Yamaha Wolverine YX70EPNG Service Manual Download Page 233 | Manualshive

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CYLINDER HEAD, CYLINDER, AND PISTON

5-20

EBS30438

REMOVING THE CYLINDER HEAD
1. Remove:

• Cylinder bolt (M6) (

×

2)

• Cylinder head bolt (M6) (

×

2)

• Cylinder head bolt (M11) (

×

4)

• Cylinder head

TIP

• Loosen the bolts in the proper sequence as

shown.

• Loosen each bolt 1/2 of a turn at a time. After

all of the bolts are fully loosened, remove them.

• M6

×

25 mm: “1”–“4”

• M11

×

208 mm: “5”–“8”

EBS30146

REMOVING THE PISTON
1. Remove:

• Piston pin clips “1”
• Piston pin “2”
• Piston “3”

NOTICE

ECB01380

Do not use a hammer to drive the piston pin
out.

TIP

• Before removing the piston pin clips, cover the

crankcase opening with a clean rag to prevent
the piston pin clips from falling into the crank-
case.

• Before removing the piston pin, deburr the pis-

ton pin clip grooves and the piston pin bore ar-
ea. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller set “4”.

• Remove the piston pin from the side of the pis-

ton that has the manufacturer’s mark “a”.

2. Remove:

• Top ring
• 2nd ring
• Oil ring

TIP

When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring
over the piston crown.

×4

×4

5

7

6

8

4

3

2

1

FWD

Piston pin puller set

90890-01304

Piston pin puller

YU-01304

2

1

a

3

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Summary of Contents for Wolverine YX70EPNG

Page 1: ...2016 17 SERVICE MANUAL YX70EPNG YXE70WPXG YXE70WPHG YXE70WDXG YXE700E YXE700SE 2MB G8198 E0 ...

Page 2: ...E700E YXE700SE SERVICE MANUAL 2017 by Yamaha Motor Co Ltd 2nd edition May 2017 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Brought to you by FordTruckMan Tinken ...

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

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

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

Page 6: ......

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

Page 8: ......

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

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

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

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

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

Page 14: ...tops TIP To switch the display between mph and km h turn the main switch to off then push and hold the SELECT button while turning the main switch to on Clock hour meter and voltage display modes Pushing the CLOCK button switches the dis play between the clock mode CLOCK the hour meter mode HOUR and the voltage display mode in the following order CLOCK HOUR CLOCK To set the clock 1 Set the display...

Page 15: ...oon as possible TIP This fuel meter is equipped with a self diagnosis system If a problem is detected in an electrical circuit all the display segments and fuel level warning indicator start flashing If this occurs check the electrical circuit Refer to SIGNALING SYSTEM on page 9 19 Self diagnosis device This model is equipped with a self diagnosis de vice for various electrical circuits If a probl...

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

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

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

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

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

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

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

Page 23: ...stakes TIP For U S A and Canada use part number starting with YM YU YS YK or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 13 1 13 9 91 9 92 9 92 9 94 9 97 9 100 9 100 9 101 9 102 9 102 9 103 9 104 9 104 9 106 9 106 9 108 9 108 9 108 9 109 9 109 9 110 Thickness gauge 90890 03180 Feeler g...

Page 24: ...90890 01526 Boots band installation tool YM 01526 4 50 8 10 8 12 8 25 8 27 Ball joint remover 90890 01474 Ball joint remover YM 01474 4 54 4 58 Ball joint remover adapter set 90890 01477 Ball joint remover adapter set YM 01477 4 54 4 58 Base plate 35mm 90890 01553 Base plate 35mm YM 01553 4 54 4 58 Ball joint installer attachment 39mm 90890 01555 Ball joint installer attachment 39mm YS 01881 A 4 5...

Page 25: ...YU 01304 5 20 Valve spring compressor 90890 04019 Valve spring compressor YM 04019 5 27 5 32 Valve spring compressor attachment 90890 01243 Valve spring compressor adapter 26 mm YM 01253 1 5 27 5 32 Valve guide remover installer set ø5 5 90890 04016 Valve guide remover 5 5 mm YM 01122 5 29 Tool name Tool No Illustration Reference pages 90890 03081 YU 33223 YU 01304 ...

Page 26: ... 5 29 Rotor holding tool 90890 04166 YM 04166 5 35 5 35 5 36 5 37 5 43 5 44 5 53 5 58 Flywheel puller M38 X P1 5 90890 04178 Flywheel puller M38 X P1 5 YM 04178 5 35 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 5 40 7 13 9 103 9 105 9 107 Sheave fixed block 90890 04135 Sheave fixed bracket YM 04135 5 53 5 57 Tool name Tool No Illustration Reference pages M38 P1 5...

Page 27: ...ve spring compressor 90890 04134 Sheave spring compressor YM 04134 5 53 5 57 Universal clutch holder 90890 04086 Universal clutch holder YM 91042 5 62 5 63 Crankcase separating tool 90890 01135 Crankcase separator YU 01135 B 5 68 5 73 8 30 Tool name Tool No Illustration Reference pages ...

Page 28: ...1275 Bolt YU 90060 5 75 8 28 Adapter M16 90890 04130 Adapter 13 YM 04059 5 75 Spacer crankshaft installer 90890 04081 Pot spacer YM 91044 5 75 Coupling gear middle shaft tool 90890 01229 Gear holder YM 01229 5 87 5 87 5 90 5 90 Bearing retainer wrench 90890 04128 Middle gear bearing retainer YM 04128 5 88 5 89 Tool name Tool No Illustration Reference pages YU 90058 YU 90059 YM 91044 ...

Page 29: ...it YU 24460 A 6 6 Radiator cap tester adapter 90890 01352 Pressure tester adapter YU 33984 6 6 Mechanical seal installer 90890 01581 Mechanical seal installer YM 01581 6 12 Middle driven shaft bearing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 6 12 Fuel pressure adapter 90890 03176 Fuel pressure adapter YM 03176 7 4 Tool name Tool No Illustration Reference pages YU 24460 A...

Page 30: ...h measurement tool 90890 01475 Middle drive gear lash tool YM 01475 8 16 Coupling gear holding tool 35 90890 01571 Coupling gear holding tool 35 YM 01571 8 27 8 31 Adapter M14 90890 04059 Adapter 10 YM 90069 8 28 Ring gear fix bolt M10 x 1 5 90890 01572 Ring gear fix bolt M10 x 1 5 YM 01572 8 29 Gear lash measurement tool 90890 01467 Gear lash measurement tool YM 01467 8 29 Tool name Tool No Illus...

Page 31: ... angle sensor 3P 90890 03213 Test harness lean angle sensor 3P YU 03213 9 102 Test harness speed sensor 3P 90890 03208 Test harness speed sensor 3P YU 03208 9 104 Test harness S pressure sensor 5S7 3P 90890 03211 Test harness S pressure sensor 5S7 3P YU 03211 9 107 Tool name Tool No Illustration Reference pages ...

Page 32: ...SPECIAL TOOLS 1 23 ...

Page 33: ...IGHTENING TORQUES 2 11 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 11 ENGINE TIGHTENING TORQUES 2 12 CHASSIS TIGHTENING TORQUES 2 17 LUBRICATION AND SEALING POINTS 2 24 ENGINE 2 24 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 ENGINE OIL LUBRICATION CHART 2 25 LUBRICATION DIAGRAMS 2 27 COOLING SYSTEM DIAGRAMS 2 33 CABLE ROUTING 2 39 ...

Page 34: ...Overall width 1540 mm 60 6 in Overall height 1885 mm 74 2 in Wheelbase 2065 mm 81 3 in Ground clearance 290 mm 11 4 in Minimum turning radius 4600 mm 181 in Maximum water depth 37 cm 15 in Weight Curb weight 589 0 kg 1299 lb YXE70WDXG 595 0 kg 1312 lb YX70EPNG YXE70WPXG YXE70WPHG YXE700E Maximum loading limit 327 0 kg 721 lb Total weight of operator passenger cargo accessories and tongue Loading R...

Page 35: ...UBE Type SAE 0W 30 10W 30 10W 40 15W 40 20W 40 or 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Without oil filter cartridge replacement 2 20 L 2 33 US qt 1 94 Imp qt With oil filter cartridge replacement 2 30 L 2 43 US qt 2 02 Imp qt Quantity disassembled 3 10 L 3 28 US qt 2 73 Imp qt Differential gear oil Type SAE 80 API GL 4 Hypoid gear o...

Page 36: ... Camshaft journal diameter 21 946 21 963 mm 0 8640 0 8647 in Camshaft journal to camshaft cap clearance 0 037 0 075 mm 0 0015 0 0030 in Camshaft lobe dimensions Lobe height Intake limit 33 8 mm 1 331 in Base circle diameter Intake limit 24 85 mm 0 978 in Lobe height Exhaust limit 30 75 mm 1 211 in Base circle diameter Exhaust limit 22 35 mm 0 880 in Valve valve seat valve guide Valve clearance col...

Page 37: ...20 in Out of round limit 0 050 mm 0 0020 in Piston Piston to cylinder clearance 0 040 0 075 mm 0 0016 0 0030 in Diameter 102 960 102 975 mm 4 0535 4 0541 in Measuring point from piston skirt bottom 11 0 mm 0 43 in Piston pin bore inside diameter limit 23 035 mm 0 9069 in Piston pin outside diameter limit 22 974 mm 0 9045 in Piston ring Top ring Ring type Barrel End gap installed limit 0 50 mm 0 01...

Page 38: ...0 010 in Shifting mechanism Shift fork thickness 5 76 5 89 mm 0 2268 0 2319 in Air filter Air filter element Wet element Air filter oil grade Foam air filter oil Fuel pump Pump type Electrical Throttle body Type quantity 44EHS 1 ID mark 2MB1 00 Throttle valve size 100 Fuel injector Model quantity EAT291 1 Fuel injector resistance 11 5 12 5 Ω Throttle position sensor Resistance 2 64 6 16 kΩ Idling ...

Page 39: ...Rear wheel Wheel type Panel wheel Rim size 12 7 5AT Wheel material Steel Radial wheel runout limit 2 0 mm 0 08 in Lateral wheel runout limit 2 0 mm 0 08 in Front tire Type Tubeless Size 26 8 12NHS Manufacturer model MAXXIS MU09 Wear limit front 3 0 mm 0 12 in Rear tire Type Tubeless Size 26 10 12NHS Manufacturer model MAXXIS MU10 Wear limit rear 3 0 mm 0 12 in Tire air pressure measured on cold ti...

Page 40: ...ont suspension Type Double wishbone Spring shock absorber type Coil spring gas oil damper Shock absorber travel 142 0 mm 5 59 in Installed length 329 0 mm 12 95 in Wheel travel 246 mm 9 7 in Spring preload adjusting positions Minimum 313 5 mm 12 34 in Standard 305 5 mm 12 03 in Maximum 298 5 mm 11 75 in Rebound damping adjusting positions Minimum 30 click s out from the fully turned in position St...

Page 41: ...rned in position Maximum 1 click s out from the fully turned in position Compression damping setting for fast compression damping Minimum 2 turn s out from the fully turned in position Standard 1 1 4 turn s out from the fully turned in position Maximum Adjusting bolt fully turned in Compression damping setting for slow compression damping Minimum 18 click s out from the fully turned in position St...

Page 42: ...em AC magneto Standard output 14 0 V 35 0 A at 5000 r min Stator coil resistance 0 15 0 22 Ω Rectifier regulator Regulator type Semi conductor short circuit Regulated voltage DC 14 3 14 7 V Rectifier capacity DC 50 0 A Battery Model U1 H11L Voltage capacity 12 V 28 0 Ah Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 35 0 35 0 W 2 Tail brake light 12 V 5 0 21 0 W 2 In...

Page 43: ...empty 139 00 141 00 Ω EPS torque sensor Coil resistance 0 875 1 625 kΩ for EPS models Auxiliary DC output Jack capacity 12 V 10 0 A 120 W Fuel injection sensor Crankshaft position sensor resistance 152 228 Ω Intake air pressure sensor output voltage 3 594 3 684 V at 101 kPa 1 01 kgf cm 14 psi Intake air temperature sensor resistance 5 40 6 60 kΩ at 0 C 32 F 290 390 Ω at 80 C 176 F Coolant temperat...

Page 44: ... To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kgf ft lbf 10 mm 6 mm 6 0 ...

Page 45: ...screw M32 1 11 Nm 1 1 m kgf 8 0 ft lbf Timing mark accessing screw M14 1 4 0 Nm 0 40 m kgf 2 9 ft lbf AC magneto crankshaft position sensor lead holder bolt M5 2 3 0 Nm 0 30 m kgf 2 2 ft lbf AC magneto rotor nut M14 1 160 Nm 16 m kgf 116 ft lbf Starter clutch bolt M6 8 14 Nm 1 4 m kgf 10 ft lbf Thermostat cover bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Thermostat cover air bleed bolt M6 1 10 Nm 1 0 m k...

Page 46: ... 0 30 m kgf 2 2 ft lbf Secondary sheave assembly nut M16 1 100 Nm 10 m kgf 72 ft lbf Secondary sheave spring retaining nut M36 1 90 Nm 9 0 m kgf 65 ft lbf Clutch housing assembly bolt M6 9 10 Nm 1 0 m kgf 7 2 ft lbf Clutch carrier assembly nut M22 1 190 Nm 19 m kgf 137 ft lbf Left hand threads Stake Crankcase bolt M8 M8 3 26 Nm 2 6 m kgf 19 ft lbf Crankcase bolt M6 M6 14 10 Nm 1 0 m kgf 7 2 ft lbf...

Page 47: ... Nm 19 m kgf 137 ft lbf Starter motor bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Starter motor cover bolt M5 2 4 9 Nm 0 49 m kgf 3 5 ft lbf Brush set bolt M6 1 11 Nm 1 1 m kgf 8 0 ft lbf Starter motor lead nut M6 1 4 9 Nm 0 49 m kgf 3 5 ft lbf Engine ground lead bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Spark plug M10 1 11 Nm 1 1 m kgf 8 0 ft lbf Stator coil assembly bolt M6 3 10 Nm 1 0 m kgf 7 2 ft lbf Thro...

Page 48: ...hten the cylinder head bolts M11 to 30 Nm 3 0 m kgf 22 ft lbf in the proper tightening se quence 6 Tighten the cylinder head bolts M11 to the specified angle 85 90 in the proper tightening se quence 7 Tighten the cylinder head bolts M11 to the specified angle 85 90 in the proper tightening se quence 8 Tighten the cylinder head bolts M6 and cylinder bolts M6 to 10 Nm 1 0 m kgf 7 2 ft lbf in the pro...

Page 49: ...TIGHTENING TORQUES 2 16 TIP Oil pump bolt Tighten the oil pump bolts to 10 Nm 1 0 m kgf 7 2 ft lbf in the proper tightening sequence 10 6 1 2 9 11 5 7 3 8 4 3 1 2 ...

Page 50: ...encer joint clamp screw air intake silencer side M6 1 2 0 Nm 0 20 m kgf 1 4 ft lbf Throttle body joint clamp screw throttle body side M5 1 2 8 Nm 0 28 m kgf 2 0 ft lbf Throttle body joint clamp screw cyl inder head side M5 1 3 0 Nm 0 30 m kgf 2 2 ft lbf Throttle cable locknut accelerator pedal end M6 1 2 5 Nm 0 25 m kgf 1 8 ft lbf Fuel tank bolt M6 3 7 Nm 0 7 m kgf 5 1 ft lbf Fuel tank bracket bol...

Page 51: ...ut rear left M10 1 48 Nm 4 8 m kgf 35 ft lbf Side frame nut front right M10 2 70 Nm 7 0 m kgf 51 ft lbf Side frame nut rear right M10 1 48 Nm 4 8 m kgf 35 ft lbf Rear upper frame bolt M10 4 70 Nm 7 0 m kgf 51 ft lbf Rear lower frame bolt M10 4 70 Nm 7 0 m kgf 51 ft lbf Rear upper frame and rear lower frame nut M10 2 41 Nm 4 1 m kgf 30 ft lbf Skid plate bolt M6 6 7 Nm 0 7 m kgf 5 1 ft lbf Side guar...

Page 52: ...t clamp screw drive belt cover side M6 1 2 0 Nm 0 20 m kgf 1 4 ft lbf V belt cooling exhaust duct joint clamp screw V belt cooling exhaust duct side M4 1 1 5 Nm 0 15 m kgf 1 1 ft lbf V belt cooling exhaust duct bolt M6 1 9 Nm 0 9 m kgf 6 5 ft lbf V belt cooling exhaust duct plate bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Front wheel nut M12 8 75 Nm 7 5 m kgf 54 ft lbf Rear wheel nut M12 8 75 Nm 7 5 m kg...

Page 53: ...hose holder bolt M6 4 7 Nm 0 7 m kgf 5 1 ft lbf Front brake hose union bolt M10 2 27 Nm 2 7 m kgf 20 ft lbf Rear brake hose union bolt M10 2 27 Nm 2 7 m kgf 20 ft lbf Brake caliper bleed screw M8 4 5 Nm 0 5 m kgf 3 6 ft lbf Front brake caliper bolt M10 4 48 Nm 4 8 m kgf 35 ft lbf Rear brake caliper bolt M10 4 48 Nm 4 8 m kgf 35 ft lbf Front brake pad bolt M10 4 17 Nm 1 7 m kgf 12 ft lbf Rear brake...

Page 54: ... M10 1 23 Nm 2 3 m kgf 17 ft lbf Final gear oil drain bolt M10 1 23 Nm 2 3 m kgf 17 ft lbf Final drive case cover bolt M8 10 28 Nm 2 8 m kgf 20 ft lbf Ring gear bearing housing bolt M10 8 52 Nm 5 2 m kgf 38 ft lbf Final drive pinion gear bearing hous ing bolt M8 4 28 Nm 2 8 m kgf 20 ft lbf Ring gear stopper nut M8 1 16 Nm 1 6 m kgf 12 ft lbf Rear drive shaft coupling gear nut final drive assembly ...

Page 55: ...ssembly bolts to 48 Nm 4 8 m kgf 35 ft lbf in the proper tightening sequence Steering assembly tightening sequence TIP Fuel pump nut Tighten the fuel pump nuts to 7 Nm 0 7 m kgf 5 1 ft lbf in the proper tightening sequence Horn switch lead nut except for CDN 2 2 3 Nm 0 23 m kgf 1 7 ft lbf Horn bolt except for CDN M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Item Thread size Q ty Tightening torque Remarks 1 2 3 ...

Page 56: ...ightening sequence TIP Final drive assembly bolt and nut Tighten the final drive assembly bolts and nuts to specification in the proper tightening sequence Final drive assembly tightening sequence 6 1 3 5 2 4 4 9 8 2 2 1 1 7 5 3 3 6 FWD ...

Page 57: ...bolt Dipstick mating surface Starter idler gear inner surface Starter idler gear shafts Starter wheel gear Starter clutch Clutch housing shaft end Clutch carrier assembly One way clutch bearing Reverse idle gear shaft Reverse idle gear Secondary shaft Middle driven pinion gear inner surface Middle driven shaft splines Shift drum Shift forks and shift fork guide bar Shift fork and transmission gear...

Page 58: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EBS20020 LUBRICATION SYSTEM CHART AND DIAGRAMS EBS30022 ENGINE OIL LUBRICATION CHART 13 12 11 10 9 1 8 5 4 7 2 3 6 ...

Page 59: ...S 2 26 1 Oil pan 2 Oil strainer 3 Oil pump 4 Relief valve 5 Oil cooler 6 Oil bypass valve 7 Oil filter cartridge 8 Drive axle 9 Reverse idle gear shaft 10 Oil pipe crankcase 11 Oil hose crankcase to cylinder 12 Crankshaft 13 Cylinder head ...

Page 60: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 EBS30023 LUBRICATION DIAGRAMS 6 1 2 3 4 5 7 8 9 3 ...

Page 61: ...YSTEM CHART AND DIAGRAMS 2 28 1 Oil hose crankcase to cylinder 2 Oil pipe crankcase 3 Oil filter cartridge 4 Oil strainer 5 Oil pump 6 Oil pipe AC magneto cover 7 Reverse idle gear shaft 8 Drive axle 9 Relief valve ...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 1 2 3 4 5 ...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Camshaft 2 Crankshaft 3 Oil strainer 4 Oil pump 5 Oil pump driven sprocket ...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 3 6 1 2 7 8 4 5 ...

Page 65: ...ICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Oil cooler outlet hose 2 Oil cooler inlet hose 3 Oil cooler inlet pipe 4 Oil outlet hose 5 Oil inlet hose 6 Oil cooler outlet pipe 7 Oil outlet pipe 8 Oil inlet pipe ...

Page 66: ...COOLING SYSTEM DIAGRAMS 2 33 EBS20021 COOLING SYSTEM DIAGRAMS 6 1 2 2 6 1 3 4 4 5 5 ...

Page 67: ...COOLING SYSTEM DIAGRAMS 2 34 1 Radiator 2 Radiator outlet hose 3 Radiator outlet pipe 4 Radiator inlet pipe 5 Radiator inlet hose 6 Radiator cap ...

Page 68: ...COOLING SYSTEM DIAGRAMS 2 35 4 3 3 4 1 2 ...

Page 69: ...COOLING SYSTEM DIAGRAMS 2 36 1 Radiator outlet pipe 2 Water pump inlet hose 3 Thermostat outlet hose 4 Radiator inlet pipe ...

Page 70: ...COOLING SYSTEM DIAGRAMS 2 37 2 1 4 3 5 6 ...

Page 71: ...COOLING SYSTEM DIAGRAMS 2 38 1 Thermostat outlet hose 2 Water pump inlet hose 3 Water pump 4 Water pump outlet pipe 5 Water pump outlet hose 6 Water jacket joint ...

Page 72: ...CABLE ROUTING 2 39 EBS20022 CABLE ROUTING Frame front left view A B C D E F G H 2 F 3 4 7 9 10 1 6 4 8 3 4 11 3 5 3 5 1 2 9 12 13 1 5 ...

Page 73: ...le and brake light switch lead with the holder D Fasten the radiator fan motor lead with the holder on the radiator fan motor cover E Fasten the coolant reservoir hose with the holder on the radiator fan cover F Fasten the throttle cable to the radiator inlet hose with the plastic band Be sure to route the throttle cable to the outside of the radiator inlet hose G Route the right headlight lead an...

