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Yamaha Rhino 450 YXR45FAV, Service Manual

The Yamaha Rhino 450 YXR45FAV is a rugged and versatile off-road vehicle designed for all kinds of adventures. To ensure its optimal performance and maintenance, you can conveniently download the free Service Manual from manualshive.com. This comprehensive manual provides detailed instructions and insights to keep your Yamaha Rhino running smoothly.

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10 - 4

TRBL

SHTG

FAULTY GEAR SHIFTING/

FAULTY CLUTCH PERFORMANCE

EBS00542

FAULTY GEAR SHIFTING

HARD SHIFTING

Refer to “CLUTCH SLIPPING”.

SHIFT LEVER DOES NOT MOVE
Shift drum and shift forks

• Groove jammed with impurities 
• Seized shift fork 
• Bent shift fork guide bar

Transmission

• Seized transmission gear 
• Jammed impurities 
• Incorrectly assembled transmission

Shift guide

• Broken shift guide

JUMPS OUT OF GEAR
Shift forks

• Worn shift fork

Shift drum

• Improper thrust play 
• Worn shift drum groove

Transmission

• Worn gear dog

EBS00543

FAULTY CLUTCH PERFORMANCE

ENGINE OPERATES BUT VEHICLE WILL NOT MOVE
V-belt

• Bent, damaged or worn V-belt 
• V-belt slips

Primary pulley cam and primary pulley 
slider

• Damaged or worn primary pulley cam 
• Damaged or worn primary pulley slider

Transmission

• Damaged transmission gears

CLUTCH SLIPPING
Clutch spring

• Damaged, loose or worn clutch shoe spring

Clutch shoe

• Damaged or worn clutch shoe

Primary sliding sheave

• Seized primary sliding sheave

POOR STARTING PERFORMANCE
V-belt

• V-belt slips 
• Oil or grease on the V-belt

Primary sliding sheave

• Faulty operation 
• Worn pin groove 
• Worn pin

Clutch shoe

• Bent, damaged or worn clutch shoe

Summary of Contents for Rhino 450 YXR45FAV

Page 1: ...LIT 11616 19 43 2P5 F8197 10 YXR45FAV SERVICE MANUAL ...

Page 2: ... by Yamaha Motor Corporation U S A First Edition August 2005 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A LIT 11616 19 43 ...

Page 3: ...and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE _ Designs and specifications are subject to change without notice EBS00003 IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means...

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

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

Page 6: ......

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

Page 8: ...OTTER PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 CHECKING OF CONNECTIONS 1 4 SPECIAL TOOLS 1 5 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 5 CHASSIS SPECIFICATIONS 2 13 ELECTRICAL SPECIFICATIONS 2 15 TIGHTENING TORQUES 2 18 ENGINE TIGHTENING TORQUES 2 18 CHASSIS TIGHTENING TORQUES 2 21 LUBRICATION POINTS AND LUBRICANT TYPES 2 24 ENGINE 2 24 HOW TO USE THE CONV...

Page 9: ...20 CHECKING THE COOLANT TEMPERATURE WARNING LIGHT 3 25 CHECKING THE V BELT 3 25 CLEANING THE SPARK ARRESTER 3 27 CHASSIS 3 28 ADJUSTING THE BRAKE PEDAL 3 28 ADJUSTING THE PARKING BRAKE 3 29 CHECKING THE BRAKE FLUID LEVEL 3 30 CHECKING THE FRONT BRAKE PADS 3 31 CHECKING THE REAR BRAKE PADS 3 31 CHECKING THE BRAKE HOSES AND BRAKE PIPES 3 31 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 32 ADJUSTING THE SELE...

Page 10: ...NG THE CYLINDER HEAD 4 11 CHECKING THE TAPPET COVERS 4 12 CHECKING THE TIMING CHAIN TENSIONER 4 12 CHECKING THE CAMSHAFT SPROCKET 4 12 CHECKING THE CYLINDER HEAD 4 13 INSTALLING THE CYLINDER HEAD 4 14 CAMSHAFT ROCKER ARMS AND VALVES 4 17 REMOVING THE CAMSHAFT AND ROCKER ARMS 4 19 REMOVING THE VALVES AND VALVE SPRINGS 4 19 CHECKING THE CAMSHAFT 4 20 CHECKING THE ROCKER ARMS AND CAMSHAFT 4 20 CHECKI...

Page 11: ...RY AND SECONDARY SHEAVES 4 49 CLUTCH 4 50 REMOVING THE CLUTCH 4 52 CHECKING THE CLUTCH 4 52 INSTALLING THE CLUTCH 4 53 CRANKCASE 4 55 STARTER MOTOR TIMING CHAIN AND OIL FILTER 4 55 CRANKCASE 4 58 CRANKCASE BEARINGS 4 59 REMOVING THE OIL PUMP DRIVE GEAR 4 60 SEPARATING THE CRANKCASE 4 60 CHECKING THE TIMING CHAIN AND GUIDE 4 61 CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE 4 61 CHECKING THE RELIE...

Page 12: ... DRIVEN GEAR SHIMS 4 81 INSTALLING THE MIDDLE DRIVE SHAFT 4 84 INSTALLING THE MIDDLE DRIVE PINION GEAR SHAFT 4 87 MEASURING THE MIDDLE GEAR BACKLASH 4 87 CHAPTER 5 COOLING SYSTEM RADIATOR AND COOLANT RESERVOIR 5 1 CHECKING THE RADIATOR 5 3 WATER PUMP 5 4 DISASSEMBLING THE WATER PUMP 5 6 CHECKING THE WATER PUMP 5 6 ASSEMBLING THE WATER PUMP 5 7 OIL COOLER 5 9 CHECKING THE OIL COOLER 5 11 CHAPTER 6 ...

Page 13: ... CONSTANT VELOCITY JOINTS FINAL DRIVE GEAR AND REAR DRIVE SHAFT 7 18 ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS 7 24 DISASSEMBLING THE FINAL DRIVE GEAR 7 24 REMOVING THE FINAL DRIVE ROLLER BEARINGS 7 25 INSTALLING THE FINAL DRIVE ROLLER BEARINGS 7 26 POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR 7 26 CHECKING THE REAR DRIVE SHAFT 7 31 CHECKING THE FINAL DRIVE GEAR ASSEMBLY 7 31 MEASURING...

Page 14: ...THE BRAKE MASTER CYLINDER 8 26 INSTALLING THE BRAKE MASTER CYLINDER 8 27 FRONT BRAKE CALIPERS 8 29 REAR BRAKE CALIPER 8 31 REMOVING THE REAR BRAKE CALIPER 8 35 DISASSEMBLING THE FRONT BRAKE CALIPERS 8 35 DISASSEMBLING THE REAR BRAKE CALIPER 8 35 CHECKING THE FRONT AND REAR BRAKE CALIPERS 8 36 ASSEMBLING THE FRONT BRAKE CALIPERS 8 37 ASSEMBLING THE REAR BRAKE CALIPER 8 38 INSTALLING THE FRONT BRAKE...

Page 15: ...EAR SHOCK ABSORBERS 8 67 CHAPTER 9 ELECTRICAL ELECTRICAL COMPONENTS 9 1 CHECKING THE SWITCHES 9 3 CHECKING THE SWITCHES 9 3 CHECKING A SWITCH SHOWN IN THE MANUAL 9 3 CHECKING THE SWITCH CONTINUITY 9 5 CHECKING THE BULBS AND BULB SOCKETS 9 7 TYPES OF BULBS 9 7 CHECKING THE CONDITION OF THE BULBS 9 7 CHECKING THE CONDITION OF THE BULB SOCKETS 9 9 IGNITION SYSTEM 9 10 CIRCUIT DIAGRAM 9 10 TROUBLESHOO...

Page 16: ...9 52 TROUBLESHOOTING 9 53 CARBURETOR HEATING SYSTEM 9 57 CIRCUIT DIAGRAM 9 57 TROUBLESHOOTING 9 58 CHAPTER 10 TROUBLESHOOTING STARTING FAILURE HARD STARTING 10 1 FUEL SYSTEM 10 1 ELECTRICAL SYSTEM 10 1 COMPRESSION SYSTEM 10 2 POOR IDLE SPEED PERFORMANCE 10 2 POOR IDLE SPEED PERFORMANCE 10 2 POOR MEDIUM AND HIGH SPEED PERFORMANCE 10 2 POOR MEDIUM AND HIGH SPEED PERFORMANCE 10 2 FAULTY DRIVE TRAIN 1...

Page 17: ...OOR STARTING PERFORMANCE 10 4 POOR SPEED PERFORMANCE 10 5 OVERHEATING 10 5 OVERHEATING 10 5 FAULTY BRAKE 10 5 POOR BRAKING EFFECT 10 5 SHOCK ABSORBER MALFUNCTION 10 5 MALFUNCTION 10 5 UNSTABLE HANDLING 10 6 UNSTABLE HANDLING 10 6 LIGHTING SYSTEM 10 6 HEADLIGHT DOES NOT COME ON 10 6 BULB BURNT OUT 10 6 ...

Page 18: ...FICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts 1 VEHICLE IDENTIFICATION ...

Page 19: ...bly clean all parts and place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EB101010 REPLACEMENT PARTS 1 Use only genuine Yamaha parts for all replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance...

Page 20: ... visi ble When installing oil seals apply a light coating of lithium soap based grease to the seal lips Oil bearings liberally when install ing if appropriate 1 Oil seal CAUTION Do not use compressed air to spin the bearings dry This will damage the bearing surfaces 1 Bearing EB101050 CIRCLIPS 1 Check all circlips carefully before reassem bly Always replace piston pin clips after one use Replace d...

Page 21: ...terminals several times 3 Check connector leads Looseness Bend up the pin 1 and con nect the terminals 4 Connect connector terminals NOTE The two terminals click together 5 Check continuity using a pocket tester NOTE If there is no continuity clean the terminals When checking the wire harness be sure to perform steps 1 to 3 As a quick remedy use a contact revitalizer available at most part stores ...

Page 22: ... and CDN P N 90890 Tool No Tool name Function Illustration Bolt 90890 01083 YU 01083 1 Weight 90890 01084 YU 01083 3 Slide hammer bolt M6 weight These tools are used to remove the rocker arm shafts 90890 01135 YU 01135 B Crankcase separating tool This tool is used to separate the crank case 90890 01225 YM 01225 A Valve guide remover 7 0 mm This tool is needed to remove and install the valve guides...

Page 23: ...oat chamber 90890 01325 YU 24460 01 Radiator cap tester This tool is used to check the cooling sys tem 90890 01348 YM 01348 Locknut wrench This tool is needed when removing or installing the secondary sheave spring 90890 01352 YU 33984 Radiator cap tester adapter This tool is used to check the cooling sys tem 90890 01404 YM 01404 Flywheel puller This tool is needed to remove the rotor 90890 01426 ...

Page 24: ...older This tool is needed to hold the primary sheave when removing or installing the sheave bolts Compression gauge 90890 03081 Engine compression tester YU 33223 Extension 90890 04082 Compression gauge Adapter compression gauge These tools are needed to measure engine compression 90890 03112 YU 03112 C Pocket tester This instrument is needed for checking the electrical system 90890 03141 YU 03141...

Page 25: ...he crank shaft 90890 04062 YM 04062 Universal joint holder This tool is needed when removing or installing the universal joint yoke nut 90890 04086 YM 91042 Universal clutch holder This tool is needed to hold the clutch car rier when removing or installing the car rier nut 90890 04088 Buffer boss installer set These tools are used to install the crank shaft 90890 04128 YM 04128 Bearing retainer wr...

Page 26: ...he ignition system components 90890 06760 YU 39951 B Digital tachometer This instrument is needed for observing engine rpm 90890 85505 Yamaha bond No 1215 Three Bond No 1215 This bond is used on crankcase mating surfaces etc YM 01477 Ball joint remover installer attachment set This tool is used to remove and install the ball joints YU 90050 Crankshaft installer set These tools are used to install ...

Page 27: ...11 02 in Minimum turning radius 3 900 mm 153 5 in Basic weight With oil and full fuel tank 501 kg 1 105 lb for USA and CDN 514 kg 1 133 lb for Europe Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 421 cm3 Bore stroke 84 5 75 0 mm 3 33 2 95 in Compression ratio 10 0 1 Standard compression pressure at sea level 1 270 kPa 12 7 kg cm2 ...

Page 28: ... gear oil Periodic oil change 0 25 L 0 22 Imp qt 0 26 US qt Total amount 0 28 L 0 25 Imp qt 0 30 US qt Differential gear case oil Periodic oil change 0 32 L 0 28 Imp qt 0 34 US qt Total amount 0 33 L 0 29 Imp qt 0 35 US qt Air filter Engine Wet element Intake duct Dry element Fuel Type Unleaded gasoline only for USA Regular unleaded gasoline only for CDN and Europe Fuel tank capacity 30 L 6 60 Imp...

Page 29: ...me Caster angle 5 0 Camber angle 0 Kingpin angle 12 Kingpin offset 0 mm 0 in Trail 26 mm 1 02 in Tread STD front 1 115 mm 43 90 in rear 1 105 mm 43 50 in Toe in 15 25 mm 0 59 0 98 in Tire Type Tubeless Size front 25 8 12NHS rear 25 10 12NHS Manufacturer front MAXXIS rear MAXXIS Type front M951Y rear M952Y Tire pressure cold tire Maximum load 406 kg 895 lb for USA and CDN 393 kg 866 lb for Europe O...

Page 30: ...antity Headlight 12 V 30 W 30 W 2 Tail brake light 12 V 5 W 21 W 2 Indicator lights For USA Neutral indicator light 12 V 1 7 W 1 Reverse indicator light 12 V 1 7 W 1 Coolant temperature warning light 12 V 1 7 W 1 Parking brake indicator light 12 V 1 7 W 1 Four wheel drive indicator light 12 V 1 7 W 1 Differential gear lock indicator light 12 V 1 7 W 1 For CDN and Europe Neutral indicator light LED...

Page 31: ...nd limit 0 01 mm 0 0004 in Taper limit 0 05 mm 0 0020 in Camshaft Drive method Chain drive left Cam dimensions Intake A 40 62 40 72 mm 1 5992 1 6031 in 40 52 mm 1 5953 in B 32 18 32 28 mm 1 2669 1 2709 in 32 08 mm 1 2630 in Exhaust A 40 62 40 72 mm 1 5992 1 6031 in 40 52 mm 1 5953 in B 32 18 32 28 mm 1 2669 1 2709 in 32 08 mm 1 2630 in Camshaft runout limit 0 03 mm 0 0012 in A B ...

Page 32: ...0 0079 in Valve dimensions A head diameter IN 39 9 40 1 mm 1 5709 1 5787 in EX 33 9 34 1 mm 1 3346 1 3425 in B face width IN 2 26 mm 0 0890 in EX 2 26 mm 0 0890 in C seat width IN 1 2 1 4 mm 0 0472 0 0551 in 1 6 mm 0 0630 in EX 1 2 1 4 mm 0 0472 0 0551 in 1 6 mm 0 0630 in D margin thickness IN 1 0 1 4 mm 0 0394 0 0551 in EX 0 8 1 2 mm 0 0315 0 0472 in Stem outside diameter IN 6 975 6 990 mm 0 2746...

Page 33: ...472 0 0551 in 1 6 mm 0 0630 in Valve spring Inner spring Free length IN 39 90 mm 1 57 in 37 9 mm 1 49 in EX 39 90 mm 1 57 in 37 9 mm 1 49 in Set length valve closed IN 33 6 mm 1 32 in EX 33 6 mm 1 32 in Compressed pressure installed IN 104 9 120 6 N 10 70 12 30 kg 23 58 27 11 lb EX 104 9 120 6 N 10 70 12 30 kg 23 58 27 11 lb Tilt limit IN 2 5 1 7 mm 2 5 0 067 in EX 2 5 1 7 mm 2 5 0 067 in Directio...

Page 34: ... 2 5 1 9 mm 2 5 0 075 in EX 2 5 1 9 mm 2 5 0 075 in Direction of winding top view IN Clockwise EX Clockwise Piston Piston to cylinder clearance 0 040 0 065 mm 0 0016 0 0026 in 0 15 mm 0 0059 in Piston size D 84 445 84 460 mm 3 3246 3 3252 in Measuring point H 5 0 mm 0 20 in Piston off set 0 5 mm 0 0197 in Off set direction Intake side Piston pin bore inside diameter 20 004 20 015 mm 0 7876 0 7880 ...

Page 35: ...ring Type Taper Dimensions B T 1 0 3 6 mm 0 0394 0 1417 in End gap installed 0 40 0 60 mm 0 0157 0 0236 in 0 95 mm 0 0374 in Side clearance installed 0 02 0 06 mm 0 0008 0 0024 in 0 12 mm 0 0047 in Oil ring Dimensions B T 2 0 2 8 mm 0 0787 0 1102 in End gap installed 0 20 0 70 mm 0 0079 0 0276 in Crankshaft Crank width A 62 95 63 00 mm 2 4783 2 4803 in Runout limit C1 0 03 mm 0 0012 in C2 0 03 mm ...

Page 36: ...24 in Shifter Shifter type Shift drum and guide bar Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Carburetor I D mark 2P51 00 Main jet M J 133 8 Main air jet M A J 140 Jet needle J N 5ERB1 1 Needle jet N J P 0M 922 Pilot air jet P A J 1 80 Pilot air jet P A J 2 1 6 Pilot outlet P O 0 95 Pilot jet P J 20 Bypass 1 B P 1 0 8 Bypass 2 B P 2 0 8 Bypass 3 B P 3 0 8...

Page 37: ...re check location Cylinder head Cooling system Radiator core Width 380 mm 14 96 in Height 238 mm 9 37 in Thickness 24 mm 0 94 in Radiator cap opening pressure 110 0 140 0 kPa 1 1 1 4 kg cm2 15 64 19 91 psi Radiator capacity including all routes 2 7 L 2 38 Imp qt 2 85 US qt Coolant reservoir Capacity 0 35 L 0 31 Imp qt 0 37 US qt From low to full level 0 20 L 0 18 Imp qt 0 21 US qt Water pump Type ...

Page 38: ... Lubrication chart Cylinder head tightening sequence Oil strainer Oil pump Oil cooler Clutch Piston Piston pin Crank pin Oil filter Bypass valve Camshaft Rocker arm Valve Transmission Timing chain area Pressure feed Splashed scavenge ...

Page 39: ...ar suspension Shock absorber travel 81 mm 3 19 in Spring free length 328 mm 12 91 in Spring fitting length 273 2 mm 10 76 in Spring rate K1 44 1 N mm 4 50 kg mm 251 99 lb in K2 117 7 N mm 12 00 kg mm 671 96 lb in Stroke K1 0 60 mm 0 2 36 in K2 60 81 mm 2 36 3 19 in Optional spring No Front wheel Type Panel wheel Rim size 12 6 0 AT Rim material Steel Rim runout limit radial 2 0 mm 0 08 in lateral 2...

Page 40: ...ake fluid type DOT 4 Rear disc brake Type Single Disc outside diameter thickness 165 0 5 0 mm 6 50 0 20 in 4 5 mm 0 18 in Pad thickness inner 5 6 mm 0 22 in 1 5 mm 0 06 in Pad thickness outer 5 6 mm 0 22 in 1 5 mm 0 06 in Master cylinder inside diameter 17 46 mm 0 69 in Caliper cylinder inside diameter 32 03 mm 1 26 in Brake fluid type DOT 4 Accelerator pedal and brake pedal Accelerator pedal free...

Page 41: ...er F8T40378 MITSUBISHI Ignition coil Model manufacturer 2JN YAMAHA Minimum spark gap 6 0 mm 0 24 in Primary winding resistance 0 18 0 28 Ω at 20 C 68 F Secondary winding resistance 6 32 9 48 kΩ at 20 C 68 F Spark plug cap Type Resin type Resistance 10 kΩ Charging system Type A C magneto generator Model manufacturer F4T46473 MITSUBISHI Nominal output 14 V 23 A at 5 000 r min Charging coil resistanc...

