Yamaha Grizzly550 User Manual Download

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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL

DRIVE ASSEMBLY AND REAR DRIVE SHAFT

8-21

Expander

Washer

Bearing

Final drive pinion gear bearing housing

For assembly, reverse the disassembly pro-
cedure.

Disassembling the final drive assembly

Order

Job/Parts to remove

Q’ty

Remarks

(4)

New

23 Nm (2.3 m

•

kg, 17 ft

•

Ib)

23 Nm (2.3 m

•

kg, 17 ft

•

Ib)

23 Nm (2.3 m

•

kg, 17 ft

•

Ib)

23 Nm (2.3 m

•

kg, 17 ft

•

Ib)

10 Nm (1.0 m

•

kg, 7.2 ft

•

Ib)

(11)

Summary of Contents for Grizzly550

Page 1: ......

Page 2: ...mation for this vehicle Use this segment as your major point of reference and information Supplementary Information if available These segments are updates and additions to the core information They are added as needed when certain changes are made to the model Be sure to check these for additional information that may be lacking from the core information section ...

Page 3: ... 6 7 8 1 Serviceable with engine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed 8 Electrical data 9 Engine oil 10 Gear oil 11 Molybdenum disulfide oil 12 Brake fluid 13 Wheel bearing grease 14 Lithium soap based grease 15 Molybdenum disulfide grease 16 Silicone grease 17 Apply locking agent LOCTITE 18 Replace the part with a new one tec...

Page 4: ......

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

Page 6: ......

Page 7: ...5FGP YFM7FGP only 1 5 EPS ELECTRIC POWER STEERING SYSTEM BLOCK DIAGRAM YFM5FGP YFM7FGP only 1 7 INSTRUMENT FUNCTIONS 1 9 IMPORTANT INFORMATION 1 11 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 11 REPLACEMENT PARTS 1 11 GASKETS OIL SEALS AND O RINGS 1 11 LOCK WASHERS PLATES AND COTTER PINS 1 11 BEARINGS AND OIL SEALS 1 12 CIRCLIPS 1 12 CHECKING THE CONNECTIONS 1 13 SPECIAL TOOLS 1 14 techsparkstudio c...

Page 8: ...ICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the front left side of the frame EAS20150 MODEL LABEL The model label 1 is affixed to the location shown in the illustration This information will be needed to order spare parts ...

Page 9: ...ements 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 manner To accom modate 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 fuel ratio required by the engine...

Page 10: ...on timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake air temperature 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 posi tion sensor As a result the vo...

Page 11: ...FEATURES 1 4 techsparkstudio com ...

Page 12: ...FEATURES 1 5 EAS28P1033 OUTLINE OF THE EPS ELECTRIC POWER STEERING SYSTEM YFM5FGP YFM7FGP only 1 2 3 d a e f 4 5 6 8 7 c b ...

Page 13: ...sor 2 Engine starting RPM information from ECU 3 Battery 4 Steering stem 5 EPS control unit 6 EPS motor 7 Torque sensor 8 EPS unit a Operates steering b Twists torsion bar c Sends the torque sensor signal d EPS control unit calculates assist power e Electricity output switched by EPS control unit f Activates EPS motor techsparkstudio com ...

Page 14: ...FEATURES 1 7 EAS28P1034 EPS ELECTRIC POWER STEERING SYSTEM BLOCK DIAGRAM YFM5FGP YFM7FGP only 1 2 4 5 18 7 8 9 12 11 6 13 14 17 16 15 10 3 ...

Page 15: ...gnal 13 Intake air pressure sensor signal 14 Lean angle sensor signal 15 Ignition coil 16 Fuel pump 17 Fuel injector 18 Meter assembly Multifunction display Speedometer Odometer Tripmeter A Trip meter B Clock Fuel meter Gear position Indicator and warning lights EPS warning Engine trouble warning Coolant temperature warning Reverse indicator Neutral indicator Park indicator High range indicator Lo...

Page 16: ...ton switches the dis play between the clock mode CLOCK and the hour meter mode HOUR in the following order CLOCK HOUR CLOCK To set the clock 1 Set the display to the clock mode 2 Push the SELECT button and RESET but ton together for at least three seconds 3 When the hour digits start flashing push the RESET button to set the hours 4 Push the SELECT button and the minute digits will start flashing ...

Page 17: ...e the multi function display will indicate a two digit fault code If the multifunction display indicates such a fault code note the code number and check the vehicle NOTICE ECA28P1028 If the multifunction display indicates a fault code the vehicle should be checked as soon as possible in order to avoid engine damage 1 Fault code display 1 techsparkstudio com ...

Page 18: ... correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

Page 19: ... bearings liberally when installing if appropriate NOTICE ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfac es EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite th...

Page 20: ...ral times 3 Check All connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector TIP Make sure all connections are tight 5 Check Continuity with the pocket tester TIP 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 available at m...

Page 21: ...avoid any mistakes TIP For U S A and Canada use part numbers starting with YM YU or ACC For others use part numbers starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 13 9 81 9 82 9 83 9 87 9 89 9 90 9 91 9 92 9 93 9 94 9 95 9 96 9 97 9 98 Thickness gauge 90890 03079 Narrow gauge set YM 34483 3 5 Tappet adjusting tool 9089...

Page 22: ...ension gauge YM 03170 3 28 Ring nut wrench 90890 01268 Spanner wrench YU 01268 3 31 3 32 Ball joint remover 90890 01474 YM 01474 4 57 4 61 Ball joint remover attachment set 90890 01480 Ball joint adapter set YM 01480 4 57 4 61 Ball joint remover short shaft set 90890 01514 YM 01514 4 57 Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 5 18 5 20 Tool name Tool No Illustration Referen...

Page 23: ...spring compressor adapter 26 mm YM 01253 1 5 22 5 27 Valve guide remover ø6 90890 04064 Valve guide remover 6 0 mm YM 04064 A 5 23 Valve guide installer ø6 90890 04065 Valve guide installer 6 0 mm YM 04065 A 5 23 Valve guide reamer ø6 90890 04066 Valve guide reamer 6 0 mm YM 04066 5 23 Tool name Tool No Illustration Reference pages YU 01083 3 techsparkstudio com ...

Page 24: ... 5 38 5 50 5 54 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 36 Yamaha bond No 1215 90890 85505 Three Bond No 1215 5 38 5 66 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 5 42 7 7 Sheave fixed block 90890 04135 Sheave fixed bracket YM 04135 5 50 5 53 Tool name Tool No Illustration Reference pages YU 01304 ...

Page 25: ...50 5 53 Sheave spring compressor 90890 04134 YM 04134 5 50 5 53 Universal clutch holder 90890 04086 YM 91042 5 58 5 59 Crankcase separating tool 90890 01135 Crankcase separator YU 01135 B 5 70 Tool name Tool No Illustration Reference pages techsparkstudio com ...

Page 26: ...lt YU 90060 5 72 Adapter M16 90890 04130 Adapter 13 YM 04059 5 72 Spacer crankshaft installer 90890 04081 Pot spacer YM 91044 5 72 Spacer 90890 01309 Pot spacer YU 90059 5 72 Coupling gear middle shaft tool 90890 01229 Gear holder YM 01229 5 82 5 85 Tool name Tool No Illustration Reference pages YU 90058 YU 90059 YM 91044 ø35 ...

Page 27: ...0 01511 Middle drive gear lash tool YM 01230 5 86 8 29 Radiator cap tester 90890 01325 Radiator pressure tester YU 24460 01 6 3 Radiator cap tester adapter 90890 01352 Radiator pressure tester adapter YU 33984 6 3 Mechanical seal installer 90890 04132 Water pump seal installer YM 33221 A 6 9 Tool name Tool No Illustration Reference pages YU 24460 01 YU 33984 techsparkstudio com ...

Page 28: ...7 Boots band installation tool 90890 01526 YM 01526 8 9 8 11 8 22 8 24 Ring gear fix bolt M10 90890 01527 YM 01527 8 13 Gear lash measurement tool 90890 01475 Middle drive gear lash tool YM 01475 8 13 Ring gear fix bolt M14 90890 01524 YM 01524 8 29 Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 9 91 Tool name Tool No Illustration Reference pages M10 P1 25 M14 P1 5 ...

Page 29: ...13 TIGHTENING TORQUES 2 16 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 16 ENGINE TIGHTENING TORQUES 2 17 CHASSIS TIGHTENING TORQUES 2 20 LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ENGINE 2 24 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 LUBRICATION DIAGRAMS 2 27 COOLING SYSTEM DIAGRAMS 2 31 CABLE ROUTING 2 33 techsparkstudio com ...

Page 30: ...PY Dimensions Overall length 2065 mm 81 3 in Overall width 1180 mm 46 5 in Overall height 1240 mm 48 8 in Seat height 905 mm 35 6 in Wheelbase 1250 mm 49 2 in Ground clearance 275 mm 10 8 in Minimum turning radius 3200 mm 126 in Weight With oil and fuel 294 0 kg 648 lb Maximum loading limit 220 0 kg 485 lb Total weight of rider cargo accessories and tongue ...

Page 31: ...aded gasoline only Fuel tank capacity 20 0 L 5 28 US gal 4 40 Imp gal Fuel reserve amount 4 5 L 1 19 US gal 0 99 Imp gal Engine oil Lubrication system Wet sump Type YAMALUBE 4 5W 30 or 10W 40 or 20W 50 SAE 5W 30 or SAE 10W 40 or SAE 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Total amount 2 40 L 2 54 US qt 2 11 Imp qt Without oil filter ca...

Page 32: ...p qt From low to full level 0 14 L 0 15 US qt 0 12 Imp qt Radiator cap opening pressure 93 3 122 7 kPa 0 95 1 25 kgf cm 13 5 17 8 psi Valve relief pressure 4 9 kPa 0 05 kgf cm 0 7 psi Thermostat Model manufacturer 3B4 NIPPON THERMOSTAT Valve opening temperature 50 54 C 122 129 F Valve full open temperature 70 C 158 F Valve lift full open 7 0 mm 0 28 in Radiator core Width 248 2 mm 9 77 in Height 3...

Page 33: ...aft Rocker arm inside diameter 12 000 12 018 mm 0 4724 0 4731 in Rocker arm shaft outside diameter 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 Valve valve seat valve guide Valve clearance cold Intake 0 09 0 13 mm 0 0035 0 0051 in Exhaust 0 16 0 20 mm 0 0063 0 0079 in Valve dimensions Valve head diameter A intake 32 90 33 10 mm 1 2953 1...

Page 34: ... guide inside diameter intake 6 000 6 012 mm 0 2362 0 2367 in Limit 6 050 mm 0 2382 in Valve guide inside diameter exhaust 6 000 6 012 mm 0 2362 0 2367 in Limit 6 050 mm 0 2382 in Valve stem to valve guide clearance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0031 in Valve stem to valve guide clearance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in Valve stem runout 0...

Page 35: ...92 000 92 010 mm 3 6220 3 6224 in YFM5FGY YFM5FGPY 102 000 102 010 mm 4 0157 4 0161 in YFM7FGY YFM7FGPY Wear limit 92 080 mm 3 6252 in YFM5FGY YFM5FGPY 102 080 mm 4 0189 in YFM7FGY YFM7FGPY Taper limit 0 05 mm 0 002 in Out of round limit 0 05 mm 0 002 in Piston Piston to cylinder clearance 0 030 0 055 mm 0 0012 0 0022 in Limit 0 10 mm 0 0039 in YFM5FGY YFM5FGPY 0 13 mm 0 0051 in YFM7FGY YFM7FGPY D...

Page 36: ...ng type Taper Dimensions B T 1 20 4 00 mm 0 05 0 16 in End gap installed 0 75 0 90 mm 0 03 0 04 in Limit 1 25 mm 0 049 in Ring side clearance 0 020 0 060 mm 0 0008 0 0024 in YFM5FGY YFM5FGPY 0 030 0 070 mm 0 0012 0 0028 in YFM7FGY YFM7FGPY Limit 0 12 mm 0 0047 in YFM5FGY YFM5FGPY 0 13 mm 0 0051 in YFM7FGY YFM7FGPY Oil ring Dimensions B T 2 00 2 80 mm 0 08 0 11 in YFM5FGY YFM5FGPY 2 50 2 80 mm 0 10...

Page 37: ...width 33 3 mm 1 31 in Limit 30 0 mm 1 18 in Transmission Transmission type V belt automatic Primary reduction system V belt Secondary reduction system Shaft drive Secondary reduction ratio 41 21 24 18 33 9 9 544 Operation Left hand operation Single speed automatic 2 380 0 700 1 Low range 31 16 1 938 High range 31 27 1 148 Reverse gear 23 14 28 23 2 000 Drive axle runout limit 0 06 mm 0 0024 in Shi...

Page 38: ...33 0 kPa 248 mmHg 9 7 inHg YFM5FGY YFM5FGPY 35 0 kPa 263 mmHg 10 3 inHg YFM7FGY YFM7FGPY Water temperature 85 0 95 0 C 185 0 203 0 F YFM5FGY YFM5FGPY 75 0 85 0 C 167 0 185 0 F YFM7FGY YFM7FGPY Oil temperature 80 0 90 0 C 176 0 194 0 F YFM5FGY YFM5FGPY 55 0 65 0 C 131 00 149 0 F YFM7FGY YFM7FGPY Throttle lever free play 3 0 5 0 mm 0 12 0 20 in Speed limiter length Less than 12 mm 0 47 in Shaft driv...

Page 39: ...it 2 0 mm 0 08 in Lateral wheel runout limit 2 0 mm 0 08 in Rear wheel Wheel type Panel wheel Rim size 12 7 5 AT Rim material Steel for models equipped with steel wheels Aluminum for models equipped with aluminum wheels Wheel travel 230 mm 9 1 in Radial wheel runout limit 2 0 mm 0 08 in Lateral wheel runout limit 2 0 mm 0 08 in Front tire Type Tubeless Size AT25 8 12 Manufacturer model DUNLOP KT42...

Page 40: ... 205 0 3 5 mm 8 07 0 14 in Brake disc thickness limit 3 0 mm 0 12 in Brake disc deflection limit 0 1 mm 0 004 in Brake pad lining thickness inner 5 8 mm 0 23 in Limit 1 0 mm 0 04 in Brake pad lining thickness outer 5 8 mm 0 23 in Limit 1 0 mm 0 04 in Master cylinder inside diameter 12 70 mm 0 50 in Caliper cylinder inside diameter 33 96 mm 1 34 in Recommended fluid DOT 4 Steering Steering bearing ...

Page 41: ...nstalled length 270 6 mm 10 65 in YFM5FGY YFM5FGPY 267 5 mm 10 53 in YFM7FGY YFM7FGPY Spring rate K1 31 00 N mm 3 16 kgf mm 177 01 lb in YFM5FGY YFM5FGPY 33 50 N mm 3 42 kgf mm 191 29 lb in YFM7FGY YFM7FGPY Spring rate K2 36 00 N mm 3 67 kgf mm 205 56 lb in YFM7FGY YFM7FGPY Spring stroke K1 0 0 109 2 mm 0 00 4 30 in YFM5FGY YFM5FGPY 0 0 43 0 mm 0 00 1 69 in YFM7FGY YFM7FGPY Spring stroke K2 43 0 1...

Page 42: ...ensor resistance 2 45 kΩ at 20 C 68 F 290 354 Ω at 80 C 176 F Ignition coil Model manufacturer 2JN YAMAHA Minimum ignition spark gap 6 0 mm 0 24 in Primary coil resistance 2 16 2 64 Ω at 20 C 68 F Secondary coil resistance 8 64 12 96 kΩ at 20 C 68 F Spark plug cap Material Resin Resistance 10 0 kΩ AC magneto Model manufacturer F4T39373 MITSUBISHI Standard output 14 0 V 34 0 A at 5 000 r min Stator...

Page 43: ...tarting system System type Constant mesh Starter motor Model manufacturer SM 17 MITSUBA Power output 0 80 kW Armature coil resistance 0 0050 0 0150 Ω at 20 C 68 F Brush overall length 12 0 mm 0 47 in Limit 6 50 mm 0 26 in Brush spring force 6 02 6 51 N 614 664 gf 21 69 23 45 oz Mica undercut depth 0 70 mm 0 03 in Starter relay Model manufacturer 2768113 A JIDECO Amperage 180 0 A Coil resistance 4 ...

Page 44: ... 1 2 Model manufacturer G8HN 1C4T DJ OMRON Coil resistance 94 5 115 5 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 15 0 A Radiator fan motor fuse 20 0 A Auxiliary DC jack fuse 15 0 A Fuel injection system fuse 15 0 A Four wheel drive motor fuse 15 0 A EPS fuse 40 0 A YFM5FGPY YFM7FGPY Spare fuse 40 0 A Spare fuse...

Page 45: ... warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm...

Page 46: ...t lb Drive belt case bolt M6 8 10 Nm 1 0 m kg 7 2 ft lb Bearing housing bolt primary sheave assembly M6 4 10 Nm 1 0 m kg 7 2 ft lb Bearing retainer bolt bearing housing M6 1 10 Nm 1 0 m kg 7 2 ft lb Primary sheave assembly nut M16 1 140 Nm 14 0 m kg 100 ft lb Secondary sheave assembly nut M16 1 100 Nm 10 0 m kg 72 ft lb Secondary sheave spring retain ing nut M36 1 90 Nm 9 0 m kg 65 ft lb Clutch ho...

Page 47: ... 1 10 Nm 1 0 m kg 7 2 ft lb Engine oil drain bolt M14 1 30 Nm 3 0 m kg 22 ft lb Oil filter cartridge M20 1 17 Nm 1 7 m kg 12 ft lb Oil filter cartridge union bolt M20 1 30 Nm 3 0 m kg 22 ft lb Timing chain guide bolt lower M6 2 10 Nm 1 0 m kg 7 2 ft lb Bearing retainer bolt crankcase M6 2 10 Nm 1 0 m kg 7 2 ft lb Oil pump bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Oil pump housing cover screw M5 1 5 Nm 0 ...

Page 48: ...n gear bearing housing bolt M8 4 25 Nm 2 5 m kg 18 ft lb Middle driven pinion gear bearing retainer M60 1 130 Nm 13 0 m kg 94 ft lb Left hand thread Rear drive shaft yoke nut middle gear side M16 1 150 Nm 15 0 m kg 110 ft lb Starter motor bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Starter motor lead nut M6 1 11 Nm 1 1 m kg 8 0 ft lb Spark plug M10 1 13 Nm 1 3 m kg 9 4 ft lb Stator coil assembly bolt M6 3 ...

Page 49: ...elect lever shift rod locknut shift arm side M6 1 7 Nm 0 7 m kg 5 1 ft lb Brake pedal free play adjusting nut M8 1 7 Nm 0 7 m kg 5 1 ft lb Radiator bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Radiator bracket bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Coolant reservoir bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Fuel tank bolt M6 4 7 Nm 0 7 m kg 5 1 ft lb Fuel pump nut M6 6 7 Nm 0 7 m kg 5 1 ft lb Fuel tank side cover bolt M6...