Page 74: ...CABLE ROUTING 2 41 Frame center left view A B 1 2 3 3 4 5 6 7 8 9 10 ...

Page 75: ...eat belt switch lead 5 Thermostat outlet hose 6 Wire harness 7 Reverse switch lead 8 Gear position switch lead 9 Coolant temperature sensor lead 10 Spark plug lead A Fasten the wire harness with the plastic band B Fasten the ignition coil lead and left tail brake light lead with the holder ...

Page 76: ...CABLE ROUTING 2 43 Frame front right view 1 2 2 3 4 6 7 8 8 9 10 11 11 I A B C D E F G H J D 5 12 12 6 9 ...

Page 77: ...CDN with the plastic band D Fasten the coolant reservoir breather hose to the radiator outlet hose with the holder at the location shown in the illustration E Fasten the wire harness starter motor lead and negative battery lead with the plastic band F Fasten the wire harness starter motor lead and negative battery lead with the plastic band Position the plastic band at the section of the wire harn...

Page 78: ...CABLE ROUTING 2 45 Frame center right view 1 2 3 4 5 6 7 8 9 A B B C A D E ...

Page 79: ...ctor lead 8 TPS throttle position sensor lead 9 Intake air pressure sensor lead A Fasten the wire harness with the holder B Fasten the final drive assembly breather hose with the holder C Fasten the wire harness with the plastic band D Fasten the water pump inlet hose and AC magneto lead with the holder E Fasten the negative battery lead and starter motor lead with the holder ...

Page 80: ...CABLE ROUTING 2 47 Electrical components tray top view 1 1 2 3 4 5 6 7 7 8 8 A B 9 9 10 11 12 13 13 14 14 15 15 16 17 18 19 20 21 22 23 24 1 17 17 23 C E D ...

Page 81: ...ead 20 EPS fuse for EPS models 21 ECU lead 22 Main fuse 23 Starter motor lead 24 Fuse box A Fasten the right headlight lead with the holder on the electrical components tray B Fasten the wire harness and main fuse lead with the plastic band making sure to align the band with the white tape on the harness C Fasten the left headlight lead EPS motor lead for EPS models and EPS torque sensor lead for ...

Page 82: ...CABLE ROUTING 2 49 Frame front top view A B B C D E F G 2 3 4 5 6 8 10 11 12 13 14 1 7 9 15 16 ...

Page 83: ...plastic band at the section of the wire harness where the leads branch off from the harness C Fasten the wire harness and horn lead except for CDN at the white mark on the harness with the plastic band D Fasten the throttle cable with the plastic band E Fasten the wire harness and EPS motor lead for EPS models with the plastic band Position the plastic band at the section of the wire harness befor...

Page 84: ...CABLE ROUTING 2 51 Frame center top view 1 FWD A B C 1 2 3 4 5 6 7 8 9 10 11 ...

Page 85: ...stem solenoid lead 7 Ignition coil lead 8 Seat belt switch lead 9 Thermostat outlet hose 10 Parking brake cable 11 Throttle cable A Fasten the wire harness with the holder B Fasten the parking brake cable with the holder C Fasten the thermostat outlet hose and throttle cable with the plastic band at the location shown in the illustration ...

Page 86: ...CABLE ROUTING 2 53 Frame center top view 2 FWD 1 2 2 3 3 4 4 3 4 5 6 A B C D D D E F G 7 ...

Page 87: ...itch lead with the plastic band B Fasten the parking brake switch lead with the holder C Fasten the parking brake switch lead and parking brake buzzer lead with the holder D Fasten the wire harness ground lead and starter motor lead with the plastic band E Fasten the wire harness with the holder F Fasten the fuel pump lead with the holder G Fasten the ground lead and starter motor lead with the pl...

Page 88: ...CABLE ROUTING 2 55 Fuel tank top view FWD A A B C D D D 1 1 2 2 1 3 3 4 3 4 ...

Page 89: ...sphere 4 Fuel tank breather hose fuel tank to fuel tank breather hose joint A Fasten the grommet on the fuel hose with the holder B Fasten the fuel pump lead with the holder C Insert the end of the fuel tank breather hose fuel tank breather hose joint to atmosphere into the hole in the frame D 0 3 0 mm 0 0 12 in ...

Page 90: ...CABLE ROUTING 2 57 Front brake caliper left view A 1 2 3 3 3 B B ...

Page 91: ...CABLE ROUTING 2 58 1 Front brake pipe 2 Rear brake pipe 3 Front brake hose A Fasten the grommet on the front brake hose with the holder B Fasten the front brake hose with the holder ...

Page 92: ...CABLE ROUTING 2 59 Rear brake caliper left view A B B C C C 1 2 A A C D 1 2 2 2 ...

Page 93: ...60 1 Rear brake pipe 2 Rear brake hose A Fasten the rear brake hose with the holder B Fasten the grommet on the rear brake hose with the holder C Fasten the rear brake pipe with the holder D Face the paint mark forward ...

Page 94: ...CABLE ROUTING 2 61 Front brake caliper top view A B B C D 1 2 3 3 ...

Page 95: ... pipe 2 Rear brake pipe 3 Front brake hose A Face the paint mark upward B Fasten the grommet on the front brake hose with the holder C Route the front brake hose under the front upper arm D Fasten the front brake hose with the holder ...

Page 96: ...CABLE ROUTING 2 63 Brake pipe top and left view FWD FWD A A A 1 1 1 ...

Page 97: ...CABLE ROUTING 2 64 1 Rear brake pipe A Fasten the rear brake pipe with the holder ...

Page 98: ...CABLE ROUTING 2 65 Rear brake caliper top view A A B B B C C C 1 2 2 ...

Page 99: ...ABLE ROUTING 2 66 1 Rear brake pipe 2 Rear brake hose A Fasten the rear brake pipe with the holder B Fasten the rear brake hose with the holder C Fasten the grommet on the rear brake hose with the holder ...

Page 100: ...CABLE ROUTING 2 67 Parking brake left view A B 1 1 1 1 ...

Page 101: ...CABLE ROUTING 2 68 1 Parking brake cable A Fit the parking brake cable into the holder on the final drive case B Fit the parking brake cable into the slit in the parking brake lever ...

Page 102: ...CABLE ROUTING 2 69 Final drive assembly left and right view A A C C B B E E 1 1 1 1 2 2 4 4 4 3 3 D ...

Page 103: ...ht lead right A Fasten the wire harness with the holder B Place the slack in the tail brake light lead in the area shown in the illustration C Fasten the tail brake light lead with the plastic band D Fasten the tail brake light lead right with the holder E Fasten the final drive assembly breather hose with the holder ...

Page 104: ...CABLE ROUTING 2 71 ...

Page 105: ...NG THE DIFFERENTIAL GEAR OIL 3 17 CHECKING THE FRONT BRAKE PADS 3 18 CHECKING THE REAR BRAKE PADS 3 18 CHECKING THE BRAKE FLUID LEVEL 3 18 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 19 CHECKING THE BRAKE HOSES AND BRAKE PIPES 3 20 ADJUSTING THE BRAKE PEDAL 3 21 LUBRICATING THE BRAKE PEDAL AND ACCELERATOR PEDAL 3 21 ADJUSTING THE PARKING BRAKE 3 21 ADJUSTING THE ACCELERATOR PEDAL FREE PLAY 3 22 CHECKING...

Page 106: ...special tools data and technical skills EBS30026 GENERAL MAINTENANCE AND LUBRICATION CHART NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichever comes first month 1 3 6 6 12 km mi 320 200 1200 750 2400 1500 2400 1500 4800 3000 hours 20 75 150 150 300 1 Fuel line Check fuel hose for cracks or damage Replace if necessary 2 Valves Check valve clearance Adjust if necessary 3 Spark plug Check condit...

Page 107: ...operation and free play 11 V belt Check operation Check for wear cracks or damage 12 Wheels Check damage runout Repair if necessary 13 Wheel bearings Check bearing assemblies for looseness damage Replace if damaged 14 Front and rear sus pension Check operation and for leakage Correct if necessary 15 Steering system Check operation and for looseness Replace if dam aged Check toe in Adjust if necess...

Page 108: ...er to GENERAL CHASSIS 9 on page 4 19 2 Disconnect Cylinder head breather hose Refer to THROTTLE BODY on page 7 8 Spark plug cap Refer to CAMSHAFTS on page 5 10 3 Remove Spark plug Cylinder head cover Refer to CAMSHAFTS on page 5 10 NOTICE ECB01270 Before removing the spark plug blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder 4 ...

Page 109: ...n 0 27 mm 0 0106 in 0 20 mm 0 0079 in 0 07 mm 0 0028 in c Check the thickness of the current valve pad and then calculate the sum of the values ob tained to determine the required valve pad thickness and the valve pad number TIP The number a marked on the valve pad indi cate the valve pad thickness Refer to the following table for the available valve pads If there are no available valve pads with ...

Page 110: ... g If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained 8 Install O ring Crankshaft end accessing screw 9 Install Cylinder head cover gasket Cylinder head cover Refer to CAMSHAFTS on page 5 10 Spark plug TIP Before installing the spark plug clean the spark plug and gasket surface 170 1 700 mm 0 06693 in ...

Page 111: ...park plug with a spark plug cleaner or wire brush 6 Measure Spark plug gap a with a wire thickness gauge Out of specification Regap 7 Install Spark plug TIP Before installing the spark plug clean the spark plug and gasket surface 8 Connect Spark plug cap EBS30030 CHECKING THE BREATHER HOSE 1 Remove Center storage compartment Refer to GENERAL CHASSIS 3 on page 4 6 Rear panel right Refer to GENERAL ...

Page 112: ...pler For information about connecting the Yamaha diagnostic tool refer to YAMAHA DIAGNOSTIC TOOL on page 9 39 EBS30032 CLEANING THE SPARK ARRESTER 1 Clean Spark arrester WARNING EWB03080 Select a well ventilated area free of com bustible materials Always let the exhaust system cool before performing this operation Do not start the engine when removing the tailpipe from the muffler a Remove the bol...

Page 113: ... Radiator inlet pipe 7 Thermostat outlet hose 8 Thermostat cover 9 Water pump inlet hose 10 Water pump housing 11 Water pump outlet pipe 12 Water pump outlet hose 13 Water jacket joint 14 Cracks damage Replace Coolant leakage Replace any damaged hose and pipe Refer to OIL COOLER on page 6 1 RADI ATOR on page 6 4 THERMOSTAT on page 6 8 and WATER PUMP on page 6 11 3 Install Front grill Hood Refer to...

Page 114: ...ht Refer to GENERAL CHASSIS 1 on page 4 1 Hood Refer to GENERAL CHASSIS 6 on page 4 12 2 Remove Coolant reservoir cap 1 3 Disconnect Coolant reservoir hose 2 4 Drain Coolant from the coolant reservoir 5 Connect Coolant reservoir hose 6 Remove Radiator cap 1 WARNING EWB02770 A hot radiator is under pressure Therefore do not remove the radiator cap when the en gine is hot Scalding hot fluid and stea...

Page 115: ... 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 wa ter Do not mix different types of antifreeze 11 Install Radiator cap 12 Fill Coolant reservoir with the recommended coolant to the maxi mum level mark a 13 Install Coolant ...

Page 116: ... LEV EL on page 3 9 19 Start the engine and then check for coolant leakage 20 Install Hood Refer to GENERAL CHASSIS 6 on page 4 12 Rear panel right Refer to GENERAL CHASSIS 1 on page 4 1 EBS30037 CLEANING THE AIR FILTER ELEMENT 1 Check Check hoses 1 2 Remove Center storage compartment Refer to GENERAL CHASSIS 3 on page 4 6 TIP There are check hoses 1 at the bottom of the air filter case and on the...

Page 117: ...e the air filter element to remove the excess solvent NOTICE ECB01290 Do not twist the air filter element when squeezing it c Properly dispose of the used solvent d Carefully wash the air filter element in soap water e Thoroughly rinse the air filter element with water and then let it dry NOTICE ECB01290 Do not twist the air filter element when squeezing it f Pour the recommended oil into a storag...

Page 118: ...ended engine oil to the proper level TIP With the arrow mark c pointing in the direction shown insert the dipstick completely into the oil filler hole and then remove it again to check the oil level NOTICE ECB01820 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 ...

Page 119: ...ch 2 b Lubricate the O ring 3 of a new oil filter car tridge with a thin coat of engine oil NOTICE ECB01280 Make sure the O ring 3 is positioned cor rectly in the groove of the oil filter cartridge c Tighten the new oil filter cartridge to specifi cation with the oil filter wrench 7 Install Engine oil drain bolt along with the gasket 8 Fill Crankcase with the specified amount of the recom mended e...

Page 120: ...gher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine oil pressure after warming up the engine 3 Remove Center cover Under seat storage compartment Refer to GENERAL CHASSIS 3 on page 4 6 4 Remove Main gallery bolt 1 WARNING EWB03620 The engine muffler and engine oil are ex tremely hot 5 Install Oil pressure gauge 1 Adapter 2 6 Measure Engine oil pressur...

Page 121: ...emove Final gear oil filler bolt 1 along with the gasket Final gear oil drain bolt 2 along with the gasket Completely drain the final drive case of its oil 4 Install Final gear oil drain bolt along with the gasket 5 Fill Final drive case with the specified amount of the recom mended final gear oil NOTICE ECB01690 Take care not to allow foreign material to en ter the final drive case 6 Check Oil le...

Page 122: ...erential gear oil filler bolt 1 along with the gasket Differential gear oil drain bolt 2 along with the gasket Completely drain the differential case of its oil 4 Install Differential gear oil drain bolt along with the gasket 5 Fill Differential case with the specified amount of the recom mended differential gear oil NOTICE ECB01600 Take care not to allow foreign material to en ter the differentia...

Page 123: ...EELS on page 4 23 EBS30045 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 master cylinder reser voir is horizontal 2 Check Brake fluid level Below the minimum level mark a Add the specified brake fluid to the proper level WARNING EWB02880 Use only the designated brake fluid Other brake fluids may cau...

Page 124: ... Front wheels Rear wheels Refer to FRONT AND REAR WHEELS on page 4 23 2 Bleed Hydraulic brake system a Fill the brake master cylinder reservoir to the proper level with the specified brake fluid b Install the diaphragm brake master cylinder reservoir c Connect a clear plastic hose 1 tightly to the bleed screw 2 d Place the other end of the hose into a con tainer e Slowly apply the brake several ti...

Page 125: ...Remove Rear panel left Refer to GENERAL CHASSIS 1 on page 4 1 Center storage compartment Refer to GENERAL CHASSIS 3 on page 4 6 2 Check Front brake hoses 1 Cracks damage wear Replace 3 Check Front brake pipe 2 Cracks damage Replace 4 Check Rear brake pipe 3 Cracks damage Replace 5 Check Rear brake hoses 4 Cracks damage wear Replace 1 1 1 2 1 2 3 3 3 4 4 4 4 ...

Page 126: ...e locknut to specification WARNING EWB03090 After this adjustment is performed lift the front and rear wheels off the ground by plac ing a block under the frame and spin the front and rear wheels to ensure there is no brake drag If any brake drag is noticed per form the above steps again EBS30049 LUBRICATING THE BRAKE PEDAL AND ACCELERATOR PEDAL Lubricate the pivoting point and metal to metal movi...

Page 127: ...rtment Refer to GENERAL CHASSIS 3 on page 4 6 EBS30054 ADJUSTING THE ACCELERATOR PEDAL FREE PLAY 1 Check Accelerator pedal free play a Out of specification Adjust 2 Remove Side cover left Rear panel left Refer to GENERAL CHASSIS 1 on page 4 1 Center storage compartment Refer to GENERAL CHASSIS 3 on page 4 6 3 Adjust Accelerator pedal free play a Remove the throttle cable housing cover 1 b Slide ba...

Page 128: ...0055 CHECKING THE V BELT 1 Remove Frame cross member Refer to GENERAL CHASSIS 9 on page 4 19 V belt cooling ducts Refer to GENERAL CHASSIS 10 on page 4 21 2 Remove Drive belt cover Refer to PRIMARY AND SECONDARY SHEAVES on page 5 50 3 Check V belt 1 Cracks damage wear Replace Grease oil Clean the primary and second ary sheaves Refer to REPLACING THE V BELT on page 3 25 4 Measure V belt width a Out...

Page 129: ...a Install the bolts 1 90101 06016 into the secondary fixed sheave holes TIP Tightening the bolts 1 will push the secondary sliding sheave away causing the gap between the secondary fixed and sliding sheaves to wid en b Remove the V belt 2 from the primary sheave and secondary sheave c Install a new V belt TIP Install the new V belt so that its arrow faces the direction shown in the illustration d ...

Page 130: ...g characteristics and are therefore not recommended Tire pressure WARNING EWB02980 Tire pressure below the minimum specifi cation could cause the tire to dislodge from the rim under severe riding conditions Use no more than the following pressures when seating the tire beads Front 250 kPa 2 5 kgf cm 36 psi Rear 250 kPa 2 5 kgf cm 36 psi Higher pressures and fast inflation may cause a tire to burst...

Page 131: ...k Front shock absorber assembly Refer to CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES on page 4 57 3 Check Operation Pump the front shock absorber assembly up and down several times Unsmooth operation Replace front shock absorber assembly Refer to FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES on page 4 55 EBS30430 ADJUSTING THE FRONT SHOCK ABSORBER ASSEMBLIES The following procedure applies to bo...

Page 132: ... steering nut wrench Always tighten the locknut against the adjust ing ring then torque it to specification 2 Adjust Rebound damping force a Turn the adjusting screw 1 in direction a or b Ring nut wrench 90890 01268 Spanner wrench YU 01268 Direction a Spring preload is increased suspen sion is harder Direction b Spring preload is decreased suspen sion is softer Spring preload adjusting positions M...

Page 133: ...y turned in position Standard 13 click s out from the fully turned in position Maximum 1 click s out from the fully turned in position Direction a Compression damping force is in creased suspension is harder Direction b Compression damping force is de creased suspension is softer Compression damping setting for fast compression damping Minimum 2 turn s out from the fully turned in position Standar...

Page 134: ...ock absorbers to the same setting Uneven adjustment can result in poor handling and loss of stability 1 Adjust Spring preload a Elevate the rear wheels by placing a suitable stand under the frame b Loosen the locknut 1 c Turn the adjusting ring 2 in direction a or b NOTICE ECB02470 Never attempt to turn the adjusting ring be yond the maximum or minimum setting TIP Be sure to remove all dirt and mu...

Page 135: ...aged Steering nut wrench 90890 01443 Spanner wrench YU 33975 T R Locknut 30 Nm 3 0 m kgf 22 ft lbf Direction a Rebound damping force is increased suspension is harder Direction b Rebound damping force is decreased suspension is softer Rebound damping adjusting posi tions Minimum 30 click s out from the fully turned in position Standard 14 click s out from the fully turned in position Maximum 1 cli...

Page 136: ...play Replace the tie rod end a Turn the steering wheel left until it stops b Move the steering wheel slightly to the right and left c Check for play in the tie rod ends d Turn the steering wheel right until it stops e Move the steering wheel slightly to the left and right f Check for play in the tie rod ends 4 Raise the front end of the vehicle so that there is no weight on the front wheels 5 Chec...

Page 137: ...G EWB03110 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 straight This may lead to mishandling and an accident After setting the toe in to specification run the vehicle slowly for some distance with both hands lightly holding the steering wheel and check that the steering wheel re sponds correctly If not turn eit...

Page 138: ... DRIVE SHAFT UNIVERSAL JOINTS 1 Remove Center cover Refer to GENERAL CHASSIS 3 on page 4 6 2 Lubricate Drive shaft universal joint EBS30067 CHECKING THE ENGINE MOUNT 1 Check Engine brackets Cracks damage Replace Engine mounting bolts Engine bracket nuts Loosen Tighten Refer to ENGINE REMOVAL 2 on page 5 5 EBS30068 CHECKING THE CONSTANT VELOCITY SHAFT ASSEMBLY DUST BOOTS 1 Check Dust boots 1 Damage...

Page 139: ...SHAFT on page 8 18 EBS30069 CHECKING THE FASTENER 1 Check Fasteners Damage pitting Replace Refer to GENERAL CHASSIS 1 on page 4 1 GENERAL CHASSIS 3 on page 4 6 GENERAL CHASSIS 6 on page 4 12 GENERAL CHASSIS 7 on page 4 13 and GENERAL CHASSIS 9 on page 4 19 A Front B Rear 1 1 A 1 1 B ...

Page 140: ...PERIODIC MAINTENANCE 3 35 ...

Page 141: ...E 4 11 GENERAL CHASSIS 6 4 12 GENERAL CHASSIS 7 4 13 REMOVING THE STEERING WHEEL 4 16 INSTALLING THE STEERING WHEEL 4 16 GENERAL CHASSIS 8 4 17 GENERAL CHASSIS 9 4 19 INSTALLING THE CARGO BED 4 20 GENERAL CHASSIS 10 4 21 INSTALLING THE V BELT COOLING DUCTS 4 22 FRONT AND REAR WHEELS 4 23 REMOVING THE WHEELS 4 24 REMOVING THE WHEEL HUBS 4 24 CHECKING THE WHEELS 4 24 CHECKING THE WHEEL HUBS 4 25 INS...

Page 142: ...MBLY 4 46 STEERING SYSTEM 4 47 REMOVING THE TIE ROD 4 49 CHECKING THE STEERING JOINT 4 49 CHECKING THE TIE ROD ENDS 4 49 INSTALLING THE STEERING SYSTEM 4 49 LUBRICATING THE STEERING SHAFT 4 51 STEERING KNUCKLES 4 52 REMOVING THE STEERING KNUCKLES 4 53 CHECKING THE STEERING KNUCKLES AND FRONT WHEEL BEARINGS 4 53 CHECKING THE STEERING KNUCKLE BALL JOINTS 4 53 FRONT ARMS AND FRONT SHOCK ABSORBER ASSE...

Page 143: ... 4 63 CHECKING THE REAR ARMS 4 65 HANDLING THE REAR SHOCK ABSORBER ASSEMBLIES 4 65 DISPOSING OF A REAR SHOCK ABSORBER ASSEMBLY 4 65 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES 4 65 INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES 4 66 ...