Page 42: ...ane Model manufacturer quantity GF 12 NIKKO 1 Max amperage 1 0 A Performance 101 108 db 2 m 6 6 ft Coil resistance 3 96 4 10 Ω at 20 C 68 F Headlight relay Model manufacturer G8HN 1C4T DJ Y52 OMRON Coil resistance 94 5 115 5 Ω at 20 C 68 F Four wheel drive indicator light relay for USA Model manufacturer ACA22115 1 MATSUSHITA Coil resistance 72 88 Ω at 20 C 68 F Amperage 20 A Differential gear loc...

Page 43: ...switch 2 Model manufacturer 5FU NIPPON THERMOSTAT Thermo switch 3 Model manufacturer 5GM NIPPON THERMOSTAT Circuit breaker Type Fuse Amperage for individual circuit Main fuse 30 A 1 Lighting system fuse 15 A 1 Ignition fuse 10 A 1 Auxiliary DC jack fuse 10 A 1 Four wheel drive fuse 3 A 1 Signaling system fuse 10 A 1 Carburetor heater fuse 10 A 1 Backup fuse odometer and clock 10 A 1 Spare fuse 30 ...

Page 44: ...usting locknut M7 2 20 2 0 14 Air bleed bolt coolant outlet joint M6 1 9 0 9 6 5 Coolant inlet joint Bolt M6 2 10 1 0 7 2 LT Coolant outlet joint Bolt M6 2 10 1 0 7 2 Water pump outlet pipe Bolt M6 1 10 1 0 7 2 Water pump assembly Bolt M6 2 10 1 0 7 2 Coolant drain bolt water pump Bolt M6 1 10 1 0 7 2 Radiator Bolt M6 4 7 0 7 5 1 Radiator inlet pipe radiator outlet pipe holder Bolt M6 4 7 0 7 5 1 ...

Page 45: ...kcase right Bolt M6 14 10 1 0 7 2 Starter clutch Bolt M8 6 30 3 0 22 LT Clutch carrier assembly Nut M22 1 140 14 0 100 Stake Middle drive pinion gear shaft bearing retainer Torx screw M8 4 25 2 5 18 LT Middle drive pinion gear Nut M22 1 145 14 5 105 Stake Middle drive pinion gear shaft bearing housing Bolt M8 6 32 3 2 23 Middle driven pinion gear bearing retainer Nut M65 1 110 11 0 80 LT Left hand...

Page 46: ...11 1 1 8 0 Muffler and exhaust pipe Bolt M8 2 20 2 0 14 Muffler bracket and muffler Bolt M8 1 20 2 0 14 Muffler bracket and frame Bolt M8 2 30 3 0 22 Muffler damper and muffler Bolt M6 1 10 1 0 7 2 Muffler damper and frame Nut M6 1 10 1 0 7 2 Exhaust pipe Nut M8 2 14 1 4 10 Tailpipe Bolt M6 3 10 1 0 7 2 Air duct assembly 1 Bolt M6 2 7 0 7 5 1 Engine cooling fan air duct assembly Bolt M6 1 7 0 7 5 ...

Page 47: ...otor and differential gear case cover M8 13 1 3 9 4 Differential gear case cover and differential gear case M8 25 2 5 18 Final drive gear case and frame M10 70 7 0 50 Final drive gear oil filler plug M20 23 2 3 17 Final drive gear oil drain plug M10 20 2 0 14 Ring gear bearing housing and final gear case M8 23 2 3 17 M10 40 4 0 29 Ring gear stopper nut M8 16 1 6 11 Bearing retainer and final drive...

Page 48: ...ub M8 30 3 0 22 LT Front brake caliper bleed screw M6 6 0 6 4 3 Rear wheel and rear wheel hub M10 55 5 5 40 Rear wheel hub and constant velocity joint M24 350 35 0 255 Stake Rear brake hose joint and frame M6 7 0 7 5 1 Brake pipe and brake master cylinder M10 19 1 9 13 Brake pipe and rear brake hose M10 19 1 9 13 Pedal assembly and frame M8 16 1 6 11 Brake master cylinder and pedal assembly M8 16 ...

Page 49: ...23 M12 59 5 9 43 Upper instrument panel and frame M6 7 0 7 5 1 Side frame enclosure and frame M10 64 6 4 46 Support frame enclosure and frame M10 64 6 4 46 Left support frame enclosure and right support frame enclosure M10 64 6 4 46 Support frame enclosure and side frame enclo sure M10 64 6 4 46 Top frame enclosure and side frame enclosure M10 64 6 4 46 Seat support and frame M8 16 1 6 11 Select l...

Page 50: ...haft E Rocker arm M Oil pump assembly E Oil filter cartridge oil seal LS Starter idle gear shaft E Starter wheel gear E Clutch housing assembly E Clutch carrier assembly E One way clutch bearing M Drive axle high wheel gear and low wheel gear M Middle drive gear and clutch dog shift fork groove M Driven sprocket and chain E Damper cam M Gear coupling E Shift drum E Shift fork guide bar E Shift dru...

Page 51: ...nless otherwise specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERIAL Torque Metric unit Multiplier Imperial unit m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 0...

Page 52: ...2 26 SPEC COOLANT FLOW DIAGRAMS COOLANT FLOW DIAGRAMS 1 Radiator 2 Thermo switch 3 3 Radiator outlet hose 4 Radiator inlet hose 5 Radiator outlet pipe 6 Radiator inlet pipe A A A A 1 2 3 4 5 6 ...

Page 53: ...2 27 SPEC COOLANT FLOW DIAGRAMS 1 Coolant outlet hose 2 Water pump outlet hose 3 Water pump outlet pipe 4 Radiator outlet pipe 5 Water pump inlet hose 6 Radiator inlet pipe A A A A 1 2 3 4 4 5 6 ...

Page 54: ...2 28 SPEC COOLANT FLOW DIAGRAMS 1 Coolant outlet hose 2 Radiator inlet pipe 3 Radiator inlet hose A A 1 1 2 2 3 ...

Page 55: ...2 29 SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 Camshaft 2 Crankshaft 3 Drive axle 4 Middle drive pinion gear shaft ...

Page 56: ...2 30 SPEC OIL FLOW DIAGRAMS 1 Oil filter cartridge 2 Oil pipe adapter 3 Oil delivery pipe A A A A 1 1 2 3 ...

Page 57: ...2 31 SPEC OIL FLOW DIAGRAMS 1 Oil delivery pipe 2 Oil pump 3 Oil strainer A A A A 1 2 3 ...

Page 58: ...FLOW DIAGRAMS 1 Oil cooler 2 Oil cooler inlet pipe 2 3 Oil cooler outlet pipe 2 4 Oil cooler inlet hose 5 Oil cooler outlet hose 6 Oil cooler inlet pipe 1 7 Oil cooler outlet pipe 1 B C B A A A A 3 6 7 2 1 4 2 5 3 C ...

Page 59: ...2 33 SPEC OIL FLOW DIAGRAMS 1 Oil outlet pipe 2 Oil inlet pipe 3 Oil outlet hose 4 Oil inlet hose 5 Oil cooler inlet pipe 2 6 Oil cooler outlet pipe 2 A A B B A A 5 6 3 1 2 3 4 4 ...

Page 60: ...r 6 Starter cable 7 Starter choke knob 8 Light switch 9 Coolant reservoir breather hose 0 Parking brake switch lead A Parking brake cable B Rear brake pipe C Radiator inlet hose D Front brake hoses E Radiator fan motor breather hose F Differential gear case breather hose A B A B Ê Î Ï Ð Í Ñ Ë Ë Ì È É D F 7 8 9 9 0 A B C C 1 2 3 3 4 E 5 6 ...

Page 61: ...hrottle cable parking brake switch lead and parking brake cable with the plastic clip Í Fasten the throttle cable with the metal holder Î Fasten the throttle cable to the radiator inlet hose with the plastic bands Ï 20 mm 0 79 in or less below the end of the hose protector Ð 5 mm 0 20 in or less above the end of the hose protector Ñ Route the throttle cable to the inside of the radia tor inlet hos...

Page 62: ...n the parking brake cable with the metal holder É Fasten the spark plug lead to the air duct assembly 1 with a plastic band Ê Fasten the wire harness to the frame with the plastic bands Ë Pass the tail brake light lead through the grom met left and right Ì Fasten the coolant outlet hose and ignition coil leads with the plastic clip D D A C A B C D D Í Ð Ñ Ï Ò Í Ï Î È É Ê Ì Í Ë 8 9 1 2 3 4 4 5 5 Ò ...

Page 63: ...e is no slack in the lead left and right Ï Fasten the unused coupler to the wire harness with tape Ð Fasten the tail brake light lead with the plastic holders Ñ Fasten the tail brake light lead with the plastic bands Ò Fasten the wire harness with the plastic bands D D A C A B C D D Í Ð Ñ Ï Ò Í Ï Î È É Ê Ì Í Ë 8 9 1 2 3 4 4 5 5 Ò Ñ Ð 5 5 6 7 B E E ...

Page 64: ...r hose C Gear motor couplers D Coolant reservoir hose E Radiator outlet hose F Speed sensor coupler G A C magneto couplers H Speed sensor lead I Ground lead J Parking brake switch lead K Reverse switch L Neutral switch M High range switch N Low range switch O Sub wire harness P Throttle cable Q Radiator inlet pipe R Rear brake pipe S Radiator outlet pipe E E B B E E F D C A A C D F B B B B Õ Ø È Ü...

Page 65: ...30 60 mm 1 18 2 36 in Ë 160 190 mm 6 30 7 48 in Ì Fasten the radiator outlet hose and coolant reservoir hose with the plastic clip Í 12 22 mm 0 47 0 87 in Î Fasten the wire harness starter motor lead ground lead and starter choke cable to the frame with a plastic band Ï Fasten the wire harness starter motor lead and ground lead to the frame with a plastic band E E B B E E F D C A A C D F B B B B Õ...

Page 66: ...hose with a plastic band Ó 40 60 mm 1 57 2 36 in Ô Fasten the starter choke cable with a plastic band Õ Fasten the sub wire harness with the metal holder Ö Fasten the A C magneto leads sub wire harness thermo switch 1 lead carbure tor heater leads and parking brake switch lead with a plastic band Fasten the throttle cable with a plastic band E E B B E E F D C A A C D F B B B B Õ Ø È Ü È Û Ú Ö È É ...

Page 67: ...plastic band Û Fasten the wire harness starter choke cable starter motor lead and ground lead with the plastic bands Ü Fasten the wire harness brake light switch lead and starter choke cable with a plastic band E E B B E E F D C A A C D F B B B B Õ Ø È Ü È Û Ú Ö È É Ï Î Í Ì Ñ Ó Ð Ò Ô È Ê Ë Ù Û G H I J K U L M 0 A B C D E F 1 2 4 4 6 6 7 8 9 N O P Q R S 6 6 T V 5 3 5 ...

Page 68: ...7 7 7 CABLE ROUTING 1 Final gear case breather hose 2 Vacuum hose 3 Fuel hose fuel pump to carburetor 4 Cylinder head breather hose 5 Starter choke cable 6 Air vent hose 7 Rear brake hose 8 Parking brake cable 9 Wire harness 0 Ignition coil lead A Fuel hoses fuel tank to fuel pump B Rear brake pipe C Starter motor lead D Fuel tank breather hose E Rollover valve ...

Page 69: ...he wire harness through the grommet Î Fasten the wire harness with a plastic band Ï Fasten the parking brake cable and wire har ness with the plastic clip Ð Fasten the parking brake cable with the metal holder Ñ Fasten the wire harness ignition coil lead and rear brake hose with a plastic band Ò Fasten the final gear case breather hose and fuel hose fuel pump to carburetor with the plas tic clip Ó...

Page 70: ...hose with the plastic bands Less than 1 mm 0 04 in Ø Fasten the rear brake pipe and wire harness with the plastic holder Ù Fasten the starter motor lead carburetor heater leads thermo switch 1 lead and parking brake switch lead with a plastic band Ú 20 40 C C D D E E F F A H G B A B G H C D D F F F F E E C C C Í Ï Ð Ñ Î Ò Õ Õ Ø Ë Ê É È Ì Ù Ú Ö Ö Ó Ô Ì Ì E 8 8 8 8 9 9 0 A A B C D 1 1 1 1 1 2 3 3 3 ...

Page 71: ...m hose 0 Parking brake cable È Pass the throttle cable through the cable guide É Fasten the speed sensor lead starter motor lead and ground lead with a plastic band Ê Fasten the wire harness and A C magneto leads with a plastic band Ë Fasten the wire harness with the plastic bands Ì Make sure that the plastic bands are not fas tened too tightly around the wire harness A A A A Ì Ë Í Î È É Ê Ë 8 9 0...

Page 72: ...UTING Í Fasten the rear brake pipe with a plastic band Î Fasten the wire harness speed sensor lead starter choke cable starter motor lead and ground lead with a plastic band A A A A Ì Ë Í Î È É Ê Ë 8 9 0 1 2 2 3 4 5 6 7 ...

Page 73: ...ck switch 7 Main switch 8 Starter choke knob 9 Light switch 0 Rectifier regulator A Differential gear case breather hose B Radiator fan motor breather hose C Left headlight lead D Throttle cable E Right headlight lead F Starter motor lead G Starter relay lead H Four wheel drive relay 1 I Four wheel drive relay 2 J Starter relay C C D D B A A B D D C C È É Ê Ë Ì Î Í Ï Ð Ò Ñ Ó E F G H I J K 8 9 0 A ...

Page 74: ...ator light V Coolant temperature indicator light W C D I unit È Fasten the wire harness with the plastic bands É Pass the radiator fan motor breather hose dif ferential gear case breather hose coolant reser voir breather hose and brake light switch lead through the guide Ê Pass the radiator fan motor breather hose dif ferential gear case breather hose throttle cable and brake light switch lead thr...

Page 75: ...adlight lead and differential gear case breather hose with the plastic holder Ï Fasten the starter motor lead and starter relay lead with the plastic holder Ð Fasten the positive battery lead with the plastic holder Ñ 59 61 mm 2 32 2 40 in Ò 4 mm 0 16 in of clearance or more is required around the boot Ó Make sure that the washer is installed on the side of the pedal assembly bracket towards the b...

Page 76: ... 0 Coolant reservoir hose A Ground lead B Starter relay lead È Fasten the coolant reservoir breather hose with the plastic holders É Fasten the front brake hose bushing with the plastic bands Ê Fasten the wire harness and ground lead with a plastic band Ë Fasten the differential gear case breather hose coolant reservoir hose radiator fan motor lead and thermo switch 3 lead with the plastic holder ...

Page 77: ...re special tools data and technical skills ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1 200 750 2 400 1 500 2 400 1 500 4 800 3 000 hours 20 75 150 150 300 Valves Check valve clearance Adjust if necessary Cooling system Check coolant leakage Repair if necessary Replace coolant every 24 months Spark plug Check condition Adjust gap and clean Replace if necessary ...

Page 78: ...ce damage runout Repair if necessary Wheel bearings Check bearing assemblies for looseness damage Replace if damaged Front and rear sus pension Check operation and for leakage Correct if necessary Steering system Check operation and for looseness Replace if damaged Check toe in Adjust if necessary Rear upper and lower knuckle piv ots Lubricate with lithium soap based grease Drive shaft universal j...

Page 79: ...the valve clearance when the piston is at the Top Dead Center TDC on the com pression stroke 1 Remove driver seat passenger seat console Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 2 Remove bracket 1 tappet cover intake 2 tappet cover exhaust 3 3 Disconnect spark plug cap 4 4 Remove spark plug 1 3 2 4 5 Remove air shroud 1 1 1 6 Remove timing plug 1 1 ...

Page 80: ...between the valve stem tips and their respective valve adjusting screws If there is no clearance rotate the crankshaft counterclockwise one turn c Measure the valve clearance using a thick ness gauge 3 8 Adjust valve clearance a Loosen the locknut 1 b Insert a thickness gauge 2 between the adjusting screw end and the valve end c Turn the adjusting screw 3 clockwise or counterclockwise with the tap...

Page 81: ... Nm 1 0 m kg 7 2 ft lb 11 Install spark plug 12 Connect spark plug cap 13 Install tappet cover exhaust bracket tappet cover intake NOTE Install the tappet covers with the ridge facing up È 14 Install console passenger seat driver seat Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 ADJUSTING THE IDLING SPEED 1 Start the engine and let it warm up for sev eral minutes 2 Remove driver seat p...

Page 82: ...pecification Adjust 5 Adjust engine idling speed a Turn the throttle stop screw 1 in or out until the specified idling speed is obtained Engine idling speed 1 450 1 550 r min Turning in Idling speed increases Turning out Idling speed decreases 6 Detach tachometer 7 Install console passenger seat driver seat Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 ...

Page 83: ... a Slack Remove the slack 1 a 4 Adjust throttle cable a Loosen the locknut 1 b Turn the adjuster 2 in or out until there is no slack c Tighten the locknut NOTE _ After adjusting the throttle cable depress the accelerator pedal a few times and make sure that the throttle valve 3 closes completely after releasing the accelerator pedal Turning in Slack increases Turning out Slack decreases 2 1 3 5 In...

Page 84: ...oke knob 3 fully closed to fully open position If the distance is out of specification adjust it as described below È Fully closed position É Fully open position c Pull back the boot 4 d Loosen the locknut 5 e Turn the adjuster 6 in or out until the cor rect distance is obtained f Tighten the locknut 5 g Push in the boot 4 h Connect the starter cable to the carburetor 3 Install console passenger s...

Page 85: ...e Normal color is a medium to light tan color 5 Clean the spark plug with a spark plug cleaner or wire brush 6 Measure spark plug gap a Use a wire gauge or thickness gauge Out of specification Regap 7 Install spark plug NOTE Before installing a spark plug clean the gasket surface and plug surface 8 Install console passenger seat driver seat Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 ...

Page 86: ... checking the ignition timing 1 Remove driver seat passenger seat console Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 2 Attach tachometer timing light to the spark plug lead Digital tachometer P N YU 39951 B 90890 06760 Timing light P N 90890 03141 Inductive clamp timing light P N YU 03141 3 Remove air shroud 1 1 1 4 Remove engine cooling fan 1 1 ...

Page 87: ...iming plug 6 Install engine cooling fan 7 Install air shroud 1 8 Detach timing light tachometer 9 Install console passenger seat driver seat Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 MEASURING THE COMPRESSION PRESSURE NOTE Insufficient compression pressure will result in a loss of performance 1 Check valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE ...

Page 88: ...tery is fully charged with the throttle wide open until the compression read ing on the gauge stabilizes Engine compression tester P N YU 33223 Compression gauge P N 90890 03081 Extension P N 90890 04082 Compression pressure with oil introduced into cylinder Reading Diagnosis Higher than without oil Worn or damaged piston ring s Same as with out oil Defective piston ring s valve s cylinder head ga...

Page 89: ...ARGO BED in chapter 8 3 Check engine oil level Oil level should be between the maximum 1 and minimum 2 marks Oil level low Add oil to the proper level NOTE Do not screw the dipstick 3 in when checking the oil level NOTE Recommended oil classification API Service SE SF SG type or equiva lent e g SF SE CC SF SE SD etc CAUTION Do not allow foreign material to enter the crankcase 4 Start the engine an...

Page 90: ...at Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 CHANGING THE ENGINE OIL 1 Start the engine and let it warm up for sev eral minutes 2 Stop the engine and place an oil pan under the engine 3 Remove driver seat passenger seat console Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 4 Remove engine oil filler plug dipstick 1 engine oil drain bolt 2 Drain the engine oil from the cra...

Page 91: ...cartridge 17 Nm 1 7 m kg 12 ft lb 6 Install engine oil drain bolt 1 7 Fill crankcase with sufficient oil to reach the specified level Refer to CHECKING THE ENGINE OIL LEVEL 8 Install engine oil filler plug 9 Warm up the engine for a few minutes then stop the engine 10 Check engine for engine oil leaks oil level Refer to CHECKING THE ENGINE OIL LEVEL Oil quantity Periodic oil change 2 50 L 2 20 Imp...

Page 92: ...oil filter cartridge and the oil pump for damage or leakage Refer to CRANKSHAFT AND OIL PUMP in chapter 4 d Start the engine after solving the problem s and check the engine oil pressure again e Tighten the oil gallery bolt to specification 12 Install console passenger seat driver seat Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 T R Oil gallery bolt 7 Nm 0 7 m kg 5 1 ft lb 1 CLEANING ...

