...

Page 159: ...14 5 Check Brake fluid level Below the minimum level mark Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 14 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 14 ...

Page 160: ...els Refer to GENERAL CHASSIS 1 on page 4 1 Front fender inner panel right Refer to GENERAL CHASSIS 3 on page 4 8 Footrest board right Refer to GENERAL CHASSIS 4 on page 4 11 1 Brake pedal cable 1 Disconnect 2 Brake pedal spring 1 3 Brake pedal 1 LS LS New New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 2 3 1 ...

Page 161: ...the rear brake calipers Rear wheel Refer to REAR WHEELS on page 4 23 1 Rear brake caliper bolt 2 2 Brake pad holding bolt plug 1 3 Brake pad holding bolt 1 4 Rear brake pad 2 5 Brake pad spring 1 2 3 1 4 5 5 Nm 0 5 m kgf 3 6 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R ...

Page 162: ...ar brake cable 1 Disconnect 6 Brake lever 1 7 Brake lever bracket 1 8 Union bolt 1 9 Copper washer 2 10 Rear brake hose 1 Disconnect 11 Rear brake light switch connector 2 Disconnect 12 Rear brake light switch 1 13 Rear brake master cylinder holder 1 14 Rear brake master cylinder 1 S S 13 12 11 1 2 3 14 10 9 8 6 7 5 4 New New LS LS 6 Nm 0 6 m kgf 4 3 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 7 Nm 0...

Page 163: ...R BRAKE 4 40 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder body 1 3 2 1 4 New New S BF ...

Page 164: ...EDING THE HYDRAULIC BRAKE SYSTEM on page 3 14 Rear wheel 1 Union bolt 1 2 Copper washer 2 3 Rear brake hose 1 Disconnect 4 Brake pad holding bolt plug 1 5 Brake pad holding bolt 1 Loosen 6 Rear brake caliper bolt 2 7 Rear brake caliper assembly 1 3 1 2 4 5 7 6 New 30 Nm 3 0 m kgf 22 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R ...

Page 165: ...t 1 2 Brake pad 2 3 Brake pad spring 1 4 Brake caliper bracket 1 5 Brake caliper guide pin 1 6 Brake caliper retaining pin 1 7 Brake caliper piston 1 8 Brake caliper dust seal 1 9 Brake caliper piston seal 1 10 Bleed screw 1 LT 5 Nm 0 5 m kgf 3 6 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 22 Nm 2 2 m kgf 16 ft Ibf T R S S 1 2 3 4 5 7 6 9 8 10 S New New BF ...

Page 166: ...ge 4 23 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 31 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 31 5 Adjust...

Page 167: ...0 The brake lever pivot bolt and nut have left handed threads To loosen the pivot bolt and nut turn them clockwise EBS30386 DISASSEMBLING THE REAR BRAKE CALIPERS The following procedure applies to both of the brake calipers TIP Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake caliper piston 1 Brake caliper dust seal 2 Brake caliper piston sea...

Page 168: ...ls and brake caliper piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and brake caliper piston seals EBS30389 INSTALLING THE REAR BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Install Brake caliper assembly Brake caliper bolts 1 Brake hose 2 Copper washers 3 Brake hose union bolt 4 WARNING EWB028...

Page 169: ...390 CHECKING THE REAR BRAKE MASTER CYLINDER 1 Check Brake master cylinder Damage scratches wear Replace Brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage scratches wear Replace 3 Check Brake master cylinder reservoir Cracks damage Replace Brake master cylinder reservoir diaphragm Cracks damage Replace 4 Check ...

Page 170: ...pe of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECB01320 Brake fluid may damage painted surfaces and plastic par...

Page 171: ... motor switch and differential gear lock switch 1 6 Throttle cable 1 Disconnect 7 Throttle lever assembly holder 1 8 Throttle lever assembly 1 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 0 5 Nm 0 05 m kgf 0 36 ft Ibf T R New ...

Page 172: ... cylinder 1 14 Handlebar switch left 1 15 Horn switch 1 Except for CDN 16 Handlebar grip 2 17 Handle mounted light assembly 1 18 Handlebar holder 2 19 Handlebar 1 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 0 5 Nm 0 05 m kgf ...

Page 173: ...l the handlebar within 15 from the hori zontal line shown in the illustration The handlebar holders should be installed with the punch mark a forward A Align the punch mark b on the handlebar with the lower surface of the right handlebar holder First tighten the bolts 1 on the front side of the handlebar holders and then tighten the bolts 2 on the rear side 3 Install Handlebar grips 1 a Wipe off g...

Page 174: ...bar 2 between the ends of the horn switch 6 Install Front brake master cylinder 1 Front brake master cylinder holder 2 TIP Align the end of the brake master cylinder hold er with the punch mark a on the handlebar The UP mark b on the brake master cylinder holder should face up First tighten the bolt 3 on the upper side of the brake master cylinder holder and then tighten the bolt 4 on the lower si...

Page 175: ...in coat of lithium soap based grease 9 Adjust Rear brake lever free play Refer to ADJUSTING THE REAR DISC BRAKE on page 3 12 10 Adjust Throttle lever free play Refer to ADJUSTING THE THROTTLE LE VER FREE PLAY on page 3 33 T R Throttle lever assembly cover bolt 1 5 Nm 0 15 m kgf 1 1 ft lbf 1 b a ...

Page 176: ...SSIS 3 on page 4 8 Electrical components tray Refer to GENERAL CHASSIS 4 on page 4 11 Storage compartment Refer to GENERAL CHASSIS 5 on page 4 17 Handlebar Refer to HANDLEBAR on page 4 48 1 Lock washer 1 2 Cable guide 1 3 Steering stem bushing holder 2 4 Steering stem bushing 2 5 Collar 2 4 3 4 3 5 2 1 LT 4 LS LS LT LS New New New LS LS New New 25 Nm 2 5 m kgf 18 ft Ibf T R 34 Nm 3 4 m kgf 25 ft I...

Page 177: ... stem 1 11 Plug 1 12 Oil seal 1 13 Oil seal 1 14 Bearing retainer 1 15 Bearing 1 16 Steering stem support 1 17 Steering stem bracket 1 8 13 9 6 7 10 11 17 LT 4 LS LS LT 6 16 15 14 12 LS New New LS LS New New New 25 Nm 2 5 m kgf 18 ft Ibf T R 34 Nm 3 4 m kgf 25 ft Ibf T R 51 Nm 5 1 m kgf 37 ft Ibf T R 190 Nm 19 m kgf 137 ft lbf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R ...

Page 178: ...ical components tray Refer to GENERAL CHASSIS 4 on page 4 11 Storage compartment Refer to GENERAL CHASSIS 5 on page 4 17 Handlebar Refer to HANDLEBAR on page 4 48 1 Lock washer 1 2 Cable guide 1 3 Steering stem bushing holder 2 4 Steering stem bushing 2 5 Collar 2 4 3 4 3 5 2 1 L LT 4 LT LT New New LS LS New 25 Nm 2 5 m kgf 18 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R ...

Page 179: ...ing stem pinch bolt 1 11 Steering stem 1 12 Plug 1 13 EPS motor cover 1 14 EPS unit 1 15 Steering stem bracket 1 7 L LT 4 LT LT 8 11 12 15 6 14 13 10 9 New New LS LS New 25 Nm 2 5 m kgf 18 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 51 Nm 5 1 m kgf 37 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 210 Nm 21 0 m kgf 152 ft lbf T R ...

Page 180: ...ING STEM except for EPS models 1 Install Bearing 1 Bearing retainer 2 Oil seals 3 TIP Install the bearing retainer with the damper rod holder 2 Install Steering stem support 4 Steering stem support bolts 5 temporarily tighten 3 Install Steering stem 6 4 Install Collars 7 Steering stem bushings 8 Steering stem bushing holders 9 Cable guide 10 Lock washer 11 Damper rod holder 30 mm 90890 01327 Dampe...

Page 181: ...or EPS models 1 Install Collars 1 Steering stem bushings 2 Steering stem bushing holders 3 Cable guide 4 Lock washer 5 Steering stem bracket 6 Steering stem bolts 7 temporarily tighten TIP Apply lithium soap based grease to the steering stem bushings 2 Install EPS unit 8 EPS unit bolts 9 temporarily tighten 3 Install Steering stem 10 Steering stem pinch bolt 11 temporarily tighten TIP Align the pu...

Page 182: ...groove a in the pitman arm with the steering stem spline b that is indented Install the washer so that the rubber side c of the washer faces towards the pitman arm EBS30400 INSTALLING THE PITMAN ARM for EPS models 1 Install Pitman arm 1 Washer Pitman arm nut Cotter pin T R EPS unit bolt for EPS models 30 Nm 3 0 m kgf 22 ft lbf LOCTITE Steering stem pinch bolt for EPS models 35 Nm 3 5 m kgf 25 ft l...

Page 183: ...STEERING STEM 4 60 TIP Align the punch mark a on the EPS unit with the groove b in the pitman arm 1 b a ...

Page 184: ...ELS on page 4 20 1 Brake disc guard 1 2 Front arm protector 1 3 Tie rod end locknut 2 4 Tie rod end 2 5 Tie rod 1 6 Nut 2 7 Steering knuckle 1 8 Circlip 1 9 Ball joint 1 10 Circlip 1 11 Wheel bearing 1 New New New New LS New New New 5 4 3 3 4 1 7 8 6 9 6 10 11 2 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 25 Nm 2 5 m kgf 1...

Page 185: ...ckles and front wheel bearings 1 Check Steering knuckle Damage pitting Replace 2 Check Front wheel bearing 1 Rough movement excessive free play Re place a Clean the surface of the steering knuckle b Remove the circlip 2 c Drive out the bearing WARNING EWB03790 Eye protection is recommended when using striking tools d Apply lithium soap based grease to the balls of the new bearing e Install the new...

Page 186: ...bolt 11 to install the new ball joint 5 into the steering knuckle 4 g Remove the special tools Ball joint bore inside diameter 32 45 32 50 mm 1 278 1 280 in 1 4 2 3 a Ball joint remover 90890 01474 Ball joint remover YM 01474 Ball joint remover attachment set 90890 01480 Ball joint adapter set YM 01480 Ball joint installer attachment 38mm 90890 01583 Ball joint installer attachment 38mm YM 01583 B...

Page 187: ...efer to ADJUSTING THE TOE IN on page 3 21 EBS30406 INSTALLING THE FRONT ARM PROTECTORS The following procedure applies to both of the front arm protectors 1 Install Front arm protector 1 a Fit the holders a on the front arm protector onto the lower arm b Tighten the bolt b T R Steering knuckle and tie rod nut 25 Nm 2 5 m kgf 18 ft lbf Pitman arm and tie rod nut 25 Nm 2 5 m kgf 18 ft lbf T R Front ...

Page 188: ...rake caliper assembly Refer to FRONT BRAKE on page 4 26 1 Brake disc guard 1 2 Front arm protector 1 3 Front brake hose holder 2 4 Nut 2 5 Nut Bolt 2 2 6 Front shock absorber assembly 1 7 Nut Washer Bolt 2 2 2 8 Front upper arm 1 9 Nut Bolt 2 2 9 9 7 7 7 7 9 9 5 5 3 3 6 1 4 8 5 5 4 2 New New New LS New LS FWD FWD 45 Nm 4 5 m kgf 33 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf...

Page 189: ...st cover 2 12 Bushing 4 13 Circlip 1 14 Ball joint 1 13 12 12 14 10 12 12 11 11 New New New LS New LS FWD FWD 45 Nm 4 5 m kgf 33 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 45 Nm 4 5 m kgf 33 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 190: ...ER ASSEMBLIES The following procedure applies to both of the front shock absorber assemblies 1 Check Front shock absorber assembly Oil leaks Replace the front shock absorber assembly Front shock absorber rod Bends damage Replace the front shock absorber assembly Spring Move the spring up and down Fatigue Replace the front shock absorber assembly EBS30117 CHECKING THE FRONT ARM BALL JOINTS The foll...

Page 191: ... upper arm 1 and front lower arm 2 TIP Lubricate the front upper and lower arm bolts 3 with lithium soap based grease Be sure to position the front upper and lower arm bolts 3 so that the bolt heads face for ward Install the washers 4 Temporarily tighten the front upper and lower arm nuts 5 b Install the front shock absorber assembly 6 bolts 7 and nuts 8 c Install the steering knuckle upper steeri...

Page 192: ...arm protector 1 a Fit the holders a on the front arm protector onto the lower arm b Tighten the bolt b T R Steering knuckle and front upper arm nut 30 Nm 3 0 m kgf 22 ft lbf Steering knuckle and front lower arm nut 30 Nm 3 0 m kgf 22 ft lbf T R Front upper arm nut 55 Nm 5 5 m kgf 40 ft lbf Front lower arm nut 55 Nm 5 5 m kgf 40 ft lbf T R Front arm protector bolt 7 Nm 0 7 m kgf 5 1 ft lbf Rear arm...

Page 193: ...3 Rear brake disc cleaning plate 1 4 Rear knuckle 1 5 Spacer cover 4 6 Spacer 2 7 Circlip 1 8 Wheel bearing 1 9 Stabilizer joint 2 10 Stabilizer holder 2 11 Bushing 2 12 Stabilizer 1 10 10 11 11 12 9 1 5 8 7 2 6 5 5 6 5 4 9 3 LS LS New LS 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 45 Nm 4 5 m kgf 33 ft Ibf T R 45 Nm 4 5 m...

Page 194: ...ply lithium soap based grease to the bear ing e Install the new bearing NOTICE ECB02650 Do not strike the center race or balls of the bearing Contact should be made only with the outer race f Install the new circlip EBS30120 CHECKING THE STABILIZER 1 Check Stabilizer Bends cracks damage Replace EBS30408 INSTALLING THE REAR ARM PROTECTORS The following procedure applies to both of the rear arm prot...

Page 195: ...rber assemblies Rear knuckle Stabilizer Refer to REAR KNUCKLES AND STABI LIZER on page 4 70 1 Rear brake hose guide 1 2 Nut Washer Bolt 2 1 2 3 Rear shock absorber assembly 1 4 Nut Washer Bolt 2 2 2 5 Rear upper arm 1 6 Dust cover 1 7 Nut Bolt 2 2 8 Rear lower arm 1 9 Dust cover 2 10 Bushing 4 LS 4 7 6 10 10 1 4 7 7 7 9 10 2 8 5 2 10 9 3 LS 2 4 4 2 7 Nm 0 7 m kgf 5 1 ft Ibf T R 45 Nm 4 5 m kgf 33 ...