Page 144: ...s The following procedure applies to both of the doors 1 Door hinge 1 2 Door 1 3 Door handle latch 1 4 Rubber damper 1 5 Fuel tank cap 1 Right side only 6 Side panel 1 7 Rear panel 1 1 2 4 4 3 4 6 7 5 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 145: ...ab a on the door hinge with the slot b in the frame 3 Install Door handle latch 1 TIP Adjust the position of the door handle latch so that it fully engages the bar 2 on the frame when the door is closed T R Door hinge nut 7 Nm 0 7 m kgf 5 1 ft lbf T R Door hinge bolt 7 Nm 0 7 m kgf 5 1 ft lbf T R Door handle latch nut 7 Nm 0 7 m kgf 5 1 ft lbf 1 b 1 a 1 2 1 ...

Page 146: ...eats Order Job Parts to remove Q ty Remarks 1 Seat cushion 2 2 Driver seat frame 1 3 Passenger seat frame 1 4 Seat back 2 5 Shoulder holster 2 3 3 4 4 3 4 5 3 1 2 5 3 6 Nm 0 6 m kgf 4 3 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R New New ...

Page 147: ...holes a in the vehicle frame c Install the driver seat frame bolts and then tighten the bolts to specification 3 Install Driver seat cushion Refer to INSTALLING THE SEATS on page 4 4 EBS30342 INSTALLING THE SEATS The following procedure applies to both of the seats 1 Install Seat cushion 1 WARNING EWB03120 A loose seat could cause the operator to lose control or cause the operator or passengers to...

Page 148: ...GENERAL CHASSIS 2 4 5 1 b a a ...

Page 149: ...at belt buckle rubber cover 1 4 Center cover 1 5 Under seat storage compartment 1 6 Rubber cover 1 7 Under seat compartment panel 1 8 Floor board right 1 9 Pedal assembly rubber cover 1 10 Floor board left 1 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ib...

Page 150: ... compartment Refer to GENERAL CHASSIS 3 on page 4 6 1 Driver seat belt 1 2 Seat belt rubber cover left 1 3 Passenger seat belt 1 4 Seat belt rubber cover right 1 5 Seat belt switch coupler 1 Disconnect 6 Driver seat belt buckle 1 7 Seat belt buckle bracket 1 8 Passenger seat belt buckle 1 59 Nm 5 9 m kgf 43 ft Ibf T R 59 Nm 5 9 m kgf 43 ft Ibf T R 59 Nm 5 9 m kgf 43 ft Ibf T R 3 1 2 4 5 8 7 6 ...

Page 151: ...eat belt buckle bracket 2 Install Seat belts TIP Install the seat belt anchor plates 1 so that they contact the stoppers a Fit the projection b on each seat belt 2 into the holes c in the frame T R Seat belt buckle bolt 59 Nm 5 9 m kgf 43 ft lbf T R Seat belt bolt M12 20 59 Nm 5 9 m kgf 43 ft lbf Seat belt bolt M12 18 59 Nm 5 9 m kgf 43 ft lbf Seat belt guide bolt 59 Nm 5 9 m kgf 43 ft lbf a 1 1 b...

Page 152: ...20090 GENERAL CHASSIS 5 Removing the sun top Order Job Parts to remove Q ty Remarks 1 Sun top rear bracket 4 2 Sun top front bracket 4 3 Sun top 1 4 Damper 4 5 Damper 4 8 8 4 4 4 4 2 1 4 3 5 New 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R ...

Page 153: ...bber cover right 1 2 Rear lower frame rubber cover left 1 3 Front top frame 1 4 Rear top frame 1 5 Rear upper frame 1 6 Side frame right 1 7 Side frame left 1 8 Rear lower frame 1 48 Nm 4 8 m kgf 35 ft Ibf T R 48 Nm 4 8 m kgf 35 ft Ibf T R 70 Nm 7 0 m kgf 51 ft Ibf T R 70 Nm 7 0 m kgf 51 ft Ibf T R 70 Nm 7 0 m kgf 51 ft Ibf T R 70 Nm 7 0 m kgf 51 ft Ibf T R 41 Nm 4 1 m kgf 30 ft Ibf T R 7 4 1 3 2 ...

Page 154: ...me nut rear left Rear lower frame bolts TIP Tighten the bolts and nuts in the proper tighten ing sequence as shown 1 2 and so on 1 3 2 4 5 6 5 6 FWD T R Rear upper frame bolt 70 Nm 7 0 m kgf 51 ft lbf Rear upper frame and rear lower frame nut 41 Nm 4 1 m kgf 30 ft lbf Front top frame bolt 70 Nm 7 0 m kgf 51 ft lbf Rear top frame bolt 70 Nm 7 0 m kgf 51 ft lbf Side frame nut front right 70 Nm 7 0 m...

Page 155: ...ve battery lead 1 Disconnect 8 Battery band 2 9 Battery 1 10 Front guard 1 11 Headlight coupler 2 Disconnect 12 Front grill 1 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 48 Nm 4 8 m kgf 35 ft Ibf T R 48 Nm 4 8 m kgf 35 ...

Page 156: ...der 2 For over fender models 2 Front fender 1 3 Passenger handhold 1 4 Steering wheel cover 1 5 Steering wheel 1 6 Meter assembly coupler 1 Disconnect 7 Indicator light assembly coupler 1 Disconnect 8 On Command four wheel drive switch coupler 1 Disconnect 9 Light switch coupler 1 Disconnect 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7...

Page 157: ...liary DC jack coupler 1 Disconnect 12 Horn switch lead 2 Disconnect Except for CDN 13 Instrument panel assembly 1 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 2 3 Nm 0 23 m kgf 1 7 ft Ibf T R 2 5 5 5 5 8 5 10 11 13 9 12 ...

Page 158: ...ob Parts to remove Q ty Remarks 1 Meter assembly 1 2 Indicator light assembly 1 3 On Command four wheel drive switch 1 4 Light switch 1 5 Main switch 1 6 Auxiliary DC jack 1 7 Horn switch 1 Except for CDN 8 Instrument panel 1 3 1 2 5 6 8 3 4 7 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R ...

Page 159: ...he steering wheel 3 Remove Steering wheel 1 TIP Use a general puller 2 to separate the steering wheel and steering column EBS30347 INSTALLING THE STEERING WHEEL 1 Install Steering wheel 1 TIP Install the steering wheel onto the steering col umn so that it is centered 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...

Page 160: ... coupler 2 Disconnect 2 Lean angle sensor 1 3 Starter relay 1 4 Main fuse 1 5 EPS fuse 1 For EPS models 6 ECU Engine Control Unit 1 7 EPS control unit 1 For EPS models 8 Fuse box 1 9 Differential motor relay 2 1 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 3 6 Nm 0 36 m kgf 2 6 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 1 2 6 3 4 4 9 5 5 4 1 7 8 ...

Page 161: ... 1 11 Headlight relay 1 12 Load control relay 1 13 Fuel injection system relay 1 14 Radiator fan motor relay 1 15 Electrical components tray 1 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 3 6 Nm 0 36 m kgf 2 6 ft Ibf T R 3 8 Nm 0 38 m kgf 2 8 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 10 11 12 13 14 4 FWD FWD 15 ...

Page 162: ...ect 4 Cargo bed 1 5 Latch holder 4 6 Tail brake light bracket left 1 7 Tail brake light bracket right 1 8 Tail brake light 2 9 Rear over fender 2 For over fender models 10 Heat protector 1 11 Frame cross member 1 9 Nm 0 9 m kgf 6 5 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R 33 Nm 3 3 m kgf 24 ft Ibf T R 33 Nm 3 3 m kgf 24 ft Ibf T R 1 2 ...

Page 163: ...CHASSIS 9 4 20 EBS30420 INSTALLING THE CARGO BED 1 Install Cargo bed 1 TIP Tighten the bolts 2 and 3 in the order listed and then tighten the bolts 4 T R Cargo bed bolt 9 Nm 0 9 m kgf 6 5 ft lbf 4 4 2 3 1 FWD 4 ...

Page 164: ... duct plate 1 3 V belt cooling exhaust duct joint 1 4 V belt cooling intake duct 1 5 V belt cooling intake duct joint 1 1 6 V belt cooling intake duct joint 2 1 1 2 3 4 6 5 FWD FWD 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft...

Page 165: ... on V belt cooling intake duct joint 2 with the lib on the crankcase Fit the projection b on the V belt cooling in take duct joints and V belt cooling exhaust duct joint between the projections on the V belt cooling intake duct and V belt cooling exhaust duct Align the slit c in V belt cooling intake duct joint 1 and V belt cooling exhaust duct joint with the projection on the drive belt cover a b...

Page 166: ... of the wheels 1 Wheel 1 2 Wheel cap 1 3 Wheel axle nut 1 4 Brake caliper 1 TIP Do not apply the brake pedal when the brake caliper is off of the brake disc as the brake pads will be forced shut 5 Wheel hub 1 6 Brake disc 1 FWD FWD New LT 30 Nm 3 0 m kgf 22 ft Ibf T R 48 Nm 4 8 m kgf 35 ft Ibf T R 75 Nm 7 5 m kgf 54 ft Ibf T R 350 Nm 35 0 m kgf 253 ft lbf T R 4 1 2 3 5 6 ...

Page 167: ...to all of the wheels 1 Check Tire Wheel Refer to CHECKING THE TIRES on page 3 25 and CHECKING THE WHEELS on page 3 24 WARNING EWB03020 After replacing the tire ride conservatively to allow the tire to be properly seated in the rim Failure to do so may cause an accident re sulting in vehicle damage and possible inju ry 2 Measure Radial wheel runout 1 Lateral wheel runout 2 Over the specified limit ...

Page 168: ...way from the hub EBS30088 INSTALLING THE WHEEL HUBS The following procedure applies to all of the wheel hubs 1 Install Wheel hub 1 TIP Tap lightly on the wheel hub with a soft face hammer until five threads on the end of the con stant velocity shaft will be exposed when the washer is installed 2 Install Wheel axle nut TIP Do not apply oil to the threads of the nut After tightening the nut stake th...

Page 169: ... THE WHEELS The following procedure applies to all of the wheels 1 Tighten Wheel nuts 1 WARNING EWB03130 Tapered wheel nuts are used for both the front and rear wheels Install each nut with its tapered side towards the wheel T R Front wheel nut 75 Nm 7 5 m kgf 54 ft lbf Rear wheel nut 75 Nm 7 5 m kgf 54 ft lbf 1 ...

Page 170: ...y Remarks The following procedure applies to both of the front brake calipers Front wheel Refer to FRONT AND REAR WHEELS on page 4 23 1 Brake caliper bolt 2 2 Brake pad bolt 2 3 Brake pad 2 4 Brake pad spring 1 FWD FWD 17 Nm 1 7 m kgf 12 ft Ibf T R 48 Nm 4 8 m kgf 35 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 4 1 1 2 3 ...

Page 171: ...ollowing procedure applies to both of the rear brake calipers Rear wheel Refer to FRONT AND REAR WHEELS on page 4 23 1 Brake caliper bolt 2 2 Brake pad bolt 2 3 Brake pad 2 4 Brake pad spring 1 FWD FWD 17 Nm 1 7 m kgf 12 ft Ibf T R 48 Nm 4 8 m kgf 35 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 1 1 2 4 3 ...

Page 172: ...l Refer to FRONT AND REAR WHEELS on page 4 23 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 19 1 Brake hose union bolt 1 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Brake pad bolt 2 Loosen 5 Brake caliper bolt 2 6 Brake caliper 1 FWD FWD New New 17 Nm 1 7 m kgf 12 ft Ibf T R 48 Nm 4 8 m kgf 35 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 6 5 5 4 2 2 3 1 ...

Page 173: ...el Refer to FRONT AND REAR WHEELS on page 4 23 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 19 1 Brake hose union bolt 1 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Brake pad bolt 2 Loosen 5 Brake caliper bolt 2 6 Brake caliper 1 FWD FWD New 48 Nm 4 8 m kgf 35 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 27 Nm 2 7 m kgf 20 ft Ibf T R 5 4 2 6 1 3 5 ...

Page 174: ... 2 2 Brake pad 2 3 Brake pad spring 1 4 Brake caliper bracket 1 5 Brake caliper guide pin 1 6 Brake caliper retaining pin 1 7 Brake caliper piston 2 8 Brake caliper piston dust seal 2 9 Brake caliper piston seal 2 10 Bleed screw 1 BF S New New S LT S 5 Nm 0 5 m kgf 3 6 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 22 Nm 2 2 m kgf 16 ft Ibf T R 10 3 1 2 4 6 8 7 5 9 ...

Page 175: ...2 2 Brake pad 2 3 Brake pad spring 1 4 Brake caliper bracket 1 5 Brake caliper guide pin 1 6 Brake caliper retaining pin 1 7 Brake caliper piston 2 8 Brake caliper piston dust seal 2 9 Brake caliper piston seal 2 10 Bleed screw 1 17 Nm 1 7 m kgf 12 ft Ibf T R 22 Nm 2 2 m kgf 16 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 4 6 10 8 7 5 9 3 1 2 BF S New New S LT S ...

Page 176: ...YSTEM on page 3 19 1 Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir diaphragm 1 3 Brake master cylinder reservoir diaphragm hold er 1 4 Rear brake pipe 1 Disconnect 5 Front brake pipe 1 Disconnect 6 Brake master cylinder 1 FWD FWD 1 2 5 6 4 3 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 19 Nm 1 9 m kgf 14 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R ...

Page 177: ... BRAKE DISCS The following procedure applies to all of the brake discs 1 Remove Wheels Refer to FRONT AND REAR WHEELS on page 4 23 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Hold the dial gauge at a right angle against the brake disc surface b Measure the deflection 3 0 mm 0 12 in be l...

Page 178: ...ightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install the brake pad spring and brake pads 3 Install Brake pad bolts Brake caliper 4 Check Brake fluid level Below the minimum level mark Add the specified brake fluid to the proper level Re...

Page 179: ...r Replace the brake caliper Brake caliper body 3 Cracks damage Replace the brake cali per Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWB03140 Whenever a brake caliper is disassembled replace the brake caliper piston dust seals and brake caliper piston seals EBS30095 ASSEMBLING THE BRAKE CALIPERS The following procedure applies to all of the br...

Page 180: ...ose left onto the rear brake caliper left fit the pipe section c on the end of the brake hose into the slot in the brake caliper When installing the rear brake hose right onto the rear brake caliper right make sure that the projection d on the brake hose contacts the rib on the brake caliper 2 Remove Brake caliper 3 Install Brake pad spring Brake pads Brake pad bolts Brake caliper Refer to REPLACI...

Page 181: ...rake pedal operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 19 EBS30097 CHECKING THE BRAKE MASTER CYLINDER 1 Check Brake master cylinder Damage scratches wear Replace Brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder reservoir Cracks damage Replace the brake ...

Page 182: ...cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECB01320 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 19 4 Check Brake fluid level Below the minimum level mark Add the specifie...

Page 183: ... 8 18 1 Parking brake plate 5 2 Parking brake spring 2 3 Friction plate 4 4 Parking brake cam plate 1 5 Parking brake cam plate spring 1 6 Ball 6 7 Parking brake boss 1 8 Bearing 1 9 Parking brake plate guide pin 4 10 Parking brake arm 1 11 Parking brake camshaft 1 28 Nm 2 8 m kgf 20 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R LS New LT New New LT LT LT LT LT LT 6 1 1 3 ...

Page 184: ...Center cover Refer to GENERAL CHASSIS 3 on page 4 6 1 Parking brake switch 1 2 Parking brake buzzer 1 3 Parking brake lever 1 4 Parking brake cable 1 Disconnect 7 Nm 0 7 m kgf 5 1 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 3 4 1 2 ...

Page 185: ...ure applies to both of the parking brake springs 1 Check Parking brake spring Damage Replace the parking brake springs as a set EBS30424 CHECKING THE PARKING BRAKE BOSS 1 Check Parking brake boss splines Damage pitting wear Replace the parking brake boss TIP Pitting on the parking brake boss will cause er ratic brake operation EBS30425 INSTALLING THE PARKING BRAKE 1 Install Parking brake plates Fr...

Page 186: ... EBS30105 INSTALLING THE PARKING BRAKE LEVER 1 Install Parking brake lever 2 Adjust Parking brake lever free play Refer to ADJUSTING THE PARKING BRAKE on page 3 21 T R Parking brake lever bolt 13 Nm 1 3 m kgf 9 4 ft lbf ...

Page 187: ...Refer to GENERAL CHASSIS 3 on page 4 6 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 19 Brake master cylinder Refer to FRONT AND REAR BRAKES on page 4 27 1 Brake light switch 1 2 Throttle cable 1 Disconnect 3 Pedal assembly 1 FWD FWD 1 3 2 2 5 Nm 0 25 m kgf 1 8 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R ...

Page 188: ...ts to remove Q ty Remarks 1 Pin 1 2 Brake pedal rod 1 3 Spring 1 4 Circlip 1 5 Washer 2 6 Brake pedal 1 7 Spring 1 8 Circlip 1 9 Washer 2 10 Accelerator pedal 1 11 Pedal assembly bracket 1 1 6 5 5 4 11 9 9 10 8 3 2 7 New New New LS LS LS 17 Nm 1 7 m kgf 12 ft Ibf T R ...

Page 189: ...to ADJUSTING THE BRAKE PEDAL on page 3 21 4 Adjust Brake light operation timing TIP Adjustment is correct when the brake light comes on by depressing the brake pedal less than 5 0 10 0 mm 0 20 0 39 in a 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 T R Throttle cable lockn...

Page 190: ...odels 3 EPS motor coupler 1 Disconnect For EPS models 4 EPS torque sensor coupler 1 Disconnect For EPS models 5 EPS unit 1 For EPS models 6 Steering joint 1 New New New New New LS LS 40 Nm 4 0 m kgf 29 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R 33 Nm 3 3 m kgf 24 ft Ibf T R 33 Nm 3 3 m kgf 24 ft Ibf T R 39 Nm 3 9 m kgf 28 ft Ibf T R 48 Nm 4 8 m kgf 35 ft Ibf T R 55 Nm 5...

Page 191: ...ot 2 11 Tie rod set 2 TIP Replace the tie rod and lock washer as a set New New New New New LS LS 40 Nm 4 0 m kgf 29 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 21 Nm 2 1 m kgf 15 ft Ibf T R 33 Nm 3 3 m kgf 24 ft Ibf T R 33 Nm 3 3 m kgf 24 ft Ibf T R 39 Nm 3 9 m kgf 28 ft Ibf T R 48 Nm 4 8 m kgf 35 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 4 4 9 9 7 7 10 10 8 11 11 4 ...

Page 192: ...rocedure applies to both of the tie rod ends 1 Check Tie rod end free play and movement Rough movement Replace the tie rod end 2 Check Tie rod end Bends damage Replace Rubber boot damage Replace the tie rod end EBS30109 INSTALLING THE STEERING SYSTEM 1 Install Lock washer 1 TIP Align the tabs a on the lock washer with the groove b in the steering assembly 2 Tighten Tie rod 1 a 1 T R Tie rod 55 Nm ...

Page 193: ...n the steering assembly shaft and the slit b in the steering joint with the alignment mark c on the steering assembly housing Fit the steering joint onto the steering column shaft or EPS unit shaft so that the bolt hole d in the joint is aligned with the area e on the shaft that does not have splines Boots band installation tool 90890 01526 Boots band installation tool YM 01526 T R Steering assemb...

Page 194: ...djust Toe in Refer to ADJUSTING THE TOE IN on page 3 32 EBS30426 LUBRICATING THE STEERING SHAFT Lubricate the pivoting point and metal to metal moving parts of the shaft Recommended lubricant Lithium soap based grease 1 2 d e ...

Page 195: ...o FRONT AND REAR WHEELS on page 4 23 1 Brake disc guard 1 2 Tie rod end 1 Disconnect 3 Front brake hose holder 1 4 Steering knuckle 1 5 Circlip 1 6 Ball joint 1 7 Oil seal 2 8 Bearing 2 9 Spacer 1 New New New New New New New LS LS New New 2 1 4 5 6 3 7 8 8 9 7 7 Nm 0 7 m kgf 5 1 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 39 Nm 3 9 m kgf 28 ft Ibf T R 30 Nm 3 0 m kgf 22 ...

Page 196: ...Eye protection is recommended when using striking tools d Remove the spacer 3 e Apply lithium soap based grease to the spac er new bearings and oil seals f Install the spacer to the steering knuckle g Install the new bearings TIP Install the wheel side bearing first NOTICE ECB01620 Do not strike the inner race or balls of the bearing Contact should be made only with the outer race h Install the ne...

Page 197: ...ls h Install a new circlip Ball joint bore inside diameter 32 90 32 95 mm 1 295 1 297 in Ball joint remover 90890 01474 Ball joint remover YM 01474 Ball joint remover adapter set 90890 01477 Ball joint remover adapter set YM 01477 Base plate 35mm 90890 01553 Base plate 35mm YM 01553 Ball joint installer attachment 39mm 90890 01555 Ball joint installer attachment 39mm YS 01881 A 4 3 2 a No Tool nam...

Page 198: ...to FRONT AND REAR WHEELS on page 4 23 1 Front arm protector 1 2 Front brake hose holder 1 3 Front brake hose holder 1 4 Nut 2 5 Nut Bolt front shock absorber assembly 2 2 6 Front shock absorber assembly 1 7 Nut Bolt front upper arm 2 2 8 Front upper arm 1 9 Dust cover 2 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 55 Nm 5 5...

Page 199: ...ower arm 2 2 11 Front lower arm 1 12 Dust cover 2 13 Circlip 1 14 Ball joint 1 15 Bushing 4 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R LS LS LS New New LS FWD FWD New 15 10 10 10 10 15 13 14 11 12 12 15 15 ...

Page 200: ...sorber 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 high heat High heat can cause an explosion due to excessive gas pressure Do not deform or damage the front shock absorber or gas cylinder in any way If the front shock absorber gas cylinder or both are dama...

Page 201: ...pecial tools and a new ball joint 5 to the front upper arm 4 TIP Always use a new ball joint Do not tap or damage the top of the ball joint or rubber boot 1 3 4 2 Ball joint remover 90890 01474 Ball joint remover YM 01474 Ball joint remover adapter set 90890 01477 Ball joint remover adapter set YM 01477 Base plate 35mm 90890 01553 Base plate 35mm YM 01553 Ball joint installer attachment 39mm 90890...