Page 93: ...4 Check air filter element Damage Replace 5 Install air filter element into the air intake duct grill 6 Install air intake duct grill Cleaning the engine air filter element 1 Remove driver seat passenger seat console Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 NOTE There is a check hose 1 at the bottom of the air filter case If dust and or water collects in this hose clean the air fil...

Page 94: ...nd possible engine overheating 4 Check air filter element Damaged Replace 5 Clean air filter element a Wash the element gently but thoroughly in solvent WARNING Use a cleaning solvent which is designed to clean parts only Never use gasoline or low flash point solvents as they may cause a fire or explosion b Squeeze the excess solvent out of the ele ment and let it dry CAUTION Do not twist or wring...

Page 95: ...evel The coolant level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended coolant to the proper level CAUTION Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However sof...

Page 96: ...HOOD AND CARGO BED in chapter 8 2 Lift the hood up 3 Remove coolant reservoir cap 1 4 Disconnect coolant reservoir hose 2 5 Drain coolant from the coolant reservoir 6 Connect coolant reservoir hose 7 Remove coolant drain bolt cylinder 1 along with the copper washer coolant drain bolt water pump 2 along with the copper washer ...

Page 97: ...d open the radiator cap as follows Place a thick rag or a towel over the radia tor cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped turn the radiator cap counterclockwise while pressing down on it and then remove it 9 Drain coolant 10 Disconnect coolant outlet hose 1 water pump inlet hose 2 11 Drain ...

Page 98: ...l cooling system with the specified amount of the recom mended coolant NOTE The specified amount of coolant is a standard amount Fill the cooling system with coolant until coolant comes out of the hole for the air bleed bolt Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1 1 antifreeze water Quantity Radiator capacit...

Page 99: ...lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However soft water may be used if distilled water is not available If coolant comes into contact with painted surfaces immediately wash them with water Do not mix different types of antifreeze 17 Install air bleed bolt ...

Page 100: ...ING THE COOLANT LEVEL NOTE Before checking the coolant level wait a few minutes until the coolant has settled 23 Close the hood 24 Install console passenger seat driver seat Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 CHANGING THE COOLANT ...

Page 101: ...in switch to START with the transmission in neutral posi tion Coolant temperature warning light comes on momentarily Coolant temperature and electrical circuit are OK Go ahead with riding Coolant temperature warning light does not come on Coolant temperature warning light comes on Check the electrical circuit CHECKING THE V BELT 1 Remove driver seat passenger seat console Refer to SEATS ENCLOSURE ...

Page 102: ...1 09 in 4 Replace V belt a Install the bolts 1 90101 06016 into the secondary fixed sheave hold NOTE Tightening the bolts 1 will push the secondary sliding sheave away causing the gap between the secondary fixed and sliding sheaves to widen b Remove the V belt 2 from the primary sheave and secondary sheave c Install the new V belt NOTE Install the V belt so that its arrow faces the direction shown...

Page 103: ...from the muffler a Remove the bolts 1 b Remove the tailpipe 2 by pulling it out of the muffler c Tap the tailpipe lightly with a soft face ham mer or suitable tool then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the muffler d Insert the tailpipe 2 into the muffler and align the bolt holes e Insert the bolt 1 and ...

Page 104: ...he brake master cylinder 2 Brake pedal free play 0 mm 0 0 in 2 Adjust brake pedal free play a Loosen the locknut 1 b Turn brake rod 2 in or out until the correct free play is obtained c Tighten the locknut to specification NOTE _ Make sure that there is no brake drag on the front or rear wheels Turning in Free play increases Turning out Free play decreases T R Locknut 17 Nm 1 7 m kg 12 ft lb ...

Page 105: ... the parking brake lever free play 3 Remove driver seat passenger seat console Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 4 Adjust parking brake lever free play a Pull back the adjuster cover b Loosen the locknut 1 c Turn the adjusting nut 2 in or out until the correct free play is obtained d Tighten the locknut 1 e Slide the adjuster cover to its original posi tion 5 Install console...

Page 106: ...inted surfaces or plastic parts Always clean up spilled fluid immediately WARNING Use only the designed quality brake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor perfor mance Be careful that water does not enter the master cylinder when...

Page 107: ...AR BRAKES in chapter 8 3 Operate the brake pedal 4 Install front wheels Refer to FRONT WHEELS AND BRAKE DISCS in chapter 8 Brake pad wear limit a 1 5 mm 0 06 in CHECKING THE REAR BRAKE PADS 1 Check brake pads Wear indicator grooves 1 almost disap peared Replace the brake pads as a set Refer to FRONT AND REAR BRAKES in chapter 8 2 Operate the brake pedal Brake pad wear limit a 1 5 mm 0 06 in CHECKI...

Page 108: ...right position and apply the brake pedal 5 Check brake hose clamps Loosen Tighten 6 Lower the cargo bed 7 Close the hood 8 Install console passenger seat driver seat Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 3 2 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the brake system if The system has been disassembled A brake hose or brake pipe have been loosened or removed The brake flu...

Page 109: ... to travel towards its limit h Tighten the bleed screw when the pedal limit has been reached then release the pedal i Repeat steps e to h until all the air bub bles have disappeared from the fluid j Tighten the bleed screw NOTE If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the system have disappeare...

Page 110: ... a Shift the drive select lever into the neutral position N b Loosen both locknuts 1 CAUTION The select lever shift rod locknut select lever side has left handed threads To loosen the locknut turn it clockwise c Adjust the shift rod length for smooth and correct shifting d Tighten the locknuts 1 T R Locknut 15 Nm 1 5 m kg 11 ft lb ADJUSTING THE BRAKE LIGHT SWITCH NOTE The brake light switch is ope...

Page 111: ...rake light comes on at the proper time Direction a Brake light comes on sooner Direction b Brake light comes on later CHECKING THE FINAL GEAR OIL LEVEL 1 Place the vehicle on a level surface 2 Remove oil filler plug 1 3 Check oil level Oil level should be up to the brim of the filler hole Oil level low Add oil to the proper level CAUTION Take care not to allow foreign material to enter the final g...

Page 112: ...NOTE Check the drain plug gasket If it is damaged replace it with a new one 6 Fill final gear case CAUTION Take care not to allow foreign material to enter the final gear case 7 Install oil filler plug Periodic oil change 0 25 L 0 22 Imp qt 0 26 US qt Total amount 0 28 L 0 25 Imp qt 0 30 US qt Recommended oil SAE 80 API GL 4 Hypoid gear oil T R 20 Nm 2 0 m kg 14 ft lb T R 23 Nm 2 3 m kg 17 ft lb C...

Page 113: ...he differential gear case 4 Install oil filler plug Recommended oil SAE 80 API GL 4 Hypoid gear oil T R 23 Nm 2 3 m kg 17 ft lb CHANGING THE DIFFERENTIAL GEAR OIL 1 Place the vehicle on a level surface 2 Place a container under the differential gear case 3 Remove oil filler plug 1 drain plug 2 4 Drain differential gear oil 5 Install drain plug NOTE Check the gasket drain plug If it is damaged repl...

Page 114: ... gear case 7 Install oil filler plug Periodic oil change 0 32 L 0 28 Imp qt 0 34 US qt Total amount 0 33 L 0 29 Imp qt 0 35 US qt Recommended oil SAE 80 API GL 4 Hypoid gear oil T R 23 Nm 2 3 m kg 17 ft lb CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS 1 Check dust boots 1 Damage Replace Refer to FRONT CONSTANT VELOCITY JOINTS DIFFERENTIAL GEAR AND FRONT DRIVE SHAFT in chapter 7 È Front É Rear È ...

Page 115: ...direc tion Tie rod end s have vertical play Replace the tie rod end s 4 Raise the front end of the vehicle so that there is no weight on the front wheels 5 Check ball joints and or wheel bearings Move the wheels laterally back and forth Excessive free play Replace the front arms upper and lower and or wheel bear ings ADJUSTING THE TOE IN 1 Place the vehicle on a level surface 2 Measure toe in Out ...

Page 116: ...ing and an accident After setting the toe in to specification run the vehicle slowly for some distance with both hands lightly holding the steer ing wheel and check that the steering wheel responds correctly If not turn either the right or left tie rod within the toe in specification a Mark both tie rods ends This reference point will be needed during adjustment b Loosen the locknut tie rod end 1 ...

Page 117: ...ring preload Turn the adjuster 1 to increase or decrease the spring preload ADJUSTING THE REAR SHOCK ABSORBERS WARNING Always adjust the spring preload of both shock absorbers to the same setting Uneven adjustment can cause poor han dling and loss of stability NOTE The spring preload of the shock absorbers can be adjusted to suit the operator s preference weight and the operating conditions 1 Adju...

Page 118: ...ng condi tions The following are minimums Front 63 kPa 0 63 kg cm2 9 psi Rear 91 kPa 0 91 kg cm2 13 psi 3 Use no more than Front 250 kPa 2 5 kg cm2 36 psi Rear 250 kPa 2 5 kg cm2 36 psi when seating the tire beads Higher pressures may cause the tire to burst Inflate the tires slowly and carefully Fast inflation could cause the tire to burst MAXIMUM LOADING LIMIT 1 Vehicle loading limit total weigh...

Page 119: ...his vehicle and may cause loss of control Maintain proper tire pressures Set tire pressures when the tires are cold Tire pressures must be equal in both front tires and equal in both rear tires 2 Check tire surfaces Wear damage Replace WARNING It is dangerous to ride with a worn out tire When tire wear is out of specification replace the tire immediately Cold tire pressure Front Rear Standard 70 k...

Page 120: ...tself properly on the rim CHECKING AND LUBRICATING THE CABLES WARNING A damaged cable sheath may cause corro sion and interfere with the cable move ment An unsafe condition may result so replace a damaged cable as soon as possi ble 1 Check cable sheath Damage Replace 2 Check cable operation Unsmooth operation Lubricate or replace NOTE Hold the cable end up and apply several drops of lubricant to t...

Page 121: ...3 45 CHK ADJ LUBRICATING THE PEDALS ETC LUBRICATING THE PEDALS ETC 1 Lubricate the pivoting parts Recommended lubricant Lithium soap based grease ...

Page 122: ...as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention CAUTION _ This is a sealed battery Never remove the sealing caps be...

Page 123: ...ery termi nals NOTE _ The charge state of an MF battery can be checked by measuring its open circuit volt age i e the voltage when the positive termi nal is disconnected No charging is necessary when the open cir cuit voltage equals or exceeds 12 8 V b Check the charge of the battery as shown in the charts and the following example Example c Open circuit voltage 12 0 V d Charging time 6 5 hours e ...

Page 124: ...nected 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 termi nal and that they are not shorted A cor roded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to ...

Page 125: ... charging amperage exceeded If the amperage does not exceed the standard charging amperage after 5 minutes replace the battery If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging amperage Leave the battery unused for more than 30 minutes before measurin...

Page 126: ...V Leave the battery unused for more than 30 minutes before measuring its open cir cuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the battery This type of battery charger cannot charge an MF battery A variable voltage charger is rec ommended Charger Ammeter Voltmeter NOTE Leave the battery unused for more than 30 minutes before measuring its open ci...

Page 127: ...ricate battery terminals 11 Install battery case cover 12 Close the hood CHECKING THE FUSES CAUTION Always turn off the main switch when checking or replacing a fuse Otherwise a short circuit may occur 1 Lift the hood up 2 Remove battery case cover 3 Check fuses a Connect the pocket tester to the fuse and check it for continuity NOTE Set the tester to the Ω 1 position b If the tester indicates rep...

Page 128: ...ials in place of a fuse An improper fuse may cause extensive damage to the electrical system a malfunction of the lighting and ignition systems and could possibly cause a fire 5 Install battery case cover 6 Close the hood Description Current rating Quantity Main fuse 30 A 1 Lighting system fuse 15 A 1 Ignition fuse 10 A 1 Auxiliary DC jack fuse 10 A 1 Four wheel drive fuse 3 A 1 Signaling system f...

Page 129: ...EADLIGHT BULBS 1 Lift the hood up 2 Remove headlight bulb holder cover 1 3 Disconnect headlight bulb holder coupler 1 4 Remove headlight bulb holder assembly 1 NOTE The headlight bulb cannot be removed from the headlight bulb holder To replace the head light bulb replace the headlight bulb holder assembly WARNING Keep flammable products and your hands away from the bulb while it is on since it wil...

Page 130: ...bulb thoroughly clean it with a cloth moistened with alcohol or lac quer thinner 6 Connect headlight bulb holder coupler 7 Install headlight bulb holder cover 8 Close the hood New CHANGING THE TAIL BRAKE LIGHT BULBS 1 Remove cargo bed panel 1 2 Remove tail brake light bulb holder with bulb 1 bulb NOTE Turn the bulb holder counterclockwise and remove the defective bulb WARNING Keep flammable produc...

Page 131: ...free from oil otherwise the trans parency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on the bulb thoroughly clean it with a cloth moistened with alcohol or lac quer thinner 4 Install tail brake light bulb holder with bulb 5 Install cargo bed panel Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 New T R 7 Nm 0 7 m kg 5 1 ft lb ...

Page 132: ...b Order Job Part Q ty Remarks Removing the air ducts muffler and exhaust pipe Remove the parts in the order listed Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Driver seat passenger seat console seat supports footrest cover Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Carburetor assembly air filter case Refer to...

Page 133: ... 7 m kg 5 1 ft Ib 5 New 6 New 2 6 1 T R 30 Nm 3 0 m kg 22 ft Ib Order Job Part Q ty Remarks Engine cooling fan air duct assembly Refer to ENGINE COOLING FAN AND A C MAGNETO 1 Heat protector 1 2 Muffler stay 1 3 Muffler damper 1 4 Muffler bracket 1 5 Muffler gasket 1 1 6 Exhaust pipe gasket 1 1 7 Air duct assembly 1 1 8 Air duct assembly 2 1 For installation reverse the removal pro cedure 4 ...

Page 134: ...kg 11 ft Ib Order Job Part Q ty Remarks Removing the select lever unit and coolant reservoir Remove the parts in the order listed 1 Shift arm 1 2 Select lever shift rod 1 CAUTION The select lever shift rod locknut select lever unit side has left handed threads To loosen the locknut turn it clockwise 3 Select lever unit 1 For installation reverse the removal pro cedure ...

Page 135: ...hose 1 Disconnect 4 Oil outlet hose 1 Disconnect 5 Vacuum hose 1 Disconnect 6 Spark plug cap 1 Disconnect 7 Cylinder head breather hose 1 8 Thermo switch 1 lead connector 1 Disconnect 9 Starter motor lead 1 Disconnect 10 A C magneto lead coupler 2 Disconnect 11 Speed sensor lead coupler 1 Disconnect 12 Low range switch connector 1 Disconnect White Red 13 High range switch connector 1 Disconnect Bl...

Page 136: ...NE REMOVAL 1 2 4 3 12 13 14 15 6 5 7 9 8 10 11 16 Order Job Part Q ty Remarks 15 Reverse switch connector 1 Disconnect Green White 16 Engine ground lead 1 Disconnect For installation reverse the removal pro cedure ...

Page 137: ...Ib Order Job Part Q ty Remarks Removing the engine mounting bolts Remove the parts in the order listed Front skid plate rear skid plate Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Rear wheels Refer to REAR WHEELS AND BRAKE DISC in chapter 8 Final drive gear assembly Refer to REAR CONSTANT VELOCITY JOINTS FINAL DRIVE GEAR AND REAR DRIVE SHAFT in chapter 7 ...

Page 138: ...y Remarks 1 Engine bracket nut 3 NOTE Remove the engine assembly from the top of the vehicle CAUTION Install all of the bolts nuts and then tighten them to full torque specifica tions Refer to INSTALLING THE ENGINE 2 Engine mounting bolt nut front 1 1 3 Engine mounting bolt rear 2 4 Engine assembly 1 5 Engine bracket 1 For installation reverse the removal pro cedure ...

Page 139: ... 5 NOTE Do not fully tighten the bolts and nuts 2 Tighten engine bracket nut 2 engine mounting bolt rear 4 engine mounting bolt nut front 5 2 5 1 4 4 3 5 T R 33 Nm 3 3 m kg 24 ft lb T R 42 Nm 4 2 m kg 30 ft lb T R 56 Nm 5 6 m kg 40 ft lb 3 Install air duct assembly 1 1 NOTE Be sure to align the alignment marks on air duct assembly 1 as shown in the illustrations 1 1 1 ...

Page 140: ...o ADJUSTING THE VALVE CLEARANCE in chapter 3 1 Spark plug 1 2 Camshaft sprocket cover O ring 1 1 3 Air duct assembly 2 bracket 1 4 Tappet cover O ring 2 2 5 Timing chain tensioner cap bolt 1 Refer to REMOVING THE CYLINDER HEAD and INSTALLING THE CYLIN DER HEAD 6 Timing chain tensioner gasket 1 1 7 Camshaft sprocket 1 8 Cylinder head 1 9 Cylinder head gasket 1 10 Dowel pin 2 11 O ring 1 ...

Page 141: ...4 10 ENG CYLINDER HEAD Order Job Part Q ty Remarks 12 Coolant outlet joint 1 13 Coolant outlet joint gasket 1 For installation reverse the removal pro cedure ...

Page 142: ... piston is at the Top Dead Center TDC on the compression stroke there should be clearance between the valve stem tips and their respective valve adjusting screws If there is no clearance rotate the crankshaft counterclockwise one turn 1 2 2 Loosen camshaft sprocket bolt 1 3 Loosen timing chain tensioner cap bolt 4 Remove timing chain tensioner camshaft sprocket NOTE Fasten a safety wire to the tim...

Page 143: ...ned remove them CHECKING THE TAPPET COVERS 1 Check tappet covers 1 O rings 2 Cracks damage Replace CHECKING THE TIMING CHAIN TENSIONER 1 Check one way cam operation tensioner Unsmooth operation Replace CHECKING THE CAMSHAFT SPROCKET 1 Check camshaft sprocket Wear damage Replace the camshaft sprocket and timing chain as a set a 1 4 of a tooth b Correct 1 Timing chain 2 Sprocket ...

Page 144: ...deposits rust Eliminate 3 Measure cylinder head warpage Out of specification Resurface a Place a straightedge and a thickness gauge across the cylinder head b Use a thickness gauge to measure the warpage c If the warpage is out of specification resur face the cylinder head d Place a 400 600 grit wet sandpaper on the surface plate and resurface the head using a figure eight sanding pattern NOTE To ...

Page 145: ...ate the camshaft to align the camshaft pin 1 with the match mark 2 on the cylin der head b Turn the crankshaft counterclockwise with a wrench c Align the T mark 3 on the rotor with the stationary pointer 4 on the A C magneto cover When the T mark is aligned with the stationary pointer the piston is at the Top Dead Center TDC CAUTION Do not turn the crankshaft during the cam shaft sprocket installa...

Page 146: ...rk 2 on the cylinder head i If the marks are aligned tighten the cam shaft sprocket bolt If the marks are not aligned change the meshing position of the camshaft sprocket and timing chain 3 Install timing chain tensioner a Remove the tensioner cap bolt 1 washer 2 and spring 3 b Release the timing chain tensioner one way cam 4 and push the tensioner rod 5 all the way in c Install the tensioner with...

Page 147: ...4 16 ENG CYLINDER HEAD 4 Tighten camshaft sprocket bolt 1 5 Check camshaft sprocket I mark rotor T mark Out of alignment Adjust 1 T R 60 Nm 6 0 m kg 43 ft lb ...

Page 148: ...ermo switch 1 1 3 Oil gallery bolt 1 4 Lock washer bearing retainer 1 1 5 Camshaft 1 Refer to REMOVING THE CAMSHAFT AND ROCKER ARMS and INSTALL ING THE CAMSHAFT AND ROCKER ARMS 6 Rocker arm shaft O ring 2 2 7 Rocker arm 2 8 Locknut valve adjusting screw 2 2 9 Valve cotter 4 Refer to REMOVING THE VALVES AND VALVE SPRINGS and INSTALL ING THE VALVES AND VALVE SPRINGS 10 Valve spring retainer 2 11 Out...

Page 149: ...Q ty Remarks 12 Inner valve spring 2 Refer to REMOVING THE VALVES AND VALVE SPRINGS and INSTALL ING THE VALVES AND VALVE SPRINGS 13 Intake valve 1 14 Exhaust valve 1 15 Valve stem seal 2 16 Valve spring seat 2 For installation reverse the removal pro cedure ...