Page 50: ... Steering knuckle and front lower arm nut M12 2 30 Nm 3 0 m kg 22 ft lb Steering knuckle and tie rod nut M10 2 25 Nm 2 5 m kg 18 ft lb Front upper arm nut M10 4 45 Nm 4 5 m kg 32 ft lb Front lower arm nut M10 4 45 Nm 4 5 m kg 32 ft lb Front shock absorber nut M10 4 45 Nm 4 5 m kg 32 ft lb Front brake disc guard bolt M6 6 7 Nm 0 7 m kg 5 1 ft lb Front brake hose holder bolt M6 4 7 Nm 0 7 m kg 5 1 f...

Page 51: ...ort bolt for YFM5FG YFM7FG M8 4 30 Nm 3 0 m kg 22 ft lb Pitman arm nut for YFM5FG YFM7FG M14 1 190 Nm 19 0 m kg 140 ft lb Steering stem bearing bolt for YFM5FGP YFM7FGP M10 2 51 Nm 5 1 m kg 37 ft lb Steering stem bearing nut for YFM5FGP YFM7FGP M22 1 125 Nm 12 5 m kg 90 ft lb Steering stem joint bolt for YFM5FGP YFM7FGP M8 2 35 Nm 3 5 m kg 25 ft lb EPS unit bolt for YFM5FGP YFM7FGP M8 4 30 Nm 3 0 ...

Page 52: ...evel check bolt M8 1 10 Nm 1 0 m kg 7 2 ft lb Final drive case cover bolt M8 11 23 Nm 2 3 m kg 17 ft lb Final drive pinion gear bearing housing bolt M8 4 23 Nm 2 3 m kg 17 ft lb Electrical components tray bolt M6 3 7 Nm 0 7 m kg 5 1 ft lb Battery holding bracket fitting screw M6 2 7 Nm 0 7 m kg 5 1 ft lb Battery holding bracket nut M6 2 7 Nm 0 7 m kg 5 1 ft lb ECU engine control unit bolt M6 2 7 N...

Page 53: ...nd exhaust Valve stem seal intake and exhaust Rocker arm shafts Camshaft lobes Decompressor lever pin Decompressor lever Rocker arms intake and exhaust Oil pump shaft O ring oil filter cartridge Water pump impeller shaft Dipstick mating surface Starter idler gear inner surface Starter idler gear shaft Starter wheel gear Torque limiter Clutch housing shaft end Clutch carrier assembly One way clutch...

Page 54: ...ft Shift lever 2 inner surface Shift lever 1 Shift lever 1 gear teeth and shift lever 2 gear teeth Stopper lever stopper Bearing final drive pinion gear Bearing final drive case 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 E E E E LS E E E G G ...

Page 55: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 26 techsparkstudio com ...

Page 56: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS A A A 1 2 1 3 4 5 7 6 3 A ...

Page 57: ...RICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Oil delivery pipe 1 2 Oil delivery pipe 2 3 Oil filter cartridge 4 Oil strainer 5 Drive axle 6 Relief valve assembly 7 Reverse idle gear shaft techsparkstudio com ...

Page 58: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 1 2 3 4 5 ...

Page 59: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Camshaft 2 Crankshaft 3 Oil strainer 4 Oil pump rotor 5 Oil pump driven gear techsparkstudio com ...

Page 60: ...COOLING SYSTEM DIAGRAMS 2 31 EAS20420 COOLING SYSTEM DIAGRAMS 1 2 3 8 7 6 5 4 ...

Page 61: ...NG SYSTEM DIAGRAMS 2 32 1 Coolant reservoir hose 2 Radiator inlet hose 3 Coolant reservoir 4 Water pump 5 Water pump outlet pipe 6 Water pump outlet hose 7 Radiator outlet hose 8 Radiator techsparkstudio com ...

Page 62: ...CABLE ROUTING 2 33 EAS20430 CABLE ROUTING A A B B C C D D A A B B C C D D A B C D I E F G H J K L M N O P Q R S T T U 1 2 1 2 1 2 3 4 8 9 8 9 5 6 7 8 9 10 10 11 11 11 12 13 14 15 16 ...

Page 63: ... 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 J Pass the differential case breather hose through the guide on the meter bracket K Pass the radiator fan motor breather hose through the guide on the meter bracket L Pass the EPS motor breather hose through the guide on the mete...

Page 64: ...CABLE ROUTING 2 35 A A B B B B C C C C D D C C B B A A A B C D E F G H I J K K L M N N N O P Q Q R R 1 1 4 5 5 1 2 3 4 5 6 7 8 9 9 10 11 12 13 13 K K 1 1 4 13 13 11 12 10 13 14 15 15 16 17 18 19 ...

Page 65: ...sensor lead YFM5FGP YFM7FGP only and differential motor lead in the holder and then insert the ends of the holder into the hole in the stay on the frame G Route the differential case breather hose to the inside of the frame H Fasten the differential case breather hose to the frame with the plastic band making sure to face the end of the band inward I Attach the ground lead terminal to the frame us...

Page 66: ...B D D E E E E F F G G C C B B G G A F F D D E E A A B C D E F G H I J K L M N O P Q R S T U 1 1 4 4 5 5 6 6 9 1 2 3 4 5 6 7 8 8 9 10 12 13 R 13 13 14 17 18 19 20 20 11 12 13 14 15 16 17 18 19 20 24 25 26 27 21 22 23 24 25 27 8 ...

Page 67: ...aking sure to face the end of the band inward H Route the spark plug lead to the outside of the rear brake cable and shift control cable I 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 illustration J Fasten the final drive case breather hose ground lead starter motor lead fuel injector lead coolant temperat...

Page 68: ...CABLE ROUTING 2 39 A A B B C C A A B B C C A C D E E F B 1 1 2 2 3 3 3 4 5 5 6 6 7 8 ...

Page 69: ...o tail brake light B Fasten the tail brake light lead to the frame with plastic locking ties making sure to face the end of each tie downward C Install the plastic band near the split in the wire harness D Route the tail brake light lead to the outside of the frame E Face the end of the plastic band downward F Pass the final drive case breather hose through the guide techsparkstudio com ...

Page 70: ...CABLE ROUTING 2 41 A A B B A B B C D E G H I J 1 4 5 6 7 3 2 9 6 5 7 7 9 8 10 11 11 12 13 14 15 16 32 22 33 34 A A B B K L M N O P Q R F 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 31 32 33 ...

Page 71: ...he electrical components tray E Place the couplers on the inside of the electrical components tray F To main switch and auxiliary DC jack G Route the starter motor lead above the leads in the electrical components tray H Fasten the EPS control unit lead with the holder YFM5FGP YFM7FGP only I Fasten the meter assembly lead and EPS control unit lead YFM5FGP YFM7FGP only with the twist tie J Fasten t...

Page 72: ...CABLE ROUTING 2 43 A A B B C C B C D E G F H H I J A L K 1 1 2 3 4 5 6 7 8 9 10 11 11 10 12 13 14 14 15 16 17 18 18 19 20 B A A C C B ...

Page 73: ...ose on top of the leads C Fasten the radiator fan motor breather hose and throttle body breather hose with the holder D Route the intake air pressure sensor lead to the front of the throttle body breather hose and above the ISC unit lead E Fasten the ISC unit lead with the holder F To engine G To air filter case H Route the fuel injector lead and coolant temperature sensor lead to the outside of t...

Page 74: ...CABLE ROUTING 2 45 A C D B B B B E E B B E E C D A 1 2 2 2 3 3 A B B C C D E E F 4 4 4 ...

Page 75: ...A Pass the front brake hose through the holder B Fasten the front brake hose with the holder C Pass the rear brake pipe through the holder D Fasten the rear brake pipe with the holder E Pass the rear brake hose through the holder F Fasten the rear brake hose with the holder techsparkstudio com ...

Page 76: ...CABLE ROUTING 2 47 ...

Page 77: ...HE SPARK PLUG 3 7 CHECKING THE IGNITION TIMING 3 8 MEASURING THE COMPRESSION PRESSURE 3 8 CHECKING THE ENGINE OIL LEVEL 3 9 CHANGING THE ENGINE OIL 3 10 CLEANING THE AIR FILTER ELEMENT 3 12 CHECKING THE V BELT 3 13 REPLACING THE V BELT 3 13 CHECKING THE THROTTLE BODY JOINT 3 14 CHECKING THE FUEL LINE 3 14 CHECKING THE BREATHER HOSES 3 14 CHECKING THE EXHAUST SYSTEM 3 15 CLEANING THE SPARK ARRESTER...

Page 78: ...E DIFFERENTIAL GEAR OIL LEVEL 3 26 CHANGING THE DIFFERENTIAL GEAR OIL 3 27 CHECKING THE CONSTANT VELOCITY SHAFT ASSEMBLY DUST BOOTS 3 27 CHECKING THE STEERING SYSTEM 3 28 ADJUSTING THE TOE IN 3 29 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES 3 30 ADJUSTING THE FRONT SHOCK ABSORBER ASSEMBLIES 3 31 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES 3 31 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES 3 32 CHE...

Page 79: ...techsparkstudio com ...

Page 80: ... ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichever comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and re place if necessary 2 Spark plug Check condition and clean regap or replace if nec essary 3 Valves Check valve clearance and adjust if necessary 4 Crankcase breather system Chec...

Page 81: ...eck toe in and adjust if necessary 16 Engine mount Check for cracks or other damage and replace if necessary 17 Axle boots Check for cracks or other damage and replace if necessary 18 Engine oil Change Check ATV for oil leakage and correct if necessary 19 Engine oil filter car tridge Replace 20 Differential gear oil Change Check ATV for oil leakage and correct if necessary 21 Final gear oil Change...

Page 82: ...n unusually wet or dusty areas Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged ...

Page 83: ...nect Spark plug cap 1 4 Remove Spark plug 2 5 Remove Timing mark accessing screw 1 Crankshaft end accessing screw 2 6 Measure Valve clearance Out of specification Adjust a Turn the crankshaft counterclockwise b When the piston is at TDC on the compres sion stroke align the I mark a on the AC magneto rotor with the stationary pointer b on the AC magneto cover TIP To position the piston at TDC on th...

Page 84: ...Crankshaft end accessing screw 9 Install Spark plug 10 Connect Spark plug cap 11 Install O rings 1 Camshaft sprocket cover Intake tappet cover Exhaust tappet cover 12 Install Air filter case Footrest board Front fender Right side panel Left side panel Refer to GENERAL CHASSIS on page 4 1 Thickness gauge 90890 03079 Narrow gauge set YM 34483 Tappet adjusting tool 90890 01311 Six piece tappet set YM...

Page 85: ...rect free play is obtained d Tighten the locknut e Slide the rubber cover to its original position WARNING EWA28P1004 After adjusting the free play turn the handle bar to the right and left to make sure that the engine idling speed does not increase 4 Install Left side panel Refer to GENERAL CHASSIS on page 4 1 EAS29170 ADJUSTING THE SPEED LIMITER The speed limiter keeps the throttle from becom in...

Page 86: ...isconnect Spark plug cap 3 Remove Spark plug NOTICE ECA13330 Before removing the spark plug blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder 4 Check Spark plug type Incorrect Change 5 Check Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 6 Clean...

Page 87: ...ect firing range Check the ignition system TIP When checking the ignition timing make sure that the timing light cord does not come in con tact with the exhaust muffler d Install the timing mark accessing screw 4 Detach Timing light Tachometer 5 Install Footrest board Right side panel Left side panel Refer to GENERAL CHASSIS on page 4 1 EAS20710 MEASURING THE COMPRESSION PRESSURE TIP Insufficient ...

Page 88: ...NG THE ENGINE OIL LEVEL 1 Place the vehicle on a level surface 2 Check the engine oil level on a cold engine TIP If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least 10 minutes until the oil set tles for an accurate reading 3 Remove Dipstick accessing panel Refer to GENERAL CHASSIS on page 4 1 4 Check Engine oil level The engine ...

Page 89: ...the engine oil is at the correct level otherwise engine damage may result 6 Install Dipstick accessing panel Refer to GENERAL CHASSIS on page 4 1 EAS20780 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several min utes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove Dipstick accessing panel Refer to GENERAL CHASSIS on page 4 1 4 Remove Dipstick 1 5 Remo...

Page 90: ...ine for engine oil leaks 14 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 9 15 Check Engine oil pressure a Slightly loosen the oil check bolt 1 b Start the engine and keep it idling until engine oil starts to seep from the oil check bolt If no engine oil comes out after one minute turn the engine off so that it will not seize c Check the engine oil passages the oil filter...

Page 91: ...ICE ECA28P1011 The engine should never be run without the air filter excessive piston and or cylinder wear may result 4 Check Air filter element Air filter element frame Damage Replace 5 Clean Air filter element with solvent WARNING EWA13020 Never use low flash point solvents such as gasoline to clean the air filter element Such solvents may cause a fire or an explosion NOTICE ECA13430 Do not twis...

Page 92: ...r Refer to PRIMARY AND SECONDARY SHEAVES on page 5 47 2 Check V belt 1 Cranks damage wear Replace Grease oil Clean the primary and second ary sheaves Refer to REPLACING THE V BELT on page 3 13 3 Measure V belt width a Out of specification Replace Refer to REPLACING THE V BELT on page 3 13 4 Install Drive belt cover Refer to PRIMARY AND SECONDARY SHEAVES on page 5 47 EAS28P1006 REPLACING THE V BELT...

Page 93: ...page 4 1 V belt cooling exhaust duct Refer to ENGINE REMOVAL on page 5 1 2 Check Fuel hose 1 Cracks damage Replace Loose connection Connect properly 3 Install V belt cooling exhaust duct Refer to ENGINE REMOVAL on page 5 1 Rear fender Right side panel Seat Refer to GENERAL CHASSIS on page 4 1 EAS21050 CHECKING THE BREATHER HOSES 1 Remove Left side panel Air filter case Refer to GENERAL CHASSIS on ...

Page 94: ...nsmission is in neu tral a Remove the bolts 1 b Remove the tailpipe 2 by pulling it out of the muffler and the gasket c Tap the tailpipe lightly with a soft face ham mer or suitable tool then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the muffler d Install the gasket and then insert the tailpipe into the muffler ...

Page 95: ...k and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is not available soft water may be used 3 If the coolant is at or below the minimum level mark remove the left side panel Refer to GENERAL CHASSIS on page 4 1 4 Remove the reservoir cap 1 add coolant or distilled water to the maximum level mark a install the reservoir cap a...

Page 96: ...when the en gine is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hissing sound has stopped press down on the radi ator cap and tur...

Page 97: ...s used instead of coolant check and if nec essary correct the antifreeze concentra tion 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 wa ter Do not mix different types of antifreeze 12 Fill Coolant reservoir with the recommended coolant to the maxi mum level ...

Page 98: ...g exhaust duct 15 Start the engine warm it up for ten minutes and then rev the engine five times 16 Pour the recommended coolant into the radi ator until it is full 17 Stop the engine and allow it to cool If the coolant level has dropped after the engine has cooled add sufficient coolant until it reaches the top of the radiator and then in stall the radiator cap 18 Start the engine and then check ...

Page 99: ...ner panel Refer to GENERAL CHASSIS on page 4 1 b Loosen the adjusting nut 1 and locknut 2 c Turn the adjusting nut 1 in direction a until the rear brake cable 3 is taut d Turn the adjusting nut 1 one turn in direction b and then tighten the locknut 2 e While holding the locknut 2 tighten the ad justing nut 1 f Check that there is a gap between the rear brake cable joint rear brake master cylinder ...

Page 100: ...o the proper level WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the b...

Page 101: ... has almost disap peared Replace the brake pads and brake pad spring as a set Refer to REAR BRAKE on page 4 32 4 Install Rear wheels Refer to REAR WHEELS on page 4 18 EAS21280 CHECKING THE FRONT BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps 1 Check Front brake hoses 1 Cracks damage wear Replace 2 Check Brake hose holders Loose Tighten the holder bolt 3...

Page 102: ... system is disassembled a brake hose is loosened disconnected or replaced the brake fluid level is very low brake operation is faulty TIP Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow When bleeding the hydraulic brake system make sure there is always enough brake fluid before applying the brake Ignoring this pre caution co...

Page 103: ...NG THE BRAKE FLUID LEVEL on page 3 21 WARNING EWA13110 After bleeding the hydraulic brake system check the brake operation 3 Install Rear wheels Refer to REAR WHEELS on page 4 18 EAS29220 ADJUSTING THE DRIVE SELECT LEVER CONTROL CABLE AND SHIFT ROD NOTICE ECA28P1012 Before moving the drive select lever bring the vehicle to a complete stop and return the throttle lever to its closed position Other ...

Page 104: ...t the engine and then check that the drive select lever can be shifted to each shift position and that the appropriate indicator light comes on when the lever is in each po sition TIP If the neutral indicator light does not come on when the drive select lever is in the N neutral position stop the engine Then with the drive select lever in the N neutral position and with out opening the throttle st...

Page 105: ...nstall Final gear oil level check bolt Final gear oil filler bolt EAS29250 CHECKING THE DIFFERENTIAL GEAR OIL LEVEL 1 Place the vehicle on a level surface 2 Remove Differential gear oil filler bolt 1 3 Check Differential gear oil level The differential gear oil level should be up to the brim 2 of the hole Below the brim Add the recommended dif ferential gear oil to the proper level NOTICE ECA16170...

Page 106: ... may start leaking from the differential case breather hose Therefore check the quantity of the oil not its level 7 Check Oil level Refer to CHECKING THE DIFFERENTIAL GEAR OIL LEVEL on page 3 26 8 Install Differential gear oil filler bolt EAS29270 CHECKING THE CONSTANT VELOCITY SHAFT ASSEMBLY DUST BOOTS 1 Check Dust boots 1 Damage Replace Refer to FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES DIFFERENT...

Page 107: ... vehicle so that there is no weight on the front wheels 5 Check Ball joints and 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 YFM5FGP YFM7FGP only Steering tension Above specification Adjust a Set the main switch to OFF b Place the vehicle on a suitable stand so that the front wheels are elevated ...

Page 108: ... Install the electrical components tray Refer to GENERAL CHASSIS on page 4 1 EAS29290 ADJUSTING THE TOE IN 1 Place the vehicle on a level surface 2 Measure Toe in Out of specification Adjust TIP Before measuring the toe in make sure that the tire pressure is correct a Mark both front tire tread centers b Face the handlebar straight ahead c Measure the width A between the marks d Rotate the front t...

Page 109: ...ns should be given to both the right and left tie rods 2 until the specified toe in is obtained This is to keep the length of the tie rods the same d Tighten the rod end locknuts of both tie rods TIP Adjust the tie rod ends so that A and B are equal EAS29300 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES The following procedure applies to both of the front shock absorber assemblies 1 Place the vehic...