Page 202: ... upper and lower arm bolts 3 with lithium soap based grease Be sure to position the front upper and lower arm bolts 3 so that the bolt heads face for ward Temporarily tighten the front upper and lower arm nuts 4 b Install the front shock absorber assembly 5 bolts 6 and nuts 7 TIP Install the front shock absorber assembly so that the gas cylinder is facing rearward Be sure to position the front sho...

Page 203: ...heel hub Refer to FRONT AND REAR WHEELS on page 4 23 1 Rear brake disc cleaning plate 1 2 Brake disc guard 1 3 Rear knuckle 1 4 Spacer cover 4 5 Spacer 2 6 Oil seal 2 7 Bearing 2 8 Spacer 1 9 Stabilizer joint 2 8 7 6 6 7 1 2 3 4 4 4 4 9 5 5 9 LS LS New New New FWD FWD New 9 Nm 0 9 m kgf 6 5 ft Ibf T R 60 Nm 6 0 m kgf 43 ft Ibf T R 60 Nm 6 0 m kgf 43 ft Ibf T R 90 Nm 9 0 m kgf 65 ft Ibf T R 85 Nm 8...

Page 204: ...r Job Parts to remove Q ty Remarks 10 Stabilizer holder 2 11 Bushing 2 12 Stabilizer 1 10 12 11 10 11 LS LS New New New FWD FWD New 9 Nm 0 9 m kgf 6 5 ft Ibf T R 60 Nm 6 0 m kgf 43 ft Ibf T R 60 Nm 6 0 m kgf 43 ft Ibf T R 90 Nm 9 0 m kgf 65 ft Ibf T R 85 Nm 8 5 m kgf 61 ft Ibf T R ...

Page 205: ...using striking tools d Remove the spacer 3 e Apply lithium soap based grease to the spac er new bearings and oil seals f Install the spacer to the rear knuckle g Install the new bearings TIP Install the wheel side bearing first NOTICE ECB01620 Do not strike the inner race or balls of the bearing Contact should be made only with the outer race h Install the new oil seals EBS30120 CHECKING THE STABI...

Page 206: ...o REAR KNUCKLES AND STABI LIZER on page 4 60 1 Rear constant velocity shaft dust boot guard 1 2 Rear brake hose holder 2 3 Nut Bolt rear shock absorber 2 2 4 Rear shock absorber assembly 1 5 Nut Bolt rear upper arm rear knuckle 1 1 6 Nut Bolt rear upper arm frame 2 2 7 Rear upper arm 1 8 Dust cover 2 2 2 1 7 8 8 5 5 4 3 3 3 6 6 6 6 3 7 Nm 0 7 m kgf 5 1 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 7 Nm...

Page 207: ... 1 1 10 Nut Bolt rear lower arm frame 2 2 11 Rear lower arm 1 12 Dust cover 2 13 Bushing 4 12 13 12 13 9 9 11 10 10 10 10 13 13 7 Nm 0 7 m kgf 5 1 ft Ibf T R 55 Nm 5 5 m kgf 40 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 82 Nm 8 2 m kgf 59 ft Ibf T R 82 Nm 8 2 m kgf 59 ft Ibf T R 90 Nm 9 0 m kgf 65 ft Ibf T R 90 Nm 9 0 m kgf 65 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R LS LS LS FWD FWD ...

Page 208: ...ock 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 heat can cause an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber or gas cylinder in any way If the rear shock absorber gas cylinder or both are da...

Page 209: ...e rear upper and lower arm bolts 3 so that the bolt heads face for ward Temporarily tighten the rear upper and lower arm nuts 4 b Install the rear shock absorber assembly 5 bolts 6 and nuts 7 TIP Install the rear shock absorber assembly so that the gas cylinder is facing forward Be sure to position the rear shock absorber bolts 6 so that the bolt heads face forward c Install the rear knuckle bolts...

Page 210: ...REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES 4 67 ...

Page 211: ... CYLINDER HEAD 5 21 CHECKING THE CYLINDER AND PISTON 5 21 CHECKING THE PISTON RINGS 5 22 CHECKING THE PISTON PIN 5 23 INSTALLING THE PISTON AND CYLINDER 5 23 INSTALLING THE CYLINDER HEAD 5 24 VALVES AND VALVE SPRINGS 5 26 REMOVING THE VALVES 5 27 CHECKING THE VALVES AND VALVE GUIDES 5 27 CHECKING THE VALVE SEATS 5 29 CHECKING THE VALVE SPRINGS 5 30 CHECKING THE VALVE LIFTERS 5 31 INSTALLING THE VA...

Page 212: ...ING THE PRIMARY SHEAVE SLIDERS 5 54 CHECKING THE SECONDARY SHEAVE 5 54 ASSEMBLING THE PRIMARY SHEAVE 5 55 ASSEMBLING THE SECONDARY SHEAVE 5 56 INSTALLING THE PRIMARY AND SECONDARY SHEAVES 5 57 CLUTCH 5 60 REMOVING THE CLUTCH 5 62 CHECKING THE CLUTCH 5 62 CHECKING THE CLUTCH SHOE 5 62 ASSEMBLING THE CLUTCH HOUSING 5 63 INSTALLING THE CLUTCH 5 63 CRANKCASE 5 65 SEPARATING THE CRANKCASE 5 68 CHECKING...

Page 213: ...ING THE DRIVE AXLE 5 81 ASSEMBLING THE SHIFT FORK 5 81 INSTALLING THE SHIFT FORKS AND SHIFT DRUM 5 82 MIDDLE GEAR 5 83 REMOVING THE MIDDLE DRIVE SHAFT 5 87 REMOVING THE MIDDLE DRIVEN SHAFT 5 87 CHECKING THE PINION GEARS 5 88 INSTALLING THE BEARING AND OIL SEALS 5 89 INSTALLING THE MIDDLE DRIVEN SHAFT 5 89 INSTALLING THE MIDDLE DRIVE SHAFT 5 90 MEASURING THE MIDDLE GEAR BACKLASH 5 91 ALIGNING THE M...

Page 214: ...eading on the compression gauge stabi lizes WARNING EWB03200 To prevent sparking ground the spark plug lead before cranking the engine b If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate c If the compression pressure is below the min imum specification pour a teaspoonful of en gine oi...

Page 215: ...ENGINE INSPECTION 5 2 10 Install Frame cross member Refer to GENERAL CHASSIS 9 on page 4 19 ...

Page 216: ...ust pipe Order Job Parts to remove Q ty Remarks 1 Spring 2 2 Muffler 1 3 Muffler heat protector plate 1 4 Gasket 1 5 Muffler mount 1 6 Exhaust pipe 1 7 Gasket 1 17 Nm 1 7 m kgf 12 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R New New LT 5 7 6 4 3 1 1 2 ...

Page 217: ...ket TIP Install the gasket completely onto the exhaust pipe 2 by pushing the side a of the gasket If the gasket is difficult to install tap lightly on the gasket with a soft face hammer 2 Install Muffler mount 1 3 Install Springs 1 TIP Install the springs so that the spring ends are pointing inward as shown in the illustration Installed length a 28 mm 1 10 in New New 2 1 a 1 a 1 1 ...

Page 218: ...HIFT LEVER on page 5 45 Drive belt case Refer to PRIMARY AND SECONDARY SHEAVES on page 5 50 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 14 Coolant Drain Refer to CHANGING THE COOLANT on page 3 9 Oil inlet pipe Oil outlet pipe Refer to OIL COOLER on page 6 1 Water pump inlet hose Refer to RADIATOR on page 6 4 Thermostat Refer to THERMOSTAT on page 6 8 Water pump outlet pipe Refer to...

Page 219: ...HAFT ASSEMBLIES DIFFERENTIAL AS SEMBLY AND FRONT DRIVE SHAFTS on page 8 4 Rear drive shaft Refer to REAR CONSTANT VELOCITY SHAFT ASSEMBLIES FINAL DRIVE AS SEMBLY AND REAR DRIVE SHAFT on page 8 18 1 Spark plug cap 1 Disconnect 2 Coolant temperature sensor coupler 1 Disconnect 3 Ignition coil connector 2 Disconnect 4 Reverse switch coupler 1 Disconnect 5 Gear position switch coupler 1 Disconnect 10 ...

Page 220: ...ty Remarks 6 Engine ground lead 1 Disconnect 7 Starter motor lead 1 Disconnect 8 Speed sensor coupler 1 Disconnect 9 Crankshaft position sensor coupler 1 Disconnect 10 AC magneto lead coupler 2 Disconnect 10 Nm 1 0 m kgf 7 2 ft Ibf T R 4 9 Nm 0 49 m kgf 3 5 ft Ibf T R 6 10 9 8 7 FWD FWD ...

Page 221: ...4 Engine 1 TIP Remove the engine from the top of the vehi cle 5 Engine bracket nut front 2 6 Engine bracket front 2 7 Engine mounting bolt rear 2 8 Engine mounting bolt rear 2 9 Engine bracket rear 2 LT LT LT LT FWD FWD 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 42 Nm 4 2 m kgf 30 ft Ibf T R 42 Nm 4 2 m kgf 30 ft Ibf T R 3 5 2 2 6 1 1 8 8 7 7 9 9 6 4 ...

Page 222: ... ECB01630 Make sure that the engine does not strike the brake pipe when installing it TIP Do not fully tighten the bolts and nuts 3 Tighten Engine bracket nuts front 5 Engine bracket nuts rear 7 Engine mounting bolts front M10 8 Engine mounting bolts front M6 9 T R Engine mounting bolt rear M10 42 Nm 4 2 m kgf 30 ft lbf Engine mounting bolt rear M6 10 Nm 1 0 m kgf 7 2 ft lbf LOCTITE T R Engine bra...

Page 223: ...Frame cross member Refer to GENERAL CHASSIS 9 on page 4 19 Fuel tank Refer to FUEL TANK on page 7 1 1 Spark plug cap 1 Disconnect 2 Spark plug 1 3 Breather plate cover 1 4 Breather plate cover gasket 2 5 Breather plate 1 6 Cylinder head cover 1 7 Cylinder head cover gasket 1 8 Timing chain guide upper side 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf S...

Page 224: ...sioner 1 4 Timing chain tensioner gasket 1 5 Camshaft cap 1 6 Bearing stopper 2 7 Intake camshaft 1 8 Exhaust camshaft 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R New New New New E E E E E E FWD FWD 1 3 4 8 5 6 6 8 7 2 ...

Page 225: ...shown in the illustration and the marks e and f on the sprockets are aligned with the cyl inder head mating surface d the piston is at TDC 3 Remove Timing chain tensioner Timing chain tensioner gasket 4 Remove Camshaft cap 1 Bearing stoppers 2 NOTICE ECB02430 To prevent damage to the cylinder head camshafts or camshaft cap loosen the camshaft cap bolts in stages and in a criss cross pattern workin...

Page 226: ...nal as shown c Install the camshaft cap TIP Tighten the camshaft cap bolts in the tighten ing sequence as shown Do not turn the camshaft when measuring the camshaft journal to camshaft cap clearance with the Plastigauge d Remove the camshaft cap and then mea sure the width of the Plastigauge 1 Camshaft lobe dimensions Lobe height Intake limit 33 8 mm 1 331 in Base circle diameter Intake limit 24 8...

Page 227: ...ress the timing chain tensioner rod into the timing chain tensioner housing by hand TIP While pressing the timing chain tensioner rod wind it clockwise with a flat head screwdriver un til it stops b Make sure that the timing chain tensioner rod moves in and out of the timing chain tension er housing smoothly If there is rough move ment replace the timing chain tensioner EBS30436 INSTALLING THE CAM...

Page 228: ...ed evenly or damage to the cylinder head camshaft cap and camshafts will result Do not turn the crankshaft when installing the camshaft cap to avoid damage or im proper valve timing TIP Tighten the camshaft cap bolts in the tightening sequence as shown 4 Install Timing chain tensioner gasket Timing chain tensioner a Remove the timing chain tensioner cap bolt and gasket b Install a new gasket and t...

Page 229: ...Refer to the installation steps above Timing chain guide Make sure that the timing chain guide and timing chain are positioned correctly 7 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 3 EBS30437 INSTALLING THE BREATHER PLATE 1 Install Breather plate cover gaskets Breather plate Breather plate cover TIP Tighten the breather plate cover bolts ...

Page 230: ... temperature sensor Refer to THERMOSTAT on page 6 8 Water jacket joint Refer to WATER PUMP on page 6 11 Throttle body assembly Refer to THROTTLE BODY on page 7 8 Reed valve assembly Refer to AIR INDUCTION SYSTEM on page 7 14 1 Oil hose crankcase to cylinder 1 2 Cylinder bolt 2 1st 2nd 3rd 5th 6th T R Specified angle 85 90 Specified angle 85 90 30 Nm 3 0 m kgf 22 ft Ibf 30 Nm 3 0 m kgf 22 ft Ibf 4t...

Page 231: ...nder head gasket 1 7 Dowel pin 2 1st 2nd 3rd 5th 6th T R Specified angle 85 90 Specified angle 85 90 30 Nm 3 0 m kgf 22 ft Ibf 30 Nm 3 0 m kgf 22 ft Ibf 4th Loosen 360 70 Nm 7 0 m kgf 51 ft Ibf 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R New New New E FWD FWD 4 4 3 5 3 6 7 ...

Page 232: ...ston Order Job Parts to remove Q ty Remarks 1 Timing chain guide exhaust side 1 2 Cylinder 1 3 Cylinder gasket 1 4 Dowel pin 2 5 Piston pin clip 2 6 Piston pin 1 7 Piston 1 8 Top ring 1 9 2nd ring 1 10 Oil ring 1 New New E E E E New E E FWD FWD 5 7 4 4 8 9 10 1 2 3 5 6 ...

Page 233: ...e removing the piston pin clips cover the crankcase opening with a clean rag to prevent the piston pin clips from falling into the crank case Before removing the piston pin deburr the pis ton pin clip grooves and the piston pin bore ar ea If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 4 Remove the piston pin from the side of the ...

Page 234: ...ng a figure eight sanding pattern TIP To ensure an even surface rotate the cylinder head several times EBS30147 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure the cylinder bore C with the cylin der bore gauge TIP Measure the cylinder bore C b...

Page 235: ...ing side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder TIP Use the piston crown to level the piston ring near bottom of cylinder a where cylinder wear is lowest 3 Measure Piston ring end gap Out of specification Replace the piston ring TIP The oil ring expander end gap cannot be mea sured If the oil ring rail gap is ex...

Page 236: ...Piston 1 Piston pin 2 Piston pin clips 3 TIP Apply engine oil to the piston pin Make sure the manufacturer s mark a on the piston points towards the AC magneto side Install the piston pin from the side of the piston that has the manufacturer s mark a Before installing the piston pin clips cover the crankcase opening with a clean rag to prevent the clips from falling into the crankcase 3 Install Cy...

Page 237: ... cylinder head bolts M11 to 70 Nm 7 0 m kgf 51 ft lbf in the proper tighten ing sequence d Loosen the cylinder head bolts M11 360 e Tighten the cylinder head bolts M11 to 30 Nm 3 0 m kgf 22 ft lbf in the proper tighten ing sequence f Tighten the cylinder head bolts M11 to the specified angle 85 90 in the proper tighten ing sequence g Tighten the cylinder head bolts M11 to the specified angle 85 90...

Page 238: ...ER AND PISTON 5 25 TIP Tighten the clamp screw of each clamp 2 until 6 slots are visible in the area a of the clamp as shown in the illustration T R Oil hose bolt crankcase to cylin der 18 Nm 1 8 m kgf 13 ft lbf a 1 2 3 4 ...

Page 239: ...D PISTON on page 5 17 1 Valve lifter 4 2 Valve pad 4 3 Valve cotter 8 4 Valve spring retainer 4 5 Valve spring 4 6 Intake valve 2 7 Exhaust valve 2 8 Valve stem seal intake 2 Gray 9 Valve stem seal exhaust 2 Light green 10 Valve spring seat 4 11 Valve guide 4 13 Nm 1 3 m kgf 9 4 ft Ibf T R New New 1 2 3 4 5 8 8 10 11 11 9 10 1 9 6 7 2 3 4 5 New New New New New New E E E E E E E E E E E E ...

Page 240: ...olvent a into the intake and exhaust ports b Check that the valves properly seal TIP There should be no leakage at the valve seat 1 3 Remove Valve cotters TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 4 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 Valve spring seat 5 TIP Identi...

Page 241: ...ver 1 b Install the new valve guide with the valve guide installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to ob tain the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to v...

Page 242: ... cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width TIP Where the valve seat and valve face contacted one another the blueing will have been re m...

Page 243: ...epeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply blue layout fluid b onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impres sion j Measure the valve seat width c again If the valve seat width is out of spec...

Page 244: ...l of the valves and related components 1 Deburr Valve stem end with an oil stone 2 Lubricate Valve stem 1 Valve stem end Valve stem seal 2 with the recommended lubricant 3 Install Valve spring seat 1 into the cylinder head Valve stem seal 2 Valve 3 Valve spring 4 Valve spring retainer 5 TIP Make sure each valve is installed in its original place Install the valve springs with the larger pitch a fa...

Page 245: ... the valve tip with excessive force could damage the valve 6 Lubricate Valve pad Valve lifter with the recommended lubricant 7 Install Valve pad Valve lifter TIP The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in their original position b Smaller pitch Valve spring compressor 90890 04019 Valve spring compressor YM 04019 Valve spr...

Page 246: ...r 1 4 AC magneto cover gasket 1 5 AC magneto Crankshaft position sensor lead holder 1 6 Crankshaft position sensor 1 7 Stator coil 1 FWD FWD New New New New New New E E E E LT LT LT LT E E E 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 f...

Page 247: ...key 1 14 Starter wheel gear 1 15 Bushing 1 16 Starter clutch 1 FWD FWD New New New New New New E E E E LT LT LT LT E E E 4 0 Nm 0 40 m kgf 2 9 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 3 0 Nm 0 30 m kgf 2 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 160 Nm 16 m kgf 116 ft lbf T R 14 Nm 1 4 m kgf 10 ft Ibf T R...

Page 248: ...iate sized socket between the fly wheel puller set center bolt and the crank shaft TIP Use the flywheel puller 2 Make sure the flywheel puller is centered over the AC magneto rotor EBS30152 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts 1 TIP Hold the AC magneto rotor 2 with the rotor holding tool 3 while removing the starter clutch bolts EBS30153 CHECKING THE STARTER CLUTCH 1 Check Sta...

Page 249: ...arter clutch bolts 1 TIP While holding the AC magneto rotor 2 with the rotor holding tool 3 tighten the starter clutch bolts EBS30156 INSTALLING THE AC MAGNETO ROTOR 1 Install Woodruff key AC magneto rotor 1 Washer 2 AC magneto rotor nut 3 TIP Clean the tapered portion of the crankshaft and the AC magneto rotor hub When installing the AC magneto rotor make sure the woodruff key is properly seated ...

Page 250: ...l AC magneto cover 1 TIP Align the slot a in the impeller shaft 2 with the projection b on the oil pump shaft 3 Tighten the AC magneto cover bolts in the proper tightening sequence as shown T R AC magneto rotor nut 160 Nm 16 m kgf 116 ft lbf Rotor holding tool 90890 04166 YM 04166 T R AC magneto cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 2 3 a 1 2 3 1 2 b a 3 10 6 1 2 9 11 5 7 3 8 4 ...

Page 251: ...emarks Center cover Refer to GENERAL CHASSIS 3 on page 4 6 Air intake silencer Refer to THROTTLE BODY on page 7 8 1 Engine ground lead 1 Disconnect 2 Starter motor lead 1 Disconnect 3 Starter motor 1 FWD FWD 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 3 4 9 Nm 0 49 m kgf 3 5 ft Ibf T R 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 252: ...b Parts to remove Q ty Remarks 1 Starter motor front cover 1 2 Starter motor rear cover 1 3 Washer kit 1 4 Armature assembly 1 5 Brush set 1 6 Starter motor yoke 1 2 6 3 5 3 4 1 New New New New New E 4 9 Nm 0 49 m kgf 3 5 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R ...

Page 253: ...lation Out of specification Replace the starter motor a Measure the armature assembly resistances with the digital circuit tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brush set 6 Check Gear teeth Damage wear Replace the armature as sembly 7 Check Bearing Oil seal Damage wear Replace the starter motor front ...

Page 254: ... Align the tab a on the brush 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 mo tor front and rear covers T R Starter motor cover bolt 4 9 Nm 0 49 m kgf 3 5 ft lbf b a b 3 1 2 ...

Page 255: ... ty Remarks AC magneto rotor Refer to AC MAGNETO AND STARTER CLUTCH on page 5 33 1 Timing chain stopper guide lower 1 2 Oil pump driven sprocket 1 3 Washer 1 4 Oil pump drive sprocket 1 5 Chain 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R 25 Nm 2 5 m kgf 18 ft Ibf T R FWD FWD LT LT LT 5 4 2 3 1 ...

Page 256: ...ump driven sprocket Cracks wear damage Replace EBS30526 INSTALLING THE OIL PUMP DRIVE SPROCKET AND OIL PUMP DRIVEN SPROCKET 1 Install Oil pump drive sprocket 1 TIP Install the oil pump drive sprocket so that the protruding portion a of the sprocket is facing to ward the crankcase 2 Install Washer 1 Oil pump drive sprocket nut TIP Install the washer with its rounded side a facing away from the cran...

Page 257: ... b Hold the AC magneto rotor 3 with the rotor holding tool 4 while tightening the oil pump drive sprocket nut and oil pump driven sprocket nut T R Oil pump drive sprocket nut 25 Nm 2 5 m kgf 18 ft lbf LOCTITE Oil pump driven sprocket nut 25 Nm 2 5 m kgf 18 ft lbf LOCTITE Rotor holding tool 90890 04166 YM 04166 1 2 3 4 ...

Page 258: ... cover Under seat storage compartment Refer to GENERAL CHASSIS 3 on page 4 6 1 Drive select lever shift rod 1 2 Drive select lever knob 1 3 Drive select lever guide 1 4 Dust cover 1 5 Drive select lever 1 6 Spring 1 7 Shift arm 1 FWD FWD LS New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 3 2 3 4 5 6 7 1 ...