Page 196: ...assembly Spring Move the spring up and down Fatigue Replace the rear shock absorber assembly EBS30126 INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES The following procedure applies to both of the rear upper arms rear lower arms and rear shock absorber assemblies 1 Install Rear upper arm Rear lower arm Rear shock absorber assembly a Install the rear upper arm 1 and rear lower arm 2 TIP...

Page 197: ...REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES 4 74 7 9 8 9 7 3 5 4 5 3 6 2 10 10 1 ...

Page 198: ...REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES 4 75 ...

Page 199: ...AD CYLINDER AND PISTON 5 19 REMOVING THE CYLINDER HEAD 5 22 REMOVING THE PISTON 5 22 CHECKING THE CYLINDER HEAD 5 23 CHECKING THE CYLINDER AND PISTON 5 23 CHECKING THE PISTON RINGS 5 24 CHECKING THE PISTON PIN 5 25 INSTALLING THE PISTON AND CYLINDER 5 25 INSTALLING THE CYLINDER HEAD 5 26 VALVES AND VALVE SPRINGS 5 28 REMOVING THE VALVES 5 29 CHECKING THE VALVES AND VALVE GUIDES 5 29 CHECKING THE V...

Page 200: ...ES 5 52 DISASSEMBLING THE SECONDARY SHEAVE 5 52 CHECKING THE V BELT 5 53 CHECKING THE PRIMARY SHEAVE 5 53 CHECKING THE PRIMARY SHEAVE WEIGHTS 5 53 CHECKING THE PRIMARY SHEAVE SLIDERS 5 53 CHECKING THE SECONDARY SHEAVE 5 53 ASSEMBLING THE PRIMARY SHEAVE 5 54 ASSEMBLING THE SECONDARY SHEAVE 5 55 INSTALLING THE PRIMARY AND SECONDARY SHEAVES 5 56 CLUTCH 5 59 REMOVING THE CLUTCH 5 61 CHECKING THE CLUTC...

Page 201: ...S 5 78 CHECKING THE SHIFT DRUM 5 78 CHECKING THE TRANSMISSION 5 79 CHECKING THE SECONDARY SHAFT 5 79 CHECKING THE STOPPER LEVER AND STOPPER WHEEL 5 79 ASSEMBLING THE DRIVE AXLE 5 79 ASSEMBLING THE SHIFT FORK 5 79 INSTALLING THE SHIFT FORKS AND SHIFT DRUM 5 80 MIDDLE GEAR 5 81 REMOVING THE MIDDLE DRIVE SHAFT 5 84 REMOVING THE MIDDLE DRIVEN SHAFT 5 84 CHECKING THE PINION GEARS 5 85 INSTALLING THE BE...

Page 202: ...ession gauge stabilizes WARNING EWB03200 To prevent sparking ground the spark plug lead before cranking the engine b If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate c If the compression pressure is below the min imum specification pour a teaspoonful of en gine oil into the spark plu...

Page 203: ...ENGINE INSPECTION 5 2 Top cover Refer to GENERAL CHASSIS 2 on page 4 6 ...

Page 204: ...2 V belt cooling exhaust duct joint 1 3 V belt cooling intake duct joint 1 4 V belt cooling intake duct 1 5 Exhaust pipe protector 1 6 Spring 2 7 Muffler 1 8 Gasket 1 9 Muffler bracket 1 10 Exhaust pipe 1 11 Gasket 1 6 11 6 2 3 1 9 8 7 5 10 4 New New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 33 Nm 3 3 m kgf 24 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf ...

Page 205: ...with its arrow mark a pointing toward the en gine b Align the projection on the V belt cooling in take duct joint with the rib on the crankcase in the area b shown in the illustration c Align the screw head with the seam on the V belt cooling intake duct joint in the area c shown in the illustration d Align the projection on the V belt cooling in take duct with the projection on the V belt cooling...

Page 206: ...the drive belt case in the area b shown in the il lustration c Align the screw head with the arrow mark a on the V belt cooling exhaust duct joint in the area c shown in the illustration d Align the projection on the V belt cooling ex haust duct with the projection on the V belt cooling exhaust duct joint in the area d shown in the illustration e Align the screw head with the rib on the V belt coo...

Page 207: ...e select lever unit Order Job Parts to remove Q ty Remarks 1 Drive select lever shift rod 1 2 Drive select lever unit 1 3 Shift arm 1 3 2 1 LS LT 8 Nm 0 8 m kgf 5 8 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R ...

Page 208: ... lever and trans mission are in N neutral The installed length a of the shift rod is 410 mm 16 1 in T R Shift arm bolt 14 Nm 1 4 m kgf 10 ft lbf LOCTITE Drive select lever unit bolt 7 Nm 0 7 m kgf 5 1 ft lbf Drive select lever shift rod lock nut select lever unit side 8 Nm 0 8 m kgf 5 8 ft lbf Drive select lever shift rod lock nut shift arm side 8 Nm 0 8 m kgf 5 8 ft lbf N N a 1 3 2 ...

Page 209: ...ssembly Refer to THROTTLE BODY on page 7 4 Coolant reservoir Refer to RADIATOR on page 6 4 Thermostat Refer to THERMOSTAT on page 6 7 Water pump assembly Refer to WATER PUMP on page 6 10 Differential assembly Refer to FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES DIFFERENTIAL AS SEMBLY AND FRONT DRIVE SHAFT on page 8 4 Final drive assembly Refer to REAR CONSTANT VELOCITY SHAFT ASSEMBLIES FINAL DRIVE AS...

Page 210: ...sor coupler 1 Disconnect 3 Spark plug cap 1 4 Shift control cable 1 Disconnect 5 Reverse switch lead 1 Disconnect 6 Speed sensor coupler 1 Disconnect 7 Crankshaft position sensor coupler 1 Disconnect 8 AC magneto lead coupler 1 Disconnect 9 Gear position switch coupler 1 Disconnect 10 Water pump drain hose 1 6 7 4 5 1 10 3 2 9 8 17 Nm 1 7 m kgf 12 ft Ibf T R ...

Page 211: ... side 2 6 Engine 1 TIP Remove the engine from the left side of the vehicle 7 Engine mounting bolt front M6 2 8 Engine mounting bolt front M10 2 9 Rubber damper front side 2 LT LT LT LT LT LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 42 Nm 4 2 m kgf 30 ft Ibf T R 42 Nm 4 2 m kgf 30 ft Ibf T R 42 Nm 4 2 m kgf 30 ft Ibf...

Page 212: ...t fully tighten the bolts and nuts 2 Tighten Engine mounting bolts front M10 2 Engine mounting bolts front M6 3 Engine mounting bolts rear M10 7 Engine mounting bolts rear M6 8 Rubber damper nuts front side 9 Rubber damper nuts rear side 6 7 8 5 1 2 3 6 9 4 5 8 7 2 3 1 T R Engine mounting bolt front M10 42 Nm 4 2 m kgf 30 ft lbf Engine mounting bolt front M6 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE Engi...

Page 213: ...ent Refer to GENERAL CHASSIS 5 on page 4 17 Cylinder head breather hose Refer to ENGINE REMOVAL 3 on page 5 8 1 Spark plug cap 1 Disconnect 2 Spark plug 1 3 Breather plate cover 1 4 Breather plate cover gasket 2 5 Breather plate 1 6 Cylinder head cover 1 7 Cylinder head cover gasket 1 8 Timing chain guide upper side 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 11 Nm 1 1 m kgf 8 ...

Page 214: ... tensioner 1 4 Timing chain tensioner gasket 1 5 Camshaft cap 1 6 Bearing stopper 2 7 Intake camshaft 1 8 Exhaust camshaft 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R New New New New E E E E E E 1 3 4 8 5 6 6 8 7 2 ...

Page 215: ...shown in the illustration and the marks e and f on the sprockets are aligned with the cyl inder head mating surface d the piston is at TDC 3 Remove Timing chain tensioner Timing chain tensioner gasket 4 Remove Camshaft cap 1 Bearing stoppers 2 NOTICE ECB02430 To prevent damage to the cylinder head camshafts or camshaft cap loosen the camshaft cap bolts in stages and in a criss cross pattern workin...

Page 216: ...s shown c Install the camshaft cap TIP Tighten the camshaft cap bolts in the tighten ing sequence as shown Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance with the Plastigauge d Remove the camshaft cap and then mea sure the width of the Plastigauge 1 Camshaft lobe dimensions Lobe height Intake limit 33 800 mm 1 3307 in Base circle diameter Intake limit 24 850...

Page 217: ...ress the timing chain tensioner rod into the timing chain tensioner housing by hand TIP While pressing the timing chain tensioner rod wind it clockwise with a flat head screwdriver un til it stops b Make sure that the timing chain tensioner rod moves in and out of the timing chain tension er housing smoothly If there is rough move ment replace the timing chain tensioner EBS30436 INSTALLING THE CAM...

Page 218: ...ed evenly or damage to the cylinder head camshaft cap and camshafts will result Do not turn the crankshaft when installing the camshaft cap to avoid damage or im proper valve timing TIP Tighten the camshaft cap bolts in the tightening sequence as shown 4 Install Timing chain tensioner gasket Timing chain tensioner a Remove the timing chain tensioner cap bolt and gasket b Install a new gasket and t...

Page 219: ...Refer to the installation steps above Timing chain guide Make sure that the timing chain guide and timing chain are positioned correctly 7 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 5 EBS30437 INSTALLING THE BREATHER PLATE 1 Install Breather plate cover gaskets Breather plate Breather plate cover TIP Tighten the breather plate cover bolts ...

Page 220: ... on page 5 12 Thermostat Coolant temperature sensor Refer to THERMOSTAT on page 6 7 Water jacket joint Refer to WATER PUMP on page 6 10 Throttle body assembly Refer to THROTTLE BODY on page 7 4 Reed valve assembly Refer to AIR INDUCTION SYSTEM on page 7 9 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 1st 2nd 3rd 5th 6th T...

Page 221: ... 5 Cylinder head 1 6 Cylinder head gasket 1 7 Dowel pin 2 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 1st 2nd 3rd 5th 6th T R Specified angle 85 90 Specified angle 85 90 again 30 Nm 3 0 m kgf 22 ft Ibf 30 Nm 3 0 m kgf 22 ft Ibf 4th Loosen 360 70 Nm 7 0 m kgf 51 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf T R New New New E 4 4 5 3...

Page 222: ...d piston Order Job Parts to remove Q ty Remarks 1 Timing chain guide exhaust side 1 2 Cylinder 1 3 Cylinder gasket 1 4 Dowel pin 2 5 Piston pin clip 2 6 Piston pin 1 7 Piston 1 8 Top ring 1 9 2nd ring 1 10 Oil ring 1 New New E E E E New E E 5 7 4 4 8 9 10 1 2 3 5 6 ...

Page 223: ...e removing the piston pin clips cover the crankcase opening with a clean rag to prevent the piston pin clips from falling into the crank case Before removing the piston pin deburr the pis ton pin clip grooves and the piston pin bore ar ea If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 4 Remove the piston pin from the side of the ...

Page 224: ...ng a figure eight sanding pattern TIP To ensure an even surface rotate the cylinder head several times EBS30147 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure the cylinder bore C with the cylin der bore gauge TIP Measure the cylinder bore C b...

Page 225: ...ing side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder TIP Use the piston crown to level the piston ring near bottom of cylinder a where cylinder wear is lowest 3 Measure Piston ring end gap Out of specification Replace the piston ring TIP The oil ring expander end gap cannot be mea sured If the oil ring rail gap is ex...

Page 226: ...Piston 1 Piston pin 2 Piston pin clips 3 TIP Apply engine oil to the piston pin Make sure the manufacturer s mark a on the piston points towards the AC magneto side Install the piston pin from the side of the piston that has the manufacturer s mark a Before installing the piston pin clips cover the crankcase opening with a clean rag to prevent the clips from falling into the crankcase 3 Install Cy...

Page 227: ... head bolts M11 to 70 Nm 7 0 m kgf 51 ft lbf in the proper tighten ing sequence d Loosen the cylinder head bolts M11 360 e Tighten the cylinder head bolts M11 to 30 Nm 3 0 m kgf 22 ft lbf in the proper tighten ing sequence f Tighten the cylinder head bolts M11 to the specified angle 85 90 in the proper tighten ing sequence g Tighten the cylinder head bolts M11 to the specified angle 85 90 in the p...

Page 228: ... AND PISTON 5 27 TIP Tighten the clamp screw of each clamp 2 until 6 slots are visible in the area a of the clamp as shown in the illustration T R Oil hose union bolt crankcase to cylinder 18 Nm 1 8 m kgf 13 ft lbf a 1 2 3 4 ...

Page 229: ...D PISTON on page 5 19 1 Valve lifter 4 2 Valve pad 4 3 Valve cotter 8 4 Valve spring retainer 4 5 Valve spring 4 6 Intake valve 2 7 Exhaust valve 2 8 Valve stem seal intake 2 Gray 9 Valve stem seal exhaust 2 Light green 10 Valve spring seat 4 11 Valve guide 4 13 Nm 1 3 m kgf 9 4 ft Ibf T R New New 1 2 3 4 5 8 8 10 11 11 9 10 1 9 6 7 2 3 4 5 New New New New New New E E E E E E E E E E E E ...

Page 230: ...olvent a into the intake and exhaust ports b Check that the valves properly seal TIP There should be no leakage at the valve seat 1 3 Remove Valve cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 Valve spring seat 5 TIP Identi...

Page 231: ...ver 1 b Install the new valve guide with the valve guide installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to v...

Page 232: ... cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width TIP Where the valve seat and valve face contacted one another the blueing will have been re m...

Page 233: ...ing the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply blue layout fluid b onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat t...

Page 234: ...t 3 Install Valve spring seat 1 into the cylinder head Valve stem seal 2 Valve 3 Valve spring 4 Valve spring retainer 5 TIP Make sure each valve is installed in its original place Install the valve springs with the larger pitch a facing up 4 Install Valve cotters TIP Install the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachm...

