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Yamaha GRIZZLY 700 FI YFM7FGPW, Service Manual

The Yamaha GRIZZLY 700 FI YFM7FGPW is a powerful all-terrain vehicle designed for adventure seekers. Enhance your riding experience by accessing the comprehensive Owner's Manual, available for free download at our website. This manual provides valuable information to assist you in operating and maintaining your Yamaha GRIZZLY 700 FI YFM7FGPW.

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CHK

ADJ

CHECKING AND CHARGING THE BATTERY

• If the battery becomes hot to the touch at

any time during the charging process,
disconnect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!

• As shown in the following illustration, the

open-circuit voltage of an MF battery sta-
bilizes about 30 minutes after charging
has been completed. Therefore, wait 30
minutes after charging is completed
before measuring the open-circuit volt-
age.

Summary of Contents for GRIZZLY 700 FI YFM7FGPW

Page 1: ...LIT 11616 20 11 3B4 28197 10 YFM7FGPW SERVICE MANUAL ...

Page 2: ...6 by Yamaha Motor Corporation U S A First Edition May 2006 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A LIT 11616 20 11 ...

Page 3: ...e 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 its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE _ This Servic...

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

Page 5: ...Torque F Wear limit clearance G Engine speed H Electrical data Ω V A Symbols I to N in the exploded diagrams indicate the types of lubricants and lubrication points I Apply engine oil J Apply gear oil K Apply molybdenum disulfide oil L Apply wheel bearing grease M Apply lithium soap based grease N Apply molybdenum disulfide grease Symbols O to P in the exploded diagrams indicate where to apply a l...

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

Page 7: ...ANT INFORMATION 1 9 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 9 REPLACEMENT PARTS 1 9 GASKETS OIL SEALS AND O RINGS 1 9 LOCK WASHERS PLATES AND COTTER PINS 1 10 BEARINGS AND OIL SEALS 1 10 CIRCLIPS 1 10 CHECKING THE CONNECTIONS 1 11 SPECIAL TOOLS 1 12 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 5 CHASSIS SPECIFICATIONS 2 12 ELECTRICAL SPECIFICATIONS 2 14 TIGHTENING ...

Page 8: ...AINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM 3 1 GENERAL MAINTENANCE AND LUBRICATION CHART 3 2 ENGINE SKID PLATES SEAT CARRIERS AND FENDERS 3 4 ENGINE SKID PLATES 3 4 SEAT AND SIDE PANELS 3 5 FRONT CARRIER AND FRONT GUARD 3 6 FRONT FENDERS AND FRONT GRILL 3 8 REAR CARRIER AND REAR FENDER 3 9 ELECTRICAL COMPONENTS TRAY 3 10 ELECTRICAL COMPONENTS TRAY 1 2 3 10 ELECTRICAL COMPONENTS TRAY 2 2 3 12...

Page 9: ...TER 3 43 CHASSIS 3 44 ADJUSTING THE FRONT BRAKE 3 44 ADJUSTING THE REAR BRAKE 3 44 CHECKING THE BRAKE FLUID LEVEL 3 46 CHECKING THE FRONT BRAKE PADS 3 47 CHECKING THE REAR BRAKE PADS 3 48 CHECKING THE REAR BRAKE HOSE PROTECTORS 3 48 CHECKING THE BRAKE HOSES 3 49 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 49 ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD 3 51 CHECKING THE FINAL GEAR OIL LEVEL 3 ...

Page 10: ...HECKING THE TIMING CHAIN TENSIONER 4 13 CHECKING THE CYLINDER HEAD 4 14 INSTALLING THE CYLINDER HEAD 4 15 ROCKER ARMS AND CAMSHAFT 4 18 REMOVING THE ROCKER ARMS AND CAMSHAFT 4 20 CHECKING THE CAMSHAFT 4 20 CHECKING THE DECOMPRESSION SYSTEM 4 21 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 4 21 INSTALLING THE CAMSHAFT AND ROCKER ARMS 4 22 VALVES AND VALVE SPRINGS 4 25 REMOVING THE VALVES AND VALV...

Page 11: ...ARY SHEAVE 4 55 SECONDARY SHEAVE 4 56 REMOVING THE PRIMARY AND SECONDARY SHEAVES 4 57 DISASSEMBLING THE SECONDARY SHEAVE 4 57 CHECKING THE PRIMARY SHEAVE 4 58 CHECKING THE SECONDARY SHEAVE 4 58 ASSEMBLING THE PRIMARY SHEAVE 4 59 ASSEMBLING THE SECONDARY SHEAVE 4 60 INSTALLING THE PRIMARY AND SECONDARY SHEAVES 4 62 CLUTCH 4 63 REMOVING THE CLUTCH 4 65 CHECKING THE CLUTCH 4 66 INSTALLING THE CLUTCH ...

Page 12: ...4 87 INSTALLING THE TRANSMISSION 4 88 MIDDLE GEAR 4 89 MIDDLE DRIVE SHAFT 4 89 MIDDLE DRIVEN SHAFT 4 90 REMOVING THE MIDDLE DRIVE SHAFT 4 92 REMOVING THE MIDDLE DRIVEN SHAFT 4 93 CHECKING THE PINION GEARS 4 95 SELECTING MIDDLE DRIVE AND DRIVEN GEAR SHIMS 4 96 INSTALLING THE BEARING AND OIL SEALS 4 99 INSTALLING THE MIDDLE DRIVEN SHAFT 4 100 INSTALLING THE MIDDLE DRIVE SHAFT 4 102 MEASURING THE MID...

Page 13: ... FUEL TANK 6 30 REMOVING THE FUEL PUMP 6 30 CHECKING THE FUEL PUMP BODY 6 31 CHECKING THE ROLLOVER VALVE 6 31 INSTALLING THE FUEL PUMP 6 31 INSTALLING THE FUEL HOSE 6 32 THROTTLE BODY 6 33 REMOVING THE THROTTLE BODY ASSEMBLY 6 36 CHECKING THE FUEL INJECTOR 6 36 CHECKING THE THROTTLE BODY 6 36 INSTALLING THE THROTTLE BODY ASSEMBLY 6 37 CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 6 38 CH...

Page 14: ...E PINION GEAR ASSEMBLY 7 25 POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR 7 25 ADJUSTING THE FINAL DRIVE PINION GEAR BACKLASH 7 25 ADJUSTING THE FINAL DRIVEN PINION GEAR BACKLASH 7 27 MEASURING THE FINAL DRIVEN PINION GEAR THRUST WASHER CLEARANCE 7 29 MEASURING THE WHEEL GEAR THRUST CLEARANCE 7 30 CHECKING THE REAR DRIVE SHAFT 7 31 CHECKING THE FINAL DRIVE ASSEMBLY 7 31 MEASUREMENT THE FIN...

Page 15: ...31 REMOVING THE HANDLEBAR GRIPS 8 33 CHECKING THE HANDLEBAR 8 33 INSTALLING THE HANDLEBAR 8 33 INSTALLING THE HANDLEBAR GRIPS 8 34 INSTALLING THE REAR BRAKE MASTER CYLINDER 8 34 INSTALLING THE FRONT BRAKE MASTER CYLINDER 8 35 INSTALLING THE THROTTLE LEVER ASSEMBLY 8 35 STEERING STEM 8 36 CHECKING THE STEERING STEM 8 38 INSTALLING THE STEERING STEM 8 38 INSTALLING THE PITMAN ARM 8 40 TIE RODS AND S...

Page 16: ...ON OF THE BULBS 9 8 CHECKING THE CONDITION OF THE BULB SOCKETS 9 9 IGNITION SYSTEM 9 10 CIRCUIT DIAGRAM 9 10 TROUBLESHOOTING 9 11 ELECTRIC STARTING SYSTEM 9 16 CIRCUIT DIAGRAM 9 16 STARTING CIRCUIT OPERATION 9 17 TROUBLESHOOTING 9 18 STARTER MOTOR 9 22 CHECKING THE STARTER MOTOR 9 24 ASSEMBLING THE STARTER MOTOR 9 26 CHARGING SYSTEM 9 27 CIRCUIT DIAGRAM 9 27 TROUBLESHOOTING 9 28 LIGHTING SYSTEM 9 ...

Page 17: ...C MODE 9 61 SELF DIAGNOSTIC FUNCTION TABLE EPS SYSTEM 9 64 TROUBLESHOOTING DETAILS EPS SYSTEM 9 65 CHECKING THE EPS MOTOR 9 69 CHECKING THE EPS TORQUE SENSOR 9 69 CHAPTER 10 TROUBLESHOOTING STARTING FAILURE HARD STARTING 10 1 FUEL SYSTEM 10 1 ELECTRICAL SYSTEM 10 1 COMPRESSION SYSTEM 10 2 POOR IDLE SPEED PERFORMANCE 10 2 POOR IDLE SPEED PERFORMANCE 10 2 POOR MEDIUM AND HIGH SPEED PERFORMANCE 10 2 ...

Page 18: ...MANCE 10 4 POOR SPEED PERFORMANCE 10 5 OVERHEATING 10 5 OVERHEATING 10 5 OVERCOOLING 10 5 COOLING SYSTEM 10 5 FAULTY BRAKE 10 5 POOR BRAKING EFFECT 10 5 SHOCK ABSORBER MALFUNCTION 10 6 MALFUNCTION 10 6 UNSTABLE HANDLING 10 6 UNSTABLE HANDLING 10 6 LIGHTING SYSTEM 10 6 HEADLIGHT DOES NOT COME ON 10 6 BULB BURNT OUT 10 6 ...

Page 19: ...VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the front left side of the frame EBS00011 MODEL LABEL The model label 1 is affixed at the location in the illustration This information will be needed to order spare parts VEHICLE IDENTIFICATION ...

Page 20: ...ons of the engine As the requirements for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned man ner To accommodate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fu...

Page 21: ...ion and the injection timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake air tem perature sensor coolant temperature sensor lean angle sensor and speed sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor...

Page 22: ...ssembled Engine starting RPM information from ECU Battery 4 EPS control unit calculates assist power 5 Electricity output switched by EPS control unit 6 Activates EPS motor 3 Sends the torque sensor signal 1 Operates steering 2 Twists torsion bar EPS motor Torque sensor EPS unit Steering stem EPS control unit Speed information from speed sensor ...

Page 23: ...ghts EPS warning Engine trouble warning Coolant temperature warning Reverse indicator Neutral indicator Park indicator High range indicator Low range indicator Differential lock FI and EPS self diagnostic error codes Coolant temperature sensor signal Crankshaft position sensor signal Speed sensor signal ECU Fuel injector Fuel pump Ignition coil Intake air temperature sensor signal Throttle positio...

Page 24: ...otal time the key has been turned to ON a fuel meter a self diagnosis device 1 2 3 4 5 6 7 Odometer and tripmeter modes Pushing the SELECT button switches the display between the odometer mode ODO and the tripmeter modes A and B in the fol lowing order ODO TRIP A TRIP B ODO To reset a tripmeter select it by pushing the SELECT button and then push the RESET button for at least three seconds The tri...

Page 25: ...et the min utes 6 Push the SELECT button and then release it to start the clock Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The display segments of the fuel meter disappear from F full towards E empty as the fuel level decreases When the E segment disappears and the fuel level warning indicator flashes refuel as soon as possible NOTE This fuel meter is equipped with a s...

Page 26: ... are defective the multi function display will indicate a two digit error code If the multifunction display indicates such an error code note the code number and check the vehicle ECB00810 CAUTION If the multifunction display indicates an error code the vehicle should be checked as soon as possible in order to avoid engine damage 1 Error code display 1 ...

Page 27: ...all of the parts and place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EBS00014 REPLACEMENT PARTS 1 Use only genuine Yamaha parts for all replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance bu...

Page 28: ...isible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appro priate 1 Oil seal CAUTION _ Do not spin the bearing with compressed air because this will damage the bearing surfaces 1 Bearing EBS00018 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always re...

Page 29: ...al times 3 Check all connections Loose connection Connect properly NOTE _ If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE _ Make sure all connections are tight 5 Check continuity with the pocket tester NOTE _ If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer availa...

Page 30: ... YK ACC Except for US and CDN P N 90890 Tool No Tool name How to use Illustration 90890 01083 YU 01083 1 Slide hammer bolt Slide hammer bolt 6 mm This tool is used to remove the rocker arm shaft 90890 01084 YU 01083 3 Weight This tool is used to remove the rocker arm shaft 90890 01135 YU 01135 B Crankcase separating tool Crankcase separator This tool is used to separate the crank case 90890 01229 ...

Page 31: ...is used to install the crankshaft 90890 01304 YU 01304 Piston pin puller set Piston pin puller This tool is used to remove the piston pin 90890 01309 YU 90059 Spacer Pot spacer This tool is used to install the crankshaft 90890 01311 YM 08035 A Tappet adjusting tool Valve adjuster 3 mm 4 mm This tool is necessary for adjusting the valve clearance Tool No Tool name How to use Illustration YU 90058 Y...

Page 32: ...ester adapter Radiator pressure tester adapter This tool is used to check the cooling sys tem 90890 01362 YU 33270 B Flywheel puller Heavy duty puller This tool is used to remove the AC mag neto rotor 90890 01426 YU 38411 Oil filter wrench This tool is needed to loosen or tighten the oil filter cartridge 90890 01430 YM 38404 Ring nut wrench This tool is needed to removing and installing the middle...

Page 33: ... the final gear backlash 90890 01514 Ball joint remover short shaft set These tools are used to removing or installing the ball joints 90890 01701 YS 01880 A Sheave holder Primary clutch holder This tool is needed to hold the primary sheave when removing or installing the sheave nuts 90890 03079 YM 34483 Thickness gauge Narrow gauge set This tool is used to measure the valve clearance 90890 03081 ...

Page 34: ... check the electrical systems 90890 03176 YM 03176 Fuel pressure adapter This tool is used to measure fuel pres sure 90890 04019 YM 04019 Valve spring compressor This tool is used to remove or install the valve assemblies 90890 04058 YM 04058 Middle driven shaft bearing driver Bearing driver 40 mm This tool is used to install the water pump seal 90890 04064 YM 04064 A Valve guide remover ø6 Valve ...

Page 35: ...6 YM 91042 Universal clutch holder This tool is needed to hold the clutch car rier when removing or installing the car rier nut 90890 04128 YM 04128 Bearing retainer wrench Middle gear bearing retainer This tool is needed when removing or installing the bearing retainers 90890 04130 YM 04059 Adapter M16 Adapter 13 This tool is used to install the crankshaft 90890 04132 YM 33221 A Mechanical seal i...

Page 36: ...ded when removing or installing the secondary sheave spring 90890 06754 YM 34487 Ignition checker Opama pet 4000 spark checker This instrument is necessary for checking the ignition system components 90890 06760 YU 39951 B Digital tachometer This tool is needed for checking engine rpm 90890 85505 Yamaha bond No 1215 Three bond No 1215 This bond is used on crankcase mating surfaces etc Tool No Tool...

Page 37: ...troke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 686 0 cm3 41 86 cu in Bore stroke 102 0 84 0 mm 4 02 3 31 in Compression ratio 9 20 1 Standard compression pressure at sea level 450 kPa 4 50 kg cm2 64 0 psi Starting system Electric starter Lubrication system Wet sump Oil type or grade Engine oil API service SE SF SG type or higher JASO standard MA Final gear oil SAE 80...

Page 38: ...l reserve amount 4 5 L 0 99 Imp gal 1 19 US gal Fuel injector Type quantity 297500 1010 1 Manufacturer DENSO Spark plug Type manufacturer CR8E NGK Spark plug gap 0 7 0 8 mm 0 028 0 031 in Clutch type Wet centrifugal automatic Transmission Primary reduction system V belt Secondary reduction system Shaft drive Secondary reduction ratio 41 21 24 18 33 9 9 544 Transmission type V belt automatic Operat...

Page 39: ...e Front brake type Dual disc brake operation Right hand operation Rear brake type Dual disc brake operation Left hand and right foot operation Suspension Front suspension Double wishbone Rear suspension Double wishbone Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 180 mm 7 1 in Rear wheel travel 230 mm 9 1 in E...

Page 40: ...al indicator light LED Reverse indicator light LED Coolant temperature warning light LED Engine trouble warning light LED EPS warning light LED Park indicator light LED On command four wheel drive differential gear lock indicator LCD High range indicator light LED Low range indicator light LED Differential gear lock indicator light LED Item Standard ...

Page 41: ...Maximum taper 0 05 mm 0 002 in Out of round 0 05 mm 0 002 in Camshaft Drive system Chain drive left Camshaft lobe dimensions Intake measurement A 43 488 43 588 mm 1 7121 1 7161 in 43 388 mm 1 7082 in B 36 959 37 059 mm 1 4551 1 4590 in 36 859 mm 1 4511 in Exhaust measurement A 43 129 43 229 mm 1 6980 1 7019 in 43 029 mm 1 6941 in B 37 007 37 107 mm 1 4570 1 4609 in 36 907 mm 1 4530 in Maximum cams...

Page 42: ...ad diameter A Intake 37 90 38 10 mm 1 4921 1 5000 in Exhaust 31 90 32 10 mm 1 2559 1 2638 in Valve face width B Intake 2 26 mm 0 0890 in Exhaust 2 26 mm 0 0890 in Valve seat width C Intake 1 00 1 20 mm 0 0394 0 0472 in 1 60 mm 0 0630 in Exhaust 1 00 1 20 mm 0 0394 0 0472 in 1 60 mm 0 0630 in Valve margin thickness D Intake 0 80 1 20 mm 0 0315 0 0472 in Exhaust 0 80 1 20 mm 0 0315 0 0472 in Valve s...

Page 43: ...m 0 0394 0 0472 in 1 60 mm 0 0630 in Valve spring Free length Intake 38 79 mm 1 53 in 36 85 mm 1 45 in Exhaust 38 79 mm 1 53 in 36 85 mm 1 45 in Installed length valve closed Intake 35 00 mm 1 38 in Exhaust 35 00 mm 1 38 in Compressed spring force installed Intake 169 199 N 17 23 20 29 kgf 37 99 44 73 lb Exhaust 169 199 N 17 23 20 29 kgf 37 99 44 73 lb Spring tilt Intake 2 5 1 70 mm 2 5 0 067 in E...

Page 44: ...m 0 9052 0 9055 in 22 971 mm 0 9044 in Piston pin to piston pin bore clear ance 0 004 0 024 mm 0 0002 0 0009 in 0 074 mm 0 0029 in Piston rings Top ring Ring type Barrel Dimensions B T 1 20 3 80 mm 0 05 0 15 in End gap installed 0 20 0 35 mm 0 008 0 014 in 0 60 mm 0 024 in Ring side clearance 0 030 0 070 mm 0 0012 0 0028 in 0 12 mm 0 0047 in 2nd ring Ring type Taper Dimensions B T 1 20 4 00 mm 0 0...

Page 45: ... 0157 in Balancer Balancer drive method Gear Automatic centrifugal clutch Clutch shoe thickness 1 5 mm 0 06 in 1 0 mm 0 04 in Clutch in revolution 1 850 2 250 r min Clutch stall revolution 3 500 4 100 r min Transmission Maximum main axle runout 0 06 mm 0 0024 in Maximum drive axle runout 0 06 mm 0 0024 in Shifting mechanism Shift mechanism type Shift drum and guide bar Decompression device Device ...

Page 46: ... 50 kg cm2 at 1 600 r min 7 1 psi at 1 600 r min Pressure check location Cylinder head Cooling system Radiator core Width 340 0 mm 13 39 in Height 248 2 mm 9 77 in Depth 22 0 mm 0 87 in Radiator cap opening pressure 93 3 122 7 kPa 0 933 1 227 kg cm2 13 27 17 45 psi Coolant reservoir capacity Up to the maximum level mark 0 17 L 0 15 Imp qt 0 18 US qt From low to full level 0 14 L 0 12 Imp qt 0 15 U...

Page 47: ...2 11 SPEC ENGINE SPECIFICATIONS Cylinder head tightening sequence 3 1 4 2 7 8 5 6 ...

Page 48: ... Shock absorber travel 109 2 mm 4 30 in Spring free length 314 5 mm 12 38 in Installed length 271 0 mm 10 67 in Spring rate K1 33 50 N mm 3 42 kg mm 191 28 lb in Spring rate K2 36 00 N mm 3 67 kg mm 205 56 lb in Spring stroke K1 0 46 5 mm 0 1 83 in Spring stroke K2 46 5 109 2 mm 1 83 4 30 in Optional spring available No Front wheel Type Panel wheel Rim size 12 6 0 AT Rim material Aluminum Maximum ...

Page 49: ...1 34 in Brake fluid type DOT 4 Rear disc brake Type Dual Disc outside diameter thickness 205 0 3 5 mm 8 07 0 14 in Brake disc minimum thickness 3 0 mm 0 12 in Brake disc maximum deflection 0 1 mm 0 004 in Pad thickness inner 5 8 mm 0 23 in 1 0 mm 0 04 in Pad thickness outer 5 8 mm 0 23 in 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...

Page 50: ...g cap Material Resin Resistance 10 0 kΩ AC magneto Model manufacturer F4T393 MITSUBISHI Standard output 14 0 V 35 0 A at 5 000 r min Stator coil resistance color 0 108 0 132 Ω at 20 C 68 F white white Rectifier regulator Type Semiconductor short circuit Model manufacturer FH012AA SHINDENGEN No load regulated voltage DC 14 2 14 8 V Rectifier capacity 50 0 A Withstand voltage 40 0 V Electric startin...

Page 51: ... Model manufacturer ACM33211 MATSUSHITA Coil resistance 96 0 Ω Radiator fan motor relay Model manufacturer ACM33211 MATSUSHITA Coil resistance 96 0 Ω Circuit breaker Circuit breaker type Fuse Fuses Main fuse 40 0 A Headlight fuse 15 0 A Signaling system fuse 5 0 A Ignition fuse 10 0 A Auxiliary DC jack fuse 15 0 A Fuel injection system fuse 15 0 A Four wheel drive motor fuse 10 0 A EPS fuse 40 0 A...

Page 52: ...r cap Bolt M16 1 20 2 0 14 Timing chain tensioner Bolt M6 2 10 1 0 7 2 Bearing retainer camshaft Bolt M6 2 10 1 0 7 2 LT Camshaft sprocket cover Bolt M6 2 10 1 0 7 2 Tappet cover Bolt M6 8 10 1 0 7 2 Camshaft sprocket Bolt M7 2 20 2 0 14 Crankcase Bolt M8 2 26 2 6 19 Bolt M6 4 10 1 0 7 2 Bolt M6 8 10 1 0 7 2 Engine oil drain bolt Bolt M14 1 30 3 0 22 Oil filter cartridge M20 1 17 1 7 12 Oil filter...

Page 53: ...drive shaft coupling gear nut middle gear side Nut M16 1 115 11 5 85 Middle driven shaft bearing retainer Nut M55 1 80 8 0 58 Left hand thread Middle driven pinion gear bearing retainer Nut M60 1 130 13 0 94 Left hand thread Rear drive shaft coupling gear nut middle gear side Nut M16 1 150 15 0 110 LT Middle driven pinion gear bearing housing Bolt M8 4 25 2 5 18 Primary sheave assembly Nut M16 1 1...