Page 110: ...o both of the rear shock absorber assemblies 1 Place the vehicle on a level surface 2 Check Damper rod Bends damage Replace the rear shock absorber assembly Refer to REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES on page 4 67 Oil leakage Excessive oil leakage Replace the rear shock absorber assembly Refer to REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES on page 4 67 Spring Fatigue Replace the rear sh...

Page 111: ...50 Tire characteristics influence the handling of vehicles The tires listed below have been approved by Yamaha Motor Co Ltd for this model If other tire combinations are used they can adversely affect your vehicle s han dling characteristics and are therefore not recommended Tire pressure WARNING EWA14960 Tire pressure below the minimum specifi cation could cause the tire to dislodge from the rim ...

Page 112: ...nd equal in both rear tires 2 Check Tire surfaces Wear damage Replace WARNING EWA28P1006 It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit a replace the tire immediately Tire air pressure measured on cold tires Recommended Front 35 kPa 0 35 kgf cm 5 0 psi Rear 30 kPa 0 30 kgf cm 4 4 psi Minimum Front 32 kPa 0 32 kgf cm 4 6 psi Rear 27 kPa 0 27 kgf cm 4 0 psi M...

Page 113: ...uter cable may cause the cable to corrode and interfere with its movement Re place damaged outer cable and inner cables as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubricate TIP Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubricating device 3 Apply Lithium soap based grease onto end of the c...

Page 114: ...cooled down TIP Unhook the headlight bulb holder and then re move the defective bulb 5 Install Headlight bulb Secure the new headlight bulb with the head light bulb holder NOTICE ECA13690 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb ge...

Page 115: ...ELECTRICAL SYSTEM 3 36 Direction a Headlight beam is raised Direction b Headlight beam is lowered a b 1 techsparkstudio com ...

Page 116: ...ELECTRICAL SYSTEM 3 37 ...

Page 117: ...EPLACING THE FRONT BRAKE PADS 4 27 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 27 CHECKING THE FRONT BRAKE CALIPERS 4 28 ASSEMBLING THE FRONT BRAKE CALIPERS 4 28 INSTALLING THE FRONT BRAKE CALIPERS 4 29 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 29 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 30 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 30 REAR BRAKE 4 32 INTRODUCTION 4 38 CHECKING THE REAR BRAKE ...

Page 118: ...STEERING KNUCKLE BALL JOINTS 4 56 INSTALLING THE TIE RODS 4 58 INSTALLING THE FRONT ARM PROTECTORS 4 58 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 4 59 CHECKING THE FRONT ARMS 4 61 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES 4 61 CHECKING THE FRONT ARM BALL JOINTS 4 61 INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 4 62 INSTALLING THE FRONT ARM PROTECTORS 4 63 REAR KNUCKLES AND...

Page 119: ...techsparkstudio com ...

Page 120: ...the engine skid plates Order Job Parts to remove Q ty Remarks 1 Front engine skid plate 1 2 Center engine skid plate 1 3 Rear engine skid plate 1 For installation reverse the removal proce dure 1 2 3 7 Nm 0 7 m kg 5 1 ft Ib T R T R 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 121: ...e Q ty Remarks 1 Seat 1 TIP 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 proce dure 6 4 1 3 2 5 techsparkstudio com ...

Page 122: ...y holding bracket 1 4 Battery lead 2 Disconnect NOTICE ECA28P1013 First disconnect the negative battery lead then disconnect the positive lead 5 Battery 1 6 Upper panel 1 7 Front guard 1 8 Front guard cover 2 For installation reverse the removal proce dure 3 4 4 5 6 1 2 2 7 8 4 4 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 T R 34 Nm 3 4 m kg 24 ft Ib T R 26 Nm 2...

Page 123: ...er to Removing the 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 removal proce dure 6 5 2 3 3 3 4 4 1 1 5 7 Nm 0 7 m kg 5 1 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 techsparkstudio com ...

Page 124: ...ls 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 proce dure 4 1 2 4 2 5 3 6 6 6 7 Nm 0 7 m kg 5 1 ft Ib T R 34 Nm 3 4 m kg 24 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R ...

Page 125: ...all Rear fender TIP The bolts may be tightened to the specified torque in any tightening sequence However in stall the front bolts 1 and tighten them tempo rarily before installing the rear bolts 2 T R Rear fender bolt 7 Nm 0 7 m kg 5 1 ft lb 1 2 techsparkstudio com ...

Page 126: ...ry lead then disconnect the positive lead 3 Battery 1 4 Lean angle sensor coupler 1 Disconnect 5 Lean angle sensor 1 6 Four wheel drive motor relay 1 1 7 Four wheel drive motor relay 2 1 8 Headlight relay 1 9 EPS control unit coupler 5 Disconnect YFM5FGP YFM7FGP only 10 EPS electric power steering control unit 1 YFM5FGP YFM7FGP only 11 ECU coupler 2 Disconnect 12 ECU engine control unit 1 7 Nm 0 7...

Page 127: ...er 1 Disconnect For installation reverse the removal proce dure Removing the electrical components tray 1 2 Order Job Parts to remove Q ty Remarks 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 6 7 8 3 11 12 13 11 14 2 9 10 9 9 9 4 5 2 1 techsparkstudio com ...

Page 128: ...r relay 3 1 10 Left handlebar switch coupler 2 Disconnect 11 On command four wheel drive motor switch and differential gear lock switch coupler 2 Disconnect 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 4 3 2 18 1 5 6 1...

Page 129: ...onents tray 1 For installation reverse the removal proce dure Removing the electrical components tray 2 2 Order Job Parts to remove Q ty Remarks 4 3 2 18 1 5 6 12 17 13 20 16 15 4 19 14 7 8 9 10 11 7 Nm 0 7 m kg 5 1 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 techsparkstudio com ...

Page 130: ...fer to Removing the seat and side pan els 1 Footrest 2 2 Footrest board 2 3 Footrest bracket 2 For installation reverse the removal proce dure 4 5 1 4 1 2 3 2 3 4 4 5 5 5 7 Nm 0 7 m kg 5 1 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 53 Nm 5 3 m kg 38 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R ...

Page 131: ...Install Footrest board TIP Tighten the footrest board bolts to the specified torque in the proper tightening sequence as shown 2 Install Footrest TIP Install the footrest with the oval hole a facing in ward T R Footrest board bolt 7 Nm 0 7 m kg 5 1 ft lb T R Footrest bolt 7 Nm 0 7 m kg 5 1 ft lb 4 1 2 3 FWD a techsparkstudio com ...

Page 132: ...er case cover 1 2 Air filter element 1 3 Air filter element frame 1 4 Intake air temperature sensor coupler 1 Disconnect 5 Air filter case joint clamp screw 1 Loosen 6 Cylinder head breather hose 1 Disconnect 7 Air filter case 1 8 Intake air temperature sensor 1 For installation reverse the removal proce dure New New 1 2 3 8 7 5 6 4 7 Nm 0 7 m kg 5 1 ft Ib T R ...

Page 133: ...l cap 1 3 Front wheel axle nut 1 4 Front brake caliper assembly 1 TIP Do not squeeze the front brake lever when the brake caliper is off of the brake disc as the brake pads will be forced shut 5 Front wheel hub 1 6 Front brake disc 1 For installation reverse the removal proce dure LT LT 3 2 5 6 4 1 T R 30 Nm 3 0 m kg 22 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib T R 260 Nm 26 0 m kg 190 ft lb T R 30 Nm 3 0...

Page 134: ...ut 1 Lateral wheel runout 2 Over the specified limit Replace the wheel or check the wheel bearing play Refer to CHECKING THE STEERING KNUCKLES AND FRONT WHEEL BEAR INGS on page 4 56 3 Check Wheel balance Out of balance Adjust WARNING EWA15000 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 re sulting in vehicle ...

Page 135: ... stake the collar of the nut into the notch of the shaft 2 Check Brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 26 EAS28P1011 INSTALLING THE FRONT WHEELS The following procedure applies to both of the front wheels 1 Install Wheel TIP The arrow mark 1 on the tire must point in the direction of wheel rotation 2 Tighten Wheel nuts 1 WARNING EWA28P1007 Tapered wheel nuts 1 are used for b...

Page 136: ...FRONT WHEELS 4 17 ...

Page 137: ...3 Rear wheel axle nut 1 4 Rear brake caliper assembly 1 TIP Do not squeeze the rear brake lever and brake pedal when the brake caliper is off of the brake disc as the brake pads will be forced shut 5 Rear wheel hub 1 6 Rear brake disc 1 For installation reverse the removal proce dure LT LT 3 2 5 6 4 1 T R 30 Nm 3 0 m kg 22 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib T R 260 Nm 26 0 m kg 190 ft lb T R 30 Nm ...

Page 138: ... on page 4 66 3 Check Wheel balance Refer to CHECKING THE FRONT WHEELS on page 4 15 EAS29440 CHECKING THE REAR WHEEL HUBS The following procedure applies to both of the rear wheel hubs 1 Check Wheel hub 1 Cracks damage Replace Splines wheel hub 2 Wear damage Replace EAS28P1012 INSTALLING THE REAR BRAKE DISCS The following procedure applies to both of the rear brake discs 1 Install Brake disc TIP I...

Page 139: ...applies to both of the rear wheels 1 Install Wheel TIP The arrow mark 1 on the tire must point in the direction of wheel rotation 2 Tighten Wheel nuts 1 WARNING EWA28P1007 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 Wheel nut 55 Nm 5 5 m kg 40 ft lb techsparkstudio com ...

Page 140: ...of the front brake calipers Front wheel Refer to FRONT WHEELS on page 4 14 1 Front brake caliper bolt 2 2 Brake pad holding bolt plug 1 3 Brake pad holding bolt 1 4 Front brake pad 2 5 Brake pad spring 1 For installation reverse the removal proce dure 1 2 3 4 5 T R 30 Nm 3 0 m kg 22 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib FWD ...

Page 141: ... diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Front brake lever cover 1 5 Brake lever 1 6 Union bolt 1 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 proce dure S 11 10 9 1 2 3 12 8 7 6 5 4 T R 6...

Page 142: ...ng the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure 3 2 1 4 New New S FWD ...

Page 143: ... page 3 23 Front wheel Refer to FRONT WHEELS on page 4 14 1 Union bolt 1 2 Copper washer 2 3 Front brake hose 1 Disconnect 4 Brake pad holding bolt plug 1 5 Brake pad holding bolt 1 Loosen 6 Front brake caliper bolt 2 7 Front brake caliper assembly 1 For installation reverse the removal proce dure 6 1 3 2 7 4 5 T R 30 Nm 3 0 m kg 22 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib New...

Page 144: ...ont brake calipers 1 Brake pad holding bolt 1 2 Brake pad 2 3 Brake pad spring 1 4 Brake caliper bracket 1 5 Brake caliper piston 1 6 Brake caliper dust seal 1 7 Brake caliper piston seal 1 8 Bleed screw 1 For assembly reverse the disassembly pro cedure S S 2 8 1 3 4 5 6 7 T R 5 Nm 0 5 m kg 3 6 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib S New New FWD BF ...

Page 145: ...et im mediate medical attention EAS22240 CHECKING THE FRONT BRAKE DISCS The following procedure applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEELS on page 4 14 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Hold the dial gauge at a right angle against the brake disc sur...

Page 146: ...screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper piston into the brake caliper with your finger c Tighten the bleed screw d Install new brake pads and a new brake pad spring 3 Install Brake pad holding bolt Brake pad holding bolt plug Brake caliper 4 Check Brake fluid level Below the minimum level mark Add the recommended brake fluid ...

Page 147: ...ston Brake caliper cylinder 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA28P1002 Whenever a brake caliper is disassembled replace the brake caliper piston seals and dust seals EAS22410 ASSEMBLING THE FRONT BRAKE CALIPERS T...

Page 148: ...ling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 4 Check Brake fluid leve...

Page 149: ...e union bolt WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING on page 2 33 TIP While holding the brake hose tighten the union bolt as shown Turn the handlebar to the left and right to make sure the brake hose does not touch other parts e g wire harness cables leads Correct if necessary 3 Install Front brake lever cover 1 a Spread apar...

Page 150: ...illing be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 6 Check Br...

Page 151: ...rear brake calipers Rear wheel Refer to REAR WHEELS on page 4 18 1 Rear brake caliper bolt 2 2 Brake pad holding bolt plug 1 3 Brake pad holding bolt 1 4 Rear brake pad 2 5 Brake pad spring 1 For installation reverse the removal proce dure 2 3 1 4 5 T R 30 Nm 3 0 m kg 22 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib techsparkstudio com ...

Page 152: ... Rear brake lever cover 1 5 Shift control cable 1 Disconnect 6 Rear brake cable 1 Disconnect 7 Brake lever 1 8 Brake lever bracket 1 9 Union bolt 1 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 S S 14 13 12 1 2 3 15 11 10 9 7 8 6 5 4 New New T R 6 Nm 0 6 m kg 4 3 ft Ib T R 7 N...

Page 153: ...moval proce dure Removing the rear brake master cylinder Order Job Parts to remove Q ty Remarks S S 14 13 12 1 2 3 15 11 10 9 7 8 6 5 4 New New T R 6 Nm 0 6 m kg 4 3 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib R 6 Nm 0 6 m kg 4 3 ft Ib LS LS T T R 27 Nm 2 7 m kg 19 ft Ib techsparkstudio com ...

Page 154: ...ling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure 3 2 1 4 New New S ...

Page 155: ... on page 3 23 Rear wheel Refer to REAR WHEELS on page 4 18 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 removal proce dure 3 1 2 4 5 7 6 T R 30 Nm 3 0 m kg 22 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib New t...

Page 156: ...ear brake calipers 1 Brake pad holding bolt 1 2 Brake pad 2 3 Brake pad spring 1 4 Brake caliper bracket 1 5 Brake caliper piston 1 6 Brake caliper dust seal 1 7 Brake caliper piston seal 1 8 Bleed screw 1 For assembly reverse the disassembly pro cedure S S 1 2 3 4 5 7 6 8 T R 5 Nm 0 5 m kg 3 6 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib S New New BF ...

Page 157: ...LS on page 4 18 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 26 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 26 ...

Page 158: ... 23 EAS28P1004 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove Brake lever Brake lever bracket NOTICE ECA28P1006 The brake lever pivot bolt and nut have left handed threads To loosen the pivot bolt and nut turn them clockwise EAS22600 DISASSEMBLING THE REAR BRAKE CALIPERS The following procedure applies to both of the brake calipers TIP Before disassembling the brake caliper drain the brake fluid...

Page 159: ...brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they will cause the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seal and dust seal EAS22670 INSTALLING THE REAR BRAKE CALIPERS The following procedure applies to both of the brake calipers 1 Install Brak...

Page 160: ...mended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 21 5 Check Brake lever and pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 EAS22710 CHECKING THE REAR BRAKE MASTER CYLINDER 1 Check Brake master cylinder Damage scratches wear Replace Brake fluid delivery passages brake master cylinder bo...

Page 161: ...e left handed threads To tighten the pivot bolt and nut turn them counterclockwise 4 Install Rear brake lever cover 1 TIP Fit the holes in the rear brake lever cover over the bolt head a and nut b 5 Fill Brake master cylinder reservoir with the specified amount of the recom mended brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to dete...

Page 162: ...stem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 7 Check Brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 21 8 Check Brake lever and pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 23 ...

Page 163: ...rottle lever assembly 1 6 Front brake light switch connector 2 Disconnect 7 Front brake master cylinder holder 1 8 Front brake master cylinder 1 9 Rear brake light switch connector 2 Disconnect 10 Rear brake master cylinder holder 1 11 Rear brake master cylinder 1 12 Left handlebar switch 1 13 Handlebar grip 2 14 Handlebar holder 2 1 11 9 6 14 14 12 13 5 8 3 4 7 10 2 2 15 13 T R 20 Nm 2 0 m kg 14 ...

Page 164: ...andlebar 1 For installation reverse the removal proce dure Removing the handlebar Order Job Parts to remove Q ty Remarks 1 11 9 6 14 14 12 13 5 8 3 4 7 10 2 2 15 13 T R 20 Nm 2 0 m kg 14 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 165: ... shown in the illustration The upper handlebar holders should be in stalled with the punch mark a forward A First tighten the bolts 1 on the front side of the handlebar holders and then tighten the bolts 2 on the rear side 3 Install Handlebar grip 1 a Wipe off grease or oil on the handlebar sur face a with a lacquer thinner b Apply a thin coat of rubber adhesive onto the left and right ends of the...

Page 166: ...ster cylinder holder 2 TIP Align the end of the brake master cylinder hold er with the punch mark a on the handlebar The UP mark b on the brake master cylinder holder should face up Install the brake master cylinder holder so that the gaps between the brake master cylinder and the brake master cylinder holder are equal 6 Install Throttle lever assembly 1 Throttle lever assembly holder TIP Align th...

Page 167: ...able guide 1 3 Steering stem bushing 2 4 Collar 2 5 Oil seal 2 6 Tie rod end nut 2 7 Tie rod 2 Disconnect 8 Pitman arm nut 1 9 Pitman arm 1 10 Steering stem 1 11 Steering stem support 1 12 Oil seal 1 13 Oil seal 1 8 13 9 6 7 4 3 3 10 16 5 5 2 1 New New New New New New New LT LT LS 4 T R 23 Nm 2 3 m kg 17 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 25 Nm 2 5 m kg 18 ft Ib LS LS LS LS LT 6 New 11 15 14 12...

Page 168: ...ing the steering stem for YFM5FG YFM7FG Order Job Parts to remove Q ty Remarks 8 13 9 6 7 4 3 3 10 16 5 5 2 1 New New New New New New New LT LT LS 4 T R 23 Nm 2 3 m kg 17 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 25 Nm 2 5 m kg 18 ft Ib LS LS LS LS LT 6 New 11 15 14 12 T R 190 Nm 19 0 m kg 140 ft lb T R 51 Nm 5 1 m kg 37 ft Ib LS ...

Page 169: ...2 Disconnect 8 Pitman arm nut 1 9 Pitman arm 1 10 Steering stem joint bolt 2 11 Steering stem 1 12 Collar 1 13 Bearing nut 1 14 Collar 1 15 Steering stem bearing 1 35 Nm 3 5 m kg 25 ft Ib T R 14 13 12 8 9 6 7 16 4 3 3 11 20 5 5 2 1 15 10 19 18 17 New New New New New LT LT LT LT LS 10 4 T R 23 Nm 2 3 m kg 17 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 210 Nm 21 0 m kg 150 ft l...

Page 170: ...g the steering stem for YFM5FGP YFM7FGP Order Job Parts to remove Q ty Remarks 35 Nm 3 5 m kg 25 ft Ib T R 14 13 12 8 9 6 7 16 4 3 3 11 20 5 5 2 1 15 10 19 18 17 New New New New New LT LT LT LT LS 10 4 T R 23 Nm 2 3 m kg 17 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 210 Nm 21 0 m kg 150 ft lb T R 25 Nm 2 5 m kg 18 ft Ib T R 125 Nm 12 5 m kg 90 ft lb LS LS LT 6 51 Nm 5 1 m kg...

