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Yamaha rhino 700 2008, Service Manual, Page: 103 / 497

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Yamaha rhino 700 2008 Service Manual Download Page 103

3 - 19

CHK

ADJ

CHECKING THE THROTTLE BODY JOINT/

CHECKING THE FUEL HOSE/CHECKING THE BREATHER HOSES

EAS00094

CHECKING THE THROTTLE BODY JOINT

1. Remove:

• seats
• rear console

Refer to “SEATS, REAR CONSOLE AND
INSTRUMENT PANELS” in chapter 8.

2. Check:

• throttle body joint 

1

Cracks/damage 

→

 Replace.

Refer to “THROTTLE BODY” in chapter 6.

3. Install:

• rear console
• seats

Refer to “SEATS, REAR CONSOLE AND
INSTRUMENT PANELS” in chapter 8.

1

EAS00096

CHECKING THE FUEL HOSE

1. Remove:

• seats
• rear console

Refer to “SEATS, REAR CONSOLE AND
INSTRUMENT PANELS” in chapter 8.

2. Check:

• fuel hose 

1

Cracks/damage 

→

 Replace.

Loose connection 

→

 Connect properly.

3. Install:

• rear console
• seats

Refer to “SEATS, REAR CONSOLE AND
INSTRUMENT PANELS” in chapter 8.

1

EAS00098

CHECKING THE BREATHER HOSES

1. Remove:

• seats
• rear console

Refer to “SEATS, REAR CONSOLE AND
INSTRUMENT PANELS” in chapter 8.

Summary of Contents for rhino 700 2008

Page 1: ...SERVICE MANUAL 2008 LIT 11616 21 58 5B4 F8197 10 YXR70FX ...

Page 2: ...y Yamaha Motor Corporation U S A First edition September 2007 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 21 58 ...

Page 3: ...st satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP _ This Service Manual contains informati...

Page 4: ...d 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 way by ...

Page 5: ...ce G Engine speed H Electrical data Ω V A Symbols I to P 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 brake fluid M Apply wheel bearing grease N Apply lithium soap based grease O Apply molybdenum disulfide grease P Apply silicone grease Symbols Q to R in the exploded diagrams indicate w...

Page 6: ......

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

Page 8: ...SSEMBLY 1 7 REPLACEMENT PARTS 1 7 GASKETS OIL SEALS AND O RINGS 1 7 LOCK WASHERS PLATES AND COTTER PINS 1 8 BEARINGS AND OIL SEALS 1 8 CIRCLIPS 1 8 CHECKING THE CONNECTIONS 1 9 SPECIAL TOOLS 1 10 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 5 CHASSIS SPECIFICATIONS 2 12 ELECTRICAL SPECIFICATIONS 2 15 TIGHTENING TORQUES 2 17 ENGINE TIGHTENING TORQUES 2 17 CHASSIS TIGH...

Page 9: ...3 ADJUSTING THE THROTTLE CABLE 3 6 CHECKING THE SPARK PLUG 3 7 CHECKING THE IGNITION TIMING 3 9 MEASURING THE COMPRESSION PRESSURE 3 10 CHECKING THE ENGINE OIL LEVEL 3 13 CHANGING THE ENGINE OIL 3 14 CLEANING THE AIR FILTER ELEMENT 3 16 CHECKING THE THROTTLE BODY JOINT 3 19 CHECKING THE FUEL HOSE 3 19 CHECKING THE BREATHER HOSES 3 19 CHECKING THE COOLANT LEVEL 3 20 CHANGING THE COOLANT 3 21 CHECKI...

Page 10: ...IL 3 41 CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS 3 43 CHECKING THE STEERING SYSTEM 3 43 ADJUSTING THE TOE IN 3 44 ADJUSTING THE FRONT SHOCK ABSORBERS 3 45 ADJUSTING THE REAR SHOCK ABSORBERS 3 48 CHECKING THE TIRES 3 51 CHECKING THE WHEELS 3 53 CHECKING AND LUBRICATING THE CABLES 3 54 LUBRICATING THE PEDAL ETC 3 54 ELECTRICAL SYSTEM 3 55 CHECKING AND CHARGING THE BATTERY 3 55 CHECKING THE FU...

Page 11: ...KING THE VALVES AND VALVE SPRINGS 4 29 INSTALLING THE VALVES AND VALVE SPRINGS 4 33 CYLINDER AND PISTON 4 36 REMOVING THE PISTON 4 37 CHECKING THE CYLINDER AND PISTON 4 37 CHECKING THE PISTON RINGS 4 39 CHECKING THE PISTON PIN 4 40 INSTALLING THE PISTON AND CYLINDER 4 41 AC MAGNETO 4 44 REMOVING THE AC MAGNETO ROTOR 4 47 CHECKING THE STATOR COIL AND CRANKSHAFT POSITION SENSOR 4 48 CHECKING THE STA...

Page 12: ...SE BEARINGS 4 73 SEPARATING THE CRANKCASE 4 74 CHECKING THE TIMING CHAIN AND GUIDE 4 74 CHECKING THE RELIEF VALVE 4 74 CHECKING THE BEARINGS 4 75 CHECKING THE CRANKCASE 4 75 ASSEMBLING THE CRANKCASE 4 75 INSTALLING THE SHIFT LEVER 4 76 CRANKSHAFT AND OIL PUMP 4 77 OIL PUMP 4 78 REMOVING THE CRANKSHAFT 4 79 CHECKING THE OIL PUMP 4 79 CHECKING THE OIL STRAINER 4 80 CHECKING THE CRANKSHAFT 4 80 ASSEM...

Page 13: ...R AND COOLANT RESERVOIR 5 1 CHECKING THE RADIATOR 5 3 INSTALLING THE RADIATOR 5 4 THERMOSTAT 5 5 CHECKING THE THERMOSTAT 5 6 INSTALLING THE THERMOSTAT 5 6 WATER PUMP 5 7 DISASSEMBLING THE WATER PUMP 5 9 CHECKING THE WATER PUMP 5 9 ASSEMBLING THE WATER PUMP 5 10 OIL COOLER 5 12 CHECKING THE OIL COOLER 5 14 CHAPTER 6 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 6 1 CIRCUIT DIAGRAM 6 2 ECU SELF DIAGNO...

Page 14: ... CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 6 44 CHAPTER 7 DRIVE TRAIN TROUBLESHOOTING 7 1 CHECKING NOISES 7 1 TROUBLESHOOTING CHART 7 3 FRONT CONSTANT VELOCITY JOINTS DIFFERENTIAL GEAR AND DRIVE SHAFT 7 4 DISASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS 7 10 DISASSEMBLING THE UNIVERSAL JOINT 7 11 REMOVING THE DIFFERENTIAL GEAR ASSEMBLY 7 11 CHECKING THE FRONT CONSTANT VELOCITY JOINTS 7 1...

Page 15: ...ASH 7 38 ASSEMBLING THE FINAL GEAR CASE 7 40 CHAPTER 8 CHASSIS SEATS ENCLOSURE HOOD AND CARGO BED 8 1 FRONT GUARD AND HOOD 8 1 SEATS REAR CONSOLE AND INSTRUMENT PANELS 8 2 REMOVING THE STEERING WHEEL 8 4 INSTALLING THE STEERING WHEEL 8 4 SIDE DOORS 8 5 PANELS AND FRONT CONSOLE 8 6 REMOVING THE SIDE PANELS 8 8 INSTALL THE SIDE PANELS 8 8 CARGO BED 8 9 SKID PLATES 8 11 INSTALLING THE REAR SKID PLATE...

Page 16: ...PARKING BRAKE DISC 8 44 ASSEMBLING THE PARKING BRAKE 8 44 PEDAL ASSEMBLY 8 47 STEERING SYSTEM 8 49 STEERING SHAFT AND STEERING ASSEMBLY 8 49 DISASSEMBLING THE STEERING ASSEMBLY 8 52 CHECKING THE STEERING JOINT 8 52 CHECKING THE STEERING ASSEMBLY 8 52 ASSEMBLING THE STEERING ASSEMBLY 8 53 INSTALLING THE STEERING SYSTEM 8 54 TIE ROD AND STEERING KNUCKLE 8 55 REMOVING THE STEERING KNUCKLES 8 56 CHECK...

Page 17: ... 8 72 INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER 8 73 CHAPTER 9 ELECTRICAL ELECTRICAL COMPONENTS 9 1 CHECKING SWITCH CONTINUITY 9 3 CHECKING THE SWITCHES 9 4 CHECKING THE BULBS AND BULB SOCKETS 9 6 TYPES OF BULBS 9 6 CHECKING THE CONDITION OF THE BULBS 9 7 CHECKING THE CONDITION OF THE BULB SOCKETS 9 8 IGNITION SYSTEM 9 9 CIRCUIT DIAGRAM 9 9 TROUBLESHOOTING 9 10 ELECTRIC STARTING SYSTEM 9 14...

Page 18: ...50 TROUBLESHOOTING 9 51 2WD 4WD SELECTING SYSTEM 9 53 CIRCUIT DIAGRAM 9 53 TROUBLESHOOTING 9 54 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 10 3...

Page 19: ...MANCE 10 4 POOR SPEED PERFORMANCE 10 5 OVERHEATING 10 5 OVERHEATING 10 5 OVERCOOLING 10 5 COOLING SYSTEM 10 5 FAULTY BRAKE 10 5 POOR BRAKING EFFECT 10 5 SHOCK ABSORBER MALFUNCTION 10 6 MALFUNCTION 10 6 UNSTABLE HANDLING 10 6 UNSTABLE HANDLING 10 6 LIGHTING SYSTEM 10 6 HEADLIGHT DOES NOT COME ON 10 6 BULB BURNT OUT 10 6 ...

Page 20: ...ION NUMBER The vehicle identification number 1 is stamped into the frame EBS00011 MODEL LABEL The model label 1 is affixed to the frame under the driver seat Record the information on this label in the space provided This infor mation will be needed to order spare parts 1 VEHICLE IDENTIFICATION ...

Page 21: ...e As the requirements for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned man ner To accommodate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio require...

Page 22: ...ction timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake air tem perature sensor coolant temperature sensor lean angle sensor and speed sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a result the...

Page 23: ...y which shows the battery voltage a fuel meter a self diagnosis device 1 2 3 4 5 6 7 8 Odometer and tripmeter modes 1 Odometer Tripmeter A Tripmeter B 2 TRIP ODO button Pushing the TRIP ODO button switches the display between the odometer mode ODO and the tripmeter modes A and B in the fol lowing order ODO TRIP A TRIP B ODO To reset a tripmeter select it by pushing the TRIP ODO button and then hol...

Page 24: ... by pushing the M but ton 5 Push the button and then release it to start the clock Voltage display mode This display shows the battery voltage btry appears for 1 second when the voltage display mode is first selected and then the battery voltage is shown If the battery voltage is less than 10 volts LO is displayed and if the voltage is above 16 volts HI is displayed TIP LO or HI is displayed only ...

Page 25: ...the display segments and fuel level warning indicator will start flashing If this occurs check the electrical circuit 1 2 3 Self diagnosis device 1 Error code display This model is equipped with a self diagnosis device for various electrical circuits If any of those circuits are defective the engine trouble warning light will come on or flash and then the multi function display will indicate a two...

Page 26: ...all of the parts and place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EBS00014 REPLACEMENT PARTS 1 Use only genuine Yamaha parts for all replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance bu...

Page 27: ...isible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appro priate 1 Oil seal NOTICE _ Do not spin the bearing with compressed air because this will damage the bearing surfaces 1 Bearing EBS00018 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always rep...

Page 28: ...ral times 3 Check all connections Loose connection Connect properly TIP _ If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector TIP _ Make sure all connections are tight 5 Check continuity with the pocket tester TIP _ If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer availabl...

Page 29: ... YK ACC Except for US and CDN P N 90890 Tool No Tool name How to use Illustration 90890 01083 YU 01083 1 Slide hammer bolt Slide hammer bolt 6 mm This tool is used to remove the rocker arm shaft 90890 01084 YU 01083 3 Weight This tool is used to remove the rocker arm shaft 90890 01135 YU 01135 B Crankcase separating tool Crankcase separator This tool is used to separate the crank case 90890 01229 ...

Page 30: ...nkshaft installer bolt Bolt This tool is used to install the crankshaft 90890 01304 YU 01304 Piston pin puller set Piston pin puller This tool is used to remove the piston pin 90890 01309 YU 90059 Spacer Pot spacer This tool is used to install the crankshaft 90890 01311 YM A5970 Tappet adjusting tool Six piece tappet set This tool is necessary for adjusting the valve clearance Tool No Tool name Ho...

Page 31: ... tester adapter Radiator pressure tester adapter This tool is used to check the cooling sys tem 90890 01362 YU 33270 B Flywheel puller Heavy duty puller This tool is used to remove the AC mag neto rotor 90890 01426 YU 38411 Oil filter wrench This tool is needed to loosen or tighten the oil filter cartridge 90890 01430 YM 38404 Ring nut wrench This tool is needed to remove and install the middle dr...

Page 32: ...e ball joints 90890 01526 YM 01526 Boot band installing tool This tool is used to remove or install the boot band 90890 01527 YM 01527 Ring gear fix bolt M10 This tool is used to hold the ring gear 90890 01701 YS 01880 A Sheave holder Primary clutch holder This tool is needed to hold the primary sheave when removing or installing the sheave nuts 90890 03081 YU 33223 Compression gauge Engine compre...

Page 33: ... sure 90890 03180 YU 26900 9 Thickness gauge Feeler gauge set This tool is used to measure the valve clearance 90890 04019 YM 04019 Valve spring compressor This tool is used to remove or install the valve assemblies 90890 04058 YM 04058 Middle driven shaft bearing driver Bearing driver 40 mm This tool is used to install the water pump seal 90890 04062 YM 04062 Universal joint holder This tool is n...

Page 34: ...This tool is used to install the crankshaft 90890 04082 Extension This tool is used to measure engine com pression 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 04128 YM 04128 Bearing retainer wrench Middle gear bearing retainer This tool is needed when removing or installing the bearing retainers 908...

Page 35: ...04135 Sheave fixed block Sheave fixed bracket This tool is needed when removing or installing the secondary sheave spring 90890 06754 YM 34487 Ignition checker Opama pet 4000 spark checker This instrument is necessary for checking the ignition system components 90890 06760 YU 39951 B Digital tachometer This tool is needed for checking engine rpm 90890 85505 Yamaha bond No 1215 Three bond No 1215 T...

Page 36: ...0 mm 75 2 in Minimum ground clearance 280 mm 11 0 in Minimum turning radius 3 900 mm 154 in Basic weight With oil and fuel 540 0 kg 1 190 lb 1 2 548 0 kg 1 208 lb 3 4 Engine Engine type Liquid cooled 4 stroke SOHC Cylinder arrangement Forward inclined single cylinder Displacement 686 0 cm3 Bore stroke 102 0 84 0 mm 4 02 3 31 in Compression ratio 9 20 1 Standard compression pressure at sea level 45...

Page 37: ... 6 45 Imp gal 7 74 US gal Fuel injector Type quantity E252019 1 Manufacturer NIPPON INJECTOR Spark plug Type manufacturer CPR7EA 9 NGK Spark plug gap 0 8 0 9 mm 0 031 0 035 in Clutch type Wet centrifugal automatic Transmission Primary reduction system V belt Secondary reduction system Shaft drive Secondary reduction ratio 41 21 17 12 33 9 10 142 Transmission type V belt automatic Operation Right h...

Page 38: ...oot operation Rear brake type Dual disc brake operation Foot operation Parking brake type Single disc brake operation Right hand operation Suspension Front suspension Double wishbone Rear suspension Double wishbone Shock absorber Front shock absorber Coil spring oil damper 1 2 Coil spring gas oil damper 3 4 Rear shock absorber Coil spring oil damper 1 2 Coil spring gas oil damper 3 4 Wheel travel ...

Page 39: ...light Neutral indicator light LED Reverse indicator light LED Coolant temperature warning light LED Engine trouble warning light LED Park indicator light LED On command four wheel drive differential gear lock indicator LCD High range indicator light LED Low range indicator light LED Differential gear lock indicator light LED Item Standard ...

Page 40: ...in Maximum taper 0 05 mm 0 002 in Out of round 0 05 mm 0 002 in Camshaft Drive system Chain drive Camshaft lobe dimensions Intake measurement A 42 481 42 581 mm 1 6725 1 6764 in 42 381 mm 1 6685 in B 36 950 37 050 mm 1 4547 1 4587 in 36 850 mm 1 4508 in Exhaust measurement A 43 129 43 229 mm 1 6980 1 7019 in 43 029 mm 1 6941 in B 36 982 37 082 mm 1 4560 1 4599 in 36 882 mm 1 4520 in Maximum camsha...

Page 41: ...8 10 mm 1 4921 1 5000 in Exhaust 31 90 32 10 mm 1 2559 1 2638 in Valve face width B Intake 2 26 mm 0 0890 in Exhaust 2 26 mm 0 0890 in Valve seat width C Intake 1 00 1 20 mm 0 0394 0 0472 in 1 60 mm 0 0630 in Exhaust 1 00 1 20 mm 0 0394 0 0472 in 1 60 mm 0 0630 in Valve margin thickness D Intake 0 80 1 20 mm 0 0315 0 0472 in Exhaust 0 80 1 20 mm 0 0315 0 0472 in Valve stem diameter Intake 5 975 5 ...

Page 42: ...take 40 38 mm 1 59 in 38 36 mm 1 51 in Exhaust 40 38 mm 1 59 in 38 36 mm 1 51 in Installed length valve closed Intake 35 00 mm 1 38 in Exhaust 35 00 mm 1 38 in Compressed spring force installed Intake 171 197 N 17 44 20 09 kgf 38 44 44 29 lb Exhaust 171 197 N 17 44 20 09 kgf 38 44 44 29 lb Spring tilt Intake 2 5 1 80 mm 2 5 0 071 in Exhaust 2 5 1 80 mm 2 5 0 071 in Winding direction top view Intak...

Page 43: ...m 0 9052 0 9055 in 22 971 mm 0 9044 in Piston pin to piston pin bore clear ance 0 004 0 024 mm 0 0002 0 0009 in 0 074 mm 0 0029 in Piston rings Top ring Ring type Barrel Dimensions B T 1 20 3 80 mm 0 05 0 15 in End gap installed 0 20 0 35 mm 0 008 0 014 in 0 60 mm 0 024 in Ring side clearance 0 030 0 070 mm 0 0012 0 0028 in 0 12 mm 0 0047 in 2nd ring Ring type Taper Dimensions B T 1 20 4 00 mm 0 0...

Page 44: ...all end free play F 0 16 0 40 mm 0 0063 0 0157 in Balancer Balancer drive method Gear Automatic centrifugal clutch Clutch shoe thickness 1 5 mm 0 06 in 1 0 mm 0 04 in Clutch in revolution 1 850 2 250 r min Clutch stall revolution 3 500 4 100 r min V belt V belt width 33 3 mm 1 31 in 30 0 mm 1 18 in Transmission Maximum main axle runout 0 06 mm 0 0024 in Maximum drive axle runout 0 06 mm 0 0024 in ...

Page 45: ... 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 0067 in Oil pressure hot 50 0 kPa at 1 600 r min 0 50 kg cm2 at 1 600 r min 7 1 psi at 1 600 r min Pressure check location Cylinder head Cooling system Radiator core Width 400 0 mm 15 75 in Height 266 0 mm 10 47 in Depth 26 0 mm 1 02 in Radiator cap opening pressure 93 3 122 7 kPa 0 933 1 227 kg cm2 13 27 17 45 psi Coolant reservoir capacity Up to the maxim...

Page 46: ...2 11 SPEC ENGINE SPECIFICATIONS Cylinder head tightening sequence 6 8 5 7 2 1 4 3 ...

Page 47: ... mm 10 26 in 3 4 Spring rate K1 19 40 N mm 1 98 kgf mm 110 77 lb in Spring stroke K1 0 0 108 0 mm 0 00 4 25 in 1 2 0 0 110 0 mm 0 00 4 33 in 3 4 Optional spring available No Rear suspension Rear shock absorber assembly 81 0 mm 3 19 in 1 2 85 0 mm 3 35 in 3 4 Spring free length 328 0 mm 12 91 in 1 2 286 3 mm 11 27 in 3 4 Installed length 273 2 mm 10 76 in 1 2 235 0 mm 9 25 in 3 4 Spring rate K1 44 ...

Page 48: ...in Pad thickness inner 5 2 mm 0 20 in 1 5 mm 0 06 in Pad thickness outer 5 2 mm 0 20 in 1 5 mm 0 06 in Master cylinder inside diameter 17 46 mm 0 69 in Caliper cylinder inside diameter 27 00 mm 1 06 in Recommended fluid DOT 4 Rear disc brake Type Dual Disc outside diameter thickness 184 6 3 5 mm 7 27 0 14 in Brake disc minimum thickness 3 0 mm 0 12 in Brake disc maximum deflection 0 1 mm 0 004 in ...

Page 49: ...mum deflection 0 1 mm 0 004 in Brake pad lining thickness inner 3 2 mm 0 13 in 1 0 mm 0 04 in Brake pad lining thickness outer 3 2 mm 0 13 in 1 0 mm 0 04 in Brake lever and brake pedal Accelerator pedal free play 0 mm 0 in Brake pedal free play 0 mm 0 in Parking brake cable free play The maximum free play is equal to one click of the parking brake lever Item Standard Limit ...

Page 50: ...k plug cap Material Resin Resistance 10 0 kΩ AC magneto Model manufacturer F004T39372 MITSUBISHI Standard output 14 0 V 33 5 A at 5 000 r min Stator coil resistance color 0 099 0 121 Ω at 20 C 68 F white white Rectifier regulator Type Semiconductor short circuit Model manufacturer FH012AA SHINDENGEN No load regulated voltage DC 14 2 14 8 V Rectifier capacity 50 0 A Withstand voltage 40 0 V Electri...

Page 51: ...ance 96 0 Ω Four wheel drive motor relay 3 Model manufacturer ACM33211 MATSUSHITA Coil resistance 96 0 Ω Headlight relay Model manufacturer G8HN 1C4T DJ OMRON Coil resistance 105 0 Ω Four wheel drive motor relay 1 Model manufacturer G8HN 1C4T DJ OMRON Coil resistance 105 0 Ω Four wheel drive motor relay 2 Model manufacturer G8HN 1C4T DJ OMRON Coil resistance 105 0 Ω Circuit breaker Circuit breaker...