Page 235: ... Hitting the valve tip with excessive force could damage the valve 6 Lubricate Valve pad Valve lifter with the recommended lubricant 7 Install Valve pad Valve lifter TIP The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in their original position Recommended lubricant Engine oil ...

Page 236: ... REMOVAL 2 on page 5 6 Water pump housing Refer to WATER PUMP on page 6 10 1 Oil pipe AC magneto cover 1 2 Lead holder bracket 1 3 AC magneto cover 1 4 AC magneto cover gasket 1 5 AC magneto crankshaft position sensor lead holder 1 New New New New New New E E E E LT LT LT LT E E E 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ib...

Page 237: ...ft 2 1 12 AC magneto rotor 1 13 Woodruff key 1 14 Starter wheel gear 1 15 Bushing 1 16 Starter clutch 1 New New New New New New E E E E LT LT LT LT E E E 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 160 Nm 16 m kgf 116 ft lbf T R 14 Nm 1 4 m kgf 10 ft Ibf T...

Page 238: ...iate sized socket between the fly wheel puller set center bolt and the crank shaft TIP Use the flywheel puller 2 Make sure the flywheel puller is centered over the AC magneto rotor EBS30152 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts 1 TIP Hold the AC magneto rotor 2 with the rotor holding tool 3 while removing the starter clutch bolts EBS30153 CHECKING THE STARTER CLUTCH 1 Check Sta...

Page 239: ...arter clutch bolts 1 TIP While holding the AC magneto rotor 2 with the rotor holding tool 3 tighten the starter clutch bolts EBS30156 INSTALLING THE AC MAGNETO ROTOR 1 Install Woodruff key AC magneto rotor 1 Washer 2 AC magneto rotor nut 3 TIP Clean the tapered portion of the crankshaft and the AC magneto rotor hub When installing the AC magneto rotor make sure the woodruff key is properly seated ...

Page 240: ...l AC magneto cover 1 TIP Align the slot a in the impeller shaft 2 with the projection b on the oil pump shaft 3 Tighten the AC magneto cover bolts in the proper tightening sequence as shown T R AC magneto rotor nut 160 Nm 16 m kgf 116 ft lbf Rotor holding tool 90890 04166 YM 04166 T R AC magneto cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 2 3 a 1 2 3 1 2 b a 3 10 6 1 2 9 11 5 7 3 8 4 ...

Page 241: ... the starter motor Order Job Parts to remove Q ty Remarks Muffler Refer to ENGINE REMOVAL 1 on page 5 3 1 Starter motor lead 1 Disconnect 2 Engine ground lead 1 Disconnect 3 Starter motor 1 2 3 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R ...

Page 242: ...Job Parts to remove Q ty Remarks 1 Starter motor front cover 1 2 Starter motor rear cover 1 3 Brush set 1 4 Armature assembly 1 5 Starter motor yoke 1 5 Nm 0 5 m kgf 3 6 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R 1 3 5 4 4 2 LS New New New New New LS New New New ...

Page 243: ...e place the starter motor 4 Measure Brush length a Out of specification Replace the brush set 5 Check Gear teeth Damage wear Replace the gear 6 Check Bearing Oil seal Damage wear Replace the defective part s EBS30158 ASSEMBLING THE STARTER MOTOR 1 Install Starter motor yoke 1 Starter motor front cover 2 Starter motor rear cover 3 TIP Align the match marks a on the starter motor yoke with the match...

Page 244: ...ELECTRIC STARTER 5 43 a b b 1 2 3 ...

Page 245: ...ve Q ty Remarks AC magneto rotor Refer to AC MAGNETO AND STARTER CLUTCH on page 5 35 1 Timing chain stopper guide lower 1 2 Oil pump driven sprocket 1 3 Washer 1 4 Oil pump drive sprocket 1 5 Chain 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R LT LT LT 5 4 2 3 1 ...

Page 246: ...ump driven sprocket Cracks wear damage Replace EBS30526 INSTALLING THE OIL PUMP DRIVE SPROCKET AND OIL PUMP DRIVEN SPROCKET 1 Install Oil pump drive sprocket 1 TIP Install the oil pump drive sprocket so that the protruding portion a of the sprocket is facing to ward the crankcase 2 Install Washer 1 Oil pump drive sprocket nut TIP Install the washer with its rounded side a facing away from the cran...

Page 247: ... b Hold the AC magneto rotor 3 with the rotor holding tool 4 while tightening the oil pump drive sprocket nut and oil pump driven sprocket nut T R Oil pump drive sprocket nut 25 Nm 2 5 m kgf 18 ft lbf LOCTITE Oil pump driven sprocket nut 25 Nm 2 5 m kgf 18 ft lbf LOCTITE Rotor holding tool 90890 04166 YM 04166 1 2 3 4 ...

Page 248: ...r unit shift arm Refer to ENGINE REMOVAL 2 on page 5 6 1 Shift lever cover 1 2 Shift lever cover gasket 1 3 Dowel pin 1 4 Oil seal 1 5 Shift lever 1 1 6 Stopper lever spring 1 7 Shift lever 2 1 8 Stopper lever 1 E E LS New New LS E 5 1 2 4 3 8 7 6 14 Nm 1 4 m kgf 10 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 249: ...ection a on the stopper le ver 2 facing toward the collar Install the shift lever 2 3 with the marks b facing the stopper spring 2 Install Shift lever 2 assembly 1 TIP Align the projection a on the shift drum with the slit b in the stopper lever 3 Install Shift lever 1 1 TIP When installing shift lever 1 align the alignment mark a on shift lever 1 with the punch marks b on shift lever 2 2 4 Instal...

Page 250: ...ge 5 3 1 Drive belt cover 1 2 Rubber gasket 1 3 Bearing housing 1 4 Dowel pin 2 5 Primary sheave assembly 1 6 V belt 1 7 Primary fixed sheave 1 8 Secondary sheave assembly 1 9 Drive belt case 1 10 Rubber gasket 1 11 Rubber gasket 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 100 Nm 10 0 m kgf 72 ft Ibf T R 140 Nm 14 m ...

Page 251: ...mary sheave Apply Yamaha Grizzly grease or Yamaha grease F Order Job Parts to remove Q ty Remarks 1 Primary sheave cap 1 2 Primary sheave slider 4 3 Primary sheave cam 1 4 Primary sheave weight 8 5 Spacer 1 6 Oil seal 2 7 Primary sliding sheave 1 8 O ring 1 ...

Page 252: ...ly Yamaha grease H or POLYREX EM Order Job Parts to remove Q ty Remarks 1 Secondary sheave spring retaining nut 1 2 Upper spring seat 1 3 Compression spring 1 4 Lower spring seat 1 5 Guide pin 4 6 Secondary sliding sheave 1 7 O ring 2 8 Secondary fixed sheave 1 9 Oil seal 2 ...

Page 253: ...ve 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 se cure it c Tighten the sheave spring compressor nut 5 and compress the spring d Loosen the secondary sheave spring retain ing nut 1 with the locknut wrench 3 e Remove the secondary sheave spring retain ing nut 1 f Remove the sheave spring compressor and l...

Page 254: ...f the pri mary sheave weights 1 Check Primary sheave weight Cracks damage wear Replace 2 Measure Primary sheave weight outside diameter a Out of specification Replace EBS30172 CHECKING THE PRIMARY SHEAVE SLIDERS The following procedure applies to all of the pri mary sheave sliders 1 Check Primary sheave slider Cracks damage wear Replace EBS30173 CHECKING THE SECONDARY SHEAVE 1 Check Secondary fixe...

Page 255: ...Primary sheave weights 3 Primary sheave cam TIP Remove any excess grease 2 Install Oil seals 1 into the primary sliding sheave 2 3 Lubricate Spacer inner surface Primary sliding sheave inner surface TIP Apply Yamaha Grizzly grease or Yamaha grease F 2 5 g to the inner surface of the spacer Apply Yamaha Grizzly grease or Yamaha grease F 2 5 g to the inner surface of the pri mary sliding sheave Free...

Page 256: ...ded lubricant TIP Apply Yamaha grease H or POLYREX EM 15 g to the inner surfaces of the secondary sheaves 3 Install Secondary sliding sheave 4 Install Guide pins 1 5 Lubricate Guide pin grooves 1 with the recommended lubricant TIP Apply Yamaha grease H or POLYREX EM 5 0 g to the guide pin grooves 6 Install Lower spring seat 1 Compression spring 2 Upper spring seat 3 Secondary sheave spring retaini...

Page 257: ...ry sheave V belt Primary fixed sheave Primary sheave Washer Nuts TIP Be sure to push in the primary sheave cam 1 when installing the primary sheave so that the primary sheave weights 2 will be properly po sitioned a Install the washer 3 with its rounded side b facing away from the primary shave assembly Tightening the bolts 4 90101 06016 will push the secondary sliding sheave away causing the gap ...

Page 258: ...ve 3 and V belt 4 are positioned as shown in the illustra tion 3 Tighten Primary sheave assembly nut 1 TIP Use the rotor holding tool 2 to hold the primary sheave 4 Tighten Secondary sheave assembly nut 1 b 3 4 A Correct position B Incorrect position T R Primary sheave assembly nut 140 Nm 14 m kgf 100 ft lbf Rotor holding tool 90890 04166 YM 04166 T R Secondary sheave assembly nut 100 Nm 10 m kgf ...

Page 259: ...and then tighten the sec ondary sheave assembly nut 5 Lubricate Bearing housing bearing inner surface and ball with the recommended lubricant TIP Apply 2 3 g or more of Shell Sunlight Grease 3 to the bearing inner surface and ball as shown in the illustration Recommended lubricant Shell Sunlight Grease 3 1 ...

Page 260: ...case Refer to PRIMARY AND SECONDARY SHEAVES on page 5 49 1 Clutch housing assembly 1 2 Clutch housing assembly gasket 1 3 Dowel pin 2 4 Clutch carrier assembly nut 1 Left hand thread 5 Clutch carrier assembly 1 7 1 3 3 2 4 5 10 Nm 1 0 m kgf 7 2 ft Ibf T R 190 Nm 19 m kgf 137 ft lbf T R LS New E E E ...

Page 261: ...ng the clutch housing assembly Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Circlip 1 3 Bearing housing 1 4 Circlip 1 5 Bearing 1 6 Seal ring 1 7 One way clutch bearing 1 8 Bearing 1 9 Clutch housing 1 6 7 8 9 E New ...

Page 262: ... clutch bearing must be installed with the flange side facing inward 2 Check One way clutch operation a Install the one way clutch bearing and clutch carrier assembly to the clutch housing and hold the clutch carrier assembly b When turning the clutch housing clockwise A it should turn freely otherwise the one way clutch assembly is faulty and must be re placed c When turning the clutch housing co...

Page 263: ...has left hand threads To tighten the clutch carrier assembly nut turn it counterclockwise TIP Lubricate the threads of the clutch carrier as sembly nut with engine oil Use a universal clutch holder 2 to hold the clutch carrier assembly 2 Lock the threads with a drift punch 3 Install Dowel pins 1 Gasket Clutch housing assembly a Clutch shoe wear limit Installed depth a 2 5 2 7 mm 0 10 0 11 in Insta...

Page 264: ...CLUTCH 5 63 TIP Tighten the bolts in stages using a crisscross pattern After tightening the bolts check that the clutch housing assembly rotates smoothly 1 ...

Page 265: ...44 Shift levers Refer to SHIFT LEVER on page 5 47 Clutch carrier assembly Refer to CLUTCH on page 5 59 1 Oil filter cartridge 1 2 Oil filter cartridge union bolt 1 3 Adapter 1 E E LT New New New New New New New New LT LT LT E E E E 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 17 Nm 1 7 m kgf...

Page 266: ...ght 1 13 Crankcase left 1 E E LT New New New New New New New New LT LT LT E E E E 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 22 Nm 2 2 m kgf 16 ft Ibf T R 26 Nm 2 6 m kgf 19 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 18 Nm 1 8 m kgf...

Page 267: ...ND OIL PUMP on page 5 70 Middle drive shaft Middle driven shaft Refer to MIDDLE GEAR on page 5 81 Transmission Refer to TRANSMISSION on page 5 75 1 Collar 1 2 O ring 1 3 Oil seal 1 4 Bearing retainer 1 5 Spacer 1 6 Crankshaft seal 2 7 Bearing 9 E E E E E LT LT LT E E LS New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 6 5 1 2 3 7 7 7 7 4 7 7 ...

Page 268: ...ect the end of the crankshaft place an appropriate sized socket between the crankcase separating tool bolt and the crankshaft Do not tap on the crankshaft EBS30183 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1 Check Timing chain Damage stiffness Replace the timing chain and camshaft sprocket as a set 2 Check Timing chain guide intake side Damage wear Replace EBS30185 CHECKING THE BEARINGS 1 C...

Page 269: ...ny sealant to come into contact with the oil gallery 4 Fit the right crankcase onto the left crank case Tap lightly on the crankcase with a soft face hammer NOTICE ECB01730 Before tightening the crankcase bolts make sure the transmission gears shift correctly when the shift drum assembly is turned by hand 5 Install Crankcase bolts 6 Tighten Crankcase bolts M8 40 mm 1 M6 90 mm 2 M6 60 mm 3 M6 30 mm...

Page 270: ...ngs and oil de livery hole 8 Check Crankshaft and transmission operation Rough operation Repair 9 Install Gasket Oil cooler Oil filter cartridge union bolt Refer to INSTALLING THE OIL COOLER on page 6 3 A Crankcase right B Crankcase left 4 4 1 4 3 4 4 3 B 2 3 3 1 6 4 4 New ...

Page 271: ...rankshaft and oil pump Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 64 1 Oil pump 1 2 Crankshaft 1 3 Balancer 1 4 Bearing 1 5 Plug 1 6 Spring 1 7 Steel ball 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R E 3 2 4 5 6 7 1 ...

Page 272: ...ssembling the oil pump Order Job Parts to remove Q ty Remarks 1 Oil pump housing cover 1 2 Pin 1 3 Oil pump shaft 1 4 Oil pump inner rotor 1 5 Oil pump outer rotor 1 6 Oil pump housing 1 E 6 3 2 5 4 1 E E 5 Nm 0 5 m kgf 3 6 ft Ibf T R ...