Page 150: ... hammer bolt and weight 3 to remove the rocker arm shafts Slide hammer bolt M6 P N YU 01083 1 90890 01083 Weight P N YU 01083 3 90890 01084 REMOVING THE VALVES AND VALVE SPRINGS 1 Check valve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVES AND VALVE SPRINGS a Pour a clean solvent 1 into the intake and exhaust ports b Check that th...

Page 151: ... Pitting scratches blue discoloration Replace 2 Measure cam lobe dimensions a and b Out of specification Replace Valve spring compressor P N YM 04019 90890 04019 Camshaft lobe limit Intake a 40 52 mm 1 5953 in b 32 08 mm 1 2630 in Exhaust a 40 52 mm 1 5953 in b 32 08 mm 1 2630 in CHECKING THE ROCKER ARMS AND CAMSHAFT 1 Check camshaft lobe contact surface 1 valve adjusting screws 2 Blue discolorati...

Page 152: ...ter a of the rocker arm holes Out of specification Replace d Measure the outside diameter b of the rocker arm shafts Out of specification Replace e Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter Out of specification Replace the defec tive part s Rocker arm inside diameter 12 000 12 018 mm 0 4724 0 4731 in Limit 12 078 mm 0 4755 in R...

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

Page 154: ...alve stem runout Out of specification Replace NOTE When installing a new valve always replace the guide If the valve is removed or replaced always replace the valve stem seal 6 Eliminate carbon deposits from the valve face and valve seat 7 Check valve seats Pitting wear Reface the valve seat 8 Measure valve seat width a Out of specification Reface the valve seat Runout limit 0 01 mm 0 0004 in Valv...

Page 155: ... seat must be refaced 9 Lap valve face valve seat NOTE After refacing the valve seat or replacing the valve and valve guide the valve seat and valve face should be lapped a Apply a coarse lapping compound to the valve face CAUTION Do not let the compound enter the gap between the valve stem and the guide b Apply molybdenum disulfide oil to the valve stem c Install the valve into the cylinder head ...

Page 156: ...alve seat to make a clear pattern i Measure the valve seat width again If the valve seat width is out of specification reface and relap the valve seat 10 Measure valve spring free length a Out of specification Replace 11 Measure compressed spring force a Out of specification Replace b Installed length Free length valve spring Inner 39 90 mm 1 57 in Limit 37 9 mm 1 49 in Outer 43 27 mm 1 70 in Limi...

Page 157: ... valve stem seals valves valve springs inner and outer valve spring retainers NOTE Install the valve springs with the larger pitch a facing upwards b Smaller pitch New 3 Install valve cotters NOTE Install the valve cotters while compressing the valve spring with the valve spring compressor 1 4 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION...

Page 158: ...nto the rocker arm shafts 2 Install rocker arms 1 rocker arm shafts intake and exhaust 2 NOTE Use a slide hammer bolt 3 to install the rocker arm shafts Slide hammer bolt M6 P N YU 01083 1 90890 01083 Weight P N YU 01083 3 90890 01084 3 Install camshaft 1 NOTE Install the camshaft pin hole a facing up ...

Page 159: ...Water pump outlet hose pipe Refer to WATER PUMP in chapter 5 1 Coolant inlet joint 1 2 Timing chain guide exhaust 1 3 Cylinder O ring 1 1 Refer to INSTALLING THE CYLINDER 4 Cylinder gasket 1 5 Dowel pin 2 6 O ring 1 7 Piston pin clip 2 Refer to REMOVING THE PISTON and INSTALLING THE PISTON 8 Piston pin 1 9 Piston 1 10 Piston ring set 1 For installation reverse the removal pro cedure ...

Page 160: ... prevent the piston pin clip from falling into the crankcase CAUTION Do not use a hammer to drive the piston pin out 2 Remove piston rings NOTE Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown Piston pin puller P N YU 01304 90890 01304 CHECKING THE TIMING CHAIN GUIDE 1 Check timing chain guide exhaust Wear damage Replace CHECKING THE CYLINDE...

Page 161: ... the cylinder and the piston and piston rings as a set Cylinder bore C 84 500 84 510 mm 3 3268 3 3272 in Maximum taper T 0 05 mm 0 0020 in Out of round R 0 01 mm 0 0004 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 2nd step a Measure piston skirt diameter P with a micrometer a 5 0 mm 0 20 in from the piston bottom edge b If out of s...

Page 162: ...S 1 Measure ring side clearance Use a thickness gauge Out of specification Replace the piston and rings as a set NOTE Clean carbon from the piston ring grooves and rings before measuring the side clearance 2 Install piston ring in cylinder NOTE Insert a ring into the cylinder and push it approximately 40 mm 1 6 in into the cylinder Push the ring with the piston crown so that the ring will be at a ...

Page 163: ...de diameter a If out of specification replace the piston pin b Measure the piston pin bore inside diameter b c Calculate the piston pin to piston clearance with the following formula End gap Standard Limit Top ring 0 20 0 40 mm 0 0079 0 0157 in 0 65 mm 0 0256 in 2nd ring 0 40 0 60 mm 0 0157 0 0236 in 0 95 mm 0 0374 in Oil ring 0 20 0 70 mm 0 0079 0 0276 in Piston pin outside diameter 19 991 20 000...

Page 164: ...ston and piston rings liberally with engine oil 2 Position top ring 2nd ring oil ring Offset the piston ring end gaps as shown a Top ring end b Oil ring end upper rail c Oil ring end lower rail d 2nd ring end e 20 mm 0 79 in 3 Install piston 1 piston pin 2 piston pin clips 3 NOTE Apply engine oil onto the piston pin piston rings and piston Be sure that the arrow mark a on the piston points to the ...

Page 165: ... coating of engine oil INSTALLING THE CYLINDER 1 Install cylinder NOTE Install the cylinder with one hand while com pressing the piston rings with the other hand CAUTION Be careful not to damage the timing chain damper during installation Pass the timing chain through the timing chain cavity ...

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

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

Page 168: ...4 37 ENG ENGINE COOLING FAN AND A C MAGNETO Order Job Part Q ty Remarks 18 Starter idle gear 1 For installation reverse the removal pro cedure ...

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

Page 170: ...d the starter clutch b When turning the starter wheel gear coun terclockwise È the starter clutch and the wheel gear should be engaged If not the starter clutch is faulty Replace it c When turning the starter wheel gear clock wise É the starter wheel gear should turn freely If not the starter clutch is faulty Replace it T R Starter clutch bolt 30 Nm 3 0 m kg 22 ft lb LOCTITE 2 Check starter idle g...

Page 171: ... NOTE Before installing the rotor clean the outside of the crankshaft and the inside of the rotor After installing the rotor check that the rotor rotates smoothly If not reinstall the key and rotor 3 Install dowel pins gasket A C magneto cover NOTE When installing the A C magneto cover use a long rod to hold the rotor in position from the outside This will make assembly easier Be careful not to da...

Page 172: ...g the engine cooling fan pulley base do not forget to install the O ring Primary sheave holder P N YS 01880 A Sheave holder P N 90890 01701 1 T R 50 Nm 5 0 m kg 36 ft lb 2 5 Install air shroud 1 engine cooling fan air duct assembly 1 NOTE Install the engine cooling fan air duct assembly with the arrow mark a towards the air shroud 1 T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 173: ...bly Refer to ENGINE REMOVAL 1 Drive belt cover 1 2 Rubber gasket 1 3 Bearing housing 1 4 Dowel pin 2 5 Primary sliding sheave assembly 1 Refer to REMOVING THE PRIMARY AND SECONDARY SHEAVES and INSTALLING THE PRIMARY AND SECONDARY SHEAVES 6 V belt 1 7 Primary fixed sheave 1 8 V belt case cooling fan 1 9 Spacer 1 10 Secondary sheave assembly 1 For installation reverse the removal pro cedure ...

Page 174: ... sliding sheave Remove the parts in the order listed 1 Primary pulley sheave cap 1 Refer to ASSEMBLING THE PRIMARY SHEAVE 2 Primary pulley slider 4 3 Spacer 4 4 Primary pulley cam 1 5 Primary pulley weight 8 6 Spacer 1 7 Oil seal 2 8 Primary sliding sheave 1 9 O ring 1 For assembly reverse the disassembly procedure ...

Page 175: ...ove the parts in the order listed 1 Spring seat 1 Refer to DISASSEMBLING THE SEC ONDARY SHEAVE and ASSEMBLING THE SECONDARY SHEAVE 2 Compression spring 1 3 Spring seat 1 4 Guide pin 4 5 Secondary sliding sheave 1 6 O ring 2 7 Secondary fixed sheave 1 8 Oil seal 1 9 Oil seal 1 For assembly reverse the disassembly procedure ...

Page 176: ...ECONDARY SHEAVE 1 Remove primary sheave spring retainer nut 1 a Attach the sheave fixed block 2 locknut wrench 3 and sheave spring compressor 4 to the secondary sheave assembly b Place the sheave fixed block in a vise and secure it c Tighten the sheave spring compressor nut 5 and compress the spring d Loosen the nut 1 with the locknut wrench 3 e Remove the nut 1 f Remove the sheave spring compress...

Page 177: ...Replace 3 Check primary sliding sheave primary fixed sheave Cracks damage Replace CHECKING THE SECONDARY SHEAVE 1 Check secondary fixed sheave smooth operation secondary sliding sheave smooth operation Scratches damage Replace as a set 2 Check torque cam grooves 1 Wear damage Replace 3 Check guide pins 2 Wear damage Replace 4 Check secondary sheave spring Damage Replace 5 Measure secondary sheave ...

Page 178: ...rizzly grease 90 g to the whole outer surface of the weights and install Apply Yamaha Grizzly grease to the inner surface of the spacer Apply Yamaha Grizzly grease to the inner surface of the primary sliding sheave 3 Install spacer sliders 1 primary pulley cam 2 primary sliding sheave cap T R 3 Nm 0 3 m kg 2 2 ft lb ASSEMBLING THE SECONDARY SHEAVE 1 Apply BEL RAY assembly lube to the secondary sli...

Page 179: ...he secondary sheave assembly b Place the sheave fixed block in a vise and secure it c Tighten the sheave spring compressor nut 1 and compress the spring d Install the primary sheave spring retainer nut 2 and tighten it to the specified torque using the locknut wrench NOTE Be sure to install the primary sheave spring retainer nut with its chamfered side a facing the spring seat Sheave fixed block P...

Page 180: ...ing the gap between the secondary fixed and sliding sheaves to widen Install the V belt so that its arrow faces the direction show in the illustration 2 Install spacer V belt case cooling fan 1 primary sheave nut 2 secondary sheave nut 3 NOTE Install the V belt case cooling fan with the 2P5 mark facing outward Use the sheave holder 4 to hold the primary sheave First tighten the primary sheave nut ...

Page 181: ...he order listed Primary and secondary sheaves Refer to PRIMARY AND SECONDARY SHEAVES 1 Clutch housing assembly 1 Refer to REMOVING THE CLUTCH and INSTALLING THE CLUTCH 2 Gasket dowel pin 1 2 3 One way clutch bearing 1 4 Clutch carrier assembly 1 For installation reverse the removal pro cedure ...

Page 182: ...y Remarks Disassembling the clutch housing Remove the parts in the order listed 1 Oil seal 1 2 Circlip 1 3 Bearing housing 1 4 Circlip 1 5 Bearing 1 6 Circlip 1 7 Bearing 1 8 Clutch housing 1 For assembly reverse the disassembly procedure ...

Page 183: ...utch carrier assembly Universal clutch holder P N YM 91042 90890 04086 CHECKING THE CLUTCH 1 Check clutch housing 1 Heat damage wear damage Replace one way clutch bearing 2 Chafing wear damage Replace NOTE Replace the one way clutch assembly and clutch housing as a set The one way clutch bearing should be installed in the clutch carrier assembly with the arrow mark facing toward the clutch housing...

Page 184: ...ne way clutch assembly is faulty Replace it 2 Check clutch shoe Heat damage Replace 3 Measure clutch shoe thickness Out of specification Replace Clutch shoe thickness 1 5 mm 0 06 in Clutch shoe wear limit a 1 0 mm 0 04 in INSTALLING THE CLUTCH 1 Install clutch carrier assembly clutch carrier assembly nut 1 NOTE Use a clutch holding tool 2 to hold the clutch carrier assembly 2 Lock the threads with...

Page 185: ...rrier assembly with the arrow mark a facing toward the clutch hous ing 4 Install dowel pins gasket clutch housing assembly NOTE Tighten the bolts in stages using a criss cross pattern After tightening the bolts check that the clutch housing assembly to counterclockwise rotates smoothly New T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 186: ... to ENGINE REMOVAL Cylinder head Refer to CYLINDER HEAD Cylinder and piston Refer to CYLINDER AND PISTON A C magneto rotor Refer to ENGINE COOLING FAN AND A C MAGNETO Primary and secondary sheaves Refer to PRIMARY AND SECONDARY SHEAVES Clutch carrier assembly Refer to CLUTCH 1 Oil filter cartridge 1 2 Oil outlet pipe O ring 1 1 3 Oil inlet pipe O ring 1 1 4 Oil pipe adapter O ring 1 1 5 Relief val...

Page 187: ...VE GEAR and INSTALLING THE OIL PUMP DRIVE GEAR 7 Oil pump driven gear 1 8 Timing chain guide intake 1 9 Timing chain 1 10 Starter motor O ring 1 1 11 Speed sensor 1 12 Shift drum stopper 1 13 Low range switch 1 14 High range switch 1 15 Neutral switch 1 16 Reverse switch 1 17 Oil filler cap 1 18 Bearing cover gasket 1 1 ...

Page 188: ...4 57 ENG CRANKCASE Order Job Part Q ty Remarks 19 Oil delivery pipe 1 20 Oil strainer cover O ring 1 1 21 Compression spring 1 22 Oil strainer 1 For installation reverse the removal procedure ...

Page 189: ... the order listed 1 Shift lever cover gasket 1 1 Refer to INSTALLING THE SHIFT LEVER 2 Shift lever 1 O ring 1 1 3 Shift lever 2 assembly 1 4 Right crankcase 1 Refer to SEPARATING THE CRANK CASE and ASSEMBLING THE CRANKCASE 5 Dowel pin 2 6 Left crankcase 1 For installation reverse the removal pro cedure ...

Page 190: ...kcase bearings Remove the parts in the order listed Crankshaft and oil pump Refer to CRANKSHAFT AND OIL PUMP Transmission Refer to TRANSMISSION Middle drive driven shaft Refer to MIDDLE GEAR 1 Oil seal 3 2 Bearing retainer 2 3 Bearing 10 For installation reverse the removal pro cedure ...

Page 191: ...ch holding tool 2 and loosen the oil pump drive gear nut c Remove the clutch carrier assembly Universal clutch holder P N YM 91042 90890 04086 SEPARATING THE CRANKCASE 1 Separate right crankcase a Remove the crankcase bolts NOTE Loosen each bolt 1 4 of a turn at a time and after all the bolts are loosened remove them Loosen the bolts in stages using a criss cross pattern È Right crankcase É Left c...

Page 192: ...the crankcase halves separate evenly c Remove the dowel pins CHECKING THE TIMING CHAIN AND GUIDE 1 Check timing chain Cracks stiff Replace the timing chain and camshaft sprocket as a set 2 Check timing chain guide intake Wear damage Replace CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE 1 Check oil strainer 1 Damage Replace Contaminants Clean with engine oil 2 Check oil delivery pipe Cracks damag...

Page 193: ...ating surfaces and crankcase mating surfaces thoroughly 3 Check crankcase Cracks damage Replace oil delivery passages Clogged Blow out with compressed air CHECKING THE BEARINGS 1 Check bearing Clean and lubricate then rotate the inner race with a finger Roughness Replace INSTALLING THE BEARING RETAINER bearing retainer 1 NOTE Install the bearing retainer with the L mark facing outward 1 T R 10 Nm ...

Page 194: ...check whether the transmission is functioning properly by manually rotating the shift drum in both directions 4 Tighten crankcase bolts follow the proper tightening sequence È Left crankcase É Right crankcase NOTE Tighten the bolts in stages using a crisscross pattern 5 Apply 4 stroke engine oil to the crank pin bearing and oil delivery hole 6 Check crankshaft and transmission operation Unsmooth o...

Page 195: ... Nm 1 4 m kg 10 ft lb INSTALLING THE OIL PUMP DRIVE GEAR 1 Install straight key oil pump drive gear lock washer oil pump drive gear nut New 2 Tighten oil pump drive gear nut a Temporary install the clutch carrier assem bly 1 b Hold the clutch carrier assembly with a clutch holding tool 2 and tighten the oil pump drive gear nut Universal clutch holder P N YM 91042 90890 04086 T R 50 Nm 5 0 m kg 36 ...

Page 196: ...d oil pump Remove the parts in the order listed Crankcase separation Refer to CRANKCASE 1 Washer circlip 1 1 2 Oil pump assembly gasket 1 1 3 Balancer 1 Refer to REMOVING THE CRANK SHAFT and INSTALLING THE CRANKSHAFT AND BALANCER 4 Crankshaft seal 2 5 Crankshaft 1 For installation reverse the removal pro cedure ...

Page 197: ...PUMP Order Job Part Q ty Remarks Disassembling the oil pump Remove the parts in the order listed 1 Rotor cover 1 2 Pin 2 3 Shaft 1 4 Pin 1 5 Inner rotor 1 6 Outer rotor 1 7 Oil pump housing 1 For assembly reverse the disassembly procedure ...

Page 198: ...driven gear oil pump housing rotor cover Cracks wear damage Replace 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 Inner rotor to outer rotor tip clearance less than 0 15 mm 0 0059 in Limit 0 23 mm 0 0091 in Outer rotor to oil pump housing clearanc...

Page 199: ...side clearance D Out of specification Replace the crank shaft runout C Out of specification Replace the crank shaft The crankshaft 1 and the crank pin 2 oil pas sages must be properly interconnected with a tolerance of less than 1 mm 0 04 in Crank width 62 95 63 00 mm 2 4783 2 4803 in Big end side clearance 0 25 0 75 mm 0 0098 0 0295 in Limit 1 0 mm 0 0394 in Runout limit C1 0 03 mm 0 0012 in C2 0...

Page 200: ...ON Apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier Crankshaft installer bolt 1 P N YU 90060 90890 01275 Crankshaft installer set P N YU 90050 Buffer boss installer set 2 P N 90890 04088 Adapter 11 P N YM 33279 Spacer crankshaft 3 P N YM 90070 A 90890 04060 2 Install crankshaft seals NOTE Install the crankshaft seals in the correct place ...

Page 201: ...moving the transmission Remove the parts in the order listed Crankcase separation Refer to CRANKCASE 1 Driven sprocket 1 2 Chain 1 3 Clutch dog 2 1 4 Shift fork L 1 5 Spring 1 6 Low wheel gear 1 7 Secondary shaft 1 8 Middle driven gear 1 9 Drive axle 1 10 Guide bar 1 ...

Page 202: ...NSMISSION Order Job Part Q ty Remarks 11 Shift fork R 1 12 Spring 1 13 Shift drum 1 14 Clutch dog 1 1 15 High wheel gear 1 16 Middle drive gear 1 17 Spacer O ring 1 1 For installation reverse the removal pro cedure ...

Page 203: ...k guide bar Roll the guide bar on a flat surface Bends Replace WARNING Do not attempt to straighten a bent guide bar 3 Check shift fork movement on the guide bar Unsmooth operation Replace the shift fork and the guide bar 4 Check springs Cracks damage Replace CHECKING THE SHIFT DRUM 1 Check shift drum grooves Scratches wear damage Replace ...

Page 204: ...ar Replace mated dogs Rounded edges cracks missing portions Replace 3 Check gear movement Unsmooth Repeat steps 1 and 2 or replace the defective parts CHECKING THE SECONDARY SHAFT AND DRIVEN SPROCKET 1 Check gear teeth Blue discoloration pitting wear Replace 2 Check gear movement Unsmooth Repeat steps 1 or replace the defective parts CHECKING THE CHAIN 1 Check chain Cracks shift Replace the chain ...