Page 171: ...the bolt Pass the cable and hoses through the cable guide Refer to CABLE ROUTING on page 2 33 EAS28P1015 INSTALLING THE STEERING STEM for YFM5FGP YFM7FGP 1 Install EPS unit 1 Washers EPS unit bolts 2 2 Install Steering stem 3 Steering stem bearing 4 Collar 5 Bearing nut 6 TIP Install the steering stem bearing with the UP mark facing up 3 Install Oil seals 7 Collars 8 Steering stem bushings 9 Cable...

Page 172: ...P Bend the lock washer tab e along a flat side of the bolt Pass the cable and hoses through the cable guide Refer to CABLE ROUTING on page 2 33 EAS28P1016 INSTALLING THE PITMAN ARM for YFM5FG YFM7FG 1 Install Pitman arm 1 Washer Pitman arm nut Cotter pin TIP Align the groove a in the pitman arm with the steering stem spline b that is indented EAS29590 INSTALLING THE PITMAN ARM for YFM5FGP YFM7FGP ...

Page 173: ...STEERING STEM 4 54 TIP Align the punch mark a on the EPS unit with the groove b in the pitman arm 1 b a techsparkstudio com ...

Page 174: ...ELS on page 4 14 1 Brake disc guard 1 2 Front arm protector 1 3 Tie rod 1 4 Nut 1 5 Nut 1 6 Steering knuckle 1 7 Circlip 1 8 Clip 1 9 Rubber boot 1 10 Ball joint 1 11 Circlip 1 12 Wheel bearing 1 For installation reverse the removal proce dure T R 7 Nm 0 7 m kg 5 1 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 25 Nm 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 ...

Page 175: ...uckle Damage pitting Replace 2 Check Front wheel bearing 1 Rough movement excessive free play Re place a Clean the surface of the steering knuckle b Remove the circlip 2 c Drive out the bearing WARNING EWA15040 Eye protection is recommended when using striking tools d Apply lithium soap based grease to the balls of the new bearing e Install the new bearing NOTICE ECA16190 Do not strike the center ...

Page 176: ...base 12 in place while turning in the short bolt 14 to install the new ball joint 7 into the steering knuckle 8 g Remove the ball joint remover attachment set short shaft set h Apply lithium soap based grease to the new ball joint Ball joint remover 90890 01474 YM 01474 Ball joint bore inside diameter 32 45 32 50 mm 1 278 1 280 in 1 2 3 6 4 5 a Ball joint remover 90890 01474 YM 01474 Ball joint re...

Page 177: ... wheel side 2 Adjust Toe in Refer to ADJUSTING THE TOE IN on page 3 29 EAS28P1070 INSTALLING THE FRONT ARM PROTECTORS The following procedure applies to both of the front arm protectors 1 Install Front arm protector 1 a Fit the holders a on the front arm protector onto the lower arm b Tighten the nut b T R Tie rod nut 25 Nm 2 5 m kg 18 ft lb T R Front arm protector nut 7 Nm 0 7 m kg 5 1 ft lb b a ...

Page 178: ...fer to FRONT BRAKE on page 4 21 1 Brake disc guard 1 2 Front arm protector 1 3 Front brake hose holder 2 4 Nut 1 5 Nut 1 6 Nut bolt 2 2 7 Front shock absorber assembly 1 8 Nut bolt 2 2 9 Front upper arm 1 10 Nut bolt 2 2 11 Front lower arm 1 12 Dust cover 2 9 11 18 18 10 10 8 8 8 8 10 10 6 6 6 6 3 3 14 16 13 13 15 7 1 12 12 17 4 5 2 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 7 Nm ...

Page 179: ...orber assemblies Order Job Parts to remove Q ty Remarks 9 11 18 18 10 10 8 8 8 8 10 10 6 6 6 6 3 3 14 16 13 13 15 7 1 12 12 17 4 5 2 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 7 Nm 0 7 m kg 5 1 ft Ib T R 30 Nm 3 0 m kg 22 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 45 Nm 4 5 m kg 32 ft Ib New New New LS New 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib ...

Page 180: ...f the front shock absorber assemblies 1 Check Front shock absorber assembly Oil leaks Replace the front shock absorber assembly Front shock absorber rod Bends damage Replace the front shock absorber assembly Spring Move the spring up and down Fatigue Replace the front shock absorber assembly EAS29770 CHECKING THE FRONT ARM BALL JOINTS The following procedure applies to both of the front arm ball j...

Page 181: ... AND FRONT SHOCK ABSORBER ASSEMBLIES The following procedure applies to both of the front upper arms front lower arms and front shock absorber assemblies 1 Install Front upper arm Front lower arm Front shock absorber assembly a Install the front upper arm 1 and front lower arm 2 TIP Lubricate the front upper and lower arm bolts 3 with lithium soap based grease Be sure to position the front upper a...

Page 182: ...ing procedure applies to both of the front arm protectors 1 Install Front arm protector 1 a Fit the holders a on the front arm protector onto the lower arm b Tighten the nut b T R Upper steering knuckle nut 25 Nm 2 5 m kg 18 ft lb Lower steering knuckle nut 30 Nm 3 0 m kg 22 ft lb T R Front arm nut 45 Nm 4 5 m kg 32 ft lb T R Front arm protector nut 7 Nm 0 7 m kg 5 1 ft lb 9 8 1 5 7 6 7 6 4 3 2 b ...

Page 183: ...4 Rear arm protector holder 1 5 Rear brake hose protector 1 6 Rear brake hose holder 1 7 Rear knuckle 1 8 Spacer cover 4 9 Spacer 2 10 Circlip 1 11 Wheel bearing 1 12 Stabilizer joint 2 13 Stabilizer holder 2 13 13 14 14 15 5 6 12 1 8 11 10 2 9 8 8 9 8 7 12 3 4 LS LS LS T R 30 Nm 3 0 m kg 22 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 45 Nm 4 5 m kg 32 ft Ib New T R 7 Nm 0 7 ...

Page 184: ...d stabilizer Order Job Parts to remove Q ty Remarks 13 13 14 14 15 5 6 12 1 8 11 10 2 9 8 8 9 8 7 12 3 4 LS LS LS T R 30 Nm 3 0 m kg 22 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 45 Nm 4 5 m kg 32 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 51 Nm 5 1 m kg 37 ft Ib T R 51 Nm 5 1 m kg 37 ft Ib T R ...

Page 185: ...Do not strike the center race or balls of the bearing Contact should be made only with the outer race f Install the new circlip EAS29820 CHECKING THE STABILIZER 1 Check Stabilizer Bends cracks damage Replace EAS28P1005 INSTALLING THE REAR ARM PROTECTORS The following procedure applies to both of the rear arm protectors 1 Install Rear arm protector 1 Rear arm protector holder 2 a Install the rear a...

Page 186: ...es Rear knuckle Stabilizer Refer to REAR KNUCKLES AND STABI LIZER on page 4 64 1 Rear brake hose guide 2 2 Nut Washer Bolt 2 1 2 3 Rear shock absorber assembly 1 4 Nut Bolt 2 2 5 Rear upper arm 1 6 Dust cover 1 7 Nut Bolt 2 2 8 Rear lower arm 1 9 Dust cover 2 10 Bushing 4 For installation reverse the removal proce dure LS 4 7 6 10 10 1 4 7 7 7 9 10 2 8 5 2 10 9 3 LS 2 4 2 T R 45 Nm 4 5 m kg 32 ft ...

Page 187: ...ge Replace the rear shock absorber assembly Spring Move the spring up and down Fatigue Replace the rear shock absorber assembly EAS29870 INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES The following procedure applies to both of the rear upper arms rear lower arms and rear shock absorber assemblies 1 Install Rear upper arm Rear lower arm Rear shock absorber assembly a Install the rear u...

Page 188: ...REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES 4 69 7 6 7 6 4 3 5 2 8 8 1 ...

Page 189: ...OCKER ARMS AND ROCKER ARM SHAFTS 5 19 INSTALLING THE CAMSHAFT AND ROCKER ARMS 5 19 VALVES AND VALVE SPRINGS 5 21 REMOVING THE VALVES 5 22 CHECKING THE VALVES AND VALVE GUIDES 5 22 CHECKING THE VALVE SEATS 5 24 CHECKING THE VALVE SPRINGS 5 25 INSTALLING THE VALVES 5 26 CYLINDER AND PISTON 5 28 REMOVING THE PISTON 5 29 CHECKING THE CYLINDER AND PISTON 5 29 CHECKING THE PISTON RINGS 5 30 CHECKING THE...

Page 190: ...RY SHEAVE SLIDERS 5 51 CHECKING THE SECONDARY SHEAVE 5 51 ASSEMBLING THE PRIMARY SHEAVE 5 52 ASSEMBLING THE SECONDARY SHEAVE 5 52 INSTALLING THE PRIMARY AND SECONDARY SHEAVES 5 54 CLUTCH 5 56 REMOVING THE CLUTCH 5 58 CHECKING THE CLUTCH 5 58 CHECKING THE CLUTCH SHOE 5 58 ASSEMBLING THE CLUTCH HOUSING 5 59 INSTALLING THE CLUTCH 5 59 CRANKCASE 5 61 SEPARATING THE CRANKCASE 5 65 CHECKING THE TIMING C...

Page 191: ...7 ASSEMBLING THE SHIFT FORK ASSEMBLY 5 77 INSTALLING THE SHIFT FORKS AND SHIFT DRUM 5 77 MIDDLE GEAR 5 79 REMOVING THE MIDDLE DRIVE SHAFT 5 82 REMOVING THE MIDDLE DRIVEN SHAFT 5 82 CHECKING THE PINION GEARS 5 83 INSTALLING THE BEARING AND OIL SEALS 5 84 INSTALLING THE MIDDLE DRIVEN SHAFT 5 84 INSTALLING THE MIDDLE DRIVE SHAFT 5 85 MEASURING THE MIDDLE GEAR BACKLASH 5 86 ALIGNING THE MIDDLE GEAR 5 ...

Page 192: ... CHASSIS on page 4 1 1 V belt cooling exhaust duct 1 2 V belt cooling exhaust duct joint 1 3 V belt cooling intake duct joint 1 4 V belt cooling intake duct 1 5 Exhaust pipe protector 1 6 Spring 2 7 Muffler 1 8 Gasket 1 9 Muffler bracket 1 10 Exhaust pipe 1 11 Gasket 2 For installation reverse the removal proce dure 6 11 6 2 3 1 9 8 7 5 10 4 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib ...

Page 193: ...row mark a pointing toward the en gine b Align the projection on the V belt cooling in take duct joint with the rib on the crankcase in the area b shown in the illustration c Align the screw head with the seam on the V belt cooling intake duct joint in the area c shown in the illustration d Align the projection on the V belt cooling in take duct with the projection on the V belt cooling intake duc...

Page 194: ...he drive belt case in the area b shown in the il lustration c Align the screw head with the arrow mark a on the V belt cooling exhaust duct joint in the area c shown in the illustration d Align the projection on the V belt cooling ex haust duct with the projection on the V belt cooling exhaust duct joint in the area d shown in the illustration e Align the screw head with the rib on the V belt cool...

Page 195: ... Q ty Remarks 1 Drive select lever shift rod 1 2 Drive select lever unit 1 3 Shift arm 1 For installation reverse the removal proce dure 3 2 1 2 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 7 Nm 0 7 m kg 5 1 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib LS LT techsparkstudio com ...

Page 196: ... lever shift rod 3 TIP Make sure that the drive select lever and trans mission are in N neutral The installed length a of the shift rod is 413 mm 16 3 in T R Shift arm bolt 14 Nm 1 4 m kg 10 ft lb LOCTITE Drive select lever unit bolt 7 Nm 0 7 m kg 5 1 ft lb Drive select lever shift rod lock nut 7 Nm 0 7 m kg 5 1 ft lb N N a 1 3 2 ...

Page 197: ...n page 6 4 Water pump assembly Refer to WATER PUMP on page 6 7 Oil delivery pipe 2 Refer to CYLINDER HEAD on page 5 10 Oil delivery pipe 1 Refer to AC MAGNETO AND STARTER CLUTCH on page 5 34 Differential assembly Refer to FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES DIFFERENTIAL AS SEMBLY AND FRONT DRIVE SHAFT on page 8 3 Final drive assembly Refer to REAR CONSTANT VELOCITY SHAFT ASSEMBLIES FINAL DRIV...

Page 198: ...ontrol cable 1 Disconnect 5 Reverse switch lead 1 Disconnect 6 Speed sensor coupler 1 Disconnect 7 Crankshaft position sensor coupler 1 Disconnect 8 AC magneto coupler 1 Disconnect 9 Gear position switch coupler 1 Disconnect For installation reverse the removal proce dure Disconnecting the leads cables and hoses Order Job Parts to remove Q ty Remarks 6 7 4 5 1 3 9 2 8 17 Nm 1 7 m kg 12 ft Ib T R ...

Page 199: ...from the left side of the vehicle 5 Rubber damper nut rear side 2 6 Rubber damper rear side 2 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 proce dure T R 42 Nm 4 2 m kg 30 ft Ib T R 42 Nm 4 2 m kg 30 ft Ib T R 42 Nm 4 2 m kg 30 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 T R...

Page 200: ...ghten 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 7 8 4 1 2 3 5 9 6 4 8 7 2 3 1 T R Engine mounting bolt front low er side 42 Nm 4 2 m kg 30 ft lb Engine mounting bolt front up per side 10 N...

Page 201: ... chain tensioner cap bolt 1 9 Timing chain tensioner 1 10 Gasket 1 11 Camshaft sprocket 1 12 Decompressor assembly 1 13 Cylinder head 1 New New New LS LS E LS New 12 11 LS 4 3 New LS New New M 4 5 1 2 New 15 14 10 9 8 5 4 6 13 7 New E T R 10 Nm 1 0 m kg 7 2 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 20 Nm 2 0 m kg 14 ...

Page 202: ...10 9 8 5 4 6 13 7 New E T R 10 Nm 1 0 m kg 7 2 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 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 T R 35 Nm 3 5 m kg 25 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 38 Nm 3 8 m kg 27 ft Ib T R 10 ...

Page 203: ...nsioner cap bolt 4 Remove Timing chain tensioner along with the gasket Camshaft sprocket Timing chain TIP To prevent the timing chain from falling into the crankcase fasten it with a wire 5 Remove Cylinder head TIP Loosen the bolts in the proper sequence as shown Loosen each bolt 1 2 of a turn at a time After all of the bolts are fully loosened remove them EAS24160 CHECKING THE CYLINDER HEAD 1 Eli...

Page 204: ...heck Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprocket and the timing chain as a set EAS23940 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER The following procedure applies to both of the tappet covers 1 Check Tappet cover Camshaft sprocket cover Damage wear Replace EAS23960 CHECKING THE TIMING CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage Replace 2 ...

Page 205: ... pointer d on the cylin der head e Install the timing chain 2 onto the camshaft sprocket 3 and then install the camshaft sprocket onto the camshaft and then finger tighten the camshaft sprocket bolts 4 TIP When installing the camshaft sprocket be sure to keep the timing chain as tight as possible on the exhaust side NOTICE ECA28P1031 Do not turn the crankshaft when installing the camshaft to avoid...

Page 206: ...the installation steps above 7 Tighten Camshaft sprocket bolts 1 Decompressor assembly bolts 2 NOTICE ECA13750 Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine TIP While holding the AC magneto rotor nut with a wrench tighten the camshaft sprocket bolts and decompressor assembly bolts After tightening t...

Page 207: ...CYLINDER HEAD 5 16 8 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 4 techsparkstudio com ...

Page 208: ...er arm shaft 2 3 Intake rocker arm 1 4 Exhaust rocker arm 1 5 Locknut 4 6 Valve adjusting screw 4 7 Camshaft 1 NOTICE ECA28P1026 Do not disassemble the camshaft assem bly 8 Decompressor lever 1 9 Decompressor lever pin 1 10 Bearing 1 For installation reverse the removal proce dure M E M E E LT 1 7 9 8 2 E 10 4 2 3 5 5 5 5 E 6 6 6 6 E T R 10 Nm 1 0 m kg 7 2 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib T R 14 ...

Page 209: ... Measure Camshaft lobe dimensions a and b Out of specification Replace the camshaft 3 Measure Camshaft runout Out of specification Replace the camshaft Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 Weight 90890 01084 YU 01083 3 2 1 Camshaft lobe dimensions Intake A 43 488 43 588 mm 1 7121 1 7161 in Limit 43 388 mm 1 7082 in Intake B 36 959 37 059 mm 1 4551 1 4590 in Limit 36 859 ...

Page 210: ...ft Blue discoloration excessive wear pit ting scratches Replace or check the lubri cation system 3 Measure Rocker arm inside diameter Out of specification Replace 4 Measure Rocker arm shaft outside diameter Out of specification Replace 5 Calculate Rocker arm to rocker arm shaft clearance Out of specification Replace the defective part s TIP Calculate the clearance by subtracting the rock er arm sh...

Page 211: ...cate Rocker arms Rocker arm shafts 6 Install Exhaust rocker arm 1 Exhaust rocker arm shaft 2 Intake rocker arm Intake rocker arm shaft TIP Use a slide hammer bolt 3 to install the rocker arm shaft Make sure the rocker arm shafts are complete ly pushed into the cylinder head Installed depth 0 mm 0 in b Installed depth Recommended lubricant Camshaft Molybdenum disulfide oil Camshaft bearing decompre...

Page 212: ...AD on page 5 10 Rocker arms Rocker arm shafts Camshaft Refer to ROCKER ARMS AND CAM SHAFT on page 5 17 1 Valve cotter 8 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 For installation reverse the removal proce dure M M M M M New New New New 7 6 5 5 4 4 3 2 1 6 7 7 6 3 2 3 2 1 2 3 6 7 8 8 ...

Page 213: ...emove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 3 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 Valve spring seat 5 TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EAS24290 CHECKING THE VALVES AND VALVE GUIDES The following proc...

Page 214: ...stem to valve guide clearance TIP After replacing the valve guide reface the valve seat 3 Eliminate Carbon deposits from the valve face and valve seat Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0031 in Valve stem to valve guide clear ance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in Valve guide position 12 7 13 1 mm 0 50 0 52 in...

Page 215: ...its from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width C a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat widt...

Page 216: ...of the lapping compound TIP For the best lapping results lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h In...

Page 217: ...nded lubricant 3 Install Valve spring seat 1 Valve stem seal 2 Free length intake 40 38 mm 1 59 in Limit 38 36 mm 1 51 in Free length exhaust 40 38 mm 1 59 in Limit 38 36 mm 1 51 in Installed compression spring force intake 171 00 197 00 N 17 44 20 09 kgf 38 44 44 29 lbf Installed compression spring force exhaust 171 00 197 00 N 17 44 20 09 kgf 38 44 44 29 lbf Installed length intake 35 00 mm 1 38...