Page 273: ...ck Oil pump Cracks damage wear Replace the oil pump 2 Measure Inner rotor to outer rotor tip clearance a Outer rotor to oil pump housing clearance b 3 Check Oil pump operation Rough movement Replace the oil pump EBS30190 CHECKING THE OIL STRAINER 1 Check Oil strainer Damage Replace the oil pump Contaminants Clean with solvent EBS30184 CHECKING THE RELIEF VALVE 1 Check Steel ball 1 Spring 2 Damage ...

Page 274: ... with the groove a in the inner rotor 3 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 72 EBS30193 INSTALLING THE CRANKSHAFT 1 Install Balancer 1 Crankshaft 2 NOTICE ECB01890 Apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier TIP Install the balancer 1 and crankshaft 2 at the same time Align the hole a in the balancer w...

Page 275: ...he proper tightening sequence as shown Crankshaft installer pot 90890 01274 Installing pot YU 90058 Crankshaft installer bolt 90890 01275 Bolt YU 90060 Adapter M16 90890 04130 Adapter 13 YM 04059 Spacer crankshaft installer 90890 04081 Pot spacer YM 91044 T R Oil pump bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 2 3 4 5 6 1 2 a b 3 1 2 ...

Page 276: ...se Separate Refer to CRANKCASE on page 5 64 Middle driven gear Refer to MIDDLE GEAR on page 5 81 1 Shift drum stopper bolt 1 2 Spring 1 3 Ball 1 4 Shift drum 1 5 Shift fork assembly 1 6 Shift fork R 1 7 Spring 1 8 Shift fork L 1 9 Shift fork guide bar 1 E E E E E E E E New New New M M E E New 18 Nm 1 8 m kgf 13 ft Ibf T R 1 2 3 4 9 8 6 7 5 ...

Page 277: ...ts to remove Q ty Remarks 10 Secondary shaft 1 11 Drive axle assembly 1 12 Collar 1 13 Reverse idle gear 1 14 Bearing 1 15 Reverse idle gear shaft 1 16 Stopper lever 1 17 Stopper lever shaft 1 E E E E E E E E New New New M M E E New 18 Nm 1 8 m kgf 13 ft Ibf T R 17 16 10 15 13 14 12 11 ...

Page 278: ...r 1 3 High wheel gear 1 4 Washer 1 5 Clutch dog 1 6 Circlip 1 7 Washer 1 8 Collar 1 9 Low wheel gear 1 10 Washer 1 11 Circlip 1 12 Middle drive gear 1 13 Circlip 1 14 Washer 1 15 Bearing 1 16 Reverse wheel gear 1 17 Stopper wheel 1 18 Drive axle 1 New LS New New LS M M 17 18 16 1 3 4 5 6 7 9 8 2 10 11 12 13 14 15 ...

Page 279: ...RKS The following procedure applies to both of the shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING EWB02750 Do not attempt to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Rough moveme...

Page 280: ... part s EBS30199 CHECKING THE SECONDARY SHAFT 1 Check Gear teeth Blue discoloration pitting wear Replace EBS30555 CHECKING THE STOPPER LEVER AND STOPPER WHEEL 1 Check Stopper lever pawl 1 Bends damage wear Replace the stopper lever and stopper wheel as a set Stopper wheel 2 Damage wear Replace the stopper wheel and stopper lever as a set Stopper lever shaft 3 Bends damage wear Replace EBS30200 ASS...

Page 281: ... Reverse idle gear 1 Drive axle assembly 2 Secondary shaft 3 Shift fork assembly 4 Shift drum 5 TIP Install the shift fork assembly 4 with the L mark a facing the left crankcase 2 Check Shift operation Rough operation Repair TIP Oil each gear and bearing thoroughly Before assembling the crankcase make sure that the transmission is in neutral and that the gears turn freely New New New a b 4 1 2 5 3...

Page 282: ... drive pinion gear 1 4 Middle drive pinion gear shim Refer to ALIGNING THE MIDDLE GEAR on page 5 89 5 Middle drive shaft assembly 1 6 Middle driven gear 1 7 Circlip 1 8 Middle drive shaft 1 9 Middle drive shaft bearing housing assembly 1 10 Bearing retainer 2 11 Bearing 1 12 Bearing housing 1 New LT LT LT LT LT LT LT New LT LT LT E E 190 Nm 19 m kgf 137 ft lbf T R 38 Nm 3 8 m kgf 27 ft Ibf T R 29 ...

Page 283: ...r nut middle gear side 1 4 Rear drive shaft coupling gear middle gear side 1 5 Middle driven pinion gear assembly 1 6 Middle driven pinion gear shim Refer to ALIGNING THE MIDDLE GEAR on page 5 89 7 Middle driven pinion gear 1 8 Bearing 1 9 Oil seal 1 150 Nm 15 m kgf 108 ft lbf T R 115 Nm 11 5 m kgf 83 ft lbf T R LT M E New M 25 Nm 2 5 m kgf 18 ft Ibf T R 80 Nm 8 0 m kgf 58 ft Ibf T R 130 Nm 13 m k...

Page 284: ...read 11 Bearing 1 12 O ring 1 13 Bearing housing 1 14 Oil seal 1 15 Middle driven shaft bearing retainer 1 Left hand thread 16 Bearing 1 17 Middle driven shaft 1 150 Nm 15 m kgf 108 ft lbf T R 115 Nm 11 5 m kgf 83 ft lbf T R LT M E New M 25 Nm 2 5 m kgf 18 ft Ibf T R 80 Nm 8 0 m kgf 58 ft Ibf T R 130 Nm 13 m kgf 94 ft lbf T R 12 10 11 17 16 13 15 14 ...

Page 285: ...ve shaft coupling gear 2 TIP Use the coupling gear middle shaft tool 3 to hold the front drive shaft coupling gear 2 Remove Rear drive shaft coupling gear nut 1 Washer Rear drive shaft coupling gear 2 TIP Use the coupling gear middle shaft tool 3 to hold the rear drive shaft coupling gear 3 Remove Bearing housing assembly 1 a Clean the surface of the bearing housing as sembly b Place the bearing h...

Page 286: ...ft hand threads To loosen the re tainer turn it clockwise c Remove the bearing retainer and bearing 5 Remove Oil seal 1 Middle driven shaft bearing retainer 2 TIP Attach the ring nut wrench 3 NOTICE ECB01750 The middle driven shaft bearing retainer has left hand threads To loosen the retainer turn it clockwise 6 Remove Middle driven shaft 1 with bearing EBS30205 CHECKING THE PINION GEARS 1 Check D...

Page 287: ... retainer 1 a Wrap the bearing housing in a folded rag and then secure the bearing housing edge in a vise b Attach the bearing retainer wrench 2 c Tighten the bearing retainer Installed depth a of bearing 0 9 1 4 mm 0 035 0 055 in Installed depth b of oil seal 1 0 1 5 mm 0 039 0 059 in Installed depth a of oil seal 1 0 1 5 mm 0 039 0 059 in T R Middle driven shaft bearing re tainer 80 Nm 8 0 m kgf...

Page 288: ...coupling gear 5 Install Front drive shaft coupling gear 1 Washer Front drive shaft coupling gear nut 2 TIP Use the coupling gear middle shaft tool 3 to hold the front drive shaft coupling gear EBS30208 INSTALLING THE MIDDLE DRIVE SHAFT 1 Install Circlip Middle driven gear 1 onto the middle drive shaft 2 T R Rear drive shaft coupling gear nut middle gear side 150 Nm 15 m kgf 108 ft lbf LOCTITE Coup...

Page 289: ...djust Refer to ALIGNING THE MIDDLE GEAR on page 5 89 a Temporarily install the left crankcase b Wrap a rag 1 around a screwdriver 2 and then insert it into the installation hole a of the left crankcase speed sensor to hold the mid dle driven gear c Attach the final gear backlash band 3 and dial gauge 4 T R Middle drive shaft bearing retain er bolt 29 Nm 2 9 m kgf 21 ft lbf LOCTITE T R Middle drive...

Page 290: ... a Position the middle gears with the appropri ate shim s that has had its respective thick ness calculated from information marked on the crankcase bearing housings and pinion gears b To find middle drive pinion gear shim thick ness A use the following formula a a numeral usually a decimal number on the bearing housing is either added to or subtracted from 0 6 b 17 0 c 55 0 d a numeral usually a ...

Page 291: ... middle driven pin ion gear assembly the overall length of the as sembly will change Therefore be sure to measure distance f to select the correct middle driven pinion gear shim thickness g a numeral usually a decimal number on the middle driven pinion gear is either add ed to or subtracted from 49 0 h a numeral usually a decimal number on the middle driven pinion gear is either add ed to or subtr...

Page 292: ...him thickness is 0 81 mm The chart instructs you however to round off 1 to 0 Shims are supplied in the following thickness es TIP If the specified middle gear backlash cannot be obtained with a calculated shim thickness in crease or decrease the shim thickness If the shim thickness is increased the actual middle gear backlash will increase and if the shim thickness is decreased the actual middle g...

Page 293: ...ING THE RADIATOR 6 6 INSTALLING THE RADIATOR 6 6 THERMOSTAT 6 7 CHECKING THE THERMOSTAT 6 8 INSTALLING THE THERMOSTAT 6 8 WATER PUMP 6 10 DISASSEMBLING THE WATER PUMP 6 12 CHECKING THE WATER PUMP 6 12 ASSEMBLING THE WATER PUMP 6 12 INSTALLING THE WATER PUMP HOUSING 6 13 INSTALLING THE WATER JACKET JOINT 6 13 ...

Page 294: ...8 Footrest board left Refer to GENERAL CHASSIS 4 on page 4 11 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 24 Coolant Drain Refer to CHANGING THE COOLANT on page 3 29 Oil cooler outlet hose Oil cooler inlet hose Refer to WATER PUMP on page 6 10 New New New New New New E E 18 Nm 1 8 m kgf 13 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 35 Nm 3 5 m kgf 25 ft ...

Page 295: ...l cooler 1 4 Oil pipe crankcase 1 5 Oil hose crankcase to cylinder head 1 6 Oil hose joint 1 7 Oil pipe AC magneto cover 1 New New New New New New E E 18 Nm 1 8 m kgf 13 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 7 1 2 3 4 5 6 ...

Page 296: ...ith a cloth dampened with lacquer thinner 3 Install Gasket Oil cooler 1 Oil filter cartridge union bolt 2 TIP Make sure the projection a on the oil cooler touches the projection b on the crankcase 4 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 29 Crankcase with the specified amount of the recom mended engine oil Refer to CHANGING...

Page 297: ...S 2 on page 4 6 Front fenders Refer to GENERAL CHASSIS 3 on page 4 8 Footrest board left Refer to GENERAL CHASSIS 4 on page 4 11 Coolant Drain Refer to CHANGING THE COOLANT on page 3 29 1 Radiator fan motor coupler 1 Disconnect 2 Radiator fan motor breather hose 1 3 Coolant reservoir hose 1 4 Coolant reservoir breather hose 1 5 Coolant reservoir cap 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5...

Page 298: ...he radiator Order Job Parts to remove Q ty Remarks 6 Coolant reservoir 1 7 Radiator outlet hose 1 8 Radiator inlet hose 1 9 Radiator 1 10 Radiator fan 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 4 10 9 7 6 8 ...

Page 299: ...e sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 9 25 EBS30214 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 29 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure Radiator cap opening pressure Below t...

Page 300: ...er to GENERAL CHASSIS 1 on page 4 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 29 1 Radiator inlet hose 1 Disconnect 2 Thermostat cover 1 3 Thermostat 1 4 Coolant temperature sensor coupler 1 Disconnect 5 Coolant temperature sensor 1 LS New New New 20 Nm 2 0 m kgf 14 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 1 2 3 5 4 ...

Page 301: ... damage Replace EBS30216 INSTALLING THE THERMOSTAT 1 Install Copper washer Coolant temperature sensor NOTICE ECB01910 Use extreme care when handling the coolant temperature sensor Replace any part that was dropped or subjected to a strong im pact 2 Install Thermostat 1 Gasket 2 Thermostat cover 3 TIP Install the thermostat with its breather hole a facing up 3 Fill Cooling system with the specified...

Page 302: ...THERMOSTAT 6 9 5 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 6 ...

Page 303: ...r to GENERAL CHASSIS 4 on page 4 11 AC magneto cover Refer to AC MAGNETO AND STARTER CLUTCH on page 5 35 Coolant Drain Refer to CHANGING THE COOLANT on page 3 29 1 Radiator outlet hose 1 Disconnect 2 Water jacket joint 1 3 Water pump outlet hose 1 4 Water pump outlet pipe 1 5 Oil cooler outlet hose 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 8 Nm ...

Page 304: ...reather hose 1 10 Water pump housing 1 11 Gasket 1 12 Impeller 1 Left hand thread 13 Washer 1 14 Impeller shaft 1 15 Water pump seal 1 16 Bearing 1 17 Oil seal 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 8 10 11 12 13 15 14 16 17 9 6 7 New New New New LS LS New LS ...

Page 305: ... WATER PUMP 1 Install Bearing 1 Oil seal 2 into the AC magneto cover TIP Install the oil seal with a socket that matches its outside diameter 2 Install Mechanical seal 1 NOTICE ECB02410 Never lubricate the mechanical seal surface with oil or grease TIP Use the special tools and a press to press the mechanical seal straight in until its flange a touches the AC magneto cover 1 1 2 New Installed dept...

Page 306: ... in the area a of the clamp as shown in the illustration Position the screw head of each clamp within the range shown in the il lustration EBS30471 INSTALLING THE WATER JACKET JOINT 1 Install Clamps 1 onto the water pump outlet hose Water pump outlet hose 2 onto the water jacket joint Water jacket joint 3 TIP Tighten the clamp screw of each clamp 1 until 4 slots remain in the area a of the clamp a...