Page 205: ...t fork L 6 NOTE Be sure to install the shift forks R and L as shown in the illustration and make sure that the shift fork guide pin is properly seated in the shift drum groove 2 Check shift operation Unsmooth operation Repair NOTE Oil each gear and bearing thoroughly Before assembling the crankcase be sure that the transmission is in neutral and that the gears turn freely ...

Page 206: ... to CRANKCASE Transmission Refer to TRANSMISSION 1 Middle drive pinion gear shaft bearing housing 1 2 Middle drive pinion gear 1 Refer to REMOVING THE MIDDLE DRIVE PINION GEAR SHAFT and INSTALLING THE MIDDLE DRIVE PIN ION GEAR SHAFT 3 Shim Refer to SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS 4 Middle drive pinion gear shaft 1 5 Bearing retainer 2 For installation reverse the removal pro cedur...

Page 207: ...ive shaft coupling 1 2 Circlip 2 Refer to REMOVING THE MIDDLE DRIVE SHAFT and INSTALLING THE MIDDLE DRIVE SHAFT 3 Bearing 2 4 Universal joint 1 5 Universal joint yoke 1 6 Bearing housing 1 7 Shim Refer to SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS 8 Middle driven pinion gear 1 Refer to REMOVING THE MIDDLE DRIVE SHAFT and INSTALLING THE MIDDLE DRIVE SHAFT 9 Bearing retainer 1 ...

Page 208: ...4 77 ENG MIDDLE GEAR Order Job Part Q ty Remarks 10 Damper cam 1 11 Spring 1 12 Gear coupling 1 13 Bearing retainer 1 14 Middle drive shaft 1 For installation reverse the removal pro cedure ...

Page 209: ...Secure the middle drive pinion gear shaft in the vise with a clean rag 3 Remove middle drive pinion gear nut middle drive pinion gear shim s REMOVING THE MIDDLE DRIVE SHAFT 1 Remove drive shaft coupling nut 1 washer drive shaft coupling NOTE Use the coupling gear middle shaft tool 2 to hold the drive shaft coupling Coupling gear middle shaft tool P N YM 01229 90890 01229 1 2 ...

Page 210: ...move middle driven pinion gear nut 1 washer universal joint yoke NOTE Use the universal joint holder 2 to hold the universal joint yoke 4 Remove bearing housing assembly 1 a Clean the outside surface of the middle driven pinion gear b Place the middle driven pinion gear onto a hydraulic press CAUTION Never directly press the middle driven pinion gear end with a hydraulic press this will result in ...

Page 211: ...r bearing retainer has left handed threads To loosen the retainer turn it clockwise d Remove the bearing retainer and bearing 6 Remove bearing retainer 1 bearing NOTE Attach the ring nut wrench 2 CAUTION The middle drive shaft bearing retainer has left handed threads To loosen the retainer turn it clockwise Middle gear bearing retainer P N YM 04128 Bearing retainer wrench P N 90890 04128 Ring nut ...

Page 212: ...heck universal joint movement Roughness Replace universal joint SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS When the drive and driven gear bearing hous ing assembly and or crankcase replaced be sure to adjust the gear shims 1 and 2 1 Select middle drive pinion gear shim 1 middle driven pinion gear shim 2 a Position middle drive and driven pinion gear by using shims 1 and 2 with their respec t...

Page 213: ...f the bearing housing is marked 04 a is 10 54 2 b is 55 3 If the crankcase left is marked 66 03 c is 66 03 4 Therefore the shim thickness is 0 47 mm A 66 03 10 54 55 0 49 5 Round off hundredths digit and select appropriate shim s In the example above the calculated shim thickness is 0 49 mm The chart instructs you however to round off 9 to 10 Shims are supplied in the following thickness Middle dr...

Page 214: ...mal number on the left crankcase specifies a thick ness of 95 8 Example 1 If the bearing housing is marked 03 d is 76 03 2 If the driven pinion gear is marked 02 e is 59 02 3 If the driven pinion gear is marked 10 f is 79 40 4 If the crankcase left is marked 95 79 g is 95 79 5 Therefore the shim thickness is 0 57 mm B 76 03 59 02 79 40 95 79 0 05 0 57 6 Round off hundredths digit and select approp...

Page 215: ... 15 0 20 0 30 0 40 0 50 0 60 INSTALLING THE MIDDLE DRIVE SHAFT 1 Install bearing retainer 1 NOTE Attach the ring nut wrench 2 CAUTION The middle drive shaft bearing retainer has left handed threads To tighten the retainer turn it counterclockwise Ring nut wrench P N YM 38404 90890 01430 LT T R 80 Nm 8 0 m kg 58 ft lb ...

Page 216: ...etainer turn it counterclockwise 3 Install shims 1 bearing housing NOTE Install the shims so that the tabs are positioned as shown in the illustration Middle gear bearing retainer P N YM 04128 Bearing retainer wrench P N 90890 04128 T R Bearing retainer 110 Nm 11 0 m kg 80 ft lb LT 4 Install universal joint yoke washer middle driven pinion gear nut 1 NOTE Use the universal joint holder 2 to hold t...

Page 217: ...o all the way onto a bearing if a needle is out of place d Press each bearing into the universal joint using a suitable socket NOTE The bearing must be inserted far enough into the universal joint so that the circlip can be installed e Install the circlips 2 into the groove of each bearing 6 Install drive shaft coupling washer drive shaft coupling nut 1 NOTE Use the coupling gear middle shaft tool...

Page 218: ...sert it into the installation hole 1 of the speed sensor in the right crankcase to hold the middle driven pinion gear c Attach the gear lash measurement tool 3 and dial gauge 4 a 8 11 mm 0 32 in d Measure the gear lash while rotating the middle driven pinion gear back and forth NOTE Measure the gear lash at 4 positions Rotate the middle driven pinion gear 90 each time e If the gear lash is incorre...

Page 219: ...il cooler Refer to OIL COOLER Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Thermo switch 3 coupler 1 Disconnect 2 Coolant reservoir hose 1 Disconnect 3 Radiator fan breather hose 1 Disconnect 4 Radiator inlet hose 1 5 Radiator outlet hose 1 6 Water pump inlet hose 1 7 Coolant outlet hose 1 8 Radiator 1 9 Radiator fan 1 RADIATOR AND COOLANT RESERVOIR 5 ...

Page 220: ... COOL RADIATOR AND COOLANT RESERVOIR Order Job Part Q ty Remarks 10 Thermo switch 3 1 11 Coolant reservoir 1 12 Coolant reservoir breather hose 1 Disconnect For installation reverse the removal pro cedure ...

Page 221: ... cap opening pressure Below the specified pressure Replace the radiator cap a Attach the radiator cap tester 1 and adapter 2 onto the radiator cap 3 b Apply the specified pressure for ten sec onds and make sure that there is no drop in pressure 4 Check radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM in chapter 9 Radiator cap opening pressure 110 0 140 0 kPa 1 1 1 4...

Page 222: ...senger seat console Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Water pump outlet hose 1 2 Water pump outlet pipe 1 3 O ring 1 4 Water pump inlet hose 1 5 Water pump breather hose 1 6 Water pump assembly 1 7 O ring 1 For installation reverse the removal pro cedure ...

Page 223: ...ater pump Remove the parts in the order listed 1 Water pump housing cover 1 2 Gasket 1 3 Circlip 1 4 Impeller 1 5 Rubber damper holder 1 6 Rubber damper 1 7 Water pump seal 1 8 Oil seal 1 9 Bearing 1 0 Water pump housing 1 For assembly reverse the disassembly procedure ...

Page 224: ...the water pump seal from the outside of the water pump housing 2 Water pump housing 3 Remove bearing 1 oil seal 2 NOTE Tap out the bearing and oil seal from the inside of the water pump housing 3 Water pump housing CHECKING THE WATER PUMP 1 Check water pump housing cover 1 water pump housing 2 impeller 3 rubber damper 4 rubber damper holder 5 Cracks damage wear Replace 2 Check water pump outlet pi...

Page 225: ... socket 3 that matches its outside diameter New 2 Install water pump seal 1 into the water pump housing 2 NOTE Before installing the water pump seal 1 apply tap water or coolant onto its outer surface CAUTION Never lubricate the water pump seal sur face with oil or grease NOTE Install the water pump seal with the special tools È Push down Mechanical seal installer 3 P N YM 33221 A 90890 04078 Midd...

Page 226: ...ubber damper 1 rubber damper holder 2 NOTE Before installing the rubber damper apply tap water or coolant onto its outer surface CAUTION Make sure that the rubber damper and rub ber damper holder are flush with the impel ler New New ...

Page 227: ...he parts in the order listed Driver seat passenger seat console left side panel right side panel footrest cover Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Oil cooler inlet pipe 1 oil cooler outlet pipe 1 1 1 2 O ring 2 3 Oil cooler 1 4 Oil cooler inlet hose 1 5 Oil cooler outlet hose 1 6 Oil outlet hose 1 7 Oil inlet ho...

Page 228: ...New R 7 Nm 0 7 m kg 5 1 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib 1 2 2 3 4 6 7 8 4 5 Order Job Part Q ty Remarks 8 Oil cooler inlet pipe 2 oil cooler outlet pipe 2 1 1 For installation reverse the removal pro cedure ...

Page 229: ...1 Check oil cooler Obstruction Clean Apply compressed air to the rear of the oil cooler Damage Repair or replace the oil cooler NOTE Straighten any flattened fins with a thin flat head screwdriver 2 Check oil hoses oil pipes Cracks damage Replace ...

Page 230: ...parts in the order listed Driver seat passenger seat console right side panel right corner panel right protector passenger seat support Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 1 Vacuum hose 1 2 Fuel hose fuel tank to fuel pump 2 3 Fuel filter 1 4 Fuel hose fuel pump to carburetor 1 5 Fuel pump 1 6 Fuel tank breather hose 2 7 Rollover valve 1 8 Fuel tank stay 2 FUEL PUMP AND FUEL T...

Page 231: ...EL PUMP AND FUEL TANK 4 3 5 2 8 1 10 6 7 6 9 2 T R 30 Nm 3 0 m kg 22 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks 9 Fuel tank cap 1 10 Fuel tank 1 For installation reverse the removal pro cedure 6 ...

Page 232: ... ENCLOSURE HOOD AND CARGO BED in chapter 8 2 Place a container under the end of the fuel hose 1 1 3 Check fuel pump operation Suck on the end of the vacuum hose 1 4 Install right protector console passenger seat driver seat Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Fuel flows Fuel pump is OK Fuel does not flow Replace the fuel pump 1 ...

Page 233: ...ake duct console 1 Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 1 Cylinder head breather hose 1 Disconnect 2 Air filter case joint 1 3 Air filter case 1 4 Carburetor joint air filter case 1 5 Air vent hose 1 6 Starter cable starter plunger 1 1 7 Fuel hose 1 Disconnect 8 Carburetor heater connector 2 Disconnect 9 Carburetor assembly 1 10 Drain hose 1 11 Throttle valve cover 1 ...

Page 234: ...FUEL CARBURETOR 3 4 5 2 14 12 11 8 6 9 1 7 10 13 Order Job Part Q ty Remarks 12 Throttle cable end 1 13 Throttle cable 1 14 Carburetor joint intake manifold 1 For installation reverse the removal pro cedure ...

Page 235: ... NOTE Before disassembling the carburetor make sure to note the number of times the pilot screw is turned in from the set position to its seated position 1 Throttle stop screw 1 2 Vacuum chamber cover 1 3 Spring 1 4 Jet needle holder 1 5 Spring 1 6 Jet needle set 1 7 Piston valve 1 8 Coasting enricher diaphragm 1 ...

Page 236: ...1 0 Drain screw 1 A Float chamber 1 B Float 1 Refer to ASSEMBLING THE CARBURE TOR C Needle valve set 1 D Main jet 1 E Needle jet 1 Refer to ASSEMBLING THE CARBURE TOR F Pilot jet 1 G Starter jet 1 H Carburetor heater 1 For assembly reverse the disassembly procedure ...

Page 237: ...racks damage Replace fuel passage Contamination Clean as indicated fuel chamber body Contamination Clean a Wash the carburetor in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compressed air 2 Check float 1 float tang 2 Damage Replace 3 Check needle valve seat 1 needle valve 2 O ring 3 Contamination wear damage Replace as...

Page 238: ...acuum chamber cover 1 spring 2 Cracks damage Replace 6 Check diaphragm coasting enricher 1 spring 2 cover 3 Tears diaphragm damage Replace 7 Check jet needle 1 main jet 2 needle jet 3 pilot air jet 4 pilot jet 5 starter jet 6 starter plunger 7 Bends wear damage Replace Blockage Blow out the jets with com pressed air ...

Page 239: ...TION Before assembling wash all of the parts in a clean petroleum based solvent 1 Measure float height a Out of specification Adjust a Hold the carburetor in an upside down posi tion b Measure the distance from the front mating surface of the float chamber gasket removed to the top of the float NOTE The float arm should be resting on the needle valve but not compressing it c If the float height is...

Page 240: ...hamber line e Measure the fuel level a with the gauge f If the fuel level is incorrect adjust the fuel level g Remove the carburetor h Check the valve seat and needle valve i If either is worn replace them both j If both are fine adjust the float level by bending the float tang 4 slightly k Install the carburetor l Recheck the fuel level Fuel level 4 0 5 0 mm 0 16 0 20 in Above the float chamber m...

Page 241: ...tall carburetor assembly NOTE Align the tab a on the carburetor body with the slot b in the carburetor joint intake mani fold a b 2 Install air filter case joint NOTE Align the tab a on the air filter case joint with the slot b in the air filter case b a ...

Page 242: ...lunk from a shaft drive component or area 3 A locked up condition of the shaft drive train mechanism no power transmitted from the engine to the front and or rear wheel A Bearing damage B Improper gear lash C Gear tooth damage D Broken drive shaft E Broken gear teeth F Seizure due to lack of lubrication G Small foreign objects lodged between the moving parts Check notes 1 Investigate any unusual n...

Page 243: ...le and possible injury to the rider 2 Check drained oil Drained oil shows large amounts of metal particles Check the bearing for seizure NOTE A small amount of metal particles in the oil is normal 3 Check oil leakage a Clean the entire vehicle thoroughly then dry it b Apply a leak localizing compound or dry powder spray to the shaft drive c Road test the vehicle for the distance nec essary to loca...

Page 244: ...D BRAKE DISC in chapter 8 YES Check the front constant velocity joints Feel for bearing damage NO Constant velocity joint bearings and differen tial gear bearings are probably not damaged Repeat the test or remove the individual components YES NO Check the parking brake adjustment Adjust per instructions Refer to ADJUSTING THE PARKING BRAKE in chapter 3 YES Check the rear constant velocity joints ...

Page 245: ...nt constant veloc ity joints differential gear and front drive shaft Remove the parts in the order listed Front skid plate Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Differential gear oil Drain Steering knuckle Refer to STEERING SYSTEM in chap ter 8 Front lower arms Refer to FRONT ARMS AND FRONT SHOCK ABSORBERS in chapter 8 1 Constant velocity joint 2 2 Gear motor coupler 2 Disconnec...

Page 246: ...FERENTIAL GEAR AND FRONT DRIVE SHAFT LS LS LS 6 5 3 2 4 T R 55 Nm 5 5 m kg 40 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib 1 1 LS LS LS Order Job Part Q ty Remarks 5 Front drive shaft 1 6 Compression spring 1 For installation reverse the removal pro cedure ...

Page 247: ...bling the constant velocity joints Remove the parts in the order listed 1 Circlip 1 2 Boot band 2 Refer to ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS 3 Boot band 2 4 Dust boot 2 5 Circlip 1 6 Double off set joint 1 7 Circlip 1 8 Ball bearing 1 9 Joint shaft assembly 1 For assembly reverse the disassembly procedure ...

Page 248: ... 1 Gear motor O ring 1 1 NOTE Do not disassemble the gear motor 2 Circlip 2 Refer to DISASSEMBLING THE UNI VERSAL JOINT and ASSEMBLING THE UNIVERSAL JOINT 3 Bearing 2 4 Universal joint 1 5 Universal joint yoke O ring 1 1 6 Stopper bolt shaft 1 1 7 Shift fork with shift fork sliding gear 1 8 Differential gear case cover O ring 1 1 9 Drive clutch 1 0 Circlip bearing 1 1 A Adapter 1 ...

Page 249: ...ght Refer to MEASURING AND ADJUST ING THE DIFFERENTIAL GEAR LASH C Differential gear unit 1 D Shim left Refer to MEASURING AND ADJUST ING THE DIFFERENTIAL GEAR LASH E Bearing 1 F Bearing 1 G Circlip bearing 1 1 H Drive pinion gear 1 I Differential gear case 1 J Bearing 1 For assembly reverse the disassembly procedure ...

Page 250: ... may be necessary to lightly tap the yoke with a punch d Repeat the steps for the opposite bearing e Remove the yoke 2 Remove universal joint yoke Use a universal joint holder 1 Universal joint holder P N YM 04062 90890 04062 DISASSEMBLING THE DIFFERENTIAL GEAR 1 Remove differential gear unit 1 CAUTION The differential gear unit is assembled into a proper unit at the factory by means of specialize...

Page 251: ...ways use a new boot band 3 Check balls and ball races inner surface of double off set joint Pitting wear damage Replace CHECKING THE DIFFERENTIAL GEAR 1 Check gear teeth Pitting galling wear Replace drive pinion gear and differential gear unit as a set bearings Pitting damage Replace oil seals O rings Damage Replace 2 Check drive shaft splines universal joints drive pinion gear splines Wear damage...

Page 252: ...1 as shown in the illustra tions CAUTION Do not use a 12 V battery to operate the pinion gear Do not connect the batteries to the gear motor when it is installed in the gear case The gear motor should be checked when it is removed from the gear case È Check that the pinion gear 2 turns counter clockwise É Check that the pinion gear 2 turns clockwise NOTE Do not disassemble the gear motor È É ASSEM...

Page 253: ...h the boot bands 3 at the grooves in the joint shaft 3 Check free play thrust movement Excessive play Replace the joint assem bly Molybdenum disulfide grease 70 g 2 5 oz per dust boot front wheel side 45 g 1 6 oz per dust boot dif ferential gear case side New ASSEMBLING THE DIFFERENTIAL GEAR 1 Measure gear lash Refer to MEASURING AND ADJUSTING THE DIFFERENTIAL GEAR LASH 2 Install gear motor a Slid...

Page 254: ... motor on the differential gear case cover 8 so that the shift fork sliding gear 9 does not move CAUTION If the position of the shift fork sliding gear is moved the position of the differential gear and the indicator light display may dif fer and the 2WD or differential lock mode may not be activated d Remove the 8 mm bolts and then install the motor with the gear motor bolts T R Gear motor bolts ...

Page 255: ...the bearing 1 onto the yoke CAUTION Check each bearing The needles can eas ily fall out of their races Slide the yoke back and forth on the bearings the yoke will not go all the way onto a bearing if a needle is out of plate d Press each bearing into the universal joint using a suitable socket NOTE The bearing must be inserted far enough into the universal joint so that the circlip can be installe...

Page 256: ...ed 4 Attach gear lash measurement tool 1 dial gauge 2 a Measuring point is 21 mm 0 83 in 5 Measure gear lash Gently rotate the gear coupling from engagement to engagement NOTE Measure the gear lash at four positions Rotate the shaft 90 each time Gear lash measurement tool P N YM 01467 90890 01467 Differential gear lash 0 05 0 25 mm 0 002 0 010 in Adjusting the differential gear lash 1 Remove shim ...

Page 257: ...ferential gear lash exceeds the specifi cation increase the thickness of the right shim s by 0 1 mm 0 004 in and decrease the thickness of the left shim s by 0 1 mm 0 004 in b Measure the differential gear lash again Too little gear lash Reduce right shim thickness Too large gear lash Increase right shim thickness Ring gear shim left and right Thickness mm 0 1 0 5 0 2 1 0 0 3 1 5 0 4 CHECKING THE ...

Page 258: ... NOTE Repeat this step several times to obtain an average figure During this test the other front wheel will turn in the opposite direction 4 Out of specification Replace the differen tial gear assembly 5 Within specification Install the wheel cap T R Front wheel starting torque differential gear preload New unit 17 25 Nm 1 7 2 5 m kg 12 18 ft lb Minimum 10 Nm 1 0 m kg 7 2 ft lb ...