Page 54: ...2 18 SPEC TIGHTENING TORQUES NOTE Temporarily tighten the cylinder bolts to 15 Nm 1 5 m kg 11 ft lb and then tighten them to 50 Nm 5 0 m kg 36 ft lb ...

Page 55: ...iator bracket and frame M6 7 0 7 5 1 Rear upper arm and frame M10 45 4 5 32 LS Rear lower arm and frame M10 45 4 5 32 LS Rear shock absorber and frame M10 45 4 5 32 Rear shock absorber and rear lower arm M10 45 4 5 32 Rear knuckle and rear upper arm M10 45 4 5 32 Rear knuckle and rear lower arm M10 45 4 5 32 Rear brake hose guide and rear lower arm M6 7 0 7 5 1 Stabilizer joint and stabilizer M10 ...

Page 56: ...lding bolt M6 17 1 7 12 Rear knuckle and brake disc guard M6 7 0 7 5 1 Steering knuckle and brake disc guard M6 7 0 7 5 1 Brake master cylinder and brake master cylinder holder M6 7 0 7 5 1 Brake lever pivot M6 6 0 6 4 3 Silicone grease Handlebar holder and steering shaft M8 20 2 0 14 Brake hose joint and frame M6 10 1 0 7 2 Brake hose joint and brake hose M10 19 1 9 13 Brake hose union bolt M10 2...

Page 57: ...se drain bolt M10 10 1 0 7 2 Differential gear case cover and differential gear case M8 24 2 4 17 Differential gear motor and differential gear case cover M6 11 1 1 8 0 Front drive shaft coupling gear and differential drive pinion gear M14 62 6 2 45 LT Final gear case filler plug M14 23 2 3 17 Final gear case drain bolt M14 23 2 3 17 Final gear oil level check bolt M8 10 1 0 7 2 Final gear case an...

Page 58: ...nless otherwise specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERIAL Torque Metric unit Multiplier Imperial unit m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 0...

Page 59: ...ake and exhaust M Rocker arm shafts E Camshaft lobes M Decompressor lever pin E Decompressor lever spring E Rocker arms intake and exhaust M Oil pump shaft E O ring oil filter cartridge LS Water pump impeller shaft M Dipstick mating surface E Starter idler gear inner surface E Starter idler gear shaft E Starter wheel gear E Torque limiter E Clutch housing shaft end LS Clutch carrier assembly E One...

Page 60: ...Shift lever 1 gear teeth and shift lever 2 gear teeth E Stopper lever stopper E Bearing final drive pinion gear assembly G Bearing final gear G AC magneto lead grommet Yamaha bond No 1215 Three bond No 1215 Crankcase mating surface Yamaha bond No 1215 Three bond No 1215 Lubrication point Lubricant ...

Page 61: ...GRAMS 1 Coolant reservoir hose 2 Radiator inlet hose 3 Fast idle plunger outlet hose 4 Coolant reservoir 5 Water pump 6 Water pump outlet pipe 7 Water pump outlet hose 8 Radiator outlet hose 9 Radiator 0 Fast idle plunger inlet hose A A 3 0 1 2 3 4 9 8 7 6 5 ...

Page 62: ...2 26 SPEC OIL FLOW DIAGRAMS EBS00026 OIL FLOW DIAGRAMS 1 Oil delivery pipe 2 Oil filter cartridge 3 Oil strainer 4 Drive axle 5 Relief valve assembly 6 Reverse idle gear shaft B B B B 1 2 3 4 2 6 5 ...

Page 63: ...2 27 SPEC OIL FLOW DIAGRAMS 1 Camshaft 2 Crankshaft 3 Oil strainer 4 Oil pump rotor 5 Oil pump driven gear 1 2 4 5 3 ...

Page 64: ...cable 6 Shift control cable 7 Rear brake hose 8 Left handlebar switch lead 9 Rear brake light switch lead 0 Radiator fan motor breather hose A Differential gear case breather hose B EPS motor breather hose C Radiator fan motor lead D Meter assembly lead E Final gear case breather hose B B A A È Ï Î Í Ì Ø Ù Ù Ë Ê É 4 5 6 7 8 9 2 1 D C 8 9 E A 0 8 9 0 2 1 Ñ 0 Ò A Ó Ô Õ Ö B 3 2 1 C C C C D D A A B B ...

Page 65: ... of the left handlebar switch lead and rear brake light switch lead Ë Pass the rear brake hose and throttle cable through the guide making sure to route the cable behind the hose Ì Pass the rear brake cable and shift control cable through the guide Í Pass the front brake hose through the guide Î Route the throttle cable behind the rear brake cable and shift control cable B B A A È Ï Î Í Ì Ø Ù Ù Ë ...

Page 66: ...r brake light switch lead with the plastic bands at the bends in the handlebar making sure to route the leads under the handlebar and to face the ends of the bands forward Ñ Pass the radiator fan motor breather hose through the guide on the meter bracket making sure to face the end of the hose downward Ò Pass the differential gear case breather hose through the guide on the meter bracket making su...

Page 67: ...e to the inside of the frame Fasten the front brake light switch lead on com mand four wheel drive motor switch and differ ential gear lock switch lead left handlebar switch lead and rear brake light switch lead with a plastic locking tie Be sure to fasten the plastic locking tie above the couplers and fasten it around the protective sleeves of the leads not the leads themselves Ø Pass the final g...

Page 68: ...ential gear lock switch lead with the plastic bands at the bends in the handlebar making sure to route the leads under the handlebar and to face the ends of the bands forward Ú 20 50 mm 0 79 1 97 in B B A A È Ï Î Í Ì Ø Ù Ù Ë Ê É 4 5 6 7 8 9 2 1 D C 8 9 E A 0 8 9 0 2 1 Ñ 0 Ò A Ó Ô Õ Ö B 3 2 1 C C C C D D A A B B Ð Ð Ú D D Ú ...

Page 69: ...ose 0 Speed sensor lead A Crankshaft position sensor lead B Differential gear motor lead C EPS torque sensor lead D Fast idle plunger outlet hose E Radiator outlet hose F Gear position switch lead G Reverse switch lead H Shift control cable I Starter motor lead È Face the end of the coolant reservoir breather hose downward Ó Ò Ñ Ð Ï Ô Õ Õ Ú Ø Ø Ù Ö Î Í È É Ê Ë Ì 1 D C B D 5 E F 0 9 A G 5 I H 1 4 C...

Page 70: ...ector lead under the fuel hose Í Fasten the radiator outlet hose to the frame with the plastic band making sure to face the end of the band inward Î Route the EPS motor breather hose under the coolant reservoir hose Ï Place the EPS torque sensor lead and differen tial gear motor lead in the holder and then insert the ends of the holder into the hole in the stay on the frame Ð Route the differentia...

Page 71: ...lder is facing outward Õ Face the end of the plastic band inward Ö Route the fuel tank drain hose and position the end of the hose as shown in the illustration Pass the speed sensor lead AC magneto lead and final gear case breather hose through the guide in the order listed Ø Route the speed sensor lead AC magneto lead and final gear case breather hose to the right of the reverse switch Ù Route th...

Page 72: ...ontrol cable under the gear posi tion switch lead speed sensor lead and crank shaft position sensor lead Ó Ò Ñ Ð Ï Ô Õ Õ Ú Ø Ø Ù Ö Î Í È É Ê Ë Ì 1 D C B D 5 E F 0 9 A G 5 I H 1 4 C 1 4 E A 2 3 5 6 7 8 9 0 A 4 E E A A B B C C D A A E E B B C C D ...

Page 73: ...ck lead A EPS motor lead B Differential gear motor lead C EPS torque sensor lead D Radiator fan motor lead E Radiator inlet hose F EPS motor breather hose G Spark plug lead H Rear brake cable I Shift control cable J Fuel tank drain hose K Gear position switch lead L AC magneto lead A A B B F F E E D C C D A A B B C C D D E E F F È Ï Î Í É 3 2 1 N M L K J L 5 1 N 6 1 B A C G I H I O B P 7 1 7 5 6 Ð...

Page 74: ... cooling duct 1 Ë Route the radiator fan motor lead between the electrical components tray and the radiator inlet hose Ì Fasten the radiator fan motor lead to the frame with the plastic band making sure to face the end of the band inward Í Route the fuel tank drain hose to the inside of the leads and fuel hose making sure to position the end of the drain hose as shown in the illus tration A A B B ...

Page 75: ...se breather hose and wire harness Ð Face the end of the plastic band inward Ñ Pass the plastic band through the hole in the plastic cover and then fasten the leads and hose with the band making sure to face the end of the band downward Ò Insert the projection on the coupler into the hole in the frame from the inside of the frame Ó Face the end of the plastic band inward Ô Fasten the spark plug lea...

Page 76: ... Fasten the tail brake light lead to the frame with a plastic locking tie making sure to face the end of the tie downward Ê Install the plastic band near the split in the wire harness Ë Route the tail brake light lead to the outside of the frame Ì Face the end of the plastic band downward Í Pass the final gear case breather hose through the guide É Ë Ì Ì Í È Ê 1 2 3 4 5 7 6 2 1 6 8 3 5 3 A A B B C...

Page 77: ...r lead A Ignition coil lead B Meter lead C Lean angle sensor lead D Coolant reservoir breather hose E Positive battery lead F Coolant reservoir hose G EPS motor breather hose H Differential gear case breather hose I Radiator fan motor breather hose J Ground lead K Relay lead L Wire harness K C C A A D D E E F F E E F F C C D D B B A A G G È Ô Ó Ñ Ò Ð Í Ì É Ë Ê É I H G D C B 5 0 A 9 8 L C 6 4 5 3 7...

Page 78: ...sten the left handlebar switch lead on com mand four wheel drive motor switch and differ ential gear lock switch lead front brake light switch lead and rear brake light switch lead with the clamp Ï Fasten the joint coupler lead with the clamp Ð Pass the coolant reservoir breather hose through the guides on the plastic cover and elec trical components tray and route it under the positive battery le...

Page 79: ...asten the coolant reservoir hose with the holder on the electrical components tray Ô Pass the hoses and ground lead through the opening in the electrical components tray Õ Route the coolant reservoir breather hose above the other hoses Ö Route the hoses to the inside of the bolt K C C A A D D E E F F E E F F C C D D B B A A G G È Ô Ó Ñ Ò Ð Í Ì É Ë Ê É I H G D C B 5 0 A 9 8 L C 6 4 5 3 7 E F 3 4 5 ...

Page 80: ...ead 9 TPS lead 0 Intake air temperature sensor lead A Fuel injector lead B Coolant temperature sensor lead C Rectifier regulator lead D AC magneto lead E Fuel hose F Tail brake light lead G Fuel pump lead H Fast idle plunger outlet hose I Wire harness È Route the final gear case breather hose on top of the leads C C B B B B C C Ï H Î É Ë Ì Í Ñ G 8 B 9 0 A C D E F 0 I F Ë Ê A A 5 4 6 7 È 1 2 3 A A ...

Page 81: ...t lead with the holder making sure that the coupler is positioned to the rear of the holder Î Route the throttle cable under the plastic cover Ï Route the fast idle plunger outlet hose above the plastic cover Ð Pass the throttle cable through the guide on the plastic cover Ñ Insert the projection on the wire harness holder into the hole in the plastic cover C C B B B B C C Ï H Î É Ë Ì Í Ñ G 8 B 9 ...

Page 82: ...keep in mind that if the ATV isn t used for a long period of time the month maintenance intervals should be followed Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTE NANCE JOB Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 16...

Page 83: ...nec essary 7 Tires Check tread depth and for damage and replace if necessary Check air pressure and balance and correct if nec essary 8 Wheel bearings Check for looseness or damage and replace if necessary 9 Upper and lower arm pivots Lubricate with lithium soap based grease 10 V belt Check for wear cracks or other damage and replace if necessary 11 Drive shaft univer sal joint Lubricate with lith...

Page 84: ...for oil leakage and correct if neces sary 25 Cooling system Check coolant level and ATV for coolant leakage and correct if necessary Replace coolant Every 2 years 26 Moving parts and cables Lubricate 27 Drive select lever safety system cable Check operation and adjust or replace if necessary 28 Throttle lever housing and cable Check operation and correct if necessary Check throttle cable free play...

Page 85: ...0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the engine skid plates Remove the parts in the order listed 1 Front engine skid plate 1 2 Center engine skid plate 1 3 Rear engine skid plate 1 For installation reverse the removal pro cedure ENGINE SKID PLATES SEAT CARRIERS AND FENDERS ...

Page 86: ...ve the parts in the order listed 1 Seat 1 NOTE Pull up the seat lock lever then pull up on the rear of the seat 2 Battery cover 1 3 Fuel tank cover 1 4 Left side panel 1 5 Right side panel 1 6 Dipstick accessing panel 1 For installation reverse the removal pro cedure ENGINE SKID PLATES SEAT CARRIERS AND FENDERS ...

Page 87: ... ft Ib Order Job Part Q ty Remarks Removing the front carrier and front guard Remove the parts in the order listed Front engine skid plate Refer to ENGINE SKID PLATES Seat side panels Refer to SEAT AND SIDE PANELS 1 Front carrier 1 2 Front carrier bracket 2 3 Battery holding bracket 1 4 Battery lead 2 Disconnect CAUTION First disconnect the negative battery lead then disconnect the positive lead 5...

Page 88: ...kg 19 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 26 Nm 2 6 m kg 19 ft Ib Order Job Part Q ty Remarks 7 Front guard 1 8 Front guard cover 2 For installation reverse the removal pro cedure ENGINE SKID PLATES SEAT CARRIERS AND FENDERS ...

Page 89: ...marks Removing the front fenders and front grill Remove the parts in the order listed Seat side panels Refer to SEAT AND SIDE PANELS Front carrier front guard Refer to FRONT CARRIER AND FRONT GUARD 1 Front fender inner panel 2 2 Auxiliary DC jack coupler 1 Disconnect 3 Main switch coupler 1 Disconnect 4 Front fender 2 5 Headlight coupler 2 Disconnect 6 Front grill 1 For installation reverse the re...

Page 90: ...48 Nm 4 8 m kg 35 ft Ib T R 34 Nm 3 4 m kg 24 ft Ib Order Job Part Q ty Remarks Removing the rear carrier and rear fender Remove the parts in the order listed Seat side panels Refer to SEAT AND SIDE PANELS 1 Rear carrier 1 2 Rear carrier bracket 2 3 Storage compartment 1 4 Tail brake light cover 1 5 Tail brake light connector 3 Disconnect 6 Rear fender 1 For installation reverse the removal pro ce...

Page 91: ...mpo nents tray Remove the parts in the order listed Front fender front grill Refer to FRONT FENDERS AND FRONT GRILL 1 Battery holding bracket 1 2 Battery lead 2 Disconnect CAUTION First disconnect the negative battery lead then disconnect the positive lead 3 Battery 1 4 Lean angle sensor coupler 1 Disconnect 5 Lean angle sensor 1 6 EPS control unit coupler 5 Disconnect ELECTRICAL COMPONENTS TRAY ...

Page 92: ...7 EPS electric power steering control unit 1 8 Four wheel drive motor relay 3 1 9 Rear brake relay 1 10 Four wheel drive motor relay 2 1 11 Four wheel drive motor relay 1 1 12 Headlight relay 1 13 Radiator fan motor coupler 1 Disconnect 14 ECU coupler 1 Disconnect 15 ECU engine control unit 1 For installation reverse the removal pro cedure ...

Page 93: ...the electrical compo nents tray Remove the parts in the order listed 1 Starter relay coupler 1 Disconnect 2 Starter relay 1 3 Fuse box 1 4 EPS fuse 1 5 Main fuse 1 6 Spare fuse 1 7 Radiator fan motor relay 1 8 Fuel injection system relay 1 9 Starting circuit cut off relay 1 10 Left handlebar switch coupler 2 Disconnect 11 On command four wheel drive motor switch and differential gear lock switch c...

Page 94: ...ks 12 Front brake light switch connector 2 Disconnect 13 Rear brake light switch connector 2 Disconnect 14 Meter assembly coupler 1 Disconnect 15 Meter assembly 1 16 Frame ground terminal 1 17 Ignition coil connector 2 Disconnect 18 Differential gear motor coupler 1 Disconnect 19 Wire harness 1 20 Electrical components tray 1 For installation reverse the removal pro cedure ...

Page 95: ... ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib Order Job Part Q ty Remarks Removing the footrest boards Remove the parts in the order listed Seat side panels Refer to SEAT AND SIDE PANELS 1 Footrest 2 2 Footrest board 2 3 Footrest bracket 2 For installation reverse the removal pro cedure ...

Page 96: ...ter element 1 3 Air filter element frame 1 4 Air filter case joint clamp screw 1 Loosen 5 Intake air temperature sensor coupler 1 Disconnect 6 Breather hose air filter case to throttle body 1 Disconnect 7 Breather hose air filter case to fast idle plunger unit 1 Disconnect 8 Cylinder head breather hose 1 Disconnect 9 Intake air temperature sensor 1 10 Air filter case 1 For installation reverse the...

Page 97: ... be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove left side panel Refer to SEAT AND SIDE PANELS front fender Refer to FRONT FENDERS AND FRONT GRILL footrest board Refer to FOOTREST BOARDS air filter case Refer to AIR FILTER CASE 2 Remove fast idle plunger unit 1 1 3 Remove intake tappet cover 1 exhaust tappet cover camshaft sprocket cover 2 1 2 A...

Page 98: ...e piston is at the top dead center TDC on the compression stroke align the I mark a on the AC magneto rotor with the stationary pointer b on the AC magneto cover NOTE To position the piston at top dead center TDC on the compression stroke align the I mark c on the camshaft sprocket with the stationary pointer d on the cylinder head as shown in the illustration Valve clearance cold Intake valve 0 0...

Page 99: ...is obtained d Hold the adjusting screw to prevent it from moving and tighten the locknut to the speci fied torque e Measure the valve clearance again f 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 9 Install timing mark accessing screw crankshaft end accessing screw 10 Install spark plug 11 Connec...

Page 100: ... to FRONT FENDERS AND FRONT GRILL left side panel Refer to SEAT AND SIDE PANELS New T R 10 Nm 1 0 m kg 7 2 ft lb 1 New New T R 10 Nm 1 0 m kg 7 2 ft lb New T R 10 Nm 1 0 m kg 7 2 ft lb EBS00051 ADJUSTING THE ENGINE IDLING SPEED 1 Remove fuel tank cover Refer to SEAT AND SIDE PANELS 2 Start the engine and let it warm up for sev eral minutes 3 Attach tachometer to the spark plug lead 4 Measure engin...

Page 101: ...EE PLAY 8 Install fuel tank cover Refer to SEAT AND SIDE PANELS Direction a Idling speed becomes higher Direction b Idling speed becomes lower Throttle lever free play 3 0 5 0 mm 0 12 0 20 in b a 1 EBS00052 ADJUSTING THE THROTTLE LEVER FREE PLAY NOTE _ Engine idling speed should be adjusted prop erly before adjusting the throttle lever free play 1 Measure throttle lever free play a Out of specific...

Page 102: ...rottle lever side of the cable Direction a Free play is increased Direction b Free play is decreased 1 3 a b 2 Second step f Slide back the rubber cover 4 g Loosen the locknut 5 h Turn the adjusting bolt 6 in direction c or d until the correct free play is obtained i Tighten the locknut j Slide the rubber cover to its original posi tion WARNING _ After adjusting the free play turn the han dlebar t...

Page 103: ... 2 in direction b or c until the specified speed limiter length is obtained c Tighten the locknut WARNING _ Particularly for a beginner rider the speed limiter should be screwed in com pletely Screw it out little by little as their riding technique improves Never remove the speed limiter for a beginning rider For proper throttle lever operation do not turn out the adjuster more than 12 mm 0 47 in ...

Page 104: ...e insulator 2 Abnormal color Replace Normal color is a medium to light tan color 6 Clean spark plug with a spark plug cleaner or wire brush 7 Measure spark plug gap a Use a wire gauge or thickness gauge Out of specification Regap 8 Tighten spark plug NOTE _ Before installing a spark plug clean the gasket surface and plug surface 9 Connect spark plug cap 10 Install right side panel Refer to SEAT AN...

Page 105: ...ft side panel right side panel Refer to SEAT AND SIDE PANELS footrest board Refer to FOOTREST BOARDS 2 Attach tachometer timing light to spark plug lead Digital tachometer 90890 06760 YU 39951 B Timing light 90890 03141 Inductive clamp timing light YU 03141 3 Check ignition timing a Warm up the engine and keep it at the specified speed b Remove the timing mark accessing screw 1 Engine speed 1 350 ...

Page 106: ...sing screw 4 Detach timing light tachometer 5 Install footrest board Refer to FOOTREST BOARDS right side panel left side panel Refer to SEAT AND SIDE PANELS T R Timing mark accessing screw 6 Nm 0 6 m kg 4 3 ft lb a b EBS00061 MEASURING THE COMPRESSION PRESSURE NOTE _ Insufficient compression pressure will result in a loss of performance 1 Measure valve clearance Out of specification Adjust Refer t...

Page 107: ...event it from falling into the cylinder 6 Attach extension 1 compression gauge 2 7 Measure compression pressure Out of specification Refer to steps c and d a Set the main switch to ON Compression gauge 90890 03081 Engine compression tester YU 33223 Extension 90890 04082 Compression pressure at sea level Minimum 392 kPa 3 92 kg cm2 55 8 psi Standard 450 kPa 4 50 kg cm2 64 0 psi Maximum 504 kPa 5 04...

Page 108: ...s Eliminate d If the compression pressure is below the minimum specification squirt a few drops of oil into the cylinder and measure again Refer to the following table 8 Install spark plug 9 Connect spark plug cap 10 Install V belt cooling duct 2 Refer to ENGINE REMOVAL in chapter 4 right side panel Refer to SEAT AND SIDE PANELS Compression pressure with oil applied into the cylinder Reading Diagn...

Page 109: ...etween the minimum level mark a and maximum level mark b Oil level low Add oil to the proper level NOTE To obtain an accurate oil level reading the dip stick must be inserted completely into the oil filter hole CAUTION Do not allow foreign material to enter the crankcase 5 Check the engine oil level again CAUTION Be sure the engine oil is at the correct level otherwise engine damage may result Rec...

Page 110: ...f 2 Place a container under the engine oil drain bolt 3 Remove dipstick accessing panel Refer to SEAT AND SIDE PANELS 4 Remove dipstick 1 1 5 Remove engine oil drain bolt 1 along with the gasket 6 Drain engine oil completely from the crankcase 1 7 If the oil filter cartridge is also to be replaced perform the following procedure a Remove the oil filter cartridge 1 with an oil filter wrench 2 Oil f...