Page 307: ...FUEL PUMP 7 2 INSTALLING THE FUEL TANK 7 3 THROTTLE BODY 7 4 REMOVING THE THROTTLE BODY ASSEMBLY 7 6 CHECKING THE INJECTOR 7 6 CHECKING THE THROTTLE BODY 7 6 INSTALLING THE THROTTLE BODY ASSEMBLY 7 6 CHECKING THE FUEL PRESSURE 7 7 ADJUSTING THE THROTTLE POSITION SENSOR 7 7 AIR INDUCTION SYSTEM 7 9 CHECKING THE AIR INDUCTION SYSTEM 7 13 INSTALLING THE AIR INDUCTION SYSTEM 7 13 ...

Page 308: ... Refer to GENERAL CHASSIS 3 on page 4 8 1 Fuel tank breather hose 2 2 Fuel tank breather hose joint 1 3 Fuel tank shield 1 4 Fuel pump coupler 1 Disconnect 5 Fuel hose connector holder 1 6 Fuel hose 1 7 Fuel tank 1 8 Fuel pump assembly 1 9 Damper 1 New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 2 1 1 9 4 7 8 5 6 3 6 ...

Page 309: ...fuel hose To remove the fuel hose from the throttle body slide the fuel hose connector cover 2 on the end of the hose in direction of the arrow shown press the two buttons 3 on the sides of the connector and then remove the hose Before removing the hose place a few rags in the area under where it will be removed 3 Remove Fuel tank TIP Do not set the fuel tank down on the installation surface of th...

Page 310: ...d 2nd holes on the right side of the frame Make sure that the shorter end of the damper is facing outward as shown in the illustration 2 Install Fuel hose Fuel hose connector holder 1 Fuel pump coupler NOTICE ECB02010 When installing the fuel hose make sure that it is securely connected and that the fuel hose holder is in the correct position other wise the fuel hose will not be properly in stalle...

Page 311: ...2 Throttle position sensor coupler 1 Disconnect 3 ISC Idle Speed Control unit coupler 1 Disconnect 4 Fuel hose 1 Disconnect 5 Throttle cable housing cover 1 6 Throttle cable 1 Disconnect 7 Fuel injector coupler 1 Disconnect 8 Throttle body joint clamp screw 2 Loosen 9 Throttle body assembly 1 10 Throttle body breather hose 1 11 Throttle body joint 1 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 2 8 Nm 0 28 m k...

Page 312: ...move Q ty Remarks 1 Intake air pressure sensor 1 2 Intake air pressure sensor hose 1 3 Throttle position sensor 1 4 Fuel rail 1 5 Fuel injector 1 6 Throttle body 1 LS New New 3 6 Nm 0 36 m kgf 2 6 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 1 2 4 3 5 6 ...

Page 313: ... two buttons 2 on the sides of the connector and then disconnect the hose Before disconnecting the hose place a few rags in the area under where it will be discon nected EBS30230 CHECKING THE INJECTOR 1 Check Injector Damage Replace EBS30231 CHECKING THE THROTTLE BODY 1 Check Throttle body Cracks damage Replace the throttle body 2 Check Fuel passages Obstructions Clean a Wash the throttle body in ...

Page 314: ... direction of the arrow and remove the fuel hose Before removing the hose place a few rags in the area under where it will be removed d Connect the pressure gauge 3 and adapter 4 to the fuel pump and fuel hose e Start the engine f Measure the fuel pressure Out of specification Replace the fuel pump EBS30234 ADJUSTING THE THROTTLE POSITION SENSOR WARNING EWB03070 Handle the throttle position sensor...

Page 315: ... tighten the throttle position sensor screws 2 to specification Positive tester probe yellow wire harness color Negative tester probe black blue wire harness color Test harness TPS 3P 90890 03204 Test harness TPS 3P YU 03204 Digital circuit tester 90890 03174 Model 88 Multimeter with ta chometer YU A1927 Throttle position sensor output voltage 0 63 0 73 V yellow black blue T R Throttle position se...

Page 316: ...AIR INDUCTION SYSTEM 7 9 EBS20057 AIR INDUCTION SYSTEM 3 4 1 2 3 4 1 2 ...

Page 317: ...AIR INDUCTION SYSTEM 7 10 1 Air induction system hose air filter case to air cut off valve 2 Air cut off valve 3 Air induction system hose air cut off valve to reed valve assembly 4 Reed valve assembly ...

Page 318: ...s Refer to GENERAL CHASSIS 1 on page 4 1 1 Air cut off valve coupler 1 Disconnect 2 Air induction system hose air filter case to air cut off valve 1 3 Air induction system hose air cut off valve to reed valve assembly 1 4 Air cut off valve 1 5 Air cut off valve bracket 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 4 5 1 3 ...

Page 319: ...AIR INDUCTION SYSTEM 7 12 Removing the reed valve Order Job Parts to remove Q ty Remarks 1 Reed valve cover 1 2 Reed valve assembly 1 3 Reed valve plate 1 1 2 3 LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 320: ...o flow during idle and closes to cut off the flow when the vehicle is be ing driven However if the coolant temperature is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value 1 Check Hoses Loose connections Connect properly Cracks damage Replace 2 Check Reed valve Reed valve stopp...

Page 321: ...REAR CONSTANT VELOCITY SHAFT ASSEMBLIES FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT 8 15 DISASSEMBLING THE REAR CONSTANT VELOCITY SHAFT ASSEMBLIES 8 21 CHECKING THE REAR CONSTANT VELOCITY SHAFT ASSEMBLIES 8 22 ASSEMBLING THE REAR CONSTANT VELOCITY SHAFT ASSEMBLIES 8 22 DISASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY 8 23 CHECKING THE REAR DRIVE SHAFT 8 24 CHECKING THE FINAL DRIVE ASSEMBLY 8 24 AS...

Page 322: ...ronounced hesitation or jerky movement during acceleration deceleration or sustained speed This must not be confused with engine surging or transmission characteristics 2 A rolling rumble noticeable at low speed a high pitched whine a clunk from a shaft drive com ponent or area 3 A locked up condition of the shaft drive train mechanism no power transmitted from the en gine to the front and or rear...

Page 323: ...ow speed opera tion This noise must be distinguished from normal vehicle operation Diagnosis Possible broken gear teeth WARNING EWB02910 Stop riding immediately if broken gear teeth are suspected This condition could result in the shaft drive assembly locking up causing a loss of control and possible injury to the rider 2 Check Drained oil Drained oil shows large amounts of metal particles Check t...

Page 324: ...RONT WHEELS on page 4 20 and REAR WHEELS on page 4 23 3 Check the front constant velocity shaft assemblies Feel for bearing damage Constant velocity shaft bearings and differ ential bearings are probably not damaged Repeat the test or remove the individual components 4 Check the rear brake adjustment Adjust per instructions Refer to AD JUSTING THE REAR DISC BRAKE on page 3 12 5 Check the rear cons...

Page 325: ... on page 4 1 Steering knuckles Refer to TIE RODS AND STEERING KNUCKLES on page 4 61 Front arms Refer to FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES on page 4 65 Differential gear oil Drain Refer to CHANGING THE DIFFERENTIAL GEAR OIL on page 3 26 1 Front constant velocity shaft assembly 2 2 Differential motor coupler 1 Disconnect 3 Differential case breather hose 1 Disconnect 4 Differential asse...

Page 326: ...y shaft assemblies differential assembly and front drive shaft Order Job Parts to remove Q ty Remarks 6 Spring 1 7 Damper 1 8 Front drive shaft coupling sleeve 1 9 Dust seal 1 10 Dust seal 1 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 66 Nm 6 6 m kgf 48 ft Ibf T R LS New New LS LS LS LS LT LT LT LT 9 10 8 7 6 ...

Page 327: ...fferential side Order Job Parts to remove Q ty Remarks The following procedure applies to both of the front constant velocity shaft assemblies 1 Clip 1 2 Boot band 1 3 Boot band 1 4 Dust boot 1 5 Clip 1 6 Double offset joint 1 7 Circlip 1 8 Ball bearing 1 9 Boot band 1 10 Boot band 1 11 Dust boot 1 12 Constant velocity joint 1 13 Clip 1 14 Constant velocity shaft 1 ...

Page 328: ... 3 Front drive shaft yoke nut differential case side 1 4 Front drive shaft yoke differential case side 1 5 Differential case cover 1 6 O ring 1 7 Differential gear assembly 1 8 Differential gear assembly shim Refer to ADJUSTING THE DIFFEREN TIAL GEAR BACKLASH on page 8 13 9 Bearing 1 LT LS LS New New New New New New LS LS 5 7 1 2 5 6 8 9 62 Nm 6 2 m kgf 45 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R ...

Page 329: ...ty Remarks 10 Bearing 1 11 Oil seal 1 12 Clip 1 13 Differential pinion gear 1 14 Bearing 1 15 Bearing 1 16 Oil seal 2 17 Differential case 1 LT LS LS New New New New New New LS LS 5 62 Nm 6 2 m kgf 45 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 13 15 16 17 10 16 11 12 14 ...

Page 330: ...joint Clip TIP Secure the constant velocity shaft in a vise and then remove the constant velocity joint using hammers EBS30241 CHECKING THE FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES The following procedure applies to both of the front constant velocity shaft assemblies 1 Check Double offset joint splines Constant velocity joint splines Constant velocity shaft splines Wear damage Replace 2 Check Dus...

Page 331: ...it the constant velocity shaft into the con stant velocity joint using a hammer 2 Install Dust boot Ball bearing 1 Circlip 2 Double offset joint 3 Clip 4 TIP Securely install the circlip into the groove in the constant velocity shaft Securely install the clip into the groove in the double offset joint 3 Apply Molybdenum disulfide grease into the double offset joint constant velocity joint and dust...

Page 332: ... sembled into a proper unit at the factory by means of specialized equipment Do not at tempt to disassemble this unit Disassembly will result in the malfunction of the unit EBS30246 CHECKING THE DIFFERENTIAL ASSEMBLY 1 Check Gear teeth Pitting galling wear Replace differential pinion gear and differential gear assembly as a set Bearings Pitting damage Replace Oil seals O rings Damage Replace 2 Che...

Page 333: ...l case cover to the left as shown in the illustration to put it into the 2WD mode b Connect two C size batteries to the differen tial motor terminal 2 to operate the differen tial motor pinion gear 3 Operate the differential motor pinion gear until the mark 4 on the differential motor pinion gear is aligned with the mark 5 on the differential motor case NOTICE ECB01650 Do not use a 12 V battery to...

Page 334: ... tighten the bolt until it holds the ring gear Otherwise the ring gear will be dam aged 4 Attach Gear lash measurement tool 2 Dial gauge 3 5 Measure Gear backlash Gently rotate the differential pinion gear from engagement to engagement TIP Measure the gear backlash at four positions Ro tate the differential pinion gear 90 each time EBS30252 ADJUSTING THE DIFFERENTIAL GEAR BACKLASH 1 Remove Differe...

Page 335: ... Adjust Gear backlash a Select the suitable shims using the following chart b Measure the differential gear backlash again Thinner shim Differential gear backlash is increased Thicker shim Differential gear backlash is decreased Differential gear assembly shims Thickness mm 0 1 0 2 0 3 0 4 1 2 ...

Page 336: ...st wheel models Order Job Parts to remove Q ty Remarks Rear skid plate Refer to GENERAL CHASSIS 1 on page 4 1 Rear fender Refer to GENERAL CHASSIS 3 on page 4 8 Rear arms Refer to REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES on page 4 72 Final gear oil Drain Refer to CHANGING THE FINAL GEAR OIL on page 3 27 1 Rear constant velocity shaft assembly 2 2 Final drive case breather hose 1 Disconnect 3 T...

Page 337: ...e assembly and rear drive shaft A For panel wheel models B For cast wheel models Order Job Parts to remove Q ty Remarks 4 Final drive assembly 1 5 Rear drive shaft 1 6 Spring 1 7 Damper 1 8 Rear drive shaft coupling sleeve 1 9 Dust seal 1 10 Dust seal 1 10 8 9 7 6 5 4 LS LS LS LS New New A B 55 Nm 5 5 m kgf 40 ft Ibf T R 66 Nm 6 6 m kgf 48 ft Ibf T R ...

Page 338: ...al drive side Order Job Parts to remove Q ty Remarks The following procedure applies to both of the rear constant velocity shaft assemblies 1 Clip 1 2 Boot band 1 3 Boot band 1 4 Dust boot 1 5 Clip 1 6 Double offset joint 1 7 Circlip 1 8 Ball bearing 1 9 Boot band 1 10 Boot band 1 11 Dust boot 1 12 Constant velocity joint 1 13 Clip 1 14 Constant velocity shaft 1 ...

Page 339: ...al drive case cover 1 TIP Working in a crisscross pattern loosen each bolt 1 4 of a turn After all the bolts are loos ened remove them 4 Dowel pin 2 5 Gasket 1 6 Oil seal 1 7 Bearing 1 8 Bearing 1 9 Wheel gear shim Refer to SELECTING THE WHEEL GEAR SHIM S on page 8 28 10 Nm 1 0 m kgf 7 2 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 ...

Page 340: ...hrust washer Refer to SELECTING THE FINAL DRIVEN PINION GEAR SHIM FINAL DRIVE CASE SIDE AND THRUST WASHER on page 8 26 15 Final driven pinion gear shim final drive case side Refer to SELECTING THE FINAL DRIVEN PINION GEAR SHIM FINAL DRIVE CASE SIDE AND THRUST WASHER on page 8 26 16 Oil seal 1 17 Bearing 1 18 Bearing 1 19 Final drive case 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T...

Page 341: ... shaft yoke final drive case side 1 23 Final drive pinion gear 1 24 Oil seal 1 25 Bearing 1 26 Expander 1 27 Washer 1 28 Bearing 1 29 Final drive pinion gear bearing housing 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 4 New New New New New New New New LS G G G G LS LS LS G G LS LT 11 20 21 ...

Page 342: ... 4 Dust boot 5 TIP Before removing the clip slide the dust boot away from the double offset joint 3 Remove Boot band 1 Use the boot band installation tool 2 4 Remove Dust boot Constant velocity joint Clip TIP Secure the constant velocity shaft in a vise and then remove the constant velocity joint using hammers Boots band installation tool 90890 01526 Boots band installation tool YM 01526 A Final d...

Page 343: ...E REAR CONSTANT VELOCITY SHAFT ASSEMBLIES The following procedure applies to both of the rear constant velocity shaft assemblies 1 Install Clip 1 Constant velocity joint 2 Constant velocity shaft 3 Dust boot a Install the clip b Install the constant velocity joint TIP Install the clip into the groove in the constant velocity shaft as shown Secure the constant velocity joint in a vise and then fit ...