Page 259: ... gasket 1 4 Dowel pin 1 5 Oil seal 1 6 Spacer 1 7 Shift lever 1 1 8 Stopper lever spring 1 9 Shift lever 2 1 10 Stopper lever 1 11 Spacer 1 E E LS New New New New LS E LT FWD FWD 1 7 2 11 3 5 6 4 10 9 8 13 Nm 1 3 m kgf 9 4 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 260: ...ll Collar 1 onto the stopper lever 2 Shift lever 2 3 Washer 4 Stopper spring 5 TIP Make sure the projection a on the stopper le ver 2 facing toward the collar Install the shift lever 2 3 with the marks b facing the stopper spring 3 Install Shift lever 2 assembly 1 TIP Align the projection a on the shift drum with the slit b in the stopper lever 4 Install Shift lever 1 1 TIP When installing shift l...

Page 261: ...nsmission may be damaged 1 Adjust Drive select lever shift rod a Make sure the drive select lever and trans mission are in N neutral b Loosen both locknuts 1 NOTICE ECB02460 The drive select lever shift rod locknut drive select lever side has left handed threads To loosen the locknut turn it clockwise c Turn the main switch to ON and then adjust the length a of the shift rod to the drive se lect l...

Page 262: ...SHIFT LEVER 5 49 T R Drive select lever shift rod lock nut 15 Nm 1 5 m kgf 11 ft lbf ...

Page 263: ...HASSIS 10 on page 4 21 1 Drive belt cover 1 2 Rubber gasket 1 3 Bearing housing 1 4 Dowel pin 2 5 Primary sheave assembly 1 6 V belt 1 7 Primary fixed sheave 1 8 Secondary sheave assembly 1 9 Drive belt case 1 10 Rubber gasket 1 11 Rubber gasket 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 100 Nm 10 0 m kgf 72 ft Ibf ...

Page 264: ...e F Order Job Parts to remove Q ty Remarks 1 Primary sheave cap 1 2 Primary sheave slider 4 3 Primary sheave cam 1 4 Primary sheave weight 8 5 Spacer 1 6 Oil seal 2 7 Primary sliding sheave 1 8 O ring 1 High Power Greaseless Sheave Option Please Contact Hunterworks com 601 771 0070 Hunterworks com click to save ...

Page 265: ...EX EM Order Job Parts to remove Q ty Remarks 1 Secondary sheave spring retaining nut 1 2 Upper spring seat 1 3 Compression spring 1 4 Lower spring seat 1 5 Guide pin 4 6 Secondary sliding sheave 1 7 O ring 2 8 Secondary fixed sheave 1 9 Oil seal 2 High Power Secondary Springs Available Hunterworks com ...

Page 266: ...ve fixed block 2 locknut wrench 3 and sheave spring compressor 4 to the secondary sheave assembly b Place the sheave fixed block in a vise and se cure it c Tighten the sheave spring compressor nut 5 and compress the spring d Loosen the secondary sheave spring retain ing nut 1 with the locknut wrench 3 e Remove the secondary sheave spring retain ing nut 1 f Remove the sheave spring compressor and l...

Page 267: ...f the pri mary sheave weights 1 Check Primary sheave weight Cracks damage wear Replace 2 Measure Primary sheave weight outside diameter a Out of specification Replace EBS30172 CHECKING THE PRIMARY SHEAVE SLIDERS The following procedure applies to all of the pri mary sheave sliders 1 Check Primary sheave slider Cracks damage wear Replace EBS30173 CHECKING THE SECONDARY SHEAVE 1 Check Secondary fixe...

Page 268: ...Primary sheave weights 3 Primary sheave cam TIP Remove any excess grease 2 Install Oil seals 1 into the primary sliding sheave 2 3 Lubricate Spacer inner surface Primary sliding sheave inner surface TIP Apply Yamaha Grizzly grease or Yamaha grease F 2 5 g to the inner surface of the spacer Apply Yamaha Grizzly grease or Yamaha grease F 2 5 g to the inner surface of the pri mary sliding sheave Free...

Page 269: ...ded lubricant TIP Apply Yamaha grease H or POLYREX EM 15 g to the inner surfaces of the secondary sheaves 3 Install Secondary sliding sheave 4 Install Guide pins 1 5 Lubricate Guide pin grooves 1 with the recommended lubricant TIP Apply Yamaha grease H or POLYREX EM 5 0 g to the guide pin grooves 6 Install Lower spring seat 1 Compression spring 2 Upper spring seat 3 Secondary sheave spring retaini...

Page 270: ...ry sheave V belt Primary fixed sheave Primary sheave Washer Nuts TIP Be sure to push in the primary sheave cam 1 when installing the primary sheave so that the primary sheave weights 2 will be properly po sitioned a Install the washer 3 with its rounded side b facing away from the primary shave assembly Tightening the bolts 4 90101 06016 will push the secondary sliding sheave away causing the gap ...

Page 271: ...ve 3 and V belt 4 are positioned as shown in the illustra tion 3 Tighten Primary sheave assembly nut 1 TIP Use the rotor holding tool 2 to hold the primary sheave 4 Tighten Secondary sheave assembly nut 1 b 3 4 A Correct position B Incorrect position T R Primary sheave assembly nut 190 Nm 19 m kgf 137 ft lbf Rotor holding tool 90890 04166 YM 04166 T R Secondary sheave assembly nut 100 Nm 10 m kgf ...

Page 272: ...and then tighten the sec ondary sheave assembly nut 5 Lubricate Bearing housing bearing inner surface and ball with the recommended lubricant TIP Apply 2 3 g or more of Shell Sunlight Grease 3 to the bearing inner surface and ball as shown in the illustration Recommended lubricant Shell Sunlight Grease 3 1 ...

Page 273: ... Refer to PRIMARY AND SECONDARY SHEAVES on page 5 50 1 Clutch housing assembly 1 2 Clutch housing assembly gasket 1 3 Dowel pin 2 4 Clutch carrier assembly nut 1 Left hand threads 5 Clutch carrier assembly 1 7 1 3 3 2 4 5 10 Nm 1 0 m kgf 7 2 ft Ibf T R 190 Nm 19 m kgf 137 ft lbf T R LS New E E E FWD FWD ...

Page 274: ...ng the clutch housing assembly Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Circlip 1 3 Bearing housing 1 4 Circlip 1 5 Bearing 1 6 Seal ring 1 7 One way clutch bearing 1 8 Bearing 1 9 Clutch housing 1 6 7 8 9 E New ...

Page 275: ... clutch bearing must be installed with the flange side facing inward 2 Check One way clutch operation a Install the one way clutch bearing and clutch carrier assembly to the clutch housing and hold the clutch carrier assembly b When turning the clutch housing clockwise A it should turn freely otherwise the one way clutch assembly is faulty and must be re placed c When turning the clutch housing co...

Page 276: ...has left hand threads To tighten the clutch carrier assembly nut turn it counterclockwise TIP Lubricate the threads of the clutch carrier as sembly nut with engine oil Use a universal clutch holder 2 to hold the clutch carrier assembly 2 Lock the threads with a drift punch 3 Install Dowel pins 1 Gasket Clutch housing assembly a Clutch shoe wear limit Installed depth a 2 5 2 7 mm 0 10 0 11 in Insta...

Page 277: ...CLUTCH 5 64 TIP Tighten the bolts in stages using a crisscross pattern After tightening the bolts check that the clutch housing assembly rotates smoothly 1 ...

Page 278: ... to SHIFT LEVER on page 5 45 Clutch carrier assembly Refer to CLUTCH on page 5 60 1 Oil filter cartridge 1 2 Oil filter cartridge union bolt 1 3 Adapter 1 LT New New New New New New New New New LT LT LT E E E E E E FWD FWD 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ib...

Page 279: ...se left 1 15 Crankcase right 1 LT New New New New New New New New New LT LT LT E E E E E E FWD FWD 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 15 Nm 1 5 m kgf 11 ft Ibf T R 17 Nm 1 7 m kgf 12 ft Ibf T R 22 Nm 2 2 m kgf 16 ft Ibf T R 26 Nm 2 6 m kgf 19 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T R 35 Nm 3 5 m kgf 25 ft Ibf T ...

Page 280: ...ND OIL PUMP on page 5 71 Middle drive shaft Middle driven shaft Refer to MIDDLE GEAR on page 5 83 Transmission Refer to TRANSMISSION on page 5 76 1 Collar 1 2 O ring 1 3 Oil seal 1 4 Bearing retainer 1 5 Spacer 1 6 Crankshaft seal 2 7 Bearing 9 E E E E E LT LT LT E E LS New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 6 5 1 2 3 7 7 7 7 4 7 7 ...

Page 281: ...ct the end of the crankshaft place an appropriate sized socket between the crankcase separating tool bolt and the crankshaft Do not tap on the crankshaft EBS30183 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1 Check Timing chain Damage stiffness Replace the timing chain and camshaft sprocket as a set 2 Check Timing chain guide intake side Damage wear Replace EBS30185 CHECKING THE BEARINGS 1 Ch...

Page 282: ...t allow any sealant to come into contact with the oil gallery 4 Fit the left crankcase onto the right crank case Tap lightly on the crankcase with a soft face hammer NOTICE ECB01730 Before tightening the crankcase bolts make sure the transmission gears shift correctly when the shift drum assembly is turned by hand 5 Install Crankcase bolts 6 Tighten Crankcase bolts M8 40 mm 1 M6 90 mm 2 M6 60 mm 3...

Page 283: ...eration Rough operation Repair 9 Install O ring 1 onto the adapter Adapter 2 Oil filter cartridge union bolt TIP Align the pin a in the adapter with the hole b in the crankcase A Crankcase left B Crankcase right A 1 2 3 3 2 4 4 2 3 4 4 1 4 3 4 4 3 B 6 2 3 3 1 4 New T R Oil filter cartridge union bolt 68 Nm 6 8 m kgf 49 ft lbf a 2 b 1 New ...

Page 284: ...rankshaft and oil pump Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 65 1 Oil pump 1 2 Crankshaft 1 3 Balancer 1 4 Bearing 1 5 Plug 1 6 Spring 1 7 Steel ball 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R E 3 2 4 5 6 7 1 ...

Page 285: ...ssembling the oil pump Order Job Parts to remove Q ty Remarks 1 Oil pump housing cover 1 2 Pin 1 3 Oil pump shaft 1 4 Oil pump inner rotor 1 5 Oil pump outer rotor 1 6 Oil pump housing 1 E 6 3 2 5 4 1 E E 5 Nm 0 5 m kgf 3 6 ft Ibf T R ...

Page 286: ...eck Oil pump Cracks damage wear Replace the oil pump 2 Measure Inner rotor to outer rotor tip clearance a Outer rotor to oil pump housing clearance b 3 Check Oil pump operation Rough movement Replace the oil pump EBS30190 CHECKING THE OIL STRAINER 1 Check Oil strainer Damage Replace the oil pump Contaminants Clean with solvent EBS30184 CHECKING THE RELIEF VALVE 1 Check Steel ball 1 Spring 2 Damage...

Page 287: ... with the groove a in the inner rotor 3 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 73 EBS30193 INSTALLING THE CRANKSHAFT 1 Install Balancer 1 Crankshaft 2 NOTICE ECB01890 Apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier TIP Install the balancer 1 and crankshaft 2 at the same time Align the hole a in the balancer w...

Page 288: ...he proper tightening sequence as shown Crankshaft installer pot 90890 01274 Installing pot YU 90058 Crankshaft installer bolt 90890 01275 Bolt YU 90060 Adapter M16 90890 04130 Adapter 13 YM 04059 Spacer crankshaft installer 90890 04081 Pot spacer YM 91044 T R Oil pump bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 2 3 4 5 6 1 2 a b 3 1 2 ...

Page 289: ...te Refer to CRANKCASE on page 5 65 Middle driven gear Refer to MIDDLE GEAR on page 5 83 1 Shift drum stopper bolt 1 2 Spring 1 3 Ball 1 4 Shift drum 1 5 Shift fork assembly 1 6 Shift fork R 1 7 Spring 1 8 Shift fork L 1 9 Shift fork guide bar 1 10 Secondary shaft 1 E E E E E E New New M M E E E New 18 Nm 1 8 m kgf 13 ft Ibf T R 1 2 3 4 10 9 8 6 7 5 ...

Page 290: ...shift drum and shift forks Order Job Parts to remove Q ty Remarks 11 Drive axle assembly 1 12 Collar 1 13 Reverse idle gear 1 14 Bearing 1 15 Reverse idle gear shaft 1 E E E E E E New New M M E E E New 18 Nm 1 8 m kgf 13 ft Ibf T R 15 13 14 12 11 ...

Page 291: ...ling the drive axle assembly Order Job Parts to remove Q ty Remarks 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 New LS New New LS M M 1 3 4 5 6 7 9 8 2 ...

Page 292: ...e axle assembly Order Job Parts to remove Q ty Remarks 10 Washer 1 11 Circlip 1 12 Middle drive gear 1 13 Circlip 1 14 Washer 1 15 Bearing 1 16 Reverse wheel gear 1 17 Collar 1 18 Drive axle 1 New LS New New LS M M 17 18 16 10 11 12 13 14 15 ...

Page 293: ...e following procedure applies to both of the shift forks 1 Check Shift fork cam follower 1 Shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check Shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING EWB02750 Do not attempt to straighten a bent shift fork guide bar 3 Check Shift fork movement along the shift fork guide bar Rough movement Rep...

Page 294: ...smission gear movement Rough movement Replace the defective part s EBS30199 CHECKING THE SECONDARY SHAFT 1 Check Gear teeth Blue discoloration pitting wear Replace EBS30200 ASSEMBLING THE DRIVE AXLE 1 Install Washer 1 Circlip 2 TIP Be sure the circlip sharp edged corner a is positioned opposite side to the washer and gear Be sure the circlip ends b are positioned at axle spline groove c EBS30201 A...

Page 295: ...aft 3 Shift fork assembly 4 Shift drum 5 TIP Install the shift fork assembly 4 with the L mark a facing the right crankcase 2 Check Shift operation Rough operation Repair TIP Oil each gear and bearing thoroughly Before assembling the crankcase make sure that the transmission is in neutral and that the gears turn freely 1 2 3 4 5 a 4 ...

Page 296: ...e drive pinion gear nut 1 3 Middle drive pinion gear 1 4 Middle drive pinion gear shim Refer to ALIGNING THE MIDDLE GEAR on page 5 92 5 Middle drive shaft assembly 1 6 Middle driven gear 1 7 Circlip 1 8 Middle drive shaft 1 9 Middle drive shaft bearing housing assembly 1 New LT LT LT LT LT LT LT New LT LT LT E E 190 Nm 19 m kgf 137 ft lbf T R 38 Nm 3 8 m kgf 27 ft Ibf T R 7 8 6 5 1 9 29 Nm 2 9 m k...

Page 297: ...der Job Parts to remove Q ty Remarks 10 Bearing retainer 2 11 Bearing 1 12 Washer 1 13 Bearing housing 1 New LT LT LT LT LT LT LT New LT LT LT E E 190 Nm 19 m kgf 137 ft lbf T R 38 Nm 3 8 m kgf 27 ft Ibf T R 12 13 11 10 10 29 Nm 2 9 m kgf 21 ft Ibf T R ...

Page 298: ... nut middle gear side 1 4 Front drive shaft coupling gear middle gear side 1 5 Middle driven pinion gear assembly 1 6 Middle driven pinion gear shim Refer to ALIGNING THE MIDDLE GEAR on page 5 92 7 Middle driven pinion gear 1 8 Bearing 1 9 Oil seal 1 LT M E M New 25 Nm 2 5 m kgf 18 ft Ibf T R 80 Nm 8 0 m kgf 58 ft Ibf T R 130 Nm 13 m kgf 94 ft lbf T R 190 Nm 19 m kgf 137 ft lbf T R 8 7 4 9 3 190 N...

Page 299: ...eads 11 Bearing 1 12 O ring 1 13 Bearing housing 1 14 Oil seal 1 15 Middle driven shaft bearing retainer 1 Left hand threads 16 Bearing 1 17 Middle driven shaft 1 LT M E New M 25 Nm 2 5 m kgf 18 ft Ibf T R 80 Nm 8 0 m kgf 58 ft Ibf T R 130 Nm 13 m kgf 94 ft lbf T R 190 Nm 19 m kgf 137 ft lbf T R 12 10 11 17 16 13 190 Nm 19 m kgf 137 ft lbf T R 15 14 ...

Page 300: ... shaft coupling gear 2 TIP Use the coupling gear middle shaft tool 3 to hold the rear drive shaft coupling gear 2 Remove Front drive shaft coupling gear nut 1 Washer Front drive shaft coupling gear 2 TIP Use the coupling gear middle shaft tool 3 to hold the front drive shaft coupling gear 3 Remove Bearing housing assembly 1 a Clean the surface of the bearing housing as sembly b Place the bearing h...

Page 301: ...ft hand threads To loosen the re tainer turn it clockwise c Remove the bearing retainer and bearing 5 Remove Oil seal 1 Middle driven shaft bearing retainer 2 TIP Attach the ring nut wrench 3 NOTICE ECB01750 The middle driven shaft bearing retainer has left hand threads To loosen the retainer turn it clockwise 6 Remove Middle driven shaft 1 with bearing EBS30205 CHECKING THE PINION GEARS 1 Check D...

Page 302: ... retainer 1 a Wrap the bearing housing in a folded rag and then secure the bearing housing edge in a vise b Attach the bearing retainer wrench 2 c Tighten the bearing retainer Installed depth a of bearing 0 9 1 4 mm 0 035 0 055 in Installed depth b of oil seal 1 0 1 5 mm 0 039 0 059 in Installed depth a of oil seal 1 0 1 5 mm 0 039 0 059 in T R Middle driven shaft bearing re tainer 80 Nm 8 0 m kgf...

Page 303: ...aft coupling gear 5 Install Rear drive shaft coupling gear 1 Washer Rear drive shaft coupling gear nut 2 TIP Use the coupling gear middle shaft tool 3 to hold the rear drive shaft coupling gear EBS30208 INSTALLING THE MIDDLE DRIVE SHAFT 1 Install Circlip Middle driven gear 1 onto the middle drive shaft 2 T R Front drive shaft coupling gear nut middle gear side 190 Nm 19 m kgf 137 ft lbf LOCTITE Co...

Page 304: ...r backlash Out of specification Adjust Refer to ALIGNING THE MIDDLE GEAR on page 5 92 a Temporarily install the right crankcase b Wrap a rag 1 around a screwdriver 2 and then insert it into the installation hole a of the right crankcase speed sensor to hold the mid dle driven gear c Attach the final gear backlash band 3 and dial gauge 4 T R Middle drive shaft bearing retain er bolt 29 Nm 2 9 m kgf...

Page 305: ... a Position the middle gears with the appropri ate shim s that has had its respective thick ness calculated from information marked on the crankcase bearing housings and pinion gears b To find middle drive pinion gear shim thick ness A use the following formula a a numeral usually a decimal number on the bearing housing is either added to or subtracted from 0 6 b 17 0 c 55 0 d a numeral usually a ...

Page 306: ... middle driven pin ion gear assembly the overall length of the as sembly will change Therefore be sure to measure distance f to select the correct middle driven pinion gear shim thickness g a numeral usually a decimal number on the middle driven pinion gear is either add ed to or subtracted from 61 0 h a numeral usually a decimal number on the middle driven pinion gear is either add ed to or subtr...

Page 307: ...him thickness is 0 81 mm The chart instructs you however to round off 1 to 0 Shims are supplied in the following thickness es TIP If the specified middle gear backlash cannot be obtained with a calculated shim thickness in crease or decrease the shim thickness If the shim thickness is increased the actual middle gear backlash will increase and if the shim thickness is decreased the actual middle g...

Page 308: ...MIDDLE GEAR 5 95 ...

Page 309: ...N 6 3 RADIATOR 6 4 CHECKING THE RADIATOR 6 6 INSTALLING THE RADIATOR 6 6 THERMOSTAT 6 8 CHECKING THE THERMOSTAT 6 9 INSTALLING THE THERMOSTAT 6 9 WATER PUMP 6 11 DISASSEMBLING THE WATER PUMP 6 12 CHECKING THE WATER PUMP 6 12 ASSEMBLING THE WATER PUMP 6 12 INSTALLING THE WATER JACKET JOINT 6 13 ...

Page 310: ...ge 4 12 Air filter case Refer to AIR FILTER CASE on page 7 5 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 14 1 Oil cooler outlet hose 1 2 Oil cooler inlet hose 1 3 Horn 1 Except for CDN 4 Oil cooler guard 1 5 Oil cooler 1 6 Oil cooler bracket 1 New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 4 3 5 6 2 1 ...

Page 311: ...ks 7 Oil inlet hose 1 8 Oil outlet hose 1 9 Oil inlet pipe 1 10 Oil outlet pipe 1 11 Oil cooler outlet pipe 1 12 Oil cooler inlet pipe 1 New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 12 8 7 9 10 11 ...

Page 312: ...ce TIP Straighten any flattened fins with a thin flat head screwdriver 2 Check Oil cooler hoses Oil cooler pipes Oil hoses Oil pipes Cracks damage wear Replace EBS30575 INSTALLING THE HORN except for CDN 1 Install Horn TIP Align the projection a on the oil cooler guard with the slot b on the horn bracket T R Horn bolt except for CDN 7 Nm 0 7 m kgf 5 1 ft lbf a b ...

Page 313: ...adiator cap 1 2 Coolant reservoir hose 1 3 Coolant reservoir breather hose 1 4 Coolant reservoir cap 1 5 Coolant reservoir 1 6 Radiator inlet hose 1 7 Radiator outlet hose 1 8 Thermostat outlet hose 1 9 Water pump inlet hose 1 8 1 2 3 4 5 6 4 7 9 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 314: ...et pipe 1 12 Radiator fan motor coupler 1 Disconnect 13 Radiator bracket 1 14 Radiator 1 15 Radiator fan motor breather hose 1 16 Radiator fan 1 10 16 12 14 13 15 4 11 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 315: ...b Apply the specified pressure for ten seconds and make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 9 29 EBS30214 INSTALLING THE RADIATOR 1 Install Radiator outlet pipe 1 Radiator inlet pipe 2 TIP Align the punch marks a on the radiator inlet pipe and outlet pipe with the hose clamp 2 Fill Cooling system with th...