Page 111: ...e oil drain bolt along with the gasket 10 Fill crankcase with the specified amount of the recom mended engine oil 11 Install dipstick 12 Start the engine warm it up for several min utes and then turn it off 13 Check engine for engine oil leaks 14 Check engine oil level Refer to CHECKING THE ENGINE OIL LEVEL T R Oil filter cartridge 17 Nm 1 7 m kg 12 ft lb Quantity Total amount 2 40 L 2 11 Imp qt 2...

Page 112: ...dge and the oil pump for damage or leakage Refer to CRANKSHAFT AND OIL PUMP in chapter 4 d Start the engine after solving the problem s and check the engine oil pressure again e Tighten the oil gallery bolt to specification T R Oil gallery bolt 10 Nm 1 0 m kg 7 2 ft lb 1 EBS00073 CLEANING THE AIR FILTER ELEMENT 1 Remove fuel tank cover left side panel right side panel Refer to SEAT AND SIDE PANELS...

Page 113: ...filter element Use compressed air to blow off dust from the inner surface of the element a Wash the element gently but thoroughly in solvent WARNING _ Use a cleaning solvent which is designed to clean parts only Never use gasoline or low flash point solvents as they may cause a fire or explosion b Squeeze the excess solvent out of the ele ment and let it dry CAUTION _ Do not twist or wring out the...

Page 114: ...ng surface matches the sealing surface of the case so there is no air leak 7 Install air filter case cover 8 Install right side panel left side panel fuel tank cover Refer to SEAT AND SIDE PANELS EAS00094 CHECKING THE THROTTLE BODY JOINT 1 Remove left side panel Refer to SEAT AND SIDE PANELS 2 Check throttle body joint 1 Cracks damage Replace Refer to THROTTLE BODY in chapter 6 3 Install left side...

Page 115: ...elt cooling duct 2 Refer to ENGINE REMOVAL in chapter 4 rear fender Refer to REAR CARRIER AND REAR FENDER right side panel seat Refer to SEAT AND SIDE PANELS 1 EAS00098 CHECKING THE BREATHER HOSES 1 Remove left side panel Refer to SEAT AND SIDE PANELS air filter case Refer to AIR FILTER CASE 2 Check cylinder head breather hose 1 breather hose air filter case to throttle body 2 breather hose air fi...

Page 116: ...olant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However soft water may be used if distilled water is not available 3 If the coolant is at or below the minimum level mark remove the left side panel Refer to SEAT AND SIDE PANELS 4 Remove the reservoir cap 1 add coolant or distilled water to the maximum level mark a install the reservoir cap a...

Page 117: ...ause seri ous injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radia tor cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped press down on the radiator cap and turn it counterclockwise to remove 1 7 Remove coolant drain bolt 1 along with the copper...

Page 118: ...wers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with water Do not mix different types of antifreeze Recommended antifreeze High...

Page 119: ...allow all of the air to escape from the air bleed bolt hole e When coolant begins to flow out of the bolt hole tighten the cylinder head air bleed bolt to specification f Install the V belt cooling duct 2 15 Start the engine warm it up for ten minutes and then rev the engine five times 16 Pour the recommended coolant into the radiator until it is full 17 Stop the engine and allow it to cool If the...

Page 120: ...Refer to FRONT FENDERS AND FRONT GRILL left footrest board Refer to FOOTREST BOARDS 2 Check radiator 1 radiator inlet hose 2 coolant reservoir 3 coolant reservoir hose 4 radiator outlet hose 5 water jacket 6 water pump outlet hose 7 water pump outlet pipe 8 water pump housing 9 Cracks damage Replace Refer to COOLING SYSTEM in chapter 5 3 Install left footrest board Refer to FOOTREST BOARDS front f...

Page 121: ...h ON and the engine stop switch to RUN Coolant temperature warning light does not come on Coolant temperature warning light comes on Push start switch with transmission in neutral Coolant temperature warning light comes on momentarily Coolant temperature warning light does not come on Check the electrical circuit Refer to SIGNALING SYSTEM in chapter 9 Coolant temperature and electrical circuit are...

Page 122: ...and secondary sheave 3 Measure V belt width 2 Out of specification Replace V belt width 31 7 mm 1 25 in Limit 31 3 mm 1 23 in 4 Replace V belt a Install the bolts 1 90101 06016 into the secondary fixed sheave hold NOTE _ Tightening the bolts 1 will push the secondary sliding sheave away causing the gap between the secondary fixed and sliding sheaves to widen b Remove the V belt 1 from the primary ...

Page 123: ...ocedure applies to all of the exhaust pipe gaskets 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 torques T R Exhaust pipe nut 7 20 Nm 2 0 m kg 14 ft lb Muffler and muffler bracket bolt 8 20 Nm 2 0 m kg 14 ft lb Muffler bolt 9 20 Nm 2 0 m kg 14 ft lb Exhaust pipe protector bolt 0 7 N...

Page 124: ...ft face ham mer or suitable tool then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tail pipe housing d Install the gasket and then insert the tailpipe into the muffler and align the bolt holes e Insert the bolts 1 and tighten them f Remove the purging bolt 3 g Start the engine and rev it up approximately twenty times while momenta...

Page 125: ...end of the brake lever 0 mm 0 in a EBS00085 ADJUSTING THE REAR BRAKE WARNING _ Always adjust both the brake pedal and the rear brake lever whenever adjusting the rear brake 1 Measure rear brake lever free play a Out of specification Bleed the rear brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM Rear brake lever free play at the end of the brake lever 0 mm 0 in a 2 Measure brake pedal fre...

Page 126: ...he locknut 1 b Turn the adjusting bolt 2 until the brake pedal height is within the specified limits c Tighten the locknut 1 d Loosen the locknut 3 e Turn the adjusting nut 4 in direction a or b until the specified brake pedal free play is obtained f Tighten the locknut 3 Brake pedal height 56 7 mm 2 23 in T R Locknut 7 Nm 0 7 m kg 5 1 ft lb Direction a Brake pedal free play is increased Direction...

Page 127: ...teps again 6 Install front fender inner panel Refer to FRONT FENDERS AND FRONT GRILL EBS00087 CHECKING THE BRAKE FLUID LEVEL 1 Place the vehicle on a level surface NOTE _ When checking the brake fluid level make sure that the top of the brake fluid reservoir top is horizontal 2 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level È Front brake ...

Page 128: ...luid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately NOTE _ In order to ensure a correct reading of the brake fluid level make sure that the top of the brake master cylinder reservoir is horizontal EBS00088 CHECKING THE FRONT BRAKE PADS 1 Remove front wheels Refer to FRONT AND REAR WHEELS in chapter 8 2 Check brake pads Wear indicator groov...

Page 129: ...R BRAKES in chapter 8 3 Operate the brake lever or brake pedal 4 Install rear wheels Refer to FRONT AND REAR WHEELS in chapter 8 Brake pad wear limit a 1 0 mm 0 04 in a CHECKING THE REAR BRAKE HOSE PROTECTORS 1 Remove rear wheels Refer to FRONT AND REAR WHEELS in chapter 8 2 Check rear brake hose protectors 1 Wear indicator 2 becomes visible Replace the rear brake hose protector Refer to REAR KNUC...

Page 130: ...ar brake 4 Check brake hoses Apply the brake lever several times Fluid leakage Replace the hoses Refer to FRONT AND REAR BRAKES in chapter 8 1 2 1 1 2 2 EBS00094 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING _ Bleed the hydraulic brake system when ever the system is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low brake operation is faulty NOTE _ Be ca...

Page 131: ...per level with the recommended brake fluid b Install the diaphragm brake master cylinder reservoir c Connect a clear plastic hose 1 tightly to the bleed screw 2 È Front É Rear d Place the other end of the hose into a con tainer e Slowly apply the brake several times f Fully squeeze the brake lever or fully depress the brake pedal and hold it in posi tion g Loosen the bleed screw NOTE _ Loosening t...

Page 132: ... 3 Install rear wheel Refer to FRONT AND REAR WHEELS in chapter 8 EBS00100 ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD 1 NEUTRAL 2 HIGH 3 LOW 4 REVERSE 5 PARK 6 Control cable 7 Select lever shift rod WARNING _ Before moving the select lever bring the vehicle to a complete stop and return the throttle lever to its closed position Other wise the transmission may be damaged 1 Adjust brake ...

Page 133: ...d then verify that the select lever cannot be shifted to REVERSE from NEU TRAL or to PARK from REVERSE d If the operation of the select lever is incor rect repeat steps a to c e Tighten the locknut a 3 1 2 Shift rod a Make sure that the select lever and trans mission are in HIGH b Loosen both locknuts 1 c Adjust the length a of the shift rod to 413 mm 16 3 in d Tighten the locknuts e Start the eng...

Page 134: ...ow Add oil to the proper level CAUTION _ Take care not allow foreign material to enter the final gear case 4 Install final gear oil level check bolt Recommended oil SAE80 API GL 4 Hypoid gear oil 1 2 T R 10 Nm 1 0 m kg 7 2 ft lb EBS00102 CHANGING THE FINAL GEAR OIL 1 Place the vehicle on a level surface 2 Remove final gear oil filler bolt 1 3 Place a receptacle under the final gear case 1 4 Remove...

Page 135: ...ter the final gear case 8 Check oil level Refer to CHECKING THE FINAL GEAR OIL LEVEL 9 Install final gear oil level check bolt final gear oil filler bolt Periodic oil change 0 20 L 0 18 Imp qt 0 21 US qt Total amount 0 25 L 0 22 Imp qt 0 26 US qt Recommended oil SAE80 API GL 4 Hypoid gear oil T R 23 Nm 2 3 m kg 17 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb T R 23 Nm 2 3 m kg 17 ft lb CHANGING THE FINAL GE...

Page 136: ... CAUTION _ Take care not allow foreign material to enter the differential gear case 4 Install differential gear oil filler bolt Recommended oil SAE80 API GL 4 Hypoid gear oil 1 2 T R 23 Nm 2 3 m kg 17 ft lb EBS00104 CHANGING THE DIFFERENTIAL GEAR OIL 1 Place the vehicle on a level surface 2 Place a receptacle under the differential gear case 3 Remove differential gear oil filler bolt differential ...

Page 137: ...re not to allow foreign material to enter the differential gear case 7 Install differential gear oil filler bolt Periodic oil change 0 215 L 0 19 Imp qt 0 23 US qt Total amount 0 23 L 0 20 Imp qt 0 24 US qt Recommended oil SAE80 API GL 4 Hypoid gear oil T R 23 Nm 2 3 m kg 17 ft lb EBS00105 CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS 1 Check dust boots 1 Damage Replace Refer to FRONT CONSTANT V...

Page 138: ... rod end s 4 Raise the front end of the vehicle so that there is no weight on the front wheels 5 Check ball joints and or wheel bearings Move the wheels laterally back and forth Excessive free play Replace the front arms upper and lower and or wheel bear ings 6 Measure steering tension Above specification Adjust a Turn the main switch to OFF b Place the vehicle on a suitable stand so that the fron...

Page 139: ...e steering stem joint moves smoothly on the serrations of the steering stem and shaft of the EPS unit c Tighten the steering stem bearing bolts to specification d Tighten the steering stem bracket bolts to specification e Tighten the steering stem joint bolts to specification f Measure the steering tension again g Repeat the above procedure until the steer ing tension is below specification T R St...

Page 140: ... formula given below g If the toe in is incorrect adjust it Ê Forward 3 Adjust toe in WARNING _ Be sure that both tie rods are turned the same amount If not the vehicle will drift right or left even though the handlebar is positioned straight This may lead to mis handling and an accident After setting the toe in to specification run the vehicle slowly for some distance with both hands lightly hold...

Page 141: ...09 CHECKING THE FRONT AND REAR SHOCK ABSORBERS 1 Place the vehicle on a level place 2 Check damper rod Bends damage Replace the front rear shock absorber assembly Refer to FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES and REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES in chapter 8 oil leakage Excessive oil leakage Replace the front rear shock absorber assembly Refer to FRONT ARMS AND FRONT SHOCK AB...

Page 142: ... in chapter 8 È Front shock absorber É Rear shock absorber È É EBS00110 ADJUSTING THE FRONT SHOCK ABSORBERS WARNING _ Always adjust the spring preload for both front shock absorber to the same setting Uneven adjustment can cause poor han dling and loss of stability 1 Adjust spring preload Turn the adjuster 1 in direction a or b Direction a Spring preload is increased suspension is harder Direction...

Page 143: ...r Direction b Spring preload is decreased suspension is softer Standard position 2 Minimum position 1 Maximum position 5 1 2 3 4 5 1 a b EBS00115 CHECKING THE TIRES WARNING _ This model is equipped with low pressure tires It is important that they be inflated correctly and maintained at the proper pressures TIRE CHARACTERISTICS 1 Tire characteristics influence the han dling of ATVs The tires liste...

Page 144: ...s may cause the tire to burst Inflate the tires slowly and carefully Fast inflation could cause the tire to burst MAXIMUM LOADING LIMIT 1 Vehicle load limits 220 kg 485 lb Total weight of the cargo trailer hitch vertical load rider and accessories 2 Front carrier 45 0 kg 99 lb 3 Rear carrier 85 0 kg 187 lb 4 Front storage box 0 5 kg 1 lb 5 Rear storage box 2 0 kg 4 lb 6 Trailer hitch Pulling load ...

Page 145: ...hicle and may cause loss of control Maintain proper tire pressures Set tire pressures when the tires are cold Tire pressures must be equal in both front tires and equal in both rear tires 2 Check tire surfaces Wear damage Replace WARNING _ It is dangerous to ride with a worn out tire When tire wear is out of specification replace the tire immediately Cold tire pressure Front Rear Standard 35 kPa 0...

Page 146: ...self properly on the rim EBS00117 CHECKING AND LUBRICATING THE CABLES WARNING _ A damaged cable sheath may cause corro sion and interfere with the cable move ment An unsafe condition may result so replace a damaged cable as soon as possi ble 1 Check cable sheath Damage Replace 2 Check cable operation Unsmooth operation Lubricate or replace NOTE _ Hold the cable end up and apply several drops of lu...

Page 147: ...J LUBRICATING THE LEVERS AND PEDALS EBS00118 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the levers and pedals Recommended lubricant Lithium soap based grease ...

Page 148: ...r permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention CAUTION _ This is a sealed battery Never remove the sealing caps because the balance between cell...

Page 149: ...isconnect battery leads from the battery terminals CAUTION _ First disconnect the negative battery lead 1 and then the positive battery lead 2 3 Remove battery 4 Check battery charge a Connect a pocket tester to the battery termi nals NOTE _ The charge state of an MF battery can be checked by measuring its open circuit volt age i e the voltage when the positive termi nal is disconnected No chargin...

Page 150: ...possible to regulate the charging current on the battery charger be careful not to overcharge the battery When charging a battery be sure to remove it from the vehicle If charging has to be done with the battery mounted on the vehicle disconnect the negative battery lead from the battery terminal To reduce the chance of sparks do not plug in the battery charger until the bat tery charger leads are...

Page 151: ...ct the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of an MF battery sta bilizes about 30 minutes after charging has been completed Therefore wait 30 minutes after charging is completed before measuring the open circuit volt age ...

Page 152: ...THE BATTERY If the amperage does not exceed the standard charging amperage after 5 minutes replace the battery If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging amperage Leave the battery unused for more than 30 minutes before measuring its open circu...

Page 153: ...rge the battery until the charging voltage reaches 15 V This type of battery charger cannot charge an MF battery A variable voltage charger is recommended Leave the battery unused for more than 30 minutes before measuring its open cir cuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the battery Constant amperage chargers are not suitable for charging...

Page 154: ...h Loose connection Connect properly 9 Lubricate battery terminals 10 Install battery holding bracket front carrier Refer to FRONT CARRIER AND FRONT GUARD battery cover Refer to SEAT AND SIDE PANELS Recommended lubricant Dielectric grease 2 1 EBS00121 CHECKING THE FUSES The following procedure applies to all of the fuses CAUTION _ To avoid a short circuit always set the main switch to OFF when chec...

Page 155: ... _ 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 c Set on the switches to verify if the electrical circuit is operational Pocket tester 90890 03112 Analog pocket tester YU 03112 C ...

Page 156: ...to the electrical system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install battery cover Refer to SEAT AND SIDE PANELS Items Amperage rating Q ty Main fuse 40 A 1 EPS fuse 40 A 1 Fuel injection system fuse 15 A 1 Ignition fuse 10 A 1 Headlight fuse 15 A 1 Four wheel drive motor fuse 10 A 1 Radiator fan motor fuse 15 A 1 Signaling sys tem fuse 5 A 1 Au...

Page 157: ...djust headlight beam vertically a Turn the adjusting screw 1 in direction a or b Direction a Headlight beam is raised Direction b Headlight beam is lowered a b 1 EBS00124 REPLACING THE HEADLIGHT BULBS 1 Remove cover at the rear of the headlight 1 1 2 Remove headlight bulb cover 1 1 3 Disconnect headlight coupler 1 1 ...

Page 158: ...b until it cools down 5 Install bulb Secure the new bulb with the headlight unit CAUTION _ Avoid touching the glass part of the bulb Keep it free from oil otherwise the trans parency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on the bulb thoroughly clean it with a cloth moistened with alcohol or lac quer thinner 6 Install headlight bulb holder 7 Connect ...

Page 159: ...ler and exhaust pipe Remove the parts in the order listed Front fender rear fender Refer to ENGINE SKID PLATES SEAT CARRIERS AND FENDERS in chapter 3 Left footrest board Refer to FOOTREST BOARDS in chap ter 3 Air filter case Refer to AIR FILTER CASE in chapter 3 Meter assembly Refer to ELECTRICAL COMPONENTS TRAY in chapter 3 1 V belt cooling duct 2 1 2 V belt cooling duct 1 1 3 Exhaust pipe protec...

Page 160: ...m 0 7 m kg 5 1 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib New New Order Job Part Q ty Remarks 6 Gasket 1 7 Muffler bracket 1 8 Exhaust pipe 1 9 Gasket 2 For installation reverse the removal pro cedure ENGINE REMOVAL 4 ...

Page 161: ...m 1 5 m kg 11 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib Order Job Part Q ty Remarks Removing the select lever unit Remove the parts in the order listed 1 Select lever shift rod 1 Refer to INSTALLING THE SELECT LEVER UNIT 2 Select lever unit 1 3 Shift arm 1 For installation reverse the removal pro cedure ...

Page 162: ...ase Refer to AIR FILTER CASE in chapter 3 Throttle body assembly Refer to THROTTLE BODY in chapter 6 Fuel tank fuel tank shield Refer to FUEL TANK in chapter 6 Coolant reservoir Refer to RADIATOR in chapter 5 Thermostat Refer to THERMOSTAT in chapter 5 Water pump assembly Refer to WATER PUMP in chapter 5 Oil delivery pipe Refer to CYLINDER HEAD Final gear case assembly Refer to REAR CONSTANT VELOC...

Page 163: ...Fast idle plunger inlet hose 1 3 Coolant temperature sensor coupler 1 Disconnect 4 Spark plug cap 1 5 Shift control cable 1 Disconnect 6 Reverse switch lead 1 Disconnect 7 Speed sensor coupler 1 Disconnect 8 Crankshaft position sensor coupler 1 Disconnect 9 AC magneto coupler 1 Disconnect 10 Gear position switch coupler 1 Disconnect For installation reverse the removal pro cedure ENGINE REMOVAL ...

Page 164: ...LT LT 4 9 7 7 9 8 8 1 5 3 2 3 2 6 6 Order Job Part Q ty Remarks Removing the engine mounting bolts Remove the parts in the order listed 1 Rubber damper nut front side 2 Refer to INSTALLING THE ENGINE 2 Engine mounting bolt rear upper side 2 3 Engine mounting bolt rear lower side 2 4 Engine 1 5 Rubber damper nut rear side 2 CAUTION Make sure that the engine does not strike the brake pipe when remov...

Page 165: ...Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT LT LT LT 4 9 7 7 9 8 8 1 5 3 2 3 2 6 6 Order Job Part Q ty Remarks 6 Rubber damper rear side 2 Refer to INSTALLING THE ENGINE 7 Engine mounting bolt front upper side 2 8 Engine mounting bolt front lower side 2 9 Rubber damper front side 2 For installation reverse the removal pro cedure ENGINE REMOVAL ...

Page 166: ...Make sure that the engine does not strike the brake pipe when installing it NOTE _ Do not fully tighten the bolts and nuts 2 Tighten engine mounting bolts front lower side 2 engine mounting bolts front upper side 3 engine mounting bolts rear lower side 7 engine mounting bolts rear upper side 8 rubber damper nuts front side 9 rubber damper nuts rear side 5 3 7 9 5 8 1 4 4 8 6 7 2 3 2 1 T R 42 Nm 4 ...

Page 167: ...ver unit 2 select lever shift rod 3 NOTE Make sure that the select lever and transmis sion are in NEUTRAL The installed length a of the shift rod is 413 mm 16 3 in 2 1 3 a N N T R 14 Nm 1 4 m kg 10 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb T R 15 Nm 1 5 m kg 11 ft lb ENGINE REMOVAL ...

Page 168: ... m kg 25 ft Ib New T R 35 Nm 3 5 m kg 25 ft Ib New T R 13 Nm 1 3 m kg 9 4 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib M 4 5 1 2 New 6 16 15 11 10 9 5 4 7 14 8 New E Order Job Part Q ty Remarks Removing the cylinder head Remove the parts in the order listed Throttle body assembly Refer to THROTTLE BODY in chapter 6 Thermostat coolant temperature sen sor Refer to THERMOSTAT in chapter 5 Air ducts exhaust pipe...

Page 169: ...T R 10 Nm 1 0 m kg 7 2 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib New T R 35 Nm 3 5 m kg 25 ft Ib New T R 13 Nm 1 3 m kg 9 4 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib M 4 5 1 2 New 6 16 15 11 10 9 5 4 7 14 8 New E Order Job Part Q ty Remarks 9 Timing chain tensioner cap bolt 1 Refer to REMOVING THE CYLINDER HEAD and INSTALLING THE CYLIN DER HEAD 10 Timing chain tensioner 1 11 Gasket 1 12 Camshaft sprocket 1 13 Dec...

Page 170: ... at top dead center TDC on the compression stroke align the I mark c on the camshaft sprocket with the stationary pointer d on the cylinder head as shown in the illustration a b d c 2 Loosen camshaft sprocket bolts 1 decompressor assembly bolts 2 NOTE While holding the AC magneto rotor nut with a wrench loosen the camshaft sprocket bolts and decompressor assembly bolts 3 Loosen timing chain tensio...

Page 171: ...he camshaft sprocket and timing chain as a set a 1 4 of a tooth b Correct 1 Roller 2 Sprocket EBS00227 CHECKING THE TAPPET COVERS 1 Check tappet covers camshaft sprocket cover Cracks damage Replace EBS00229 CHECKING THE TIMING CHAIN TENSIONER 1 Check timing chain tensioner Cracks damage Replace 2 Check one way cam operation Rough movement Replace the timing chain tensioner 3 Check timing chain ten...

Page 172: ...deposits rust Eliminate 3 Measure cylinder head warpage Out of specification Resurface the cylin der head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern NOTE...