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

Page 53: ... 1 0 7 2 Water jacket joint Bolt M6 2 10 1 0 7 2 Crankshaft end accessing screw Bolt M36 1 10 1 0 7 2 Timing mark accessing screw Bolt M14 1 6 0 6 4 3 Drive belt cover Bolt M6 12 10 1 0 7 2 Drive belt case Bolt M6 8 10 1 0 7 2 V belt cooling duct 1 bracket Bolt M6 2 10 1 0 7 2 Bearing housing primary sheave assembly Bolt M6 4 10 1 0 7 2 Bearing retainer bearing housing Bolt M6 1 10 1 0 7 2 AC magn...

Page 54: ... 9 0 65 Secondary sheave assembly Nut M16 1 100 10 0 72 Shift lever cover Bolt M6 4 10 1 0 7 2 Shift lever 2 assembly Bolt M6 1 14 1 4 10 Shift drum stopper Bolt M14 1 18 1 8 13 Crankcase plug bolt Bolt M14 1 18 1 8 13 Select lever unit Bolt M8 3 15 1 5 11 Shift arm Bolt M6 1 14 1 4 10 Shift rod locknut select lever unit side Nut M8 1 15 1 5 11 Left hand thread Shift rod locknut shift arm side Nut...

Page 55: ...mper plate and frame M8 16 1 6 11 Side door bracket and side door M6 7 0 7 5 1 Frame and hinge M8 23 2 3 17 LT Frame and latch M6 8 0 8 5 8 LT Handle latch and side door M5 5 0 5 3 6 Fuel tank and fuel pump M6 8 0 8 5 8 Front bumper and frame M12 59 5 9 43 M10 32 3 2 23 Cargo bed release lever M8 16 1 6 11 M6 7 0 7 5 1 Gas spring assembly and cargo bed assembly M8 16 1 6 11 Gas spring assembly and...

Page 56: ... 32 Steering knuckle and tie rod M12 39 3 9 28 Steering knuckle and front upper arm M12 30 3 0 22 Steering knuckle and front lower arm M12 30 3 0 22 Steering knuckle and brake disc guard M6 7 0 7 5 1 Front arm protector and front lower arm M6 7 0 7 5 1 Front wheel and front wheel hub M10 55 5 5 40 Front wheel hub and constant velocity joint M20 350 35 0 250 Stake Front brake caliper and steering k...

Page 57: ...2 7 19 Parking brake lever assembly and parking brake lever assembly bracket M6 13 1 3 9 4 Parking brake lever assembly bracket and frame M10 32 3 2 23 Parking brake cable holder and frame M6 7 0 7 5 1 Parking brake assembly and final drive gear assembly M10 40 4 0 29 Parking brake disc and final drive gear assembly M6 10 1 0 7 2 Parking brake pad holding bolt M10 17 1 7 12 LT Parking brake arm nu...

Page 58: ...9 M8 23 2 3 17 Ring gear stopper nut M8 16 1 6 11 Bearing retainer and final gear pinion gear bear ing housing M65 170 17 0 125 Left hand thread LT Drive shaft coupling gear and final drive pinion gear M12 80 8 0 58 Part to be tightened Thread size Tightening torque Remarks Nm m kg ft lb ...

Page 59: ...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 60: ...s intake and exhaust M Rocker arm shafts E Camshaft lobes M Decompressor lever pin E Decompressor lever spring E Rocker arms intake and exhaust M Oil pump shaft E O ring oil filter cartridge LS Water pump impeller shaft M Dipstick mating surface E Starter idler gear inner surface E Starter idler gear shaft E Starter wheel gear E Torque limiter E Clutch housing shaft end LS Clutch carrier assembly ...

Page 61: ...ICANT TYPES Shift lever 1 E Shift lever 1 gear teeth and shift lever 2 gear teeth E AC magneto lead grommet Yamaha bond No 1215 Three bond No 1215 Crankcase mating surface Yamaha bond No 1215 Three bond No 1215 Lubrication points Lubricant ...

Page 62: ...2 27 SPEC COOLANT FLOW DIAGRAMS COOLANT FLOW DIAGRAMS 1 Radiator outlet pipe 2 Radiator inlet hose 3 Radiator outlet hose 4 Radiator cap 5 Radiator 6 Radiator inlet pipe 6 1 1 2 5 4 4 5 A A 3 3 2 ...

Page 63: ...COOLANT FLOW DIAGRAMS 1 Radiator inlet pipe 2 Thermostat outlet hose 3 Thermostat 4 Radiator outlet pipe 5 Water pump inlet hose 6 Water pump 7 Water pump outlet pipe 8 Water pump outlet hose 1 2 2 1 3 4 5 6 7 8 ...

Page 64: ...EBS00026 OIL FLOW DIAGRAMS 1 Oil delivery pipe 2 2 Oil delivery pipe 3 3 Oil delivery pipe 1 4 Oil filter cartridge 5 Oil strainer 6 Reverse idle gear shaft 7 Drive axle 8 Relief valve assembly 6 7 8 4 2 1 4 3 4 5 1 2 B B A A B B ...

Page 65: ...2 30 SPEC OIL FLOW DIAGRAMS 1 Camshaft 2 Crankshaft 3 Oil strainer 4 Oil pump rotor 5 Oil pump driven gear 1 2 4 5 3 ...

Page 66: ... delivery pipe 2 3 Oil outlet hose 4 Oil inlet hose 5 Oil cooler inlet pipe 2 6 Oil cooler outlet pipe 2 7 Oil cooler outlet hose 8 Oil cooler outlet pipe 1 9 Oil cooler inlet pipe 1 0 Oil cooler A Oil cooler inlet hose 5 6 1 2 A A A 9 0 8 7 6 5 4 3 7 9 8 0 ...

Page 67: ...mostat outlet hose 7 Radiator inlet pipe 8 Brake pipe 9 Radiator inlet hose 0 Front brake hose A Radiator fan motor breather hose B Differential gear case breather hose C Coolant reservoir breather hose D Parking brake switch lead E Reverse switch lead F Gear position switch lead E F 8 9 9 0 A A B C D 1 2 2 3 3 4 5 6 7 È É Ê Ë Ì Í Î B C A A B C ...

Page 68: ... the excess of the hoses through the guide in the upper instrument panel so that there is no slack in the hoses Ì Fasten the radiator inlet hose and throttle cable with the plastic band Í 10 20 mm 0 39 0 79 in Î Route the throttle cable to the inside of the radia tor inlet hose E F 8 9 9 0 A A B C D 1 2 2 3 3 4 5 6 7 È É Ê Ë Ì Í Î B C A A B C ...

Page 69: ...ad 7 Parking brake cable 8 Thermostat outlet hose 9 Coolant temperature sensor lead 0 Reverse switch lead A Gear position switch lead B Brake pipe È Fasten the wire harness to the frame with the plastic bands É 30 Ê Fasten the parking brake cable at the white tape with the holder Ë Route the wire harness through the frame Ì Fasten the brake pipe to the frame with the plas tic bands ...

Page 70: ...there is no slack in the lead Ï Fasten the unused coupler to the wire harness with tape Ð Fasten the tail brake light lead with the plastic holder Ñ Fasten the tail brake light lead with the plastic band Ò Fasten the wire harness with the plastic band 0 8 A 2 1 2 3 4 5 6 6 6 6 8 9 7 2 È É Í Í Î Ï Ð Ð Ñ Ñ Ò Ò A C D B D E E 2 B 7 Ë Ê Ì B A C E E ...

Page 71: ...ase breather hose 9 Front brake hose 0 Differential gear motor lead A Radiator outlet hose B Water pump inlet hose C Oil inlet hose D Oil outlet hose E Ground lead F Starter motor lead G Coolant reservoir hose H Coolant reservoir breather hose I Wire harness J Lean angle sensor lead K Brake light switch lead UP UP E E F G H I I I I I I J L 0 A B E F C D 1 K 2 2 3 0 3 4 4 5 6 8 9 7 M N O P Q R È È ...

Page 72: ... the wire harness with the plastic band É Fasten the left headlight lead right headlight lead and radiator fan motor lead to the frame with a plastic band Ê 30 60 mm 1 18 2 36 in Ë 220 250 mm 8 66 9 84 in Ì Fasten the differential gear motor lead with the plastic band Í Fasten the radiator outlet hose and coolant res ervoir hose with the plastic clip Î Fasten the wire harness and brake light switc...

Page 73: ...nlet pipe with the plastic band Ó Fasten the brake pipe with the plastic band Ô Fasten the radiator outlet pipe with the plastic band Õ Fasten the AC magneto crankshaft position sen sor lead and fuel pump fuel sender lead with the plastic band UP UP E E F G H I I I I I I J L 0 A B E F C D 1 K 2 2 3 0 3 4 4 5 6 8 9 7 M N O P Q R È È È È É É Ê Ë Ì Í Î Ï Ð Ð Ñ Ò Ó Ô Õ F F C C G G C C G G F F A B E D ...

Page 74: ...ound lead 8 Water pump inlet hose 9 Oil delivery pipe 2 0 Oil delivery pipe 3 A Water pump outlet pipe B Water pump outlet hose C Brake pipe D Rear brake hose E Wire harness F Fuel tank breather hose G Fuel hose H Fuel pump fuel sender lead E F F G H H 8 9 0 A B C 2 C C C D 1 1 1 1 1 1 2 2 2 3 4 5 6 6 7 7 Ï Ê É Ê Ë Ì Í Î Ð Ñ Ò Õ Ô Ó Ö È Ø F F H H I I A A B B C C E D G E G D I I A A B B C C F F H H...

Page 75: ...der Í Fasten the brake pipe with the plastic band Î 55 65 mm 2 17 2 56 in Ï Fasten the final gear case breather hose with the plastic holder Ð Fasten the fuel tank breather hose with the plas tic holder Ñ Fasten the fuel hose with the plastic holder Ò Fasten the fuel pump fuel sender lead with the plastic band Ó Fasten the starter motor lead and ground lead with the plastic band Ô 50 60 mm 1 97 2 ...

Page 76: ... the brake pipe with the plastic holder Ø Fasten the fuel pump fuel sender lead with the plastic holder E F F G H H 8 9 0 A B C 2 C C C D 1 1 1 1 1 1 2 2 2 3 4 5 6 6 7 7 Ï Ê É Ê Ë Ì Í Î Ð Ñ Ò Õ Ô Ó Ö È Ø F F H H I I A A B B C C E D G E G D I I A A B B C C F F H H ...

Page 77: ... A AC magneto crankshaft position sensor lead B Throttle body breather hose C Oil delivery pipe 2 D Oil delivery pipe 3 E Fuel hose F Throttle position sensor lead G Fuel injector lead H Intake air pressure sensor lead I Final gear case breather hose J Rear brake hose K Spark plug lead L Parking brake cable E F H G I J J 8 I 8 9 0 A A B C D 1 2 3 4 5 6 7 8 2 3 4 5 67 7 K L M N O P Q È É Ê Ë Ë Ì Í ...

Page 78: ...h the plastic band making sure to align the red tape on the leads and harness with the band Ê Fasten the throttle body breather hose and wire harness with the plastic band Ë Fasten the starter motor lead and ground lead with the holder Ì Fasten the fuel hose with the plastic holder Í Make sure that the plastic band is not fastened too tightly around the wire harness Î Fasten the wire harness with ...

Page 79: ...astic band Ó Fasten the throttle cable at the white mark with the plastic band Ô Fasten the brake pipe with the plastic band Õ Fasten the wire harness and AC magneto crank shaft position sensor lead with the plastic band E F H G I J J 8 I 8 9 0 A A B C D 1 2 3 4 5 6 7 8 2 3 4 5 67 7 K L M N O P Q È É Ê Ë Ë Ì Í Î Ð Ï Ñ Ò Ó Ô Õ C A A B A A B C D D ...

Page 80: ... lock switch lead 9 Main switch lead 0 Light switch lead A Coolant reservoir breather hose B Rectifier regulator lead C Brake light switch lead D Throttle cable E Differential gear case breather hose F Radiator fan motor breather hose G Left headlight lead H Oil cooler inlet pipe 2 oil cooler outlet pipe 2 I Right headlight lead J Starter motor lead K Starter relay lead H I J K A A D E F G B C D 8...

Page 81: ...older É Fasten the differential gear case breather hose and coolant reservoir breather hose with the plastic holder Ê Fasten the light switch lead with the plastic band Ë Fasten the main switch lead and light switch lead with the plastic holder Ì Fasten the coolant reservoir breather hose with the plastic holder H I J K A A D E F G B C D 8 9 0 1 2 3 4 5 6 7 L M N O P Q R S È É Ê Ë Ì Í Î Ï Ð Ñ Ò Ó ...

Page 82: ...fan motor breather hose dif ferential gear case breather hose brake light switch lead and coolant reservoir breather hose through the hose guide Ð Fasten the throttle cable with the plastic holder Ñ Fasten the left headlight lead radiator fan motor breather hose differential gear case breather hose radiator fan motor lead and coolant reser voir breather hose with the plastic band Ò Fasten the oil ...

Page 83: ... lead and coolant reservoir breather hose with the plastic band Ô Fasten the positive battery lead with the plastic holder Õ 4 mm 0 16 in of clearance or more is required around the boot Ö 59 61 mm 2 32 2 40 in H I J K A A D E F G B C D 8 9 0 1 2 3 4 5 6 7 L M N O P Q R S È É Ê Ë Ì Í Î Ï Ð Ñ Ò Ó Ô Õ Ö B B A B B A ...

Page 84: ...h lead 8 Ground lead 9 Rectifier regulator lead 0 Wire harness A Radiator fan motor lead B Brake pipe C Front brake hose D Oil cooler inlet pipe 2 oil cooler outlet pipe 2 E Starter relay lead È Fasten the left headlight lead with the plastic band É Fasten the front brake hose with the plastic band Ê Fasten the right headlight lead with the plastic band E 8 8 9 0 0 A B C C D 1 3 4 2 3 4 5 6 7 È É ...

Page 85: ...r an hour meter follow the km mi or hours mainte nance intervals However keep in mind that if the vehicle isn t used for a long period of time the month maintenance intervals should be followed Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 3 6 6 12 km mi 320 200 1...

Page 86: ...ake Check operation brake pad wear fluid leakage Correct if necessary Replace pads if worn to the limit Rear brake Check operation brake pad wear fluid leakage Correct if necessary Replace pads if worn to the limit Parking brake Check operation and free play brake pad wear Correct if necessary Replace pads if worn to the limit Accelerator pedal Check operation and free play V belt Check operation ...

Page 87: ...ture When the valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove seats rear console Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 center protector Refer to PANELS AND FRONT CON SOLE in chapter 8 2 Remove intake tappet cover 1 exhaust tappet cover camshaft sprocket cover 2 1 2 3 Disconnect spark plug cap 1 4 Re...

Page 88: ...at the top dead center TDC on the compression stroke align the I mark a on the camshaft sprocket with the stationary pointer b on the cylinder head Valve clearance cold Intake valve 0 09 0 13 mm 0 0035 0 0051 in Exhaust valve 0 16 0 20 mm 0 0063 0 0079 in a b c Measure the valve clearance with a thick ness gauge 1 Out of specification Adjust Thickness gauge 90890 03180 Feeler gauge set YU 26900 9 ...

Page 89: ...event it from moving and tighten the locknut to the speci fied torque e Measure the valve clearance again f If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained 8 Install crankshaft end accessing screw 9 Install spark plug 10 Connect spark plug cap Tappet adjusting tool 90890 01311 Six piece tappet set Y...

Page 90: ...AND FRONT CON SOLE in chapter 8 rear console seats Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 New T R 10 Nm 1 0 m kg 7 2 ft lb 1 New New T R 10 Nm 1 0 m kg 7 2 ft lb New T R 10 Nm 1 0 m kg 7 2 ft lb ADJUSTING THE THROTTLE CABLE 1 Remove seats rear console Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 2 Remove throttle valve cover 1 1 3 Check throttle cable a Slack Re...

Page 91: ...at the throttle valve 3 closes completely after releasing the accelerator pedal Direction a Free play is increased Direction b Free play is decreased a b 2 1 3 5 Install throttle valve cover 6 Install rear console seats Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 EBS00057 CHECKING THE SPARK PLUG 1 Remove seats rear console Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8...

Page 92: ...cleaner or wire brush 7 Measure spark plug gap a Use a wire gauge or thickness gauge Out of specification Regap 8 Tighten spark plug TIP _ Before installing a spark plug clean the gasket surface and plug surface 9 Connect spark plug cap 10 Install rear console seats Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Spark plug gap 0 8 0 9 mm 0 031 0 035 in T R 13 Nm 1 3 m kg 9 4 ft lb ...

Page 93: ... REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 fuel tank Refer to FUEL PUMP AND FUEL TANK in chapter 6 2 Attach tachometer timing light to spark plug lead Digital tachometer 90890 06760 YU 39951 B Timing light 90890 03141 Inductive clamp timing light YU 03141 3 Check ignition timing a Warm up the engine and keep it at the specified speed b Remove the timing mark accessing screw 1 Engine speed 1 ...

Page 94: ...ew 4 Detach timing light tachometer 5 Install fuel tank Refer to FUEL PUMP AND FUEL TANK in chapter 6 rear console seats Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 T R Timing mark accessing screw 6 Nm 0 6 m kg 4 3 ft lb a b EBS00061 MEASURING THE COMPRESSION PRESSURE TIP _ Insufficient compression pressure will result in a loss of performance 1 Measure valve clearance Out of sp...

Page 95: ...vent it from falling into the cylinder 6 Attach extension 1 compression gauge 2 7 Measure compression pressure Out of specification Refer to steps c and d a Set the main switch to ON Compression gauge 90890 03081 Engine compression tester YU 33223 Extension 90890 04082 Compression pressure at sea level Minimum 392 kPa 3 92 kg cm2 55 8 psi Standard 450 kPa 4 50 kg cm2 64 0 psi Maximum 504 kPa 5 04 ...

Page 96: ...rbon deposits Eliminate d If the compression pressure is below the minimum specification squirt a few drops of oil into the cylinder and measure again Refer to the following table 8 Install spark plug 9 Connect spark plug cap 10 Install rear console seats Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 Compression pressure with oil applied into the cylinder Reading Diagnosis Higher ...

Page 97: ... level TIP To obtain an accurate oil level reading the dip stick must be inserted completely into the oil filter hole NOTICE Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD c or higher and do not use oils labeled ENERGY CONSERVING II d Do not allow foreign materi...

Page 98: ...fer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 EBS00069 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several min utes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove seats rear console Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 4 Remove dipstick 1 1 5 Remove engine oil drain bolt 1 along with the gasket 6 Drain engine oil complet...

Page 99: ...cifi cation with an oil filter wrench e Lower the cargo bed 8 Check engine oil drain bolt gasket Damage Replace 9 Install engine oil drain bolt along with the gasket 10 Fill crankcase with the specified amount of the recom mended engine oil 11 Install dipstick 12 Start the engine warm it up for several min utes and then turn it off Oil filter wrench 90890 01426 YU 38411 T R Oil filter cartridge 17...

Page 100: ...n the engine off so that it will not seize c Check the engine oil passages the 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 check bolt to specification T R Oil check bolt 10 Nm 1 0 m kg 7 2 ft lb 1 EBS00073 CLEANING THE AIR FILTER ELE...

Page 101: ... 1 3 Remove air filter case cover 1 1 4 Remove air filter element 1 air filter element frame 2 NOTICE _ The engine should never be run without the air filter excessive piston and or cylinder wear may result 5 Check air filter element air filter element frame Damage Replace 1 1 2 ...

Page 102: ... twist or wring out the element This could damage the foam material c Apply Yamaha foam air filter oil or other quality foam air filter oil to the element d Squeeze out the excess oil TIP _ The element should be wet but not dripping 7 Install air filter element frame air filter element TIP _ Make sure its sealing surface matches the sealing surface of the case so there is no air leak 8 Install air...

Page 103: ... 6 3 Install rear console seats Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 1 EAS00096 CHECKING THE FUEL HOSE 1 Remove seats rear console Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 2 Check fuel hose 1 Cracks damage Replace Loose connection Connect properly 3 Install rear console seats Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 1 EAS00098 C...

Page 104: ...ed on a cold engine since the level varies with engine tem perature 2 Check coolant level The coolant level should be between the minimum level mark a and maximum level mark b in the coolant reservoir Below the minimum level mark Add the recommended coolant to the proper level NOTICE _ Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant ...

Page 105: ...oir hose 2 1 6 Remove radiator cap 1 WARNING _ A hot radiator is under pressure Therefore do not remove the radiator cap when the engine is hot Scalding hot fluid and steam may be blown out which could cause seri ous injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radia tor cap and slowly turn the radiator cap counterclockwise toward the det...

Page 106: ...T R 10 Nm 1 0 m kg 7 2 ft lb 11 Fill cooling system with the specified amount of the recom mended coolant Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1 1 antifreeze water Quantity Total amount 2 35 L 2 07 Imp qt 2 48 US qt Coolant reservoir capacity up to the maximum level mark 0 32 L 0 28 Imp qt 0 34 US qt From m...

Page 107: ...owers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with water Do not mix different types of antifreeze 12 Fill coolant reservoir ...

Page 108: ...tes and then rev the engine five times 16 Pour the recommended coolant into the radiator until it is full 17 Stop the engine and allow it to cool If the coolant level has dropped after the engine has cooled add sufficient coolant until it reaches the top of the radiator and then install the radiator cap 18 Start the engine and then check for coolant leakage 19 Install fuel tank Refer to FUEL PUMP ...

Page 109: ...ator inlet pipe 6 radiator outlet pipe 7 thermostat outlet hose 8 water pump inlet hose 9 water jacket 0 water pump outlet hose A water pump outlet pipe B water pump housing C Cracks damage Replace Refer to COOLING SYSTEM in chapter 5 oil cooler D oil cooler inlet pipe 1 oil cooler outlet pipe 1 E oil cooler inlet hose F oil cooler outlet hose G oil cooler inlet pipe 2 oil cooler outlet pipe 2 H o...

Page 110: ...t checking method Turn the main switch ON Coolant temperature warning light does not come on Coolant temperature warning light comes on Turn the main switch to START with the transmission in neutral position Coolant temperature warning light comes on momentarily Coolant temperature warning light does not come on Check the electrical circuit Refer to SIGNALING SYSTEM in chapter 9 Coolant temperatur...

Page 111: ...sheave and secondary sheave 3 Measure V belt width 2 Out of specification Replace V belt width 33 3 mm 1 31 in Limit 30 0 mm 1 18 in 4 Replace V belt a Install the bolts 1 90101 06018 into the secondary fixed sheave hold TIP _ Tightening the bolts 1 will push the secondary sliding sheave away causing the gap between the secondary fixed and sliding sheaves to widen 80 mm 3 15 in 1 b Remove the V be...