Page 344: ...nt velocity shaft a Install the dust boots b Install the dust boot bands Use the boot band installation tool 6 5 Check Thrust movement free play Excessive play Replace the constant ve locity shaft assembly EBS30256 DISASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY 1 Remove Rear drive shaft yoke nut 1 a Place a folded rag as shown b Secure the final drive pinion gear in the vise c Remove the rear ...

Page 345: ...S30410 ASSEMBLING THE FINAL DRIVE CASE 1 Install Oil seals 1 EBS30262 ASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY 1 Install Rear drive shaft yoke nut 1 a Place a folded rag as shown b Secure the final drive pinion gear in the vise c Tighten the rear drive shaft yoke nut temporarily d Secure the final drive pinion gear bearing housing in a vice and then turn the nut with a torque wrench to chec...

Page 346: ...im thick ness A use the following formula a 55 mm b a numeral usually a decimal number on the final drive pinion gear either added to or subtracted from 22 2 c a numeral usually a decimal number on the final drive pinion gear bearing housing either added to or subtracted from 67 8 d a numeral usually a decimal number on the final drive case either added to or sub tracted from 100 Example a 55 If 0...

Page 347: ...ear shim final drive case side 1 Thrust washer 2 a To find the final driven pinion gear shim final drive case side and thrust washer thickness B use the following formula e a numeral usually a decimal number on the final drive case either added to or sub tracted from 71 6 f a numeral usually a decimal number on the final driven pinion gear either added to or subtracted from 51 0 g a numeral usuall...

Page 348: ... round off 6 to 5 at the hundredth place Thus the shim and thrust washer thickness is 5 15 mm Shim and thrust washer are supplied in the following thicknesses TIP Be sure to use one of each of the final driven pin ion gear shim final drive case side 1 and thrust washer 2 to obtain the shim and thrust washer thickness EBS30411 SELECTING THE FINAL DRIVEN PINION GEAR SHIM FINAL DRIVE CASE COVER SIDE ...

Page 349: ...chart TIP Measure the thickness of the originally fitted shim s and then calculate the required new shim thickness to bring the final driven pinion gear thrust clearance within the specified limits b Repeat the measurement steps until the final driven pinion gear thrust clearance is within the specified limits EBS30414 SELECTING THE WHEEL GEAR SHIM S 1 Measure Wheel gear thrust clearance D a Place...

Page 350: ...wise the ring gear will be dam aged 4 Attach Final gear backlash band 2 Dial gauge 3 5 Measure Gear backlash Gently rotate the final drive pinion gear from engagement to engagement TIP When measuring the gear backlash be sure the right side gear oil level check bolt side of the final drive case assembly is facing down ward Measure the gear backlash at four positions Rotate the final drive pinion g...

Page 351: ...en pinion gear shim fi nal drive case cover side 4 thickness by 0 2 mm 0 008 in for every 0 2 mm 0 008 in that the final driven pinion gear shim final drive case side 2 and thrust washer 3 are de creased TIP Be sure to use one of each of the final driven pin ion gear shim final drive case side 2 and thrust washer 3 to obtain the shim and thrust washer thickness Thinner shim Final gear backlash is ...

Page 352: ...REAR CONSTANT VELOCITY SHAFT ASSEMBLIES FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT 8 31 ...

Page 353: ...T DIAGRAM 9 15 TROUBLESHOOTING 9 17 SIGNALING SYSTEM 9 19 CIRCUIT DIAGRAM 9 19 TROUBLESHOOTING 9 21 COOLING SYSTEM 9 25 CIRCUIT DIAGRAM 9 25 TROUBLESHOOTING 9 27 FUEL INJECTION SYSTEM 9 29 CIRCUIT DIAGRAM 9 29 ECU SELF DIAGNOSTIC FUNCTION 9 31 TROUBLESHOOTING METHOD 9 32 YAMAHA DIAGNOSTIC TOOL 9 32 TROUBLESHOOTING DETAILS FUEL INJECTION SYSTEM 9 35 FUEL PUMP SYSTEM 9 59 CIRCUIT DIAGRAM 9 59 TROUBL...

Page 354: ...CKING THE IGNITION COIL 9 91 CHECKING THE CRANKSHAFT POSITION SENSOR 9 91 CHECKING THE LEAN ANGLE SENSOR 9 92 CHECKING THE STARTER MOTOR OPERATION 9 92 CHECKING THE STATOR COIL 9 93 CHECKING THE RECTIFIER REGULATOR 9 93 CHECKING THE FUEL SENDER 9 93 CHECKING THE SPEED SENSOR 9 94 CHECKING THE RADIATOR FAN MOTOR 9 94 CHECKING THE RADIATOR FAN MOTOR CIRCUIT BREAKER 9 95 CHECKING THE COOLANT TEMPERAT...

Page 355: ......

Page 356: ... G L B G Y L Y B R G P L R W B Br L W G R W OFF ON Gy B R Br Br L R Y Br Y Br L Br L R W R W Br Y Br Y B Y R Y L Y Y L Y L Y Y B B Y G R R L B G Y B W L W B W B G R G Y Br B B W B W B W B W Br Y Br Y Br Y Br Y L B Sb L P GyW B Gy G W R B W Y G W R Gy G Y L L B Sb P Y L W G Y Br W R B Gy G W R W R G G R L Y R Y L R Y R Lg G R L W P W B G O L R L Y B B R B Y W G W B Y W W G P L R G R W R W P L Br L ...

Page 357: ...Main switch 5 Main fuse 6 Battery 9 Engine ground 11 Joint coupler 16 ECU Engine Control Unit 17 Ignition coil 18 Spark plug 25 Lean angle sensor 46 Engine stop switch 61 Ignition fuse 66 Frame ground 1 A Wire harness B Negative battery sub wire harness ...

Page 358: ...TERY on page 9 85 Clean the battery terminals Recharge or replace the battery 3 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 4 Re gap clean or replace the spark plug 4 Check the spark plug cap Refer to CHECKING THE SPARK PLUG CAP on page 9 90 Replace the spark plug cap 5 Check the ignition coil Refer to CHECKING THE IGNI TION COIL on page 9 91 Replace the ignition coil 6 Check t...

Page 359: ...ne stop switch is faulty Replace the handlebar switch left 9 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 9 92 Replace the lean angle sensor 10 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM on page 9 1 Properly connect or repair the ignition sys tem wiring Replace the ECU ...

Page 360: ... Br Y R Y G L B G Y L Y B R G P L R W B Br L W G R W OFF ON Gy B R Br Br L R Y Br Y Br L Br L R W R W Br Y Br Y B Y R Y L Y Y L Y L Y Y B B Y G R R L B G Y B W L W B W B G R G Y Br B B W B W B W B W Br Y Br Y Br Y Br Y L B Sb L P GyW B Gy G W R B W Y G W R Gy G Y L L B Sb P Y L W G Y Br W R B Gy G W R W R G G R L Y R Y L R Y R Lg G R L W P W B G O L R L Y B B R B Y W G W B Y W W G P L R G R W R W ...

Page 361: ...ay 9 Engine ground 10 Starter motor 11 Joint coupler 16 ECU Engine Control Unit 27 Gear position switch 45 Start switch 46 Engine stop switch 54 Rear brake light switch 60 Signaling system fuse 61 Ignition fuse 66 Frame ground 1 A Wire harness B Negative battery sub wire harness ...

Page 362: ...tion switch is closed The transmission is in park the park switch circuit of the gear position switch is closed The rear brake lever is pulled to the handlebar or the brake pedal is pushed down the rear brake light switch circuit is closed 13 1 2 3 4 5 6 7 8 9 10 11 12 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Start switch 7 Signaling system fuse 8 Rear brake light...

Page 363: ...battery terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 9 92 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 42 Repair or replace the starter motor 5 Check the starter relay Refer to CHECKING THE ...

Page 364: ...eft 9 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 9 81 Replace the rear brake light switch 10 Check the gear position switch Refer to CHECKING THE SWITCHES on page 9 81 Replace the gear position switch 11 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM on page 9 5 Properly connect or repair the starting sys tem wiring Replace the ECU ...

Page 365: ...ELECTRIC STARTING SYSTEM 9 10 ...

Page 366: ...B B Y Y W ON OFF OFF PUSH A R W R B Br Y R Y G L B G Y L Y B Gy B R Br Br L R Y Br Y Br L Br L R W R W Br Y Br Y B Y R Y L Y Y L Y L Y Y B B B B Br Br R B Br Lg R BY R R B L L B B B B B Y Y L G G Y B L B Y Y Y G Y Y G L L Br Br Br Br P B B B B B G P W B R R W W W W W W B L B R L Br Br L L L L L Br Br Br R L R W R W R L R W R W W W Br B Br B R R Y L Y Br B R W R R B B B B B R R Y L B W B B B B B Y ...

Page 367: ...CHARGING SYSTEM 9 12 2 AC magneto 3 Rectifier regulator 5 Main fuse 6 Battery 9 Engine ground 66 Frame ground 1 67 Frame ground 2 A Wire harness B Negative battery sub wire harness ...

Page 368: ...er to CHECKING AND CHARGING THE BATTERY on page 9 85 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 9 93 The stator coil is faulty Replace the crank shaft position sensor stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 9 93 Replace the rectifier regulator 5 Check the en...

Page 369: ...CHARGING SYSTEM 9 14 ...

Page 370: ... G L B G Y L Y B R G P L R W B Br L W G R W OFF ON Gy B R Br Br L R Y Br Y Br L Br L R W R W Br Y Br Y B Y R Y L Y Y L Y L Y Y B B Y G R R L B G Y B W L W B W B G R G Y Br B B W B W B W B W Br Y Br Y Br Y Br Y L B Sb L P GyW B Gy G W R B W Y G W R Gy G Y L L B Sb P Y L W G Y Br W R B Gy G W R W R G G R L Y R Y L R Y R Lg G R L W P W B G O L R L Y B B R B Y W G W B Y W W G P L R G R W R W P L Br L ...

Page 371: ...e 6 Battery 9 Engine ground 11 Joint coupler 47 Light switch 48 Handle mounted light 49 Headlight 50 Headlight relay 2 51 Headlight relay 1 52 Tail brake light 59 Headlight fuse 66 Frame ground 1 A Wire harness B Negative battery sub wire harness ...

Page 372: ...ses Main and headlight Refer to CHECKING THE FUS ES on page 9 84 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 9 85 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 9 81 Replace the main switch 5 Check the light switch Refer to CHECKING THE SWITCHES on page 9 81 The light switch is...

Page 373: ...NG SYSTEM 9 18 NG OK 8 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 9 15 Properly connect or repair the lighting sys tem wiring Replace the headlight unit or tail brake light unit ...

Page 374: ...Y G L B G Y L Y B R G P L R W B Br L W G R W OFF ON Gy B R Br Br L R Y Br Y Br L Br L R W R W Br Y Br Y B Y R Y L Y Y L Y L Y Y B B Y G R R L B G Y B W L W B W B G R G Y Br B B W B W B W B W Br Y Br Y Br Y Br Y L B Sb L P GyW B Gy G W R B W Y G W R Gy G Y L L B Sb P Y L W G Y Br W R B Gy G W R W R G G R L Y R Y L R Y R Lg G R L W P W B G O L R L Y B B R B Y W G W B Y W W G P L R G R W R W P L Br L...

Page 375: ...warning light 32 Park indicator light 33 Reverse indicator light 34 Neutral indicator light 35 High range indicator light 36 Low range indicator light 38 Differential motor 39 Fuel sender 44 Override switch 52 Tail brake light 53 Diode 54 Rear brake light switch 55 Front brake light switch 60 Signaling system fuse 61 Ignition fuse 66 Frame ground 1 68 Horn switch except for CDN 69 Horn except for ...

Page 376: ...1 Check the fuses Main ignition and signaling sys tem Refer to CHECKING THE FUS ES on page 9 84 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 9 85 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 9 81 Replace the main switch 4 Check the entire signaling system wiring Refer to CIRCU...

Page 377: ...page 9 19 Properly connect or repair the signaling system wiring Replace the tail brake light unit or ECU 1 Check the gear position switch Refer to CHECKING THE SWITCHES on page 9 81 Replace the gear position switch 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 9 19 Properly connect or repair the signaling system wiring Replace the meter assembly or ECU 1 Check the re...

Page 378: ... the differential motor 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 9 19 Properly connect or repair the signaling system wiring Replace the meter assembly or ECU 1 Check the override switch Refer to CHECKING THE SWITCHES on page 9 81 The override switch is faulty Replace the handlebar switch left 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on...

Page 379: ... the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 9 19 Properly connect or repair the signaling system wiring Replace the meter assembly 1 Check the speed sensor Refer to CHECKING THE SPEED SENSOR on page 9 94 Replace the speed sensor 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 9 19 Properly connect or repair the signaling system wiring Replace th...

Page 380: ...G L B G Y L Y B R G P L R W B Br L W G R W OFF ON Gy B R Br Br L R Y Br Y Br L Br L R W R W Br Y Br Y B Y R Y L Y Y L Y L Y Y B B Y G R R L B G Y B W L W B W B G R G Y Br B B W B W B W B W Br Y Br Y Br Y Br Y L B Sb L P GyW B Gy G W R B W Y G W R Gy G Y L L B Sb P Y L W G Y Br W R B Gy G W R W R G G R L Y R Y L R Y R Lg G R L W P W B G O L R L Y B B R B Y W G W B Y W W G P L R G R W R W P L Br L B...

Page 381: ...11 Joint coupler 16 ECU Engine Control Unit 21 Coolant temperature sensor 56 Radiator fan motor 57 Radiator fan motor circuit breaker 58 Radiator fan motor relay 61 Ignition fuse 64 Radiator fan motor fuse 66 Frame ground 1 A Wire harness B Negative battery sub wire harness ...

Page 382: ...harge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 9 81 Replace the main switch 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 9 94 The radiator fan motor is faulty and must be replaced 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 9 88 Replace the radiator fan motor relay 6 Check the radiator f...