Page 259: ...nt velocity joints final drive gear and rear drive shaft Remove the parts in the order listed Rear skid plate Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Muffler exhaust pipe Refer to ENGINE REMOVAL in chapter 4 Final gear oil Drain Rear knuckle Refer to REAR KNUCKLES AND STA BILIZER in chapter 8 Rear lower arm Refer to REAR ARMS AND REAR SHOCK ABSORBERS in chapter 8 Brake caliper ass...

Page 260: ...OTE Remove the constant velocity joint on the right side of the vehicle rotate the final gear assembly slightly so that the con stant velocity joint on the left side clears the frame and then remove it 2 Final drive gear case breather hose 1 Disconnect 3 Final drive gear assembly 1 4 Compression spring 1 5 Coupling gear 1 6 Rear drive shaft 1 For installation reverse the removal pro cedure ...

Page 261: ...ng the rear constant velocity joints Remove the parts in the order listed 1 Circlip 1 2 Boot band 2 Refer to ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS 3 Boot band 2 4 Dust boot 2 5 Circlip 1 6 Double off set joint 1 7 Circlip 1 8 Ball bearing 1 9 Joint shaft assembly 1 For assembly reverse the disassembly procedure ...

Page 262: ...o REAR WHEELS AND BRAKE DISC in chapter 8 1 Bolt 4 2 Final drive pinion gear shim Refer to POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR 3 Drive shaft coupling 1 Refer to DISASSEMBLING THE FINAL DRIVE GEAR and ASSEM BLING THE FINAL DRIVE GEAR ASSEMBLY 4 Final drive pinion gear 1 5 Inner race 1 6 Oil seal 1 7 Bearing retainer 1 8 Bearing 1 9 O ring 1 0 Final drive pinion gear bearing housin...

Page 263: ... 2 NOTE Working in a crisscross pattern loosen each bolt 1 4 of a turn After all the bolts are loosened remove them C Bolt 6 D Oil seal 1 E Bearing 1 F O ring 1 G Ring gear bearing housing 1 H Ring gear shim Refer to POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR I Ring gear 1 J Thrust washer 1 K Oil seal 1 L Final gear case 1 ...

Page 264: ...NTS FINAL DRIVE GEAR AND REAR DRIVE SHAFT Order Job Part Q ty Remarks M Bearing 1 Refer to REMOVING THE FINAL DRIVE ROLLER BEARINGS and INSTALLING THE FINAL DRIVE ROLLER BEARINGS N Bearing 1 For assembly reverse the disassembly procedure ...

Page 265: ...bands NOTE The new boot bands may differ from the orig inal ones The dust boots should be fastened with the boot bands 3 at the grooves in the joint shaft Molybdenum disulfide grease 70 g 2 5 oz per dust boot rear wheel side 65 g 2 3 oz per dust boot final gear case side New 3 Check free play thrust movement Excessive play Replace the joint assem bly DISASSEMBLING THE FINAL DRIVE GEAR 1 Remove dri...

Page 266: ...2 on the gear end to protect the thread from damage c Press the gear end and remove the bearing housing assembly 3 Remove bearing retainer a Place a folded rag 1 b Secure the final drive pinion gear bearing housing edge in the vise c Attach the bearing retainer wrench 2 d Remove the bearing retainer CAUTION The bearing retainer has left handed threads To loosen the retainer turn it clockwise Beari...

Page 267: ...L DRIVE ROLLER BEARINGS 1 Install roller bearing final drive pinion gear a Heat the main housing only to 150 C 302 F b Install the roller bearing outer race using the proper adapter c Install the inner race onto the drive pinion gear 2 Install roller bearing ring gear 1 Use a suitable press tool 2 and a press to install the above components into the main housing New POSITIONING THE FINAL DRIVE PIN...

Page 268: ...sually a decimal number on the final gear case either added to or sub tracted from 112 Example 1 a 92 5 2 If 98 is stamped on the final drive pinion gear bearing housing b 34 0 98 34 98 3 If 48 is stamped on the final drive pinion gear bearing housing c 55 0 48 55 48 4 If 03 is stamped on the final gear case d 112 0 03 112 03 5 Therefore A is 0 97 A 92 5 55 48 34 98 112 03 0 97 6 Round off the hun...

Page 269: ...acted from 50 f a numeral usually a decimal number on the outside of the ring gear bearing hous ing and added to 1 g a numeral usually a decimal number on the inside of the ring gear either added to or subtracted from 35 h bearing thickness considered constant Example 1 If 98 is stamped on the final gear case e 50 0 98 50 98 2 If 55 is stamped on the ring gear bearing housing f 1 0 55 1 55 3 If 05...

Page 270: ...he thrust washer 1 Measure ring gear thrust clearance C a Place four pieces of Plastigauge between the originally fitted thrust washer and the ring gear b Install the final gear assembly and tighten the bolts to specification NOTE Do not turn the drive pinion gear and ring gear when measuring the clearance with Plasti gauge Hundredths Rounded value 0 1 2 0 3 4 5 6 7 5 8 9 10 Ring gear shim Thickne...

Page 271: ...t b Repeat the measurement steps until the ring gear thrust clearance is within the specified limits Ring gear thrust clearance 0 1 0 2 mm 0 004 0 008 in Thrust washer Thickness mm 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 Adjusting the ring gear stopper 1 Install ring gear stopper nut 2 Adjust ring gear stopper clearance a Finger tighten the ring gear stopper 1 until it contacts the ring ge...

Page 272: ... and or the ring gear bearing housing are replaced be sure to adjust the shim of the final drive pinion gear and or ring gear 2 Check gear teeth Pitting galling wear Replace the drive pinion gear and ring gear as a set oil seals O rings Damage Replace 3 Check bearings Damage Replace NOTE Reusing roller bearings is acceptable but Yamaha recommends installing new ones Do not reuse the oil seal When ...

Page 273: ... size 1 into the drain plug hole CAUTION Finger tighten the bolt until it holds the ring gear Otherwise the ring gear will be dam aged 4 Attach gear lash measurement tool 1 dial gauge 2 a Measuring point is 31 1 mm 1 22 in Gear lash measurement tool P N YM 01467 90890 01467 5 Measure gear lash Gently rotate the gear coupling from engagement to engagement NOTE Measure the gear lash at four position...

Page 274: ...kness by 0 2 mm 0 008 in for every 0 2 mm of ring gear shim increase c If reduced by more than 0 2 mm 0 008 in Increase the thrust washer thickness by 0 2 mm 0 008 in for every 0 2 mm that the ring gear shim is decreased Too little gear lash Reduce shim thickness Too large gear lash Increase shim thickness Ring gear shim Thickness mm 0 25 0 30 0 35 0 40 0 45 0 50 Thrust washer Thickness mm 1 0 1 1...

Page 275: ... 3 m kg 17 ft lb T R 40 Nm 4 0 m kg 29 ft lb 3 Install bearing retainer a Place a folded rag 1 b Secure the final drive pinion gear bearing housing edge in a vise NOTE Apply locking agent LOCTITE to the threads of bearing retainer c Attach the bearing retainer wrench 2 d Tighten the bearing retainer CAUTION The bearing retainer has left hand threads Turn the retainer counterclockwise to tighten it...

Page 276: ...rag 1 b Secure the drive shaft coupling edge in the vise c Tighten the drive shaft coupling nut 5 Check final drive gear operation Unsmooth operation Replace the final drive gear assembly Insert the double off set joint into the final drive gear and turn the gear back and forth T R Drive shaft coupling nut 80 Nm 8 0 m kg 58 ft lb ...

Page 277: ... Nm 5 9 m kg 43 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the front guard and hood Remove the parts in the order listed 1 Front guard protector 1 2 Front guard 1 3 Headlight coupler 2 Disconnect 4 Hood 1 For installation reverse the removal pro cedure SEATS ENCLOSURE HOOD AND CARGO BED 8 ...

Page 278: ...emoving the seats console and instrument panels Remove the parts in the order listed 1 Driver seat 1 2 Passenger seat 1 3 Air intake duct 1 4 Console 1 5 Steering wheel cover 1 6 Steering wheel 1 7 Pedal cover 1 8 Light switch coupler 1 Disconnect 9 Main switch coupler 1 Disconnect 10 On Command four wheel drive switch and differential gear lock switch 2 Disconnect 11 Indicator warning light coupl...

Page 279: ... 13 10 11 9 8 12 3 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib Order Job Part Q ty Remarks 12 Auxiliary DC jack connector 2 Disconnect 13 Nut starter cable 1 1 14 Upper instrument panel 1 15 Lower instrument panel 1 For installation reverse the removal pro cedure ...

Page 280: ...0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the panels and footrest cover Remove the parts in the order listed 1 Left side panel 1 2 Right side panel 1 3 Left corner panel 1 4 Right corner panel 1 5 Left protector 1 1 6 Right protector 1 1 7 Footrest cover 1 8 Driver seat support 1 9 Passenger seat support 1 For installation reverse the removal pro cedure ...

Page 281: ...11 ft Ib R 16 Nm 1 6 m kg 11 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the cargo bed Remove the parts in the order listed 1 Tail brake light connector 6 Disconnect 2 Gas spring assembly 2 3 Pin 2 4 Cargo bed assembly 1 For installation reverse the removal pro cedure ...

Page 282: ... ft Ib R 7 Nm 0 7 m kg 5 1 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib Order Job Part Q ty Remarks Disassembling the cargo bed Remove the parts in the order listed 1 Cargo bed mat 1 2 Tailgate cable 2 3 Hinge cover 2 4 Tailgate 1 5 Cargo bed panel 2 6 Tail brake light bulb holder 2 7 Cargo bed release lever 1 8 Cargo hook 4 9 Cargo bed 1 For assembly reverse the disassembly procedure ...

Page 283: ...RGO BED SKID PLATES T R 7 Nm 0 7 m kg 5 1 ft Ib 2 1 7 7 7 7 Order Job Part Q ty Remarks Removing the skid plates Remove the parts in the order listed 1 Front skid plate 1 2 Rear skid plate 1 For installation reverse the removal pro cedure ...

Page 284: ...SURE HOOD AND CARGO BED INSTALLING THE REAR SKID PLATE 1 Install rear skid plate 1 NOTE Make sure that the hole a in the rear skid plate is towards the left side of the vehicle È Forward É Left side Ê Right side È É Ê 1 a ...

Page 285: ... 43 ft Ib 6 1 2 3 5 7 4 8 4 8 4 8 R 59 Nm 5 9 m kg 43 ft Ib 7 Order Job Part Q ty Remarks Removing the enclosure and seat belts Remove the parts in the order listed 1 Front top frame 1 2 Rear top frame 1 3 Left support frame 1 4 Right support frame 1 5 Left side frame 1 6 Right side frame 1 7 Seat belt 2 8 Buckle 2 For installation reverse the removal pro cedure ...

Page 286: ...40 ft Ib T R 350 Nm 35 0 m kg 255 ft lb Order Job Part Q ty Remarks Removing the front wheels Remove the parts in the order listed Place the vehicle on a level surface WARNING Securely support the vehicle so there is no danger of it falling over 1 Front wheel 1 Refer to INSTALLING THE FRONT WHEELS 2 Center cap 1 3 Axle nut 1 Refer to INSTALLING THE FRONT WHEEL HUBS ...

Page 287: ...T R 55 Nm 5 5 m kg 40 ft Ib T R 350 Nm 35 0 m kg 255 ft lb Order Job Part Q ty Remarks 4 Brake caliper assembly 1 NOTE Do not depress the brake pedal when the brake caliper is off of the brake disc as the brake pads will be forced shut 5 Front wheel hub 1 6 Brake disc 1 For installation reverse the removal pro cedure ...

Page 288: ...ce Out of balance Adjust WARNING After replacing the tire ride conservatively to allow the tire to be properly seated in the rim Failure to do so may cause an accident resulting in vehicle damage and possible injury Wheel runout limit Radial 2 2 0 mm 0 08 in Lateral 3 2 0 mm 0 08 in CHECKING THE FRONT WHEEL HUBS 1 Check wheel hub 1 Cracks damage Replace splines wheel hub 2 Wear damage Replace 1 2 ...

Page 289: ... minimum thickness 3 0 mm 0 12 in INSTALLING THE FRONT WHEEL HUBS 1 Install axle nut NOTE Do not apply oil to the seat of the nut After tightening the nut stake the collar of the nut into the notch of the shaft New T R 350 Nm 35 0 m kg 255 ft lb INSTALLING THE FRONT WHEELS 1 Install wheel NOTE The arrow mark 1 on the tire must point in the direction of rotation È of the wheel 2 Tighten wheel nuts ...

Page 290: ...emarks Removing the rear wheels Remove the parts in the order listed Place the vehicle on a level surface WARNING Securely support the vehicle so there is no danger of it falling over 1 Rear wheel 1 Refer to INSTALLING THE REAR WHEELS 2 Center cap 1 3 Axle nut 1 Refer to INSTALLING THE REAR WHEEL HUBS 4 Rear wheel hub 1 For installation reverse the removal pro cedure ...

Page 291: ...ty Remarks Removing the rear brake disc Remove the parts in the order listed Brake caliper assembly Refer to FRONT AND REAR BRAKES Final drive gear Refer to REAR CONSTANT VELOCITY JOINTS FINAL DRIVE GEAR AND REAR DRIVE SHAFT in chapter 7 1 Rear brake disc 1 For installation reverse the removal pro cedure ...

Page 292: ...alance Adjust Wheel runout limit Radial 2 0 mm 0 08 in Lateral 2 0 mm 0 08 in CHECKING THE REAR WHEEL HUBS 1 Check wheel hub 1 Cracks damage Replace splines wheel hub 2 Wear damage Replace 1 2 CHECKING THE REAR BRAKE DISC 1 Check brake disc Galling damage Replace 2 Measure brake disc deflection Out of specification Replace brake disc thickness a Out of specification Replace Brake disc maximum defl...

Page 293: ...SC INSTALLING THE REAR WHEEL HUBS 1 Install axle nut Refer to INSTALLING THE FRONT WHEEL HUBS New INSTALLING THE REAR WHEELS 1 Install wheel Refer to INSTALLING THE FRONT WHEELS 2 Tighten wheel nuts Refer to INSTALLING THE FRONT WHEELS ...

Page 294: ...3 ft Ib Order Job Part Q ty Remarks Removing the front brake pads Remove the parts in the order listed Front wheel Refer to FRONT WHEELS AND BRAKE DISCS 1 Brake caliper mounting bolt 2 Refer to REPLACING THE FRONT BRAKE PADS 2 Brake pad holding bolt 2 3 Brake pad 2 4 Pad spring 1 For installation reverse the removal pro cedure ...

Page 295: ...brake pads Remove the parts in the order listed Rear skid plate Refer to SEATS ENCLOSURE HOOD AND CARGO BED 1 Spring 1 Refer to REPLACING THE REAR BRAKE PADS 2 Parking brake cable 1 3 Brake caliper mounting bolt 2 4 Brake pad holding bolt 2 5 Brake pad piston side 1 6 Brake pad 1 7 Insulator pad shim 2 2 8 Pad spring 1 For installation reverse the removal pro cedure ...

Page 296: ...ay cause eye injury splash brake fluid onto painted surfaces or plastic parts as this may cause dam age disconnect any hydraulic connection as this would require the entire brake sys tem to be disassembled drained cleaned properly filled and bled after reassembly REPLACING THE FRONT BRAKE PADS NOTE It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads 1 Meas...

Page 297: ...e brake caliper bleed screw d Install the retaining bolts and brake caliper 3 Check brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 4 Check brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 T R Brake caliper bleed screw 6 Nm 0 6 m kg 4 3 ft lb T R Brake pad holding bolt 18 Nm 1 8 m kg 13 ft lb Brake ...

Page 298: ... container b Loosen the brake caliper bleed screw and then turn the brake caliper piston 3 clock wise until section a of the brake caliper pis ton is level with the surface of the brake caliper body NOTE Align an end b of the groove in the brake cali per piston with the punch mark c on the brake caliper body c Tighten the brake caliper bleed screw d Install new brake pads new insulators new brake ...

Page 299: ...bolts 3 Check brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 4 Check brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 T R Brake pad holding bolt 17 Nm 1 7 m kg 12 ft lb Brake caliper mounting bolt 40 Nm 4 0 m kg 29 ft lb ...

Page 300: ... Removing the brake master cylinder Remove the parts in the order listed Brake fluid Drain 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm 1 3 Brake fluid reservoir float 1 4 Union bolt 1 Refer to INSTALLING THE BRAKE MASTER CYLINDER 5 Copper washer 2 6 Brake hose 1 Disconnect 7 Brake pipe 1 Disconnect 8 Brake master cylinder 1 For installation reverse the removal pro cedure ...

Page 301: ...ing the brake master cyl inder Remove the parts in the order listed 1 Dust boot 1 Refer to ASSEMBLING THE BRAKE MASTER CYLINDER 2 Circlip 1 3 Primary brake master cylinder kit 1 4 Secondary brake master cylinder kit stopper 1 5 Gasket 1 6 Secondary brake master cylinder kit 1 For assembly reverse the disassembly procedure ...

Page 302: ...e master cylinder kit Scratches wear damage Replace as a set È Primary brake master cylinder kit É Secondary brake master cylinder kit 1 È É 3 Check brake fluid reservoir 1 brake fluid reservoir diaphragm 2 Cracks damage Replace 2 1 EB702060 ASSEMBLING THE BRAKE MASTER CYLINDER WARNING All internal brake components should be cleaned and lubricated with new brake fluid only before installation When...

Page 303: ...s Always clean up spilled brake fluid immediately WARNING Use only the designated quality brake fluid other brake fluids may deteriorate the rubber seals causing leakage and poor brake performance Refill with the same type of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor brake performance Be careful that water does not enter the brake master cylinder w...

Page 304: ... to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level Brake fluid level is under the MIN level line Fill up Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 6 Adjust brake pedal free play Refer to ADJUSTING THE BRAKE PEDAL in chapter 3 ...

Page 305: ... in the order listed Brake fluid Drain Front wheel Refer to FRONT WHEELS AND BRAKE DISCS 1 Union bolt 1 Refer to INSTALLING THE FRONT BRAKE CALIPERS 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Brake pad holding bolt 2 Loosen 5 Brake caliper mounting bolt 2 6 Brake caliper assembly 1 For installation reverse the removal pro cedure ...

Page 306: ...ing the front brake cali pers Remove the parts in the order listed 1 Brake pad holding bolt 2 2 Brake pad 2 3 Pad spring 1 4 Caliper bracket 1 5 Brake caliper piston 2 Refer to DISASSEMBLING THE FRONT BRAKE CALIPERS and ASSEMBLING THE FRONT BRAKE CALIPERS 6 Dust seal 2 7 Caliper piston seal 2 8 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 307: ...7 8 9 10 New Order Job Part Q ty Remarks Removing the rear brake caliper Remove the parts in the order listed Rear skid plate Refer to SEATS ENCLOSURE HOOD AND CARGO BED Brake fluid Drain 1 Parking brake switch coupler 1 Disconnect 2 Spring 1 3 Parking brake cable 1 4 Parking brake lever assembly mount ing bolt 1 5 Parking brake lever assembly 1 ...

Page 308: ... R 7 Nm 0 7 m kg 5 1 ft Ib 1 2 3 4 5 6 7 8 9 10 New Order Job Part Q ty Remarks 6 Union bolt 1 Refer to INSTALLING THE REAR BRAKE CALI PER 7 Copper washer 2 8 Brake hose 1 Disconnect 9 Brake caliper mounting bolt 2 10 Brake caliper assembly 1 For installation reverse the removal pro cedure ...

Page 309: ... Remarks Disassembling the rear brake cali per Remove the parts in the order listed 1 Brake pad holding bolt 2 Refer to ASSEMBLING THE REAR BRAKE CALIPER 2 Brake pad piston side 1 3 Brake pad 1 4 Insulator pad shim 2 2 5 Pad spring 1 6 Brake caliper bracket 1 7 Parking brake arm nut 1 Refer to ASSEMBLING THE REAR BRAKE CALIPER 8 Parking brake arm 1 9 Set bolt 1 0 Parking brake arm shaft 1 A Parkin...