Page 112: ...T SYSTEM The following procedure applies to all of the exhaust pipe gaskets 1 Check exhaust pipe 2 1 exhaust pipe 1 2 muffler 3 muffler brackets 4 springs 5 Cracks damage Replace gaskets 6 Exhaust gas leaks Replace 2 Check tightening torques T R Exhaust pipe nut 7 20 Nm 2 0 m kg 14 ft lb Muffler and muffler bracket bolt 8 20 Nm 2 0 m kg 14 ft lb Muffler bracket and frame bolt 9 30 Nm 3 0 m kg 22 f...

Page 113: ...uffler and the gasket c Tap the tailpipe lightly with a soft face ham mer or suitable tool then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside of the tail pipe housing d Install the gasket and then insert the tailpipe into the muffler and align the bolt holes e Insert the bolts 1 and tighten them f Start the engine and rev it up approximat...

Page 114: ...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 TIP _ Make sure that there is no brake drag on the front or rear wheels Turning in Free play is increased Turning out Free play is decreased T R Locknut 17 Nm 1 7 m kg 12 ft lb ...

Page 115: ...ng brake lever free play a The maximum free play is equal to one click of the parking brake lever Incorrect Adjust a 4 Adjust parking brake mechanical a Move the parking brake lever to the released position b Remove the spring c Loosen the parking brake arm nut 1 d Turn the push rod 2 in fully and then turn it out 3 4 turn e Tighten the parking brake arm nut 1 f Install the spring 2 1 T R 17 Nm 1 ...

Page 116: ...obtained d Tighten the locknut 2 e Slide the adjuster cover 1 to its original position Direction a Free play is increased Direction b Free play is decreased a b 2 1 3 6 Install rear console seats Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 CHECKING THE BRAKE FLUID LEVEL 1 Place the vehicle on a level surface TIP When checking the brake fluid level make sure that the top of the brake f...

Page 117: ... result in a harmful chemical reaction and lead to poor perfor mance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in a vapor lock 4 Close the hood Recommended brake fluid DOT 4 1 CHECKING THE FRONT BRAKE PADS 1 Remove front wheels Refer to FRONT AND REAR WHEELS in chapter 8 2 Check brake pads We...

Page 118: ...Replace the brake pads as a set Refer to FRONT AND REAR BRAKES in chapter 8 3 Operate the brake pedal 4 Install rear wheels Refer to FRONT AND REAR WHEELS in chapter 8 Brake pad wear limit a 1 5 mm 0 06 in CHECKING THE PARKING BRAKE PADS 1 Check brake pads Wear indicator groove 1 almost disap peared Replace the brake pads as a set Refer to PARKING BRAKE in chapter 8 2 Operate the parking brake Bra...

Page 119: ...t brake hoses 1 front brake pipe 2 rear brake pipes 3 rear brake hoses 4 Cracks wear damage Replace Fluid leakage Replace all damaged parts Refer to FRONT AND REAR BRAKES in chapter 8 TIP Hold the vehicle in an upright position and apply the brake pedal 5 Check brake hose holders Loosen Tighten 6 Lower the cargo bed 7 Close the hood 8 Install rear console seats Refer to SEATS ENCLOSURE HOOD AND CA...

Page 120: ...Connect a clear plastic hose 1 tightly to the caliper bleed screw 2 È Front É Rear d Place the other end of the hose into a con tainer e Slowly apply the brake pedal several times f Push down on the pedal and hold it g Loosen the bleed screw and allow the pedal 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 u...

Page 121: ...5 Select lever shift rod NOTICE Before shifting you must stop the vehicle and take your foot off the accelerator pedal Otherwise the transmission may be dam aged 1 Adjust select lever shift rod a Make sure the select lever is in NEUTRAL b Loosen both locknuts 1 NOTICE The select lever shift rod locknut select lever side has left handed threads To loosen the locknut turn it clockwise c Adjust the s...

Page 122: ...Hold the main body 1 of the brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the brake light comes on at the proper time 4 Close the hood Direction a Brake light comes on sooner Direction b Brake light comes on later 1 a b 2 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 l...

Page 123: ...L GEAR OIL 1 Place the vehicle on a level surface 2 Remove rear skid plate 1 3 Place a container under the final gear case to collect the used oil 1 4 Remove oil filler plug 1 1 5 Remove drain plug 1 6 Drain final gear oil 1 7 Install drain plug TIP Check the drain plug gasket If it is damaged replace it with a new one T R 20 Nm 2 0 m kg 14 ft lb ...

Page 124: ... gear case 9 Install oil filler plug 10 Install rear skid plate 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 23 Nm 2 3 m kg 17 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb CHECKING THE DIFFERENTIAL GEAR OIL 1 Place the vehicle on a level surface 2 Remove oil filler plug 1 1 1 ...

Page 125: ...r level NOTICE Take care not allow foreign material to enter the 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 receptacle under the differential gear case 3 Remove front skid plate 1 1 4 Remove oil filler plug 1 1 ...

Page 126: ... 1 T R 10 Nm 1 0 m kg 7 2 ft lb 8 Fill differential gear case NOTICE Take care not to allow foreign material to enter the differential gear case 9 Install oil filler plug 10 Install front skid plate Periodic oil change 0 18 L 0 16 Imp qt 0 19 US qt Total amount 0 20 L 0 18 Imp qt 0 21 US qt Recommended oil SAE 80 API GL 4 Hypoid gear oil T R 23 Nm 2 3 m kg 17 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb ...

Page 127: ...mbly bearings Try to move the steering wheel up and down and back and forth Excessive play Replace the steering shaft assembly 3 Check tie rod ends Turn the steering wheel to the left and right until it stops completely and then move the steering wheel slightly in the opposite direc tion Vertical play Replace the tie rod end 4 Raise the front end of the vehicle so that there is no weight on the fr...

Page 128: ... opposite one another e Measure distance É between the marks f Calculate the toe in using the formula given below g If the toe in is incorrect adjust it 3 Adjust toe in WARNING Be sure that both tie rods are turned the same amount If not the vehicle will drift right or left even though the steering wheel is positioned straight This may lead to mishandling and an accident After setting the toe in t...

Page 129: ...T R Locknut rod end 40 Nm 4 0 m kg 29 ft lb ADJUSTING THE FRONT SHOCK ABSORBERS For models equipped with oil damper shock absorbers WARNING Always adjust the spring load of both shock absorbers to the same setting Uneven adjustment can cause poor han dling and loss of stability TIP The spring preload of the shock absorbers can be adjusted to suit the operator s preference weight and the operating ...

Page 130: ...the locknut 1 with the ring nut wrench 2 c Turn the adjusting ring 3 in direction a or b TIP _ Be sure to remove all dirt and mud from around the locknut and adjusting ring before adjusting NOTICE _ Never attempt to turn the adjusting ring beyond the maximum or minimum setting d Tighten the locknut to specification Ring nut wrench 90890 01268 Spanner wrench YU 01268 Direction a Spring preload is i...

Page 131: ...justing screw may be dam aged Direction a Rebound damping force is increased Direction b Rebound damping force is decreased From the fully turned in position Standard 10 clicks out Minimum 12 clicks out Maximum 9 clicks out a b 1 3 Adjust compression damping force a Turn the adjusting screw 1 in direction a or b Direction a Compression damping force is increased Direction b Compression damping for...

Page 132: ...sorbers WARNING Always adjust the spring load of both shock absorbers to the same setting Uneven adjustment can cause poor han dling and loss of stability TIP The spring preload of the shock absorbers can be adjusted to suit the operator s preference weight and the operating conditions 1 Adjust spring preload Turn the adjuster 1 to increase or decrease the spring preload Standard position 2 Minimu...

Page 133: ...locknut 1 with the ring nut wrench 2 c Turn the adjusting ring 3 in direction a or b TIP _ Be sure to remove all dirt and mud from around the locknut and adjusting ring before adjusting NOTICE _ Never attempt to turn the adjusting ring beyond the maximum or minimum setting d Tighten the locknut to specification Ring nut wrench 90890 01268 Spanner wrench YU 01268 Direction a Spring preload is incre...

Page 134: ...justing screw may be dam aged Direction a Rebound damping force is increased Direction b Rebound damping force is decreased From the fully turned in position Standard 12 clicks out Minimum 20 clicks out Maximum 3 clicks out a b 1 3 Adjust compression damping force a Turn the adjusting screw 1 in direction a or b Direction a Compression damping force is increased Direction b Compression damping for...

Page 135: ...g character istics and are therefore not recom mended TIRE PRESSURE 1 Recommended tire pressure Front 70 kPa 0 70 kg cm2 10 psi Rear 98 kPa 0 98 kg cm2 14 psi 2 Tire pressure below the minimum speci fication could cause the tire to dislodge from the rim under severe riding 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 ...

Page 136: ...t on trailer hitch point 50 kg 110 lb Be extra careful of the vehicle balance and stability when towing a trailer 1 Measure tire pressure cold tire pressure Out of specification Adjust TIP A tire pressure gauge 1 is included as stan dard equipment If dust or the like is stuck to this gauge it will not provide the correct readings Therefore take two measurements of the tire s pressure and use the s...

Page 137: ... 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 Tire wear limit a Front and rear 3 0 mm 0 12 in CHECKING THE WHEELS 1 Check wheels 1 Damage bends Replace TIP Always balance the wheel when a tire or wheel has been changed or replaced WARNING Never attempt even small re...

Page 138: ...ace a damaged cable as soon as possi ble 1 Check cable sheath Damage Replace 2 Check cable operation Unsmooth operation Lubricate or replace TIP Hold the cable end up and apply several drops of lubricant to the cable 3 Apply lithium soap based grease onto end of the cable Recommended lubricant Yamaha chain and cable lube or engine oil LUBRICATING THE PEDALS ETC 1 Lubricate the pivoting parts Recom...

Page 139: ...electrolyte 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 NOTICE _ This is a sealed battery Never remove the seal...

Page 140: ... leads from the battery terminals NOTICE _ First disconnect the negative battery lead 1 and then the positive battery lead 2 3 Remove battery 4 Check battery charge a Connect a pocket tester to the battery termi nals TIP _ 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...

Page 141: ...e to regulate the charging current on the battery charger be careful not to overcharge the battery When charging a battery be sure to remove it from the vehicle If charging has to be done with the battery mounted on the vehicle disconnect the negative battery lead from the battery terminal To reduce the chance of sparks do not plug in the battery charger until the bat tery charger leads are connec...

Page 142: ...ct the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of an MF battery sta bilizes about 30 minutes after charging has been completed Therefore wait 30 minutes after charging is completed before measuring the open circuit volt age ...

Page 143: ... THE BATTERY If the amperage does not exceed the standard charging amperage after 5 minutes replace the battery If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging amperage Leave the battery unused for more than 30 minutes before measuring its open circ...

Page 144: ...arge the battery until the charging voltage reaches 15 V This type of battery charger cannot charge an MF battery A variable voltage charger is recommended Leave the battery unused for more than 30 minutes before measuring its open cir cuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the battery Constant amperage chargers are not suitable for chargin...

Page 145: ...ttery lead 2 8 Check battery terminals Dirt Clean with a wire brush Loose connection Connect properly 9 Lubricate battery terminals 10 Install battery cover Recommended lubricant Dielectric grease 1 2 EBS00121 CHECKING THE FUSES The following procedure applies to all of the fuses NOTICE _ To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove battery ...

Page 146: ..._ Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage c Set on the switches to verify if the electrical circuit is operational Pocket tester 90890 03112 Analog pocket tester YU 03112 C ...

Page 147: ...xtensive damage to the electrical system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install battery cover Items Amperage rating Q ty Main fuse 40 A 1 Backup fuse 10 A 1 Fuel injection system fuse 10 A 1 Ignition fuse 10 A 1 Headlight fuse 15 A 1 Four wheel drive motor fuse 10 A 1 Radiator fan motor fuse 25 A 1 Signaling sys tem fuse 10 A 1 Auxiliary DC...

Page 148: ...IGHT BEAMS 1 Adjust headlight beam vertically a Turn the adjusting screw 1 in direction a or b Direction a Headlight beam is raised Direction b Headlight beam is lowered CHANGING THE HEADLIGHT BULBS 1 Lift the hood up 2 Remove cover at the rear of the headlight 1 3 Remove headlight bulb holder cover 1 ...

Page 149: ...he headlight bulb holder NOTICE Avoid touching the glass part of the bulb Keep it free from oil otherwise the trans parency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on the bulb thoroughly clean it with a cloth moistened with alcohol or lac quer thinner 6 Install headlight bulb holder headlight bulb holder cover cover at the rear of the headlight 7 Clos...

Page 150: ...ouch the bulb until it cools down 4 Install bulb Secure the new bulb with the tail brake light bulb holder NOTICE Avoid touching the glass part of the bulb Keep it free from oil otherwise the trans parency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on the bulb thoroughly clean it with a cloth moistened with alcohol or lac quer thinner 5 Install tail brak...

Page 151: ... belt cooling ducts muffler and exhaust pipes 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 Seats rear console Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 Left protector Refer to PANELS AND FRONT CON SOLE in chapter 8 Cargo bed Refer to CARGO BED in chapter 8 Air intake...

Page 152: ...hrottle body assembly Refer to THROTTLE BODY in chapter 6 Fuel tank Refer to FUEL PUMP AND FUEL TANK in chapter 6 Front drive shaft Refer to FRONT CONSTANT VELOC ITY JOINTS DIFFERENTIAL GEAR AND DRIVE SHAFT in chapter 7 Rear drive shaft Refer to REAR CONSTANT VELOCITY JOINTS FINAL DRIVE GEAR AND DRIVE SHAFT in chapter 7 1 Heat protector 1 2 Spring 5 3 Exhaust pipe 2 1 4 Gasket 2 5 Muffler bracket ...

Page 153: ... kg 5 1 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib Order Job Part Q ty Remarks 7 Exhaust pipe 1 1 8 Gasket 2 9 V belt cooling duct 1 1 10 V belt cooling duct 2 1 For installation reverse the removal pro cedure ENGINE REMOVAL ...

Page 154: ...duct 2 with the rib on the crank case and fit the projection c on the section b between the projections on the section d of the duct a b c b d 1 2 Install V belt cooling duct 1 1 TIP Fit the projections a and b on the sections c and d of V belt cooling duct 1 between the projections on the section e of the duct c a e d e b 1 ENGINE REMOVAL ...

Page 155: ... 2 T R 15 Nm 1 5 m kg 11 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib Order Job Part Q ty Remarks Removing the shift arm Remove the parts in the order listed 1 Select lever shift rod 1 2 Shift arm 1 For installation reverse the removal pro cedure ...

Page 156: ...isted 1 Cylinder head breather hose 1 2 Water pump inlet hose 1 Disconnect 3 Water pump outlet pipe hose 1 1 4 Water pump breather hose 1 5 Thermostat outlet hose 1 Disconnect 6 Oil outlet hose 1 Disconnect 7 Oil inlet hose 1 Disconnect 8 Spark plug cap 1 Disconnect 9 Starter motor lead 1 Disconnect 10 Engine ground lead 1 Disconnect 11 Reverse switch lead 1 Disconnect 12 Gear position switch coup...

Page 157: ...R 10 Nm 1 0 m kg 7 2 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib LS 1 8 5 11 6 7 9 10 2 4 3 13 15 14 12 Order Job Part Q ty Remarks 14 AC magneto coupler 2 Disconnect 15 Crankshaft position sensor coupler 1 Disconnect For installation reverse the removal pro cedure ...

Page 158: ...Job Part Q ty Remarks Removing the engine mounting bolts Remove the parts in the order listed Primary and secondary sheave assem bly drive belt case Refer to PRIMARY AND SECONDARY SHEAVES 1 Rubber damper nut rear side 2 Refer to INSTALLING THE ENGINE 2 Engine mounting bolt front upper side 2 3 Engine mounting bolt front lower side 2 4 Engine 1 5 Rubber damper nut front side 2 6 Rubber damper front...

Page 159: ... Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT LT LT LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 42 Nm 4 2 m kg 30 ft Ib T R 42 Nm 4 2 m kg 30 ft Ib 7 8 9 9 7 8 3 2 6 6 3 2 5 1 1 5 4 Order Job Part Q ty Remarks 9 Rubber damper rear side 2 Refer to INSTALLING THE ENGINE For installation reverse the removal pro cedure ENGINE REMOVAL ...

Page 160: ... engine 6 engine mounting bolts front lower side 7 engine mounting bolts front upper side 8 rubber damper nuts rear side 9 TIP _ Do not fully tighten the bolts and nuts 4 Tighten rubber damper nuts front side 5 engine mounting bolts front lower side 7 engine mounting bolts front upper side 8 rubber damper nuts rear side 9 3 2 1 1 3 2 7 8 4 4 7 8 5 9 9 5 6 T R 42 Nm 4 2 m kg 30 ft lb LT T R 10 Nm 1...

Page 161: ...9 4 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 38 Nm 3 8 m kg 27 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib Order Job Part Q ty Remarks Removing the cylinder head 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 Seats rear console Refer to SEATS REAR...

Page 162: ... 25 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 38 Nm 3 8 m kg 27 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib Order Job Part Q ty Remarks Thermostat coolant temperature sen sor Refer to THERMOSTAT in chapter 5 Air ducts exhaust pipes Refer to ENGINE REMOVAL 1 Spark plug cap 1 Disconnect 2 Spark plug 1 3 Cylinder head breather hose 1 4 Camshaft sprocket cover 1 5 Tappet cover 2 6 Oil de...

Page 163: ...Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 38 Nm 3 8 m kg 27 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib Order Job Part Q ty Remarks 13 Cylinder head 1 Refer to REMOVING THE CYLINDER HEAD and INSTALLING THE CYLIN DER HEAD 14 Cylinder head gasket ...

Page 164: ... at top dead center TDC on the compression stroke align the I mark c on the camshaft sprocket with the stationary pointer d on the cylinder head as shown in the illustration a b d c 2 Loosen camshaft sprocket bolts 1 decompressor assembly bolts 2 TIP While holding the AC magneto rotor nut with a wrench loosen the camshaft sprocket bolts and decompressor assembly bolts 3 Loosen timing chain tension...

Page 165: ...e camshaft sprocket and timing chain as a set a 1 4 of a tooth b Correct 1 Roller 2 Sprocket EBS00227 CHECKING THE TAPPET COVERS 1 Check tappet covers camshaft sprocket cover Cracks damage Replace EBS00229 CHECKING THE TIMING CHAIN TENSIONER 1 Check timing chain tensioner Cracks damage Replace 2 Check one way cam operation Rough movement Replace the timing chain tensioner 3 Check timing chain tens...

Page 166: ...deposits rust Eliminate 3 Measure cylinder head warpage Out of specification Resurface the cylin der head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern TIP ...

Page 167: ...orque them in two stages New 3 1 4 2 7 8 5 6 4 2 3 4 3 1 T R 35 Nm 3 5 m kg 25 ft lb T R 35 Nm 3 5 m kg 25 ft lb T R 38 Nm 3 8 m kg 27 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 4 Install decompressor assembly camshaft sprocket onto the camshaft a Install the decompressor assembly onto the camshaft and then finger tighten the decompressor assembly bolts 1 b Turn the crankshaft counterclockwise c Align the...

Page 168: ...r washer 2 and spring 3 b Release the timing chain tensioner one way cam 4 and push the timing chain tensioner rod 5 all the way into the timing chain ten sioner housing c Install the timing chain tensioner and gasket 6 onto the cylinder TIP Install the gasket with its beaded side facing the timing chain tensioner end d Install the spring and timing chain tensioner cap bolt 6 Turn crankshaft sever...

Page 169: ...s 1 decompressor assembly bolts 2 TIP While holding the AC magneto rotor nut with a wrench tighten the camshaft sprocket bolts and decompressor assembly bolts After tightening the decompressor assembly bolts check that decompressor assembly moves smoothly NOTICE _ Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging ...

Page 170: ...ty Remarks Removing the rocker arms and cam shaft Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Bearing retainer 1 Refer to REMOVING THE ROCKER ARMS AND CAMSHAFT and INSTALLING THE CAMSHAFT AND ROCKER ARMS 2 Rocker arm shaft 2 3 Intake rocker arm 1 4 Exhaust rocker arm 1 5 Locknut 4 6 Valve adjusting screw 4 7 Camshaft 1 8 Decompressor lever 1 NOTICE Do not disassembl...

Page 171: ...10 Nm 1 0 m kg 7 2 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib M Order Job Part Q ty Remarks 9 Decompressor lever pin 1 Refer to REMOVING THE ROCKER ARMS AND CAMSHAFT and INSTALLING THE CAMSHAFT AND ROCKER ARMS 10 Bearing 1 For installation reverse the removal pro cedure ...

Page 172: ...SHAFT 1 Check cam lobes Pitting scratches blue discoloration Replace 2 Measure cam lobe dimensions a and b Out of specification Replace Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 Weight 90890 01084 YU 01083 3 Camshaft lobe dimensions Intake a 42 481 42 581 mm 1 6725 1 6764 in Limit 42 381 mm 1 6685 in b 36 950 37 050 mm 1 4547 1 4587 in Limit 36 850 mm 1 4508 in Exhaust a 43 1...

Page 173: ...eck that the decompressor lever pin 1 projects from the camshaft c Check that the decompressor cam 2 moves smoothly 2 1 EBS00239 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to both of the rocker arms and rocker arm shafts 1 Check rocker arm Damage wear Replace 2 Check rocker arm shaft Blue discoloration excessive wear pitting scratches Replace or check the lubric...

Page 174: ...m the rocker arm inside diameter Out of specification Replace the defective part s Rocker arm shaft outside diame ter 11 981 11 991 mm 0 4717 0 4721 in Rocker arm to rocker arm shaft clearance 0 009 0 037 mm 0 0004 0 0015 in EAS00243 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1 Install bearing 1 onto the cylinder head TIP Apply engine oil to the bearing Install the bearing so that the seal is facing ...

Page 175: ...ant Engine oil 3 Install decompressor lever pin 1 decompressor lever 2 TIP _ Install the decompressor lever pin 1 and decompressor lever 2 in the camshaft 3 as shown in the illustration 3 1 2 4 Install camshaft 1 TIP Install the camshaft so that its projections a are aligned horizontally as shown 5 Lubricate rocker arm shafts Recommended lubricant Engine oil 1 a ...

Page 176: ...m shaft 2 intake rocker arm intake rocker arm shaft TIP _ Use a slide hammer bolt 3 to install the rocker arm shafts Make sure the rocker arm shafts intake and exhaust are completely pushed into the cyl inder head Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 3 2 1 ...