Page 383: ...COOLING SYSTEM 9 28 NG OK 8 Check the entire cooling system wiring Refer to CIRCUIT DIAGRAM on page 9 25 Properly connect or repair the cooling sys tem wiring Replace the ECU ...

Page 384: ... Y R Y G L B G Y L Y B R G P L R W B Br L W G R W OFF ON Gy B R Br Br L R Y Br Y Br L Br L R W R W Br Y Br Y B Y R Y L Y Y L Y L Y Y B B Y G R R L B G Y B W L W B W B G R G Y Br B B W B W B W B W Br Y Br Y Br Y Br Y L B Sb L P GyW B Gy G W R B W Y G W R Gy G Y L L B Sb P Y L W G Y Br W R B Gy G W R W R G G R L Y R Y L R Y R Lg G R L W P W B G O L R L Y B B R B Y W G W B Y W W G P L R G R W R W P L...

Page 385: ...nit 17 Ignition coil 18 Spark plug 19 Fuel injector 20 Intake air temperature sensor 21 Coolant temperature sensor 22 Speed sensor 23 TPS throttle position sensor 24 Intake air pressure sensor 25 Lean angle sensor 26 Air induction system solenoid 27 Gear position switch 29 Multi function meter 30 Engine trouble warning light 40 Fuel pump 46 Engine stop switch 58 Radiator fan motor relay 61 Ignitio...

Page 386: ...Engine trouble warning light indication and fuel injection system operation The warning light flashes when any one of the conditions listed below is present and the start switch is pushed Checking for a defective engine trouble warning light bulb The engine trouble warning light comes on for around 2 seconds after the main switch has been turned to on If the warning light does not come on under th...

Page 387: ...the malfunction history in the diagnostic mode code No 62 Refer to SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 10 7 TIP Turning the main switch to off will not erase the malfunction history The engine operation is not normal but the engine trouble warning light does not come on 1 Check the operation of the following sensors and actuators in the diagnostic mode Refer to TROUBLESHOOTI...

Page 388: ...ignition timing Connecting the Yamaha diagnostic tool Remove the protective cap and then connect the Yamaha diagnostic tool to the coupler 1 TIP When the Yamaha diagnostic tool is connected to the vehicle the operation of the multi function meter and indicators will be different from the normal operation Yamaha diagnostic tool 90890 03231 Fault diagnosis mode Fault codes recorded on the ECU are re...

Page 389: ...st of the malfunction detected in the past already recovered are displayed 2 Detected The item list of the malfunction currently occurred are displayed 3 Code The following icons and the fault code numbers for the detected malfunctions are displayed 4 ECU The types of the control units are displayed 2 3 1 4 5 6 7 8 9 10 11 12 A B A Detected malfunction B Recovered malfunction ...

Page 390: ...OOTING DETAILS FUEL INJECTION SYSTEM This section describes the measures per fault code number displayed on the Yamaha diagnostic tool or multi function meter display Check and service the items or components that are the probable cause of the malfunction following the order given After the check and service of the malfunctioning part has been completed reset the Yamaha diagnos tic tool or multi f...

Page 391: ...ness Between crankshaft position sensor coupler and ECU cou pler gray gray Between crankshaft position sensor coupler and joint cou pler black blue black blue Between joint coupler and ECU coupler black blue black blue Crank the engine Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Installed condition of crank shaft position sensor Check for l...

Page 392: ...r broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to on Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between intake air pressure sensor coupler and ECU cou pler pink pi...

Page 393: ...ot change when engine is cranking Check the intake air pressure sensor Replace if defective Refer to CHECKING THE IN TAKE AIR PRESSURE SEN SOR on page 9 97 Turn the main switch to on Fault code number is not dis played Service is finished Fault code number is displayed Go to item 6 6 Malfunction in ECU Replace the ECU Fault code No 13 Item Intake air pressure sensor open or short circuit detected ...

Page 394: ... m 3300 ft above sea lev el Approx 90 kPa 675 1 mmHg 26 6 inHg 2000 m 6700 ft above sea lev el Approx 80 kPa 600 0 mmHg 23 6 inHg 3000 m 9800 ft above sea lev el Approx 70 kPa 525 0 mmHg 20 7 inHg When engine is cranking Make sure that the indication value changes The value does not change when engine is cranking Check the intake air pressure sensor Replace if defective Refer to CHECKING THE IN TA...

Page 395: ...r blue blue black blue black blue Turn the main switch to on Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Installed condition of throttle po sition sensor Check for looseness or pinch ing Improperly installed sensor Reinstall or adjust the sensor Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 7 7 Turn the main switch to on Fault co...

Page 396: ... Reinstall or adjust the sensor Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 7 7 Turn the main switch to on then push the throttle le ver Fault code number is not dis played Service is finished Fault code number is displayed Go to item 2 2 Defective throttle position sen sor Check throttle position sensor signal Execute the diagnostic mode Code No 01 When the throttle valve is fully cl...

Page 397: ...etween coolant temperature sensor coupler and ECU cou pler green yellow green yellow Between coolant temperature sensor coupler and joint cou pler black blue black blue Between joint coupler and ECU coupler black blue black blue Turn the main switch to on Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Installed condition of coolant temperature...

Page 398: ...Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to on Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Wire harness continuity Open or short circuit R...

Page 399: ...re Remove the lean angle sensor and incline it more than 65 degrees Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 The vehicle has overturned Raise the vehicle upright Turn the main switch to on then to off and then back to on Fault code number is not dis played Service is finished Fault code number is displayed Go to item 2 2 Installed conditio...

Page 400: ...heck the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between ignit...

Page 401: ... tool screen come on during the operation Procedure The operating sound can be heard when ISC valve operates Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion A 1 Locate the malfunction Execute the diagnostic mode Code No 54 Fully closes the ISC Idle Speed Control valve and then fully opens the valve ISC operating sound is heard Go to item A 2 ISC op...

Page 402: ...oses the ISC Idle Speed Control valve and then fully opens the valve ISC operating sound is heard Go to item A 2 for the compo nent other than ISC Idle Speed Control unit is defective ISC operating sound is not heard Go to item B 2 B 2 Connection of ISC Idle Speed Control unit coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and ...

Page 403: ...dy as sembly Execute the diagnostic mode Code No 54 ISC operating sound is heard Go to item B 8 ISC operating sound is not heard Go to item B 7 B 7 Malfunction in ECU Replace the ECU B 8 Delete the fault code Start the engine and let it idle for approximately 10 seconds Check that the fault code num ber is not displayed Fault code No 37 Item A Component other than ISC Idle Speed Control unit is de...

Page 404: ... re place the wire harness Execute the diagnostic mode Code No 36 Operating sound Go to item 6 No operating sound Go to item 4 4 Wire harness continuity Open or short circuit Replace the wire harness Between fuel injector coupler and ECU coupler red black red black Between fuel injector coupler and joint coupler red blue red blue Execute the diagnostic mode Code No 36 Operating sound Go to item 6 ...

Page 405: ...played Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between lean angle sensor coupler and ECU coupler yellow green yellow green Between lean angle sensor coupler and joint coupler blue blue black blue black blue Between joint coupler and ECU coupler blue blue black blue black blue Turn the main switch to on then to off and then back to on Fault code number ...

Page 406: ...6 Fault code number is displayed Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between speed sensor coupler and joint coupler white white Between joint coupler and ECU coupler white white Between speed sensor coupler and joint coupler blue blue black blue black blue Between joint coupler and ECU coupler blue blue black blue black blue Turn the main switch to...

Page 407: ...rocedure Check that the fuel injection system relay is actuated five times by listen ing for the operating sound Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of fuel injection sys tem relay coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of t...

Page 408: ...ne and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is displayed Go to item 5 5 Defective fuel injection system relay Execute the diagnostic mode Code No 09 Fuel system voltage is below 3 V Replace the fuel injection system relay Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Serv...

Page 409: ...idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is displayed Repeat the maintenance job Fault code No 50 Item Faulty ECU Engine Control Unit memory When this malfunction is detected in the ECU the fault code number might not appear Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No Indicated Procedure Item P...

Page 410: ...Service is finished Fault code number is displayed Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between meter assembly cou pler and ECU coupler yellow blue yellow blue Turn the main switch to on Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Defective meter assembly Replace the meter assembly Turn the m...

Page 411: ...t code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Defective meter assembly Replace the meter assembly Turn the main switch to on Fault code number is not dis played Service is finished Fault code number is displayed Go to item 5 5 Malfunction in ECU Replace the ECU Fault code No Er 2 Item ECU Engine Control Unit internal malfunction output signal err...

Page 412: ...n output signal error data from the ECU cannot be received correctly Fault code No Er 4 Item ECU Engine Control Unit internal malfunction input signal error non registered data has been received from the meter assembly Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Indicated Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of serv...

Page 413: ...ed Service is finished Fault code number is displayed Go to item 4 4 Defective meter assembly Replace the meter assembly Turn the main switch to on Fault code number is not dis played Service is finished Fault code number is displayed Go to item 5 5 Malfunction in ECU Replace the ECU Fault code No Er 4 Item ECU Engine Control Unit internal malfunction input signal error non registered data has bee...

Page 414: ...Y G L B G Y L Y B R G P L R W B Br L W G R W OFF ON Gy B R Br Br L R Y Br Y Br L Br L R W R W Br Y Br Y B Y R Y L Y Y L Y L Y Y B B Y G R R L B G Y B W L W B W B G R G Y Br B B W B W B W B W Br Y Br Y Br Y Br Y L B Sb L P GyW B Gy G W R B W Y G W R Gy G Y L L B Sb P Y L W G Y Br W R B Gy G W R W R G G R L Y R Y L R Y R Lg G R L W P W B G O L R L Y B B R B Y W G W B Y W W G P L R G R W R W P L Br L...

Page 415: ...6 Battery 7 Fuel injection system fuse 9 Engine ground 11 Joint coupler 12 Fuel injection system relay 16 ECU Engine Control Unit 40 Fuel pump 46 Engine stop switch 61 Ignition fuse 66 Frame ground 1 A Wire harness B Negative battery sub wire harness ...

Page 416: ... the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 9 81 Replace the main switch 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 9 81 The engine stop switch is faulty Replace the handlebar switch left 5 Check the fuel injection system re lay Refer to CHECKING THE RE LAYS on page 9 88 Replace the fuel injection ...

Page 417: ...FUEL PUMP SYSTEM 9 62 ...

Page 418: ... Br Y R Y G L B G Y L Y B R G P L R W B Br L W G R W OFF ON Gy B R Br Br L R Y Br Y Br L Br L R W R W Br Y Br Y B Y R Y L Y Y L Y L Y Y B B Y G R R L B G Y B W L W B W B G R G Y Br B B W B W B W B W Br Y Br Y Br Y Br Y L B Sb L P GyW B Gy G W R B W Y G W R Gy G Y L L B Sb P Y L W G Y Br W R B Gy G W R W R G G R L Y R Y L R Y R Lg G R L W P W B G O L R L Y B B R B Y W G W B Y W W G P L R G R W R W ...

Page 419: ...ECU Engine Control Unit 37 On Command four wheel drive motor switch and differential lock switch 38 Differential motor 41 Four wheel drive motor relay 1 42 Four wheel drive motor relay 2 61 Ignition fuse 62 Four wheel drive motor fuse 66 Frame ground 1 A Wire harness B Negative battery sub wire harness ...

Page 420: ...3 Check the main switch Refer to CHECKING THE SWITCHES on page 9 81 Replace the main switch 4 Check the On Command four wheel drive motor switch and differ ential lock switch Refer to CHECKING THE SWITCHES on page 9 81 Replace the On Command four wheel drive motor switch and differential lock switch 5 Check the four wheel drive motor relay 1 Refer to CHECKING THE RE LAYS on page 9 88 Replace the f...

Page 421: ...WD 4WD SELECTING SYSTEM 9 66 NG OK 8 Check the entire 2WD 4WD select ing system wiring Refer to CIRCUIT DIAGRAM on page 9 63 Properly connect or repair the 2WD 4WD selecting system wiring Replace the ECU ...

Page 422: ... OFF PUSH LOCK 4WD 2WD A R W R B Br Y R Y G L B G Y L Y B R G P L R W B Br L W G R W OFF ON Gy B R Br Br L R Y Br Y Br L Br L R W R W Br Y B Y R Y L Y L Y L Y Y B B Y G R R L B G Y B W L W B W B G R G Y Br B B W G R B W B W B W Br Y Br Y Br Y Br Y L B Sb L P GyW B Gy G W R B W Y G W R Gy G Y L L B Sb P Y L W G Y Br W R B Gy O W G W R W R G G R L Y R Y L R Y R Lg G R L W P W B G O L R L Y B B R B Y...

Page 423: ...Joint coupler 13 EPS torque sensor 14 EPS motor 15 EPS electric power steering control unit 16 EPS self diagnosis signal connector 21 ECU Engine Control Unit 27 Speed sensor 42 EPS warning light 67 Ignition fuse 72 Frame ground 1 A Wire harness B Negative battery sub wire harness C EPS electric power steering control unit ...

Page 424: ... be defective TIP If the engine is stopped using the engine stop switch and the main switch is in the on position the EPS warning light comes on to indicate that the power assistance for the steering is not function ing If the steering usage is too heavy i e excessive steering use when the vehicle is traveling at a slow speed the power assist is reduced to protect the EPS motor from overheating EB...

Page 425: ...esent fault codes Past malfunction signaling mode While the present malfunction mode is activated briefly disconnect the connector 1 ground it again and leave it grounded The signaling mode is activated after 5 seconds The EPS warning light starts to show past fault codes 4 Turn the main switch to off to cancel the diagnostic mode TIP The diagnostic mode can also be canceled by riding the vehicle ...

Page 426: ... k h i b e d c f B A 5 5 2 0 5 3 0 5 5 1 3 2 j a EPS self diagnosis signal connector b Diagnostic mode c EPS warning light d Disconnected e On f Off g Grounded h Normal mode diagnostic mode not activated i Mode selection judgment j Present malfunction signaling mode k Past malfunction signaling mode A The EPS warning light comes on for 5 seconds during the diagnostic mode selection judgment B Disp...

Page 427: ... EPS self diagnosis signal connector b Disconnected c Grounded Fault code No Item Symptom Probable cause of mal function 11 13 15 16 EPS torque sensor No normal signals are received from the torque sensor Open or short circuit in wire harness Malfunction in torque sen sor Malfunction in EPS control unit 21 Speed sensor No normal signals are received from the speed sensor Open or short circuit in w...