Page 316: ...GING THE COOLANT on page 3 9 3 Check Cooling system Leaks Repair or replace any faulty part 4 Measure Radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR on page 6 6 ...

Page 317: ...s Coolant Drain Refer to CHANGING THE COOLANT on page 3 9 1 Coolant temperature sensor coupler 1 Disconnect 2 Coolant temperature sensor 1 3 Thermostat outlet hose 1 Disconnect 4 Thermostat cover 1 5 Thermostat 1 LS New New New 3 4 5 2 1 20 Nm 2 0 m kgf 14 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 318: ...STAT 1 Install Copper washer Coolant temperature sensor NOTICE ECB01910 Use extreme care when handling the coolant temperature sensor Replace any part that was dropped or subjected to a strong im pact 2 Install Thermostat 1 Gasket 2 Thermostat cover 3 TIP Install the thermostat with its breather hole a facing up 3 Fill Cooling system with the specified amount of the recom mended coolant Refer to C...

Page 319: ...THERMOSTAT 6 10 Refer to CHECKING THE RADIATOR on page 6 6 ...

Page 320: ...ing 1 6 Gasket 1 7 AC magneto cover 1 8 AC magneto cover gasket 1 9 Impeller 1 Left hand threads 10 Washer 1 11 Impeller shaft 1 12 Mechanical seal 1 13 Bearing 1 14 Oil seal 1 FWD FWD New New New New New New New LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T ...

Page 321: ... WATER PUMP 1 Install Bearing 1 Oil seal 2 into the AC magneto cover TIP Install the oil seal with a socket that matches its outside diameter 2 Install Mechanical seal 1 NOTICE ECB02410 Never lubricate the mechanical seal surface with oil or grease TIP Use the special tools and a press to press the mechanical seal straight in until its flange a touches the AC magneto cover 1 1 2 New Installed dept...

Page 322: ...INSTALLING THE WATER JACKET JOINT 1 Install Clamps 1 onto the water pump outlet hose Water pump outlet hose 2 onto the water jacket joint Water jacket joint 3 TIP Tighten the clamp screw of each clamp 1 until 4 slots remain in the area a of the clamp as shown in the illustration T R Impeller 10 Nm 1 0 m kgf 7 2 ft lbf T R Water jacket joint bolt 10 Nm 1 0 m kgf 7 2 ft lbf b upward 1 b a 1 2 1 3 ...

Page 323: ...CHECKING THE FUEL PRESSURE 7 4 AIR FILTER CASE 7 5 INSTALLING THE AIR FILTER CASE 7 7 THROTTLE BODY 7 8 REMOVING THE THROTTLE BODY 7 11 CHECKING THE FUEL INJECTOR 7 11 CHECKING THE THROTTLE BODY 7 11 CHECKING THE THROTTLE BODY JOINT 7 11 INSTALLING THE THROTTLE BODY 7 11 ADJUSTING THE THROTTLE POSITION SENSOR 7 13 AIR INDUCTION SYSTEM 7 14 CHECKING THE AIR INDUCTION SYSTEM 7 17 INSTALLING THE AIR ...

Page 324: ...Fuel tank breather hose 2 2 Fuel tank breather hose joint 1 3 Fuel pump coupler 1 Disconnect 4 Fuel hose connector holder 1 5 Fuel hose 1 6 Fuel tank retainer 1 7 Damper 2 8 Fuel tank bracket 1 9 Fuel tank 1 10 Damper 4 11 Fuel pump 1 1 7 7 6 11 2 1 4 3 6 5 10 10 10 9 8 New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 16 Nm...

Page 325: ...from the fuel rail slide the fuel hose connector cover 2 on the end of the hose in direction of the arrow shown press the two buttons 3 on the sides of the connector and then disconnect the hose Before removing the hose place a few rags in the area under where it will be removed EBS30222 REMOVING THE FUEL PUMP 1 Remove Fuel pump bracket Fuel pump Fuel pump gasket NOTICE ECB01450 Do not drop the fu...

Page 326: ... pump with the pro jection b on the fuel tank Tighten the nuts to specification in the proper tightening sequence as shown EBS30226 INSTALLING THE FUEL TANK 1 Install Dampers 1 TIP Fit the projection a on the dampers into the hole b in the frame 2 Install Fuel tank 1 Fuel tank bracket 2 Fuel tank bracket bolts 3 Fuel tank bolts 4 Fuel tank retainer 5 Fuel tank retainer bolts 6 TIP Finger tighten t...

Page 327: ...rection of the arrow shown EBS30227 CHECKING THE FUEL PRESSURE 1 Check Fuel pressure a Remove the cargo bed Refer to GENERAL CHASSIS 9 on page 4 19 b Disconnect the fuel hose 1 from the fuel rail Refer to REMOVING THE THROTTLE BODY on page 7 11 c Connect the pressure gauge 2 and adapter 3 to the fuel rail and fuel hose d Start the engine e Measure the fuel pressure Out of specification Replace the...

Page 328: ...over 1 2 Air filter element holder 1 3 Air filter element 1 4 Air filter element frame 1 5 Intake air temperature sensor coupler 1 Disconnect 6 Air filter case joint clamp screw 2 Loosen 7 Air filter case joint 1 8 Air intake duct joint clamp screw 2 Loosen 9 Air intake duct joint 1 8 8 9 5 7 6 6 1 2 3 4 New New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft I...

Page 329: ...Parts to remove Q ty Remarks 10 Air filter case 1 11 Intake air temperature sensor 1 12 Air intake duct 1 11 10 New New 12 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R ...

Page 330: ...he air filter case 2 TIP Align the projection a on the air intake duct joint between the projections b on the air filter case 2 Install Air filter case joint 1 to the air filter case TIP Align the projection a on the air filter case joint with the slot b on the air intake silencer 2 1 2 a b 2 a b 1 ...

Page 331: ...t 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 8 Fuel hose 1 Disconnect 9 Cylinder head breather hose 1 New LS 4 1 8 5 2 7 3 9 6 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 2 8 Nm 0 28 m kgf 2 0 ft Ibf T R 3...

Page 332: ...1 14 Throttle body joint 1 15 Air induction system solenoid hose air intake si lencer to air induction system solenoid 1 Disconnect 16 Air filter case joint clamp screw 1 Loosen 17 Air intake silencer 1 New LS 12 15 16 10 10 11 13 14 12 17 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 2 0 Nm 0 20 m kgf 1 4 ft Ibf T R 2 8 Nm 0 28 m kgf 2 0 ft Ibf T R 3 5 Nm 0 35 m kgf 2 5 ft Ibf...

Page 333: ...move Q ty Remarks 1 Intake air pressure sensor 1 2 Intake air pressure sensor hose 1 3 Throttle position sensor 1 4 Fuel rail 1 5 Fuel injector 1 6 Throttle body 1 New New New 1 2 3 4 5 6 3 5 Nm 0 35 m kgf 2 5 ft Ibf T R 3 6 Nm 0 36 m kgf 2 6 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R ...

Page 334: ...JECTOR 1 Check Fuel injector Obstruction Replace and check the fuel pump fuel supply system Deposit Replace Damage Replace 2 Check Fuel injector resistance Refer to CHECKING THE FUEL INJEC TOR on page 9 108 EBS30231 CHECKING THE THROTTLE BODY 1 Check Throttle body Cracks damage Replace the throttle body 2 Check Fuel passages Obstructions Clean a Wash the throttle body in a petroleum based solvent ...

Page 335: ...uel hose NOTICE ECB01920 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Connect the fuel hose securely onto the fuel rail until a distinct click in heard To connect the fuel hose onto the fuel rail slide the fuel hose connector cover 1...

Page 336: ...t the digital circuit tester to the test harness TPS 3P c Turn the main switch to on d Measure the throttle position sensor voltage e Adjust the throttle position sensor angle so that the voltage is within the specified range f After adjusting the throttle position sensor an gle tighten the throttle position sensor screws 2 Test harness TPS 3P 90890 03204 Test harness TPS 3P YU 03204 Digital circu...

Page 337: ...BS20057 AIR INDUCTION SYSTEM 1 2 3 5 4 1 Air intake silencer 2 Air induction system hose air intake silencer to air cut off valve 3 Air cut off valve 4 Air induction system hose air cut off valve to reed valve cover 5 Reed valve ...

Page 338: ... GENERAL CHASSIS 9 on page 4 19 1 Air induction system solenoid coupler 1 Disconnect 2 Air induction system hose air cut off valve to reed valve cover 1 3 Air induction system hose air intake silencer to air cut off valve 1 4 Air cut off valve 1 5 Air cut off valve bracket 1 1 2 4 3 5 9 Nm 0 9 m kgf 6 5 ft Ibf T R ...

Page 339: ...AIR INDUCTION SYSTEM 7 16 Removing the reed valve Order Job Parts to remove Q ty Remarks 1 Reed valve cover 1 2 Reed valve assembly 1 3 Reed valve plate 1 LT LT 3 2 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 340: ...flow during idle and closes to cut off the flow when the vehicle is be ing driven However if the coolant temperature is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value 1 Check Hoses Loose connections Connect properly Cracks damage Replace 2 Check Reed valve Reed valve stopper...

Page 341: ...N 8 13 ASSEMBLING THE FRONT DRIVE SHAFT 8 14 ASSEMBLING THE DIFFERENTIAL ASSEMBLY 8 14 ASSEMBLING THE UNIVERSAL JOINT 8 15 MEASURING THE DIFFERENTIAL GEAR BACKLASH 8 16 ADJUSTING THE DIFFERENTIAL GEAR BACKLASH 8 17 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT 8 18 DISASSEMBLING THE REAR CONSTANT VELOCITY SHAFT ASSEMBLIES 8 25 CHECKING THE REAR CONSTANT VELOCITY...

Page 342: ...ronounced hesitation or jerky movement during acceleration deceleration or sustained speed This must not be confused with engine surging or transmission characteristics 2 A rolling rumble noticeable at low speed a high pitched whine a clunk from a shaft drive com ponent or area 3 A locked up condition of the shaft drive train mechanism no power transmitted from the en gine to the front and or rear...

Page 343: ...damage c A slight thunk evident at low speed opera tion This noise must be distinguished from normal vehicle operation Diagnosis Possible broken gear teeth WARNING EWB02910 Stop riding immediately if broken gear teeth are suspected This condition could result in the shaft drive assembly locking up causing a loss of control and possible injury to the rider 2 Check Drained oil Drained oil shows larg...

Page 344: ...cation Refer to FRONT AND REAR WHEELS on page 4 23 3 Check the front constant velocity shaft assemblies Feel for bearing damage Constant velocity shaft bearings and differ ential bearings are probably not damaged Repeat the test or remove the individual components 4 Check the parking brake adjust ment Adjust per instructions Refer to AD JUSTING THE PARKING BRAKE on page 3 21 5 Check the rear const...

Page 345: ...guard Refer to GENERAL CHASSIS 6 on page 4 12 Air filter case Refer to AIR FILTER CASE on page 7 5 Steering knuckles Refer to STEERING KNUCKLES on page 4 52 Differential gear oil Drain Refer to CHANGING THE DIFFERENTIAL GEAR OIL on page 3 17 1 Front constant velocity shaft assembly 2 2 Differential motor coupler 1 Disconnect 3 Differential assembly breather hose 1 Disconnect 3 1 1 2 LS LS LS LS LS...

Page 346: ... Front drive shaft differential side 1 7 Dust seal 1 8 Universal joint 2 9 Universal joint yoke 2 10 Front drive shaft middle gear side 1 11 Support bearing housing 1 12 Support bearing rubber 1 13 Oil seal 1 14 Oil seal 1 15 Bearing 1 4 10 6 8 7 9 8 5 9 13 12 11 15 14 LS LS LS LS LS LS LS New New New New New New New New New LS LT 18 Nm 1 8 m kgf 13 ft Ibf T R 60 Nm 6 0 m kgf 43 ft Ibf T R 60 Nm 6...

Page 347: ...semblies A Wheel side B Differential side Order Job Parts to remove Q ty Remarks The following procedure applies to both of the front constant velocity shaft assemblies 1 Boot band 1 2 Boot band 1 3 Dust boot 1 4 Clip 1 5 Double offset joint 1 6 Circlip 1 7 Ball bearing 1 8 Boot band 1 9 Boot band 1 5 2 3 1 8 9 6 7 4 New New New New New New ...

Page 348: ...MBLY AND FRONT DRIVE SHAFTS 8 7 Disassembling the front constant velocity shaft assemblies A Wheel side B Differential side Order Job Parts to remove Q ty Remarks 10 Dust boot 1 11 Constant velocity joint 1 12 Clip 1 13 Constant velocity shaft 1 10 12 11 13 New ...

Page 349: ...ive shaft yoke differential case side 1 4 Bracket 1 5 Differential case cover 1 6 Differential gear assembly 1 7 Differential gear assembly shim Refer to ADJUSTING THE DIFFEREN TIAL GEAR BACKLASH on page 8 17 8 Bearing 1 9 Bearing 1 10 Oil seal 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R 62 Nm 6 2 m kgf 45 ft Ibf T R 2...

Page 350: ...Parts to remove Q ty Remarks 11 Clip 1 12 Differential pinion gear 1 13 Bearing 1 14 Bearing 1 15 Oil seal 2 16 Differential case 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R 62 Nm 6 2 m kgf 45 ft Ibf T R 24 Nm 2 4 m kgf 17 ft Ibf T R New 13 11 14 12 15 3 16 LS LS LS LS LS New New New New New 15 ...

Page 351: ...joint EBS30240 DISASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES The following procedure applies to both of the front constant velocity shaft assemblies 1 Remove Boot bands Clip 1 Double offset joint 2 Circlip 3 Ball bearing 4 Dust boot 5 TIP Before removing the clip slide the dust boot away from the double offset joint 2 Remove Boot bands 1 TIP Use the boot band installation tool 2 3 Rem...

Page 352: ...T CONSTANT VELOCITY SHAFT ASSEMBLIES The following procedure applies to both of the front constant velocity shaft assemblies 1 Install Clip 1 Constant velocity joint 2 Constant velocity shaft 3 Dust boot a Install a new clip b Install the constant velocity joint TIP Install the clip into the groove in the constant velocity shaft as shown Secure the constant velocity joint in a vise and then fit th...

Page 353: ...ands 4 and 5 TIP Use the boot band installation tool 6 5 Check Thrust movement free play Excessive play Replace the constant ve locity shaft assembly EBS30243 REMOVING THE FRONT DRIVE SHAFT YOKE 1 Remove Front drive shaft yoke TIP Use the universal joint holder 1 to hold the front drive shaft yoke then loosen the front drive shaft yoke nut B Differential side Molybdenum disulfide grease 60 80 g 2 ...

Page 354: ...over Cracks damage Replace TIP When the differential case and or the differential case cover are replaced be sure to adjust the shim of the differential gear assembly 2 Check Gear teeth Pitting galling wear Replace TIP When the differential pinion gear and or the dif ferential assembly are replaced be sure to ad just the shim of the differential gear assembly 3 Check Bearings Damage Replace EBS302...

Page 355: ...he right front constant velocity shaft assembly side as shown in the illustration to put it into the 2WD mode b Connect two C size batteries to the differen tial motor terminal 2 to operate the differen tial motor pinion gear 3 Operate the differential motor pinion gear until the mark A Check that the differential motor pinion gear 2 turns counterclockwise B Check that the differential motor pinio...

Page 356: ...r differential lock mode may not be activated d Remove the 6 mm bolts and then install the motor with the differential motor bolts 4 Check Differential assembly operation Unsmooth operation Replace the differen tial assembly Insert the double offset joint into the differen tial assembly and turn the gears back and forth 5 Install Front drive shaft yoke Washer Front drive shaft yoke nut TIP Use the...

Page 357: ...d e Install new circlips 2 into the groove of each bearing EBS30251 MEASURING THE DIFFERENTIAL GEAR BACKLASH 1 Secure the differential case in a vise or anoth er supporting device 2 Remove Drain bolt Gasket 3 Install Ring gear fix bolt M10 1 into the drain bolt hole NOTICE ECB01250 Finger tighten the bolt until it holds the ring gear Otherwise the ring gear will be dam aged 4 Attach Gear lash meas...

Page 358: ...erential gear assembly shim s 1 Differential gear assembly 2 2 Adjust Gear backlash a Select the suitable shims using the following chart b Measure the differential gear backlash again Thinner shim Differential gear backlash is increased Thicker shim Differential gear backlash is decreased Differential gear assembly shims Thickness mm 0 1 0 2 0 3 0 4 2 1 ...

Page 359: ...ty Remarks Rear knuckles Refer to REAR KNUCKLES AND STABI LIZER on page 4 60 Final gear oil Drain Refer to CHANGING THE FINAL GEAR OIL on page 3 16 1 Rear constant velocity shaft assembly 2 2 Final drive assembly breather hose 1 Disconnect 3 Parking brake cable 1 Disconnect 4 Final drive assembly bracket upper side 1 5 Final drive assembly 1 6 Rear drive shaft 1 7 Spring 1 33 Nm 3 3 m kgf 24 ft Ib...

Page 360: ...mblies final drive assembly and rear drive shaft Order Job Parts to remove Q ty Remarks 8 Damper 1 9 Rear drive shaft coupling sleeve 1 10 Dust seal 1 11 Dust seal 1 12 Final drive assembly bracket lower side 1 33 Nm 3 3 m kgf 24 ft Ibf T R 33 Nm 3 3 m kgf 24 ft Ibf T R 105 Nm 10 5 m kgf 76 ft lbf T R LS LS New New New 4 8 11 10 9 12 ...

Page 361: ...blies A Wheel side B Final drive side Order Job Parts to remove Q ty Remarks The following procedure applies to both of the rear constant velocity shaft assemblies 1 Boot band 1 2 Boot band 1 3 Clip 1 4 Double offset joint 1 5 Circlip 1 6 Ball bearing 1 7 Dust boot 1 8 Boot band 1 9 Boot band 1 4 2 7 1 8 9 5 6 3 New New New New New New New ...

Page 362: ...R DRIVE SHAFT 8 21 Disassembling the rear constant velocity shaft assemblies A Wheel side B Final drive side Order Job Parts to remove Q ty Remarks 10 Dust boot 1 11 Constant velocity joint 1 12 Clip 1 13 Constant velocity shaft 1 13 10 12 11 New New New New New New New ...

Page 363: ...r bearing housing gasket 1 4 Dowel pin 2 5 Final drive ring gear shim ring gear bearing housing side 6 Final drive ring gear 1 7 Final drive ring gear shim final drive case side 8 Bearing 1 9 Bearing 1 97 Nm 9 7 m kgf 70 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 52 Nm 5 2 m kgf 38 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R LS LS New New New ...

Page 364: ...rive as sembly side 1 13 Final drive case cover assembly 1 14 Final drive case cover gasket 1 15 Dowel pin 2 16 Parking brake kit Refer to PARKING BRAKE on page 4 40 17 Final drive case cover 1 18 Oil seal 1 19 Final drive pinion gear assembly 1 97 Nm 9 7 m kgf 70 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 52 Nm 5 2 m kgf 38 ft Ibf T R 16 N...

Page 365: ...drive pinion gear bearing housing 1 22 Final drive pinion gear 1 23 Bearing 1 24 Final drive pinion gear shim 25 Bearing 1 26 Bearing 1 27 Final drive case 1 97 Nm 9 7 m kgf 70 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R 52 Nm 5 2 m kgf 38 ft Ibf T R 16 Nm 1 6 m kgf 12 ft Ibf T R LS LS New New New New New LT LT LS New New New LT LT LT 21 23 ...

Page 366: ... CHECKING THE REAR CONSTANT VELOCITY SHAFT ASSEMBLIES The following procedure applies to both of the rear constant velocity shaft assemblies 1 Check Double offset joint splines Constant velocity joint splines Constant velocity shaft splines Wear damage Replace 2 Check Dust boots Cracks damage Replace NOTICE ECB01590 Always use a new boot band 3 Check Balls and ball races Inner surface of double of...

Page 367: ...clip into the groove in the constant velocity shaft Securely install the clip into the groove in the double offset joint 3 Apply Molybdenum disulfide grease into the double offset joint constant velocity joint and dust boots TIP Molybdenum disulfide grease is included in the repair kit 4 Install Dust boots 1 Boot bands 2 3 TIP The dust boots should be fastened with the boot bands 2 and 3 at the gr...

Page 368: ... gear 2 Remove Rear drive shaft coupling gear final drive as sembly side 1 TIP Push up the rear drive shaft coupling gear using suitable tools as shown in the illustration NOTICE ECB02420 Be careful not to damage the oil seal with the tips of the tools 3 Remove Final drive pinion gear assembly 1 TIP Remove the final drive pinion gear assembly with the crankshaft installer pot 2 crankshaft installe...

Page 369: ... Final drive case cover Cracks damage Replace TIP When the final drive case and or the final drive case cover are replaced be sure to adjust the shim of the final drive pinion gear and or ring gear 2 Check Gear teeth Pitting galling wear Replace the final drive pinion gear and ring gear as a set TIP When the final drive pinion gear and ring gear are replaced be sure to adjust the shim of the fi na...

Page 370: ...lash Gently rotate the final drive pinion gear from engagement to engagement TIP While pulling the final drive pinion gear outward and gently turning the gear back and forth measure the backlash Measure the gear backlash at four positions Rotate the final drive pinion gear 90 each time EBS30261 ADJUSTING THE FINAL GEAR BACKLASH 1 Remove Final drive ring gear 1 Bearings 2 T R Ring gear stopper nut ...

Page 371: ... ASSEMBLING THE FINAL DRIVE ASSEMBLY 1 Install Final drive pinion gear assembly 1 a Install the crankcase separating tool 2 b Screw in the center bolt 3 of the crankcase separating tool several turns to press the final drive pinion gear assembly slightly into the fi nal drive case 4 TIP Press the final drive pinion gear assembly until the four final drive pinion gear assembly bolts can be installe...

Page 372: ...l drive assembly bracket lower side 3 TIP Tighten the bolts and nuts to specification in the proper tightening sequence shown T R Rear drive shaft coupling gear nut final drive assembly side 97 Nm 9 7 m kgf 70 ft lbf LOCTITE Coupling gear holding tool 35 90890 01571 Coupling gear holding tool 35 YM 01571 1 2 T R Final drive assembly bracket bolt upper side 33 Nm 3 3 m kgf 24 ft lbf Final drive ass...