Page 173: ...them in two stages New 3 1 4 2 7 8 5 6 4 2 3 4 3 1 T R 35 Nm 3 5 m kg 25 ft lb T R 35 Nm 3 5 m kg 25 ft lb T R 38 Nm 3 8 m kg 27 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 4 Install decompressor assembly camshaft sprocket onto the camshaft a Install the decompressor assembly onto the camshaft and then finger tighten the decompressor assembly bolts 1 b Turn the crankshaft counterclockwise c Align the I mar...

Page 174: ...er washer 2 and spring 3 b Release the timing chain tensioner one way cam 4 and push the timing chain tensioner rod 5 all the way into the timing chain ten sioner housing c Install the timing chain tensioner and gasket 6 onto the cylinder NOTE Install the gasket with its beaded side facing the timing chain tensioner end d Install the spring and timing chain tensioner cap bolt 6 Turn crankshaft sev...

Page 175: ...s 1 decompressor assembly bolts 2 NOTE While holding the AC magneto rotor nut with a wrench tighten the camshaft sprocket bolts and decompressor assembly bolts After tightening the decompressor assembly bolts check that decompressor assembly moves smoothly CAUTION _ Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damagin...

Page 176: ...ty Remarks Removing the rocker arms and cam shaft Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Bearing retainer 1 Refer to REMOVING THE ROCKER ARMS AND CAMSHAFT and INSTALLING THE CAMSHAFT AND ROCKER ARMS 2 Rocker arm shaft 2 3 Intake rocker arm 1 4 Exhaust rocker arm 1 5 Locknut 4 6 Valve adjusting screw 4 7 Camshaft 1 8 Decompressor lever 1 CAUTION Do not disassemb...

Page 177: ...b T R 14 Nm 1 4 m kg 10 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib Order Job Part Q ty Remarks 9 Decompressor lever pin 1 Refer to REMOVING THE ROCKER ARMS AND CAMSHAFT and INSTALLING THE CAMSHAFT AND ROCKER ARMS 10 Bearing 1 For installation reverse the removal pro cedure ROCKER ARMS AND CAMSHAFT ...

Page 178: ...SHAFT 1 Check cam lobes Pitting scratches blue discoloration Replace 2 Measure cam lobe dimensions a and b Out of specification Replace Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 Weight 90890 01084 YU 01083 3 Camshaft lobe dimensions Intake a 43 488 43 588 mm 1 7121 1 7161 in Limit 43 388 mm 1 7082 in b 36 959 37 059 mm 1 4551 1 4590 in Limit 36 859 mm 1 4511 in Exhaust a 43 1...

Page 179: ...eck that the decompressor lever pin 1 projects from the camshaft c Check that the decompressor cam 2 moves smoothly 2 1 EBS00239 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to both of the rocker arms and rocker arm shafts 1 Check rocker arm Damage wear Replace 2 Check rocker arm shaft Blue discoloration excessive wear pitting scratches Replace or check the lubric...

Page 180: ...m the rocker arm inside diameter Out of specification Replace the defective part s Rocker arm shaft outside diame ter 11 981 11 991 mm 0 4717 0 4721 in Rocker arm to rocker arm shaft clearance 0 009 0 037 mm 0 0004 0 0015 in EAS00243 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1 Install bearing 1 onto the cylinder head NOTE Apply engine oil to the bearing Install the bearing so that the seal is facing...

Page 181: ...Install decompressor lever pin 1 decompressor lever 2 NOTE _ Install the decompressor lever pin 1 and decompressor lever 2 in the camshaft 3 as shown in the illustration 3 1 2 4 Install camshaft 1 NOTE Install the camshaft so that its projection a becomes horizontal 5 Lubricate rocker arm shafts Recommended lubricant Engine oil 1 a ...

Page 182: ...m shaft 2 intake rocker arm intake rocker arm shaft NOTE _ Use a slide hammer bolt 3 to install the rocker arm shaft Make sure the rocker arm shafts intake and exhaust are completely pushed into the cyl inder head Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 3 2 1 ...

Page 183: ...linder head Refer to CYLINDER HEAD Rocker arms rocker arm shafts cam shaft Refer to ROCKER ARMS AND CAM SHAFT 1 Valve cotter 8 Refer to REMOVING THE VALVES AND VALVE SPRINGS and INSTALL ING THE VALVES AND VALVE SPRINGS 2 Valve spring retainer 4 3 Valve spring 4 4 Exhaust valve 2 5 Intake valve 2 6 Valve stem seal 4 7 Valve spring seat 4 8 Valve guide 4 Refer to CHECKING THE VALVES AND VALVE SPRING...

Page 184: ...k the valve face valve seat and valve seat width Refer to CHECKING THE VALVES AND VALVE SPRINGS a Pour a clean solvent a into the intake and exhaust ports b Check that the valve seals properly There should be no leakage at the valve seat 1 2 Remove valve cotters NOTE _ Attach a valve spring compressor 1 and attachment 2 between the valve spring retainer and the cylinder head to remove the valve co...

Page 185: ...e EBS00240 CHECKING THE VALVES AND VALVE SPRINGS The following procedure applies to all of the valves and valve guides 1 Measure valve stem to valve guide clearance Out of specification Replace the valve guide Stem to guide clearance valve guide inside diameter a valve stem diameter b Stem to guide clearance Intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 08 mm 0 0031 in Exhaust 0 025 0 052 mm 0 00...

Page 186: ... guide bore the valve guide using a valve guide reamer 3 to obtain proper stem to guide clearance NOTE _ After replacing the valve guide reface the valve seat 3 Check valve face Pitting wear Grind the face valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace Valve guide position a 12 7 13 1 mm 0 50 0 52 in Valve guide remover ø6 90890 04064 Valve guide remover 6...

Page 187: ...rom the valve face and valve seat 7 Check valve seats Pitting wear Reface the valve seat Runout limit 0 040 mm 0 0016 in 8 Measure valve seat width a Out of specification Reface the valve seat a Apply Mechanic s blueing dye Dykem b to 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 pattern d Measure the val...

Page 188: ...valve guide b Apply molybdenum disulfide oil to the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the compound NOTE _ For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands e Apply a fine lapping compound to the valve face and repeat the abo...

Page 189: ...alve spring free length 38 79 mm 1 53 in Limit 36 85 mm 1 45 in 11 Measure compressed spring force a Out of specification Replace b Installed length Compressed spring force 169 0 199 0 N at 35 00 mm 17 23 20 29 kg at 35 00 mm 37 99 44 73 lb at 1 38 in 12 Measure spring tilt a Out of specification Replace Spring tilt limit 2 5 1 70 mm 0 067 in EBS00241 INSTALLING THE VALVES AND VALVE SPRINGS The fo...

Page 190: ...rings 4 valve spring retainers 5 NOTE _ Install the valve springs with the larger pitch a facing upwards b Smaller pitch 4 Install valve cotters NOTE _ Install the valve cotters while compressing the valve spring with the valve spring compressor 1 and attachment 2 Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attach ment 90890 01243 Valve spring compressor adapter 26 mm YM 0...

Page 191: ...33 ENG 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a piece of wood CAUTION _ Hitting the valve tip with excessive force could damage the valve VALVES AND VALVE SPRINGS ...

Page 192: ... Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD Water jacket joint Refer to WATER PUMP in chapter 5 1 Timing chain guide exhaust side 1 2 Cylinder 1 Refer to INSTALLING THE PISTON AND CYLINDER 3 Cylinder gasket 1 4 Dowel pin 2 5 Piston pin clip 2 Refer to REMOVING THE PISTON and INSTALLING THE PISTON AND CYLINDER 6 Piston pin 1 7 Piston 1 8 Top ring 1 9 2nd ring 1 10 Oil...

Page 193: ...s are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 4 CAUTION _ Do not use a hammer to drive the piston pin out Piston pin puller set 90890 01304 Piston pin puller YU 01304 1 2 3 2 Remove piston rings NOTE _ Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown as shown in the illustration EBS00...

Page 194: ...m 0 39 in from the bottom edge of the pis ton d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula Cylinder bore C 102 000 102 010 mm 4 0157 4 0161 in Taper limit T 0 05 mm 0 002 in Out of round R 0 05 mm 0 002 in C Maximum D T Maximum D1 or D2 Maximum D5 or D6 R Maximum D1 D3 or D5 Minimum D2 D4 or D6 Piston...

Page 195: ...s from the piston ring grooves and piston rings Piston ring side clearance Top ring 0 030 0 070 mm 0 0012 0 0028 in Limit 0 12 mm 0 0047 in 2nd ring 0 030 0 070 mm 0 0012 0 0028 in Limit 0 13 mm 0 0051 in 2 Install piston ring into the cylinder NOTE _ Level the piston ring into the cylinder with the piston crown a 50 mm 1 97 in 3 Measure piston ring end gap Out of specification Replace the piston ...

Page 196: ... piston pin Blue discoloration grooves Replace the piston pin and then check the lubrication system 2 Measure piston pin outside diameter a Out of specification Replace the piston pin Piston pin outside diameter 22 991 23 000 mm 0 9052 0 9055 in Limit 22 971 mm 0 9044 in 3 Measure piston pin bore inside diameter b Out of specification Replace the piston Piston pin bore inside diameter 23 004 23 01...

Page 197: ...nce Piston pin bore diameter b Piston pin outside diameter a Piston pin to piston clearance 0 004 0 024 mm 0 0002 0 0009 in Limit 0 074 mm 0 0029 in EBS00252 INSTALLING THE PISTON AND CYLINDER 1 Install top ring 1 2nd ring 2 oil ring expander 3 lower oil ring rail 4 upper oil ring rail 5 NOTE _ Be sure to install the piston rings so that the manufacturer s marks or numbers face up ...

Page 198: ...l cylinder gasket dowel pins 4 Lubricate piston piston rings cylinder with the recommended lubricant Recommended lubricant Engine oil 2 3 1 a New New New 5 Offset piston ring end gaps a Top ring b Oil ring expander c Upper oil ring rail d Lower oil ring rail e 2nd ring È Exhaust side e a b d c 120 120 120 45 45 90 È 6 Install cylinder 1 timing chain guide exhaust side NOTE _ While compressing the ...

Page 199: ...E Lubricate the cylinder bolt 1 threads and mat ing surface with engine oil 8 Tighten cylinder bolts 1 1st cylinder bolts 1 2nd cylinder bolts timing chain side 2 1 1 2 2 E E T R 15 Nm 1 5 m kg 11 ft lb T R 50 Nm 5 0 m kg 36 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 200: ...T LT Order Job Part Q ty Remarks Removing the AC magneto Remove the parts in the order listed Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Left footrest board Refer to FOOTREST BOARDS in chap ter 3 Select lever unit Refer to SELECT LEVER UNIT Water pump Refer to WATER PUMP in chapter 5 1 AC magneto coupler 1 Disconnect 2 Cr...

Page 201: ...0 m kg 50 ft lb T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib LT LT Order Job Part Q ty Remarks 5 AC magneto cover gasket 1 6 Dowel pin 2 7 Lead holder 1 8 Crankshaft position sensor 1 9 Stator coil 1 10 Torque limiter 1 11 Starter idle gear 1 12 Starter idle gear shaft 1 13 AC magneto rotor 1 Refer to REMOVING THE AC MAG NETO ROTOR and INSTALLING THE AC MAGNETO ROTOR 14 Starter clutch 1...

Page 202: ...t Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib LT LT E T R 70 Nm 7 0 m kg 50 ft lb T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib LT LT Order Job Part Q ty Remarks 17 Washer 1 For installation reverse the removal pro cedure AC MAGNETO ...

Page 203: ...oosen the AC mag neto rotor nut Do not allow the sheave holder to touch the projection on the rotor Sheave holder 90890 01701 Primary clutch holder YS 01880 A 3 2 1 3 Remove AC magneto rotor 1 with the starter clutch woodruff key CAUTION To protect the end of the crankshaft place an appropriate sized socket between the flywheel puller set center bolt and the crankshaft NOTE Use the flywheel puller...

Page 204: ...new one and clinch the end of the bolt NOTE _ The arrow mark on the starter clutch must face inward away from the AC magneto rotor a Install the starter wheel gear to the starter clutch and hold the starter clutch b When turning the starter wheel gear counter clockwise È the starter clutch and the wheel gear should be engaged If not the starter clutch is faulty Replace it c When turning the starte...

Page 205: ...E LIMITER torque limiter Damage wear Replace NOTE Do not disassemble the torque limiter EBS00268 INSTALLING THE AC MAGNETO ROTOR 1 Install stator coil 1 NOTE Align the projection a on the stator coil with the slot b in the AC magneto cover T R Stator coil bolt 7 Nm 0 7 m kg 5 1 ft lb 1 a b LT T R 7 Nm 0 7 m kg 5 1 ft lb 2 Apply Sealant 1 into the slit Yamaha bond No 1215 90890 85505 Three bond No ...

Page 206: ...t reinstall the key and rotor 4 Tighten AC magneto rotor nut 1 NOTE _ While holding the AC magneto rotor 2 with the sheave holder 3 tighten the AC magneto rotor nut Sheave holder 90890 01701 Primary clutch holder YS 01880 A 3 2 1 T R 70 Nm 7 0 m kg 50 ft lb 5 Install AC magneto cover lead holder 1 AC magneto cover bolts NOTE _ Tighten the AC magneto cover bolts in stages using a crisscross pattern...

Page 207: ...in the order listed Starter wheel gear Refer to AC MAGNETO 1 Lock washer 1 Refer to REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR and INSTALLING THE BALANCER DRIVE GEAR BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR 2 Balancer driven gear 1 3 Oil pump drive gear 1 4 Chain 1 5 Straight key 1 BALANCER GEARS AND OIL PUMP GEARS ...

Page 208: ... BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR 7 Oil pump driven gear 1 8 Plate 1 9 Spring 8 Refer to REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR and INSTALLING THE BALANCER DRIVE GEAR BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR 10 Pin 4 11 Balancer drive gear 1 For installation reverse the removal pro cedure BALANCER GEARS AND OIL PUMP GEARS ...

Page 209: ... balancer driven gear 5 then loosen the nuts 5 4 3 1 2 CHECKING THE OIL PUMP DRIVE 1 Check oil pump drive gear oil pump driven gear Cracks wear damage Replace CHECKING THE BALANCER DRIVE 1 Check balancer drive gear balancer driven gear Damage wear Replace the balancer drive gear and balancer driven gear as a set Excessive noise during operation Replace the balancer drive gear and bal ancer driven ...

Page 210: ...th the punch mark b on the bal ancer driven gear Install the oil pump driven gear with the 3B4 mark c facing out 2 3 c a b 1 3 Install lock washers oil pump driven gear nut 1 balancer driven gear nut 2 NOTE Place an aluminum plate 3 between the teeth of the balancer drive gear 4 and bal ancer driven gear 5 then tighten the nuts Apply the engine oil to the thread of axles and nuts 4 Bend the lock w...

Page 211: ... Removing the primary and second ary sheaves Remove the parts in the order listed Front fender rear fender Refer to ENGINE SKID PLATES SEAT CARRIERS AND FENDERS in chapter 3 Right footrest board Refer to FOOTREST BOARDS in chap ter 3 Air ducts Refer to ENGINE REMOVAL 1 Drive belt cover 1 2 Rubber gasket 1 3 Bearing housing 1 4 Dowel pin 2 5 Primary sheave assembly 1 Refer to REMOVING THE PRIMARY A...

Page 212: ... kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 1 T R 100 Nm 10 0 m kg 72 ft lb T R 140 Nm 14 0 m kg 100 ft lb LS T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks 9 Drive belt case 1 10 Rubber gasket 1 11 Rubber gasket 1 For installation reverse the removal pro cedure PRIMARY AND SECONDARY SHEAVES ...

Page 213: ...he primary sheave Remove the parts in the order listed 1 Primary pulley sheave cap 1 Refer to ASSEMBLING THE PRIMARY SHEAVE 2 Primary pulley slider 4 3 Primary pulley cam 1 4 Primary pulley weight 8 5 Collar 1 6 Oil seal 2 7 Primary sliding sheave 1 8 O ring 1 For assembly reverse the disassembly procedure ...

Page 214: ...ave Remove the parts in the order listed 1 Nut 1 Refer to DISASSEMBLING THE SEC ONDARY SHEAVE and ASSEMBLING THE SECONDARY SHEAVE 2 Spring seat 1 3 Compression spring 1 4 Spring seat 1 5 Guide pin 4 6 Secondary sliding sheave 1 7 O ring 2 8 Secondary fixed sheave 1 9 Oil seal 2 For assembly reverse the disassembly procedure ...

Page 215: ...SASSEMBLING THE SECONDARY SHEAVE 1 Remove nut 1 a Attach the sheave fixed block 2 locknut wrench 3 and sheave spring compressor 4 to the secondary sheave assembly b Place the sheave fixed block in a vise and secure it c Tighten the sheave spring compressor nut 5 and compress the spring d Loosen the nut 1 with the locknut wrench 3 e Remove the nut 1 f Remove the sheave spring compressor and locknut...

Page 216: ... sheave splines Wear cracks damage Replace primary pulley cam Cracks damage Replace 3 Check primary sliding sheave primary fixed sheave Cracks damage Replace EBS00275 CHECKING THE SECONDARY SHEAVE 1 Check secondary fixed sheave smooth operation secondary sliding sheave smooth operation Scratches damage Replace as a set 2 Check torque cam grooves 1 Wear damage Replace 3 Check guide pins 2 Wear dama...

Page 217: ...ARY SHEAVE 1 Clean primary sliding sheave face 1 primary fixed sheave face 2 collar 3 weights 4 primary sliding sheave cam face NOTE _ Remove any excess grease 2 Install weights 1 NOTE _ Apply Yamaha Grizzly grease 90 g to the whole outer surface of the weights and install Apply Yamaha Grizzly grease 2 5 g to the inner surface of the collar Apply Yamaha Grizzly grease 2 5 g to the inner surface of...

Page 218: ...ASSEMBLING THE SECONDARY SHEAVE 1 Apply BEL RAY assembly lube to the secondary sliding sheave 1 inner surface and oil seals BEL RAY assembly lube to the bearings oil seals and inner surface of the secondary fixed sheave 2 2 Install guide pins 1 3 Apply BEL RAY assembly lube to the guide pin sliding grooves 1 and oil seals 2 New ...

Page 219: ...in a vise and secure it c Tighten the sheave spring compressor nut 1 and compress the spring d Install the nut 2 and tighten it to the speci fied torque using the locknut wrench e Remove the sheave spring compressor locknut wrench and sheave fixed block Sheave fixed block 90890 04135 Sheave fixed bracket YM 04135 Locknut wrench 90890 01348 YM 01348 Sheave spring compressor 90890 04134 YM 04134 T R...

Page 220: ...the secondary fixed and sliding sheaves to widen Install the V belt so that its arrow faces the direction shown in the illustration 2 Tighten primary sheave nut 1 secondary sheave nut 2 NOTE _ Use the sheave holder 3 to hold the primary sheave First tighten the primary sheave nut 1 then tighten the secondary sheave nut 2 Sheave holder 90890 01701 Primary clutch holder YS 01880 A T R 140 Nm 14 0 m ...

Page 221: ...e order listed Primary sheave secondary sheave Refer to PRIMARY AND SECONDARY SHEAVES 1 Clutch housing assembly 1 Refer to REMOVING THE CLUTCH and INSTALLING THE CLUTCH 2 Gasket 1 3 Dowel pin 2 4 One way clutch bearing 1 5 Nut 1 6 Clutch carrier assembly 1 For installation reverse the removal pro cedure ...

Page 222: ... Remarks Disassembling the clutch housing assembly Remove the parts in the order listed 1 Oil seal 1 2 Circlip 1 3 Bearing housing 1 4 Circlip 1 5 Bearing 1 6 Circlip 1 7 Bearing 1 8 Clutch housing 1 For assembly reverse the disassembly procedure ...

Page 223: ... 4 of a turn Remove them after all of them are loosened 2 Straighten punched portion of the nut 1 3 Remove nut 1 CAUTION The clutch carrier assembly nut has left handed threads To loosen the clutch car rier assembly nut turn it clockwise NOTE _ Use a clutch holding tool 2 to hold the clutch carrier assembly Universal clutch holder 90890 04086 YM 91042 ...

Page 224: ... and clutch carrier assembly to the clutch hous ing and hold the clutch carrier assembly b When turning the clutch housing clockwise È the clutch housing should turn freely If not the one way clutch assembly is faulty Replace it c When turning the clutch housing counter clockwise É the clutch housing and crank shaft should be engaged If not the one way clutch assembly is faulty Replace it 3 Check ...

Page 225: ...s with a drift punch Universal clutch holder 90890 04086 YM 91042 New T R 190 Nm 19 0 m kg 140 ft lb 3 Install one way clutch bearing NOTE _ The one way clutch bearing should be installed in the clutch carrier assembly with the OUT SIDE mark a facing toward the clutch housing 4 Install dowel pins gasket clutch housing assembly NOTE _ Tighten the bolts in stages using a criss cross pattern After ti...

Page 226: ...er Job Part Q ty Remarks Removing the timing chain and oil filter Remove the parts in the order listed Engine Refer to ENGINE REMOVAL Cylinder head Refer to CYLINDER HEAD Cylinder piston Refer to CYLINDER AND PISTON AC magneto rotor starter wheel gear Refer to AC MAGNETO Balancer driven gear oil pump driven gear Refer to BALANCER GEARS AND OIL PUMP GEARS Primary sheave assembly secondary sheave as...

Page 227: ...b T R 68 Nm 6 8 m kg 49 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib New New New New New New New New LS LS LS LS LT E E LT LT LT LT LS 2 5 6 9 8 1 7 4 3 Order Job Part Q ty Remarks 5 Speed sensor 1 6 Dipstick 1 7 Relief valve assembly 1 8 Reverse switch 1 9 Gear position switch 1 For installation reverse the removal pro cedure CRANKCASE ...

Page 228: ...er Job Part Q ty Remarks Separating the crankcase Remove the parts in the order listed 1 Shift lever cover 1 Refer to INSTALLING THE SHIFT LEVER 2 Gasket 1 3 Dowel pin 1 4 Shift lever 1 1 5 Shift lever 2 assembly 1 6 Shift drum stopper 1 Spring identification color red 7 Stopper lever stopper 1 Spring identification color yellow 8 Right crankcase 1 Refer to SEPARATING THE CRANK CASE and ASSEMBLING...

Page 229: ...marks Removing the crankcase bearings Remove the parts in the order listed Crankshaft oil pump Refer to CRANKSHAFT AND OIL PUMP Transmission Refer to TRANSMISSION Middle drive shaft middle driven shaft Refer to MIDDLE GEAR 1 Collar 1 2 O ring 1 3 Oil seal 1 4 Bearing retainer 1 5 Spacer 1 6 Crank seal 2 7 Bearing 9 For installation reverse the removal pro cedure ...