Page 218: ...lve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve b Smaller pitch Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attach me...

Page 219: ...er to WATER PUMP on page 6 7 1 Timing chain guide exhaust side 1 2 Cylinder 1 3 Cylinder gasket 1 4 Dowel pin 2 5 Piston pin clip 2 6 Piston pin 1 7 Piston 1 8 Top ring 1 9 2nd ring 1 10 Oil ring 1 For installation reverse the removal proce dure T R 1st 15 Nm 1 5 m kg 11 ft lb 2nd 50 Nm 5 0m kg 36 ft lb T R 10 Nm 1 0 m kg 7 2 ft Ib E E E E E 1 2 7 3 4 4 5 6 5 10 9 8 New New New techsparkstudio com...

Page 220: ...t to remove remove it with the piston pin puller set 4 2 Remove Top ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS24400 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to...

Page 221: ...GY YFM5FGPY 102 080 mm 4 0189 in YFM7FGY YFM7FGPY Taper limit 0 05 mm 0 002 in Out of round limit 0 05 mm 0 002 in C maximum of D1 D6 T maximum of D1 or D2 maximum of D5 or D6 R maximum of D1 D3 or D5 minimum of D2 D4 or D6 Diameter D 91 955 91 970 mm 3 6203 3 6209 in YFM5FGY YFM5FGPY 101 955 101 970 mm 4 0140 4 0146 in YFM7FGY YFM7FGPY b 10 mm 0 39 in from the bottom edge of the piston Piston to ...

Page 222: ...ecification Replace the piston pin 3 Measure Piston pin bore diameter b Out of specification Replace the piston 4 Calculate Piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set a 50 mm 1 97 in Top ring End gap installed 0 20 0 35 mm 0 008 0 014 in Limit 0 60 mm 0 024 in 2nd ring End gap installed 0 75 0 90 mm 0 03 0 04 in Limit 1 25 mm 0 049 in Oi...

Page 223: ...all Cylinder gasket Dowel pins 4 Lubricate Piston Piston rings Cylinder with the recommended lubricant 5 Offset Piston ring end gaps 6 Install Cylinder 1 Timing chain guide exhaust side TIP While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide exhaust side through the timing chain cavity 7 Install Cylinder bolts 1 TIP...

Page 224: ...ISTON 5 33 8 Tighten Cylinder bolts 1 Cylinder bolts timing chain side 2 T R Cylinder bolt 1st 15 Nm 1 5 m kg 11 ft lb 2nd 50 Nm 5 0 m kg 36 ft lb Cylinder bolt timing chain side 10 Nm 1 0 m kg 7 2 ft lb E E 2 1 1 2 ...

Page 225: ...er to WATER PUMP on page 6 7 1 Oil delivery pipe 1 1 2 AC magneto coupler 1 Disconnect 3 Crankshaft position sensor coupler 1 Disconnect 4 Lead holder 1 5 AC magneto cover 1 6 AC magneto cover gasket 1 7 Dowel pin 2 8 Lead holder 1 LT 7 7 2 1 3 LT New 5 6 LS LT 17 13 12 15 14 18 E E E 11 16 E New New New 10 8 9 4 10 LT LT E LT LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 7 Nm...

Page 226: ...everse the removal proce dure Removing the AC magneto and starter clutch Order Job Parts to remove Q ty Remarks LT 7 7 2 1 3 LT New 5 6 LS LT 17 13 12 15 14 18 E E E 11 16 E New New New 10 8 9 4 10 LT LT E LT LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 30 Nm 3 0 m kg 22 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 10 Nm 1 0 m kg 7 2 ft Ib 18 Nm 1 8 m kg 13 ft Ib T R 18 Nm 1 8 m kg ...

Page 227: ...the end of the crankshaft place an appropriate sized socket between the fly wheel puller set center bolt and the crank shaft TIP Use the flywheel puller 2 Install the flywheel puller bolts to the threaded holes of the starter clutch Make sure the flywheel puller is centered over the AC magneto rotor EAS24560 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts 1 TIP Hold the AC magneto rotor ...

Page 228: ...hen turning the starter wheel gear counter clockwise A the starter clutch and the start er wheel gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter wheel gear clock wise B it should turn freely otherwise the starter clutch is faulty and must be replaced EAS28P1039 CHECKING THE TORQUE LIMITER 1 Check Torque limiter Damage wear Replace TIP Do no...

Page 229: ...ted in the keyway of the crankshaft 4 Tighten AC magneto rotor nut 1 TIP Hold the AC magneto rotor 2 with the sheave holder 3 while tightening the AC magneto ro tor nut Do not allow the sheave holder to touch the projection on the AC magneto rotor 5 Install AC magneto cover Lead holder 1 AC magneto cover bolts TIP Tighten the AC magneto cover bolts in stages using a crisscross pattern T R Stator c...

Page 230: ...AC MAGNETO AND STARTER CLUTCH 5 39 1 ...

Page 231: ...b Parts to remove Q ty Remarks Muffler Refer to ENGINE REMOVAL on page 5 1 1 Starter motor lead 1 Disconnect 2 Ground lead 1 Disconnect 3 Starter motor 1 For installation reverse the removal proce dure 2 3 1 T R 10 Nm 1 0 m kg 7 2 ft Ib 11 Nm 1 1 m kg 8 0 ft Ib T R techsparkstudio com ...

Page 232: ...Remarks 1 Starter motor front cover 1 2 Starter motor rear cover 1 3 Brush holder set 1 4 Armature assembly 1 5 Starter motor yoke 1 For assembly reverse the disassembly pro cedure 1 3 5 4 4 2 LS New New New New New LS New New New 5 Nm 0 5 m kg 3 6 ft Ib T R 11 Nm 1 1 m kg 8 0 ft Ib T R ...

Page 233: ...y resistances with the digital circuit tester b If any resistance is out of specification re place the starter motor 4 Measure Brush length a Out of specification Replace the brushes as a set 5 Measure Brush spring force Out of specification Replace the brush springs as a set 6 Check Gear teeth Damage wear Replace the gear Mica undercut depth 0 70 mm 0 03 in Digital circuit tester 90890 03174 Mode...

Page 234: ...fective part s EAS24800 ASSEMBLING THE STARTER MOTOR 1 Install Starter motor yoke 1 Starter motor front cover 2 Starter motor rear cover 3 TIP Align the alignment marks a on the starter mo tor yoke with the match marks b on the front and starter motor rear covers a b b 1 2 3 ...

Page 235: ...to remove Q ty Remarks Starter wheel gear Refer to AC MAGNETO AND STARTER CLUTCH on page 5 34 1 Lock washer 1 2 Balancer driven gear 1 3 Oil pump drive gear 1 4 Chain 1 5 Straight key 1 6 Lock washer 1 7 Oil pump driven gear 1 8 Plate 1 9 Spring 8 10 Pin 4 11 Balancer drive gear 1 For installation reverse the removal proce dure techsparkstudio com ...

Page 236: ...driven gear as a set EAS28P1044 INSTALLING THE BALANCER DRIVE GEAR BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR 1 Install Pin Spring Balancer drive gear onto the buffer boss TIP Align the punch mark a on the balancer drive gear with the hole b to the buffer boss 2 Install Balancer drive gear 1 Balancer driven gear 2 Oil pump driven gear 3 TIP Align the punch mark a on the balancer drive gear with...

Page 237: ...BALANCER GEARS AND OIL PUMP GEARS 5 46 4 Bend the lock washer tabs along the balancer driven gear nut and oil pump driven gear nut 5 2 3 4 1 techsparkstudio com ...

Page 238: ... Drive belt cover 1 2 Rubber gasket 1 3 Bearing housing 1 4 Dowel pin 2 5 Primary sheave assembly 1 6 V belt 1 7 Primary fixed sheave 1 8 Secondary sheave assembly 1 9 Drive belt case 1 10 Rubber gasket 1 11 Rubber gasket 1 For installation reverse the removal proce dure 2 3 4 5 6 7 8 9 10 4 11 8 11 New New New New E 1 LS 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...

Page 239: ... primary sheave Order Job Parts to remove Q ty Remarks 1 Primary sheave cap 1 2 Primary sheave slider 4 3 Primary sheave cam 1 4 Primary sheave weight 8 5 Collar 1 6 Oil seal 2 7 Primary sliding sheave 1 8 O ring 1 For assembly reverse the disassembly pro cedure techsparkstudio com ...

Page 240: ...mbling the secondary sheave Order Job Parts to remove Q ty Remarks 1 Nut 1 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 pro cedure ...

Page 241: ...d block in a vise and se cure it c Tighten the sheave spring compressor nut 5 and compress the spring d Loosen the nut 1 with the locknut wrench 3 e Remove the nut 1 f Remove the sheave spring compressor and locknut wrench EAS24670 CHECKING THE V BELT 1 Check V belt 1 Cracks damage wear Replace Grease oil Clean the primary and second ary sheave 2 Measure V belt width a Out of specification Replace...

Page 242: ...ARY SHEAVE SLIDERS The following procedure applies to all of the pri mary sheave sliders 1 Check Primary sheave slider Cracks damage wear Replace EAS24710 CHECKING THE SECONDARY SHEAVE 1 Check Secondary fixed sheave Secondary sliding sheave Cracks damage wear Replace the sec ondary fixed and sliding sheaves as a set 2 Check Torque cam grooves 1 Damage wear Replace the secondary fixed and sliding s...

Page 243: ...Yamaha Grizzly grease 2 5 g to the in ner surface of the collar Apply Yamaha Grizzly grease 2 5 g to the in ner surface of the primary sliding sheave EAS24730 ASSEMBLING THE SECONDARY SHEAVE 1 Install Oil seals 1 2 Lubricate Secondary sliding sheave 1 Free length 124 2 mm 4 89 in YFM5FGY YFM5FGPY 130 6 mm 5 14 in YFM7FGY YFM7FGPY Limit 121 7 mm 4 79 in YFM5FGY YFM5FGPY 128 0 mm 5 04 in YFM7FGY YFM...

Page 244: ...sheave fixed block locknut wrench and sheave spring compressor to the secondary sheave b Place the sheave fixed block in a vise and se cure it c Tighten the sheave spring compressor nut 1 and compress the spring d Install the nut 2 and tighten it to the specified torque using the locknut wrench e Remove the sheave spring compressor lock nut wrench and sheave fixed block Recommended lubricant BEL R...

Page 245: ...n in the illustration 2 Check Primary sheave weights position Out of specification Repeat step 1 TIP To check that the primary sheave weights 1 are installed correctly make sure that the sec ondary sheave 2 primary sheave 3 and V belt 4 are positioned as shown in the illustra tion 3 Tighten Primary sheave nut 1 Secondary sheave nut 2 TIP Use the sheave holder 3 to hold the primary sheave First tig...

Page 246: ...PRIMARY AND SECONDARY SHEAVES 5 55 ...

Page 247: ...ty Remarks Primary sheave Secondary sheave Refer to PRIMARY AND SECONDARY SHEAVES on page 5 47 1 Clutch housing assembly 1 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 proce dure techsparkstudio com ...

Page 248: ... the clutch housing assembly Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Circlip 1 3 Bearing housing 1 4 Circlip 1 5 Bearing 1 6 Circlip 1 7 Bearing 1 8 Clutch housing 1 For assembly reverse the disassembly pro cedure ...

Page 249: ...st be installed with the flange side facing in 2 Check One way clutch operation a Install the one way clutch bearing and clutch carrier assembly to the clutch housing and hold the clutch carrier assembly b When turning the clutch housing clockwise A it should turn freely otherwise the one way clutch assembly is faulty and must be re placed c When turning the clutch housing counter clockwise B the ...

Page 250: ...sembly 2 Lock the threads with a drift punch 3 Install One way clutch bearing TIP 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 Installed depth a 2 5 2 7 mm 0 10 0 11 in 2 Clutch housing Installed depth a 0 mm 0 in 2 Bearing housing 2 1 a New 2 a 1 New New T...

Page 251: ...CLUTCH 5 60 TIP Tighten the bolts in stages using a crisscross pattern After tightening the bolts check that the clutch housing assembly rotates smoothly techsparkstudio com ...

Page 252: ... OIL PUMP GEARS on page 5 44 Primary sheave assembly Secondary sheave assembly Refer to PRIMARY AND SECONDARY SHEAVES on page 5 47 Clutch carrier assembly Refer to CLUTCH on page 5 56 1 Timing chain guide intake side 1 2 Timing chain guide lower 1 3 Timing chain 1 4 Oil filter cartridge 1 5 Speed sensor 1 6 Dipstick 1 LT T R 7 Nm 0 7 m kg 5 1 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T R 10 Nm 1 0 m kg 7 ...

Page 253: ...ridge Order Job Parts to remove Q ty Remarks LT T R 7 Nm 0 7 m kg 5 1 ft Ib T R 17 Nm 1 7 m kg 12 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 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib LT New New New New New New New New LS LS LS LS LT E LT LT LT LT LS 2 5 6 9 8 1 7 4 3 techsparkstudio com ...

Page 254: ...r white 7 Stopper lever stopper 1 Spring identification color red 8 Right crankcase 1 9 Dowel pin 2 10 Left crankcase 1 For assembly reverse the disassembly pro cedure 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 T R 26 Nm 2 6 m kg 19 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib New New New New LS LS E E E E 1 4...

Page 255: ...n Refer to TRANSMISSION on page 5 73 Middle drive shaft Middle driven shaft Refer to MIDDLE GEAR on page 5 79 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 proce dure E E E E E E New New LS LS 7 7 7 7 7 7 7 E LT LT 4 7 3 2 1 5 6 LT T R 10 Nm 1 0 m kg 7 2 ft Ib techsparkstudio com ...

Page 256: ...rfaces Work slowly and carefully and make sure the crankcase halves sepa rate evenly EAS24180 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1 Check Timing chain Damage stiffness Replace the timing chain and camshaft sprocket as a set 2 Check Timing chain guide intake side Damage wear Replace EAS28P1050 CHECKING THE RELIEF VALVE 1 Check Spring seat 1 Spring 2 Relief valve body 3 Relief valve 4 D...

Page 257: ...into contact with the oil gallery 4 Install Dowel pins 2 5 Fit the right crankcase onto the left crank case Tap lightly on the case with a soft ham mer NOTICE ECA28P1034 Before installing and torquing the crankcase holding bolts be sure to check whether the transmission is functioning properly by manually rotating the shift drum in both di rections 6 Install Lead holders Crankcase bolts 7 Tighten ...

Page 258: ...h operation Repair EAS28P1052 INSTALLING THE SHIFT LEVER 1 Install Shift lever 2 assembly 1 Shift lever 1 2 TIP When installing the shift lever 1 align the punch mark a on the shift lever 1 with the punch marks b on the shift lever 2 A Right crankcase B Left crankcase T R Shift lever 2 assembly bolt 14 Nm 1 4 m kg 10 ft lb A 3 3 2 B 3 3 3 1 3 2 2 ...

Page 259: ...nd oil pump Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 61 1 Oil pump 1 2 Gasket 1 3 Balancer 1 4 Crankshaft 1 For installation reverse the removal proce dure 3 4 2 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib New techsparkstudio com ...

Page 260: ... oil pump Order Job Parts to remove Q ty Remarks 1 Oil pump housing cover 1 2 Pin 1 3 Oil pump shaft 1 4 Inner rotor 1 5 Outer rotor 1 6 Oil pump housing 1 For assembly reverse the disassembly pro cedure E 6 3 2 5 4 1 E T R 5 Nm 0 5 m kg 3 6 ft Ib ...

Page 261: ...2 Measure Inner rotor to outer rotor tip clearance a Outer rotor to oil pump housing clearance b Oil pump housing to inner rotor and outer rotor clearance c Out of specification Replace the oil pump 3 Check Oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s Crankcase separating tool 90890 01135 Crankcase separator YU 01135 B 1 2 Inner rotor to outer rotor tip cl...

Page 262: ... crankshaft Bearing Cracks damage wear Replace the crank shaft 5 Check Crankshaft journal Scratches wear Replace the crankshaft Crankshaft journal oil passage Obstruction Blow out with compressed air EAS25010 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft with the recommended lubricant 2 Install Oil pump housing 1 Outer rotor 2 Inner rotor 3 Oil pump shaft 4 Pin 5 TIP T...

Page 263: ...nkshaft against scratches and to make installation easier TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft as sembly bottoms against the bearing Crankshaft installer pot 90890 01274 Installing pot YU 90058 Crankshaft installer bolt 90890 01275 Bolt YU 90060 ...

Page 264: ...ven gear Refer to MIDDLE GEAR on page 5 79 1 Shift drum 1 2 Shift fork assembly 1 3 Shift fork R 1 4 Spring 1 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 11 Stopper lever 1 12 Stopper lever shaft 1 For installation reverse the removal proce dure M 1 7 6 8 5 10 12 11 9 4 3 2 New New New New New E E E E ...

Page 265: ...3 High wheel gear 1 4 Washer 1 5 Clutch dog 1 6 Circlip 1 7 Washer 1 8 Collar 1 9 Low wheel gear 1 10 Washer 1 11 Circlip 1 12 Middle drive gear 1 13 Circlip 1 14 Washer 1 15 Bearing 1 16 Reverse wheel gear 1 17 Stopper wheel 1 M M M M M M M New New New 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 17 techsparkstudio com ...

Page 266: ... 75 18 Drive axle 1 For assembly reverse the disassembly pro cedure Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks M M M M M M M New New New 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 17 ...

Page 267: ...wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING EWA12840 Do not attempt to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set 4 Check Spring Cracks damage Replace EAS28P1057 CHECKING THE SHIFT DRUM 1 C...

Page 268: ...tting wear Replace EAS28P1059 CHECKING THE STOPPER LEVER AND STOPPER WHEEL 1 Check Stopper lever pawl 1 Bends damage wear Replace the stopper lever and stopper wheel as a set Stopper wheel 2 Damage wear Replace the stopper wheel and stopper lever as a set Stopper lever shaft 3 Bends damage wear Replace EAS28P1060 ASSEMBLING THE SHIFT FORK ASSEMBLY 1 Install Shift fork guide bar 1 Shift fork L 2 Sp...

Page 269: ...rds the left and right sides of the crankcase respectively 2 Check Shift operation Rough operation Repair TIP Oil each gear and bearing thoroughly Before assembling the crankcase make sure that the transmission is in neutral and that the gears turn freely 1 2 3 4 5 a 6 b techsparkstudio com ...

Page 270: ...1 Bearing housing 1 2 Middle drive pinion gear nut 1 3 Middle drive pinion gear 1 4 Middle drive pinion gear shim Refer to ALIGNING THE MIDDLE GEAR on page 5 87 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 proce dure 190 Nm 19 0 m kg 140 ft lb T R New LT LT LT LT LT New LT LT E ...