Page 373: ...CIRCUIT DIAGRAM except for EPS models 9 19 CIRCUIT DIAGRAM for EPS models 9 21 TROUBLESHOOTING 9 23 COOLING SYSTEM 9 29 CIRCUIT DIAGRAM 9 29 TROUBLESHOOTING 9 31 FUEL INJECTION SYSTEM 9 33 CIRCUIT DIAGRAM except for EPS models 9 33 CIRCUIT DIAGRAM for EPS models 9 35 ECU SELF DIAGNOSTIC FUNCTION 9 37 TROUBLESHOOTING METHOD 9 38 YAMAHA DIAGNOSTIC TOOL 9 39 TROUBLESHOOTING DETAILS FUEL INJECTION SYS...

Page 374: ...E CRANKSHAFT POSITION SENSOR 9 101 CHECKING THE LEAN ANGLE SENSOR 9 102 CHECKING THE STARTER MOTOR OPERATION 9 102 CHECKING THE STATOR COIL 9 103 CHECKING THE RECTIFIER REGULATOR 9 103 CHECKING THE FUEL SENDER 9 103 CHECKING THE FUEL METER FUEL LEVEL WARNING LIGHT 9 104 CHECKING THE SPEED SENSOR 9 104 CHECKING THE PARKING BRAKE BUZZER 9 105 CHECKING THE RADIATOR FAN MOTOR 9 105 CHECKING THE RADIAT...

Page 375: ......

Page 376: ...W W W W W R L B Br Y Br Y Br R Br R Br R Br L Br Y G W L B Br Y W B Br Y L Y R Y Br B L Y Br R R B Br R Br B Br R L R R L R L R R R R R R B B B B B B B B R W B R B B B B B B B B B B B B B B B Br R Br Y Br W B G Y B Br L L L Y Y Y Y Y B B B B B B B B B B B B B Y L Y Y L L B G Y B B Y B Br R Br R P W B G O L B Y Br B B R Gy G Sb L Gy W W R L W B W B G R Y L G R B R B G G R Y B Y R R Y R L Br L P L R...

Page 377: ...on sensor 5 Frame ground 6 Main switch 7 Engine ground 8 Battery 9 Main fuse 21 ECU Engine Control Unit 22 Ignition coil 23 Spark plug 30 Lean angle sensor 34 Joint coupler 60 Ignition fuse B Wire harness C Negative battery sub wire harness ...

Page 378: ...RY on page 9 95 Clean the battery terminals Recharge or replace the battery 3 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 6 Re gap or replace the spark plug 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 9 101 Ignition system is OK 5 Check the spark plug cap Refer to CHECKING THE SPARK PLUG CAP on page 9 100 Replace the spark plug cap 6 Check t...

Page 379: ... on page 9 89 Replace the main switch 9 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 9 102 Replace the lean angle sensor 10 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM on page 9 1 Properly connect or replace the wire har ness Replace the ECU ...

Page 380: ...Gy B L W W W W W W R L B Br Y Br Y Br R Br R Br R Br L Br Y G W L B Br Y W B Br Y L Y R Y Br B L Y Br R R B Br R Br B Br R L R R L R L R R R R R R B B B B B B B B R W B R B B B B B B B B B B B B B B B Br R Br Y Br W B G Y B Br L L L Y Y Y Y Y B B B B B B B B B B B B B Y L Y Y L L B G Y B B Y B Br R Br R P W B G O L B Y Br B B R Gy G Sb L Gy W W R L W B W B G R Y L G R B R B G G R Y B Y R R Y R L B...

Page 381: ... Main switch 7 Engine ground 8 Battery 9 Main fuse 11 Starter relay 12 Starter motor 17 Gear position switch 21 ECU Engine Control Unit 34 Joint coupler 56 Brake light switch 60 Ignition fuse 62 Signaling system fuse B Wire harness C Negative battery sub wire harness ...

Page 382: ...ons is met The transmission is in neutral the neutral circuit of the gear position switch is closed The brake pedal is pressed the brake light switch circuit is closed 11 1 10 5 3 6 7 8 9 4 2 1 Battery 2 Main fuse 3 Ignition fuse 4 Main switch 5 Load control relay 6 Signaling system fuse 7 Brake light switch 8 ECU Engine Control Unit 9 Gear position switch 10 Starter relay 11 Starter motor ...

Page 383: ...motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 9 102 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 40 Repair or replace the starter motor 5 Check the starter relay Refer to CHECKING THE RE LAYS on page 9 97 Replace the starter relay 6 Check the load contr...

Page 384: ...eck the gear position switch Refer to CHECKING THE SWITCHES on page 9 89 Replace the gear position switch 10 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM on page 9 5 Properly connect or replace the wire har ness Replace the ECU ...

Page 385: ...ELECTRIC STARTING SYSTEM 9 10 ...

Page 386: ... W W W W W R L B Br Y Br Y Br R Br R Br R Br L Br Y G W L B Br Y W B Br Y L Y R Y Br B L Y Br R R B Br R Br B Br R L R R L R L R R R R R R B B B B B B B B R W B R B B B B B B B B B B B B B B B Br R Br Y Br W B G Y B Br L L L Y Y Y Y Y B B B B B B B B B B B B B Y L Y Y L L B G Y B B Y B Br R Br R P W B G O L B Y Br B B R Gy G Sb L Gy W W R L W B W B G R Y L G R B R B G G R Y B Y R R Y R L Br L P L ...

Page 387: ...CHARGING SYSTEM 9 12 2 AC magneto 3 Rectifier regulator 5 Frame ground 8 Battery 9 Main fuse B Wire harness C Negative battery sub wire harness ...

Page 388: ...attery Refer to CHECKING AND CHARGING THE BATTERY on page 9 95 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 9 103 Replace the crankshaft position sen sor stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 9 103 Replace the rectifier regulator 5 Check the entire charging ...

Page 389: ...CHARGING SYSTEM 9 14 ...

Page 390: ... W W W W W R L B Br Y Br Y Br R Br R Br R Br L Br Y G W L B Br Y W B Br Y L Y R Y Br B L Y Br R R B Br R Br B Br R L R R L R L R R R R R R B B B B B B B B R W B R B B B B B B B B B B B B B B B Br R Br Y Br W B G Y B Br L L L Y Y Y Y Y B B B B B B B B B B B B B Y L Y Y L L B G Y B B Y B Br R Br R P W B G O L B Y Br B B R Gy G Sb L Gy W W R L W B W B G R Y L G R B R B G G R Y B Y R R Y R L Br L P L ...

Page 391: ... Load control relay 5 Frame ground 6 Main switch 8 Battery 9 Main fuse 52 Light switch 53 Headlight relay 54 Headlight 57 Tail brake light 60 Ignition fuse 63 Headlight fuse B Wire harness C Negative battery sub wire harness ...

Page 392: ...adlight Refer to CHECKING THE FUS ES on page 9 94 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 9 95 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 9 89 Replace the main switch 5 Check the light switch Refer to CHECKING THE SWITCHES on page 9 89 Replace the light switch 6 Check t...

Page 393: ...LIGHTING SYSTEM 9 18 NG OK 8 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 9 15 Properly connect or replace the wire har ness The lighting system circuit is OK ...

Page 394: ... ON Gy B L W W W W W W R L B Br Y Br Y Br R Br R Br R Br L Br Y G W L B Br Y W B Br Y L Y R Y Br B L Y Br R R B Br R Br B Br R L R R L R L R R R R R R B B B B B B B B R W B R B B B B B B B B B B B B B B B Br R Br Y Br W B G Y B Br L L L Y Y Y Y Y B B B B B B B B B B B B B Y L Y Y L L B G Y B B Y B Br R Br R P W B G O L B Y Br B B R Gy G Sb L Gy W W R L W B W B G R Y L G R B R B G G R Y B Y R R Y R...

Page 395: ...ht assembly 37 Helmet indicator light 38 Seat belt indicator light 39 Meter assembly 40 Multi function meter 42 Coolant temperature warning light 43 Parking brake indicator light 44 Reverse indicator light 45 Neutral indicator light 46 High range indicator light 47 Low range indicator light 49 Fuel sender 56 Brake light switch 57 Tail brake light 60 Ignition fuse 61 Backup fuse 62 Signaling system...

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

Page 397: ...Helmet indicator light 44 Seat belt indicator light 45 Meter assembly 46 Multi function meter 48 Coolant temperature warning light 49 Parking brake indicator light 50 Reverse indicator light 51 Neutral indicator light 52 High range indicator light 53 Low range indicator light 56 Fuel sender 63 Brake light switch 64 Tail brake light 67 Ignition fuse 68 Backup fuse 69 Signaling system fuse 75 Horn s...

Page 398: ...ING THE FUS ES on page 9 94 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 9 95 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 9 89 Replace the main switch 4 Check the load control relay Refer to CHECKING THE RE LAYS on page 9 97 Replace the load control relay 5 Check the entire s...

Page 399: ...e the brake light switch 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM ex cept for EPS models on page 9 19 and CIRCUIT DIAGRAM for EPS models on page 9 21 Properly connect or replace the wire har ness This circuit is OK 1 Check the gear position switch Refer to CHECKING THE SWITCHES on page 9 89 Replace the gear position switch 2 Check the entire signaling system wiring Refer...

Page 400: ...g brake switch 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM ex cept for EPS models on page 9 19 and CIRCUIT DIAGRAM for EPS models on page 9 21 Properly connect or replace the wire har ness Replace the meter assembly or ECU 1 Check the coolant temperature sen sor Refer to CHECKING THE COOL ANT TEMPERATURE SENSOR on page 9 106 Replace the coolant temperature sensor 2 Check th...

Page 401: ...r 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM ex cept for EPS models on page 9 19 and CIRCUIT DIAGRAM for EPS models on page 9 21 Properly connect or replace the wire har ness Replace the meter assembly or ECU 1 Check the seat belt switch Refer to CHECKING THE SWITCHES on page 9 89 Replace the driver seat belt buckle 2 Check the entire signaling system wiring Refer to CIRCU...

Page 402: ...RAM for EPS models on page 9 21 Properly connect or replace the wire har ness Replace the ECU 1 Check the horn switch Refer to CHECKING THE SWITCHES on page 9 89 Replace the horn switch 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM ex cept for EPS models on page 9 19 and CIRCUIT DIAGRAM for EPS models on page 9 21 Properly connect or replace the wire har ness Replace the horn...

Page 403: ...SIGNALING SYSTEM 9 28 ...

Page 404: ...W W W W W R L B Br Y Br Y Br R Br R Br R Br L Br Y G W L B Br Y W B Br Y L Y R Y Br B L Y Br R R B Br R Br B Br R L R R L R L R R R R R R B B B B B B B B R W B R B B B B B B B B B B B B B B B Br R Br Y Br W B G Y B Br L L L Y Y Y Y Y B B B B B B B B B B B B B Y L Y Y L L B G Y B B Y B Br R Br R P W B G O L B Y Br B B R Gy G Sb L Gy W W R L W B W B G R Y L G R B R B G G R Y B Y R R Y R L Br L P L R...

Page 405: ...in fuse 21 ECU Engine Control Unit 26 Coolant temperature sensor 34 Joint coupler 58 Radiator fan motor fuse 60 Ignition fuse 65 Radiator fan motor 66 Radiator fan motor circuit breaker 67 Radiator fan motor relay B Wire harness C Negative battery sub wire harness ...

Page 406: ...he battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 9 89 Replace the main switch 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 9 105 Replace the radiator fan motor 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 9 97 Replace the radiator fan motor relay 6 Check the radiator fan motor circuit breaker Refer to CHECKI...

Page 407: ...COOLING SYSTEM 9 32 NG OK 8 Check the entire cooling system wiring Refer to CIRCUIT DIAGRAM on page 9 29 Properly connect or replace the wire har ness Replace the ECU ...

Page 408: ...A OFF ON Gy B L W W W W W W R L B Br Y Br Y Br R Br R Br R Br L Br Y G W L B Br Y W B Br Y L Y R Y Br B L Y Br R R B Br R Br B Br R L R R L R L R R R R R R B B B B B B B B R W B R B B B B B B B B B B B B B B B Br R Br Y Br W B G Y B Br L L L Y Y Y Y Y B B B B B B B B B B B B B Y L Y Y L L B G Y B B Y B Br R Br R P W B G O L B Y Br B B R Gy G Sb L Gy W W R L W B W B G R Y L G R B R B G G R Y B Y R ...

Page 409: ...C Idle Speed Control unit 21 ECU Engine Control Unit 22 Ignition coil 23 Spark plug 24 Fuel injector 25 Intake air temperature sensor 26 Coolant temperature sensor 27 Speed sensor 28 TPS throttle position sensor 29 Intake air pressure sensor 30 Lean angle sensor 34 Joint coupler 39 Meter assembly 40 Multi function meter 41 Engine trouble warning light 50 Fuel pump 60 Ignition fuse 61 Backup fuse 6...

Page 410: ... W W W W W R L B Br Y Br Y Br R Br R Br R Br L Br Y G W L B Br Y W B Br Y R B L Y R Y Br B L Y Br R R B Br R Br B Br R L R R L R L R R R R R R R R B B B B B B B B R R W B R B B B B B B B B B B B B B B B Br R Br Y Br W B G Y B Br L L L Y Y Y Y Y B B B B B B B B B B B B B Y L Y Y L L B G Y B B Y B Br R Br R P W B G O L B Y Br B B R Gy G Sb L Gy W W R L W B W B G R Y L G R B R B G G R Y B Y R R Y R L...

Page 411: ...C Idle Speed Control unit 22 ECU Engine Control Unit 23 Ignition coil 24 Spark plug 25 Fuel injector 26 Intake air temperature sensor 27 Coolant temperature sensor 28 Speed sensor 29 TPS throttle position sensor 30 Intake air pressure sensor 31 Lean angle sensor 35 Joint coupler 45 Meter assembly 46 Multi function meter 47 Engine trouble warning light 57 Fuel pump 67 Ignition fuse 68 Backup fuse 6...

Page 412: ...ow is present and the main switch is turned to start Checking for a defective engine trouble warning light bulb The engine trouble warning light comes on for around 2 seconds after the main switch has been turned to on If the warning light does not come on under these conditions the warning light LED may be defective ECU detects an abnormal signal from a sensor If the ECU detects an abnormal signa...

Page 413: ...GNOSTIC CODE TABLE on page 10 7 TIP Turning the main switch to off will not erase the malfunction history The engine operation is not normal but the engine trouble warning light does not come on 1 Check the operation of the following sensors and actuators in the diagnostic mode Refer to TROUBLESHOOTING DETAILS FUEL INJECTION SYSTEM on page 9 41 and SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABL...

Page 414: ...he basic vehicle functions such as ad justing the ignition timing Connecting the Yamaha diagnostic tool Remove the protective cap and then connect the Yamaha diagnostic tool to the coupler 1 TIP When the Yamaha diagnostic tool is connected to the vehicle the operation of the multi function meter and indicators will be different from the normal operation Yamaha diagnostic tool 90890 03231 Fault dia...

Page 415: ...st of the malfunction detected in the past already recovered are displayed 2 Detected The item list of the malfunction currently occurred are displayed 3 Code The following icons and the fault code numbers for the detected malfunctions are displayed 4 ECU The types of the control units are displayed 2 3 1 4 5 6 7 8 9 10 11 12 A B A Detected malfunction B Recovered malfunction ...

Page 416: ... the items or components that are the probable cause of the malfunction fol lowing the order given After the check and service of the malfunctioning part has been completed reset the multi function me ter display according to the Confirmation of service completion Fault code No Fault code number displayed on the multi function meter when the engine failed to work normally Diagnostic code No Diagno...

Page 417: ...talled condition of crank shaft position sensor Check for looseness or pinch ing Improperly installed sensor Reinstall or replace the sensor Crank the engine Fault code number is not dis played Service is finished Fault code number is displayed Go to item 5 5 Defective crankshaft position sensor Check the crankshaft position sensor Refer to CHECKING THE CRANKSHAFT POSITION SENSOR on page 9 101 Rep...

Page 418: ...switch to on Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between intake air pressure sensor coupler and ECU cou pler pink pink Between intake air pressure sensor coupler and joint cou pler blue blue black blue black blue Between joint coupler and ECU coupler blue blue bl...

Page 419: ... Turn the main switch to on Fault code number is not dis played Service is finished Fault code number is displayed Go to item 6 6 Malfunction in ECU Replace the ECU Fault code No 13 Item Intake air pressure sensor open or short circuit detected Fault code No 14 Item Intake air pressure sensor hose system malfunction clogged or de tached hose Fail safe system Able to start engine Able to drive vehi...

Page 420: ...if defective Refer to CHECKING THE IN TAKE AIR PRESSURE SEN SOR on page 9 107 Fault code No 14 Item Intake air pressure sensor hose system malfunction clogged or de tached hose Fault code No 15 Item Throttle position sensor open or short circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 01 Indicated Throttle position sensor signal 14 20 fully closed po...

Page 421: ...not dis played Service is finished Fault code number is displayed Go to item 4 4 Installed condition of throttle po sition sensor Check for looseness or pinch ing Improperly installed sensor Reinstall or adjust the sensor Refer to ADJUSTING THE THROTTLE POSITION SEN SOR on page 7 13 Turn the main switch to on Fault code number is not dis played Service is finished Fault code number is displayed Go...

Page 422: ...hen press the accelerator pedal Fault code number is not dis played Service is finished Fault code number is displayed Go to item 2 2 Defective throttle position sen sor Check throttle position sensor signal Execute the diagnostic mode Code No 01 When the throttle valve is fully closed A value of 14 20 is indicated An indicated value is out of the specified range Replace the throttle position sens...

Page 423: ...etween coolant temperature sensor coupler and ECU cou pler green yellow green yellow Between coolant temperature sensor coupler and joint cou pler black blue black blue Between joint coupler and ECU coupler black blue black blue Turn the main switch to on Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Installed condition of coolant temperature...

Page 424: ...Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to on Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Wire harness continuity Open or short circuit R...

Page 425: ...re Remove the lean angle sensor and incline it more than 65 degrees Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 The vehicle has overturned Raise the vehicle upright Turn the main switch to on then to off and then back to on Fault code number is not dis played Service is finished Fault code number is displayed Go to item 2 2 Installed conditio...

Page 426: ...heck the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between ignit...

Page 427: ...rmation of service com pletion A 1 Locate the malfunction Execute the diagnostic mode Code No 54 Fully closes the ISC Idle Speed Control valve and then fully opens the valve ISC operating sound is heard Go to item A 2 ISC operating sound is not heard Go to item B 2 for the defective ISC Idle Speed Con trol unit A 2 Incorrect speed sensor signal Check the speed sensor Execute the diagnostic mode Co...

Page 428: ... compo nent other than ISC Idle Speed Control unit is defective ISC operating sound is not heard Go to item B 2 B 2 Connection of ISC Idle Speed Control unit coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Execute th...

Page 429: ...dy as sembly Execute the diagnostic mode Code No 54 ISC operating sound is heard Go to item B 8 ISC operating sound is not heard Go to item B 7 B 7 Malfunction in ECU Replace the ECU B 8 Delete the fault code Start the engine and let it idle for approximately 10 seconds Check that the fault code num ber is not displayed Fault code No 37 Item A Component other than ISC Idle Speed Control unit is de...

Page 430: ...ely or re place the wire harness Execute the diagnostic mode Code No 36 Operating sound Go to item 6 No operating sound Go to item 4 4 Wire harness continuity Open or short circuit Replace the wire harness Between fuel injector coupler and ECU coupler red red Between fuel injector coupler and joint coupler red blue red blue Execute the diagnostic mode Code No 36 Operating sound Go to item 6 No ope...

Page 431: ...played Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between lean angle sensor coupler and ECU coupler yellow green yellow green Between lean angle sensor coupler and joint coupler blue blue black blue black blue Between joint coupler and ECU coupler blue blue black blue black blue Turn the main switch to on then to off and then back to on Fault code number ...

Page 432: ... number is not dis played Go to item 6 Fault code number is displayed Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between speed sensor coupler and ECU coupler except for EPS models white white Between speed sensor coupler and joint coupler for EPS mod els white white Between joint coupler and ECU coupler for EPS models white white Between speed sensor coup...

Page 433: ...n the Yamaha di agnostic tool screen go off When the relay is off the CHECK indicator and on the Yamaha diagnostic tool screen come on Procedure Check that the fuel injection system relay is actuated five times by listen ing for the operating sound Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Connection of fuel injection sys tem relay coupler ...

Page 434: ...oximately 5 seconds Fault code number is not dis played Service is finished Fault code number is displayed Go to item 5 5 Defective fuel injection system relay Execute the diagnostic mode Code No 09 Fuel system voltage is below 3 V Replace the fuel injection system relay Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code ...

Page 435: ...o 46 Item Charging voltage is abnormal Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Indicated Procedure Item Probable cause of malfunc tion and check Maintenance job Confirmation of service com pletion 1 Malfunction in charging system Check the charging system Refer to CHARGING SYS TEM on page 9 11 Defective rectifier regulator or AC magneto Replace Defective conn...

Page 436: ...condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to on Fault code number is not dis played Service is finished Fault code number is displayed Go to item 2 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins...

Page 437: ...d check the pins bent or broken terminals and locking condition of the pins Improperly connected Con nect the coupler securely or re place the wire harness Turn the main switch to on Fault code number is not dis played Service is finished Fault code number is displayed Go to item 3 3 Wire harness continuity Open or short circuit Replace the wire harness Between meter assembly cou pler and ECU coup...

Page 438: ...ault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Defective meter assembly Replace the meter assembly Turn the main switch to on Fault code number is not dis played Service is finished Fault code number is displayed Go to item 5 5 Malfunction in ECU Replace the ECU Fault code No Er 3 Item ECU Engine Control Unit internal malfunction output signal ...

Page 439: ...ontinuity Open or short circuit Replace the wire harness Between meter assembly cou pler and ECU coupler yellow blue yellow blue Turn the main switch to on Fault code number is not dis played Service is finished Fault code number is displayed Go to item 4 4 Defective meter assembly Replace the meter assembly Turn the main switch to on Fault code number is not dis played Service is finished Fault c...