Page 230: ... a soft hammer to tap on one side of the crankcase Tap only on reinforced portions of the crankcase Do not tap on the crank case mating surfaces Work slowly and carefully Make sure that the crankcase halves separate evenly c Remove the dowel pins È É EBS00335 CHECKING THE TIMING CHAIN AND GUIDE 1 Check timing chain Cracks stiff Replace the timing chain and camshaft sprocket as a set 2 Check intake...

Page 231: ...t 2 Clean all the gasket mating surfaces and crankcase mating surfaces thoroughly 3 Check crankcase Cracks damage Replace oil delivery passages Clogged Blow out with compressed air EBS00342 ASSEMBLING THE CRANKCASE 1 Apply sealant 1 to the mating surfaces of both case halves NOTE Apply two coats of sealant to the area a shown in the illustration 2 Install dowel pins 2 Yamaha bond No 1215 90890 855...

Page 232: ...e bolts follow the proper tightening sequence È Right crankcase É Left crankcase NOTE _ Tighten the bolts in stages using a crisscross pattern 6 Apply 4 stroke engine oil to the crankshaft pin bearing and oil deliv ery hole 7 Check crankshaft and transmission operation Unsmooth operation Repair INSTALLING THE SHIFT LEVER 1 Install shift lever 2 assembly 1 shift lever 1 2 NOTE When installing the s...

Page 233: ...kg 7 2 ft Ib New Order Job Part Q ty Remarks Removing the crankshaft and oil pump Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Oil pump 1 2 Gasket 1 3 Balancer 1 4 Crankshaft 1 Refer to REMOVING THE CRANK SHAFT and INSTALLING THE CRANK SHAFT For installation reverse the removal pro cedure ...

Page 234: ...5 m kg 3 6 ft Ib Order Job Part Q ty Remarks Disassembling the oil pump Remove the parts in the order listed 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 For assembly reverse the disassembly procedure ...

Page 235: ... pump housing clearance b oil pump housing to inner rotor and outer rotor clearance c Out of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing 3 Check oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing clear...

Page 236: ... 1 Measure crank width a Out of specification Replace the crank shaft 2 Measure side clearance d Out of specification Replace the crank shaft 3 Measure runout c Out of specification Replace the crank shaft Crank width 74 95 75 00 mm 2 951 2 953 in Big end side clearance 0 350 0 650 mm 0 0138 0 0256 in Limit 1 0 mm 0 04 in Runout limit 0 030 mm 0 0012 in a c d c ...

Page 237: ... pin 5 with the groove a in the inner rotor 3 1 2 3 5 4 a a EBS00362 INSTALLING THE CRANKSHAFT 1 Install crankshaft 1 Crankshaft installer pot 2 90890 01274 Installing pot YU 90058 Pot installer YU 90059 Crankshaft installer bolt 3 90890 01275 Bolt YU 90060 Adapter M16 4 90890 04130 Adapter 13 YM 04059 Spacer crankshaft installer 5 90890 04081 Pot spacer YM 91044 Spacer 6 90890 01309 Pot spacer YU...

Page 238: ...Cen ter TDC with one hand while turning the nut of the installing tool with the other Operate the installing tool until the crankshaft bottoms against the bearing CAUTION _ Apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier ...

Page 239: ...rankcase Separate Refer to CRANKCASE Middle driven gear Refer to MIDDLE GEAR 1 Shift drum 1 Refer to REMOV ING THE TRANS MISSION and INSTALLING THE TRANSMISSION 2 Shift fork assembly 1 3 Shift fork R 1 4 Spring 1 Refer to ASSEM BLING THE SHIFT FORK ASSEMBLY 5 Shift fork L 1 6 Shift fork guide bar 1 7 Secondary shaft 1 8 Drive axle assembly 1 9 Reverse idle gear 1 10 Reverse idle gear shaft 1 ...

Page 240: ... 3 2 New New New New New E E E E Order Job Part Q ty Remarks 11 Stopper lever 1 Refer to REMOVING THE TRANSMIS SION and INSTALLING THE TRANS MISSION 12 Stopper lever shaft 1 For installation reverse the removal pro cedure TRANSMISSION ...

Page 241: ... New New New Order Job Part Q ty Remarks Disassembling the drive axle assembly Remove the parts in the order listed 1 Washer 1 2 Collar 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 0 Washer 1 A Circlip 1 B Middle drive gear 1 C Circlip 1 ...

Page 242: ... F H G B 0 2 3 4 5 6 7 8 9 M M M M M M M New New New Order Job Part Q ty Remarks D Washer 1 E Bearing 1 F Reverse wheel gear 1 G Stopper wheel 1 H Drive axle 1 For assembly reverse the disassembly procedure TRANSMISSION ...

Page 243: ... the shift drum d Remove the shift fork assembly EBS00349 CHECKING THE SHIFT FORKS 1 Check shift fork cam follower 1 shift fork pawl 2 Scoring bends wear damage Replace 2 Check guide bar Roll the guide bar on a flat surface Bends Replace WARNING _ Do not attempt to straighten a bent guide bar 3 Check shift fork movement on the guide bar Unsmooth operation Replace the shift fork and the guide bar 4...

Page 244: ...k transmission gears Blue discoloration pitting wear Replace the defective gear s transmission gear dogs Cracks damage rounded edges Replace the defective gear s 3 Check transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 4 Check transmission gear movement Rough movement Replace the defective part s 5 Check circlips Bends...

Page 245: ... stop per 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 ASSEMBLING THE SHIFT FORK ASSEMBLY 1 Install shift fork guide bar 1 shift fork L 2 spring 3 shift fork R 4 circlips 5 NOTE Install the shift forks with their 3B4 marks a facing each other 3B4 New New a 4 2 1 5 3 5 New TRANSMISSI...

Page 246: ...assembly 4 shift drum 5 NOTE _ Install the shift forks 6 with the L mark a and R mark b facing towards the left and right sides of the crankcase respectively 1 2 4 5 3 a 6 b 2 Check shift operation Unsmooth operation Repair NOTE _ Oil each gear and bearing thoroughly Before assembling the crankcase make sure that the transmission is in neutral and that the gears turn freely ...

Page 247: ...rankcase Separate Refer to CRANKCASE 1 Bearing housing 1 2 Middle drive pinion gear nut 1 Refer to REMOVING THE MIDDLE DRIVE SHAFT and INSTALLING THE MIDDLE DRIVE SHAFT 3 Middle drive pinion gear 1 4 Middle drive gear shim 5 Middle drive shaft 1 6 Bearing retainer 2 7 Bearing 1 8 Circlip 1 9 Middle driven gear 1 For installation reverse the removal pro cedure ...

Page 248: ...t coupling gear nut middle gear side 1 Refer to REMOVING THE MIDDLE DRIVEN SHAFT and INSTALLING THE MIDDLE DRIVEN SHAFT 2 Front drive shaft coupling gear middle gear side 1 3 Middle driven pinion gear assembly 1 4 Rear drive shaft coupling gear nut middle gear side 1 5 Rear drive shaft coupling gear middle gear side 1 6 Bearing housing 1 7 O ring 1 8 Middle driven gear shim 9 Middle driven pinion ...

Page 249: ...NG THE MIDDLE DRIVEN SHAFT and INSTALLING THE MIDDLE DRIVEN SHAFT 11 Middle driven pinion gear bearing retainer 1 12 Bearing 1 13 Middle driven shaft bearing retainer 1 14 Bearing 1 15 Middle driven shaft 1 For installation reverse the removal pro cedure MIDDLE GEAR ...

Page 250: ...gear nut 2 Loosen middle drive pinion gear nut 1 NOTE _ Secure the middle drive shaft in the vise with a clean rag 3 Remove middle drive pinion gear nut middle drive pinion gear shim s 4 Remove middle driven gear 1 circlip middle drive shaft 2 NOTE Press the middle drive shaft end and remove the middle driven gear 1 2 ...

Page 251: ...ear middle shaft tool 90890 01229 Gear holder YM 01229 1 3 2 2 Remove rear drive shaft coupling gear nut middle gear side 1 washer rear drive shaft coupling gear middle gear side 2 NOTE Use the coupling gear middle shaft tool 3 to hold the coupling gear Coupling gear middle shaft tool 90890 01229 Gear holder YM 01229 1 2 3 3 Remove bearing housing assembly 1 a Clean the outside of the bearing hous...

Page 252: ...ess the middle driven pinion gear end and remove the bearing housing 4 Remove middle driven pinion gear bearing retainer bearing a Attach the folded rag 1 b Secure the bearing housing edge in the vise c Attach the bearing retainer wrench 2 CAUTION _ The middle driven pinion gear bearing retainer has left handed threads To loosen the retainer turn it clockwise d Remove the bearing retainer and bear...

Page 253: ...earing retainer has left handed threads To loosen the retainer turn it clockwise Ring nut wrench 90890 01430 YM 38404 2 1 3 6 Remove middle driven shaft 1 with bearing 1 EBS01021 CHECKING THE PINION GEARS 1 Check drive pinion gear teeth driven pinion gear teeth Pitting galling wear Replace 2 Check O ring Damage Replace bearings Pitting damage Replace ...

Page 254: ...using shims 1 and 2 with their respective thickness calculated from information marked on crankcase bearing housing and drive gear end 1 Shim thickness A 2 Shim thickness B b To find shim thickness A use following for mula Where 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 decimal number on the right crank...

Page 255: ...rankcase is marked 9 01 e is 9 01 6 Therefore the shim thickness is 1 40 mm A 9 01 64 97 17 0 55 0 0 58 1 40 7 Round off hundredths digit and select appropriate shim s In the example above the calculated shim thickness is 1 40 mm The chart instructs you however to round off 0 to 0 Shims are supplied in the following thickness Hundredths Round value 0 1 2 0 3 4 5 6 7 5 8 9 10 Middle drive pinion ge...

Page 256: ...rom 49 0 h a numeral usually a decimal number on the middle driven pinion gear is either added to or subtracted from 80 5 i a numeral usually a decimal number on the left crankcase specifies a thickness of 99 98 j a numeral usually a decimal number on the right crankcase specifies a thickness of 8 12 Example 1 If the bearing housing is marked 03 f is 77 53 2 If the driven pinion gear is marked 0 g...

Page 257: ...4 5 6 7 5 8 9 10 Middle drive pinion gear shim Thickness mm 0 10 0 40 0 15 0 50 0 20 0 60 0 30 j INSTALLING THE BEARING AND OIL SEALS 1 Install bearing 1 oil seal 2 oil seal 3 4 Middle drive pinion gear bearing retainer 5 Bearing housing 6 Middle driven shaft bearing retainer 7 Crankcase Installed depth of bearing a 0 9 1 4 mm 0 035 0 055 in Installed depth of oil seal b 1 0 1 5 mm 0 039 0 059 in ...

Page 258: ...1430 YM 38404 1 LT T R 80 Nm 8 0 m kg 58 ft lb 2 2 Install middle driven pinion gear bearing retainer 1 a Secure the bearing housing edge in the vise with a clean rag b Attach the bearing retainer wrench 2 c Tighten the bearing retainer CAUTION _ The middle driven pinion gear bearing retainer has left handed threads To tighten the retainer turn it counterclockwise Bearing retainer wrench 90890 041...

Page 259: ... side 2 NOTE Use the coupling gear middle shaft tool 3 to hold the coupling gear Coupling gear middle shaft tool 90890 01229 Gear holder YM 01229 2 1 3 LT T R 150 Nm 15 0 m kg 110 ft lb 5 Install front drive shaft coupling gear middle gear side 1 washer front drive shaft coupling gear nut middle gear side 2 NOTE Use the coupling gear middle shaft tool 3 to hold the coupling gear Coupling gear midd...

Page 260: ...01022 MEASURING THE MIDDLE GEAR BACKLASH 1 Measure gear lash 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 middle driven gear c Attach the final gear backlash band 3 and dial gauge 4 b 45 mm 1 8 in d Measure the gear lash while rotating the middle driven shaft back and fo...

Page 261: ...4 103 ENG MIDDLE GEAR e If the gear lash is incorrect adjust the gear lash by middle driven pinion gear shims and or middle drive pinion gear shim s ...

Page 262: ...efer to FRONT FENDERS AND FRONT GRILL in chapter 3 Front guard Refer to FRONT CARRIER AND FRONT GUARD in chapter 3 Left footrest board Refer to FOOTREST BOARDS in chap ter 3 Air filter case Refer to AIR FILTER CASE in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Radiator fan motor coupler 1 Disconnect 2 Radiator fan breather hose 1 3 Coolant reservoir hose 1 4 Coolant reser...

Page 263: ...kg 5 1 ft Ib Order Job Part Q ty Remarks 5 Coolant reservoir cap 1 6 Coolant reservoir 1 7 Fast idle plunger outlet hose 1 8 Radiator outlet hose 1 9 Radiator inlet hose 1 10 Radiator bracket 1 11 Radiator 1 12 Radiator fan 1 For installation reverse the removal pro cedure RADIATOR ...

Page 264: ...sure Replace the radiator cap a Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap 3 b Apply the specified pressure for ten sec onds and make sure there is no drop in pressure 4 Check radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM in chapter 9 Radiator cap opening pressure 93 3 122 7 kPa 0 933 1 227 kg cm2 13 27 17 45 psi Radia...

Page 265: ...the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check cooling system Leaks Repair or replace any faulty part 3 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR ...

Page 266: ...ob Part Q ty Remarks Removing the thermostat Remove the parts in the order listed Air filter case Refer to AIR FILTER CASE in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Radiator inlet hose 1 Disconnect 2 Thermostat cover 1 3 Thermostat 1 4 Coolant temperature sensor 1 5 Copper washer 1 For installation reverse the removal pro cedure ...

Page 267: ...sed É Fully open NOTE _ If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause seri ous overheating or overcooling 2 Check thermostat housing cover thermostat housing cylinder head Cracks damage Replace EBS00133 INSTALLING THE THERMOSTAT 1 Install thermostat 1 O ring 2 thermostat cover 3 NOTE _ Install the thermostat with its breather hole a facing up 2 Fill cooli...

Page 268: ... pump Remove the parts in the order listed Left footrest board Refer to FOOTREST BOARDS in chap ter 3 Left front fender Refer to FRONT FENDERS AND FRONT GRILL in chapter 3 AC magneto cover Refer to AC MAGNETO in chapter 4 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Radiator outlet hose 1 Disconnect 2 Water jacket joint 1 3 Water pump outlet hose 1 4 Water pump outlet pipe 1 5 Water ...

Page 269: ... New T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LS Order Job Part Q ty Remarks 7 Gasket 1 8 Circlip 1 9 Impeller shaft 1 10 Water pump seal 1 11 Bearing 1 12 Oil seal 1 For installation reverse the removal pro cedure WATER PUMP ...

Page 270: ...er 2 2 1 2 Remove bearing 1 oil seal 2 NOTE _ Tap out the bearing and oil seal from the out side of the AC magneto cover 3 1 2 3 EBS00139 CHECKING THE WATER PUMP 1 Check water pump housing impeller shaft Cracks damage wear Replace 2 Check water jacket water jacket outlet hose water jacket outlet pipe Cracks damage wear Replace bearing Rough movement Replace ...

Page 271: ... diameter Installed depth of oil seal a 8 1 8 7 mm 0 32 0 34 in 3 1 2 New a New 2 Install water pump seal 1 into the AC magneto cover 2 CAUTION _ Never lubricate the water pump seal sur face with oil or grease NOTE _ Install the water pump seal with the special tools È Push down Mechanical seal installer 3 90890 04132 Water pump seal installer YM 33221 A Middle driven shaft bearing driver 4 90890 ...

Page 272: ... Measure impeller shaft tilt Out of specification Replace CAUTION _ Make sure the rubber damper and rubber damper holder are flush with the impeller 1 Straightedge 2 Impeller shaft Impeller shaft tilt limit 0 15 mm 0 006 in ...

Page 273: ...tion system relay 4 Engine trouble warning light 5 Intake air pressure sensor 6 TPS throttle position sensor 7 Intake air temperature sensor 8 Fuel injector 9 Fuel pump 0 Speed sensor A Crankshaft position sensor B Coolant temperature sensor C Spark plug D Ignition coil 1 2 3 4 5 6 7 8 9 0 A B C D FUEL INJECTION SYSTEM ...

Page 274: ...6 2 FI FUEL INJECTION SYSTEM 6 ...

Page 275: ... O Y Lg W R G W L R G R R L O W Y R W B B R Gy G Y W B W L B B L W R L R B Br W BLACK B L Br B L W BLACK Br ON OFF 4WD 2WD LOCK PUSH OFF OFF Br B R B W R G B R B W R G B R B R B B Br O W L B G R W L B G W L L R R R R W R Br L Br P P B Br L Br R Br L Br L Br Y Br L R Y R R B B B B B B B B B W W W W R W W Br L W B R Br L R W B W B O Gy G B R W B G R Y B Y R Lg R L L R Sb Br L W Y W Y W W R Y L Br W ...

Page 276: ...system relay K ECU engine control unit L Ignition coil M Spark plug N Fuel injector O Intake air temperature sensor P Coolant temperature sensor Q Speed sensor R TPS throttle position sensor S Intake air pressure sensor T Lean angle sensor W Multifunction meter X Engine trouble warning light c Fuel pump n Engine stop switch s Ignition fuse ...

Page 277: ...cteristic operation and alerts the rider of the detected malfunction by illuminating the engine trou ble warning light After the engine has been stopped the low est fault code number appears on the odom eter tripmeter LCD Once a fault code has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation Th...

Page 278: ... sor open or short circuit Intake air temperature sensor open or short circuit detected Able Able 30 Lean angle sensor latch up detected The vehicle has overturned Unable Unable 33 Ignition coil faulty ignition Malfunction detected in the primary wire of ignition coil Unable Unable 39 Injector open circuit Injector open circuit detected Unable Unable 41 Lean angle sensor open or short circuit Lean...

Page 279: ... Refer to Rein statement method in TROUBLESHOOTING DETAILS Turn the main switch to OFF turn the main switch back to ON and then check if the fault code number is still displayed Repairs completed No fault code number displayed Erasing the malfunction history The malfunction history is stored even if the main switch is turned OFF The malfunction history must be erased in the diagnostic mode Refer t...

Page 280: ...conds or more NOTE All displays on the meter disappear dIAG appears on the LCD meter 4 Simultaneously press the SELECT and RESET buttons for 2 seconds or more to execute the selection 5 Select the diagnostic code number that applies to the item that was verified with the fault code number by pressing the SELECT and RESET buttons NOTE The diagnostic code number appears on the LCD meter 01 70 To dec...

Page 281: ...n the LCD meter Actuator operation Set the engine stop switch to ON to oper ate the actuator If the engine stop switch is set to ON set it to OFF and then set it to ON again 7 Turn the main switch to OFF to cancel the diagnostic mode NOTE To perform a reliable diagnosis make sure to turn off the power supply before every check and then start right from the beginning ...

Page 282: ...perature sensor Malfunction in ECU Improperly installed intake air temperature sensor D05 30 The vehicle has overturned Overturned Malfunction in ECU D08 33 Malfunction detected in the primary lead of the ignition coil Open or short circuit in wire harness Malfunction in ignition coil Malfunction in ECU Malfunction in a component of ignition cut off circuit sys tem D30 D32 39 Open circuit detected...

Page 283: ... the rear wheel is rotated The number is cumulative and does not reset each time the wheel is stopped D08 Lean angle sensor Remove the lean angle sensor and incline it more than 65 degrees Upright 0 4 1 4 Overturned 3 7 4 4 D09 Fuel system voltage battery voltage Approximately 12 0 Set the engine stop switch to RUN and then compare with the actually measured battery voltage If the bat tery voltage...

Page 284: ...ode No Item Actuation Checking method D30 Ignition coil Actuates the ignition coil five times in one second intervals The engine trouble warning light also flashes five times Check the spark five times Connect an ignition checker D36 Injector Actuates the injector five times in one second inter vals Check the operating sound of the injector five times D50 Fuel pump relay Actuates the fuel pump rel...

Page 285: ... Connections Crankshaft position sensor cou pler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire har ness Repair or replace if there is an open or short circuit Between the crankshaft position sensor coupler and ECU cou ...

Page 286: ...the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Turning the main switch to ON 2 Open or short circuit in wire har ness Repair or replace if there is an open or short circuit Between intake air pressure sen sor coupler and ECU coupler black blue black blue pink pink blue blue 3 Defective ...

Page 287: ...tarting the engine and operating it at idle 2 Intake air pressure sensor mal function at intermediate electrical potential Check and repair the connec tion Replace it if there is a malfunc tion 3 Connections Intake air pressure sensor cou pler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction rep...

Page 288: ...CU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire har ness Repair or replace if there is an open or short circuit Between throttle position sensor coupler and ECU coupler blue blue yellow yellow black blue black blue 4 Throttle position sens...

Page 289: ...o 21 Symptom Coolant temperature sensor open or short circuit detected Diagnostic code No D06 Coolant temperature sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of coolant tem perature sensor Check the installed area for loose ness or pinching Turning the main switch to ON 2 Connections Coolant temperature sensor cou pler Main wi...

Page 290: ...ntake air temperature sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire har ness Repair or replace if there is an open or short circuit Between intake air temperature sensor coupler and ECU coupler brown whi...

Page 291: ...ine can not be restarted unless the main switch is first turned OFF 2 Installed condition of the lean angle sensor Check for looseness or pinching 3 Connections Lean angle sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 4 Defective lean ...

Page 292: ...k the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler or con nector securely Starting the engine and operating it at idle 2 Open or short circuit in wire har ness Repair or replace if there is an open or short circuit Between ignition coil connector and ECU coupler orange orange Between ignition coil connector and left handlebar switch cou...

Page 293: ...s for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Cranking the engine Con nect the fuel injector cou pler 2 Open or short circuit in wire har ness and or sub wire harness 2 Repair or replace if there is an open or short circuit Between injector coupler and ECU coupler red blue red blue red black re...

Page 294: ...oupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Turning the main switch to ON 2 Open or short circuit in lead wire Repair or replace if there is an open or short circuit Between lean angle sensor cou pler and ECU coupler blue blue yellow green yellow green black blue black blue 3 Defective le...

Page 295: ...er If there is a malfunction repair it and connect the coupler securely Starting the engine and activating the vehicle speed sensor by oper ating the vehi cle at 20 to 30 km h 2 Open or short circuit in speed sen sor lead Repair or replace if there is an open or short circuit Between speed sensor coupler and ECU coupler blue blue white white black blue black blue 3 Gear for detecting vehicle speed...

Page 296: ...l injection system relay coupler and ECU coupler blue red blue red red blue red blue Between fuel injection system relay coupler and starter relay coupler brown black brown black Between fuel injection system relay coupler and left handlebar switch coupler red black red black 3 Malfunction or open circuit in fuel pump relay Execute the diagnostic mode Code No D09 Replace if defective If there is n...

Page 297: ...3 3 Malfunction in rectifier regulator Replace if defective Refer to CHARGING SYSTEM in chapter 9 4 Open or short circuit in wire har ness Repair or replace if there is an open or short circuit Between battery lead and main switch coupler red red Between main switch coupler and ignition fuse brown blue brown blue Between ignition fuse and ECU coupler brown brown Fault code No 50 Symptom Faulty ECU...