Page 177: ...linder head Refer to CYLINDER HEAD Rocker arms rocker arm shafts cam shaft Refer to ROCKER ARMS AND CAM SHAFT 1 Valve cotter 8 Refer to REMOVING THE VALVES AND VALVE SPRINGS and INSTALL ING THE VALVES AND VALVE SPRINGS 2 Valve spring retainer 4 3 Valve spring 4 4 Exhaust valve 2 5 Intake valve 2 6 Valve stem seal 4 7 Valve spring seat 4 8 Valve guide 4 Refer to CHECKING THE VALVES AND VALVE SPRING...

Page 178: ...k the valve face valve seat and valve seat width Refer to CHECKING THE VALVES AND VALVE SPRINGS a Pour a clean solvent a into the intake and exhaust ports b Check that the valve seals properly There should be no leakage at the valve seat 1 2 Remove valve cotters TIP _ Attach a valve spring compressor 1 and attachment 2 between the valve spring retainer and the cylinder head to remove the valve cot...

Page 179: ...e EBS00240 CHECKING THE VALVES AND VALVE SPRINGS The following procedure applies to all of the valves and valve guides 1 Measure valve stem to valve guide clearance Out of specification Replace the valve guide Stem to guide clearance valve guide inside diameter a valve stem diameter b Stem to guide clearance Intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 08 mm 0 0031 in Exhaust 0 025 0 052 mm 0 00...

Page 180: ... guide bore the valve guide using a valve guide reamer 3 to obtain proper stem to guide clearance TIP _ After replacing the valve guide reface the valve seat 3 Check valve face Pitting wear Grind the face valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace Valve guide position a 12 7 13 1 mm 0 50 0 52 in Valve guide remover ø6 90890 04064 Valve guide remover 6 ...

Page 181: ...om the valve face and valve seat 7 Check valve seats Pitting wear Reface the valve seat Runout limit 0 040 mm 0 0016 in 8 Measure valve seat width a Out of specification Reface the valve seat a Apply Mechanic s blueing dye Dykem b to the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear pattern d Measure the valv...

Page 182: ...valve guide b Apply molybdenum disulfide oil to the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the compound TIP _ For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands e Apply a fine lapping compound to the valve face and repeat the abov...

Page 183: ...alve spring free length 40 38 mm 1 59 in Limit 38 36 mm 1 51 in 11 Measure compressed spring force a Out of specification Replace b Installed length Compressed spring force 171 0 197 0 N at 35 00 mm 17 44 20 09 kg at 35 00 mm 38 44 44 29 lb at 1 38 in 12 Measure spring tilt a Out of specification Replace Spring tilt limit 2 5 1 80 mm 0 071 in EBS00241 INSTALLING THE VALVES AND VALVE SPRINGS The fo...

Page 184: ...prings 4 valve spring retainers 5 TIP _ Install the valve springs with the larger pitch a facing upwards b Smaller pitch 4 Install valve cotters TIP _ Install the valve cotters while compressing the valve spring with the valve spring compressor 1 and attachment 2 Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attach ment 90890 01243 Valve spring compressor adapter 26 mm YM 01...

Page 185: ...4 35 ENG VALVES AND VALVE SPRINGS 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a mallet NOTICE _ Hitting the valve tip with excessive force could damage the valve ...

Page 186: ... Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD Water jacket joint Refer to WATER PUMP in chapter 5 1 Timing chain guide exhaust side 1 2 Cylinder 1 Refer to INSTALLING THE PISTON AND CYLINDER 3 Cylinder gasket 1 4 Dowel pin 2 5 Piston pin clip 2 Refer to REMOVING THE PISTON and INSTALLING THE PISTON AND CYLINDER 6 Piston pin 1 7 Piston 1 8 Top ring 1 9 2nd ring 1 10 Oil...

Page 187: ...as are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 4 NOTICE _ Do not use a hammer to drive the piston pin out Piston pin puller set 90890 01304 Piston pin puller YU 01304 1 2 3 2 Remove piston rings TIP _ Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown as shown in the illustration EBS002...

Page 188: ...m 0 39 in from the bottom edge of the pis ton d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula Cylinder bore C 102 000 102 010 mm 4 0157 4 0161 in Taper limit T 0 05 mm 0 002 in Out of round R 0 05 mm 0 002 in C Maximum D T Maximum D1 or D2 Maximum D5 or D6 R Maximum D1 D3 or D5 Minimum D2 D4 or D6 Piston...

Page 189: ...s from the piston ring grooves and piston rings Piston ring side clearance Top ring 0 030 0 070 mm 0 0012 0 0028 in Limit 0 12 mm 0 0047 in 2nd ring 0 030 0 070 mm 0 0012 0 0028 in Limit 0 13 mm 0 0051 in 2 Install piston ring into the cylinder TIP _ Level the piston ring into the cylinder with the piston crown a 50 mm 1 97 in 3 Measure piston ring end gap Out of specification Replace the piston r...

Page 190: ... piston pin Blue discoloration grooves Replace the piston pin and then check the lubrication system 2 Measure piston pin outside diameter a Out of specification Replace the piston pin Piston pin outside diameter 22 991 23 000 mm 0 9052 0 9055 in Limit 22 971 mm 0 9044 in 3 Measure piston pin bore inside diameter b Out of specification Replace the piston Piston pin bore inside diameter 23 004 23 01...

Page 191: ...ance Piston pin bore diameter b Piston pin outside diameter a Piston pin to piston clearance 0 004 0 024 mm 0 0002 0 0009 in Limit 0 074 mm 0 0029 in EBS00252 INSTALLING THE PISTON AND CYLINDER 1 Install top ring 1 2nd ring 2 oil ring expander 3 lower oil ring rail 4 upper oil ring rail 5 TIP _ Be sure to install the piston rings so that the manufacturer marks or numbers face up ...

Page 192: ...ips cover the crankcase opening with a clean rag to prevent the clips from falling into the crank case 3 Install cylinder gasket dowel pins 4 Lubricate piston piston rings cylinder with the recommended lubricant Recommended lubricant Engine oil 2 3 1 a New New New 5 Offset piston ring end gaps a Top ring b Upper oil ring rail c Oil ring expander d Lower oil ring rail e 2nd ring È Exhaust side e a ...

Page 193: ...s the timing chain and timing chain guide exhaust side through the timing chain cav ity 1 7 Install cylinder bolts TIP Lubricate the threads of the cylinder bolts 1 and mating surface with engine oil 8 Tighten cylinder bolts 1 1st cylinder bolts 1 2nd cylinder bolts timing chain side 2 1 1 2 2 E E T R 15 Nm 1 5 m kg 11 ft lb T R 50 Nm 5 0 m kg 36 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 194: ...emarks Removing the AC magneto Remove the parts in the order listed Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Seats rear console Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 Water pump Refer to WATER PUMP in chapter 5 Oil delivery pipe 2 oil delivery pipe 3 Refer to OIL COOLER in chapter 5 1 AC magneto ...

Page 195: ... Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 60 Nm 6 0 m kg 43 ft Ib Order Job Part Q ty Remarks 5 AC magneto cover gasket 1 6 Dowel pin 2 7 Lead holder 1 8 Crankshaft position sensor 1 9 Stator coil 1 10 Torque limiter 1 11 Starter idle gear 1 12 Starter idle gear shaft 1 13 AC magneto rotor 1 Refer to REMOVING THE AC MAG NETO ROTOR and INSTALLING THE AC MAGNETO ROTOR 14 Start...

Page 196: ... T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 60 Nm 6 0 m kg 43 ft Ib Order Job Part Q ty Remarks 17 Washer 1 For installation reverse the removal pro cedure ...

Page 197: ...oosen the AC mag neto rotor nut Do not allow the sheave holder to touch the projection on the rotor Sheave holder 90890 01701 Primary clutch holder YS 01880 A 3 2 1 3 Remove AC magneto rotor 1 with the starter clutch woodruff key NOTICE To protect the end of the crankshaft place an appropriate sized socket between the flywheel puller set center bolt and the crankshaft TIP Use the flywheel puller 2...

Page 198: ... new one and clinch the end of the bolt TIP _ The arrow mark on the starter clutch must face inward away from the AC magneto rotor a Install the starter wheel gear to the starter clutch and hold the starter clutch b When turning the starter wheel gear 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 starte...

Page 199: ...HE TORQUE LIMITER 1 Check torque limiter Damage wear Replace TIP Do not disassemble the torque limiter EBS00268 INSTALLING THE AC MAGNETO ROTOR 1 Install stator coil 1 TIP Align the projection a on the stator coil with the slot b in the AC magneto cover T R Stator coil bolt 7 Nm 0 7 m kg 5 1 ft lb LOCTITE a 1 b 2 Apply sealant 1 into the slit Yamaha bond No 1215 90890 85505 Three bond No 1215 1 ...

Page 200: ...t reinstall the key and rotor 4 Tighten AC magneto rotor nut 1 TIP _ While holding the AC magneto rotor 2 with the sheave holder 3 tighten the AC magneto rotor nut Sheave holder 90890 01701 Primary clutch holder YS 01880 A 3 2 1 T R 60 Nm 6 0 m kg 43 ft lb 5 Install AC magneto cover pipe holder 1 AC magneto cover bolts TIP _ Tighten the AC magneto cover bolts in stages using a crisscross pattern 1...

Page 201: ...d oil pump gears Remove the parts in the order listed Starter wheel gear Refer to AC MAGNETO 1 Lock washer 1 Refer to REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR and INSTALLING THE BALANCER DRIVE GEAR BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR 2 Balancer driven gear 1 3 Oil pump drive gear 1 4 Chain 1 5 Straight key 1 ...

Page 202: ...NSTALLING THE BAL ANCER DRIVE GEAR BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR 7 Oil pump driven gear 1 8 Plate 1 9 Spring 8 Refer to REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR and INSTALLING THE BALANCER DRIVE GEAR BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR 10 Pin 4 11 Balancer drive gear 1 For installation reverse the removal pro cedure ...

Page 203: ...h of the balancer drive gear 4 and balancer driven gear 5 then loosen the nuts 5 4 3 1 2 CHECKING THE OIL PUMP DRIVE 1 Check oil pump drive gear oil pump driven gear Cracks wear damage Replace CHECKING THE BALANCER DRIVE 1 Check balancer drive gear balancer driven gear Damage wear Replace the balancer drive gear and balancer driven gear as a set Excessive noise during operation Replace the balance...

Page 204: ...k a on the balancer drive gear with the punch mark b on the bal ancer driven gear Install the oil pump driven gear with the 3B4 mark c facing out 2 3 c a b 1 3 Install lock washers oil pump driven gear nut 1 balancer driven gear nut 2 TIP Place an aluminum plate 3 between the teeth of the balancer drive gear 4 and bal ancer driven gear 5 then tighten the nuts Apply the engine oil to the thread of ...

Page 205: ...1 0 m kg 7 2 ft Ib T R 100 Nm 10 0 m kg 72 ft lb Order Job Part Q ty Remarks Removing the primary and second ary sheaves Remove the parts in the order listed Seats rear console Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 Left side panel left corner panel driver seat support seat rail Refer to PANELS AND FRONT CON SOLE in chapter 8 V belt cooling ducts Refer to ENGINE REMOVAL 1 D...

Page 206: ...Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 100 Nm 10 0 m kg 72 ft lb Order Job Part Q ty Remarks 5 Primary 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 fan 1 9 Spacer 1 10 Secondary sheave assembly 1 11 Drive belt case 1 12 Rubber gasket 1 13 Rubber gasket 1 For installation reverse the ...

Page 207: ...he primary sheave Remove the parts in the order listed 1 Primary pulley sheave cap 1 Refer to ASSEMBLING THE PRIMARY SHEAVE 2 Primary pulley slider 4 3 Primary pulley cam 1 4 Primary pulley weight 8 5 Collar 1 6 Oil seal 2 7 Primary sliding sheave 1 8 O ring 1 For assembly reverse the disassembly procedure ...

Page 208: ...ave Remove the parts in the order listed 1 Nut 1 Refer to DISASSEMBLING THE SEC ONDARY SHEAVE and ASSEMBLING THE SECONDARY SHEAVE 2 Spring seat 1 3 Compression spring 1 4 Spring seat 1 5 Guide pin 4 6 Secondary sliding sheave 1 7 O ring 2 8 Secondary fixed sheave 1 9 Oil seal 2 For assembly reverse the disassembly procedure ...

Page 209: ...SASSEMBLING THE SECONDARY SHEAVE 1 Remove nut 1 a Attach the sheave fixed block 2 locknut wrench 3 and sheave spring compressor 4 to the secondary sheave assembly b Place the sheave fixed block in a vise and secure it c Tighten the sheave spring compressor nut 5 and compress the spring d Loosen the nut 1 with the locknut wrench 3 e Remove the nut 1 f Remove the sheave spring compressor and locknut...

Page 210: ... sheave splines Wear cracks damage Replace primary pulley cam Cracks damage Replace 3 Check primary sliding sheave primary fixed sheave Cracks damage Replace EBS00275 CHECKING THE SECONDARY SHEAVE 1 Check secondary fixed sheave smooth operation secondary sliding sheave smooth operation Scratches damage Replace as a set 2 Check torque cam grooves 1 Wear damage Replace 3 Check guide pins 2 Wear dama...

Page 211: ...MARY SHEAVE 1 Clean primary sliding sheave face 1 primary fixed sheave face 2 collar 3 weights 4 primary sliding sheave cam face TIP _ Remove any excess grease 2 Install weights 1 TIP _ Apply Yamaha Grizzly grease 90 g to the whole outer surface of the weights and install Apply Yamaha Grizzly grease 2 5 g to the inner surface of the collar Apply Yamaha Grizzly grease 2 5 g to the inner surface of ...

Page 212: ...ASSEMBLING THE SECONDARY SHEAVE 1 Apply BEL RAY assembly lube to the secondary sliding sheave 1 inner surface and oil seals BEL RAY assembly lube to the bearings oil seals and inner surface of the secondary fixed sheave 2 2 Install guide pins 1 3 Apply BEL RAY assembly lube to the guide pin sliding grooves 1 and oil seals 2 New ...

Page 213: ...in a vise and secure it c Tighten the sheave spring compressor nut 1 and compress the spring d Install the nut 2 and tighten it to the speci fied torque using the locknut wrench e Remove the sheave spring compressor locknut wrench and sheave fixed block Sheave fixed block 90890 04135 Sheave fixed bracket YM 04135 Locknut wrench 90890 01348 YM 01348 Sheave spring compressor 90890 04134 YM 04134 T R...

Page 214: ...utward Tightening the bolts 3 will push the second ary sliding sheave away causing the gap between the secondary fixed and sliding sheaves to widen Install the V belt so that its arrow faces the direction shown in the illustration a 2 1 80 mm 3 15 in 3 b 2 Tighten primary sheave nut 1 secondary sheave nut 2 TIP _ Use the sheave holder 3 to hold the primary sheave First tighten the primary sheave n...

Page 215: ...e order listed Primary sheave secondary sheave Refer to PRIMARY AND SECONDARY SHEAVES 1 Clutch housing assembly 1 Refer to REMOVING THE CLUTCH and INSTALLING THE CLUTCH 2 Gasket 1 3 Dowel pin 2 4 One way clutch bearing 1 5 Nut 1 6 Clutch carrier assembly 1 For installation reverse the removal pro cedure ...

Page 216: ... Remarks Disassembling the clutch housing assembly Remove the parts in the order listed 1 Oil seal 1 2 Circlip 1 3 Bearing housing 1 4 Circlip 1 5 Bearing 1 6 Circlip 1 7 Bearing 1 8 Clutch housing 1 For assembly reverse the disassembly procedure ...

Page 217: ... 4 of a turn Remove them after all of them are loosened 2 Straighten punched portion of the nut 1 3 Remove nut 1 NOTICE The clutch carrier assembly nut has left handed threads To loosen the clutch car rier assembly nut turn it clockwise TIP _ Use a clutch holding tool 2 to hold the clutch carrier assembly Universal clutch holder 90890 04086 YM 91042 ...

Page 218: ...and clutch carrier assembly to the clutch hous ing and hold the clutch carrier assembly b When turning the clutch housing clockwise È the clutch housing should turn freely If not the one way clutch assembly is faulty Replace it c When turning the clutch housing counter clockwise É the clutch housing and crank shaft should be engaged If not the one way clutch assembly is faulty Replace it 3 Check c...

Page 219: ...s with a drift punch Universal clutch holder 90890 04086 YM 91042 New T R 190 Nm 19 0 m kg 140 ft lb 3 Install one way clutch bearing TIP _ The one way clutch bearing should be installed in the clutch carrier assembly with the OUT SIDE mark a facing toward the clutch housing 4 Install dowel pins gasket clutch housing assembly TIP _ Tighten the bolts in stages using a criss cross pattern After tigh...

Page 220: ...0 9 1 8 4 5 3 Order Job Part Q ty Remarks Removing the timing chain and oil filter Remove the parts in the order listed Engine Refer to ENGINE REMOVAL Cylinder head Refer to CYLINDER HEAD Cylinder piston Refer to CYLINDER AND PISTON AC magneto rotor starter wheel gear Refer to AC MAGNETO Balancer driven gear oil pump driven gear Refer to BALANCER GEARS AND OIL PUMP GEARS Primary sheave assembly se...

Page 221: ...g 49 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib New New New New New New New New New LS LS LS LS LT E E LT LT LT LT LS LS 2 6 7 10 9 1 8 4 5 3 Order Job Part Q ty Remarks 4 Oil filter cartridge 1 5 Oil pipe adapter 1 6 Speed sensor 1 7 Dipstick 1 8 Relief valve assembly 1 9 Reverse switch 1 10 Gear position switch 1 For installation reverse the removal pro cedure ...

Page 222: ...New New LS LS E E E 1 4 2 3 3 5 6 8 8 9 7 Order Job Part Q ty Remarks Separating the crankcase Remove the parts in the order listed 1 Shift lever cover 1 Refer to INSTALLING THE SHIFT LEVER 2 Gasket 1 3 Dowel pin 1 4 Shift lever 1 1 5 Shift lever 2 assembly 1 6 Shift drum stopper 1 7 Left crankcase 1 Refer to SEPARATING THE CRANK CASE and ASSEMBLING THE CRANKCASE 8 Dowel pin 2 9 Right crankcase 1 ...

Page 223: ...marks Removing the crankcase bearings Remove the parts in the order listed Crankshaft oil pump Refer to CRANKSHAFT AND OIL PUMP Transmission Refer to TRANSMISSION Middle drive shaft middle driven shaft Refer to MIDDLE GEAR 1 Collar 1 2 O ring 1 3 Oil seal 1 4 Bearing retainer 1 5 Spacer 1 6 Crank seal 2 7 Bearing 9 For installation reverse the removal pro cedure ...

Page 224: ...mmer to tap on one side of the crankcase Tap only on reinforced portions of the crankcase Do not tap on the crank case mating surfaces Work slowly and carefully Make sure that the crankcase halves separate evenly c Remove the dowel pins È É EBS00335 CHECKING THE TIMING CHAIN AND GUIDE 1 Check timing chain Cracks stiff Replace the timing chain and camshaft sprocket as a set 2 Check intake side timi...

Page 225: ...nt 2 Clean all the gasket mating surfaces and crankcase mating surfaces thoroughly 3 Check crankcase Cracks damage Replace oil delivery passages Clogged Blow out with compressed air EBS00342 ASSEMBLING THE CRANKCASE 1 Apply sealant 1 to the mating surfaces of both case halves TIP Apply two coats of sealant to the area a shown in the illustration 2 Install dowel pins 2 Yamaha bond No 1215 90890 855...

Page 226: ...s follow the proper tightening sequence È Left crankcase É Right crankcase TIP _ Tighten the bolts in stages using a crisscross pattern 6 Apply 4 stroke engine oil to the crankshaft pin bearing and oil deliv ery hole 7 Check crankshaft and transmission operation Unsmooth operation Repair INSTALLING THE SHIFT LEVER 1 Install shift lever 2 assembly 1 shift lever 1 2 TIP When installing the shift lev...

Page 227: ...kg 7 2 ft Ib New Order Job Part Q ty Remarks Removing the crankshaft and oil pump Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Oil pump 1 2 Gasket 1 3 Balancer 1 4 Crankshaft 1 Refer to REMOVING THE CRANK SHAFT and INSTALLING THE CRANK SHAFT For installation reverse the removal pro cedure ...

Page 228: ...5 m kg 3 6 ft Ib Order Job Part Q ty Remarks Disassembling the oil pump Remove the parts in the order listed 1 Oil pump housing cover 1 2 Pin 1 3 Oil pump shaft 1 4 Oil pump inner rotor 1 5 Oil pump outer rotor 1 6 Oil pump housing 1 For assembly reverse the disassembly procedure ...

Page 229: ... pump housing clearance b oil pump housing to inner rotor and outer rotor clearance c Out of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing 3 Check oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s Inner rotor to outer rotor tip clearance Less than 0 12 mm 0 0047 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing clear...

Page 230: ... 1 Measure crank width a Out of specification Replace the crank shaft 2 Measure side clearance d Out of specification Replace the crank shaft 3 Measure runout c Out of specification Replace the crank shaft Crank width 74 95 75 00 mm 2 951 2 953 in Big end side clearance 0 350 0 650 mm 0 0138 0 0256 in Limit 1 0 mm 0 04 in Runout limit 0 030 mm 0 0012 in a c d c ...

Page 231: ...p shaft 4 align the pin 5 with the groove a in the inner rotor 3 1 2 3 5 4 a a EBS00362 INSTALLING THE CRANKSHAFT 1 Install crankshaft 1 Crankshaft installer pot 2 90890 01274 YU 90058 Crankshaft installer bolt 3 90890 01275 Bolt YU 90060 Adapter M16 4 90890 04130 Adapter 13 YM 04059 Spacer crankshaft installer 5 90890 04081 Pot spacer YM 91044 Spacer 6 90890 01309 Pot spacer YU 90059 1 5 6 4 2 3 ...

Page 232: ...Cen ter TDC with one hand while turning the nut of the installing tool with the other Operate the installing tool until the crankshaft bottoms against the bearing NOTICE _ Apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier ...

Page 233: ... listed Crankcase Separate Refer to CRANKCASE Middle driven gear Refer to MIDDLE GEAR 1 Shift drum 1 Refer to REMOV ING THE TRANS MISSION and INSTALLING THE TRANSMISSION 2 Shift fork assembly 1 3 Shift fork R 1 4 Spring 1 Refer to ASSEM BLING THE SHIFT FORK ASSEMBLY 5 Shift fork L 1 6 Shift fork guide bar 1 7 Secondary shaft 1 8 Drive axle assembly 1 9 Reverse idle gear 1 ...