Page 428: ... in the charging system Refer to CHARGING SYSTEM on page 9 11 Malfunction in EPS control unit Fault code No Item Symptom Probable cause of mal function Fault code No 11 13 15 16 Symptom EPS torque sensor no normal signals are received from the EPS torque sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections EPS torque sensor coupler Check the l...

Page 429: ...pen or short circuit Between speed sensor coupler and joint coupler white white Between joint coupler and EPS control unit coupler white white 3 Defective speed sensor Replace if defective Refer to CHECKING THE SPEED SENSOR on page 9 94 4 Malfunction in EPS control unit Replace the EPS control unit Fault code No 22 Symptom No normal signals are received from the ECU Order Item components and proba...

Page 430: ... red red black black 3 Defective EPS motor Replace if defective Refer to CHECKING THE EPS MO TOR for EPS models on page 9 98 4 Malfunction in EPS control unit Replace the EPS control unit Fault code No 52 Symptom Relay contacts in the EPS control unit are welded together Order Item components and probable cause Check or maintenance job Reinstatement method 1 Malfunction in EPS control unit Replace...

Page 431: ...t Turning the main switch to off Fault code No 55 Symptom Battery voltage has increased Abnormality exists between the EPS and the ECU Order Item components and probable cause Check or maintenance job Reinstatement method 1 Faulty battery Replace the battery Refer to CHECKING AND CHARGING THE BATTERY on page 9 85 Turning the main switch to off 2 Malfunction in rectifier regulator Replace if defect...

Page 432: ...ELECTRICAL COMPONENTS 9 77 EBS20084 ELECTRICAL COMPONENTS 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 18 1 2 3 ...

Page 433: ... Main fuse 8 Fuse box ignition headlights four wheel drive motor radiator fan motor signaling system auxiliary DC jack 9 Radiator fan motor circuit breaker 10 Rectifier regulator 11 Reverse switch 12 Gear position switch 13 Auxiliary DC jack 14 Main switch 15 Differential motor 16 EPS torque sensor for EPS models 17 EPS motor for EPS models 18 Horn except for CDN 19 Radiator fan motor ...

Page 434: ...ELECTRICAL COMPONENTS 9 79 1 2 3 5 7 8 9 10 11 12 13 14 15 16 17 18 19 4 6 ...

Page 435: ...ar brake light switch 7 Intake air temperature sensor 8 Intake air pressure sensor 9 TPS throttle position sensor 10 ISC Idle Speed Control unit 11 Fuel pump 12 Speed sensor 13 Crankshaft position sensor 14 Coolant temperature sensor 15 Ignition coil 16 Air induction system solenoid 17 Battery 18 ECU Engine Control Unit 19 EPS control unit for EPS models ...

Page 436: ... Br Y Y W 10 ON OFF R Br L Br L W G R B 12 Br P P B BLACK B Br 1 Main switch 2 Light switch 3 Engine stop switch 4 Start switch 5 Override switch 6 On Command four wheel drive motor switch and differential gear lock switch 7 Four wheel drive motor switch differential motor 8 Gear position switch 9 Reverse switch 10 Rear brake light switch 11 Front brake light switch 12 Horn switch except for CDN ...

Page 437: ...ocket tester to 0 and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch t...

Page 438: ...03000 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of a handle mounted light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the handle mounted light bulb gets soiled thoroughly c...

Page 439: ...TIP Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Set the main switch to off b Install a new fuse of the correct amperage rating c Set the switch es to on to verify if the electri cal circuit is operational d If the fuse immediately blows again check the electrical circuit WARNING EWB03660 Never use a fuse with an amperage rating oth...

Page 440: ...390 This is a VRLA Valve Regulated Lead Acid battery Never remove the sealing caps be cause the balance between cells will not be maintained and battery performance will deteriorate Charging time charging amperage and charging voltage for a VRLA Valve Regu lated Lead Acid battery are different from those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged as expl...

Page 441: ...s are connected to the battery Before removing the battery 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 terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes...

Page 442: ...re than 30 minutes Charging method using a constant volt age charger a Measure the open circuit voltage prior to charging TIP Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery TIP If the current is lower than the standa...

Page 443: ...ry 12 V to the relay terminal as shown Check the relay operation Out of specification Replace Starter relay Headlight relay 1 Headlight relay 2 Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe L Y R Y Br BR W R B 2 1 4 3 Result Continuity between ...

Page 444: ...inal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 R W 1 Positive tester probe 2 Negative tester probe 3 Negative tester probe Result Continuity between 1 and 2 No continuity between 1 and 3 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe Result No continu...

Page 445: ...the spark plug cap from the spark plug lead b Connect the pocket tester Ω 1k to the spark plug cap as shown 1 Positive tester probe 2 Negative tester probe 3 Negative tester probe Result Continuity between 1 and 2 No continuity between 1 and 3 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe Result No continuity between...

Page 446: ...BS30302 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace the crank shaft position sensor stator assembly a Connect the pocket tester Ω 100 to the crankshaft position sensor coupler as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Primary coil res...

Page 447: ...g starting with step 4 Refer to TROUBLESHOOTING on page 10 1 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWB03700 A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity ...

Page 448: ...re the charging voltage EBS30307 CHECKING THE FUEL SENDER 1 Disconnect Fuel pump coupler from the wire harness 2 Remove Fuel pump assembly from the fuel tank 3 Check Fuel sender resistance Out of specification Replace the fuel pump assembly a Connect the pocket tester Ω 10 to the fuel sender terminal as shown Stator coil resistance 0 15 0 22 Ω Pocket tester 90890 03112 Analog pocket tester YU 0311...

Page 449: ...oltage reading should cycle from 0 6 V to 4 8 V to 0 6 V to 4 8 V EBS30310 CHECKING THE RADIATOR FAN MOTOR 1 Check Radiator fan motor Faulty rough movement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect the battery DC 12 V as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe green yellow 1 Negative tester probe black white 2 ...

Page 450: ...re sensor with special care Never subject the coolant temperature sen sor to strong shocks If the coolant tem perature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 100 to the coolant temperature sensor terminals as shown b Immerse the coolant temperature sensor 1 in a container filled with coolant 2 TIP Make s...

Page 451: ... the fuel injector coupler from wire harness b Connect the pocket tester Ω 1 to the fuel injector terminals as shown c Measure the fuel injector resistance EBS30317 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 1 Check Air induction system solenoid resistance Out of specification Replace a Disconnect the air induction system solenoid coupler from the wire harness b Connect the pocket tester Ω 1 to th...

Page 452: ... it 2 Check Intake air temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 100 to the in take air temperature sensor terminal as shown b Immerse the intake air temperature sensor 1 in a container filled with water 2 TIP Make sure that the air temperature sensor termi nals do not get wet c Place a thermometer 3 in the water d Slowly heat the water then let it co...

Page 453: ...Check EPS torque sensor resistance Out of specification Replace the EPS unit a Connect the pocket tester Ω 1k to the EPS torque sensor coupler terminal as shown b Measure the EPS torque sensor resistance Continuity Positive tester probe red 1 Negative tester probe black 2 No continuity Positive tester probe red 1 Negative tester probe EPS motor body 3 No continuity Positive tester probe black 2 Ne...

Page 454: ...ELECTRICAL COMPONENTS 9 99 ...

Page 455: ... MOVE 10 4 JUMPS OUT OF GEAR 10 4 FAULTY CLUTCH 10 4 OVERHEATING 10 4 OVERCOOLING 10 5 POOR BRAKING PERFORMANCE 10 5 FAULTY SHOCK ABSORBER ASSEMBLY 10 5 UNSTABLE HANDLING 10 5 FAULTY LIGHTING OR SIGNALING SYSTEM 10 5 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 10 7 SELF DIAGNOSTIC FUNCTION TABLE 10 7 COMMUNICATION ERROR WITH THE METER 10 7 DIAGNOSTIC CODE SENSOR OPERATION TABLE 10 7 DIAGNOS...

Page 456: ...rated or contaminated fuel 2 Fuel pump Faulty fuel pump Faulty fuel injection system relay Clogged or damaged fuel hose 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug...

Page 457: ...l Broken or shorted primary or secondary coils Faulty spark plug lead Cracked or broken ignition coil 4 Ignition system Faulty ECU Faulty crankshaft position sensor Broken AC magneto rotor woodruff key 5 Valve train Improperly adjusted valve clearance Improperly adjusted valve timing EBS30324 POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to STARTING FAILURES on page 10 1 Engine 1 Air filter Clogged...

Page 458: ...1 A pronounced hesitation or jerky movement during acceleration deceleration or sustained speed This must not be confused with engine surging or transmission characteristics 2 A rolling rumble noticeable at low speed a high pitched whine a clunk from a shaft drive com ponent or area 3 A locked up condition of the shaft drive mecha nism no power transmitted from the engine to the front and or rear ...

Page 459: ... Damaged or worn clutch shoe 3 Primary sliding sheave Seized primary sliding sheave Poor starting performance 1 V belt V belt slips Oil or grease on the V belt 2 Primary sliding sheave Faulty operation Worn pin groove Worn pin 3 Clutch shoe Bent damaged or worn clutch shoe Poor speed performance 1 V belt Oil or grease on the V belt 2 Primary pulley weight s Faulty operation Worn primary pulley wei...

Page 460: ... absorber spring Bent or damaged damper rod EBS30334 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering Incorrect toe in Bent steering stem Improperly installed steering stem Damaged bearing or bearing race Bent tie rods Deformed steering knuckles 3 Shock absorber Faulty shock absorber spring Leaking oil 4 Tire s Uneven tire pressures left and right Incorrect tire pres...

Page 461: ...TROUBLESHOOTING 10 6 Too many electrical accessories Incorrect connection Faulty tail brake light assembly ...

Page 462: ...n coil 37 Component other than ISC Idle Speed Control unit is defective ISC operating sound is heard Defective ISC Idle Speed Control unit ISC operating sound is not heard 39 Fuel injector open or short circuit detected 41 Lean angle sensor open or short circuit detected 42 Speed sensor no normal signals are received from the speed sensor 43 Fuel system voltage incorrect voltage supplied to the fu...

Page 463: ...number in creases when the rear wheels are rotated The number is cumulative and does not reset each time the wheel is stopped 08 Lean angle sensor output voltage Remove the lean angle sen sor and incline it more than 65 degrees Upright 3 6 4 4 Overturned 0 7 1 3 09 Fuel system voltage battery voltage Approximately 12 0 Turn the main switch to on and then compare the actually measured battery volta...

Page 464: ... Yamaha diagnostic tool screen come on each time the fuel injector is actuated Disconnect the fuel pump coupler and then check that fuel injector is actuated five times by listening for the oper ating sound 48 Air induction system solenoid Actuates the air induction sys tem solenoid five times at one second intervals The CHECK indicator and on the Yamaha diagnostic tool screen come on each time th...

Page 465: ...the Yamaha diagnostic tool screen go off When the relay is off the CHECK indicator and on the Yamaha diagnostic tool screen come on Check that the radiator fan motor relay is actuated five times by listening for the oper ating sound 54 ISC valve Fully closes the ISC valve and then opens the valve This oper ation takes approximately 3 sec onds The CHECK indicator and on the Yamaha diagnostic tool s...

Page 466: ...ay 59 Headlight fuse 60 Signaling system fuse 61 Ignition fuse 62 Four wheel drive motor fuse 63 Auxiliary DC jack fuse 64 Radiator fan motor fuse 65 Auxiliary DC jack 66 Frame ground 1 67 Frame ground 2 68 Horn switch except for CDN 69 Horn except for CDN A Wire harness B Negative battery sub wire har ness YF70GPG YF70GPSG YF70GPL G YFM70GPXG YFM70GPHG YF M70GPSG YFM70GPLG YFM70 0FWAD 2016 1 Cran...

Page 467: ...e battery sub wire har ness C EPS electric power steering control unit EBS30002 COLOR CODE B Black Br Brown G Green Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Yellow B G Black Green B L Black Blue B R Black Red B W Black White B Y Black Yellow Br B Brown Black Br L Brown Blue Br W Brown White Br Y Brown Yellow G L Green Blue G R Green Red G W Green White G Y Green Ye...

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Page 471: ...Y B R G P L R W B Br L W G R W OFF ON Gy B R Br Br L R Y Br Y Br L Br L R W R W Br Y Br Y B Y R Y L Y Y L Y L Y Y B B Y G R R L B G Y B W L W B W B G R G Y Br B B W B W B W B W Br Y Br Y Br Y Br Y L B Sb L P GyW B Gy G W R B W Y G W R Gy G Y L L B Sb P Y L W G Y Br W R B Gy G W R W R G G R L Y R Y L R Y R Lg G R L W P W B G O L R L Y B B R B Y W G W B Y W W G P L R G R W R W P L Br L Br Br L O O R...

Page 472: ... Gy Gy B B Gy Gy B B A B B A B ON OFF OFF PUSH LOCK 4WD 2WD A OFF ON B B 1 2 3 4 5 6 7 8 9 10 11 11 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 49 49 51 50 52 53 55 54 56 57 58 59 60 61 62 63 64 65 66 67 48 69 68 ...

Page 473: ... A R W R B Br Y R Y G L B G Y L Y B R G P L R W B Br L W G R W OFF ON Gy B R Br Br L R Y Br Y Br L Br L R W R W Br Y B Y R Y L Y L Y L Y Y B B Y G R R L B G Y B W L W B W B G R G Y Br B B W G R B W B W B W Br Y Br Y Br Y Br Y L B Sb L P GyW B Gy G W R B W Y G W R Gy G Y L L B Sb P Y L W G Y Br W R B Gy O W G W R W R G G R L Y R Y L R Y R Lg G R L W P W B G O L R L Y B B R B Y W G W B Y W W G P L R...

Page 474: ...B Gy B Gy B B B Gy B B B B Gy B B Gy Gy B B Gy Gy B B A B B A B OFF ON B B B B B B Gy Gy Gy Gy B 1 2 3 4 5 6 7 8 9 10 11 12 12 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 55 55 57 56 58 59 61 60 62 63 64 65 66 67 68 69 70 71 72 73 54 A B 75 74 B C ...

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