Page 271: ... side 1 3 Middle driven pinion gear assembly 1 4 Rear drive shaft yoke nut middle gear side 1 5 Rear drive shaft yoke middle gear side 1 6 Bearing housing 1 7 O ring 1 8 Middle driven pinion gear shim Refer to ALIGNING THE MIDDLE GEAR on page 5 87 9 Middle driven pinion gear 1 10 Bearing 1 11 Middle driven pinion gear bearing retainer 1 12 Bearing 1 13 Middle driven shaft bearing retainer 1 14 Bea...

Page 272: ...MIDDLE GEAR 5 81 15 Middle driven shaft 1 For installation reverse the removal proce dure Removing the middle driven shaft Order Job Parts to remove Q ty Remarks ...

Page 273: ...e gear side 2 TIP Use the coupling gear middle shaft tool 3 to hold the front drive shaft coupling sleeve 2 Remove Rear drive shaft yoke nut middle gear side 1 Washer Rear drive shaft yoke middle gear side 2 TIP Use the coupling gear middle shaft tool 3 to hold the rear drive shaft coupling sleeve 3 Remove Bearing housing assembly 1 a Clean the surface of the bearing housing as sembly b Place the ...

Page 274: ... er has left handed threads To loosen the re tainer turn it clockwise c Remove the bearing retainer and bearing 5 Remove Oil seal 1 Middle driven shaft bearing retainer 2 TIP Attach the ring nut wrench 3 NOTICE ECA28P1038 The middle driven shaft bearing retainer has left handed threads To loosen the retainer turn it clockwise 6 Remove Middle driven shaft 1 with bearing EAS28P1064 CHECKING THE PINI...

Page 275: ... retainer wrench 2 c Tighten the bearing retainer NOTICE ECA28P1040 The middle driven pinion gear bearing retain er has left handed threads To tighten the re tainer turn it counterclockwise 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 Installed depth of oil seal c 1 0 1 5 mm 0 039 0 059 in 4 Middle drive pinion gear bearing retainer...

Page 276: ...ont drive shaft yoke nut middle gear side 2 TIP Use the coupling gear middle shaft tool 3 to hold the coupling yoke EAS28P1067 INSTALLING THE MIDDLE DRIVE SHAFT 1 Install Circlip Middle driven gear 1 to the middle drive shaft 2 T R Rear drive shaft yoke nut middle gear side 150 Nm 15 0 m kg 110 ft lb LOCTITE Coupling gear middle shaft tool 90890 01229 Gear holder YM 01229 1 2 1 1 T R Front drive s...

Page 277: ...p a rag 1 around a screwdriver 2 and then insert it into the installation hole a of the left crankcase speed sensor to hold the mid dle driven gear c Attach the final gear backlash band 3 and dial gauge 4 d Measure the gear lash while rotating the mid dle driven shaft back and forth TIP Measure the gear lash at 4 positions Rotate the middle driven gear 90 each time T R Bearing retainer bolt 29 Nm ...

Page 278: ...rankcase middle driven shaft bearing housing and middle driven pinion gear b To find middle drive pinion gear shim thick ness A use the following formula a a numeral usually a decimal number on the bearing housing is either added to or subtracted from 0 6 b 17 0 c 55 0 d a numeral usually a decimal number on the right crankcase specifies a thickness of 65 0 e a numeral usually a decimal number on ...

Page 279: ...ce f to select the correct middle driven pinion gear shim thickness g a numeral usually a decimal number on the middle driven pinion gear is either add ed to or subtracted from 49 0 h a numeral usually a decimal number on the middle driven pinion gear is either add ed to or subtracted from 80 5 i a numeral usually a decimal number on the left crankcase specifies a thickness of 99 98 j a numeral us...

Page 280: ...0 05 0 72 Round off hundredth digit and select appro priate shim s In the example above the calculated shim thickness is 0 72 mm The chart instructs you however to round off 2 to 0 Shims are supplied in the following thickness es Hundredth Rounded value 0 1 2 0 3 4 5 6 7 5 8 9 10 h i j Middle driven pinion gear shim Thickness mm 0 10 0 15 0 20 0 30 0 40 0 50 0 60 ...

Page 281: ...HE RADIATOR 6 3 INSTALLING THE RADIATOR 6 3 THERMOSTAT 6 4 CHECKING THE THERMOSTAT 6 5 INSTALLING THE THERMOSTAT 6 5 WATER PUMP 6 7 DISASSEMBLING THE WATER PUMP 6 9 CHECKING THE WATER PUMP 6 9 ASSEMBLING THE WATER PUMP 6 9 techsparkstudio com ...

Page 282: ...ain Refer to CHANGING THE COOLANT on page 3 17 1 Radiator fan motor coupler 1 Disconnect 2 Radiator fan motor breather hose 1 3 Coolant reservoir hose 1 4 Coolant reservoir breather hose 1 5 Coolant reservoir cap 1 6 Coolant reservoir 1 7 Radiator outlet hose 1 8 Radiator inlet hose 1 9 Radiator bracket 1 10 Radiator 1 11 4 10 9 7 6 5 4 8 1 2 3 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft ...

Page 283: ...ator fan 1 For installation reverse the removal proce dure Removing the radiator Order Job Parts to remove Q ty Remarks 11 4 10 9 7 6 5 4 8 1 2 3 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib techsparkstudio com ...

Page 284: ... sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 9 27 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 17 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure Radiator cap opening pressure Below th...

Page 285: ... ENGINE REMOVAL on page 5 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 17 1 Radiator inlet hose 1 Disconnect 2 Thermostat cover 1 3 Thermostat 1 4 Coolant temperature sensor coupler 1 Disconnect 5 Coolant temperature sensor 1 For installation reverse the removal proce dure New New 2 3 LS 1 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 18 Nm 1 8 m kg 13 ft Ib New 5 4 tech...

Page 286: ...cylinder head Cracks damage Replace EAS26480 INSTALLING THE THERMOSTAT 1 Install Copper washer Coolant temperature sensor NOTICE ECA28P1016 Use extreme care when handling the coolant temperature sensor Replace any part that was dropped or subjected to a strong im pact 2 Install Thermostat 1 O ring 2 Thermostat cover 3 TIP Install the thermostat with its breather hole a facing up 3 Fill Cooling sys...

Page 287: ...THERMOSTAT 6 6 5 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 3 techsparkstudio com ...

Page 288: ...4 Coolant Drain Refer to CHANGING THE COOLANT on page 3 17 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 pump breather hose 1 6 Water pump housing 1 7 Gasket 1 8 Circlip 1 9 Impeller shaft 1 10 Water pump seal 1 New New New New New E 2 3 4 LS New 6 7 M 9 10 LS 12 11 8 5 1 New T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg ...

Page 289: ...rse the removal proce dure Removing the water pump Order Job Parts to remove Q ty Remarks New New New New New E 2 3 4 LS New 6 7 M 9 10 LS 12 11 8 5 1 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 techsparkstudio com ...

Page 290: ...hose Cracks damage wear Replace EAS26560 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 into the AC magneto cover 2 TIP Before installing the oil seal apply tap water or coolant onto its outer surface Install the oil seal with a socket 3 that match es its outside diameter 2 Install Water pump seal 1 into the AC magneto cover 2 NOTICE ECA14080 Never lubricate the water pump seal surface with oil or...

Page 291: ...ll Impeller shaft 1 Circlip TIP After installation check that the impeller shaft ro tates smoothly 3 Mechanical seal installer 4 Middle driven shaft bearing driver A Push down Impeller shaft tilt limit 0 15 mm 0 006 in 1 Straightedge 2 Impeller A 1 New 2 3 4 New 1 techsparkstudio com ...

Page 292: ...WATER PUMP 6 11 ...

Page 293: ...NK BREATHER HOSE JOINT 7 2 INSTALLING THE FUEL PUMP 7 2 INSTALLING THE FUEL TANK 7 3 THROTTLE BODY 7 4 REMOVING THE THROTTLE BODY ASSEMBLY 7 6 CHECKING THE INJECTOR 7 6 CHECKING THE THROTTLE BODY 7 6 INSTALLING THE THROTTLE BODY ASSEMBLY 7 6 CHECKING THE FUEL PRESSURE 7 7 ADJUSTING THE THROTTLE POSITION SENSOR 7 7 techsparkstudio com ...

Page 294: ...se connector holder 1 4 Fuel hose 1 5 Fuel tank breather hose 2 6 Fuel tank breather hose joint 1 7 Fuel tank overflow hose 1 8 Fuel tank 1 9 Fuel pump assembly 1 10 Final drive case breather hose 1 Disconnect 11 Fuel tank shield 1 12 Damper 2 For installation reverse the removal proce dure 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 7 Nm 0 7 m kg 5...

Page 295: ...nder where it will be removed 3 Remove Fuel tank TIP Do not set the fuel tank down on the installation surface of the fuel pump Be sure to lean the fuel tank in an upright position EAS26640 REMOVING THE FUEL PUMP 1 Remove Fuel pump bracket Fuel pump Fuel pump gasket NOTICE ECA14720 Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender EAS26670 CHECKIN...

Page 296: ...er NOTICE ECA28P1020 When installing the fuel hose make sure that it is securely connected and that the fuel hose holder is in the correct position other wise the fuel hose will not be properly in stalled TIP Install the fuel hose connector holder 1 se curely 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...

Page 297: ...r coupler 1 Disconnect 3 Throttle body breather hose 1 4 ISC unit coupler 1 Disconnect 5 Throttle cable housing cover 1 6 Throttle cable 1 Disconnect 7 Throttle body joint clamp screw 2 Loosen 8 Throttle body assembly 1 9 Fuel hose 1 Disconnect 10 Fuel injector coupler 1 Disconnect 11 Throttle body joint 1 For installation reverse the removal proce dure 11 7 7 New LS T R 3 Nm 0 3 m kg 2 2 ft Ib 5 ...

Page 298: ...arks 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 Throttle body 1 NOTICE ECA28P1021 The throttle body should not be disas sembled For assembly reverse the disassembly pro cedure 6 2 1 3 5 4 New New LS ...

Page 299: ...eck Throttle body Cracks damage Replace the throttle body 2 Check Fuel passages Obstructions Clean a Wash the throttle body in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages with compressed air EAS28P1022 INSTALLING THE THROTTLE BODY ASSEMBLY 1 Install Throttle body joint 1 TIP Align the projection a on the cylinder head with the slot b...

Page 300: ...he pressure gauge 3 and adapter 4 to the fuel pump and fuel hose e Start the engine f Measure the fuel pressure Out of specification Replace the fuel pump EAS27030 ADJUSTING THE THROTTLE POSITION SENSOR 1 Check Throttle position sensor Refer to CHECKING THE THROTTLE PO SITION SENSOR on page 9 96 2 Adjust Throttle position sensor angle a Connect the throttle position sensor coupler to the throttle ...

Page 301: ...age e Adjust the throttle position sensor angle so that the voltage is within the specified range f After adjusting the throttle position sensor an gle tighten the throttle position sensor screws 3 Throttle position sensor output voltage 0 63 0 73 V yellow black blue 3 3 techsparkstudio com ...

Page 302: ...THROTTLE BODY 7 9 ...

Page 303: ...ELOCITY SHAFT ASSEMBLIES FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT 8 15 DISASSEMBLING THE REAR CONSTANT VELOCITY SHAFT ASSEMBLIES 8 22 CHECKING THE REAR CONSTANT VELOCITY SHAFT ASSEMBLIES 8 22 ASSEMBLING THE REAR CONSTANT VELOCITY SHAFT ASSEMBLIES 8 23 DISASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY 8 24 CHECKING THE REAR DRIVE SHAFT 8 24 CHECKING THE FINAL DRIVE ASSEMBLY 8 24 ASSEMBLING THE FI...

Page 304: ...le broken gear teeth WARNING EWA13790 Stop riding immediately if broken gear teeth are suspected This condition could result in the shaft drive assembly locking up causing a loss of control and possible injury to the rider 2 Check Drained oil Drained oil shows large amounts of metal particles Check the bearing for seizure TIP A small amount of metal particles in the oil is nor mal 3 Check Oil leak...

Page 305: ...rque to specification Refer to FRONT WHEELS on page 4 14 and REAR WHEELS on page 4 18 3 Check the front constant velocity shaft assemblies Feel for bearing damage Constant velocity shaft bearings and differ ential bearings are probably not damaged Repeat the test or remove the individual components 4 Check the rear brake adjustment Adjust per instructions Refer to AD JUSTING THE REAR DISC BRAKE on...

Page 306: ...ASSIS on page 4 1 Steering knuckles Refer to TIE RODS AND STEERING KNUCKLES on page 4 55 Front arms Refer to FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES on page 4 59 Differential gear oil Drain Refer to CHANGING THE DIFFERENTIAL GEAR OIL on page 3 27 1 Front constant velocity shaft assembly 2 2 Differential motor coupler 1 Disconnect 3 Differential case breather hose 1 Disconnect 4 Differential...

Page 307: ...seal 1 10 Dust seal 1 For installation reverse the removal proce dure Removing the front constant velocity shaft assemblies differential assembly and front drive shaft Order Job Parts to remove Q ty Remarks LS 1 1 3 9 10 2 8 7 6 5 4 New New LS LS LS LS LT LT T R 55 Nm 5 5 m kg 40 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib LT techsparkstudio com ...

Page 308: ...ft assemblies Order Job Parts to remove Q ty Remarks The following procedure applies to both of the front constant velocity shaft assemblies 1 Clip 1 2 Boot band 1 3 Boot band 1 4 Dust boot 1 5 Clip 1 6 Double offset joint 1 7 Circlip 1 8 Ball bearing 1 9 Boot band 1 10 Boot band 1 11 Dust boot 1 12 Constant velocity joint 1 13 Clip 1 ...

Page 309: ...EMBLY AND FRONT DRIVE SHAFT 8 6 A Wheel side B Differential side 14 Constant velocity shaft 1 For assembly reverse the disassembly pro cedure Disassembling the front constant velocity shaft assemblies Order Job Parts to remove Q ty Remarks techsparkstudio com ...

Page 310: ...ide 1 4 Front drive shaft yoke differential case side 1 5 Differential case cover 1 6 O ring 1 7 Differential gear assembly 1 8 Differential gear assembly shim Refer to ADJUSTING THE DIFFEREN TIAL GEAR BACKLASH on page 8 13 9 Bearing 1 10 Bearing 1 11 Oil seal 1 12 Clip 1 13 Differential pinion gear 1 14 Bearing 1 T R 62 Nm 6 2 m kg 45 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib ...

Page 311: ...erse the disassembly pro cedure Disassembling the differential assembly Order Job Parts to remove Q ty Remarks T R 62 Nm 6 2 m kg 45 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 11 Nm 1 1 m kg 8 0 ft Ib LT LS LS New New New New New New LS LS 13 15 5 16 17 10 7 1 2 5 16 6 8 9 3 4 11 12 14 techsparkstudio com ...

Page 312: ...tant velocity joint Clip TIP Secure the constant velocity shaft in a vise and then remove the constant velocity joint using hammers EAS29960 CHECKING THE FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES The following procedure applies to both of the front constant velocity shaft assemblies 1 Check Double offset joint splines Constant velocity joint splines Constant velocity shaft splines Wear damage Repla...

Page 313: ... con stant velocity joint using a hammer 2 Install Dust boot Ball bearing 1 Circlip 2 Double offset joint 3 Clip 4 TIP Securely install the circlip into the groove in the constant velocity shaft Securely install the clip into the groove in the double offset joint 3 Apply Molybdenum disulfide grease into the double offset joint constant velocity joint and dust boots TIP Molybdenum disulfide grease ...

Page 314: ...s of specialized equipment Do not at tempt to disassemble this unit Disassembly will result in the malfunction of the unit EAS29970 CHECKING THE DIFFERENTIAL ASSEMBLY 1 Check Gear teeth Pitting galling wear Replace differential pinion gear and differential gear assembly as a set Bearings Pitting damage Replace Oil seals O rings Damage Replace 2 Check Drive shaft splines Pinion gear splines Wear da...

Page 315: ...o the 2WD mode b Connect two C size batteries to the differen tial motor terminal 2 to operate the differen tial motor pinion gear 3 Operate the differential motor pinion gear until the mark 4 on the differential motor pinion gear is aligned with the mark 5 on the differential motor case NOTICE ECA16230 Do not use a 12 V battery to operate the dif ferential motor pinion gear c Insert 6 mm bolts 6 ...

Page 316: ...d 4 Attach Gear lash measurement tool 2 Dial gauge 3 5 Measure Gear backlash Gently rotate the differential pinion gear from engagement to engagement TIP Measure the gear backlash at four positions Ro tate the differential pinion gear 90 each time EAS30030 ADJUSTING THE DIFFERENTIAL GEAR BACKLASH 1 Remove Differential gear assembly shim s 1 Differential gear assembly 2 2 Adjust Gear backlash a Sel...

Page 317: ...FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES DIFFEREN TIAL ASSEMBLY AND FRONT DRIVE SHAFT 8 14 b Measure the differential gear backlash again techsparkstudio com ...

Page 318: ...d plate Rear fender Refer to GENERAL CHASSIS on page 4 1 Rear arms Refer to REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES on page 4 67 Final gear oil Drain Refer to CHANGING THE FINAL GEAR OIL on page 3 26 1 Rear constant velocity shaft assembly 2 2 Final drive case breather hose 1 Disconnect 3 Trailer hitch 1 4 Final drive assembly 1 5 Rear drive shaft 1 6 Spring 1 7 Damper 1 8 Rear drive shaft co...

Page 319: ...1 For installation reverse the removal proce dure Removing the rear constant velocity shaft assemblies final drive assembly and rear drive shaft Order Job Parts to remove Q ty Remarks 1 3 10 8 9 7 6 2 5 1 4 T R 55 Nm 5 5 m kg 40 ft Ib T R 66 Nm 6 6 m kg 48 ft Ib LS LS LS LS New New techsparkstudio com ...

Page 320: ...t assemblies Order Job Parts to remove Q ty Remarks The following procedure applies to both of the rear constant velocity shaft assemblies 1 Clip 1 2 Boot band 1 3 Boot band 1 4 Dust boot 1 5 Clip 1 6 Double offset joint 1 7 Circlip 1 8 Ball bearing 1 9 Boot band 1 10 Boot band 1 11 Dust boot 1 12 Constant velocity joint 1 13 Clip 1 ...

Page 321: ...EMBLY AND REAR DRIVE SHAFT 8 18 A Wheel side B Final drive side 14 Constant velocity shaft 1 For assembly reverse the disassembly pro cedure Disassembling the rear constant velocity shaft assemblies Order Job Parts to remove Q ty Remarks techsparkstudio com ...