Page 440: ...W W W W W W R L B Br Y Br Y Br R Br R Br R Br L Br Y G W L B Br Y W B Br Y L Y R Y Br B L Y Br R R B Br R Br B Br R L R R L R L R R R R R R B B B B B B B B R W B R B B B B B B B B B B B B B B B Br R Br Y Br W B G Y B Br L L L Y Y Y Y Y B B B B B B B B B B B B B Y L Y Y L L B G Y B B Y B Br R Br R P W B G O L B Y Br B B R Gy G Sb L Gy W W R L W B W B G R Y L G R B R B G G R Y B Y R R Y R L Br L P L...

Page 441: ...e ground 6 Main switch 8 Battery 9 Main fuse 10 Fuel injection system fuse 13 Fuel injection system relay 21 ECU Engine Control Unit 34 Joint coupler 50 Fuel pump 60 Ignition fuse B Wire harness C Negative battery sub wire harness ...

Page 442: ...fer to CHECKING AND CHARGING THE BATTERY on page 9 95 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 9 89 Replace the main switch 4 Check the fuel injection system re lay Refer to CHECKING THE RE LAYS on page 9 97 Replace the fuel injection system relay 5 Check the fuel pump Refer to CHECKING THE FUEL PUMP BODY on page 7 2...

Page 443: ...FUEL PUMP SYSTEM 9 68 ...

Page 444: ... Gy B L W W W W W W R L B Br Y Br Y Br R Br R Br R Br L Br Y G W L B Br Y W B Br Y L Y R Y Br B L Y Br R R B Br R Br B Br R L R R L R L R R R R R R B B B B B B B B R W B R B B B B B B B B B B B B B B B Br R Br Y Br W B G Y B Br L L L Y Y Y Y Y B B B B B B B B B B B B B Y L Y Y L L B G Y B B Y B Br R Br R P W B G O L B Y Br B B R Gy G Sb L Gy W W R L W B W B G R Y L G R B R B G G R Y B Y R R Y R L ...

Page 445: ...erential motor 18 On Command four wheel drive switch 21 ECU Engine Control Unit 34 Joint coupler 39 Meter assembly 40 Multi function meter 48 On Command differential gear lock indicator light 51 Differential motor relay 2 59 Differential motor fuse 60 Ignition fuse 62 Signaling system fuse B Wire harness C Negative battery sub wire harness ...

Page 446: ...ignition and signaling system Refer to CHECKING THE FUS ES on page 9 94 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 9 95 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 9 89 Replace the main switch 4 Check the On Command four wheel drive switch Refer to CHECKING THE SWITCHES on ...

Page 447: ...tor 9 Check the entire 2WD 4WD select ing system wiring Refer to CIRCUIT DIAGRAM on page 9 69 Properly connect or replace the 2WD 4WD selecting system wiring Replace the meter assembly or ECU 1 Check the differential motor posi tion switch Refer to CHECKING THE DIF FERENTIAL MOTOR POSITION SWITCH on page 9 109 Replace the differential motor 2 Check the entire 2WD 4WD select ing system wiring Refer...

Page 448: ...tart A B C A B C D B OFF ON Gy B L W W W W W W R L B Br Y Br Y Br R Br R Br R Br L Br Y G W L B Br Y W B Br Y R B L Y R Y Br B L Y Br R R B Br R Br B Br R L R R L R L R R R R R R R R B B B B B B B B R R W B R B B B B B B B B B B B B B B B Br R Br Y Br W B G Y B Br L L L Y Y Y Y Y B B B B B B B B B B B B B Y L Y Y L L B G Y B B Y B Br R Br R P W B G O L B Y Br B B R Gy G Sb L Gy W W R L W B W B G R...

Page 449: ... 10 EPS fuse 22 ECU Engine Control Unit 28 Speed sensor 35 Joint coupler 36 EPS unit 37 EPS motor 38 EPS torque sensor 39 EPS self diagnosis signal connector 40 EPS control unit 45 Meter assembly 55 EPS warning light 67 Ignition fuse 69 Signaling system fuse B Wire harness C Negative battery sub wire harness D EPS control unit ...

Page 450: ...to on If the warning light does not come on the electrical circuit may be defective TIP If the steering usage is too heavy i e excessive steering use when the vehicle is traveling at a slow speed the power assist is reduced to protect the EPS motor from overheating EBS30288 EPS WARNING LIGHT DURING NORMAL OPERATION The EPS warning light comes on initially for 2 seconds after the main switch is tur...

Page 451: ... The EPS warning light starts to show present fault codes Past malfunction signaling mode While the present malfunction mode is activated briefly disconnect the connector 1 ground it again and leave it grounded The signaling mode is activated after 5 seconds The EPS warning light starts to show past fault codes 4 Turn the main switch to off to cancel the diagnostic mode TIP The diagnostic mode can...

Page 452: ...a d i g g k h i b e d c f B A 5 5 2 0 5 3 0 5 5 1 3 2 j a EPS self diagnosis signal connector b Diagnostic mode c EPS warning light d Disconnected e On f Off g Grounded h Normal mode diagnostic mode not activated i Mode selection judgment j Present malfunction signaling mode k Past malfunction signaling mode A The EPS warning light comes on for 5 seconds during the diagnostic mode selection judgme...

Page 453: ...PS self diagnosis signal connector b Disconnected c Grounded Fault code No Item Symptom Probable cause of mal function 11 13 15 16 EPS torque sensor No normal signals are received from the EPS torque sensor Open or short circuit in wire harness Malfunction in torque sen sor Malfunction in EPS control unit 21 Speed sensor No normal signals are received from the speed sensor Open or short circuit in...

Page 454: ... in the charging system Refer to CHARGING SYSTEM on page 9 11 Malfunction in EPS control unit Fault code No Item Symptom Probable cause of mal function Fault code No 11 13 15 16 Symptom EPS torque sensor no normal signals are received from the EPS torque sensor Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections EPS torque sensor coupler Check the l...

Page 455: ...pen or short circuit Between speed sensor coupler and joint coupler white white Between joint coupler and EPS control unit coupler white white 3 Defective speed sensor Replace if defective Refer to CHECKING THE SPEED SENSOR on page 9 104 4 Malfunction in EPS control unit Replace the EPS control unit Fault code No 22 Symptom No normal signals are received from the ECU Order Item components and prob...

Page 456: ...red red black black 3 Defective EPS motor Replace if defective Refer to CHECKING THE EPS MO TOR for EPS models on page 9 109 4 Malfunction in EPS control unit Replace the EPS control unit Fault code No 52 Symptom Relay contacts in the EPS control unit are welded together Order Item components and probable cause Check or maintenance job Reinstatement method 1 Malfunction in EPS control unit Replace...

Page 457: ...t Turning the main switch to off Fault code No 55 Symptom Battery voltage has increased Abnormality exists between the EPS and the ECU Order Item components and probable cause Check or maintenance job Reinstatement method 1 Faulty battery Replace the battery Refer to CHECKING AND CHARGING THE BATTERY on page 9 95 Turning the main switch to off 2 Malfunction in rectifier regulator Replace if defect...

Page 458: ...ELECTRICAL COMPONENTS 9 83 EBS20084 ELECTRICAL COMPONENTS 5 6 7 11 13 14 15 21 1 2 19 18 17 16 20 10 9 8 3 4 12 ...

Page 459: ... Gear position switch 8 Reverse switch 9 Intake air pressure sensor 10 TPS throttle position sensor 11 Fuel injector 12 ISC Idle Speed Control unit 13 Air induction system solenoid 14 Ignition coil 15 Coolant temperature sensor 16 Crankshaft position sensor 17 Speed sensor 18 Fuel sender 19 Fuel pump 20 Intake air temperature sensor 21 Differential motor ...

Page 460: ...ELECTRICAL COMPONENTS 9 85 3 4 10 12 2 1 9 8 7 5 6 13 14 11 ...

Page 461: ...mbly 4 Main switch 5 On Command four wheel drive switch 6 Light switch 7 EPS torque sensor for EPS models 8 EPS motor for EPS models 9 EPS control unit for EPS models 10 Radiator fan motor circuit breaker 11 Horn except for CDN 12 ECU Engine Control Unit 13 Rectifier regulator 14 Battery ...

Page 462: ...ELECTRICAL COMPONENTS 9 87 6 1 4 5 3 2 11 8 19 18 17 16 15 14 10 9 7 8 13 12 12 ...

Page 463: ... 5 Differential motor relay 1 6 Differential motor relay 2 7 Fuel injection system fuse 8 Spare fuse 9 Starter relay 10 EPS fuse for EPS models 11 Main fuse 12 Fuse box 13 Radiator fan motor fuse 14 Headlight fuse 15 Signaling system fuse 16 Auxiliary DC jack fuse 17 Differential motor fuse 18 Ignition fuse 19 Backup fuse ...

Page 464: ...ELECTRICAL COMPONENTS 9 89 EBS30292 CHECKING THE SWITCHES 2 4 5 3 9 4WD 2WD DIFF LOCK L W B G R L W G R B W L W Gy 7 Br Y G W 6 8 B L R B R B Br R Br R L Y off on start B off Br Y L B L 1 OFF ON Br P ...

Page 465: ...COMPONENTS 9 90 1 Horn switch except for CDN 2 Main switch 3 On Command four wheel drive switch 4 Gear position switch 5 Reverse switch 6 Seat belt switch 7 Light switch 8 Parking brake switch 9 Brake light switch ...

Page 466: ...0 and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a gi...

Page 467: ...lb until it has cooled down NOTICE ECB01960 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of a headlight bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adverse ly affected If the headlight bulb gets so...

Page 468: ...flammable products and your hands away from the bulb until it has cooled down TIP Unhook the headlight bulb holder and then re move the defective bulb 5 Install Headlight bulb Secure the new headlight bulb with the head light bulb holder NOTICE ECB01350 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the...

Page 469: ...pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Turn the main switch to off b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electrical circuit is operational Direction a Headlight beam is raised Direction b Headlight beam is lowered 1 a 1 b a No Fuses Amperage rating Q ty 1 EPS for EPS models 40 0 A 1...

Page 470: ...ush 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 atten tion NOTICE ECB01990 This is a VRLA Valve Regulated Lead Acid battery Never remove the sealing caps be cause the balance between cells will not be maintained and battery performance will deteriorat...

Page 471: ...e removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during...

Page 472: ...battery unused for more than 30 minutes 6 Install Battery 7 Connect Battery leads to the battery terminals NOTICE ECB01330 First connect the positive battery lead 1 and then the negative battery lead 2 8 Check Battery terminals Dirt Clean with a wire brush Loose connection Connect properly 9 Install Hood Refer to GENERAL CHASSIS 6 on page 4 12 EBS30298 CHECKING THE RELAYS Check each switch for con...

Page 473: ... 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 R Y L Y Br B R B 2 4 3 1 R Br L Br R B 1 2 3 4 1 Positive tester probe 2 Negative tester probe 3 Negative tester probe Result Continuity between 1 and 2 No continuity between 1 and 3 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe Result...

Page 474: ... battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 R Br R R L Br R 1 2 4 3 1 Positive tester probe 2 Negative tester probe 3 Negative tester probe Result Continuity between 1 and 2 No continuity between 1 and 3 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe Result No co...

Page 475: ...l terminals b Connect the pocket tester Ω 1 to the igni tion coil as shown 1 Positive tester probe 2 Negative tester probe 3 Negative tester probe Result Continuity between 1 and 2 No continuity between 1 and 3 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe Result No continuity between 3 and 4 Continuity between 3 and...

Page 476: ...gnition checker 1 as shown c Measure the ignition spark gap a d Crank the engine by turning the main switch to start and gradually increase the spark gap until a misfire occurs EBS30302 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace the crank shaft position sens...

Page 477: ... Refer to TROUBLESHOOTING on page 9 8 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWB02920 A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity b Check the starter mot...

Page 478: ...NG THE FUEL SENDER 1 Disconnect Fuel pump coupler from the wire harness 2 Remove Fuel pump assembly from the fuel tank 3 Check Fuel sender resistance Out of specification Replace the fuel pump assembly a Connect the pocket tester Ω 10 or Ω 100 to the fuel sender terminals as shown Stator coil resistance 0 15 0 22 Ω Digital circuit tester 90890 03174 Model 88 Multimeter with ta chometer YU A1927 Po...

Page 479: ...ion detected in fuel sender Replace the fuel pump assembly EBS30309 CHECKING THE SPEED SENSOR 1 Check Speed sensor output voltage Out of specification Replace a Connect the test harness speed sensor 3P 1 between the speed sensor coupler and wire harness as shown b Connect the pocket tester DC 20 V to the test harness speed sensor 3P Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positiv...

Page 480: ...ough movement Replace a Disconnect the radiator fan motor coupler from the wire harness b Connect the battery to the radiator fan motor coupler as shown c Check the radiator fan motor movement EBS30311 CHECKING THE RADIATOR FAN MOTOR CIRCUIT BREAKER 1 Remove Radiator fan motor circuit breaker from the wire harness 2 Check Radiator fan motor circuit breaker resistance Out of specification Replace t...

Page 481: ...down to the specified temperatures e Measure the coolant temperature sensor re sistance 3 Install Coolant temperature sensor EBS30313 CHECKING THE THROTTLE POSITION SENSOR 1 Remove Throttle position sensor from the throttle body WARNING EWB03070 Handle the throttle position sensor with special care Never subject the throttle position sensor to strong shocks If the throttle position sensor is dropp...

Page 482: ... pressure sensor 5S7 3P c Turn the main switch to on d Measure the intake air pressure sensor out put voltage EBS30315 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 1 Remove Intake air temperature sensor from the air filter case WARNING EWB02940 Handle the intake air temperature sensor with special care Never subject the intake air temperature sensor to strong shocks If the intake air temperature sen...

Page 483: ...hown c Measure the fuel injector resistance EBS30317 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 1 Check Air induction system solenoid resistance Out of specification Replace a Disconnect the air induction system solenoid coupler from the wire harness b Connect the pocket tester Ω 1 to the air in duction system solenoid terminals as shown c Measure the air induction system solenoid re sistance Pock...

Page 484: ...BS30319 CHECKING THE EPS MOTOR for EPS models 1 Remove EPS unit 2 Check EPS motor Out of specification Replace the EPS unit TIP The pocket tester and the analog pocket tester readings are shown in the following table a Connect the pocket tester Ω 1 to the EPS motor coupler terminal and EPS motor body b Check the EPS motor for continuity c Check the EPS motor for no continuity Pocket tester 90890 0...

Page 485: ...ck EPS torque sensor resistance Out of specification Replace the steering column a Connect the pocket tester Ω 1k to the EPS torque sensor coupler terminals as shown b Measure the EPS torque sensor resistance EPS torque sensor Coil resistance 0 875 1 625 kΩ for EPS mod els Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe red 1 Negative tester probe black 2 G R B W 1 ...

Page 486: ...ELECTRICAL COMPONENTS 9 111 ...

Page 487: ...10 4 JUMPS OUT OF GEAR 10 4 FAULTY CLUTCH PERFORMANCE 10 4 OVERHEATING 10 4 OVERCOOLING 10 5 POOR BRAKING PERFORMANCE 10 5 FAULTY SHOCK ABSORBER ASSEMBLY 10 5 UNSTABLE HANDLING 10 5 FAULTY LIGHTING OR SIGNALING SYSTEM 10 5 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 10 7 SELF DIAGNOSTIC FUNCTION TABLE 10 7 COMMUNICATION ERROR WITH THE METER 10 7 DIAGNOSTIC CODE SENSOR OPERATION TABLE 10 8 D...

Page 488: ... contaminated fuel 2 Fuel pump Faulty fuel pump Faulty fuel injection system relay Clogged or damaged fuel hose 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or...

Page 489: ...lator Faulty spark plug cap 3 Ignition coil Broken or shorted primary or secondary coils Faulty spark plug lead Cracked or broken ignition coil 4 Ignition system Faulty ECU Faulty crankshaft position sensor Broken AC magneto rotor woodruff key EBS30324 POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to STARTING FAILURES on page 10 1 Engine 1 Air filter Clogged air filter element Fuel system 1 Fuel pu...

Page 490: ...1 A pronounced hesitation or jerky movement during acceleration deceleration or sustained speed This must not be confused with engine surging or transmission characteristics 2 A rolling rumble noticeable at low speed a high pitched whine a clunk from a shaft drive com ponent or area 3 A locked up condition of the shaft drive mecha nism no power transmitted from the engine to the front and or rear ...

Page 491: ...utch shoe s Damaged or worn clutch shoe 3 Primary sliding sheave Seized primary sliding sheave Poor starting performance 1 V belt V belt slips Oil or grease on the V belt 2 Primary and secondary sheaves Faulty operation Worn pin groove Worn pin 3 Clutch shoe Bent damaged or worn clutch shoe Poor speed performance 1 V belt Oil or grease on the V belt 2 Primary pulley weight s Faulty operation Worn ...

Page 492: ...on Fatigued or damaged shock absorber spring Bent or damaged damper rod EBS30334 UNSTABLE HANDLING 1 Steering wheel Bent or improperly installed steering wheel 2 Steering components Incorrect toe in Bent steering shaft Improperly installed steering shaft Damaged bearing or bearing race Bent tie rods Deformed steering knuckles 3 Shock absorber assembly ies Faulty shock absorber spring Leaking gas 4...

Page 493: ...LESHOOTING 10 6 Tail brake light bulb burnt out Wrong tail brake light bulb Faulty battery Faulty brake light switch Tail brake light bulb life expired Faulty rectifier regulator Improperly grounded circuit ...

Page 494: ...ther than ISC Idle Speed Control unit is defective ISC operating sound is heard Defective ISC Idle Speed Control unit ISC operating sound is not heard 39 Fuel injector open or short circuit detected 41 Lean angle sensor open or short circuit detected 42 Speed sensor no normal signals are received from the speed sensor 43 Fuel system voltage incorrect voltage supplied to the fuel injector and fuel ...

Page 495: ...d value 06 Coolant temperature When engine is cold Dis plays temperature closer to ambient temperature When engine is hot Displays current coolant temperature Compare the actually mea sured coolant temperature with the indicated value 07 Vehicle speed pulse 0 999 Check that the number in creases when the rear wheels are rotated The number is cumulative and does not reset each time the wheel is sto...

Page 496: ...ion Procedure 30 Ignition coil Actuates the ignition coil five times at one second inter vals The CHECK indicator and on the Yamaha diag nostic tool screen come on each time the ignition coil is actuated Check that a spark is gener ated five times Connect an ignition check er 36 Fuel injector Actuates the fuel injector five times at one second inter vals The CHECK indicator and on the Yamaha diag ...

Page 497: ...tuates the radiator fan mo tor relay five times at five second intervals 2 seconds on 3 seconds off The CHECK indicator and on the Yamaha diag nostic tool screen come on each time the relay is actuat ed When the relay is on the CHECK indicator and on the Yamaha diagnostic tool screen go off When the relay is off the CHECK in dicator and on the Yamaha diagnostic tool screen come on Check that the r...

Page 498: ...gnition fuse 61 Backup fuse 62 Signaling system fuse 63 Headlight fuse 64 Auxiliary DC jack fuse 65 Radiator fan motor 66 Radiator fan motor circuit breaker 67 Radiator fan motor relay 68 Horn switch 69 Horn 70 Backup light 71 Backup light relay A Optional B Wire harness C Negative battery sub wire har ness YX70EPNG YXE70WPXG YXE70WPHG YXE700E 2016 1 Crankshaft position sensor 2 AC magneto 3 Recti...

Page 499: ...attery sub wire har ness D EPS control unit EBS30002 COLOR CODE B Black Br Brown G Green Gy Gray L Blue Lg Light green O Orange P Pink R Red Sb Sky blue W White Y Yellow B G Black Green B L Black Blue B R Black Red B W Black White B Y Black Yellow Br B Brown Black Br L Brown Blue Br R Brown Red Br W Brown White Br Y Brown Yellow G R Green Red G W Green White G Y Green Yellow Gy G Gray Green L B Bl...

Page 500: ... W W R L B Br Y Br Y Br R Br R Br R Br L Br Y G W L B Br Y W B Br Y L Y R Y Br B L Y Br R R B Br R Br B Br R L R R L R L R R R R R R B B B B B B B B R W B R B B B B B B B B B B B B B B B Br R Br Y Br W B G Y B Br L L L Y Y Y Y Y B B B B B B B B B B B B B Y L Y Y L L B G Y B B Y B Br R Br R P W B G O L B Y Br B B R Gy G Sb L Gy W W R L W B W B G R Y L G R B R B G G R Y B Y R R Y R L Br L P L R G R ...

Page 501: ... B B Gy B B B B B B Gy Gy W B B B Gy Gy Gy DIFF LOCK 4WD 2WD off off on start A B C A OFF ON 1 2 3 4 5 6 71 70 67 20 19 22 23 24 25 26 27 28 29 30 33 34 56 54 54 51 50 49 41 42 43 44 45 46 48 37 38 35 34 21 14 9 8 12 10 11 13 15 16 17 18 36 53 55 52 57 57 58 59 60 61 62 63 64 65 66 40 39 31 A 7 47 32 68 69 ...

Page 502: ... B C A B C D B OFF ON Gy B L W W W W W W R L B Br Y Br Y Br R Br R Br R Br L Br Y G W L B Br Y W B Br Y R B L Y R Y Br B L Y Br R R B Br R Br B Br R L R R L R L R R R R R R R R B B B B B B B B R R W B R B B B B B B B B B B B B B B B Br R Br Y Br W B G Y B Br L L L Y Y Y Y Y B B B B B B B B B B B B B Y L Y Y L L B G Y B B Y B Br R Br R P W B G O L B Y Br B B R Gy G Sb L Gy W W R L W B W B G R Y L G...

Page 503: ...B B Gy B B B Gy B B B B B B B B Gy Gy Gy W Gy Gy B B B Gy Gy Gy Gy DIFF LOCK 4WD 2WD off off on start A B C A B C D B OFF ON 1 2 3 4 5 6 78 77 74 21 20 23 24 25 26 27 28 29 30 31 34 35 37 38 63 61 61 58 57 56 47 48 49 50 51 52 54 55 43 44 41 35 22 15 9 10 8 13 11 12 14 16 17 18 19 40 39 42 60 62 59 64 64 65 66 67 68 69 70 71 72 73 46 45 32 A 7 53 36 33 75 76 ...

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