Page 234: ...ON M 1 7 6 8 5 10 9 4 3 2 New New New New E E E Order Job Part Q ty Remarks 10 Reverse idle gear shaft 1 Refer to REMOVING THE TRANSMIS SION and INSTALLING THE TRANS MISSION For installation reverse the removal pro cedure ...

Page 235: ... New New New Order Job Part Q ty Remarks Disassembling the drive axle assembly Remove the parts in the order listed 1 Washer 1 2 Collar 1 3 High wheel gear 1 4 Washer 1 5 Clutch dog 1 6 Circlip 1 7 Washer 1 8 Collar 1 9 Low wheel gear 1 0 Washer 1 A Circlip 1 B Middle drive gear 1 C Circlip 1 ...

Page 236: ...ION 1 A C D E F H G B 0 2 3 4 5 6 7 8 9 M M M M M M M New New New Order Job Part Q ty Remarks D Washer 1 E Bearing 1 F Reverse wheel gear 1 G Stopper wheel 1 H Drive axle 1 For assembly reverse the disassembly procedure ...

Page 237: ...um d Remove the shift fork assembly EBS00349 CHECKING THE SHIFT FORKS The following procedure applies to each shift fork 1 Check shift fork cam follower 1 shift fork pawl 2 Scoring bends wear damage Replace 2 Check guide bar Roll the guide bar on a flat surface Bends Replace WARNING _ Do not attempt to straighten a bent guide bar 3 Check shift fork movement on the guide bar Unsmooth operation Repl...

Page 238: ...k transmission gears Blue discoloration pitting wear Replace the defective gear s transmission gear dogs Cracks damage rounded edges Replace the defective gear s 3 Check transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 4 Check transmission gear movement Rough movement Replace the defective part s 5 Check circlips Bends...

Page 239: ... TIP Install the shift forks with the 3B4 mark a and 5B4 mark b facing each other 3B4 New New a b 4 2 1 5 3 5 New EBS00356 INSTALLING THE TRANSMISSION 1 Install reverse idle gear 1 drive axle assembly 2 secondary shaft 3 shift fork assembly 4 shift drum 5 TIP _ Install the shift forks 6 with the L mark a facing toward the right side of the crankcase and the R mark b facing toward the left side of ...

Page 240: ...ANSMISSION 2 Check shift operation Unsmooth operation Repair TIP _ Oil each gear and bearing thoroughly Before assembling the crankcase make sure that the transmission is in neutral and that the gears turn freely ...

Page 241: ...se Separate Refer to CRANKCASE 1 Bearing housing 1 2 Middle drive pinion gear nut 1 Refer to REMOVING THE MIDDLE DRIVE SHAFT and INSTALLING THE MIDDLE DRIVE SHAFT 3 Middle drive pinion gear 1 4 Middle drive gear shim 5 Middle drive shaft 1 6 Bearing retainer 2 7 Bearing 1 8 Washer 1 9 Circlip 1 10 Middle driven gear 1 For installation reverse the removal pro cedure ...

Page 242: ... 1 Drive shaft coupling gear nut middle gear side 1 Refer to REMOVING THE MIDDLE DRIVEN SHAFT and INSTALLING THE MIDDLE DRIVEN SHAFT 2 Drive shaft coupling gear middle gear side 1 3 Circlip 2 4 Bearing 2 5 Universal joint middle gear side 1 6 Middle driven pinion gear assembly 1 7 Universal joint yoke nut middle gear side 1 8 Universal joint yoke middle gear side 1 9 Bearing housing 1 ...

Page 243: ...FT and INSTALLING THE MIDDLE DRIVEN SHAFT 11 Middle driven gear shim 12 Middle driven pinion gear 1 13 Bearing 1 14 Middle driven pinion gear bearing retainer 1 15 Bearing 1 16 Middle driven shaft bearing retainer 1 17 Bearing 1 18 Middle driven shaft 1 For installation reverse the removal pro cedure ...

Page 244: ... gear nut 2 Loosen middle drive pinion gear nut 1 TIP _ Secure the middle drive shaft in the vise with a clean rag 3 Remove middle drive pinion gear nut middle drive pinion gear shim s 4 Remove middle driven gear 1 circlip middle drive shaft 2 TIP Press the middle drive shaft end and remove the middle driven gear 1 2 ...

Page 245: ...pling gear middle shaft tool 90890 01229 Gear holder YM 01229 1 3 2 2 Remove universal joint middle gear side a Remove the circlips 1 b Place the universal joint in a press c With a suitable diameter pipe 2 beneath the yoke 3 press the bearing 4 into the pipe as shown TIP It may be necessary to lightly tap the yoke with a punch d Repeat the steps for the opposite bearing e Remove the yoke TIP It m...

Page 246: ...ousing assembly 1 a Clean the outside of the bearing housing assembly b Place the bearing housing assembly onto a hydraulic press NOTICE Never directly press the middle driven pinion gear end with a hydraulic press this will result in damage to the middle driven pinion gear thread Install a suitable socket 2 on the middle driven pinion gear end to protect the thread from damage c Press the middle ...

Page 247: ...aring retainer has left handed threads To loosen the retainer turn it clockwise d Remove the bearing retainer and bearing Bearing retainer wrench 90890 04128 Middle gear bearing retainer YM 04128 2 1 6 Remove oil seal 1 middle driven shaft bearing retainer 2 TIP _ Attach the ring nut wrench 3 NOTICE _ The middle driven shaft bearing retainer has left handed threads To loosen the retainer turn it c...

Page 248: ... pinion gear teeth Pitting galling wear Replace 2 Check O ring Damage Replace bearings Pitting damage Replace EBS00370 SELECTING 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 shim 1 2 1 Select middle drive gear shim 1 middle driven gear shim 2 ...

Page 249: ...ded to or subtracted from 0 9 b 17 0 c 55 0 d a numeral usually a decimal number on the left crankcase specifies a thickness of 65 0 e a numeral usually a decimal number on the right crankcase specifies a thickness of 9 0 k 1 5 Example 1 If the bearing housing is marked 01 a is 0 91 2 b is 17 0 3 c is 55 0 4 If the left crankcase is marked 64 96 d is 64 96 5 If the right crankcase is marked 9 01 e...

Page 250: ...6 7 5 8 9 10 Middle drive pinion gear shim Thickness mm 0 50 0 70 1 00 0 55 0 80 0 60 0 90 c To find shim thickness B use the following formula Where f a numeral usually a decimal number on the bearing housing is either added to or subtracted from 77 5 TIP After replacing any part in the middle driven pinion gear assembly the overall length of the assembly will change Therefore be sure to measure ...

Page 251: ...ss of 8 12 Example 1 If the bearing housing is marked 03 f is 77 53 2 If the driven pinion gear is marked 02 g is 49 02 3 If the driven pinion gear is marked 02 h is 80 52 4 If the right crankcase is marked 99 98 i is 99 98 5 If the left crankcase is marked 8 12 j is 8 12 6 Therefore the shim thickness is 0 88 mm B 77 53 49 02 80 52 99 98 8 12 0 02 0 91 g h i 7 Round off the hundredth digit and se...

Page 252: ...BEARING AND OIL SEALS 1 Install bearing 1 oil seal 2 oil seal 3 4 Middle drive pinion gear bearing retainer 5 Bearing housing 6 Middle driven shaft bearing retainer 7 Crankcase Installed depth of bearing a 0 9 1 4 mm 0 035 0 055 in Installed depth of oil seal b 1 0 1 5 mm 0 039 0 059 in Installed depth of oil seal c 1 0 1 5 mm 0 039 0 059 in 1 5 4 2 a b 3 7 6 c ...

Page 253: ...1430 YM 38404 LT T R 80 Nm 8 0 m kg 58 ft lb 1 2 2 Install middle driven pinion gear bearing retainer 1 a Secure the bearing housing edge in the vise with a clean rag b Attach the bearing retainer wrench 2 c Tighten the bearing retainer NOTICE _ The middle driven pinion gear bearing retainer has left handed threads To tighten the retainer turn it counterclockwise Bearing retainer wrench 90890 0412...

Page 254: ...lder 2 to hold the yoke T R Universal joint yoke nut 150 Nm 15 0 m kg 110 ft lb LOCTITE Universal joint holder 90890 04062 YM 04062 5 Install universal joint middle gear side a Install the yoke into the universal joint b Apply wheel bearing grease to the bearings c Install the bearing 1 onto the yoke NOTICE Check each bearing The needles can eas ily fall out of their races Slide the yoke back and ...

Page 255: ...Install drive shaft coupling gear middle gear side 1 washer drive shaft coupling gear nut middle gear side 2 TIP Use the coupling gear middle shaft tool 3 to hold the coupling gear Coupling gear middle shaft tool 90890 01229 Gear holder YM 01229 2 3 1 LT T R 190 Nm 19 0 m kg 140 ft lb INSTALLING THE MIDDLE DRIVE SHAFT 1 Install circlip middle driven gear 1 to the middle drive shaft 2 Installed dep...

Page 256: ...into the installation hole a of the right crankcase speed sensor to hold the middle driven gear c Attach the gear lash measurement tool 3 and dial gauge 4 b 12 3 mm 0 48 in d Measure the gear lash while rotating the middle driven shaft back and forth TIP _ Measure the gear lash at 4 positions Rotate the middle driven gear 90 each time e If the gear lash is incorrect adjust the gear lash with middl...

Page 257: ...ove the parts in the order listed Oil cooler Refer to OIL COOLER Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Radiator fan motor coupler 1 Disconnect 2 Radiator fan motor breather hose 1 Disconnect 3 Coolant reservoir hose 1 4 Coolant reservoir breather hose 1 5 Coolant reservoir cap 1 6 Coolant reservoir 1 7 Radiator inlet hose 1 8 Radiator outlet hose 1 9 Radiator inlet pipe 1 RADI...

Page 258: ...g 5 1 ft Ib R T 7 Nm 0 7 m kg 5 1 ft Ib 3 5 4 6 15 4 4 1 8 2 7 Order Job Part Q ty Remarks 10 Radiator outlet pipe 1 11 Thermostat outlet hose 1 12 Water pump inlet hose 1 13 Oil cooler bracket 2 14 Radiator 1 15 Radiator fan 1 For installation reverse the removal pro cedure ...

Page 259: ...ecified pressure Replace the radiator cap a Install the radiator cap tester 1 and adapter 2 onto the radiator cap 3 b Apply the specified pressure for ten sec onds and make sure that there is no drop in pressure 4 Check radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM in chapter 9 Radiator cap opening pressure 93 3 122 7 kPa 0 933 1 227 kg cm2 13 27 17 45 psi Radiat...

Page 260: ...COOLANT RESERVOIR INSTALLING THE RADIATOR 1 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check cooling system Leaks Repair or replace any faulty part ...

Page 261: ...e the parts in the order listed Seats rear console Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Thermostat outlet hose 1 Disconnect 2 Thermostat cover 1 Refer to INSTALLING THE THERMO STAT 3 Thermostat 1 4 Coolant temperature sensor coupler 1 Disconnect 5 Coolant temperature sensor 1 For installation reverse the removal p...

Page 262: ...y closed É Fully open TIP _ If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause seri ous overheating or overcooling 2 Check thermostat cover thermostat housing cylinder head Cracks damage Replace EBS00133 INSTALLING THE THERMOSTAT 1 Install thermostat 1 O ring 2 thermostat cover 3 TIP _ Install the thermostat with its breather hole a facing up 2 Fill cooling sy...

Page 263: ...emove the parts in the order listed Seats rear console Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 AC magneto cover Refer to AC MAGNETO in chapter 4 1 Water pump inlet hose 1 Disconnect 2 Water jacket joint 1 3 Water pump outlet hose 1 4 Water pump outlet pipe ...

Page 264: ...kg 7 2 ft Ib R T 10 Nm 1 0 m kg 7 2 ft Ib R T 10 Nm 1 0 m kg 7 2 ft Ib LS Order Job Part Q ty Remarks 7 Gasket 1 8 Circlip 1 9 Impeller shaft 1 10 Water pump seal 1 Refer to DISASSEMBLING THE WATER PUMP and ASSEMBLING THE WATER PUMP 11 Bearing 1 12 Oil seal 1 For installation reverse the removal pro cedure ...

Page 265: ...er 2 2 1 2 Remove bearing 1 oil seal 2 TIP _ Tap out the bearing and oil seal from the out side of the AC magneto cover 3 1 2 3 EBS00139 CHECKING THE WATER PUMP 1 Check water pump housing impeller shaft Cracks damage wear Replace 2 Check water jacket water jacket outlet hose water jacket outlet pipe Cracks damage wear Replace bearing Rough movement Replace ...

Page 266: ...de diameter Installed depth of oil seal a 8 1 8 7 mm 0 32 0 34 in 3 1 2 New a New 2 Install water pump seal 1 into the AC magneto cover 2 NOTICE _ Never lubricate the water pump seal sur face with oil or grease TIP _ Install the water pump seal with the special tools È Push down Mechanical seal installer 3 90890 04132 Water pump seal installer YM 33221 A Middle driven shaft bearing driver 4 90890 ...

Page 267: ...3 Measure impeller shaft tilt Out of specification Replace NOTICE _ Make sure the rubber damper and rubber damper holder are flush with the impeller 1 Straightedge 2 Impeller shaft Impeller shaft tilt limit 0 15 mm 0 006 in ...

Page 268: ...ng the oil cooler Remove the parts in the order listed Seats rear console support side pan els front console Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Air intake duct Refer to AIR FILTER CASE AND AIR INTAKE DUCT in chapter 6 Radiator mesh Refer to FRONT GUARD AND HOOD in chapter 8 1 Oil cooler inlet pipe 1 oil cooler out...

Page 269: ...1 Nm 2 1 m kg 15 ft Ib New New New 4 2 3 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 4 4 New LS Order Job Part Q ty Remarks 5 Oil outlet hose 1 6 Oil inlet hose 1 7 Oil cooler inlet pipe 2 oil cooler outlet pipe 2 1 1 8 Oil delivery pipe 3 1 9 Oil delivery pipe 2 1 For installation reverse the removal pro cedure ...

Page 270: ...OOLER 1 Check oil cooler Obstruction Clean Apply compressed air to the rear of the oil cooler Damage Repair or replace the oil cooler TIP Straighten any flattened fins with a thin flat head screwdriver 2 Check oil hoses Cracks damage Replace ...

Page 271: ... 4 Engine trouble warning light 5 Intake air temperature sensor 6 TPS throttle position sensor 7 Intake air pressure sensor 8 Spark plug 9 Coolant temperature sensor 0 Fuel injector A ISC idle speed control unit B Fuel pump C Crankshaft position sensor D Ignition coil E Speed sensor 8 7 6 5 4 3 2 1 9 0 A B C D E FUEL INJECTION SYSTEM 6 ...

Page 272: ...P L Br L O Y R R Y Gy G W B R G B R W G Br B R Y BLACK L Y Br B W B BLACK L Br BLACK G W B Br L B G W L Br L BLACK B Br G W 4WD 2WD LOCK OFF OFF ON START Br B G W R L R W R R Br L P R R W Br R Br L Br L Br Y Br L Br R R R R B B B B B B B B W W W W R W W L Y R Y B R B Br R Br R L Y R B W B O Gy G B R W B G R Y B Y R R L L R Sb B Y Br R R Y L Y Y W Y W W R Y L Br W Br W B L R R R L G Y G Y L W B L Y...

Page 273: ...trol unit H Ignition coil I Spark plug J Fuel injector K Intake air temperature sensor L Coolant temperature sensor M Speed sensor N TPS throttle position sensor O Intake air pressure sensor P Lean angle sensor Q Gear position switch T Multifunction meter U Engine trouble warning light Fuel pump d On command four wheel drive motor switch and differ ential gear lock switch h Signaling system fuse q...

Page 274: ...cteristic operation and alerts the rider of the detected malfunction by illuminating the engine trou ble warning light After the engine has been stopped the low est fault code number appears on the odom eter tripmeter LCD Once a fault code has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation Th...

Page 275: ...rature sensor open or short circuit detected Able Able 30 Lean angle sensor latch up detected The vehicle has overturned Unable Unable 33 Ignition coil faulty ignition Malfunction detected in the primary wire of ignition coil Unable Unable 37 ISC valve stuck fully open Engine speed is high when the engine is idling Able Able 39 Injector open circuit Injector open circuit detected Unable Unable 41 ...

Page 276: ... Refer to Rein statement method in TROUBLESHOOTING DETAILS Turn the main switch to OFF turn the main switch back to ON and then check if the fault code number is still displayed Repairs completed No fault code number displayed Erasing the malfunction history The malfunction history is stored even if the main switch is turned OFF The malfunction history must be erased in the diagnostic mode Refer t...

Page 277: ...re TIP All displays on the meter disappear dIAG appears on the LCD meter 4 Simultaneously press the and TRIP ODO buttons for 2 seconds or more to execute the selection 5 Select the diagnostic code number that applies to the item that was verified with the fault code number by pressing the and TRIP ODO buttons TIP The diagnostic code number appears on the LCD meter 01 70 To decrease the selected di...

Page 278: ...er Actuator operation Set the differential gear lock switch to LOCK to operate the actuator If the differential gear lock switch is set to LOCK set it to 4WD and then set it to LOCK again 7 Turn the main switch to OFF to cancel the diagnostic mode TIP To perform a reliable diagnosis make sure to turn off the power supply before every check and then start right from the beginning ...

Page 279: ...5 30 The vehicle has overturned Overturned Malfunction in ECU d08 33 Malfunction detected in the primary lead of the ignition coil Open or short circuit in wire harness Malfunction in ignition coil Malfunction in ECU Malfunction in a component of ignition cut off circuit sys tem d30 37 Engine speed is high when the engine is idling Open circuit in wire harness Malfunction in throttle body Malfunct...

Page 280: ... meter d07 Vehicle speed pulse 0 999 Check that the number increases when the rear wheel is rotated The number is cumulative and does not reset each time the wheel is stopped d08 Lean angle sensor Remove the lean angle sensor and incline it more than 65 degrees Upright 3 7 4 4 Overturned 0 4 1 4 d09 Fuel system voltage battery voltage Approximately 12 0 Compare with the actually measured battery v...

Page 281: ...lashes five times Check the spark five times Connect an ignition checker d36 Injector Actuates the injector five times in one second inter vals Check the operating sound of the injector five times d50 Fuel injection system relay Actuates the fuel injection system relay five times in one second intervals The engine trouble warning light also flashes five times The engine trouble warning light is OF...

Page 282: ... Connections Crankshaft position sensor cou pler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire har ness Repair or replace if there is an open or short circuit Between the crankshaft position sensor coupler and ECU cou ...

Page 283: ...the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Turning the main switch to ON 2 Open or short circuit in wire har ness Repair or replace if there is an open or short circuit Between intake air pressure sen sor coupler and ECU coupler black blue black blue pink pink blue blue 3 Defective ...

Page 284: ...tarting the engine and operating it at idle 2 Intake air pressure sensor mal function at intermediate electrical potential Check and repair the connec tion Replace it if there is a malfunc tion 3 Connections Intake air pressure sensor cou pler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction rep...

Page 285: ...CU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire har ness Repair or replace if there is an open or short circuit Between throttle position sensor coupler and ECU coupler blue blue yellow yellow black blue black blue 4 Throttle position sens...

Page 286: ...o 21 Symptom Coolant temperature sensor open or short circuit detected Diagnostic code No d06 Coolant temperature sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Installed condition of coolant tem perature sensor Check the installed area for loose ness or pinching Turning the main switch to ON 2 Connections Coolant temperature sensor cou pler Main wi...

Page 287: ...ntake air temperature sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit in wire har ness Repair or replace if there is an open or short circuit Between intake air temperature sensor coupler and ECU coupler brown whi...

Page 288: ...ine can not be restarted unless the main switch is first turned OFF 2 Installed condition of the lean angle sensor Check for looseness or pinching 3 Connections Lean angle sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 4 Defective lean ...

Page 289: ... Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler or con nector securely Starting the engine and operating it at idle 2 Open or short circuit in wire har ness Repair or replace if there is an open or short circuit Between ignition coil connector and ECU coupler orange orange Between ignition coil connector and main switch coupler ...

Page 290: ... THE THROTTLE CABLE in chapter 3 3 ISC valve is stuck fully open due to disconnected ISC unit hose or cou pler High engine idle speed is detected with the ISC valve stuck fully open even though signals for the valve to close are continuously being transmitted by the ECU Check that the ISC unit coupler is not disconnected The ISC valve is stuck fully open if it does not operate when the main switch...

Page 291: ... Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Cranking the engine Con nect the fuel injector cou pler 2 Open or short circuit in the wire harness Repair or replace if there is an open or short circuit Between injector coupler and ECU coupler red blue red blue red red 3 Defecti...

Page 292: ...oupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Turning the main switch to ON 2 Open or short circuit in lead wire Repair or replace if there is an open or short circuit Between lean angle sensor cou pler and ECU coupler blue blue yellow green yellow green black blue black blue 3 Defective le...

Page 293: ...er If there is a malfunction repair it and connect the coupler securely Starting the engine and activating the vehicle speed sensor by oper ating the vehi cle at 20 to 30 km h 2 Open or short circuit in speed sen sor lead Repair or replace if there is an open or short circuit Between speed sensor coupler and ECU coupler blue blue white white black blue black blue 3 Gear for detecting vehicle speed...

Page 294: ...pair or replace if there is an open or short circuit Between fuel injection system relay coupler and ECU coupler red blue red blue Between fuel injection system relay coupler and starter relay coupler brown black brown black 3 Malfunction or open circuit in fuel pump relay Execute the diagnostic mode Code No d09 Replace if defective If there is no malfunction in the fuel injection system relay rep...

Page 295: ...gulator Replace if defective Refer to CHARGING SYSTEM in chapter 9 4 Open or short circuit in wire har ness Repair or replace if there is an open or short circuit Between battery lead and main fuse coupler red red Between main fuse coupler and ignition fuse red red Between main switch coupler and ignition fuse red black red black Between main switch coupler and ECU coupler brown red brown red Faul...

Page 296: ...5 4 25 V Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe pink terminal 1 Negative tester probe black blue terminal 2 L P B L 2 1 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 1 Remove intake air temperature sensor WARNING _ Handle the intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air tempe...