Page 322: ...ned remove them 4 Dowel pin 2 5 Gasket 1 6 Oil seal 1 7 Bearing 1 8 Bearing 1 9 Wheel gear shim Refer to SELECTING THE WHEEL GEAR SHIM S on page 8 28 10 Wheel gear 1 11 Final driven pinion gear shim final drive case cover side Refer to SELECTING THE FINAL DRIVEN PINION GEAR SHIM FINAL DRIVE CASE COVER SIDE on page 8 28 12 Pinion gear 1 4 New New New New New New New New T R 23 Nm 2 3 m kg 17 ft Ib ...

Page 323: ...seal 1 17 Bearing 1 18 Bearing 1 19 Final drive case 1 20 Rear drive shaft yoke nut final drive case side 1 21 Washer 1 22 Rear drive shaft yoke final drive case side 1 23 Final drive pinion gear 1 24 Oil seal 1 25 Bearing 1 Disassembling the final drive assembly Order Job Parts to remove Q ty Remarks 4 New New New New New New New New T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 ...

Page 324: ... the disassembly pro cedure Disassembling the final drive assembly Order Job Parts to remove Q ty Remarks 4 New New New New New New New New T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 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 6 5 3 7 9 10 17 4 16 8 11 12 13 14 15 18 4 19 2 11 20 21 22 24 25 26 27 29 28 23 1 ...

Page 325: ...ty joint Clip TIP Secure the constant velocity shaft in a vise and then remove the constant velocity joint using hammers EAS30330 CHECKING THE REAR CONSTANT VELOCITY SHAFT ASSEMBLIES The following procedure applies to both of the rear constant velocity shaft assemblies 1 Check Double offset joint splines Constant velocity joint splines Constant velocity shaft splines Wear damage Replace 2 Check Du...

Page 326: ... into the con stant velocity joint using a hammer 2 Install Dust boot Ball bearing 1 Circlip 2 Double offset joint 3 Clip 4 TIP Securely install the circlip into the groove in the constant velocity shaft Securely install the clip into the groove in the double offset joint 3 Apply Molybdenum disulfide grease into the double offset joint constant velocity joint and dust boots TIP Molybdenum disulfid...

Page 327: ...NG THE REAR DRIVE SHAFT 1 Check Drive shaft splines Coupling sleeve splines Wear damage Replace EAS30160 CHECKING THE FINAL DRIVE ASSEMBLY 1 Check Final drive case Final drive case cover Cracks damage Replace TIP When the final drive case and or the final drive case cover are replaced be sure to adjust the shim of the final drive pinion gear and or final driven pinion gear 2 Check Gear teeth Pitti...

Page 328: ...istance a is 67 5 68 1 mm 2 66 2 68 in as shown 2 Check Final drive assembly operation Unsmooth operation Replace the final drive assembly Insert the double offset joint into the final drive assembly and turn the gears back and forth EAS30110 SELECTING THE FINAL DRIVE PINION GEAR SHIM S 1 Select Final drive pinion gear shim s 1 a To find the final drive pinion gear shim thick ness A use the follow...

Page 329: ...hus the shim thickness is 0 60 mm 0 024 in Shims are supplied in the following thickness es EAS30120 SELECTING THE FINAL DRIVEN PINION GEAR SHIM FINAL DRIVE CASE SIDE AND THRUST WASHER 1 Select Final driven pinion gear shim final drive case side 1 Thrust washer 2 a To find the final driven pinion gear shim final drive case side and thrust washer thickness B use the following formula e a numeral us...

Page 330: ...0 12 50 88 If 05 is stamped on the outside of the final driven pinion gear g 24 0 0 05 23 95 h 49 8 Therefore shim and thrust washer thickness B is 5 16 B 49 8 71 57 50 88 23 95 5 16 Round off the hundredth digit and select the appropriate shim s In the example above the calculated number is 5 16 The chart instructs you to round off 6 to 5 at the hundredth place Thus the shim and thrust washer thi...

Page 331: ...e the thrust clearance Calculate the width of the flattened Plastigauge 1 e If out of specification remove the originally fit ted shim s and then select the correct shim s 2 Select Final driven pinion gear shim final drive case cover side a Select suitable final driven pinion gear shims final drive case cover side using the follow ing chart TIP Measure the thickness of the originally fitted shim s...

Page 332: ...originally fitted shim s and then calculate the required new shim thickness to bring the wheel gear thrust clearance within the specified limits b Repeat the measurement steps until the wheel gear thrust clearance is within the specified limits EAS30170 MEASURING THE FINAL GEAR BACKLASH 1 Secure the final drive case in a vise or anoth er supporting device 2 Remove Drain plug Gasket 3 Install Ring ...

Page 333: ...thickness by 0 2 mm 0 008 in for every 0 2 mm 0 008 in that the final driven pinion gear shim final drive case side 2 and thrust washer 3 are in creased c If reduced by more than 0 2 mm 0 008 in Increase the final driven pinion gear shim fi nal drive case cover side 4 thickness by 0 2 mm 0 008 in for every 0 2 mm 0 008 in that the final driven pinion gear shim final drive case side 2 and thrust wa...

Page 334: ...REAR CONSTANT VELOCITY SHAFT ASSEMBLIES FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT 8 31 ...

Page 335: ...5 TROUBLESHOOTING 9 17 SIGNALING SYSTEM 9 19 CIRCUIT DIAGRAM 9 19 TROUBLESHOOTING 9 21 COOLING SYSTEM 9 27 CIRCUIT DIAGRAM 9 27 TROUBLESHOOTING 9 29 FUEL INJECTION SYSTEM 9 31 CIRCUIT DIAGRAM 9 31 ECU SELF DIAGNOSTIC FUNCTION 9 33 SELF DIAGNOSTIC FUNCTION TABLE 9 33 TROUBLESHOOTING METHOD 9 35 DIAGNOSTIC MODE 9 36 TROUBLESHOOTING DETAILS 9 41 FUEL PUMP SYSTEM 9 55 CIRCUIT DIAGRAM 9 55 TROUBLESHOOT...

Page 336: ...K PLUG CAP 9 90 CHECKING THE IGNITION COIL 9 90 CHECKING THE IGNITION SPARK GAP 9 91 CHECKING THE CRANKSHAFT POSITION SENSOR 9 91 CHECKING THE LEAN ANGLE SENSOR 9 92 CHECKING THE STARTER MOTOR OPERATION 9 92 CHECKING THE STATOR COIL 9 92 CHECKING THE RECTIFIER REGULATOR 9 93 CHECKING THE FUEL SENDER 9 93 CHECKING THE SPEED SENSOR 9 94 CHECKING THE RADIATOR FAN MOTOR 9 94 CHECKING THE RADIATOR FAN ...

Page 337: ...techsparkstudio com ...

Page 338: ... B W G R G O W L B L B W G R G W L L O R B O R B R B R W R G Br W Br W R L B L L Y W B L B L B L B L G Y G Y Y P Y P Br L W L B L L L W P L W G Br L R G P L W G Br L Br L Y R Y Y W Y W Y W B L L B Y G Sb L R R L Lg Y R Y B G R W B B R Gy G W R Y L Br B G Y Y L G R B W O W G W W R R W R Br L Br L Br L Br Y Br R R B Br Y B Gy Br B B Y R Y R Y L Y Br Y L Y W W W B R Br L Br B R W Br R B Y R R W R B L...

Page 339: ...2 1 Crankshaft position sensor 4 Main switch 5 Frame ground 6 Main fuse 8 Battery 20 ECU engine control unit 21 Ignition coil 22 Spark plug 29 Lean angle sensor 54 Engine stop switch 59 Ignition fuse techsparkstudio com ...

Page 340: ...ttery terminals Recharge or replace the battery 3 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 7 Re gap clean or replace the spark plug 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 9 91 Ignition system is OK 5 Check the spark plug cap Refer to CHECKING THE SPARK PLUG CAP on page 9 90 Replace the spark plug cap 6 Check the ignition coil Refer t...

Page 341: ...KING THE SWITCHES on page 9 79 The engine stop switch is faulty Replace the left handlebar switch 10 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 9 92 Replace the lean angle sensor 11 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM on page 9 1 Properly connect or repair the ignition sys tem wiring Replace the ECU techsparkstudio com ...

Page 342: ... Br O L B W G R G O W L B L B W G R G W L L O R B O R B R B R W R G Br W Br W R L B L L Y W B L B L B L B L G Y G Y Y P Y P Br L W L B L L L W P L W G Br L R G P L W G Br L Br L Y R Y Y W Y W Y W B L L B Y G Sb L R R L Lg Y R Y B G R W B B R Gy G W R Y L Br B G Y Y L G R B W O W G W W R R W R Br L Br L Br L Br Y Br R R B Br Y B Gy Br B B Y R Y R Y L Y Br Y L Y W W W B R Br L Br B R W Br R B Y R R ...

Page 343: ... ground 6 Main fuse 8 Battery 10 Starter relay 11 Starter motor 16 Diode 1 20 ECU engine control unit 30 Gear position switch 54 Engine stop switch 55 Start switch 59 Ignition fuse 60 Signaling system fuse 62 Rear brake light switch techsparkstudio com ...

Page 344: ...y operate if at least one of the following conditions is met The transmission is in neutral the neutral switch circuit of the gear position switch is closed The transmission is in park the park switch circuit of the gear position switch is closed The rear brake lever is pulled to the handlebar or the brake pedal is pushed down the rear brake light switch circuit is closed 14 1 2 3 4 5 6 7 8 9 10 1...

Page 345: ...4 Ignition fuse 5 Engine stop switch 6 Start switch 7 Signaling system fuse 8 Rear brake light switch 9 ECU engine control unit 10 Park switch gear position switch 11 Neutral switch gear position switch 12 Diode 1 13 Starter relay 14 Starter motor techsparkstudio com ...

Page 346: ... to CHECKING THE START ER MOTOR OPERATION on page 9 92 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 42 Repair or replace the starter motor 5 Check the starter relay Refer to CHECKING THE RE LAYS on page 9 87 Replace the starter relay 6 Check the main switch Refer to CHECKING TH...

Page 347: ... Replace the rear brake light switch 10 Check the gear position switch Refer to CHECKING THE SWITCHES on page 9 79 Replace the gear position switch 11 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM on page 9 5 Properly connect or repair the starting sys tem wiring Replace the diode 1 or ECU techsparkstudio com ...

Page 348: ...Gy B Gy B L B B R Br L Br Br Br L R W GRAY W W R BLACK B Br B R W L Y R Y BLACK R R R R B W R R W R Br L Br L Br L Br Y R Y R Y L Y Br W W B R Br L Br B R W Br R B Y R R W R B L Br B B L Gy R R B R R R B B B B B B B B B R R B Gy R W R B Br Y R A 1 2 3 4 5 6 7 8 9 10 11 59 60 61 67 68 69 ...

Page 349: ...CHARGING SYSTEM 9 12 2 AC magneto 3 Rectifier regulator 5 Frame ground 6 Main fuse 8 Battery techsparkstudio com ...

Page 350: ...CHECKING AND CHARGING THE BATTERY on page 9 84 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 9 92 The stator coil is faulty Replace the crank shaft position sensor stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 9 93 Replace the rectifier regulator 5 Check the entire c...

Page 351: ...CHARGING SYSTEM 9 14 techsparkstudio com ...

Page 352: ...L Br B R W L Y R Y BLACK R R R R B R B B Br B Br W R R W R Br L Br L Br L Br Y Br R R B Br R Y R Y L Y Br Y L Y W W W B R Br L Br B R W Br R B Y R R W R B L L B Br W R G B R B W R G B R B B B B B Br Y Br Y R Y Br B R B L Y R L L R Y W Y Y L R Y Br Br L P P B G W B Br R Br R B L Y Lg B Y Y Y G Y G Y B G L B L Gy R R B R R R B B B B B B B B B R R B Gy R W R B Br Y R Br Gy Br R Y B BL B B Br R Y BLAC...

Page 353: ...LIGHTING SYSTEM 9 16 4 Main switch 5 Frame ground 6 Main fuse 8 Battery 53 Light switch 57 Headlight 58 Headlight relay 61 Headlight fuse 65 Tail brake light techsparkstudio com ...

Page 354: ...ES on page 9 83 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 9 84 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 9 79 Replace the main switch 5 Check the light switch Refer to CHECKING THE SWITCHES on page 9 79 The light switch is faulty Replace the left handlebar switch 6 Check...

Page 355: ...LIGHTING SYSTEM 9 18 techsparkstudio com ...

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

Page 357: ...ltifunction meter 34 Coolant temperature warning light 35 Park indicator light 36 Reverse indicator light 37 Neutral indicator light 38 High range indicator light 39 Low range indicator light 41 Fuel sender 48 Differential motor 56 Override switch 59 Ignition fuse 60 Signaling system fuse 62 Rear brake light switch 63 Front brake light switch 64 Diode 3 65 Tail brake light techsparkstudio com ...

Page 358: ...on page 9 83 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 9 84 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 9 79 Replace the main switch 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 9 19 Properly connect or repair the signaling system wiring Chec...

Page 359: ...ck the diode 3 Refer to CHECKING THE DIODE on page 9 89 Replace the diode 3 5 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 9 19 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the gear position switch Refer to CHECKING THE SWITCHES on page 9 79 Replace the gear position switch 2 Check the entire signaling system wiring Refer to CIRCUIT...

Page 360: ...n page 9 19 Properly connect or repair the signaling system wiring Replace the meter assembly or ECU 1 Check the four wheel drive motor switch differential motor Refer to CHECKING THE SWITCHES on page 9 79 Replace the differential motor 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 9 19 Properly connect or repair the signaling system wiring Replace the meter assembly ...

Page 361: ...ANT TEMPERATURE SENSOR on page 9 95 Replace the coolant temperature sensor 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 9 19 Properly connect or repair the signaling system wiring Replace the meter assembly or ECU 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 9 93 Replace the fuel pump assembly 2 Check the entire signaling system wiring Refer to C...

Page 362: ...SIGNALING SYSTEM 9 25 NG OK 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 9 19 Properly connect or repair the signaling system wiring Replace the meter assembly or ECU ...

Page 363: ...SIGNALING SYSTEM 9 26 techsparkstudio com ...

Page 364: ... B W G R G O W L B L B W G R G W L L O R B O R B R B R W R G Br W Br W R L B L L Y W B L B L B L B L G Y G Y Y P Y P Br L W L B L L L W P L W G Br L R G P L W G Br L Br L Y R Y Y W Y W Y W B L L B Y G Sb L R R L Lg Y R Y B G R W B B R Gy G W R Y L Br B G Y Y L G R B W O W G W W R R W R Br L Br L Br L Br Y Br R R B Br Y B Gy Br B B Y R Y R Y L Y Br Y L Y W W W B R Br L Br B R W Br R B Y R R W R B L...

Page 365: ...me ground 6 Main fuse 8 Battery 20 ECU engine control unit 25 Coolant temperature sensor 59 Ignition fuse 66 Radiator fan motor 67 Radiator fan motor circuit breaker 68 Radiator fan motor relay 69 Radiator fan motor fuse techsparkstudio com ...

Page 366: ...ace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 9 79 Replace the main switch 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 9 94 The radiator fan motor is faulty and must be replaced 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 9 87 Replace the radiator fan motor relay 6 Check the radiator fan motor circ...

Page 367: ...COOLING SYSTEM 9 30 NG OK 8 Check the entire cooling system wiring Refer to CIRCUIT DIAGRAM on page 9 27 Properly connect or repair the cooling sys tem wiring Replace the ECU techsparkstudio com ...

Page 368: ... Br O L B W G R G O W L B L B W G R G W L L O R B O R B R B R W R G Br W Br W R L B L L Y W B L B L B L B L G Y G Y Y P Y P Br L W L B L L L W P L W G Br L R G P L W G Br L Br L Y R Y Y W Y W Y W B L L B Y G Sb L R R L Lg Y R Y B G R W B B R Gy G W R Y L Br B G Y Y L G R B W O W G W W R R W R Br L Br L Br L Br Y Br R R B Br Y B Gy Br B B Y R Y R Y L Y Br Y L Y W W W B R Br L Br B R W Br R B Y R R ...

Page 369: ... control unit 21 Ignition coil 22 Spark plug 23 Fuel injector 24 Intake air temperature sensor 25 Coolant temperature sensor 26 Speed sensor 27 TPS throttle position sensor 28 Intake air pressure sensor 29 Lean angle sensor 30 Gear position switch 32 Multifunction meter 33 Engine trouble warning light 42 Fuel pump 43 Diode 2 54 Engine stop switch 59 Ignition fuse 68 Radiator fan motor relay techsp...

Page 370: ...is deleted Engine trouble warning light indication and FI system operation The warning light flashes when any one of the conditions listed below is present and the start switch is pushed EAS27380 SELF DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven the ECU illumi nates the engine trouble warning light and provides the engine with alte...

Page 371: ...ort 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 prima ry wire of the ignition coil Unable Unable 37 ISC valve stuck fully open Engine speed is high when the en gine is idling Able Able 39 Fuel injector open circuit Fuel inje...

Page 372: ...U memory When this malfunction is detected in the ECU the fault code number might not appear on the meter Unable Unable Fault code No Item Symptom Able un able to start Able un able to drive Fault code No Item Symptom Able un able to start Able un able to drive Er 1 ECU internal malfunc tion output signal error No signals are received from the ECU Unable Unable Er 2 ECU internal malfunc tion outpu...

Page 373: ...the engine stop switch to OFF 2 Disconnect the wire harness coupler from the fuel pump 3 Simultaneously press and hold the SELECT and RESET buttons turn the main switch to ON and continue to press the buttons for 8 seconds or more TIP All elements on the meter disappear dIAG appears on the multifunction meter 4 Simultaneously press the SELECT and RESET buttons for 2 seconds or more to execute the ...

Page 374: ...ective crankshaft position sensor Malfunction in crankshaft position sensor rotor Malfunction in ECU Improperly installed sensor 13 Intake air pressure sensor open or short circuit detect ed Open or short circuit in wire harness Defective intake air pressure sensor Malfunction in ECU d03 14 Intake air pressure sensor hose line malfunction clogged or detached hose Intake air pressure sensor hose is...

Page 375: ...Malfunction in ECU Fuel injection system fuse is blown d54 39 Fuel injector open or short circuit detected Open or short circuit in wire harness Defective fuel injector Improperly installed fuel injector d36 41 Lean angle sensor open or short circuit detected Open or short circuit in wire harness Defective lean angle sensor Malfunction in ECU d08 42 No normal signals are re ceived from the speed s...

Page 376: ...n operate the throttle while pushing the start switch If the display value changes the perfor mance is OK d05 Intake air temperature Displays the intake air tem perature Compare the actually mea sured intake air tempera ture with the meter display value d06 Coolant temperature Displays the coolant temper ature Compare the actually mea sured coolant temperature with the meter display val ue d07 Veh...

Page 377: ...eats the same process d62 Malfunction history code erasure No history 0 History exists Up to 16 fault codes To erase the history set the engine stop switch to OFF and then to RUN d70 Control number 00 255 Diag nostic code No Item Meter display Checking method Diag nostic code No Item Actuation Checking method d30 Ignition coil Actuates the ignition coil five times in one second inter vals The engi...