Page 298: ...ge 3 00 4 00 V Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe pink terminal 1 Negative tester probe black blue terminal 2 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 1 Remove intake air temperature sensor WARNING _ Handle the intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air temperature...

Page 299: ...tester probe brown white 1 Negative tester probe black blue 2 Br W B L 2 1 b Immerse the air temperature sensor 1 in a container filled with water 2 NOTE Make sure that the air temperature sensor ter minals do not get wet c Place a thermometer 3 in the water d Slowly heat the water then let it cool down to the specified temperature e Measure the air temperature sensor resis tance 3 1 2 ...

Page 300: ...E SKID PLATES SEAT CARRIERS AND FENDERS in chapter 3 1 Fuel tank side cover 1 2 Fuel pump coupler 1 Disconnect 3 Fuel hose connector holder 1 Refer to REMOVING THE FUEL TANK and INSTALLING THE FUEL HOSE 4 Fuel hose 1 5 Fuel tank breather hose 2 6 Rollover valve 1 7 Fuel tank overflow hose 1 8 Fuel tank 1 9 Fuel pump assembly 1 Refer to REMOVING THE FUEL PUMP and INSTALLING THE FUEL PUMP 10 Final d...

Page 301: ...UEL TANK 2 1 11 8 4 12 9 6 5 7 10 3 4 5 6 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib New Order Job Part Q ty Remarks 11 Fuel tank shield 1 12 Damper 2 For installation reverse the removal pro cedure ...

Page 302: ...ext insert a slotted head screwdriver etc in the slot part a of the fuel hose connector cover 1 then slide it in the direction of the arrow and remove the 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 ...

Page 303: ...Replace INSTALLING THE FUEL PUMP 1 Install fuel pump gasket fuel pump fuel pump bracket NOTE Do not damage the installation surface of the fuel tank when installing the fuel pump Always use a new fuel pump gasket Install the fuel pump in the direction shown in the illustration Install the fuel pump bracket by aligning the projection a on the fuel pump with the pro jection on the fuel tank Tighten ...

Page 304: ... the fuel hose holder is in the correct position otherwise the fuel hose will not be properly installed NOTE Install the fuel hose connector holder 1 securely onto the fuel pump until a distinct click is heard and then make sure that it does not come loose To install the fuel hose onto the throttle body slide the fuel hose connector cover 2 on the end of the hose in direction of the arrow shown ...

Page 305: ...ER CASE in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Intake air pressure sensor coupler 1 Disconnect 2 Throttle position sensor coupler 1 Disconnect 3 Breather hose air filter case to throttle body 1 4 Breather hose air filter case to fast idle plunger unit 1 5 Fast idle plunger outlet hose 1 Disconnect 6 Fast idle plunger inlet hose 1 Disconnect 7 Throttle cable housing...

Page 306: ... Loosen Refer to INSTALLING THE THROTTLE BODY ASSEM BLY 10 Throttle body assembly 1 11 Fuel hose 1 Disconnect Refer to REMOVING THE THROTTLE BODY ASSEMBLY and INSTALLING THE THROTTLE BODY ASSEMBLY 12 Fuel injector coupler 1 Disconnect 13 Throttle body joint 1 Refer to INSTALLING THE THROTTLE BODY ASSEMBLY For installation reverse the removal pro cedure ...

Page 307: ...move the parts in the order listed 1 Intake air pressure sensor 1 2 Intake air pressure sensor hose 1 3 Throttle position sensor 1 4 Injector fuel rail 1 5 Fuel injector 1 6 Fast idle plunger unit 1 7 Throttle body 1 CAUTION The throttle body should not be disas sembled For assembly reverse the disassembly procedure ...

Page 308: ...disconnect the fuel hose from the throttle body slide the fuel hose connector cover 1 on the end of the hose in direction of the arrow shown press the 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 dis connected EAS00912 CHECKING THE FUEL INJECTOR 1 Check fuel injector Damage Replace EAS0091...

Page 309: ...ttle body joint b 1 a 2 Install throttle body assembly 1 NOTE Align the projection a on the throttle body assembly with the slot b in the throttle body joint a 1 b 3 Connect fuel hose CAUTION When connecting the fuel hose make sure that it is securely connected and that the fuel hose connector cover is in the correct position otherwise the fuel hose will not be properly connected NOTE To connect t...

Page 310: ...to REAR CARRIER AND REAR FENDER in chapter 3 b Remove the fuel hose connector holder c Disconnect the fuel hose 1 from the fuel pump NOTE When removing the fuel hose from the fuel pump remove the fuel hose connector holder first and next insert a slotted head screw driver etc in the slot part a of the fuel hose connector cover 2 then slide it in the direction of the arrow and remove the fuel hose ...

Page 311: ...hrottle body c Connect the pocket tester Ω 1k to the terminals of the throttle position sensor d Measure the maximum throttle position sen sor resistance Out of specification Replace the throttle position sensor 2 Adjust throttle position sensor angle NOTE _ Before adjusting the throttle position sensor the engine idling speed should be properly adjusted a Connect the throttle position sensor coup...

Page 312: ...is within the specified range e After adjusting the throttle position sensor angle tighten the throttle position sensor screws 3 Positive digital circuit tester probe yellow 1 Negative digital circuit tester probe black blue 2 Digital circuit tester 90890 03174 Model 88 Multimeter with tachom eter YU A1927 Throttle position sensor voltage 0 63 0 73 V yellow black blue B L Y L 1 2 3 3 THROTTLE BODY...

Page 313: ...tion and deceleration Diagnosis Possible incorrect reassembly too little gear lash CAUTION _ Too little gear lash is extremely destructive to the gear teeth If a test ride following reassembly indicates this condition stop riding immediately to minimize gear dam age Symptoms Possible Causes 1 A pronounced hesitation or jerky move ment during acceleration deceleration or sustained speed This must n...

Page 314: ...etal particles Check the bearing for seizure NOTE _ A small amount of metal particles in the oil is normal 3 Check oil leakage a Clean the entire vehicle thoroughly then dry it b Apply a leak localizing compound or dry powder spray to the shaft drive c Road test the vehicle for the distance nec essary to locate the leak Leakage Check the component housing gasket and or seal for damage Damage Repla...

Page 315: ... in chapter 8 YES Check the front constant velocity joints Feel for bearing damage NO Constant velocity joint bearings and differ ential gear bearings are probably not dam aged Repeat the test or remove the individual components YES Check the rear brake adjustment NO Adjust per instructions Refer to ADJUSTING THE REAR BRAKE in chapter 3 YES Check the rear constant velocity joints Feel for bearing ...

Page 316: ...differential gear Remove the parts in the order listed Front engine skid plate front fender Refer to ENGINE SKID PLATES SEAT CARRIERS AND FENDERS in chapter 3 Steering knuckles Refer to STEERING SYSTEM in chap ter 8 Front arms Refer to FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES in chapter 8 Differential gear oil Drain Refer to CHANGING THE DIFFEREN TIAL GEAR OIL in chapter 3 1 Front constant v...

Page 317: ...b T R 55 Nm 5 5 m kg 40 ft Ib LT Order Job Part Q ty Remarks 4 Differential gear case assembly 1 5 Front drive shaft 1 6 Spring 1 7 Damper 1 8 Coupling gear 1 9 Dust seal 1 10 Dust seal 1 For installation reverse the removal pro cedure FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR ...

Page 318: ...nt velocity joints Remove the parts in the order listed The following procedure applies to both of the front constant velocity joints 1 Clip 1 2 Boot band 2 Refer to ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS 3 Boot band 1 4 Dust boot 1 5 Clip 1 6 Double off set joint 1 7 Circlip 1 8 Boot band 1 9 Dust boot 1 0 Off set joint 1 ...

Page 319: ...V Order Job Part Q ty Remarks A Clip 1 Refer to ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS B Joint shaft 1 For assembly reverse the disassembly procedure FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR ...

Page 320: ...1 2 5 6 9 8 7 0 F 5 Order Job Part Q ty Remarks Disassembling the differential gear case assembly Remove the parts in the order listed 1 Differential gear motor 1 Refer to ASSEMBLING THE DIFFER ENTIAL GEARS 2 O ring 1 3 Front drive shaft coupling gear nut 1 4 Front drive shaft coupling gear differ ential gear case side 1 5 Differential gear case cover 1 6 O ring 1 7 Differential gear assembly 1 8 ...

Page 321: ... 1 1 m kg 8 0 ft Ib LT LS LS New New New New New New LS LS G F 4 3 A B D C E 1 2 5 6 9 8 7 0 F 5 Order Job Part Q ty Remarks B Clip 1 C Differential drive pinion gear 1 D Bearing 1 E Bearing 1 F Oil seal 2 G Differential gear case 1 For assembly reverse the disassembly procedure FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR ...

Page 322: ...ear are assembled into a proper unit at the factory by means of spe cialized equipment Do not attempt to dis assemble this unit Disassembly will result in the malfunction of the unit EBS00165 CHECKING THE FRONT CONSTANT VELOCITY JOINTS 1 Check double off set joint spline ball joint spline shaft spline Wear damage Replace 2 Check dust boots Cracks damage Replace CAUTION _ Always use a new boot band...

Page 323: ...ove the spring up and down 3 Check front drive shaft Bends Replace WARNING _ Do not attempt to straighten a bent shaft this may dangerously weaken the shaft CHECKING THE DIFFERENTIAL GEAR MOTOR 1 Check differential gear motor a Connect two C size batteries to the gear motor terminals 1 as shown in illustration CAUTION Be sure to check the motor operation after removing it from the differential gea...

Page 324: ...rease is included in the repair kit 2 Install dust boots 1 boot bands 2 3 a Apply molybdenum disulfide grease into the dust boots b Install the dust boots 1 c Install the dust boot bands NOTE _ The new boot bands may differ from the orig inal ones The dust boots should be fastened with the boot bands 3 at the grooves in the joint shaft 3 Check thrust movement free play Excessive play Replace the j...

Page 325: ...he gear is aligned with the mark 5 on the gear motor case CAUTION _ Do not use a 12 V battery to operate the pinion gear c Insert 6 mm bolts 6 into the gear motor 7 and use them as a guide to set the motor on the differential gear assembly 8 so that the shift fork sliding gear 9 does not move CAUTION _ If the position of the shift fork sliding gear is moved the position of the differential gear an...

Page 326: ... MEASURING THE DIFFERENTIAL GEAR LASH 1 Secure the gear case in a vise or another supporting device 2 Remove drain plug gasket 3 Install a bolt of the specified size 1 into the drain plug hole CAUTION _ Finger tighten the bolt until it holds the ring gear Otherwise the ring gear will be dam aged 4 Attach gear lash measurement tool 2 dial gauge 3 a Measuring point is 22 5 mm 0 86 in Gear lash measu...

Page 327: ... shaft 90 each time Differential gear lash 0 05 0 25 mm 0 0020 0 0098 in EBS00176 ADJUSTING THE DIFFERENTIAL GEAR LASH 1 Remove differential drive pinion gear shim s 1 differential gear assembly 2 2 Adjust gear lash a Select the suitable shims using the following chart Too little gear lash Reduce shim thickness Too large gear lash Increase shim thickness Ring gear shim Thickness mm 0 1 0 2 0 3 0 4...

Page 328: ...ting torque of the front wheel i e differential gear preload with the torque wrench NOTE _ Repeat this step several times to obtain an average figure During this test the other front wheel will turn in the opposite direction 4 Out of specification Replace the differen tial gear assembly 5 Within specification Install the new cotter pin and wheel cap T R Front wheel starting torque differential gea...

Page 329: ...ant velocity joints and final drive gear Remove the parts in the order listed Rear engine skid plate rear fender Refer to ENGINE SKID PLATES SEAT CARRIERS AND FENDERS in chapter 3 Rear arms Refer to REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES in chapter 8 Final gear oil Drain Refer to CHANGING THE FINAL GEAR OIL in chapter 3 1 Rear constant velocity joint 2 2 Final gear case breather hose 1 Disco...

Page 330: ... 40 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib LS LS LS LS New New Order Job Part Q ty Remarks 6 Spring 1 7 Damper 1 8 Coupling gear 1 9 Dust seal 1 10 Dust seal 1 For installation reverse the removal pro cedure REAR CONSTANT VELOCITY JOINTS AND FINAL DRIVE GEAR ...

Page 331: ...nt velocity joints Remove the parts in the order listed The following procedure applies to both of the rear constant velocity joints 1 Clip 1 2 Boot band 2 Refer to ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS 3 Boot band 1 4 Dust boot 1 5 Clip 1 6 Double off set joint 1 7 Circlip 1 8 Boot band 1 9 Dust boot 1 0 Off set joint 1 ...

Page 332: ...RIV Order Job Part Q ty Remarks A Clip 1 Refer to ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS B Joint shaft 1 For assembly reverse the disassembly procedure REAR CONSTANT VELOCITY JOINTS AND FINAL DRIVE GEAR ...

Page 333: ... Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LS G G G G LS LS LS G G LS LT Order Job Part Q ty Remarks Disassembling the final gear case assembly Remove the parts in the order listed 1 Final drive pinion gear assembly 1 2 Final drive pinion gear shim 3 Final gear case cover 1 NOTE _ Working in a crisscross pattern loosen each bolt 1 4 of a turn After all the bolts are loosened remove them 4 Dowel pin 2 5 Gask...

Page 334: ...art Q ty Remarks A Thrust washer B Pinion gear 1 C Final driven pinion gear 1 D Final driven pinion gear shim E Oil seal 1 F Bearing 1 G Bearing 1 H Final gear case 1 I Rear drive shaft coupling gear nut 1 Refer to DISASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY and ASSEMBLING THE FINAL DRIVE PIN ION GEAR ASSEMBLY J Washer 1 K Rear drive shaft coupling gear final gear case side 1 L Final drive ...

Page 335: ...Nm 2 3 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LS G G G G LS LS LS G G LS LT Order Job Part Q ty Remarks O Expander 1 Refer to DISASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY and ASSEMBLING THE FINAL DRIVE PIN ION GEAR ASSEMBLY P Washer 1 Q Bearing 1 R Final drive pinion gear bearing housing 1 For assembly reverse the disassembly procedure REAR CONSTANT VELOCITY JOINTS AND FINAL DRIVE GEAR ...

Page 336: ...t bands 2 3 a Apply molybdenum disulfide grease into the dust boots b Install the dust boots 1 c Install the dust boot bands NOTE _ The new boot bands may differ from the orig inal ones The dust boots should be fastened with the boot bands 3 at the grooves in the joint shaft Molybdenum disulfide grease 40 g 1 4 oz per dust boot rear wheel side 60 g 2 1 oz per dust boot final gear case side New 3 C...

Page 337: ...iven pinion gear using the shim s EBS00185 ADJUSTING THE FINAL DRIVE PINION GEAR BACKLASH 1 Select final drive pinion gear shim s 1 a To find the final drive pinion gear shim thick ness A use the following formula a 55 mm 2 2 in 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 ...

Page 338: ...ion gear shim thickness 4 If 01 is stamped on the final gear case d 100 0 01 99 99 5 Therefore A is 0 58 A 55 67 75 22 18 99 99 0 58 6 Round off the hundredth digit and select the appropriate shim s In the example above the calculated num ber is 0 58 The chart instructs you to round off 8 to 10 at the hundredth place Thus the shim thickness is 0 60 mm 0 024 in Shims are supplied in the following t...

Page 339: ... outside of the final driven pinion gear either added to or subtracted from 51 0 g a numeral usually a decimal number on the outside of the final driven pinion gear either added to or subtracted from 24 0 h 49 8 Example 1 If 03 is stamped on the final gear case e 71 6 0 03 71 57 2 If 12 is stamped on the outside of the final driven pinion gear f 51 0 0 12 50 88 3 If 05 is stamped on the outside of...

Page 340: ...ff 6 to 5 at the hun dredth place Thus the shim thickness is 5 15 mm Shims are supplied in the following thick nesses NOTE Be sure to use one of each of the final driven pinion gear shims 1 and 2 to obtain the shim thickness Hundredths Rounded value 0 1 2 0 3 4 5 6 7 5 8 9 10 Final driven pinion gear shim 1 Thickness mm 0 25 0 30 0 35 0 40 0 45 0 50 Final driven pinion gear shim 2 Thickness mm 4 5...

Page 341: ...on gear wheel gear and driven pinion gear when measuring the clearance with Plastigauge c Remove the final driven pinion gear assem bly d Measure the thrust clearance Calculate the width of the flattened Plastigauge 1 e If out of specification select the correct washer 2 Select final driven pinion gear thrust washer a Select a suitable thrust washer using the following chart b Repeat the measureme...

Page 342: ... gear when measuring the clearance with Plastigauge c Remove the wheel gear d Measure the thrust clearance Calculate the width of the flattened Plastigauge 1 e If out of specification select the correct shim s 2 Select wheel gear thrust clearance D a Select a suitable wheel gear shim s using the following chart b Repeat the measurement steps until the wheel gear thrust clearance is within the spec...

Page 343: ...to adjust the shim thickness of the final drive pinion gear final driven pinion gear and or wheel gear 2 Check gear teeth Pitting galling wear Replace the drive pinion gear and ring gear as a set oil seals O rings Damage Replace 3 Check bearings Damage Replace NOTE _ Reusing roller bearings is acceptable but Yamaha recommends installing new ones Do not reuse the oil seal When the final drive pinio...

Page 344: ...gear Otherwise the ring gear will be dam aged 4 Attach final gear backlash band 2 dial gauge 3 a Measuring point is 31 5 mm 1 24 in 5 Measure gear lash Gently rotate the coupling gear from engagement to engagement NOTE _ When measuring the gear lash be sure the right side gear oil level check bolt side of the final gear case assembly is facing down ward Measure the gear lash at four positions Rota...

Page 345: ... 0 2 mm 0 008 in for every 0 2 mm 0 008 in of final driven pinion gear shim increase c If reduced by more than 0 2 mm 0 008 in Increase the thrust washer thickness by 0 2 mm 0 008 in for every 0 2 mm 0 008 in that the final driven pinion gear shim is decreased NOTE Be sure to use one of each of the final driven pinion gear shims 2 and 3 to obtain the shim thickness Too little gear lash Increase sh...

Page 346: ...ousing in a vice and then turn the nut with a torque wrench to check the starting torque c Out of specification Tighten the nut fur ther d Repeat step b e Repeat steps c and d until the starting torque is within specification NOTE Be careful not to exceed the specified start ing torque If the specified starting torque is exceeded replace the expander with a new one and reassemble the final drive p...

Page 347: ...7 35 DRIV REAR CONSTANT VELOCITY JOINTS AND FINAL DRIVE GEAR ASSEMBLING THE FINAL GEAR CASE 1 Install oil seals 1 Installed depth of oil seal a 5 5 mm 0 22 in a a 1 1 ...

Page 348: ...Job Part Q ty Remarks Removing the front wheels Remove the parts in the order listed The following procedure applies to both of the front wheels Place the vehicle on a level surface WARNING _ Securely support the vehicle so there is no danger of it falling over 1 Front wheel 1 Refer to INSTALLING THE WHEELS 2 Wheel cap 1 3 Front wheel axle nut 1 Refer to INSTALLING THE WHEEL HUBS FRONT AND REAR WH...

Page 349: ... New Order Job Part Q ty Remarks 4 Front brake caliper assembly 1 NOTE _ 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 Refer to INSTALLING THE BRAKE DISCS For installation reverse the removal pro cedure FRONT AND REAR WHEELS ...

Page 350: ...ew Order Job Part Q ty Remarks Removing the rear wheels Remove the parts in the order listed The following procedure applies to both of the rear wheels Place the vehicle on a level surface WARNING _ Securely support the vehicle so there is no danger of it falling over 1 Rear wheel 1 Refer to INSTALLING THE WHEELS 2 Wheel cap 1 3 Rear wheel axle nut 1 Refer to INSTALLING THE WHEEL HUBS ...

Page 351: ...Order Job Part Q ty Remarks 4 Rear brake caliper assembly 1 NOTE 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 Refer to INSTALLING THE BRAKE DISCS For installation reverse the removal pro cedure FRONT AND REAR WHEELS ...

Page 352: ... 0 08 in Rear Radial 2 2 0 mm 0 08 in Lateral 3 2 0 mm 0 08 in 3 Check wheel balance Out of balance Adjust WARNING _ After replacing the tire ride conservatively to allow the tire to be properly seated in the rim Failure to do so may cause an accident resulting in vehicle damage and possible operator injury EBS00385 CHECKING THE WHEEL HUBS 1 Check wheel hubs 1 Cracks damage Replace splines wheel h...

Page 353: ... in Rear 0 1 mm 0 004 in Brake disc minimum thickness Front 3 0 mm 0 12 in Rear 3 0 mm 0 12 in INSTALLING THE BRAKE DISCS 1 Install brake discs NOTE Install the brake discs with their spot faced side facing the bolt heads T R Brake disc bolt 30 Nm 3 0 m kg 22 ft lb LOCTITE INSTALLING THE WHEEL HUBS 1 Install wheel axle nut NOTE Do not apply oil to the seat of the nut After tightening the nut stake...

Page 354: ...eels NOTE _ The arrow mark 1 on the tire must point in the direction of rotation È of the wheel 2 Tighten wheel nuts 1 WARNING Tapered wheel nuts 1 are used for both the front and rear wheels Install each nut with its tapered side towards the wheel T R 55 Nm 5 5 m kg 40 ft lb ...

Page 355: ...Removing the front brake pads Remove the parts in the order listed The following procedure applies to both of the front brake calipers Front wheel Refer to FRONT AND REAR WHEELS 1 Front brake caliper bolt 2 Refer to REPLACING THE FRONT AND REAR BRAKE PADS 2 Brake pad holding bolt plug 1 3 Brake pad holding bolt 1 4 Front brake pad 2 5 Brake pad spring 1 For installation reverse the removal pro ced...

Page 356: ...the rear brake pads Remove the parts in the order listed The following procedure applies to both of the rear brake calipers Rear wheel Refer to FRONT AND REAR WHEELS 1 Rear brake caliper bolt 2 Refer to REPLACING THE FRONT AND REAR BRAKE PADS 2 Brake pad holding bolt plug 1 3 Brake pad holding bolt 1 4 Rear brake pad 2 5 Brake pad spring 1 For installation reverse the removal pro cedure ...

Page 357: ...e fluid onto painted surfaces or plastic parts as this may cause dam age disconnect any hydraulic connection as this would require the entire brake sys tem to be disassembled drained cleaned properly filled and bled after reassembly EBS00404 REPLACING THE FRONT AND REAR BRAKE PADS NOTE _ It is not necessary to disassemble the brake calipers and brake hoses to replace the brake pads 1 Remove brake ...

Page 358: ...n into the brake caliper c Tighten the brake caliper bleed screw d Install new brake pads and a new brake pad spring e Install the holding bolt holding bolt plug and brake caliper 3 Check brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 4 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 T R Bra...