Page 297: ...tester probe brown white 1 Negative tester probe black blue 2 Br W B L 2 1 b Immerse the air temperature sensor 3 in a container filled with water 4 TIP Make sure that the air temperature sensor ter minals do not get wet c Place a thermometer 5 in the water d Slowly heat the water then let it cool down to the specified temperature e Measure the air temperature sensor resis tance 5 3 4 ...

Page 298: ...oving the air filter case and air intake duct Remove the parts in the order listed Seats rear console Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 Side panels corner panels front con sole Refer to PANELS AND FRONT CON SOLE in chapter 8 1 Air intake duct shroud 1 2 Air filter case cover 1 3 Air filter element 1 4 Air filter element frame 1 5 Air filter joint clamp 2 Refer to INSTA...

Page 299: ...jector coupler 1 Disconnect 11 Throttle position sensor coupler 1 Disconnect 12 Intake air pressure sensor coupler 1 Disconnect 13 ISC idle speed control unit coupler 1 Disconnect 14 Coolant temperature sensor coupler 1 Disconnect 15 Parking brake lever 1 16 Shift lever 1 NOTICE The select lever shift rod locknut select lever side has left handed threads To loosen the locknut turn it clockwise 17 ...

Page 300: ... 1 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib Order Job Part Q ty Remarks 20 Air intake duct joint clamp 2 Refer to INSTALLING THE AIR INTAKE DUCT AND AIR FILTER CASE 21 Air intake duct 1 22 Intake air temperature sensor 1 23 Air intake duct joint 1 Refer to INSTALLING THE AIR INTAKE DUCT AND AIR FILTER CASE For installation reverse the removal pro cedure AIR FILTER CASE AND AIR INTAKE DUCT ...

Page 301: ... a 2 Install air intake duct joint clamp 1 throttle body side TIP Align the projection a on the air intake duct joint with the gap b in the air intake duct joint clamp 1 a b 3 Install air filter case joint 1 air filter case 2 TIP Fit the projections a and b on the air filter case joint between the projections on the air intake duct and air filter case a 1 2 b AIR FILTER CASE AND AIR INTAKE DUCT ...

Page 302: ...s rear console Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 Right side panel right corner panel right protector passenger seat support Refer to PANELS AND FRONT CON SOLE in chapter 8 1 Damper plate 1 2 Fuel sender coupler 1 Disconnect 3 Fuel pump coupler 1 Disconnect 4 Fuel hose 1 Refer to REMOVING THE FUEL TANK and INSTALLING THE FUEL HOSE 5 Fuel tank breather hose 2 6 Rollover ...

Page 303: ... 7 3 9 10 6 5 1 8 8 4 5 New T R 16 Nm 1 6 m kg 11 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib Order Job Part Q ty Remarks 8 Fuel tank holder 2 9 Fuel tank cap 1 10 Fuel tank 1 For installation reverse the removal pro cedure ...

Page 304: ...may be fuel remaining in it TIP To remove the fuel hose from the throttle body and the fuel tank slide the fuel hose connector cover 1 on the end of the hose in direction of the arrow shown press the but ton 2 on either side of the connector and then remove the hose Before removing the hose place a few rags in the area under where it will be removed 3 Remove fuel tank REMOVING THE FUEL PUMP 1 Remo...

Page 305: ...ll fuel pump gasket fuel pump fuel pump bracket TIP Do not damage the installation surface of the fuel tank when installing the fuel pump Always use a new fuel pump gasket Install the fuel pump in the direction shown in the illustration Install the fuel pump bracket by aligning the projection a on the fuel pump Tighten the nuts to the specified torque in the proper tightening sequence as shown 1 6...

Page 306: ...ANK INSTALLING THE FUEL HOSE 1 Install fuel hose fuel pump coupler TIP To install the fuel hose onto the throttle body and the fuel tank slide the fuel hose connector cover 1 on the end of the hose in direction of the arrow shown ...

Page 307: ...r listed Seats rear console Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 1 Intake air pressure sensor coupler 1 Disconnect 2 Throttle position sensor coupler 1 Disconnect 3 Throttle body breather hose 1 4 Fuel injector coupler 1 Disconnect 5 ISC idle speed control unit coupler 1 Disconnect 6 Throttle cable housing cover 1 7 Throttle cable 1 Disconnect ...

Page 308: ...er to REMOVING THE THROTTLE BODY ASSEMBLY and INSTALLING THE THROTTLE BODY ASSEMBLY 9 Air intake duct joint clamp 2 10 Air intake duct joint 1 11 Throttle body joint clamp 2 Refer to INSTALLING THE THROT TLE BODY ASSEMBLY 12 Throttle body assembly 1 13 Throttle body joint 1 For installation reverse the removal pro cedure ...

Page 309: ...y assembly Remove the parts in the order listed 1 Intake air pressure sensor 1 2 Intake air pressure sensor hose 1 3 Throttle position sensor 1 4 Injector fuel rail 1 5 Fuel injector 1 6 Throttle body 1 NOTICE The throttle body should not be disas sembled For assembly reverse the disassembly procedure ...

Page 310: ...disconnect the fuel hose from the throttle body slide the fuel hose connector cover 1 on the end of the hose in direction of the arrow shown press the button 2 on either side of the connector and then disconnect the hose Before disconnecting the hose place a few rags in the area under where it will be dis connected EAS00912 CHECKING THE FUEL INJECTOR 1 Check fuel injector Damage Replace EAS00913 C...

Page 311: ...der head with the slot b in the throttle body joint 1 a b 2 Install throttle body joint clamps 1 TIP Align the projections on the throttle body joint with the gap in each throttle body joint clamp 1 3 Install air intake duct joint air intake duct joint clamp throttle body side Refer to AIR FILTER CASE AND AIR INTAKE DUCT 4 Install throttle body assembly 1 TIP Align the projection a on the throttle...

Page 312: ...e will not be properly connected TIP To connect the fuel hose onto the throttle body slide the fuel hose connector cover 1 on the end of the hose in direction of the arrow shown 6 Install throttle cable 7 Check throttle position sensor Refer to CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 8 Adjust throttle pedal free play Refer to ADJUSTING THE THROTTLE CABLE in chapter 3 THROTTLE BODY ...

Page 313: ...1 from the fuel pump TIP Before removing the hose place a few rags in the area under where it will be removed c Connect the pressure gauge 2 and adapter 3 to the fuel pump and fuel hose d Start the engine e Measure the fuel pressure Out of specification Replace the fuel pump Pressure gauge 90890 03153 YU 03153 Fuel pressure adapter 90890 03176 YM 03176 Fuel pressure 324 kPa 3 24 kg cm2 46 1 psi 2 ...

Page 314: ... of specification Replace the throttle position sensor 2 Adjust throttle position sensor angle a Connect the throttle position sensor coupler to the throttle position sensor b Connect the digital circuit tester to the throt tle position sensor coupler Positive tester probe blue 1 Negative tester probe black blue 2 Maximum throttle position sensor resistance 3 08 5 72 kΩ blue black blue Positive di...

Page 315: ...ust the throttle position sensor angle so that the voltage is within the specified range e After adjusting the throttle position sensor angle tighten the throttle position sensor screws 3 Throttle position sensor voltage 0 68 V yellow black blue 3 3 THROTTLE BODY ...

Page 316: ...tion and deceleration Diagnosis Possible incorrect reassembly too little gear lash NOTICE _ Too little gear lash is extremely destructive to the gear teeth If a test ride following reassembly indicates this condition stop riding immediately to minimize gear dam age Symptoms Possible Causes 1 A pronounced hesitation or jerky move ment during acceleration deceleration or sustained speed This must no...

Page 317: ...metal particles Check the bearing for seizure TIP _ A small amount of metal particles in the oil is normal 3 Check oil leakage a Clean the entire vehicle thoroughly then dry it b Apply a leak localizing compound or dry powder spray to the shaft drive c Road test the vehicle for the distance nec essary to locate the leak Leakage Check the component housing gasket and or seal for damage Damage Repla...

Page 318: ... chapter 8 YES Check the front constant velocity joints Feel for bearing damage NO Constant velocity joint bearings and differ ential gear bearings are probably not dam aged Repeat the test or remove the individual components YES Check the parking brake adjustment NO Adjust per instructions Refer to ADJUSTING THE PARKING BRAKE in chapter 3 YES Check the rear constant velocity joints Feel for beari...

Page 319: ...g the front constant veloc ity joints differential gear and drive shaft Remove the parts in the order listed Front skid plate Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Differential gear oil Drain Steering knuckle Refer to STEERING SYSTEM in chap ter 8 Front lower arms Refer to FRONT ARMS AND FRONT SHOCK ABSORBERS in chapter 8 1 Front constant velocity joint 2 2 Differential gear mot...

Page 320: ...7 9 8 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 New New New Order Job Part Q ty Remarks 4 Differential gear case assembly 1 5 Compression spring 1 6 Washer 1 7 Dust seal 1 8 Dust seal 1 9 Drive shaft 1 For installation reverse the removal pro cedure ...

Page 321: ...in the order listed The following procedure applies to both of the front constant velocity joints 1 Clip 1 2 Boot band 1 Refer to DISASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS and ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS 3 Boot band 1 4 Dust boot 1 5 Clip 1 6 Double off set joint 1 7 Circlip 1 8 Ball bearing 1 9 Boot band 1 0 Boot band 1 A Dust boot 1 B Off set joint 1 ...

Page 322: ...AR AND DRIVE SHAFT È Wheel side É Gear case side Order Job Part Q ty Remarks C Clip 1 Refer to DISASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS and ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS D Joint shaft 1 For assembly reverse the disassembly procedure ...

Page 323: ... Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks Disassembling the differential gear case assembly Remove the parts in the order listed 1 Differential gear motor 1 Refer to ASSEMBLING THE DIFFER ENTIAL GEARS 2 O ring 1 3 Circlip 2 Refer to DISASSEMBLING THE UNI VERSAL JOINT and ASSEMBLING THE UNIVERSAL JOINT 4 Bearing 2 5 Universal joint 1 6 Universal joint yoke 1 7 Differential gear case cover ...

Page 324: ...T R 24 Nm 2 4 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 62 Nm 6 2 m kg 45 ft Ib New New New New New New LT LS LS New LS LS New 8 T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks C Oil seal 1 D Clip 1 E Differential drive pinion gear 1 F Bearing 1 G Bearing 1 H Oil seal 2 I Differential gear case 1 For assembly reverse the disassembly procedure ...

Page 325: ... set joint 2 circlip 3 ball bearing 4 dust boot 5 TIP Before removing the clip 1 slide the dust boot away from the double off set joint 5 1 2 È 4 3 È 2 Remove boot band 1 Use a boot band installing tool 2 Boot band installing tool 90890 01526 YM 01526 2 1 É 3 Remove off set joint clip dust boot TIP Secure the joint shaft in a vise and then remove the off set joint using hammers É ...

Page 326: ...r the opposite bearing e Remove the yoke 2 Remove universal joint yoke Use a universal joint holder 1 Universal joint holder 90890 04062 YM 04062 1 EBS00163 REMOVING THE DIFFERENTIAL GEAR ASSEMBLY 1 Remove differential gear assembly 1 TIP _ The ring gear and the differential gear should be fastened together Do not disassemble the differential gear assembly NOTICE _ The differential gear assembly i...

Page 327: ... balls and ball races inner surface of double off set joint Pitting wear damage Replace EBS00166 CHECKING THE DIFFERENTIAL GEARS 1 Check gear teeth Pitting galling wear Replace bearing Pitting damage Replace oil seal O ring Damage Replace 2 Check drive shaft splines differential drive pinion gear splines Wear damage Replace spring Fatigue Replace Move the spring up and down 3 Check drive shaft Ben...

Page 328: ...he differential gear case assembly Do not use a 12 V battery to operate the pinion gear È Check that the pinion gear 2 turns counter clockwise É Check that the pinion gear 2 turns clockwise TIP Be sure not to disassemble the gear motor and remove the pinion gear 3V 2 1 È 3V 2 1 É EBS00167 ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS È Wheel side É Gear case side 1 Install dust boot clip 1 off set...

Page 329: ...TIP Securely install the circlip into the groove in the joint shaft Securely install the clip into the groove in the double off set joint 1 2 New É New New 3 4 É New 3 Apply molybdenum disulfide grease into the ball joint assembly TIP _ Molybdenum disulfide grease is included in the repair kit 4 Install dust boots 1 boot bands 2 3 4 5 a Apply molybdenum disulfide grease into the dust boots Molybde...

Page 330: ...ed with the boot bands 3 and 5 at the grooves in the joint shaft Boot band installing tool 90890 01526 YM 01526 6 4 È 5 Check thrust movement free play Excessive play Replace the joint assem bly EBS01009 ASSEMBLING THE DIFFERENTIAL GEARS 1 Measure gear lash Refer to MEASURING THE DIFFEREN TIAL GEAR LASH 2 Install differential gear motor a Slide the shift fork sliding gear 1 which is installed to t...

Page 331: ...al gear assembly making sure that the shift fork sliding gear remains in the 2WD mode position NOTICE _ 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 Tighten the differential gear motor bolts T R Differential gear motor bolt 11 Nm 1 1 m kg 8 0 ft ...

Page 332: ...ings c Install the bearing 1 onto the yoke NOTICE 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 place d Press each bearing into the universal joint using a suitable socket TIP The bearing must be inserted far enough into the universal joint so that the circlip ca...

Page 333: ...Measuring point is 22 5 mm 0 86 in 5 Measure gear lash Gently rotate the coupling gear from engagement to engagement TIP _ Measure the gear lash at four positions Rotate the shaft 90 each time Ring gear fix bolt M10 90890 01527 YM 01527 Gear lash measurement tool 90890 01475 Middle drive gear lash tool YM 01475 Differential gear lash 0 05 0 25 mm 0 0020 0 0098 in EBS00176 ADJUSTING THE DIFFERENTIA...

Page 334: ...ng a suitable stand under the frame 2 Remove the wheel cap from the axle nut right or left 3 Measure the starting torque of the front wheel i e differential gear preload with a torque wrench TIP _ 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 With...

Page 335: ...emove the parts in the order listed Rear skid plate Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Muffler exhaust pipes Refer to ENGINE REMOVAL in chapter 4 Final gear oil Drain Rear knuckle Refer to REAR KNUCKLE AND STABI LIZER in chapter 8 Rear lower arm Refer to REAR ARMS AND REAR SHOCK ABSORBER in chapter 8 Parking brake assembly Refer to PARKING BRAKE in chapter 8 REAR CONSTANT VEL...

Page 336: ...onstant velocity joint 2 TIP 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 gear case breather hose 1 Disconnect 3 Final gear assembly 1 4 Compression spring 1 5 Damper 1 6 Coupling gear 1 7 Dust seal 1 8 Dust seal 1 ...

Page 337: ... CONSTANT VELOCITY JOINTS FINAL DRIVE GEAR AND DRIVE SHAFT 3 1 4 9 8 7 6 5 1 2 T R 70 Nm 7 0 m kg 51 ft Ib LS LS LS New New Order Job Part Q ty Remarks 9 Drive shaft 1 For installation reverse the removal pro cedure ...

Page 338: ...the order listed The following procedure applies to both of the rear constant velocity joints 1 Dust cover 1 2 Clip 1 3 Boot band 1 Refer to DISASSEMBLING THE REAR CONSTANT VELOCITY JOINTS and ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS 4 Boot band 1 5 Dust boot 1 6 Clip 1 7 Double off set joint 1 8 Circlip 1 9 Ball bearing 1 0 Boot band 1 A Boot band 1 B Dust boot 1 ...

Page 339: ...RIVE SHAFT È Wheel side É Gear case side Order Job Part Q ty Remarks C Off set joint 1 Refer to DISASSEMBLING THE REAR CONSTANT VELOCITY JOINTS and ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS D Clip 1 E Joint shaft 1 For assembly reverse the disassembly procedure ...

Page 340: ... in the order listed 1 Final drive pinion gear assembly 1 2 Final drive pinion gear shim 3 Drive shaft coupling gear 1 Refer to DISASSEMBLING THE FINAL GEAR CASE and ASSEM BLING THE FINAL GEAR CASE 4 Final drive pinion gear 1 5 Inner race 1 6 Oil seal 1 7 Bearing retainer 1 8 Bearing 1 9 Final drive pinion gear bearing housing 1 0 Ring gear stopper 1 ...

Page 341: ...VE SHAFT Order Job Part Q ty Remarks A Ring gear bearing housing 1 TIP Working in a crisscross pattern loosen each bolt 1 4 of a turn After all the bolts are loosened remove them B Oil seal 1 C Bearing 1 D Ring gear shim E Ring gear 1 F Thrust washer 1 G Oil seal 1 ...

Page 342: ... Apply Yamaha bond No 1215 90890 85505 Three bond No 1215 Order Job Part Q ty Remarks H Bearing 1 Refer to REMOVING THE FINAL DRIVE ROLLER BEARINGS and INSTALLING THE FINAL DRIVE ROLLER BEARINGS I Bearing 1 J Final gear case 1 For assembly reverse the disassembly procedure ...

Page 343: ...et joint 2 circlip 3 ball bearing 4 dust boot 5 TIP Before removing the clip 1 slide the dust boot away from the double off set joint 5 1 2 È 4 3 È 2 Remove boot band 1 Use a boot band installing tool 2 Boot band installing tool 90890 01526 YM 01526 2 1 É 3 Remove off set joint clip dust boot TIP Secure the joint shaft in a vise and then remove the off set joint using hammers É ...

Page 344: ...t joint 2 TIP Install the clip 1 into the groove in the joint shaft as shown Secure the off set joint in a vise and then fit the joint shaft into the off set joint using a hammer New 3 1 New È 3 2 1 New È È 2 Install dust boot ball bearing 1 circlip 2 double off set joint 3 clip 4 TIP Securely install the circlip into the groove in the joint shaft Securely install the clip into the groove in the d...

Page 345: ...s b Install the dust boots c Install the dust boot bands 4 5 Use a boot band installing tool 6 TIP The new boot bands may differ from the orig inal ones The dust boots should be fastened with the boot bands 3 and 5 at the grooves in the joint shaft Molybdenum disulfide grease 55 g 1 9 oz per dust boot rear wheel side 65 g 2 3 oz per dust boot final gear case side Boot band installing tool 90890 01...

Page 346: ...n a hydrau lic press NOTICE _ Never directly press the gear end with a hydraulic press this will result in damage to the gear thread Install a suitable socket 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 ...

Page 347: ...appropriately shaped punch 2 c Remove the inner race from the final drive pinion gear TIP The removal of the final drive pinion gear roller bearing is difficult and seldom necessary INSTALLING THE FINAL 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 inn...

Page 348: ... 6 in b a numeral usually a decimal number on the final drive pinion gear bearing housing either added to or subtracted from 34 c a numeral usually a decimal number on the final drive pinion gear bearing housing either added to or subtracted from 55 d a numeral usually 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 d...

Page 349: ... 2 0 3 4 5 6 7 5 8 9 10 Final drive pinion gear shim Thickness mm 0 25 0 30 0 35 0 40 0 45 0 50 Selecting ring gear shims 1 Select ring gear shim s 1 a To find the ring gear shim thickness B use the following formula e a numeral usually a decimal number on the final gear case either added to or sub tracted from 50 f a numeral usually a decimal number on the outside of the ring gear bearing hous in...

Page 350: ... 14 00 5 Therefore shim thickness B is 0 48 B 50 98 1 55 34 95 14 00 49 43 48 95 0 48 6 Round off the hundredth digit and select the appropriate shim s In the example above the calculated num ber is 0 48 The chart instructs you to round off 8 to 10 at the hundredth place Thus the shim thickness is 0 50 mm Shims are supplied in the following thick nesses Bearing thickness h 14 00 mm 0 55 in Hundred...

Page 351: ...hten the bolts to specification TIP Do not turn the drive pinion gear and ring gear when measuring the clearance with Plasti gauge T R M8 bolts ring gear bearing hous ing 23 Nm 2 3 m kg 17 ft lb M10 bolts ring gear bearing housing 40 Nm 4 0 m kg 29 ft lb C c Remove the final gear assembly d Measure the thrust clearance Calculate the width of the flattened Plastigauge 1 e If out of specification se...

Page 352: ...her 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 TIP Apply sealant to the ring gear stopper threads 2 Adjust ring gear stopper clearance a Finger tighten the ring gear stopper 1 until it contacts the ring gear 2 b Turn the ring gear stopper 120 counter clockwise c Tighten the ring gear stopper nut 3 Yamaha bond No 1215...

Page 353: ...ve 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 TIP Roller bearings may be reused but Yamaha recommends installing new ones Do not reuse the oil seals When the final drive pinion gear and or ring gear are replaced be sure to adjust the shim of the final driv...

Page 354: ...e ring gear will be dam aged Ring gear fix bolt M10 90890 01527 YM 01527 4 Attach gear lash measurement tool 1 dial gauge 2 a Measuring point is 31 1 mm 1 22 in Gear lash measurement tool 90890 01467 YM 01467 5 Measure gear lash Gently rotate the gear coupling from engagement to engagement TIP Measure the gear lash at four positions Rotate the shaft 90 each time Final gear lash 0 1 0 3 mm 0 004 0 ...

Page 355: ...ckness 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 ...

Page 356: ...b 3 Install bearing retainer a Place a folded rag 1 b Secure the final drive pinion gear bearing housing edge in the vise TIP Apply locking agent LOCTITE to the threads of bearing retainer c Attach the bearing retainer wrench 2 d Tighten the bearing retainer NOTICE The bearing retainer has left hand threads Turn the retainer counterclockwise to tighten it Bearing retainer wrench 90890 04128 Middle...

Page 357: ...g 1 b Secure the drive shaft coupling gear edge in the vise c Tighten the drive shaft coupling gear nut 5 Check final drive gear operation Unsmooth operation Replace the final 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 358: ...m kg 23 ft Ib T R 59 Nm 5 9 m kg 43 ft Ib Order Job Part Q ty Remarks Removing the front guard and hood Remove the parts in the order listed 1 Front guard 1 2 Radiator mesh 1 3 Headlight coupler 2 Disconnect 4 Hood 1 For installation reverse the removal pro cedure SEATS ENCLOSURE HOOD AND CARGO BED ...

Page 359: ... Order Job Part Q ty Remarks Removing the seats rear console and instrument panels Remove the parts in the order listed 1 Driver seat 1 2 Passenger seat 1 3 Passenger handhold strap 1 4 Passenger handhold grip 1 5 Passenger handhold bracket 1 6 Rear console 1 7 Steering wheel cover 1 Refer to REMOVING THE STEERING WHEEL and INSTALLING THE STEERING WHEEL 8 Steering wheel 1 9 Pedal cover 1 10 Light ...