Page 378: ...ection system relay five times in one second intervals The engine trouble warning light also flashes five times The engine trouble warning light is OFF when the relay is ON and the engine trouble warning light is ON when the relay is OFF Check the operating sound of the fuel injection system relay five times d51 Radiator fan motor relay Actuates the radiator fan mo tor relay and illuminates the en...

Page 379: ...coupler Main wire harness ECU 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 se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between the crankshaft position sensor coupler and ECU cou pler gray gray black blue black blue 4 ...

Page 380: ...r 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 se curely Setting the main switch to ON 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between intake air pressure sensor coupler and ECU cou pler black blue black blue pink pink blue blue 3 Defective intake a...

Page 381: ...and oper ating it at idle 2 Intake air pressure sensor malfunction at intermediate electrical potential Check and repair the connec tion Replace it if there is a malfunc tion 3 Connections Intake air pressure sensor coupler Main wire harness ECU 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...

Page 382: ...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 se curely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between throttle position sen sor coupler and ECU coupler black blue black blue yellow yellow blue blue 4 Throttle position sens...

Page 383: ...ure sensor open or short circuit detect ed Diagnostic code No d06 Coolant temperature sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of coolant tempera ture sensor Check the installed area for looseness or pinching Setting the main switch to ON 2 Connections Coolant temperature sensor coupler Main wire harness ECU coupler Check t...

Page 384: ...e brown white brown white 4 Defective intake air temperature sen sor Execute the diagnostic mode Code No d05 Replace if defective Refer to CHECKING THE IN TAKE AIR TEMPERATURE SENSOR on page 9 96 Fault code No 30 Symptom The vehicle has overturned Diagnostic code No d08 Lean angle sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 The vehicle has overtu...

Page 385: ...dition of the connector and coupler If there is a malfunction repair it and connect the connector or coupler securely Starting the en gine and oper ating it at idle 2 Open or short circuit in wire harness 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 pler red black r...

Page 386: ... Refer to ADJUSTING THE THROTTLE LEVER FREE PLAY on page 3 6 3 ISC valve is stuck fully open due to disconnected ISC unit coupler High engine idle speed is detected with the ISC valve stuck fully open even though signals for the valve to close are continuously being transmitted by the ECU Check that the ISC unit coupler is not disconnected The ISC valve is stuck fully open if it does not operate w...

Page 387: ...njector Execute the diagnostic mode Code No d36 Replace if defective Refer to CHECKING THE IN JECTOR on page 7 6 Fault code No 41 Symptom Lean angle sensor open or short circuit detected Diagnostic code No d08 Lean angle sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Lean angle sensor coupler Main wire harness ECU coupler Check the coupl...

Page 388: ...there is a malfunction repair it and connect the coupler se curely Starting the en gine and acti vating the vehicle speed sensor by oper ating the vehi cle at 20 to 30 km h 2 Open or short circuit in speed sensor 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 has...

Page 389: ...on 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 handle bar switch coupler red black red black 3 Malfunction or open circuit in fuel in jection system relay Execute the diagnostic mode Code No d09 Replace if defective If there...

Page 390: ...TERY on page 9 84 3 Malfunction in rectifier regulator Replace if defective Refer to CHARGING SYS TEM on page 9 11 4 Open or short circuit in the wire har ness Repair or replace if there is an open or short circuit Between battery 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 Sy...

Page 391: ...FUEL INJECTION SYSTEM 9 54 techsparkstudio com ...

Page 392: ... L B W G R G O W L B L B W G R G W L L O R B O R B R B R W R G Br W Br W R L B L L Y W B L B L B L B L G Y G Y Y P Y P Br L W L B L L L W P L W G Br L R G P L W G Br L Br L Y R Y Y W Y W Y W B L L B Y G Sb L R R L Lg Y R Y B G R W B B R Gy G W R Y L Br B G Y Y L G R B W O W G W W R R W R Br L Br L Br L Br Y Br R R B Br Y B Gy Br B B Y R Y R Y L Y Br Y L Y W W W B R Br L Br B R W Br R B Y R R W R B...

Page 393: ...6 4 Main switch 5 Frame ground 6 Main fuse 8 Battery 9 Fuel injection system fuse 17 Fuel injection system relay 20 ECU engine control unit 42 Fuel pump 43 Diode 2 54 Engine stop switch 59 Ignition fuse techsparkstudio com ...

Page 394: ...harge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 9 79 Replace the main switch 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 9 79 The engine stop switch is faulty Replace the left handlebar switch 5 Check the fuel injection system re lay Refer to CHECKING THE RE LAYS on page 9 87 Replace the fuel injection system relay 6 Check the f...

Page 395: ...FUEL PUMP SYSTEM 9 58 techsparkstudio com ...

Page 396: ...B Br O L B W G R G O W L B L B W G R G W L L O R B O R B R B R W R G Br W Br W R L B L L Y W B L B L B L B L G Y G Y Y P Y P Br L W L B L L L W P L W G Br L R G P L W G Br L Br L Y R Y Y W Y W Y W B L L B Y G Sb L R R L Lg Y R Y B G R W B B R Gy G W R Y L Br B G Y Y L G R B W O W G W W R R W R Br L Br L Br L Br Y Br R R B Br Y B Gy Br B B Y R Y R Y L Y Br Y L Y W W W B R Br L Br B R W Br R B Y R R...

Page 397: ...ery 20 ECU engine control unit 44 Four wheel drive motor relay 1 45 Four wheel drive motor relay 2 46 Four wheel drive motor relay 3 47 On command four wheel drive motor switch and differential lock switch 48 Differential motor 49 Four wheel drive motor fuse techsparkstudio com ...

Page 398: ... Check the main switch Refer to CHECKING THE SWITCHES on page 9 79 Replace the main switch 4 Check the on command four wheel drive motor switch and differential lock switch Refer to CHECKING THE SWITCHES on page 9 79 Replace the on command four wheel drive motor switch and differential lock switch 5 Check the four wheel drive motor relay 1 Refer to CHECKING THE RE LAYS on page 9 87 Replace the fou...

Page 399: ...Refer to CHECKING THE DIF FERENTIAL MOTOR on page 8 11 Replace the differential motor 9 Check the entire 2WD 4WD select ing system wiring Refer to CIRCUIT DIAGRAM on page 9 59 Properly connect or repair the 2WD 4WD selecting system wiring Replace the ECU techsparkstudio com ...

Page 400: ...Y BLACK R R R R B Gy R B B Br G B Br O L B W G R G O W L B L B W G R G W L L O R B O R B R B R W R G Br W Br W R L B L L Y W B L B L B L B L G Y G Y Y P Y P Br L W L B L L L W P L W G Br L R G P L W G Br L Br L Y R Y Y W Y W Y W B L L B Y G Sb L R R L Lg Y R Y B G R W B B R Gy G W R Y L Br B G Y Y L G R B W O W G W W R R W R Br L Br L Br L Br Y Br R R B Br Y B Gy Br B B Y R Y R Y L Y Br Y L Y W W ...

Page 401: ...ground 6 Main fuse 7 EPS fuse 8 Battery 12 EPS torque sensor 13 EPS motor 14 EPS electric power steering control unit 15 EPS self diagnosis signal connectors 20 ECU engine control unit 26 Speed sensor 40 EPS warning light 59 Ignition fuse A YFM5FGPY YFM7FGPY only techsparkstudio com ...

Page 402: ... ON If the warning light does not come on the electrical circuit may be defective TIP If the engine is stopped using the engine stop switch and the main switch is in the ON position the EPS warning light comes on to indicate that the power assistance for the steering is not functioning If the steering usage is too heavy i e excessive steering use when the vehicle is traveling at a slow speed the p...

Page 403: ... EPS self diagnosis signal connector ground it again and leave it grounded The signaling mode is activated after 5 seconds 4 Set the main switch to OFF to cancel the diagnostic mode TIP The diagnostic mode can also be canceled by riding the vehicle at speeds above 2 km h 1 2 mi h When the diagnostic mode is selected and during the initial lighting of the EPS warning light the EPS control unit does...

Page 404: ...s 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 the warning light goes off for 3 seconds and then the next code is signaled a d i g g k h i b e d c f B A 5 5 2 0 5 3 0 5 5 1 3 2 j a EPS self diagnosis signal connector b Diagnostic mode c EPS warning light d Disconnected e On f Off g Grounded h Normal mode...

Page 405: ...econds while the present or past malfunction mode is activated The currently selected mode remains active after the fault codes of that mode are deleted T1 Connector grounded 0 1 T1 1 6 seconds T2 Fault codes deleted Maximum 1 5 seconds required a g b e d c f 5 1 5 1 5 1 5 1 5 1 5 1 5 1 5 1 5 A a EPS self diagnosis signal connector b EPS warning light c Disconnected d Comes on e Goes off f Grounde...

Page 406: ...rness Malfunction in ECU Malfunction in EPS con trol 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 mo tor Malfunction in EPS con trol unit 52 EPS control unit Relay contacts in the EPS control unit are welded together Malfunction in EPS con trol unit 53 EPS control unit Battery voltage has dropped Faulty batter...

Page 407: ...uit 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 se curely Setting the main switch to OFF 2 Defective EPS torque sensor Replace if defective Refer to ...

Page 408: ...ire harness 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 CHECKING THE SPEED SENSOR on page 9 94 Fault code No 22 Symptom No normal signals are received from the ECU Order Item components and probable cause Check or maintenance...

Page 409: ...Refer to CHECKING THE EPS MOTOR for YFM5FGP YFM7FGP on page 9 97 Fault code No 52 Symptom Relay contacts in the EPS control unit are welded togeth er Order Item components and probable cause Check or maintenance job Reinstatement method 1 Malfunction in EPS control unit Replace the EPS control unit Setting the main switch to OFF Fault code No 53 Symptom Power supply to the EPS control unit is not ...

Page 410: ... 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 on page 9 84 Setting the main switch to OFF 2 Malfunction in rectifier regulator Replace if defectiv...

Page 411: ...EPS ELECTRIC POWER STEERING SYSTEM for YFM5FGP YFM7FGP 9 74 techsparkstudio com ...

Page 412: ...ELECTRICAL COMPONENTS 9 75 EAS27972 ELECTRICAL COMPONENTS 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 ...

Page 413: ...in fuse 8 Fuse box ignition headlights four wheel drive motor radiator fan motor signaling system auxiliary DC jack 9 Radiator fan motor circuit breaker 10 Rectifier regulator 11 Reverse switch 12 Gear position switch 13 Auxiliary DC jack 14 Main switch 15 Differential motor 16 EPS torque sensor YFM5FGP YFM7FGP only 17 EPS motor YFM5FGP YFM7FGP only 18 Radiator fan motor techsparkstudio com ...

Page 414: ...ELECTRICAL COMPONENTS 9 77 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 ...

Page 415: ... brake light switch 7 Intake air temperature sensor 8 Intake air pressure sensor 9 TPS throttle position sensor 10 ISC idle speed control unit 11 Fuel pump 12 Speed sensor 13 Crankshaft position sensor 14 Coolant temperature sensor 15 Ignition coil 16 Battery 17 ECU engine control unit 18 EPS electric power steering control unit YFM5FGP YFM7FGP only techsparkstudio com ...

Page 416: ...KING THE SWITCHES R Br L Br R B R B Br Br GRAY L Y R B Lg Lg B B L Y R Y Y L PUSH OFF R Y L Y B B Br Br G R G R Gy Gy 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 1 2 3 4 5 6 7 8 9 10 11 ON OFF R Br L Br ...

Page 417: ...h 4 Start switch 5 Override switch 6 On command four wheel drive motor switch and differential gear lock switch 7 Four wheel drive motor switch differential motor 8 Gear position switch 9 Reverse switch 10 Rear brake light switch 11 Front brake light switch techsparkstudio com ...

Page 418: ...ocket tester to 0 and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch t...

Page 419: ...WARNING EWA28P1001 Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down NOTICE ECA28P1001 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of a headlight bulb to keep it free from oil otherwise the transparenc...

Page 420: ...F when checking or replacing a fuse 1 Remove Battery cover Refer to GENERAL CHASSIS on page 4 1 2 Check Fuse a Connect the pocket tester to the fuse and check the continuity TIP Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set the switch es to on to ver...

Page 421: ... lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion NOTICE ECA28P1002 This is a VRLA Valve Regulated Lead Acid battery Never remove the sealing caps be cause the balance between cells will not be maintained and battery performance will deteriorate Charging time charging amperage and charging voltage for a VRLA Valve Regu lated Lead Acid battery are different f...

Page 422: ... charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the ba...

Page 423: ... the battery unused for more than 30 minutes Charging method using a constant volt age charger a Measure the open circuit voltage prior to charging TIP Voltage should be measured 30 minutes after the engine is stopped b Connect a charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery TIP If the curren...

Page 424: ...ect re place the relay 1 Disconnect the relay from the wire harness 2 Connect the pocket tester Ω 1 and battery 12 V to the relay terminal as shown Check the relay operation Out of specification Replace Starter relay Headlight relay First step Recommended lubricant Dielectric grease Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 2 1 Positive battery terminal 2 Negative battery termina...

Page 425: ...inuity between 3 and 5 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 L Y Y B 1 G 2 3 5 4 R W 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive tester probe 2 Negative tester probe 3 Negative tester probe Resul...

Page 426: ...probe 2 Negative tester probe 3 Negative tester probe Result Continuity between 1 and 2 No continuity between 1 and 3 1 2 3 5 4 B Y Br R Br R L R B Br B Br R Br R L G B 1 3 2 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe Result No continuity between 3 and 4 Continuity between 3 and 5 1 Positive battery terminal 2 Neg...

Page 427: ...0 CHECKING THE IGNITION COIL 1 Check Primary coil resistance Out of specification Replace a Disconnect the ignition coil connectors from the ignition coil terminals b Connect the pocket tester Ω 1 to the igni tion coil as shown c Measure the primary coil resistance 2 Check Secondary coil resistance Out of specification Replace No continuity Positive tester probe yel low white 1 Negative tester pro...

Page 428: ... the start switch and gradually increase the spark gap un til a misfire occurs EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace the crank shaft position sensor stator assembly a Connect the pocket tester Ω 100 to the crankshaft position sensor coupler as ...

Page 429: ...arter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter motor operation EAS28150 CHECKING THE STATOR COIL 1 Disconnect AC magneto coupler from th...

Page 430: ...esistance Out of specification Replace the fuel pump assembly a Connect the pocket tester Ω 10 to the fuel sender terminal as shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe white 1 Negative tester probe white 2 Positive tester probe white 1 Negative tester probe white 3 Positive tester probe white 2 Negative tester probe white 3 Charging voltage above 14 V at...

Page 431: ...ll rotation of the rear wheel the voltage reading should cycle from 0 6 V to 4 8 V to 0 6 V to 4 8 V EAS28250 CHECKING THE RADIATOR FAN MOTOR 1 Check Radiator fan motor Faulty rough movement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect the battery DC 12 V as shown c Measure the radiator fan motor movement Output voltage reading cycle 0 6 V 4 8 V 0 6 V 4 8 V 0...

Page 432: ...h special care Never subject the coolant temperature sen sor to strong shocks If the coolant temper ature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 100 to the coolant temperature sensor terminals as shown b Immerse the coolant temperature sensor 1 in a container filled with coolant 2 TIP Make sure the coola...

Page 433: ...pressure sensor coupler as shown b Set the main switch to ON c Measure the intake air pressure sensor out put voltage EAS28420 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 1 Remove Intake air temperature sensor from the air filter case WARNING EWA14110 Handle the intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air tempera...

Page 434: ...wn in the following table a Connect the pocket tester Ω 1 to the EPS motor coupler terminal and EPS motor body b Check the EPS motor for continuity c Check the EPS motor for no continuity EAS30310 CHECKING THE EPS TORQUE SENSOR for YFM5FGP YFM7FGP 1 Remove EPS unit 2 Check EPS torque sensor resistance Out of specification Replace the EPS unit a Connect the pocket tester Ω 1k to the EPS torque sens...

Page 435: ...AL COMPONENTS 9 98 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 techsparkstudio com ...

Page 436: ...ELECTRICAL COMPONENTS 9 99 ...

Page 437: ...ND HIGH SPEED PERFORMANCE 10 2 FAULTY DRIVE TRAIN 10 2 FAULTY GEAR SHIFTING 10 2 SHIFT LEVER DOES NOT MOVE 10 2 JUMPS OUT OF GEAR 10 2 FAULTY CLUTCH 10 3 OVERHEATING 10 3 OVERCOOLING 10 3 POOR BRAKING PERFORMANCE 10 4 FAULTY SHOCK ABSORBER ASSEMBLY 10 4 UNSTABLE HANDLING 10 4 FAULTY LIGHTING OR SIGNALING SYSTEM 10 4 techsparkstudio com ...

Page 438: ...rated or contaminated fuel 2 Fuel pump Faulty fuel pump Faulty fuel injection system relay Clogged or damaged fuel hose 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug...

Page 439: ...reason to believe these compo nents are damaged remove the components and check them EAS28530 FAULTY GEAR SHIFTING Shifting is difficult Refer to FAULTY CLUTCH on page 10 3 EAS3B41028 SHIFT LEVER DOES NOT MOVE Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears I...

Page 440: ...ulley weight 3 Primary fixed sheave Worn primary fixed sheave 4 Primary sliding sheave Worn primary sliding sheave 5 Secondary fixed sheave Worn secondary fixed sheave 6 Secondary sliding sheave Worn secondary sliding sheave EAS28600 OVERHEATING Engine 1 Clogged coolant passages 2 Cylinder head and piston Heavy carbon buildup 3 Engine oil Incorrect oil level Incorrect oil viscosity Inferior oil qu...

Page 441: ...pring Leaking oil 4 Tire s Uneven tire pressures left and right Incorrect tire pressure Uneven tire wear 5 Wheel s Incorrect wheel balance Deformed wheel Damaged or loose wheel bearing Bent or loose wheel axle Excessive wheel runout 6 Frame Bent frame Damaged frame EAS28710 FAULTY LIGHTING OR SIGNALING SYSTEM Headlight does not come on Wrong headlight bulb Too many electrical accessories Hard char...

Page 442: ...r wheel drive motor relay 2 46 Four wheel drive motor relay 3 47 On command four wheel drive motor switch and differential lock switch 48 Differential motor 49 Four wheel drive motor fuse 50 Auxiliary DC jack fuse 51 Auxiliary DC jack 52 Left handlebar switch 53 Light switch 54 Engine stop switch 55 Start switch 56 Override switch 57 Headlight 58 Headlight relay 59 Ignition fuse 60 Signaling syste...

Page 443: ...Y BLACK GREEN BLACK BLACK GRAY GRAY GRAY GRAY BLACK BLACK BLACK GRAY GRAY BLACK GRAY GRAY BLACK BLACK BLACK BLACK A A A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 58 57 57 59 60 61 62 63 64 65 66 67 68 69 techsparkstudio com ...

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