Page 359: ... 5 1 ft Ib Apply silicone grease Order Job Part Q ty Remarks Removing the front brake master cylinder Remove the parts in the order listed Brake fluid Drain On command four wheel drive motor switch and differential gear lock switch Refer to HANDLEBAR 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Front brake lever cover 1 5 Brake leve...

Page 360: ...ease Order Job Part Q ty Remarks 6 Union bolt 1 Refer to INSTALLING THE FRONT BRAKE MASTER CYLINDER 7 Copper washer 2 8 Front brake hose 1 Disconnect 9 Front brake light switch connector 2 Disconnect 10 Front brake light switch 1 11 Front brake master cylinder holder 1 12 Front brake master cylinder 1 For installation reverse the removal pro cedure FRONT AND REAR BRAKES ...

Page 361: ...Part Q ty Remarks Disassembling the front brake mas ter cylinder Remove the parts in the order listed 1 Dust boot 1 Refer to ASSEMBLING THE FRONT AND REAR BRAKE MASTER CYLIN DERS 2 Circlip 1 3 Brake master cylinder kit 1 For assembly reverse the disassembly procedure ...

Page 362: ... Nm 2 7 m kg 19 ft Ib Apply silicone grease Order Job Part Q ty Remarks Removing the rear brake master cyl inder Remove the parts in the order listed Brake fluid Drain 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Rear brake lever cover 1 5 Shift control cable 1 Disconnect 6 Rear brake cable 1 Disconnect 7 Brake lever 1 8 Brake lever...

Page 363: ...ilicone grease Order Job Part Q ty Remarks 9 Union bolt 1 Refer to INSTALLING THE REAR BRAKE MAS TER CYLINDER 10 Copper washer 2 11 Rear brake hose 1 Disconnect 12 Rear brake light switch connector 2 Disconnect 13 Rear brake light switch 1 14 Rear brake master cylinder holder 1 15 Rear brake master cylinder 1 For installation reverse the removal pro cedure FRONT AND REAR BRAKES ...

Page 364: ...Part Q ty Remarks Disassembling the rear brake mas ter cylinder Remove the parts in the order listed 1 Dust boot 1 Refer to ASSEMBLING THE FRONT AND REAR BRAKE MASTER CYLIN DERS 2 Circlip 1 3 Brake master cylinder kit 1 For assembly reverse the disassembly procedure ...

Page 365: ...h compressed air 2 Check brake master cylinder kit Scratches wear damage Replace as a set 3 Check brake master cylinder reservoir brake master cylinder reservoir diaphragm Cracks damage Replace EBS00415 ASSEMBLING THE FRONT AND REAR BRAKE MASTER CYLINDERS WARNING _ All internal brake components should be cleaned and lubricated with new brake fluid only before installation Whenever a master cylinde...

Page 366: ...der should face up UP Lower 2 a 1 b T R 7 Nm 0 7 m kg 5 1 ft lb 2 Install brake hose copper washers union bolt NOTE _ Tighten the union bolt while holding the brake hose as shown Turn the handlebar to the left and to the right to check that the brake hose does not touch other parts throttle cable wire harness leads etc Correct if necessary WARNING _ Proper brake hose routing is essential to insure...

Page 367: ...he same type of brake fluid mixing brake fluids may result in a harm ful reaction and lead to poor brake perfor mance Be careful that water does not enter the brake master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 4 Air bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid leve...

Page 368: ...holder should face up UP a b 1 2 T R 7 Nm 0 7 m kg 5 1 ft lb 2 Install brake hose copper washers union bolt NOTE _ Tighten the union bolt while holding the brake hose as shown Turn the handlebar to the left and to the right to check that the brake hose does not touch other parts throttle cable wire harness leads etc Correct if necessary WARNING _ Proper brake hose routing is essential to insure sa...

Page 369: ...ead to poor brake performance Be careful that water does not enter the brake master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 4 Air bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level Brake fluid level is under the LOWER level line Fill up Refer to CHECKING THE BRAKE FL...

Page 370: ... in the order listed The following procedure applies to both of the front brake calipers Brake fluid Drain Front wheel Refer to FRONT AND REAR WHEELS 1 Union bolt 1 Refer to INSTALLING THE FRONT AND REAR BRAKE CALIPERS 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 For...

Page 371: ... parts in the order listed The following procedure applies to both of the front brake calipers 1 Brake pad holding bolt 1 2 Front brake pad 2 3 Brake pad spring 1 4 Front brake caliper bracket 1 5 Caliper piston 1 Refer to DISASSEMBLING THE FRONT AND REAR BRAKE CALI PERS and ASSEMBLING THE FRONT AND REAR BRAKE CALI PERS 6 Dust seal 1 7 Caliper piston seal 1 8 Bleed screw 1 For assembly reverse the...

Page 372: ...ke calipers Remove the parts in the order listed The following procedure applies to both of the rear brake calipers Brake fluid Drain Rear wheel Refer to FRONT AND REAR WHEELS 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 For installation reverse the remov...

Page 373: ...e parts in the order listed The following procedure applies to both of the rear brake calipers 1 Brake pad holding bolt 1 2 Rear brake pad 2 3 Brake pad spring 1 4 Rear brake caliper bracket 1 5 Caliper piston 1 Refer to DISASSEMBLING THE FRONT AND REAR BRAKE CALI PERS and ASSEMBLING THE FRONT AND REAR BRAKE CALI PERS 6 Dust seal 1 7 Caliper piston seal 1 8 Bleed screw 1 For assembly reverse the d...

Page 374: ...y WARNING _ Never try to pry out the caliper piston Cover the caliper piston with a rag Be careful not to get injured when the piston is expelled from the caliper cylinder b Remove the dust seal and the caliper piston seal 2 1 3 È 2 1 3 É a EBS00429 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads As required Piston seals dust seals Every two y...

Page 375: ...damage Replace brake fluid delivery passage brake caliper body Blockage Blow out with compressed air WARNING _ Replace the caliper piston seal and dust seal whenever the brake caliper is disas sembled È Front É Rear 1 2 3 È 1 2 3 É EBS00431 ASSEMBLING THE FRONT AND REAR BRAKE CALIPERS WARNING _ All internal brake components should be cleaned and lubricated with new brake fluid only before installa...

Page 376: ...e sure that the brake pipe touches the projection a on the brake caliper WARNING _ Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING in chapter 2 È Front É Rear 2 Fill brake master cylinder reservoir CAUTION _ Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately Recommended brake fluid DOT 4 T R 30 Nm ...

Page 377: ...l reaction and lead to poor brake performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 3 Air bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 4 Check brake fluid level Brake fluid level is below the LOWER level line Add the recommended brake fl...

Page 378: ...d 1 Handlebar cover 1 2 Plastic band 4 3 On command four wheel drive motor switch and differential gear lock switch 1 4 Throttle lever assembly holder 1 Refer to INSTALLING THE THROT TLE LEVER ASSEMBLY 5 Throttle lever assembly 1 6 Front brake light switch connector 2 Disconnect 7 Front brake master cylinder holder 1 Refer to INSTALLING THE FRONT BRAKE MASTER CYLINDER 8 Front brake master cylinder...

Page 379: ...inder holder 1 Refer to INSTALLING THE REAR BRAKE MASTER CYLINDER 11 Rear brake master cylinder 1 12 Spacer 1 13 Left handlebar switch 1 14 Handlebar grip 2 Refer to REMOVING THE HANDLEBAR GRIPS and INSTALLING THE HAN DLEBAR GRIPS 15 Handlebar holder 2 Refer to INSTALLING THE HANDLE BAR 16 Handlebar 1 For installation reverse the removal pro cedure STEERING SYSTEM ...

Page 380: ... _ Do not attempt to straighten a bent handle bar as this may dangerously weaken the handlebar EBS00449 INSTALLING THE HANDLEBAR 1 Install handlebar handlebar holders NOTE _ Install the handlebar within 15 from the hori zontal line shown in the illustration The upper handlebar holders should be installed with the punched mark 1 forward 2 CAUTION _ First tighten the bolts 3 on the front side of the...

Page 381: ...ow mark L faces up on the left han dlebar grip and the arrow mark R faces up on the right handlebar EBS00453 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install left handlebar switch spacer rear brake master cylinder 1 rear brake master cylinder holder 2 NOTE _ Align the end of the brake master cylinder holder with the punch mark a on the handle bar The UP mark b on the brake master cylin der hold...

Page 382: ...ter cylinder holder with the punch mark a on the handle bar The UP mark b on the brake master cylin der holder should face up UP Lower 2 a 1 b T R 7 Nm 0 7 m kg 5 1 ft lb INSTALLING THE THROTTLE LEVER ASSEMBLY 1 Install throttle lever assembly 1 throttle lever assembly holder NOTE Align the projection a on the throttle lever assembly with the end of the brake master cyl inder holder b 1 a b ...

Page 383: ...Ib T R 125 Nm 12 5 m kg 90 ft lb LS LS LT 6 Order Job Part Q ty Remarks Removing the steering stem Remove the parts in the order listed Front fender Refer to ENGINE SKID PLATES SEAT CARRIERS AND FENDERS in chapter 3 Air filter case Refer to AIR FILTER CASE in chapter 3 Handlebar Refer to HANDLEBAR Electrical components tray Refer to ELECTRICAL COMPONENTS TRAY in chapter 3 1 Lock washer 1 Refer to ...

Page 384: ... R 125 Nm 12 5 m kg 90 ft lb LS LS LT 6 Order Job Part Q ty Remarks 8 Pitman arm nut 1 Refer to INSTALLING THE PITMAN ARM 9 Pitman arm 1 10 Steering stem 1 Refer to INSTALLING THE STEERING STEM 11 Collar 1 12 Bearing nut 1 13 Collar 1 14 Steering stem bearing 1 15 Steering stem joint bolt 2 16 Steering stem joint 1 17 EPS breather hose 1 18 EPS motor cover 1 19 EPS unit 1 Refer to INSTALLING THE S...

Page 385: ...LING THE STEERING STEM 1 Install EPS unit 1 washers EPS unit bolts 2 2 Install steering stem 3 steering stem bearing 4 collar 5 bearing nut 6 3 Install oil seals 7 collars 8 steering stem bushings 9 cable guide 0 lock washer A steering stem bracket B steering stem bolts C temporarily tighten NOTE Apply lithium soap based grease to the oil seals and steering stem bushings T R EPS unit bolt 30 Nm 3 ...

Page 386: ...ng stem joint 5 Tighten steering stem bracket bolts G NOTE Apply LOCTITE to the steering stem bracket bolts steering stem bearing bolts H NOTE Apply LOCTITE to the steering stem bearing bolts steering stem joint bolts F b a d c T R 50 Nm 5 0 m kg 36 ft lb T R 50 Nm 5 0 m kg 36 ft lb T R 30 Nm 3 0 m kg 22 ft lb 6 Tighten steering stem bolts C NOTE Bend the lock washer tab e along a flat side of the...

Page 387: ...S STEERING SYSTEM INSTALLING THE PITMAN ARM 1 Install pitman arm 1 washer pitman arm nut clip NOTE Align the punch mark b on the EPS unit with the groove a in the pitman arm 1 a b T R 210 Nm 21 0 m kg 150 ft lb ...

Page 388: ...w 3 1 8 6 7 9 2 5 4 10 11 Order Job Part Q ty Remarks Removing the tie rods and steering knuckles Remove the parts in the order listed The following procedure applies to both of the tie rods and steering knuckles Front wheel brake disc Refer to FRONT WHEELS 1 Brake disc guard 1 2 Front arm protector 1 3 Tie rod 1 Refer to INSTALLING THE TIE RODS 4 Nut 1 5 Nut 1 6 Steering knuckle 1 Refer to REMOVI...

Page 389: ...2 5 m kg 18 ft Ib T R 25 Nm 2 5 m kg 18 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 25 Nm 2 5 m kg 18 ft Ib New New New LS New LS New New New 3 1 8 6 7 9 2 5 4 10 11 Order Job Part Q ty Remarks 10 Circlip 1 11 Bearing 1 For installation reverse the removal pro cedure STEERING SYSTEM ...

Page 390: ...rod free play and movement Free play Replace the tie rod end Turns roughly Replace the tie rod end 2 Check tie rod Bends damage Replace EBS00463 CHECKING THE STEERING KNUCKLES 1 Check steering knuckle Damage pitting Replace 2 Check ball joints Damage pitting Replace the ball joint Free play Replace the ball joint Turns roughly Replace the ball joint a Clean the outside of the steering knuckle b Re...

Page 391: ...l joint remover installer set Ball joint bore inside diameter 32 00 32 05 mm 1 260 1 280 in Ball joint remover 90890 01474 YM 01474 Ball joint remover attachment set 90890 01480 Ball joint adapter set YM 01480 Ball joint remover short shaft set 90890 01514 3 Remover attachment 90890 01474 YM 01474 4 Installer spacer 90890 01480 YM 01480 5 Installer washer 90890 01474 YM 01474 6 Base 90890 01480 YM...

Page 392: ... remover installer i Install a new ball joint NOTE Always use a new ball joint set 5 2 1 3 4 6 3 Check front wheel bearing 1 Bearings allow play in the wheel hubs or the wheel turns roughly Replace a Clean the outside of the steering knuckle b Remove the circlip 2 c Drive out the bearing WARNING _ Eye protection is recommended when using striking tools d Apply lithium soap based grease to the oute...

Page 393: ...G THE TIE RODS 1 Install tie rods left and right NOTE _ The tie rod side which must be installed on the out side has grooves 1 2 Adjust toe in Refer to ADJUSTING THE TOE IN in chapter 3 T R 25 Nm 2 5 m kg 18 ft lb STEERING SYSTEM ...

Page 394: ...S New Order Job Part Q ty Remarks Removing the front arms and front shock absorber assemblies Remove the parts in the order listed The following procedure applies to both of the front arms and front shock absorber assemblies Front wheel brake disc Refer to FRONT AND REAR WHEELS Front brake caliper assembly Refer to FRONT AND REAR BRAKES 1 Brake disc guard 1 2 Front arm protector 1 3 Front brake ho...

Page 395: ...t Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib New New New LS LS New Order Job Part Q ty Remarks 10 Nut bolt 2 2 Refer to REMOVING THE FRONT ARMS and INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORB ERS 11 Front lower arm 1 12 Dust cover 2 13 Bushing 2 14 Circlip 1 15 Rubber boot 1 16 Ball joint 1 17 Bushing 2 For installation reverse the removal pro cedure FRONT ARMS AND FRONT SHOCK...

Page 396: ...he vertical movement is tight or rough or if there is binding check the bushings 2 Remove front arms È È É É EBS00470 CHECKING THE FRONT ARMS 1 Check front arms Bends damage Replace 2 Check bushings Wear damage Replace 3 Check ball joint Damage pitting Replace the ball joint Free play Replace the ball joint Turns roughly Replace the ball joint a Clean the outside of the front upper arm b Remove th...

Page 397: ...nd installer washer 9 to the front upper arm A NOTE _ Do not tap or damage the top of the ball joint Installer washer 9 must be aligned with the projection on the head of the ball joint B g Remove the ball joint remover h Install a new circlip NOTE _ Always use a new ball joint set Ball joint remover 90890 01474 YM 01474 Ball joint remover attachment set 90890 01480 Ball joint adapter set YM 01480...

Page 398: ...l front arms front shock absorber a Install the front upper arm 1 and front lower arm 2 NOTE _ Lubricate the bolts 3 with lithium soap based grease Be sure to position the bolts 3 so that the bolt head faces forward Temporarily tighten the nuts 4 b Install the front shock absorber 5 and bolts 6 c Install the steering knuckle d Install the new cotter pins e Tighten the nuts 4 T R Nut 7 45 Nm 4 5 m ...

Page 399: ...m kg 36 ft Ib New T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the rear knuckles and sta bilizer Remove the parts in the order listed The following procedure applies to both of the rear knuckles Rear wheel hubs Refer to FRONT AND REAR WHEELS 1 Brake disc guard 1 2 Plate 1 3 Rear arm protector 1 4 Rear brake hose protector 1 5 Rear brake hose holder 1...

Page 400: ... R 7 Nm 0 7 m kg 5 1 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 50 Nm 5 0 m kg 36 ft Ib T R 50 Nm 5 0 m kg 36 ft Ib New T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks 12 Stabilizer holder 2 13 Bushing 2 14 Stabilizer 1 For installation reverse the removal pro cedure REAR KNUCKLES AND STABILIZER ...

Page 401: ... of the rear knuckle b Remove the circlip 2 c Drive out the bearing WARNING _ Eye protection is recommended when using striking tools d Apply lithium soap based grease to the outer side of the bearing e Install the new bearing CAUTION _ Do not strike the center race or balls of the bearing Should be made only with the outer race f Install the new circlip 1 2 EBS01025 CHECKING THE STABILIZER 1 Chec...

Page 402: ...art Q ty Remarks Removing the rear arms and rear shock absorber assemblies Remove the parts in the order listed The following procedure applies to both of the rear arms and rear shock absorber assemblies Rear knuckle stabilizer Refer to REAR KNUCKLES AND STA BILIZER 1 Rear brake hose guide 2 2 Nut washer bolt 2 1 2 Refer to INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES 3 Rear shock a...

Page 403: ...4 5 m kg 32 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks 10 Bushing 4 Refer to INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES For installation reverse the removal pro cedure REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES ...

Page 404: ...ck rear arms Bends damage Replace 2 Check bushings Wear damage Replace EBS00478 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES 1 Check shock absorber assemblies Oil leaks Replace the shock absorber assembly spring Fatigue Replace the shock absorber assemblies Move the spring up and down ...

Page 405: ... and rear lower arm 2 NOTE _ Lubricate the bolts 3 with lithium soap based grease Be sure to position the bolts 3 so that the bolt head faces outward Temporarily tighten the nuts 4 b Install the rear shock absorber assembly 5 and bolts 6 c Install the rear knuckle d Tighten the nuts 4 T R Nut 7 45 Nm 4 5 m kg 32 ft lb T R Nut 8 45 Nm 4 5 m kg 32 ft lb T R Nut 4 45 Nm 4 5 m kg 32 ft lb 67 34 5 67 2...

Page 406: ... wheel drive motor relay 1 5 Headlight relay 6 Fuel injection system fuse 7 Starter relay 8 EPS fuse 9 Main fuse 0 Fuse box ignition headlights four wheel drive motor radiator fan motor signaling system aux iliary DC jack A Radiator fan motor circuit breaker B Rectifier regulator 1 2 3 4 5 9 8 0 B A C D E F G H J I 6 7 ELECTRICAL COMPONENTS 9 ...

Page 407: ...ECTRICAL COMPONENTS C Reverse switch D Gear position switch E Auxiliary DC jack F Main switch G Differential gear motor H EPS motor I EPS torque sensor J Radiator fan motor 1 2 3 4 5 9 8 0 B A C D E F G H J I 6 7 ...

Page 408: ...brake light switch 6 Rear brake light switch 7 Intake air temperature sensor 8 Intake air pressure sensor 9 TPS throttle position sensor 0 Fuel pump A Speed sensor B Crankshaft position sensor C Coolant temperature sensor D Ignition coil E Battery F ECU engine control unit G EPS electric power steering control unit 5 6 1 G E D C B A 7 8 9 0 F 2 3 4 ...

Page 409: ...d to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration NOTE _ indicates a ...

Page 410: ... CHECKING SWITCH CONTINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch R R GRAY Br L Br L ON OFF R B R B R W R W GRAY L B L B Lg Lg B B B R Y Y L PUSH OFF OFF R Y L Y 1 A 0 2 3 4 5 6 8 7 9 B B Br Br G R G R Gy Gy LIGHT GRAY Sb Sb L B L B L R L R L G L G BLACK 4WD 2WD LOCK Gy W L P Br Y Y Br Y Y W G W ...

Page 411: ...ch 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 8 Gear position switch 9 Reverse switch 0 Rear brake light switch A Front brake light switch ...

Page 412: ...BS The bulbs used on this vehicle are shown in the illustration on the left Bulbs a and b are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise Bulbs c is used for turn signal and tail brake lights and can be removed from the socket by...

Page 413: ...herwise it may be pulled out of the ter minal in the coupler Avoid touching the glass part of the head light bulb to keep it free from oil other wise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bulb for continuity with the pock...

Page 414: ...TION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets 1 Check bulb socket for continuity with the pocket tester No continuity Replace NOTE _ Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the respective leads of the bul...

Page 415: ... L W BLACK Br G Y G Y Y W ON OFF 4WD 2WD LOCK PUSH OFF OFF Br B R B W R G B R B W R G B R B R B B Br O W L B G R W L B G W L L R R R R W R Br L Br P P B Br L Br R Br L Br L Br Y Br L R Y R R B B B B B B B B B W W W W R W W Br L W B R Br L R W B W B O Gy G B R W B G R Y B Y R Lg R L L R Sb Br L W Y W Y W W R Y L Br W Br W B L R B R B R L G Y G Y L W B L Y P Y G Br Br B Y L B W G R W B Br L Y Sb B R...

Page 416: ... with the following special tool s EBS01043 YES NO EBS01044 YES NO The ignition system fails to operate no spark or intermittent spark Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Main and ignition fuses Check the main and ignition fuses for con tinuity Refer to CHECKING THE FUSES in chapter 3 Are the main and igniti...

Page 417: ... is it of the correct type and is its gap within spec ification Re gap or replace the spark plug 4 Ignition spark gap Disconnect the spark plug cap from the spark plug Connect the ignition checker 1 as shown 2 Spark plug cap Set the main switch to ON Measure the ignition spark gap a Crank the engine by pushing the start switch and gradually increase the spark gap until a misfire occurs Minimum ign...

Page 418: ...gnition coil connectors from the ignition coil terminals Connect the pocket tester Ω 1 to the ignition coil as shown Positive tester probe red black lead terminal 1 Negative tester probe orange lead terminal 2 Measure the primary coil resistance Primary coil resistance 3 4 4 6 Ω at 20 C 68 F Connect the pocket tester Ω 1k to the ignition coil as shown Positive tester probe red black lead terminal ...

Page 419: ...witch OK Replace the left han dlebar switch 9 Crankshaft position sensor resistance Disconnect the crankshaft position sensor coupler from the wire harness Connect the pocket tester Ω 100 to the crankshaft position sensor coupler as shown Positive tester probe green yellow 1 Negative tester probe black 2 Measure the crankshaft position sensor resistance Crankshaft position sensor resis tance 459 5...

Page 420: ...h to ON Turn the lean angle sensor to 65 Measure the lean angle sensor output volt age Lean angle sensor voltage Less than 65 5 3 55 4 45 V More than 65 5 0 65 1 35 V Is the lean angle sensor OK Replace the lean angle sensor UP L Y G B L 65 65 1 2 11 Wiring Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM Is the ignition system s wiring properly connected and without defects Repl...