Page 310: ... 4 New New LT T R 9 Nm 0 9 m kg 6 5 ft Ib Order Job Part Q ty Remarks B Parking brake case 1 Refer to ASSEMBLING THE REAR BRAKE CALIPER C Gasket 1 D Brake caliper piston 1 Refer to DISASSEMBLING THE FRONT BRAKE CALIPERS and ASSEMBLING THE REAR BRAKE CALIPER E Dust seal 1 F Caliper piston seal 1 G Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 311: ... force out the caliper piston from the brake caliper body WARNING _ Never try to pry out a caliper piston Cover the caliper piston with a rag Be careful not to get injured when the piston is expelled from the caliper cylinder b Remove the dust seals and caliper piston seals DISASSEMBLING THE REAR BRAKE CALIPER 1 Remove brake caliper piston 1 dust seal 2 caliper piston seal 3 a Turn the brake calip...

Page 312: ...e caliper cylinders 2 Wear scratches Replace the brake cali per assembly brake caliper body 3 Cracks damage Replace brake fluid delivery passage brake caliper body Blockage Blow out with compressed air WARNING Replace the caliper piston seals and dust seals whenever a brake caliper is disas sembled È Front É Rear Recommended brake component replacement schedule Brake pads As required Piston seals ...

Page 313: ...rs WARNING _ All internal brake components should be cleaned and lubricated with new brake fluid only before installation Replace the caliper piston seals and dust seals whenever a brake caliper is disas sembled Recommended brake fluid DOT 4 1 Install caliper piston seals 1 dust seals 2 1 2 New New New New 2 Install brake caliper pistons 1 1 ...

Page 314: ...ll caliper piston seal 1 dust seal 2 Recommended brake fluid DOT 4 New New 1 2 New New 2 Install brake caliper piston 1 Turn the brake caliper piston clockwise until section a of the brake caliper piston is level with the surface of the brake caliper body NOTE Align an end b of the groove in the brake cali per piston with the punch mark c on the brake caliper body 1 a b c 1 1 3 Install gasket 1 pa...

Page 315: ... brake arm shaft is screwed in completely remove the parking brake arm shaft and screw it in from a different starting position b Turn the parking brake arm shaft approxi mately 60 clockwise c Install the parking brake arm to the parking brake arm shaft so that the punch mark c on the parking brake arm is aligned with the punch mark a on the parking brake arm shaft d Turn the parking brake arm unt...

Page 316: ...n bolt 3 CAUTION _ When installing the brake hose on the brake caliper make sure that the brake pipe touches the projection a on the brake caliper WARNING _ Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING in chapter 2 2 Fill brake reservoir CAUTION _ Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediate...

Page 317: ... in vapor lock 3 Air bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 4 Check brake fluid level Brake fluid level is below the MIN level line Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 EBS00436 INSTALLING THE REAR BRAKE CALIPER 1 Install brake caliper assembly brake caliper mounting bolts brake hose 1 copper ...

Page 318: ...ul chemical reaction and lead to poor brake performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 3 Air bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 4 Check brake fluid level Brake fluid level is below the MIN level line Add the recommended ...

Page 319: ...ring wheel pedal cover upper instrument panel lower instrument panel Refer to SEATS ENCLOSURE HOOD AND CARGO BED Steering joint Refer to STEERING SYSTEM Brake master cylinder Refer to FRONT AND REAR BRAKES 1 Splash plate 1 2 Brake light switch coupler 1 Disconnect 3 Brake switch 1 4 Throttle cable 1 Disconnect 5 Pin 1 6 Brake pedal rod 1 7 Pedal assembly 1 For installation reverse the removal pro ...

Page 320: ...t Q ty Remarks Disassembling the pedal assembly Remove the parts in the order listed 1 Spring 1 2 Circlip 1 3 Washer 2 4 Brake pedal 1 5 Spring 1 6 Circlip 1 7 Washer 2 8 Accelerator pedal 1 9 Pedal assembly bracket 1 For assembly reverse the disassembly procedure ...

Page 321: ... 39 Nm 3 9 m kg 28 ft Ib Order Job Part Q ty Remarks Removing the steering column and steering assembly Remove the parts in the order listed Steering wheel cover steering wheel upper instrument panel lower instru ment panel Refer to SEATS ENCLOSURE HOOD AND CARGO BED 1 Steering shaft 1 2 Steering joint 1 3 Steering assembly 1 For installation reverse the removal pro cedure ...

Page 322: ...g assem bly Remove the parts in the order listed 1 Tie rod end locknut 2 Refer to ASSEMBLING THE STEER ING ASSEMBLY 2 Tie rod end 2 3 Plastic locking tie 2 4 Dust boot 2 5 Adjuster 1 6 Spring 1 7 Pressure pad 1 8 Oil seal 1 9 Circlip 1 0 Pinion gear 1 Refer to DISASSEMBLING THE STEERING ASSEMBLY and ASSEM BLING THE STEERING ASSEMBLY A Circlip 1 B Bearing 1 ...

Page 323: ...YSTEM 2 4 3 1 8 9 A B 7 6 5 C 2 4 1 3 New New New T R 40 Nm 4 0 m kg 29 ft Ib 0 LS Order Job Part Q ty Remarks C Steering assembly 1 Refer to ASSEMBLING THE STEERING ASSEMBLY For assembly reverse the disassembly procedure ...

Page 324: ...T 1 Check steering joint Rough movement Replace CHECKING THE STEERING ASSEMBLY 1 Check pinion gear bearing Check the bearing movement on the pinion gear by rotating with the fingers Roughness Replace 2 Check pinion needle bearing 1 Damage Replace NOTE When replacing the pinion needle bearing it is recommended to replace the steering assem bly The steering housing may be subject to damage during re...

Page 325: ...ay indicate improper adjustment or lack of lubrication 1 2 4 Check pressure pad 1 Wear damage Replace dust boots 2 Damage Replace 1 2 5 Check tie rod free play and movement Free play Replace the tie rod end Turns roughly Replace the tie rod end 6 Check tie rods Bends damage Replace ASSEMBLING THE STEERING ASSEMBLY 1 Lubricate bearing rack gear pinion gear oil seal Recommended lubricant Lithium soa...

Page 326: ...3 Apply lithium soap based grease to the gear surface of the rack gear Lithium soap based grease 5 10 g 0 2 0 4 oz New a 4 Adjust rack gear pinion gear backlash a Install the force pressure pad spring and adjuster b Tighten the adjuster 1 c Loosen the adjuster 15 25 5 Install dust boots plastic locking tie tie rod end tie rod end locknut T R Adjuster 3 9 Nm 0 39 m kg 2 8 ft lb LOCTITE 15 25 1 New ...

Page 327: ...Ib Order Job Part Q ty Remarks Removing the tie rods and steering knuckles Remove the parts in the order listed Front wheel brake disc Refer to FRONT WHEELS AND BRAKE DISCS 1 Tie rod 1 2 Brake disc guard 1 3 Nut 2 4 O ring 1 5 Brake hose holder bolt 1 6 Steering knuckle 1 Refer to REMOVING THE STEERING KNUCKLES 7 Circlip 1 8 Ball joint 1 9 Rubber boot 1 For installation reverse the removal pro ced...

Page 328: ...rod end Turns roughly Replace the tie rod end 2 Check tie rods Bends damage Replace the steering assembly CHECKING THE STEERING KNUCKLES 1 Check steering knuckles Damage pitting Replace 2 Check ball joints Damage pitting Replace the ball joint Free play Replace the ball joint Turns roughly Replace the ball joint a Clean the outside of the steering knuckle b Remove the steering knuckle oil seal c R...

Page 329: ...rt bolt 5 to remove the ball joint A from the steering knuckle f Remove the ball joint remover installer Ball joint remover installer set P N 90890 01474 Ball joint adapter set P N YM 01474 Ball joint remover installer attach ment set P N YM 01477 3 Body YM 01474 90890 01474 4 Long bolt YM 01474 90890 01474 5 Short bolt YM 01477 6 Remover washer YM 01477 7 Remover spacer YM 01477 8 Installer attac...

Page 330: ...E Always use a new ball joint set m Install a steering knuckle oil seal 3 Check front wheel bearings Bearings allow play in the wheel hubs or the wheel turns roughly Replace oil seals Damage Replace a Clean the outside of the steering knuckle b Remove the oil seals 1 c Drive out the bearings 2 WARNING Eye protection is recommended when using striking tools d Remove the spacer 3 e Apply lithium bas...

Page 331: ...8 55 CHAS STEERING SYSTEM h Install the new oil seals NOTE When installing the oil seals the seal side of the oil seal faces out ...

Page 332: ...2 LS LS 8 12 9 5 Order Job Part Q ty Remarks Removing the front arms and front shock absorbers Remove the parts in the order listed Front wheel brake disc Refer to FRONT WHEELS AND BRAKE DISCS 1 Brake disc guard 1 2 Front arm protector 1 3 Nut 2 Refer to REMOVING THE FRONT ARMS and INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORB ERS 4 Bolt nut 2 2 5 Front lower arm bushing washer 1 2 1 6 Nut bolt...

Page 333: ... New 4 LS 8 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 45 Nm 4 5 m kg 32 ft Ib 3 2 LS LS 8 12 9 5 Order Job Part Q ty Remarks 10 Circlip 1 11 Ball joint 1 12 Rubber boot 1 For installation reverse the removal pro cedure ...

Page 334: ...and down If the vertical movement is tight or rough or if there is binding check the bushings 2 Remove front arms CHECKING THE FRONT ARMS 1 Check front arms Bends damage Replace 2 Check bushings Wear damage Replace 3 Check ball joint Damage pitting Replace the ball joint Free play Replace the ball joint Turns roughly Replace the ball joint a Clean the outside of the front upper arm b Remove the ci...

Page 335: ...embled ball joint remover installer new ball joint A and installer attachment 7 to the front upper arm B NOTE Do not tap or damage the top of the ball joint h Hold the body 3 in place while turning in the long bolt 4 to install the new ball joint A into the front upper arm B i Remove the ball joint remover installer Ball joint remover installer set P N 90890 01474 Ball joint adapter set P N YM 014...

Page 336: ...ubber boot and new circlip NOTE Always use a new ball joint set CHECKING THE FRONT SHOCK ABSORBERS 1 Check shock absorber rod Bends damage Replace the shock absorber assembly shock absorber assembly Oil leaks Replace the shock absorber assembly spring Fatigue Replace the shock absorber assembly Move the spring up and down ...

Page 337: ...hium soap based grease Be sure to position the bolts 3 so that the bolt head faces outward Temporarily tighten the nuts 4 b Install the front shock absorber 5 NOTE Be sure to position the bolts 6 so that the bolt head faces forward c Install the ball joints d Install the new cotter pins e Tighten the nuts 4 T R Nut 7 45 Nm 4 5 m kg 32 ft lb T R Nut 8 30 Nm 3 0 m kg 22 ft lb T R Nut 4 45 Nm 4 5 m k...

Page 338: ...kg 40 ft Ib T R 32 Nm 3 2m kg 23 ft Ib LS Order Job Part Q ty Remarks Removing the rear knuckles and sta bilizer Remove the parts in the order listed Rear wheel hubs Refer to REAR WHEELS AND BRAKE DISC 1 O ring 1 2 Rear knuckle 1 3 Spacer cover 4 4 Spacer 2 5 Stabilizer joint 2 6 Stabilizer holder 2 7 Bushing 2 8 Stabilizer 1 For installation reverse the removal pro cedure ...

Page 339: ...NG Eye protection is recommended when using striking tools d Remove the spacer 3 e Apply lithium base grease to the bearings and oil seals f Install the spacer to the rear knuckle g Install the new bearings NOTE Install the outside bearing first CAUTION Do not strike the center race or balls of the bearing Contact should be made only with the outer race h Install a new oil seal NOTE When installin...

Page 340: ...NSTALLING THE STABILIZER 1 Install stabilizer 1 bushing 2 stabilizer holder 3 NOTE Install the bushing with its slit a facing rear ward È Forward 3 a 2 1 È T R 32 Nm 3 2 m kg 23 ft lb REAR KNUCKLES AND STABILIZER ...

Page 341: ... LS LS LS 1 Order Job Part Q ty Remarks Removing the rear arms and rear shock absorbers Remove the parts in the order listed Rear knuckle stabilizer Refer to REAR KNUCKLES AND STABI LIZER 1 Nut bolt 2 2 Refer to INSTALLING THE REAR ARMS AND REAR SHOCK ABSORB ERS 2 Rear upper arm bushing 1 2 3 Nut bolt 2 2 4 Rear shock absorber 1 5 Nut bolt 2 2 6 Rear lower arm bushing 1 2 For installation reverse ...

Page 342: ...ace 2 Check bushings 2 Wear damage Replace 1 2 2 CHECKING THE REAR SHOCK ABSORBERS 1 Check shock absorber rod Bends damage Replace the shock absorber assembly shock absorber assembly Oil leaks Replace the shock absorber assembly spring Move the spring up and down Fatigue Replace the shock absorber assembly ...

Page 343: ... sure to position the bolts 3 so that the bolt head faces inward Temporarily tighten the nuts 4 b Install the rear shock absorber 5 NOTE Be sure to position the bolts 6 so that the bolt head faces backward c Install the rear knuckle NOTE Be sure to position the bolts 8 so that the bolt head faces forward d Tighten the nuts 4 T R Nut 7 45 Nm 4 5 m kg 32 ft lb T R Nut 9 45 Nm 4 5 m kg 32 ft lb T R N...

Page 344: ...tor 5 Carburetor heater 6 Thermo switch 1 7 Ignition coil 8 Low range switch 9 High range switch 0 Neutral switch A Reverse switch B Parking brake switch C Brake light switch D Pickup coil stator assembly E Speed sensor F Gear motor G Radiator fan H Thermo switch 3 5 6 7 4 9 8 0 A B C 1 D E F G H 2 3 ELECTRICAL COMPONENTS ...

Page 345: ...ve switch and differ ential gear lock switch 6 Main switch 7 Light switch 8 Four wheel drive relay 1 9 Four wheel drive relay 2 0 Starter relay A Main fuse B Four wheel drive relay 3 C Four wheel drive indicator light relay D Headlight relay E Differential gear lock indicator light relay F Fuse box G C D I unit H Battery H F G E A 0 C B 1 2 3 4 5 6 7 8 9 D 9 ...

Page 346: ... on and off a few times when checking it Pocket tester P N YU 03112 C 90890 03112 CHECKING A SWITCH SHOWN IN THE MANUAL The terminal connections for switches main switch light switch etc are shown in a chart similar to the one on the left This chart shows the switch positions in the column and the switch lead colors in the top row For each switch position indicates the terminals with continuity Th...

Page 347: ...9 4 ELEC CHECKING THE SWITCHES ...

Page 348: ...ECKING THE SWITCHES CHECKING THE SWITCH CONTINUITY Refer to CHECKING THE SWITCHES and check for continuity between lead terminals Poor connection no continuity Correct or replace The coupler locations are circled ...

Page 349: ... Brake light switch 3 On Command four wheel drive switch and differential gear lock switch 4 Main switch 5 Light switch 6 Parking brake switch 7 Reverse switch 8 Neutral switch 9 High range switch 0 Low range switch A Four wheel drive switch ...

Page 350: ...shown in the illustration on the left Bulbs A and B are used for headlights and usually use a bulb holder which must be detached before removing the bulb The majority of these bulbs can be removed from their respective socket by turning them coun terclockwise Bulb C is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counter clockwise Bu...

Page 351: ...ss the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bulb for continuity with the pocket tester No continuity Replace NOTE Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the tester lead to terminal 1 and the tester lead t...

Page 352: ...ontinuity Replace NOTE Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket Pocket tester P N YU 03112 C 9...

Page 353: ...Br R Br R B L G Br R Br R B Y Br B B Br G R Gy L R L G Br B Br R Br R L G B BLACK B Y Br R Br R L R B BLACK Y B Br Br R Gy BLACK GRAY GRAY BLACK B B B L R L B SbGy W R Y R Y R L B W L L R B W L Y B R Y B G L R W L W W R R O W G B W W B Y L W Y L B Y L W Y L BLACK BLACK Y L B Y Br L P P B Br L R W Br L Br Br L R B R B L B L Br W L Br B G Br W L Br W Y Br B G Br W Y Br W L W Y L R B L R B B L R B R ...

Page 354: ...T SPARK NOTE Remove the following part s before trouble shooting 1 Console 2 Footrest cover Use the following special tool s for trouble shooting Opama Pet 4000 spark checker P N YM 34487 Ignition checker P N 90890 06754 Pocket tester P N YU 03112 C 90890 03112 EB802011 CONTINUITY 1 Fuses main ignition Refer to CHECKING THE SWITCHES NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check t...

Page 355: ...epair or replace the spark plug OUT OF SPECIFICATION OR NO SPARK 4 Ignition spark gap Disconnect the spark plug cap from the spark plug Connect the pulse ignition spark checker 1 as shown 2 Spark plug cap 3 Spark plug Turn the main switch to ON Check the ignition spark gap Crank the engine by pushing the starter switch and increase the spark gap until a misfiring occurs Minimum spark gap 6 0 mm 0 ...

Page 356: ...n coil connector from the wire harness Connect the pocket tester Ω 1 to the ignition coil Tester lead Orange lead terminal Tester lead Ignition coil base Check that the primary coil has the speci fied resistance Primary coil resistance 0 18 0 28 Ω at 20 C 68 F BOTH MEET SPECIFICATION Connect the pocket tester Ω 1k to the ignition coil Tester lead Orange lead terminal Tester lead Spark plug lead Ch...

Page 357: ...up coil resistance 459 561 Ω at 20 C 68 F OUT OF SPECIFICATION Replace the pickup coil stator assembly MEETS SPECIFICATION 9 Rotor rotation direction detection coil resistance Disconnect the A C magneto coupler from the wire harness Connect the pocket tester Ω 1 to the rotor rotation direction detection coil termi nal Tester lead Red terminal 1 Tester lead White Blue terminal 2 Check the rotor rot...

Page 358: ...5 ELEC IGNITION SYSTEM CORRECT 10 Wiring connection Check the connections of the entire igni tion system Refer to CIRCUIT DIAGRAM Replace the C D I unit POOR CONNECTION Properly connect the ignition system ...

Page 359: ...r R B Y Br B B Br G R Gy L R L G Br B Br R Br R L G B BLACK B Y Br R Br R L R B BLACK Y B Br Br R Gy BLACK GRAY GRAY BLACK B B B L R L B SbGy W R Y R Y R L B W L L R B W L Y B R Y B G L R W L W W R R O W G B W W B Y L W Y L B Y L W Y L BLACK BLACK Y L B Y Br L P P B Br L R W Br L Br Br L R B R B L B L Br W L Br B G Br W L Br W Y Br B G Br W Y Br W L W Y L R B L R B B L R B R Br B G B W B Br W Y B ...

Page 360: ...If the main switch is START position the starter motor can be operated only if 1 Main fuse 2 Battery 3 Starter relay 4 Starter motor 5 Diode 1 6 Signaling system fuse 7 Brake light switch 8 Ignition fuse 9 C D I unit 0 Neutral switch È TO MAIN SWITCH É FROM MAIN SWITCH The transmission is in neutral the neutral switch is closed or The brake pedal is pressed the brake light switch is closed ...

Page 361: ...E Remove the following part s before trouble shooting 1 Console Use the following special tool s for trouble shooting Pocket tester P N YU 03112 C 90890 03112 EB802011 CONTINUITY 1 Fuses main ignition signaling system Refer to CHECKING THE SWITCHES NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circ...

Page 362: ...o be sure that no flammable gas or fluid is in the vicinity DOES NOT TURN Repair or replace the starter motor CONTINUITY 4 Starter relay Remove the starter relay from the wire harness Connect the pocket tester Ω 1 and the battery 12 V to the starter relay termi nals Battery terminal Yellow Blue terminal 1 Battery terminal Blue Black terminal 2 Tester lead Red terminal 3 Tester lead Black terminal ...

Page 363: ...Tester lead Black Yellow terminal 2 Continu ity Tester lead Yellow Blue terminal 1 Tester lead Blue White terminal 3 Tester lead Black Yellow terminal 2 Tester lead Yellow Blue terminal 1 No conti nuity Tester lead Blue White terminal 3 Tester lead Yellow Blue terminal 1 NOTE When you switch the tester s positive and neg ative probes the readings in the left chart will be reversed L W B Y Y L 3 2 ...