Page 360: ... 5 m kg 25 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib Order Job Part Q ty Remarks 12 On Command four wheel drive motor switch and differential gear lock switch 2 Disconnect 13 Meter assembly coupler 1 Disconnect 14 Auxiliary DC jack connector 2 Disconnect 15 Upper instrument panel 1 16 Hinge 2 17 Glove box lid 1 18 Lower instrument panel 1 For installation reverse the removal pro cedure ...

Page 361: ... the steering wheel cover from the steering wheel a 1 INSTALLING THE STEERING WHEEL 1 Install steering wheel 1 TIP Install the steering wheel onto the steering col umn so that it is straight as shown in the illus tration 2 Operate the vehicle at low speeds and make sure that the steering wheel is straight when the vehicle is advancing straight ahead 3 Install steering wheel cover 1 T R 35 Nm 3 5 m...

Page 362: ...3 Nm 2 3 m kg 17 ft Ib Order Job Part Q ty Remarks Removing the side doors Remove the parts in the order listed The following procedure applies to both of the side doors 1 Rubber protector 2 2 Side door 1 3 Handle latch 1 4 Side door bracket 2 5 Hinge 1 6 Latch 1 For installation reverse the removal pro cedure SEATS ENCLOSURE HOOD AND CARGO BED ...

Page 363: ...kg 11 ft Ib Order Job Part Q ty Remarks Removing the panels and front con sole Remove the parts in the order listed 1 Left side panel 1 Refer to REMOVING THE SIDE PAN ELS and INSTALLING THE SIDE PANELS 2 Left corner panel 1 3 Right side panel 1 4 Right corner panel 1 5 Center protector 1 6 Left protector 1 7 Right protector 1 8 Front console 1 9 Driver seat support 1 10 Passenger seat support 1 11...

Page 364: ... 12 11 8 T R 16 Nm 1 6 m kg 11 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib T 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 12 Seat rail 1 For installation reverse the removal pro cedure SEATS ENCLOSURE HOOD AND CARGO BED ...

Page 365: ... panel and corner panel together from the vehicle making sure not to break the projections a Unhook the projections a on the side panel from the corner panel INSTALL THE SIDE PANELS 1 Install quick fastener TIP To install the quick fastener push its pin so that it protrudes from the fastener head then insert the fastener into the cover and push the pin a in with screwdriver Make sure that the pin ...

Page 366: ...t Ib 16 Nm 1 6 m kg 11 ft Ib T R T R 7 Nm 0 7 m kg 5 1 ft Ib T R 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 367: ...0 7 m kg 5 1 ft Ib 16 Nm 1 6 m kg 11 ft Ib T R T R T R T R T R T R 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 368: ...CARGO BED SKID PLATES T R 7 Nm 0 7 m kg 5 1 ft Ib 2 1 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 369: ...SURE HOOD AND CARGO BED INSTALLING THE REAR SKID PLATE 1 Install rear skid plate 1 TIP Make sure that the hole a in the rear skid plate 1 is towards the left side of the vehicle È Forward É Left side Ê Right side È É Ê 1 a ...

Page 370: ...16 ft Ib T R 22 Nm 2 2 m kg 16 ft Ib T R 65 Nm 6 5 m kg 47 ft Ib T R T R T R T R T R Order Job Part Q ty Remarks Removing the enclosure and seat belts Remove the parts in the order listed 1 Roof 1 For models equipped with a roof 2 Front top frame 1 Refer to INSTALLING THE ENCLO SURE 3 Rear top frame 1 4 Headrest 2 5 Upper support frame 1 6 Lower support frame 1 7 Left side frame 1 8 Right side fra...

Page 371: ... the bolts and nuts 3 Tighten upper support frame and side frame bolts 7 top frame and side frame bolts 8 side frame and frame nuts front side 9 lower support frame and upper support frame nuts 0 side frame and frame nuts rear side A 3 6 5 2 1 9 7 0 A A 8 4 8 4 4 T R 64 Nm 6 4 m kg 46 ft lb T R 65 Nm 6 5 m kg 47 ft lb T R 65 Nm 6 5 m kg 47 ft lb T R 65 Nm 6 5 m kg 47 ft lb T R 22 Nm 2 2 m kg 16 ft...

Page 372: ...kg 255 ft lb Order Job Part Q ty Remarks Removing the front wheels Remove the parts in the order listed The following procedure applies to both of the front wheels Place the vehicle on a level surface WARNING _ Securely support the vehicle so there is no danger of it falling over 1 Front wheel 1 Refer to INSTALLING THE WHEELS 2 Wheel cap 1 3 Front wheel axle nut 1 Refer to INSTALLING THE WHEEL HUB...

Page 373: ...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 Front brake caliper assembly 1 TIP _ 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 Front brake disc 1 For installation reverse the removal pro cedure ...

Page 374: ... 4 Order Job Part Q ty Remarks Removing the rear wheels Remove the parts in the order listed The following procedure applies to both of the rear wheels Place the vehicle on a level surface WARNING _ Securely support the vehicle so there is no danger of it falling over 1 Rear wheel 1 Refer to INSTALLING THE WHEELS 2 Wheel cap 1 3 Rear wheel axle nut 1 Refer to INSTALLING THE WHEEL HUBS ...

Page 375: ...Nm 3 0 m kg 22 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib 4 Order Job Part Q ty Remarks 4 Rear brake caliper assembly 1 TIP 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 Rear wheel hub 1 6 Rear brake disc 1 For installation reverse the removal pro cedure ...

Page 376: ... 0 08 in Rear Radial 2 2 0 mm 0 08 in Lateral 3 2 0 mm 0 08 in 3 Check wheel balance Out of balance Adjust WARNING _ After replacing the tire ride conservatively to allow the tire to be properly seated in the rim Failure to do so may cause an accident resulting in vehicle damage and possible occupant injury EBS00385 CHECKING THE WHEEL HUBS 1 Check wheel hubs 1 Cracks damage Replace splines wheel h...

Page 377: ...12 in Rear 3 0 mm 0 12 in INSTALLING THE WHEEL HUBS 1 Install wheel axle nut TIP 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 EBS00392 INSTALLING THE WHEELS 1 Install wheels TIP _ The arrow mark 1 on the tire must point in the direction of rotation È of the wheel 2 Tighten wheel nuts 1 WA...

Page 378: ...oving the front brake pads Remove the parts in the order listed The following procedure applies to both of the front brake calipers Front wheel Refer to FRONT AND REAR WHEELS 1 Front brake caliper bolt 2 Refer to REPLACING THE FRONT AND REAR BRAKE PADS 2 Brake pad holding bolt 2 3 Front brake pad 2 4 Brake pad spring 1 For installation reverse the removal pro cedure ...

Page 379: ...g the rear brake pads Remove the parts in the order listed The following procedure applies to both of the rear brake calipers Rear wheel Refer to FRONT AND REAR WHEELS 1 Rear brake caliper bolt 2 Refer to REPLACING THE FRONT AND REAR BRAKE PADS 2 Brake pad holding bolt 2 3 Rear brake pad 2 4 Brake pad spring 1 For installation reverse the removal pro cedure ...

Page 380: ...ry 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 AND REAR BRAKE PADS TIP It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads 1 Measure brake...

Page 381: ...nto the brake caliper c Tighten the brake caliper bleed screw d Install the new brake pads and a new brake pad spring e Tighten the brake pad holding bolts and brake caliper 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 Bra...

Page 382: ...y Remarks 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 Brake pipe 1 Disconnect Refer to INSTALLING THE BRAKE MASTER CYLINDER 5 Brake pipe 1 Disconnect 6 Brake master cylinder 1 For installation reverse the removal pro cedure ...

Page 383: ...rt Q ty Remarks Disassembling the brake master cyl inder Remove the parts in the order listed 1 Dust boot 1 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 384: ...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 385: ...e designated quality brake fluid other brake fluids may deteriorate the rubber seals causing leakage and poor brake performance Refill with the same type of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor brake performance Be careful that water does not enter the brake master cylinder when refilling Water will significantly lower the boiling point of the...

Page 386: ...EAR BRAKES 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 387: ...ure applies to both of the front brake calipers Brake fluid Drain Front wheel Refer to FRONT AND REAR WHEELS 1 Union bolt 1 Refer to INSTALLING THE FRONT AND REAR BRAKE CALIPERS 2 Copper washer 2 3 Front brake hose 1 Disconnect 4 Brake pad holding bolt 2 Loosen 5 Front brake caliper bolt 2 6 Front brake caliper assembly 1 For installation reverse the removal pro cedure ...

Page 388: ...ve the parts in the order listed The following procedure applies to both of the front brake calipers 1 Brake pad holding bolt 2 2 Front brake pad 2 3 Brake pad spring 1 4 Brake caliper bracket 1 5 Brake caliper piston 2 Refer to DISASSEMBLING THE FRONT AND REAR BRAKE CALI PERS 6 Brake caliper dust seal 2 7 Brake caliper piston seal 2 8 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 389: ... Remove the parts in the order listed The following procedure applies to both of the rear brake calipers Brake fluid Drain Rear wheel Refer to FRONT AND REAR WHEELS 1 Union bolt 1 Refer to INSTALLING THE FRONT AND REAR BRAKE CALIPERS 2 Copper washer 2 3 Rear brake hose 1 Disconnect 4 Brake pad holding bolt 2 Loosen 5 Rear brake caliper bolt 2 6 Rear brake caliper assembly 1 For installation revers...

Page 390: ...ers Remove the parts in the order listed The following procedure applies to both of the rear brake calipers 1 Brake pad holding bolt 2 2 Rear brake pad 2 3 Brake pad spring 1 4 Brake caliper bracket 1 5 Brake caliper piston 2 Refer to DISASSEMBLING THE FRONT AND REAR BRAKE CALI PERS 6 Brake caliper dust seal 2 7 Brake caliper piston seal 2 8 Bleed screw 1 For assembly reverse the disassembly proce...

Page 391: ...e 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 piston seals 1 2 EB702040 CHECKING THE FRONT AND REAR BRAKE CALIPERS WARNING All internal brake components should be cleaned in new brake fluid only Do not use solvents as they will cause seals to swell and distort Recommended brake component replacement sched...

Page 392: ...ssage brake caliper body Blockage Blow out with compressed air WARNING Replace the caliper piston seals and dust seals whenever the brake caliper is disas sembled 1 2 3 1 2 EBS00431 ASSEMBLING THE FRONT AND REAR BRAKE CALIPERS WARNING _ All internal brake components should be cleaned and lubricated with new brake fluid only before installation Replace the caliper piston seals and dust seal wheneve...

Page 393: ...e brake pipe touches the projection a on the brake caliper WARNING _ Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING in chapter 2 È Front É Rear 1 2 3 a New È 3 2 New 1 a É T R 48 Nm 4 8 m kg 35 ft lb New T R 27 Nm 2 7 m kg 19 ft lb 2 Fill brake master cylinder reservoir NOTICE _ Brake fluid may damage painted surfaces or plastic parts Always clean up...

Page 394: ...al 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 brake flu...

Page 395: ...emove the parts in the order listed Rear skid plate Refer to SEATS ENCLOSURE HOOD AND CARGO BED Right rear wheel Refer to REAR WHEELS 1 Spring 1 Refer to REPLACING THE PARKING BRAKE PADS 2 Parking brake bolt 2 3 Parking brake assembly 1 4 Parking brake cable 1 Disconnect 5 Parking brake pad holding bolt 2 6 Parking brake pad 2 7 Brake pad spring 1 For installation reverse the removal pro cedure ...

Page 396: ...ads and a new brake pad spring as a set T R Parking brake pad holding bolt 17 Nm 1 7 m kg 12 ft lb LOCTITE 3 Install parking brake cable 1 parking brake assembly 2 parking brake bolts TIP Turn the parking brake lever 3 to the position shown in the illustration so that there is enough space between the parking brake pads and then install the parking brake assembly 4 Adjust parking brake cable free ...

Page 397: ...Seats rear console Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS Rear skid plate Refer to SEATS ENCLOSURE HOOD AND CARGO BED Right rear wheel Refer to REAR WHEELS 1 Parking brake switch coupler 1 Disconnect 2 Parking brake lever assembly 1 3 Parking brake cable parking brake lever side 1 Disconnect 4 Spring 1 Refer to ASSEMBLING THE PARKING BRAKE 5 Parking brake bolt 2 6 Parking brake assembly...

Page 398: ... ft Ib 4 7 5 6 1 2 T R 13 Nm 1 3 m kg 9 4 ft Ib 3 Order Job Part Q ty Remarks 7 Parking brake cable parking brake side 1 Disconnect Refer to ASSEMBLING THE PARKING BRAKE For installation reverse the removal pro cedure PARKING BRAKE ...

Page 399: ...he parking brake Remove the parts in the order listed 1 Parking brake pad holding bolt 2 Refer to ASSEMBLING THE PARKING BRAKE 2 Parking brake pad 2 3 Brake pad spring 1 4 Parking brake arm nut 1 5 Parking brake arm 1 6 Parking brake piston 1 7 Push rod 1 8 Parking brake arm shaft 1 9 Parking brake bracket 1 0 Parking brake cable holder 1 A Piston seal 1 For assembly reverse the disassembly proced...

Page 400: ... Removing the parking brake disc Remove the parts in the order listed Parking brake assembly Refer to FRONT AND REAR BRAKES Final drive gear assembly Refer to REAR CONSTANT VELOCITY JOINTS FINAL DRIVE GEAR AND DRIVE SHAFT in chapter 7 1 Parking brake disc 1 For installation reverse the removal pro cedure ...

Page 401: ... THE PARKING BRAKE DISC 1 Check brake disc Galling damage Replace 2 Measure brake disc deflection Out of specification Replace brake disc thickness a Out of specification Replace Brake disc maximum deflection 0 10 mm 0 004 in Brake disc minimum thickness 3 0 mm 0 12 in a ASSEMBLING THE PARKING BRAKE 1 Install O ring parking brake arm shaft 1 TIP Fully turn in the parking brake arm shaft 1 New ...

Page 402: ... 1 TIP Install the parking brake arm onto the parking brake arm shaft and then rotate the arm until it contacts the stopper a If the parking brake arm shaft does not rotate repeat steps 1 and 2 1 a 4 Install parking brake arm nut temporarily tighten 5 Fully turn in the piston assembly 1 using a flathead screwdriver 1 6 Install brake pad spring parking brake pads parking brake pad holding bolts T R...

Page 403: ...IP Turn the parking brake lever 3 to the position shown in the illustration so that there is enough space between the parking brake pads and then install the parking brake assembly 8 Adjust parking brake cable free play Refer to ADJUSTING THE PARKING BRAKE in chapter 3 1 3 2 T R 40 Nm 4 0 m kg 29 ft lb ...

Page 404: ...ering 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 405: ... Part 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 406: ...Nm 3 9 m kg 28 ft Ib New New Order Job Part Q ty Remarks Removing the steering shaft 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 407: ... Part Q ty Remarks Disassembling the steering 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...

Page 408: ...New T R 40 Nm 4 0 m kg 29 ft Ib 0 New New LT LS LS LS LS LS LS M M T R 4 Nm 0 4 m kg 2 9 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib M Order Job Part Q ty Remarks C Steering rack assembly 1 Refer to ASSEMBLING THE STEERING ASSEMBLY For assembly reverse the disassembly procedure ...

Page 409: ... 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 TIP When replacing the pinion needle bearing it is recommended to replace the steering rack assembly The steering housing may be sub ject to damage during r...

Page 410: ...ern may indicate improper adjustment or lack of lubrication 1 2 4 Check pressure pad Wear damage Replace dust boots Damage Replace 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 Molybdenum dis...

Page 411: ...ply 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 New a 4 Adjust rack gear pinion gear backlash a Install the 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 4 Nm 0 4 m kg 2 9 ft lb LOCTITE 15 25 1 New T R 40 Nm...

Page 412: ... 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the tie rod and steering knuckle Remove the parts in the order listed Front wheel brake disc Refer to FRONT AND REAR WHEELS 1 Tie rod 1 2 Brake disc guard 1 3 Nut 2 4 O ring 1 5 Brake hose holder 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 ce...

Page 413: ...lay Replace the tie rod end Turns roughly Replace the tie rod end 2 Check tie rods Bends damage Replace CHECKING THE STEERING KNUCKLES 1 Check steering knuckles Damage pitting Replace 2 Check ball joints Damage pitting Replace the ball joint Free play Replace the ball joint Turns roughly Replace the ball joint a Clean the outside of the steering knuckle b Remove the steering knuckle oil seal c Rem...

Page 414: ...t 5 to remove the ball joint A from the steering knuckle f Remove the ball joint remover Ball joint remover 90890 01474 YM 01474 Ball joint remover adapter set 90890 01477 YM 01477 3 Body 90890 01474 YM 01474 4 Long bolt 90890 01474 YM 01474 5 Short bolt 90890 01477 YM 01477 6 Remover washer 90890 01477 YM 01477 7 Remover spacer 90890 01477 YM 01477 8 Installer attachment 90890 01477 YM 01477 9 In...

Page 415: ...se a new ball joint set m Install a steering knuckle oil seal 3 Check front wheel bearings Bearings allow play in the wheel hubs or the wheel turns roughly Replace oil seals Damage Replace a Clean the outside of the steering knuckle b Remove the oil seals 1 c Drive out the bearings 2 WARNING Eye protection is recommended when using striking tools d Remove the spacer 3 e Apply lithium base grease t...

Page 416: ...8 59 CHAS STEERING SYSTEM h Install the new oil seals TIP When installing the oil seals the seal side of the oil seal faces out ...

Page 417: ...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 AND REAR WHEELS 1 Brake disc guard 1 2 Front arm protector 1 3 Nut 2 Refer to REMOVING THE FRONT ARMS and INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 4 Nut bolt 2 2 5 Front lower arm bushing 1 2 6 Nut bolt 2 2 7 Front shock absorber 1 For models equipped ...

Page 418: ... 30 Nm 3 0 m kg 22 ft Ib 3 2 LS LS 9 10 8 T R 45 Nm 4 5 m kg 32 ft Ib New Order Job Part Q ty Remarks 8 Front shock absorber 1 For models equipped with gas oil damper shock absorbers Refer to REMOVING THE FRONT ARMS and INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 9 Nut bolt 2 2 10 Front upper arm bushing 1 2 11 Circlip 1 12 Ball joint 1 For installation reverse the removal pro cedure ...

Page 419: ...ng it up 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 lower arm b Remo...

Page 420: ...h the assembled ball joint remover new ball joint A and installer attachment 7 to the front lower arm B TIP Do not tap or damage the top of the ball joint h Hold the body 3 in place while turning in the long bolt 4 to install the new ball joint A into the front lower arm B i Remove the ball joint remover Ball joint remover 90890 01474 YM 01474 Ball joint remover adapter set 90890 01477 YM 01477 3 ...

Page 421: ...er read and make sure you understand the following information The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the front shock absorber and gas cylinder Do not tamper or attempt to open the front shock absorber or gas cylinder Do not subject the front shock absorber or gas cylinder to an open flame or any other source of ...

Page 422: ...as pressure press on the gas valve needle with a suitable tool as shown until all of the gas is released the hissing has stopped WARNING _ Wear eye protection to prevent eye damage from released gas or metal chips 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 sprin...

Page 423: ...2 TIP Lubricate the bolts 3 with lithium soap based grease Be sure to position the bolts 3 so that the bolt head faces outward Temporarily tighten the nuts 4 b Install the front shock absorber 5 c Install the ball joints d Install the new cotter pins e Tighten the nuts 4 T R Nut 6 45 Nm 4 5 m kg 32 ft lb T R Nut 7 30 Nm 3 0 m kg 22 ft lb T R Nut 4 45 Nm 4 5 m kg 32 ft lb 6 5 34 34 2 7 7 1 6 ...

Page 424: ... Ib New LS LS T R 42 Nm 4 2 m kg 30 ft Ib Order Job Part Q ty Remarks Removing the rear knuckle and sta bilizer Remove the parts in the order listed Rear wheel hubs Refer to FRONT AND REAR WHEELS 1 Brake disc guard 1 2 Plate 1 For models equipped with cast wheels 3 O ring 1 4 Rear knuckle 1 5 Spacer cover 4 6 Spacer 2 7 Stabilizer joint 2 8 Stabilizer holder 2 9 Bushing 2 10 Stabilizer 1 For insta...

Page 425: ...G Eye protection is recommended when using striking tools d Remove the spacer 3 e Apply lithium base grease to the new bear ings and oil seals f Install the spacer to the rear knuckle g Install the new bearings TIP Install the outside bearing first NOTICE 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 TIP When installi...

Page 426: ...b Part Q ty Remarks Removing the rear arms and rear shock absorber Remove the parts in the order listed Rear knuckle stabilizer Refer to REAR KNUCKLE AND STABI LIZER 1 Rear arm protector 1 Refer to INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER 2 Nut bolt 2 2 3 Rear upper arm bushing 1 2 4 Nut bolt 2 2 5 Rear shock absorber 1 For models equipped with oil damper shock absorbers Refer to INSTALLIN...

Page 427: ...LS LS LS 6 T R 7 Nm 0 7 m kg 5 1 ft Ib 1 Order Job Part Q ty Remarks 6 Rear shock absorber 1 For models equipped with gas oil damper shock absorbers Refer to INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER 7 Nut bolt 2 2 Refer to INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER 8 Rear lower arm bushing 1 2 For installation reverse the removal pro cedure ...

Page 428: ...e sure you understand the following information The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber and gas cylinder Do not tamper or attempt to open the rear shock absorber or gas cylinder Do not subject the rear shock absorber or gas cylinder to an open flame or any other source of high heat High hea...

Page 429: ... pressure press on the gas valve needle with a suitable tool as shown until all of the gas is released the hissing has stopped WARNING _ Wear eye protection to prevent eye damage from released gas or metal chips 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 M...

Page 430: ...ar lower arm 2 TIP Lubricate the bolts 3 with lithium soap based grease Be sure to position the bolts 3 so that the bolt head faces inward Temporarily tighten the nuts 4 b Install the rear shock absorber 5 c Install the rear knuckle d Tighten the nuts 4 T R Nut 6 45 Nm 4 5 m kg 32 ft lb T R Nut 7 45 Nm 4 5 m kg 32 ft lb T R Nut 4 45 Nm 4 5 m kg 32 ft lb 5 1 7 7 2 6 34 6 ...

Page 431: ...Intake air temperature sensor 7 Intake air pressure sensor 8 TPS throttle position sensor 9 ISC idle speed control unit 0 Coolant temperature sensor A Crankshaft position sensor B Speed sensor C Fuel pump D Ignition coil E Brake light switch F Differential gear motor G Radiator fan motor 1 2 B A C D E F G 0 3 4 5 6 7 8 9 ELECTRICAL COMPONENTS 9 ...