Page 421: ...D 2WD LOCK PUSH OFF OFF Br B R B W R G B R B W R G B R B R B B Br O W L B G R W L B G W L L R R R R W R Br L Br P P B Br L Br R Br L Br L Br Y Br L R Y R R B B B B B B B B B W W W W R W W Br L W B R Br L R W B W B O Gy G B R W B G R Y B Y R Lg R L L R Sb Br L W Y W Y W W R Y L Br W Br W B L R B R B R L G Y G Y L W B L Y P Y G Br Br B Y L B W G R W B Br L Y Sb B R L Y L G L R L R G R Sb Gy B B B Y ...

Page 422: ... pedal is free In this instance the starting circuit cut off relay is off so that current cannot reach the starter motor 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Signaling system fuse 7 Rear brake light switch 8 Rear brake relay 9 Diode 2 0 Gear position switch A Starting circuit cut off relay B Start switch C Diode 1 D Starter relay E Starter motor The transmissi...

Page 423: ...n and signaling system fuses Check the main ignition and signaling sys tem fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and signaling sys tem fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the batte...

Page 424: ...Negative tester probe blue black 4 Does the starting circuit cut off relay have continuity between blue white and blue black Replace the starting circuit cut off relay L W L B R B B Y 1 2 3 4 5 Starter relay Remove the starter relay from the wire harness Connect the pocket tester Ω 1 and bat tery 12 V to the starter relay as shown Positive battery terminal brown 1 Negative battery terminal blue wh...

Page 425: ... 3 7 Diode 2 Remove the diode 2 from the wire har ness Connect the pocket tester Ω 1 to the diode 2 as shown Measure the diode 2 for continuity as fol lows NOTE _ The pocket tester 90890 03112 and the ana log pocket tester YU 03112 C readings are shown in the following table Positive tester probe black yellow 1 Negative tester probe sky blue 2 Continuity Positive tester probe black yellow 1 Negati...

Page 426: ...HES Is the start switch OK Replace the left han dlebar switch 11 Rear brake light switch Check the rear brake light switch for conti nuity Refer to CHECKING THE SWITCHES Is the rear brake light switch OK Replace the rear brake light switch 12 Gear position switch Check the gear position switch for continu ity Refer to CHECKING THE SWITCHES Is the gear position switch OK Replace the gear position s...

Page 427: ...E REMOVAL in chapter 4 1 Starter motor lead 1 Disconnect 2 Ground lead 1 Disconnect 3 Starter motor 1 For installation reverse the removal pro cedure Disassembling the starter motor Remove the parts in the order listed 1 Starter motor front cover 1 Refer to ASSEMBLING THE STARTER MOTOR 2 Lock washer 1 3 Oil seal 1 4 Bearing 1 5 Shim 6 Starter motor rear cover 1 ...

Page 428: ...STARTER MOTOR Order Job Part Q ty Remarks 7 Bushing 1 Refer to ASSEMBLING THE STARTER MOTOR 8 Shim 9 Brush holder set 1 0 Armature assembly 1 A Starter motor yoke 1 For assembly reverse the disassembly procedure ...

Page 429: ...mit 27 mm 1 06 in a 3 Measure mica undercut a Out of specification Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator NOTE _ The mica of the commutator must be undercut to ensure proper operation of the commutator 4 Measure armature assembly resistances commutator and insulation Out of specification Replace the starter motor Mica undercut 0 ...

Page 430: ...ce 1 0 0250 0 0350 Ω at 20 C 68 F Insulation resistance 2 Above 1 MΩ at 20 C 68 F 5 Measure brush length a Out of specification Replace the brushes as a set Brush length wear limit 5 00 mm 0 20 in 6 Measure brush spring force Out of specification Replace the brush springs as a set 7 Check gear teeth Damage wear Replace the gear 8 Check bearing oil seal Damage wear Replace the defective part s Brus...

Page 431: ... the projection a on the brush holder set with the slot b in the starter motor yoke 2 Install starter motor yoke 1 starter motor front cover 2 starter motor rear cover 3 NOTE _ Align the match marks a on the starter motor yoke with the match marks b on the starter motor front and rear covers a b b 2 1 3 ...

Page 432: ...R BLACK R GRAY Br L B BLACK Br L R B B R R B R R R B L Br Y R Br B L W BLACK Br ON OFF Br B R B R R R R W R Br L Br Br L Br Y Br L R Y R R B B B B B B B B B W W W W R W W Br L W B R Br L R W B L Gy L B L Y R R B R B Br 8 4 7 6 s t u 1 2 3 A 5 9 0 2 AC magneto 3 Rectifier regulator 6 Main fuse 8 Battery ...

Page 433: ...the following special tool s EBS01043 YES NO EBS01044 YES NO The battery is not being charged Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Main fuse Check the main fuse for continuity Refer to CHECKING THE FUSES in chapter 3 Is the main fuse OK Replace the main fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circ...

Page 434: ...ator coil resistance Disconnect the AC magneto coupler from the wire harness Connect the pocket tester Ω 1 to the stator coils Positive tester probe white terminal 1 Negative tester probe white terminal 2 Positive tester probe white terminal 1 Negative tester probe white terminal 3 Positive tester probe white terminal 2 Negative tester probe white terminal 3 Measure the stator coil resistance Stat...

Page 435: ... BLACK Br ON OFF PUSH OFF OFF Br B R B W R G B W R G B R B B Br R R R R W R Br L Br P P B Br L Br R Br L Br L Br Y Br L R Y R R B B B B B B B B B W W W W R W W Br L W B R Br L R W Y Y W Y WB Y B B Br Y Y Br Y Y W L W B L Gy Br Y G Y B B L Y B G Br R Br Y Y B B Y L R Y Br R B L B Lg G L L B L Y R R B R B Br L B B Y L W R B 8 4 7 6 s j i k t u F q m v w n o p D B G r x r 1 2 3 A 5 y z 9 0 Y BLACK Y ...

Page 436: ...ester YU 03112 C 1 Main and headlight fuses Check the main and headlight fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main and headlight fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Rechar...

Page 437: ...eck the headlight bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the headlight bulb and socket OK Replace the head light bulb socket or both 2 Headlight relay Remove the headlight relay Connect the pocket tester Ω 1 and bat tery 12 V to the headlight relay as shown È high beam É low beam Positive battery terminal yellow 1 Negative battery terminal black 2 Positive ...

Page 438: ...ch to the headlight cou pler is faulty and must be repaired 1 Taillight bulb and socket Check the taillight bulb and socket for con tinuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the taillight bulb and socket OK Replace the taillight bulb socket or both G G Y Y B B DC20V È É 1 2 3 2 Voltage Connect the pocket tester DC 20 V to the tail brake light connectors as shown Tail brake light con...

Page 439: ...O Y Lg W R G W L R G R R L O W Y R W B B R Gy G B W L B B L W R L R B Br W BLACK B L Br B L W BLACK Br G Y G Y Y W ON OFF 4WD 2WD LOCK PUSH OFF OFF Br B R B W R G B R B W R G B R B R B B Br O W L B G R W L B G W L L R R R R W R Br L Br P P B Br L Br R Br L Br L Br Y Br L R Y R R B B B B B B B B B W W W W R W W Br L W B R Br L R W B W B O Gy G B R W B G R Y B Y R Lg R L L R Sb Br L W Y W Y W W R Y ...

Page 440: ...witch W Multifunction meter Y Coolant temperature warning light Z Park indicator light Reverse indicator light Neutral indicator light High range indicator light _ Low range indicator light b Fuel sender h Differential gear motor p Override switch s Ignition fuse t Signaling system fuse v Rear brake light switch w Front brake light switch x Tail brake light y Diode 3 ...

Page 441: ...naling system and ignition fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main signaling system and igni tion fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or re place the battery 3 ...

Page 442: ...ht switches for continu ity Refer to CHECKING THE SWITCHES Is the brake light switch OK Replace the brake light switch 3 Diode 3 Remove the diode 3 from the wire har ness Connect the pocket tester Ω 1 to the diode 3 as shown Measure the diode 3 for continuity as fol lows NOTE _ The pocket tester 90890 03112 and the ana log pocket tester YU 03112 C readings are shown in the following table Positive...

Page 443: ... The wiring circuit from the main switch to the tail brake light connector is faulty and must be repaired 1 Gear position switch Check the gear position switch for continu ity Refer to CHECKING THE SWITCHES Is the gear position switch OK Replace the gear position switch 2 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler as shown Positive tester probe brown 1 Negative tester ...

Page 444: ...cification Replace the meter assembly or ECU The wiring circuit from the main switch to the meter assem bly coupler is faulty and must be re paired Br B G Y Y L B W G R Br 2 1 1 Four wheel drive motor switch differential gear motor Check the four wheel drive motor switch for continuity Refer to CHECKING THE SWITCHES Is the four wheel drive motor switch OK Replace the differen tial gear motor 2 Vol...

Page 445: ...e the left han dlebar switch 2 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler as shown Positive tester probe brown 1 Negative tester probe black white 2 Set the main switch to ON Measure the voltage 12 V of brown 1 and black white 2 at the meter assembly coupler Is the voltage within specification Replace the meter assembly or ECU The wiring circuit from the main switch to...

Page 446: ...iner filled with coolant 2 NOTE _ Make sure the coolant temperature sensor terminals do not get wet Place a thermometer 3 in the coolant Slowly heat the coolant and then let it cool to the specified temperature indicated in the table Measure the coolant temperature sensor resistance Coolant temperature sensor resistance 290 354 Ω at 80 C 176 F WARNING _ Handle the coolant temperature sensor with s...

Page 447: ...g circuit from the main switch to the meter assem bly coupler is faulty and must be repaired Br B G Y Y L B W G R Br 2 1 1 Fuel sender Drain the fuel from the fuel tank and then remove the fuel pump assembly fuel sender from the fuel tank Connect the pocket tester Ω 10 to the fuel pump terminals as shown Positive tester probe green yellow 1 Negative tester probe black white 2 Move the fuel sender ...

Page 448: ...t from the main switch to the meter assem bly coupler is faulty and must be repaired Br B G Y Y L B W G R Br 2 1 1 Speed sensor Connect the pocket tester DC 20 V to the speed sensor coupler wire harness side as shown Positive tester probe white 1 Negative tester probe black blue 2 Turn the main switch to ON Elevate the rear wheels and slowly rotate them Measure the voltage of white and black blue ...

Page 449: ... probe black white 2 Set the main switch to ON Measure the voltage 12 V of brown 1 and black white 2 at the meter assembly coupler Is the voltage within specification Replace the meter assembly or ECU The wiring circuit from the main switch to the meter assem bly coupler is faulty and must be repaired Br B G Y Y L B W G R Br 2 1 SIGNALING SYSTEM ...

Page 450: ...G Y Y W ON OFF 4WD 2WD LOCK PUSH OFF OFF Br B R B W R G B R B W R G B R B R B B Br O W L B G R W L B G W L L R R R R W R Br L Br P P B Br L Br R Br L Br L Br Y Br L R Y R R B B B B B B B B B W W W W R W W Br L W B R Br L R W B W B O Gy G B R W B G R Y B Y R Lg R L L R Sb Br L W Y W Y W W R Y L Br W Br W B L R B R B R L G Y G Y L W B L Y P Y G Br Br B Y L B W G R W B Br L Y Sb B R L Y L G L R L R G...

Page 451: ... NO The radiator fan motor fails to turn Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Main ignition and radiator fan motor fuses Check the main ignition and radiator fan motor fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and radiator fan motor fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGIN...

Page 452: ...replaced 5 Radiator fan motor relay Remove the radiator fan motor relay from the wire harness Connect the pocket tester Ω 1 and bat tery 12 V to the radiator fan motor relay terminal as shown Check the radiator fan motor relay of conti nuity Positive battery lead brown 1 Negative battery lead yellow red 2 Positive tester probe red black 3 Negative tester probe blue 4 Does the radiator fan motor re...

Page 453: ... harness NOTE The radiator fan motor circuit breaker 1 is attached to the wire harness with black tape near the tail brake light connectors 2 Connect the pocket tester Ω 1 to the radiator fan motor circuit breaker Radiator fan motor circuit breaker resistance Zero Ω at 20 C 68 F Replace the radiator fan motor circuit breaker 2 1 ...

Page 454: ...e indicated in the table Measure the coolant temperature sensor resistance Coolant temperature sensor resistance 290 354 Ω at 80 C 176 F WARNING _ Handle the coolant temperature sensor with special care Never subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it T R Coolant temperature sensor 18 Nm 1 8 m kg 13 ft lb Does the coolant tempera...

Page 455: ...ACK B L Br B L W BLACK Br ON OFF 4WD 2WD LOCK PUSH OFF OFF G Y G Y Br B R B W R G B R B W R G B R B R B B Br O W L B G R W L B G W L L R R R R W R Br L Br P P B Br L Br R Br L Br L Br Y Br L R Y R R B B B B B B B B B W W W W R W W Br L W B R Br L R W B W B O Gy G B R W B G R Y B Y R Lg R L L R Sb Br L W Y W Y W W R Y L Br W Br W B L R B R B R L G Y G Y L W B L Y P Y G Br Br B Y L B W G R W B Br L ...

Page 456: ...stem fuses Check the main ignition and fuel injection system fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and fuel injection system fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery termina...

Page 457: ...ositive tester probe brown black 3 Negative tester probe red blue 4 Does the fuel injection system relay have continuity between brown black and red blue The fuel injection system relay is faulty and must be replaced 6 Fuel pump Check the condition of the fuel pump Refer to CHECKING THE FUEL PUMP BODY in chapter 6 Replace the fuel pump assembly 7 Wiring Check the entire fuel pump system wiring Ref...

Page 458: ... OFF OFF Y W Y W G Y G Y Br B R B W R G B R B W R G B R B R B B Br O W L B G R W L B G W L L R R R R W R Br L Br P P B Br L Br R Br L Br L Br Y Br L R Y R R B B B B B B B B B W W W W R W W Br L W B R Br L R W B W B O Gy G B R W B G R Y B Y R Lg R L L R Sb Br L W W R Y L Br W Br W B L R B R B R L G Y G Y L W B L Y P Y G Br Br B Y L B W G R W B Br L Y Sb B R L Y L G L R L R G R Sb Gy B B B Y Br B L ...

Page 459: ... NO EBS01044 YES NO EBS01041 YES NO The four wheel drive motor indicator light fails to come on Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Main and four wheel drive motor fuses Check the main and four wheel drive motor fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main and four wheel drive motor fuses OK Replace the fuse s 2 Battery Check the condition of t...

Page 460: ...1 Negative tester probe brown red 5 Check the four wheel drive motor relay 1 for continuity Replace the four wheel drive motor relay 1 5 Four wheel drive motor relay 2 Remove the four wheel drive motor relay 2 from the wire harness Connect the pocket tester Ω 1 and the battery 12 V to the four wheel drive motor relay 2 terminals Positive tester probe brown black 1 Negative tester probe black 2 Pos...

Page 461: ... 2 Positive tester probe brown 3 Negative tester probe gray 4 Check the four wheel drive motor relay 3 for continuity Replace the four wheel drive motor relay 3 7 On command four wheel drive motor switch and differential gear lock switch Check the on command four wheel drive motor switch and differential gear lock switch for continuity Refer to CHECKING THE SWITCHES Is the on command four wheel dr...

Page 462: ...inion gear 2 turns counter clockwise É Check that the pinion gear 2 turns clockwise Make sure that the drive gear shift fork sliding gear operates correctly NOTE When installing the differential gear motor refer to FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR in chapter 7 Replace the differen tial gear motor 3V 2 1 È 3V 2 1 É 9 Wiring connection Check the connections of the entire 2WD 4WD ...

Page 463: ... L W BLACK Br ON OFF 4WD 2WD LOCK PUSH OFF OFF Y W Y W G Y G Y Br B R B W R G B R B W R G B R B R B B Br O W L B G R W L B G W L L R R R R W R Br L Br P P B Br L Br R Br L Br L Br Y Br L R Y R R B B B B B B B B B W W W W R W W Br L W B R Br L R W B W B O Gy G B R W B G R Y B Y R Lg R L L R Sb Br L W W R Y L Br W Br W B L R B R B R L G Y G Y L W B L Y P Y G Br Br B Y L B W G R W B Br L Y Sb B R L Y...

Page 464: ... ON and then goes off once the engine is started If the warning light remains on or comes on after the engine is started the EPS system may be defective The electrical circuit of the warning light can be checked by turning the main switch to ON If the warning light does not come on the electrical circuit may be defective NOTE If the engine is stopped using the engine stop switch and the main switc...

Page 465: ...In addition if a malfunction is detected while the warning light comes on initially the warning light remains on Furthermore the warning light comes on whenever a malfunction has occurred NOTE The EPS system does not operate while the EPS warning light is on a Main switch b EPS warning light no malfunction detected c EPS warning light malfunction detected d OFF e ON f Off g Comes on h Initial ligh...

Page 466: ...n 5 seconds after turn ing the main switch to ON and leave it grounded The signaling mode is acti vated after 5 seconds b Past malfunction signaling mode While the present malfunction mode is activated briefly disconnect the EPS self diagnosis signal connector ground it again and leave it grounded The sig naling mode is activated after 5 sec onds 4 Turn the main switch to OFF to cancel the diagnos...

Page 467: ... past malfunction display mode is selected After the mode selection judgment is completed present or past malfunction mode the current fault code signaling stops immediately and then the first code of the mode is signaled 2 seconds later When a fault code is signaled the EPS warning light goes off for 1 second between the units of 10 and the units of 1 for the code After a fault code is signaled t...

Page 468: ...mes within 5 sec onds while the present or past malfunction mode is activated The currently selected mode remains active after the fault codes of that mode are deleted a EPS self diagnosis signal connector b Disconnected c Grounded T1 Connector grounded 0 1 T1 1 6 seconds T2 Fault codes deleted Maximum 1 5 seconds required a b c T1 T1 T1 T1 T1 T2 ...

Page 469: ... harness Malfunction in ECU Malfunction in EPS control unit 41 42 43 45 EPS motor No normal signals are received from the EPS motor Open or short circuit in wire harness Malfunction in EPS motor Malfunction in EPS control unit 52 EPS control unit Relay contacts in the EPS control unit are welded together Malfunction in EPS control unit 53 EPS control unit Battery voltage has dropped Faulty battery...

Page 470: ...or open or short circuit detected Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections EPS torque sensor coupler Check the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Turning the main switch to OFF 2 Defective EPS torque sensor Replace if...

Page 471: ...in wire har ness Repair or replace if there is an open or short circuit Between speed sensor coupler and EPS control unit coupler white white 3 Defective speed sensor Execute the diagnostic mode Code No 21 Replace if defective Refer to SIGNALING SYSTEM Fault code No 22 Symptom No normal signals are received from the ECU Order Item components and probable cause Check or maintenance job Reinstatemen...

Page 472: ...ve EPS motor Replace if defective Refer to CHECKING THE EPS MOTOR 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 the EPS control unit Turning the main switch to OFF Fault code No 53 Symptom Power supply to the EPS control unit is not ...

Page 473: ... switch to OFF Fault code No 55 Symptom Power supply to the EPS control unit is not normal High battery voltage Malfunction in control unit 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 in chapter 3 Turning the main switch to OFF 2 Malfunction in rectifier regulator Replace if d...

Page 474: ...e EPS motor for continuity c Check the EPS motor for no continuity 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 Negative tester probe EPS motor body 3 Pocket tester 90890 03112 Analog pocket tester YU 03112 C B R 1 3 2 CHECKING THE EPS TORQUE SENSOR 1...

Page 475: ...nnect the pocket tester Ω 1k to the EPS torque sensor coupler terminal as shown b Measure the EPS torque sensor resistance Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe red 1 Negative tester probe black 2 G R B W 1 2 ...

Page 476: ...ed air filter element ELECTRICAL SYSTEM Spark plug Improper plug gap Worn electrodes Wire between terminals broken Improper heat range Faulty spark plug cap Ignition coil Broken or shorted primary secondary Faulty spark plug lead Broken body Ignition system Faulty ECU Faulty crankshaft position sensor Broken AC magneto rotor woodruff key Switches and wiring Faulty main switch Faulty engine stop sw...

Page 477: ...ed piston Crankcase and crankshaft Improperly seated crankcase Seized crankshaft Valve train Improperly adjusted valve clearance Improperly adjusted valve timing EBS00538 POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE Throttle body Damaged or loose throttle body joint Improperly adjusted idle speed throttle stop screw Improper throttle cable play Flooded throttle body Electrical system Fa...

Page 478: ...le Causes 1 A pronounced hesitation or jerky move ment during acceleration deceleration or sustained speed This must not be con fused with engine surging or transmission characteristics 2 A rolling rumble noticeable at low speed a high pitched whine a clunk from a shaft drive component or area 3 A locked up condition of the shaft drive mechanism no power transmitted from the engine to the front an...

Page 479: ...ift drum groove Transmission Worn gear dog EBS00543 FAULTY CLUTCH PERFORMANCE ENGINE OPERATES BUT VEHICLE WILL NOT MOVE V belt Bent damaged or worn V belt V belt slips Primary pulley cam and primary pulley slider Damaged or worn primary pulley cam Damaged or worn primary pulley slider Transmission Damaged transmission gears CLUTCH SLIPPING Clutch spring Damaged loose or worn clutch shoe spring Clu...

Page 480: ... ECU Fuel system Faulty throttle body Damaged or loose throttle body joint Clogged air filter element Compression system Heavy carbon build up Engine oil Improper oil level Improper oil viscosity Inferior oil quality Brake Brake drag Cooling system Low coolant level Clogged or damaged radiator Damaged or faulty water pump Faulty fan motor Faulty coolant temperature sensor EBS00548 OVERCOOLING COOL...

Page 481: ...eformed steering knuckles Tires Uneven tire pressures on both sides Incorrect tire pressure Uneven tire wear Wheels Deformed wheel Loose bearing Bent or loose wheel axle Excessive wheel runout Frame Bent Damaged frame EBS00553 LIGHTING SYSTEM HEADLIGHT DOES NOT COME ON Improper bulb Too many electric accessories Hard charging broken stator coil and or faulty rectifier regulator Incorrect connectio...

Page 482: ...10 7 TRBL SHTG ...

Page 483: ...relay 2 f Four wheel drive motor relay 3 g On command four wheel drive motor switch and differential gear lock switch h Differential gear motor i Four wheel drive motor fuse j Auxiliary DC jack fuse k Auxiliary DC jack l Left handlebar switch m Light switch n Engine stop switch o Start switch p Override switch q Headlight relay r Headlight s Ignition fuse t Signaling system fuse u Headlight fuse v...

Page 484: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A ...

Page 485: ... W L R G R R L O W Y R W B B R Gy G Y W B W L B B L W R L R B Br W BLACK B L Br B L W BLACK Br ON OFF 4WD 2WD LOCK PUSH OFF OFF Br B R B W R G B R B W R G B R B R B B Br O W L B G R W L B G W L L R R R R W R Br L Br P P B Br L Br R Br L Br L Br Y Br L R Y R R B B B B B B B B B W W W W R W W Br L W B R Br L R W B W B O Gy G B R W B G R Y B Y R Lg R L L R Sb Br L W Y W Y W W R Y L Br W Br W B L R B ...

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