Page 364: ...otor lead 1 2 Starter motor O ring 1 1 For installation reverse the removal pro cedure Disassembling the starter motor Remove the parts in the order listed 1 Bracket 1 1 Refer to ASSEMBLING THE STARTER MOTOR 2 Washer 1 3 Shims 4 Bracket 2 1 5 Shims 6 Brush seat 1 brush seat 2 1 1 7 Armature coil 1 8 Yoke 1 For assembly reverse the disassembly procedure ...

Page 365: ...urement using a hacksaw blade which has been grounded to fit the commutator Outside diameter 28 mm 1 10 in Wear limit 27 mm 1 06 in Mica undercut 0 7 mm 0 03 in 4 Check armature coil insulation continuity Defects Replace the starter motor a Connect the pocket tester for the continuity check 1 and insulation check 2 b Measure the armature resistances c If the resistance is incorrect replace the sta...

Page 366: ...oil seal bushing O rings Wear damage Replace Brush length 12 5 mm 0 49 in Wear limit 5 mm 0 20 in Brush spring force 7 65 10 01 N 780 1 021 g 27 5 36 0 oz ASSEMBLING THE STARTER MOTOR 1 Install brush seat 1 1 NOTE Align the projection a on the brush seat 1 with the slot b on the yoke 2 Install yoke brackets NOTE Align the match marks a on the yoke with the match marks b on the brackets ...

Page 367: ...B Sb Br BROWN L R B Br R Br R Br R B L G Br R Br R B Y Br B B Br G R Gy L R L G Br B Br R Br R L G B BLACK B Y Br R Br R L R B BLACK Y B Br Br R Gy BLACK GRAY GRAY BLACK B B B L R L B SbGy W R Y R Y R L B W L L R B W L Y B R Y B G L R W L W W R R O W G B W W B Y L W Y L B Y L W Y L BLACK BLACK Y L B Y Br L P P B Br L R W Br L Br Br L R B R B L B L Br W L Br B G Br W L Br W Y Br B G Br W Y Br W L W...

Page 368: ...YU 39951 B 90890 06760 Pocket tester P N YU 03112 C 90890 03112 EB802011 CONTINUITY 1 Fuse main Refer to CHECKING THE SWITCHES NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the battery terminals Recharge or replace the battery EB804011 3 C...

Page 369: ...t tester Ω 1 to the charging coils Tester lead White terminal 1 Tester lead White terminal 2 Tester lead White terminal 1 Tester lead White terminal 3 Tester lead White terminal 2 Tester lead White terminal 3 Measure the charging coil resistance Charging coil resistance 0 31 0 42 Ω at 20 C 68 F OUT OF SPECIFICATION Replace the pickup coil stator assembly EB804015 CORRECT 5 Wiring connections Check...

Page 370: ...R B L G Br R Br R B Y Br B B Br G R Gy L R L G Br B Br R Br R L G B BLACK B Y Br R Br R L R B BLACK Y B Br Br R Gy BLACK GRAY GRAY BLACK B B B L R L B SbGy W R Y R Y R L B W L L R B W L Y B R Y B G L R W L W W R R O W G B W W B Y L W Y L B Y L W Y L BLACK BLACK Y L B Y Br L P P B Br L R W Br L Br Br L R B R B L B L Br W L Br B G Br W L Br W Y Br B G Br W Y Br W L W Y L R B L R B B L R B R Br B G B...

Page 371: ...Use the following special tool s for trouble shooting Pocket tester P N YU 03112 C 90890 03112 EB802011 CONTINUITY 1 Fuses main lighting system Refer to CHECKING THE SWITCHES NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the battery termin...

Page 372: ...Tester lead Green terminal 2 Battery terminal Yellow terminal 3 Battery terminal Black terminal 4 Tester lead Blue terminal 1 Tester lead Yellow terminal 5 Check the headlight relay for continuity NO CONTINUITY Replace the headlight relay EB805013 CORRECT 6 Wiring connection Check the connections of the entire light ing system Refer to CIRCUIT DIAGRAM Check the condition of each of the lighting sy...

Page 373: ...e headlight bulb holder MEETS SPECIFICATION 2 Voltage Connect the pocket tester DC 20 V to the headlight couplers Tester lead Green terminal 1 or Yellow terminal 2 Tester lead Black terminal 3 È When the light switch is on É When the light switch is on Turn the main switch to ON Turn the light switch to or Check the voltage 12 V of the Green and Yellow leads on the headlight bulb holder coupler Th...

Page 374: ...nect the pocket tester DC 20 V to the tail brake light connectors Tester lead Blue lead terminal 1 Tester lead Black lead terminal 2 MEETS SPECIFICATION Turn the main switch to ON Turn the light switch to or Check the voltage 12 V of the Blue lead on the bulb socket connector This circuit is not faulty L H OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is...

Page 375: ...9 32 ELEC LIGHTING SYSTEM ...

Page 376: ... L L B W L L B Y B B L B Sb Br BROWN L R B Br R Br R Br R B L G Br R Br R B Y Br B B Br G R Gy L R L G Br B Br R Br R L G B BLACK B Y Br R Br R L R B BLACK Y B Br Br R Gy BLACK GRAY GRAY BLACK B B B L R L B SbGy W R Y R Y R L B W L L R B W L Y B R Y B G L R W L W W R R O W G B W W B Y L W Y L B Y L W Y L BLACK Y L B Y Br L P P B Br L R W Br L Br Br L R B R B L B L Br W L Br B G Br W L Br W Y Br B ...

Page 377: ...ermo switch 1 Gear motor Diode 2 a Four wheel drive indicator light b Differential gear lock indicator light c Coolant temperature warning light d Four wheel drive indicator light relay e Differential gear lock indicator light relay g Neutral indicator light h Reverse indicator light i Parking brake indicator light j Signaling system fuse u Tail brake light ...

Page 378: ...e following special tool s for trouble shooting Pocket tester P N YU 03112 C 90890 03112 EB802011 CONTINUITY 1 Fuses main signaling system Refer to CHECKING THE SWITCHES NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the battery terminals R...

Page 379: ... 4 Wiring connections Check the connections of the entire signal system Refer to CIRCUIT DIAGRAM Check the condition of each of the signal sys tem s circuits Refer to CHECKING THE SIGNAL SYS TEM POOR CONNECTION Properly connect the signal system ...

Page 380: ...ING THE SWITCHES NO CONTINUITY Replace the brake light switch 3 Voltage Connect the pocket tester DC 20 V to the bulb socket connector Tester lead Yellow terminal 1 Tester lead Black terminal 2 MEETS SPECIFICATION Turn the main switch to ON Press the brake pedal Check the voltage 12 V of the Yellow lead on the bulb socket connector This circuit is not faulty OUT OF SPECIFICATION The wiring circuit...

Page 381: ...utral switch 3 Voltage Connect the pocket tester DC 20 V to the indicator light assembly 2 coupler Tester lead Brown terminal 1 Tester lead Sky blue terminal 2 Br B G Br W L Br W Y Br B G Br W Y Br W L R W G L R W L R R W Sb Br G L Br Sb Br L R 1 2 MEETS SPECIFICATION Turn the main switch to ON Shift the drive select lever into the neutral position N Check the voltage 12 V This circuit is not faul...

Page 382: ...e the parking brake switch 3 Voltage Connect the pocket tester DC 20 V to the indicator light assembly 2 coupler Tester lead Brown terminal 1 Tester lead Blue Red terminal 2 Br B G Br W L Br W Y Br B G Br W Y Br W L R W G L R W L R R W Sb Br G L Br Sb Br L R 1 2 MEETS SPECIFICATION Turn the main switch to ON Pull the parking brake lever up Check the voltage 12 V This circuit is not faulty OUT OF S...

Page 383: ...erse switch 3 Voltage Connect the pocket tester DC 20 V to the indicator light assembly 2 coupler Tester lead Brown terminal 1 Tester lead Green Blue terminal 2 Br B G Br W L Br W Y Br B G Br W Y Br W L R W G L R W L R R W Sb Br G L Br Sb Br L R 1 2 MEETS SPECIFICATION Turn the main switch to ON Shift the drive select lever into the reverse gear R Check the voltage 12 V Replace the C D I unit OUT ...

Page 384: ...e thermo switch 1 for continuity While heating the coolant use a thermom eter 3 to record the temperatures È The thermo switch 1 circuit is open and the coolant temperature warning light is off É The thermo switch 1 circuit is closed and the coolant temperature warning light is on Test step Coolant temperature Continuity 1 Less than 120 3 C 248 5 4 F No 2 More than 120 3 C 248 5 4 F Yes 3 More tha...

Page 385: ...o switch 1 is faulty repair it 4 Diode 2 Remove the diode from the coupler Connect the pocket tester Ω 1 to the diode terminals as shown Check the diode for continuity as follows NOTE When you switch the tester s positive and neg ative probes the readings in the left chart will be reversed 1 2 L B W L CORRECT Tester lead Blue Black terminal 1 Tester lead White Blue terminal 2 Continu ity Tester le...

Page 386: ... tester Ω 1 and the battery 12 V to the differential gear lock indicator light relay terminals Check the differential gear lock indicator light relay for continuity as follows Tester lead Black Green terminal 1 Tester lead Black terminal 2 Continu ity Battery terminal Brown terminal 3 Battery terminal Black Red terminal 4 No conti nuity Tester lead Black Green terminal 1 Tester lead Black terminal...

Page 387: ... Tester lead Black Green terminal 2 Br B G Br W L Br W Y Br B G Br W Y Br W L 1 2 MEETS SPECIFICATION Turn the main switch to ON Set the differential gear lock switch to LOCK Check the voltage 12 V Refer to 2WD 4WD SELECTING SYSTEM OUT OF SPECIFICATION The wiring circuit from the main switch to the four wheel drive switch is faulty repair it ...

Page 388: ...ester Ω 1 and the battery 12 V to the four wheel drive indi cator light relay terminals Check the four wheel drive indicator light relay for continuity as follows Tester lead White Yellow terminal 1 Tester lead Black terminal 2 Continu ity Battery terminal Brown terminal 3 Battery terminal White Black terminal 4 No conti nuity Tester lead White Yellow terminal 1 Tester lead Black terminal 2 NO CON...

Page 389: ...ster lead White Yellow terminal 2 Br B G Br W L Br W Y Br B G Br W Y Br W L 1 2 MEETS SPECIFICATION Turn the main switch to ON Set the On Command four wheel drive switch to 4WD Check the voltage 12 V Refer to 2WD 4WD SELECTING SYSTEM OUT OF SPECIFICATION The wiring circuit from the main switch to the four wheel drive switch is faulty repair it ...

Page 390: ...R B L G Br R Br R B Y Br B B Br G R Gy L R L G Br B Br R Br R L G B BLACK B Y Br R Br R L R B BLACK Y B Br Br R Gy BLACK GRAY GRAY BLACK B B B L R L B SbGy W R Y R Y R L B W L L R B W L Y B R Y B G L R W L W W R R O W G B W W B Y L W Y L B Y L W Y L BLACK BLACK Y L B Y Br L P P B Br L R W Br L Br Br L R B R B L B L Br W L Br B G Br W L Br W Y Br B G Br W Y Br W L W Y L R B L R B B L R B R Br B G B...

Page 391: ...sole Use the following special tool s for trouble shooting Pocket tester P N YU 03112 C 90890 03112 EB802011 CONTINUITY 1 Fuse main Refer to CHECKING THE SWITCHES NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the battery terminals Recharge...

Page 392: ...lead Black terminal 2 Check the operation of the radiator fan motor DOES NOT TURN Replace the radiator fan motor MEETS SPECIFICATION 5 Circuit breaker radiator fan motor Remove the circuit breaker from the wire harness Connect the pocket tester Ω 1 to the circuit breaker Circuit breaker resistance Zero Ω at 20 C 68 F OUT OF SPECIFICATION Replace the circuit breaker ...

Page 393: ...o switch 3 circuit is closed É The thermo switch 3 circuit is open Test step Coolant temperature Continuity 1 Less than 75 3 C 167 5 4 F No 2 More than 75 3 C 167 5 4 F Yes 3 More than 68 C 154 4 F Yes 4 Less than 68 C 154 4 F No Test steps 1 2 Heating phase Test steps 3 4 Cooling phase WARNING Handle the thermo switch 3 with special care Never subject it to a strong shock or allow it to be droppe...

Page 394: ...C COOLING SYSTEM EB803028 CORRECT 7 Wiring connection Check the connections of the entire cool ing system Refer to CIRCUIT DIAGRAM This circuit is not faulty POOR CONNECTION Properly connect the cooling system ...

Page 395: ...r R L G B BLACK B Y Br R Br R L R B BLACK Y B Br Br R Gy BLACK GRAY GRAY BLACK B B B L R L B SbGy W R Y R Y R L B W L L R B W L Y B R Y B G L R W L W W R R O W G B W W B Y L W Y L B Y L W Y L BLACK Y L B Y Br L P P B Br L R W Br L Br Br L R B R B L B L Br W L Br B G Br W L Br W Y Br B G Br W Y Br W L W Y L R B L R B B L R B R Br B G B W B Br W Y B BLUE W Y Br B W B BLUE B G Br B B R B R R G R W B ...

Page 396: ...OME ON NOTE Remove the following part s before trouble shooting 1 Console Use the following special tool s for trouble shooting Pocket tester P N YU 03112 C 90890 03112 EB802011 CONTINUITY 1 Fuses main four wheel drive Refer to CHECKING THE SWITCHES NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open cir...

Page 397: ...n Red terminal 5 Check the four wheel drive relay 2 for con tinuity NO CONTINUITY Replace the four wheel drive relay 2 CONTINUITY 5 Four wheel drive relay 1 Remove the four wheel drive relay 1 from the wire harness Connect the pocket tester Ω 1 and the battery 12 V to the four wheel drive relay 1 terminals Tester lead Brown Black terminal 1 Tester lead Black terminal 2 Battery terminal Brown Red t...

Page 398: ...y terminal Brown Red terminal 1 Battery terminal Yellow Black terminal 2 Tester lead Brown terminal 3 Tester lead Gray terminal 4 Check the four wheel drive relay 3 for continuity NO CONTINUITY Replace the four wheel drive relay 3 CORRECT 7 On Command four wheel drive switch and differential gear lock switch Refer to CHECKING THE SWITCHES INCORRECT Replace the On Command four wheel drive switch an...

Page 399: ... 2 turns counter clockwise É Check that the pinion gear 2 turns clockwise Make sure that the drive gear shift fork sliding gear operates correctly NOTE When installing the differential gear case in the gear motor refer to FRONT CONSTANT VELOCITY JOINTS DIFFERENTIAL GEAR AND FRONT DRIVE SHAFT in chapter 7 INCORRECT Replace the gear motor È É EB803028 CORRECT 9 Wiring connection Check the connection...

Page 400: ... R B Br R Br R Br R B L G Br R Br R B Y Br B B Br G R Gy L R L G Br B Br R Br R L G B BLACK B Y Br R Br R L R B BLACK Y B Br Br R Gy BLACK GRAY GRAY BLACK B B B L R L B SbGy W R Y R Y R L B W L L R B W L Y B R Y B G L R W L W W R R O W G B W W B Y L W Y L B Y L W Y L BLACK BLACK Y L B Y Br L P P B Br L R W Br L Br Br L R B R B L B L Br W L Br B G Br W L Br W Y Br B G Br W Y Br W L W Y L R B L R B ...

Page 401: ...ooting 1 Console Use the following special tool s for trouble shooting Pocket tester P N YU 03112 C 90890 03112 CORRECT 1 Fuses main carburetor heater Refer to CHECKING THE SWITCHES NO CONTINUITY Replace the fuse CORRECT 2 Battery Check the battery condition Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the battery terminal...

Page 402: ...t cool to the specified temperature as indicated in the table Check the thermo switch 2 for continuity at the temperatures indicated in the table È The thermo switch 2 circuit is closed É The thermo switch 2 circuit is open Test step Water temperature Continuity 1 Less than 16 3 C 60 8 5 4 F Yes 2 More than 16 3 C 60 8 5 4 F No 3 More than 11 3 C 51 8 5 4 F No 4 Less than 11 3 C 51 8 5 4 F Yes Tes...

Page 403: ... heater terminal 1 Tester lead Carburetor heater body 2 Measure the carburetor heater resistance Carburetor heater resistance 6 12 Ω at 20 C 68 F INCORRECT Replace the carburetor heater CORRECT 6 Wiring connection Check the connections on the entire car buretor heating system Refer to CIRCUIT DIAGRAM This circuit is not faulty POOR CONNECTION Properly connect the carburetor heating sys tem ...

Page 404: ...needle valve Improperly sealed valve seat Improperly adjusted fuel level Improperly set pilot jet Clogged starter jet Starter plunger malfunction Air filter Clogged air filter element ELECTRICAL SYSTEM Spark plug Improper plug gap Worn electrodes Wire between terminals broken Improper heat range Faulty spark plug cap Ignition coil Broken or shorted primary secondary Faulty spark plug lead Broken b...

Page 405: ...sted valve clearance Improperly adjusted valve timing EBS00538 POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE Carburetor Improperly returned starter plunger Loose pilot jet Clogged pilot jet Clogged pilot air jet Improperly adjusted idle speed throttle stop screw Improper throttle cable play Flooded carburetor Electrical system Faulty spark plug Faulty C D I unit Faulty pickup coil Faulty...

Page 406: ...le Causes 1 A pronounced hesitation or jerky move ment during acceleration deceleration or sustained speed This must not be con fused with engine surging or transmission characteristics 2 A rolling rumble noticeable at low speed a high pitched whine a clunk from a shaft drive component or area 3 A locked up condition of the shaft drive mechanism no power transmitted from the engine to the front an...

Page 407: ... drum groove Transmission Worn gear dog EBS00543 FAULTY CLUTCH PERFORMANCE ENGINE OPERATES BUT VEHICLE WILL NOT MOVE V belt Bent damaged or worn V belt V belt slips Primary pulley cam and primary pulley slider Damaged or worn primary pulley cam Damaged or worn primary pulley slider Transmission Damaged transmission gears CLUTCH SLIPPING Clutch spring Damaged loose or worn clutch shoe spring Clutch...

Page 408: ...n jet improper set ting Improper fuel level Clogged air filter element Compression system Heavy carbon deposit Engine oil Improper oil level Improper oil viscosity Inferior oil quality Brake Brake drag Cooling system Low coolant level Clogged or damaged radiator Damaged or faulty water pump Faulty fan motor Faulty thermo switch Oil cooling system Clogged or damaged oil cooler EBS00550 FAULTY BRAKE...

Page 409: ... pressure Uneven tire wear Wheels Deformed wheel Loose bearing Bent or loose wheel axle Excessive wheel runout Frame Bent Damaged frame EBS00553 LIGHTING SYSTEM HEADLIGHTS DO NOT COME ON Improper bulb Too many electric accessories Hard charging broken stator coil and or faulty rectifier regulator Incorrect connection Improperly grounded Poor contacts main or lights switch Bulb life expired BULB BU...

Page 410: ...t assembly 1 a Four wheel drive indicator light b Differential gear lock indicator light c Coolant temperature warning light d Four wheel drive indicator light relay e Differential gear lock indicator light relay f Indicator light assembly 2 g Neutral indicator light h Reverse indicator light i Parking brake indicator light j Signaling system fuse k Ignition fuse l Lighting system fuse m Auxiliary...

Page 411: ......

Page 412: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A ...

Page 413: ... Y B B L B Sb Br BROWN L R B Br R Br R Br R B L G Br R Br R B Y Br B B Br G R Gy L R L G Br B Br R Br R L G B BLACK B Y Br R Br R L R B BLACK Y B Br Br R Gy BLACK GRAY GRAY BLACK B B B L R L B SbGy W R Y R Y R L B W L L R B W L Y B R Y B G L R W L W W R R O W G B W W B Y L W Y L B Y L W Y L BLACK BLACK Y L B Y Br L P P B Br L R W Br L Br Br L R B R B L B L Br W L Br B G Br W L Br W Y Br B G Br W Y...

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