Page 432: ...tor 6 Four wheel drive motor relay 2 7 Four wheel drive motor relay 1 8 Starter relay 9 Fuel injection system fuse 0 Headlight relay A Fuel injection system relay B Main fuse C Radiator fan motor relay D Load control relay E Four wheel drive motor relay 3 F Fuse box G ECU engine control unit H Battery I Radiator fan motor circuit breaker H I F G C 9 8 E D A B 0 1 2 3 4 6 5 7 ...

Page 433: ...hen checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch are shown in an illustration simi lar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration TIP _ indicates a continuity of electricity between switc...

Page 434: ...etween the ter minals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch 2 3 1 R B L Y Br R Br Br R P L Gy W Br Br Y Y BLACK 6 8 7 5 4 L Y OFF ON START OFF G W L R B B B Br Br G R G R Gy Gy GRAY Sb Sb L B L B L R L R L G L G BLACK 4WD 2WD LOCK ...

Page 435: ...e light switch 2 Main switch 3 On command four wheel drive motor switch and differential gear lock switch 4 Light switch 5 Parking brake switch 6 Gear position switch 7 Reverse switch 8 Four wheel drive motor switch differential gear motor ...

Page 436: ...S The bulbs used on this vehicle are shown in the illustration on the left Bulbs a and b are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise Bulbs c are used for turn signal and tail brake lights and can be removed from the socket by...

Page 437: ...herwise it may be pulled out of the ter minal in the coupler Avoid touching the glass part of the head light bulb to keep it free from oil other wise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bulb for continuity with the pock...

Page 438: ...ITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets 1 Check bulb socket for continuity with the pocket tester No continuity Replace TIP _ Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the respective leads of the bul...

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

Page 440: ...EBS01043 YES NO EBS01044 YES NO The ignition system fails to operate no spark or intermittent spark Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Main ignition and backup fuses Check the main ignition and backup fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and backup fuses OK Rep...

Page 441: ...d condition is it of the correct type and is its gap within spec ification Re gap or replace the spark plug 4 Ignition spark gap Disconnect the spark plug cap from the spark plug Connect the ignition checker 1 as shown 2 Spark plug cap Measure the ignition spark gap a Crank the engine by setting the main switch to START and gradually increase the spark gap until a misfire occurs Minimum ignition s...

Page 442: ...ition coil connectors from the ignition coil terminals Connect the pocket tester Ω 1 to the ignition coil as shown Positive tester probe brown red lead terminal 1 Negative tester probe orange lead terminal 2 Measure the primary coil resistance Primary coil resistance 2 16 2 64 Ω at 20 C 68 F Connect the pocket tester Ω 1k to the ignition coil as shown Positive tester probe brown red lead terminal ...

Page 443: ...s the crankshaft position sensor OK Replace the crank shaft position sensor stator assembly Gy B 2 1 9 Lean angle sensor Remove the lean angle sensor Connect the pocket tester DC 20 V to the lean angle sensor coupler as shown Positive tester probe yellow green 1 Negative tester probe black blue 2 Set the main switch to ON Turn the lean angle sensor to 65 Measure the lean angle sensor output volt a...

Page 444: ... Br L BLACK B Br G W 4WD 2WD LOCK OFF OFF ON START Br B G W R L R W R R Br L P R R W Br R Br L Br L Br Y Br L Br R R R R B B B B B B B B W W W W R W W L Y R Y B R B Br R Br R L Y R B W B O Gy G B R W B G R Y B Y R R L L R Sb B Y Br R R Y L Y Y W Y W W R Y L Br W Br W B L R R R L G Y G Y L W B L Y P Y G L B O B Br Y R W Y L B W W B Br L B Sb B R L B L G L R L R G R Sb Gy B B B Y Br B L Y B L L B L ...

Page 445: ... position the starter motor can be operated only if 1 Battery 2 Main fuse 3 Backup fuse 4 Ignition fuse 5 Main switch 6 Load control relay 7 Signaling system fuse 8 Brake light switch 9 ECU engine control unit 0 Gear position switch A Diode B Starter relay C Starter motor The transmission is in neutral the neutral switch circuit of the gear position switch is closed or The brake pedal is pressed t...

Page 446: ...ackup and sig naling system fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition backup and signal ing system fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replace the bat...

Page 447: ...e black 4 Does the starter relay have continuity between red and black Replace the starter relay R Y L Y Br B R B 1 4 3 2 5 Load control relay Remove the load control relay from the wire harness Connect the pocket tester Ω 1 and bat tery 12 V to the load control relay as shown Positive battery terminal brown red 1 Negative battery terminal black 2 Positive tester probe red 3 Negative tester probe ...

Page 448: ...ty Refer to CHECKING THE SWITCHES Is the brake light switch OK Replace the brake light switch 8 Gear position switch Check the gear position switch for continu ity Refer to CHECKING THE SWITCHES Is the gear position switch OK Replace the gear position switch 9 Wiring Check the entire starting system wiring Refer to CIRCUIT DIAGRAM Is the starting system wiring properly con nected and without defec...

Page 449: ...ASE AND AIR INTAKE DUCT in chapter 6 1 Starter motor lead 1 Disconnect 2 Starter motor 1 For installation reverse the removal pro cedure Disassembling the starter motor Remove the parts in the order listed 1 Starter motor front cover 1 Refer to ASSEMBLING THE STARTER MOTOR 2 Lock washer 1 3 Oil seal 1 4 Bearing 1 5 Shim 6 Starter motor rear cover 1 STARTER MOTOR ...

Page 450: ...STARTER MOTOR Order Job Part Q ty Remarks 7 Bushing 1 Refer to ASSEMBLING THE STARTER MOTOR 8 Shim 9 Brush holder set 1 0 Armature assembly 1 A Starter motor yoke 1 For assembly reverse the disassembly procedure ...

Page 451: ...mit 27 mm 1 06 in a 3 Measure mica undercut a Out of specification Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator TIP _ The mica of the commutator must be undercut to ensure proper operation of the commutator 4 Measure armature assembly resistances commutator and insulation Out of specification Replace the starter motor Mica undercut 0 7...

Page 452: ...ce 1 0 0250 0 0350 Ω at 20 C 68 F Insulation resistance 2 Above 1 MΩ at 20 C 68 F 5 Measure brush length a Out of specification Replace the brushes as a set Brush length wear limit 5 00 mm 0 20 in 6 Measure brush spring force Out of specification Replace the brush springs as a set 7 Check gear teeth Damage wear Replace the gear 8 Check bearing oil seal Damage wear Replace the defective part s Brus...

Page 453: ... the projection a on the brush holder set with the slot b in the starter motor yoke 2 Install starter motor yoke 1 starter motor front cover 2 starter motor rear cover 3 TIP _ Align the match marks a on the starter motor yoke with the match marks b on the starter motor front and rear covers a b b 2 1 3 ...

Page 454: ...r R Y R R Br L Br R B L Y BLACK Br R Br R R B Br B R Y BLACK L Y OFF ON START Br B R R Br L P R R W Br L Br Y R R R R B B B B B B B B W W W W R W W L Y R Y B R B Br R Br R L Y R P B B L Gy R LY R R R R R B Br R Br L B R Br R 8 7 4 g B h i r q s 6 1 2 3 A 5 f 9 0 Br B B Br t A 2 AC magneto 3 Rectifier regulator 4 Main fuse 5 Frame ground 8 Battery ...

Page 455: ...ial tool s EBS01043 YES NO EBS01044 YES NO The battery is not being charged Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Main fuse Check the main fuse for continuity Refer to CHECKING THE FUSES in chapter 3 Is the main fuse OK Replace the main fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V...

Page 456: ...Stator coil resistance Disconnect the AC magneto couplers from the wire harness Connect the pocket tester Ω 1 to the stator coils Positive tester probe white terminal 1 Negative tester probe white terminal 2 Positive tester probe white terminal 1 Negative tester probe white terminal 3 Positive tester probe white terminal 2 Negative tester probe white terminal 3 Measure the stator coil resistance S...

Page 457: ...F OFF ON START Br B R L R W R R Br L P R R W Br R Br L Br L Br Y Br L Br R R R R B B B B B B B B W W W W R W W L Y R Y B R B Br R Br R L Y R P B L Y B L Gy R Y Y G Y B B L Y Y Y Br Br Y B L Y B G Br R Br Y B Gy Br Br R L G Y Y B Y L Br G L R L B R W Y R R R R R B Br R Br L B R Br R R L L R Br B Br R 8 7 4 g B _ h i C c k j r q s 6 o D l n n l 1 2 3 A 5 p m f 9 0 Br B B Br W B BLACK L Br BLACK G W ...

Page 458: ...3112 C 1 Main ignition and headlight fuses Check the main ignition and headlight fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and headlight fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery...

Page 459: ...2 Positive tester probe red 3 Negative tester probe brown blue 4 Does the load control relay have continuity between red and brown blue Replace the load control relay R Br L Br R B 1 2 3 4 6 Wiring Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM Is the lighting system wiring properly con nected and without defects Check the condition of each of the lighting system circuits Refer t...

Page 460: ... socket or both 2 Headlight relay Remove the headlight relay Connect the pocket tester Ω 1 and bat tery 12 V to the headlight relay as shown È high beam É low beam Positive battery terminal yellow 1 Negative battery terminal black 2 Positive tester probe blue 3 Negative tester probe yellow 4 or green 5 Does the headlight relay have continuity between blue and yellow È Does the headlight relay have...

Page 461: ...tch to the headlight cou pler is faulty and must be repaired 1 Taillight bulb and socket Check the taillight bulb and socket for con tinuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the taillight bulb and socket OK Replace the taillight bulb socket or both G Y G Y B B DC20V È É 1 2 3 2 Voltage Connect the pocket tester DC 20 V to the tail brake light connectors as shown Tail brake light co...

Page 462: ... BLACK P L Br L O Y R R Y Gy G W B R G B R W G Br B R Y BLACK L Y Br B W B BLACK L Br BLACK G W B Br L B G W L Br L BLACK B Br G W 4WD 2WD LOCK OFF OFF ON START Br B G W R L R W R R Br L P R R W Br R Br L Br L Br Y Br L Br R R R R B B B B B B B B W W W W R W W L Y R Y B R B Br R Br R L Y R B W B O Gy G B R W B G R Y B Y R R L L R Sb B Y Br R R Y L Y Y W Y W W R Y L Br W Br W B L R R R L G Y G Y L ...

Page 463: ...nsor M Speed sensor Q Gear position switch R Parking brake switch T Multifunction meter V Coolant temperature warning light W Park indicator light X Reverse indicator light Y Neutral indicator light Z High range indicator light Low range indicator light Fuel sender e Differential gear motor h Signaling system fuse m Brake light switch n Tail brake light q Load control relay ...

Page 464: ...et tester 90890 03112 Analog pocket tester YU 03112 C 1 Main backup signaling system and igni tion fuses Check the main backup signaling system and ignition fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main backup signaling system and ignition fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Mi...

Page 465: ...Positive tester probe red 3 Negative tester probe brown blue 4 Does the load control relay have continuity between red and brown blue Replace the load control relay R Br L Br R B 1 2 3 4 5 Wiring Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM Is the signaling system wiring properly connected and without defects Check the condition of each of the signal ing system circuits Refer ...

Page 466: ...rake light switch for continuity Refer to CHECKING THE SWITCHES Is the brake light switch OK Replace the brake light switch 3 Voltage Connect the pocket tester DC 20 V to the tail brake light connectors wire harness side as shown Positive tester probe yellow 1 Negative tester probe black 2 Set the main switch to ON Push down on the brake pedal Measure the voltage 12 V of yellow 1 on the tail brake...

Page 467: ...blue Is the wiring circuit properly connected and without defects Properly connect or repair the wiring cir cuit 3 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler as shown Positive tester probe brown yellow 1 Negative tester probe black white 2 Set the main switch to ON Measure the voltage 12 V of brown yel low 1 and black white 2 at the meter assembly coupler Is the voltag...

Page 468: ...it properly connect and without defects Properly connect or repair the wiring cir cuit 3 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler as shown Positive tester probe brown yellow 1 Negative tester probe black white 2 Set the main switch to ON Measure the voltage 12 V of brown yel low 1 and black white 2 at the meter assembly coupler Is the voltage within specification Rep...

Page 469: ...e wiring circuit properly connect and without defects Properly connect or repair the wiring cir cuit 3 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler as shown Positive tester probe brown yellow 1 Negative tester probe black white 2 Set the main switch to ON Measure the voltage 12 V of brown yel low 1 and black white 2 at the meter assembly coupler Is the voltage within spe...

Page 470: ... switch to ECU and ECU to meter assembly yellow blue Is the wiring circuit properly connect and without defects Properly connect or repair the wiring cir cuit 3 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler as shown Positive tester probe brown yellow 1 Negative tester probe black white 2 Set the main switch to ON Measure the voltage 12 V of brown yel low 1 and black white...

Page 471: ...olant Slowly heat the coolant and then let it cool to the specified temperature indicated in the table Measure the coolant temperature sensor resistance Coolant temperature sensor resistance 290 354 Ω at 80 C 176 F WARNING _ Handle the coolant temperature sensor with special care Never subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it T...

Page 472: ...switch to the meter assem bly coupler is faulty and must be repaired Y L Br Y B W Y L Br Y B W O B R W O B R W 2 1 1 Fuel sender Drain the fuel from the fuel tank and then remove the fuel pump assembly fuel sender from the fuel tank Connect the pocket tester Ω 10 to the fuel pump terminals as shown Positive tester probe orange black 1 Negative tester probe black white 2 Move the fuel sender float ...

Page 473: ...ter assembly The wiring circuit from the main switch to the meter assem bly coupler is faulty and must be repaired Y L Br Y B W Y L Br Y B W O B R W O B R W 2 1 1 Speed sensor Connect the pocket tester DC 20 V to the speed sensor coupler wire harness side as shown Positive tester probe white 1 Negative tester probe black blue 2 Turn the main switch to ON Elevate the rear wheels and slowly rotate t...

Page 474: ... tester probe black white 2 Set the main switch to ON Measure the voltage 12 V of brown yel low 1 and black white 2 at the meter assembly coupler Is the voltage within specification Replace the meter assembly or ECU The wiring circuit from the main switch to the meter assem bly coupler is faulty and must be repaired Y L Br Y B W Y L Br Y B W O B R W O B R W 2 1 ...

Page 475: ...ACK B Br G W 4WD 2WD LOCK OFF OFF ON START Br B G W R L R W R R Br L P R R W Br R Br L Br L Br Y Br L Br R R R R B B B B B B B B W W W W R W W L Y R Y B R B Br R Br R L Y R B W B O Gy G B R W B G R Y B Y R R L L R Sb B Y Br R R Y L Y Y W Y W W R Y L Br W Br W B L R R R L G Y G Y L W B L Y P Y G L B O B Br Y R W Y L B W W B Br L B Sb B R L B L G L R L R G R Sb Gy B B B Y Br B L Y B L L B L P B L Y ...

Page 476: ... motor fails to turn Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Main ignition and radiator fan motor fuses Check the main ignition and radiator fan motor fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and radiator fan motor fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in cha...

Page 477: ...nd must be replaced 5 Radiator fan motor relay Remove the radiator fan motor relay from the wire harness Connect the pocket tester Ω 1 and bat tery 12 V to the radiator fan motor relay terminal as shown Check the radiator fan motor relay of conti nuity Positive battery lead brown red 1 Negative battery lead yellow red 2 Positive tester probe red 3 Negative tester probe red blue 4 Does the radiator...

Page 478: ...the radiator fan motor circuit breaker from the wire harness Connect the pocket tester Ω 1 to the radiator fan motor circuit breaker Radiator fan motor circuit breaker resistance 0 0 05 Ω at 25 C 77 F Replace the radiator fan motor circuit breaker COOLING SYSTEM ...

Page 479: ...ure indicated in the table Measure the coolant temperature sensor resistance Coolant temperature sensor resistance 290 354 Ω at 80 C 176 F WARNING _ Handle the coolant temperature sensor with special care Never subject the coolant temperature sensor to strong shocks If the coolant temperature sensor is dropped replace it T R Coolant temperature sensor 18 Nm 1 8 m kg 13 ft lb Does the coolant tempe...

Page 480: ...K G W B Br L B G W L Br L BLACK B Br G W Br B 4WD 2WD LOCK OFF OFF ON START Br B G W R L R W R R Br L P R R W Br R Br L Br L Br Y Br L Br R R R R B B B B B B B B W W W W R W W L Y R Y B R B Br R Br R L Y R B W B O Gy G B R W B G R Y B Y R R L L R Sb B Y Br R R Y L Y Y W Y W W R Y L Br W Br W B L R R R L G Y G Y L W B L Y P Y G L B O B Br Y R W Y L B W W B Br L B Sb B R L B L G L R L R G R Sb Gy B ...

Page 481: ...12 Analog pocket tester YU 03112 C 1 Main ignition and fuel injection system fuses Check the main ignition and fuel injection system fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and fuel injection system fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage...

Page 482: ...lue red 2 Positive tester probe brown black 3 Negative tester probe red blue 4 Does the fuel injection system relay have continuity between brown black and red blue Replace the fuel injection system relay 5 Fuel pump Check the condition of the fuel pump Refer to CHECKING THE FUEL PUMP BODY in chapter 6 Replace the fuel pump assembly 6 Wiring Check the entire fuel pump system wiring Refer to CIRCUI...

Page 483: ... G W R L R W R R Br L P R R W Br R Br L Br L Br Y Br L Br R R R R B B B B B B B B W W W W R W W L Y R Y B R B Br R Br R L Y R B W B O Gy G B R W B G R Y B Y R R L L R Sb B Y Br R R Y L Y Y W Y W W R Y L Br W Br W B L R R R L G Y G Y L W B L Y P Y G L B O B Br Y R W Y L B W W B Br L B Sb B R L B L G L R L R G R Sb Gy B B B Y Br B L Y B L L B L P B L Y G L Gy G W R Sb Gy L W P L W B L L Y W B L B L ...

Page 484: ...ES NO EBS01041 YES NO The four wheel drive motor indicator light fails to come on Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Main ignition and four wheel drive motor fuses Check the main ignition and four wheel drive motor fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and four wheel drive motor fuses OK Replace the fuse s 2 Battery Check the c...

Page 485: ...1 Negative tester probe brown red 5 Check the four wheel drive motor relay 1 for continuity Replace the four wheel drive motor relay 1 5 Four wheel drive motor relay 2 Remove the four wheel drive motor relay 2 from the wire harness Connect the pocket tester Ω 1 and the battery 12 V to the four wheel drive motor relay 2 terminals Positive tester probe brown black 1 Negative tester probe black 2 Pos...

Page 486: ... 2 Positive tester probe brown 3 Negative tester probe gray 4 Check the four wheel drive motor relay 3 for continuity Replace the four wheel drive motor relay 3 7 On command four wheel drive motor switch and differential gear lock switch Check the on command four wheel drive motor switch and differential gear lock switch for continuity Refer to CHECKING THE SWITCHES Is the on command four wheel dr...

Page 487: ...pinion gear 2 turns counter clockwise É Check that the pinion gear 2 turns clockwise Make sure that the drive gear shift fork sliding gear operates correctly TIP When installing the differential gear motor refer to FRONT CONSTANT VELOCITY JOINTS DIFFERENTIAL GEAR AND DRIVE SHAFT in chapter 7 Replace the differen tial gear motor 3V 2 1 È 3V 2 1 É 9 Wiring connection Check the connections of the ent...

Page 488: ...taminated fuel Sucked in air 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 body Ignition system Faulty ECU Faulty crankshaft position sensor Broken AC magneto rotor woodruff key Switches and wi...

Page 489: ...ston ring Seized or damaged piston Crankcase and crankshaft Improperly seated crankcase Seized crankshaft Valve train Improperly adjusted valve clearance Improperly adjusted valve timing EBS00538 POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE Throttle body Damaged or loose throttle body joint Improper throttle cable play Flooded throttle body Electrical system Faulty spark plug Faulty ECU...

Page 490: ...e 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 and...

Page 491: ...ift drum groove Transmission Worn gear dog EBS00543 FAULTY CLUTCH PERFORMANCE ENGINE OPERATES BUT VEHICLE WILL NOT MOVE V belt Bent damaged or worn V belt V belt slips Primary pulley cam and primary pulley slider Damaged or worn primary pulley cam Damaged or worn primary pulley slider Transmission Damaged transmission gears CLUTCH SLIPPING Clutch spring Damaged loose or worn clutch shoe spring Clu...

Page 492: ...ulty throttle body Damaged or loose throttle body joint Clogged air filter element Compression system Heavy carbon build up Engine oil Improper oil level Improper oil viscosity Inferior oil quality Brake Brake drag Cooling system Low coolant level Clogged or damaged radiator Damaged or faulty water pump Faulty fan motor Faulty coolant temperature sensor Disconnect circuit breaker connecter EBS0054...

Page 493: ...ds Deformed steering knuckles Tires Uneven tire pressures on both sides Incorrect tire pressure Uneven tire wear Wheels Deformed wheel Loose bearing Bent or loose wheel axle Excessive wheel runout Frame Bent Damaged frame EBS00553 LIGHTING SYSTEM HEADLIGHT DOES NOT COME ON Improper bulb Too many electric accessories Hard charging broken stator coil and or faulty rectifier regulator Incorrect conne...

Page 494: ...heel drive motor relay 2 c Four wheel drive motor relay 3 d On command four wheel drive motor switch and differential gear lock switch e Differential gear motor f Auxiliary DC jack g Auxiliary DC jack fuse h Signaling system fuse i Headlight fuse j Light switch k Headlight relay l Headlight m Brake light switch n Tail brake light o Radiator fan motor p Radiator fan motor circuit breaker q Load con...

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Page 496: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A ...

Page 497: ... O Y R R Y Gy G W B R G B R W G Br B R Y BLACK L Y W B BLACK L Br BLACK G W B Br L B G W L Br L BLACK B Br G W 4WD 2WD LOCK OFF OFF ON START Br B G W R L R W R R Br L P R R W Br R Br L Br L Br Y Br L Br R R R R B B B B B B B B W W W W R W W L Y R Y B R B Br R Br R L Y B Br R B W B O Gy G B R W B G R Y B Y R R L L R Sb B Y Br R R Y L Y Y W Y W W R Y L Br W Br W B L R R R L G Y G Y L W B L Y P Y G L...

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