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Yamaha YXR70FX, Service Manual

The Yamaha YXR70FX Owner's Manual is a comprehensive guide that provides essential information and instructions for operating and maintaining your vehicle. Easily accessible for free download on our website, this manual ensures you have all the necessary details to optimize your Yamaha YXR70FX experience.

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SPEC

ELECTRICAL SPECIFICATIONS

Starter relay

Model/manufacturer

RC19-080A/MITSUBA

----

Amperage rating 

180.0 A

----

Coil winding resistance

4.18 ~ 4.62 

Ω

 at 20 °C (68 °F)

----

Fuel sender

Sender unit resistance (full)

19.00 ~ 21.00 

Ω

----

Sender unit resistance (empty)

137.00 ~ 143.00 

Ω

----

Fuel injection system relay

Model/manufacturer

ACM33211/MATSUSHITA

----

Coil resistance

96.0 

Ω

----

Radiator fan motor relay

Model/manufacturer

ACM33211/MATSUSHITA

----

Coil resistance

96.0 

Ω

----

Load control relay

Model/manufacturer

ACM33211/MATSUSHITA

----

Coil resistance

96.0 

Ω

----

Four-wheel-drive motor relay 3

Model/manufacturer

ACM33211/MATSUSHITA

----

Coil resistance

96.0 

Ω

----

Headlight relay

Model/manufacturer

G8HN-1C4T-DJ/OMRON

----

Coil resistance

105.0 

Ω

----

Four-wheel-drive motor relay 1

Model/manufacturer

G8HN-1C4T-DJ/OMRON

----

Coil resistance

105.0 

Ω

----

Four-wheel-drive motor relay 2

Model/manufacturer

G8HN-1C4T-DJ/OMRON

----

Coil resistance

105.0 

Ω

----

Circuit breaker

Circuit breaker type

Fuse 

----

Fuses

Main fuse 

40.0 A

----

Headlight fuse

15.0 A

----

Signaling system fuse

10.0 A

----

Ignition fuse

10.0 A

----

Auxiliary DC jack fuse

10.0 A

----

Fuel injection system fuse

10.0 A

----

Four-wheel-drive motor fuse

10.0 A

----

Backup fuse

10.0 A

----

Radiator fan motor fuse

25.0 A

----

Spare fuse

25.0 A
15.0 A
10.0 A

----
----
----

Item

Standard

Limit

Summary of Contents for YXR70FX

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

Page 2: ...Yamaha Motor Corporation U S A First edition September 2007 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly proh...

Page 3: ...t satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all its models Modifications and sig nificant cha...

Page 4: ...clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 a...

Page 5: ...ce G Engine speed H Electrical data V A Symbols I to P in the exploded diagrams indicate the types of lubricants and lubrication points I Apply engine oil J Apply gear oil K Apply molybdenum disulfide...

Page 6: ......

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

Page 8: ...SEMBLY 1 7 REPLACEMENT PARTS 1 7 GASKETS OIL SEALS AND O RINGS 1 7 LOCK WASHERS PLATES AND COTTER PINS 1 8 BEARINGS AND OIL SEALS 1 8 CIRCLIPS 1 8 CHECKING THE CONNECTIONS 1 9 SPECIAL TOOLS 1 10 CHAPT...

Page 9: ...ADJUSTING THE THROTTLE CABLE 3 6 CHECKING THE SPARK PLUG 3 7 CHECKING THE IGNITION TIMING 3 9 MEASURING THE COMPRESSION PRESSURE 3 10 CHECKING THE ENGINE OIL LEVEL 3 13 CHANGING THE ENGINE OIL 3 14 C...

Page 10: ...L 3 41 CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS 3 43 CHECKING THE STEERING SYSTEM 3 43 ADJUSTING THE TOE IN 3 44 ADJUSTING THE FRONT SHOCK ABSORBERS 3 45 ADJUSTING THE REAR SHOCK ABSORBERS 3 48...

Page 11: ...ING THE VALVES AND VALVE SPRINGS 4 29 INSTALLING THE VALVES AND VALVE SPRINGS 4 33 CYLINDER AND PISTON 4 36 REMOVING THE PISTON 4 37 CHECKING THE CYLINDER AND PISTON 4 37 CHECKING THE PISTON RINGS 4 3...

Page 12: ...E BEARINGS 4 73 SEPARATING THE CRANKCASE 4 74 CHECKING THE TIMING CHAIN AND GUIDE 4 74 CHECKING THE RELIEF VALVE 4 74 CHECKING THE BEARINGS 4 75 CHECKING THE CRANKCASE 4 75 ASSEMBLING THE CRANKCASE 4...

Page 13: ...AND COOLANT RESERVOIR 5 1 CHECKING THE RADIATOR 5 3 INSTALLING THE RADIATOR 5 4 THERMOSTAT 5 5 CHECKING THE THERMOSTAT 5 6 INSTALLING THE THERMOSTAT 5 6 WATER PUMP 5 7 DISASSEMBLING THE WATER PUMP 5...

Page 14: ...CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 6 44 CHAPTER 7 DRIVE TRAIN TROUBLESHOOTING 7 1 CHECKING NOISES 7 1 TROUBLESHOOTING CHART 7 3 FRONT CONSTANT VELOCITY JOINTS DIFFERENTIAL GEAR AND DR...

Page 15: ...SH 7 38 ASSEMBLING THE FINAL GEAR CASE 7 40 CHAPTER 8 CHASSIS SEATS ENCLOSURE HOOD AND CARGO BED 8 1 FRONT GUARD AND HOOD 8 1 SEATS REAR CONSOLE AND INSTRUMENT PANELS 8 2 REMOVING THE STEERING WHEEL 8...

Page 16: ...ARKING BRAKE DISC 8 44 ASSEMBLING THE PARKING BRAKE 8 44 PEDAL ASSEMBLY 8 47 STEERING SYSTEM 8 49 STEERING SHAFT AND STEERING ASSEMBLY 8 49 DISASSEMBLING THE STEERING ASSEMBLY 8 52 CHECKING THE STEERI...

Page 17: ...8 72 INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER 8 73 CHAPTER 9 ELECTRICAL ELECTRICAL COMPONENTS 9 1 CHECKING SWITCH CONTINUITY 9 3 CHECKING THE SWITCHES 9 4 CHECKING THE BULBS AND BULB SOCKETS 9...

Page 18: ...0 TROUBLESHOOTING 9 51 2WD 4WD SELECTING SYSTEM 9 53 CIRCUIT DIAGRAM 9 53 TROUBLESHOOTING 9 54 CHAPTER 10 TROUBLESHOOTING STARTING FAILURE HARD STARTING 10 1 FUEL SYSTEM 10 1 ELECTRICAL SYSTEM 10 1 CO...

Page 19: ...ANCE 10 4 POOR SPEED PERFORMANCE 10 5 OVERHEATING 10 5 OVERHEATING 10 5 OVERCOOLING 10 5 COOLING SYSTEM 10 5 FAULTY BRAKE 10 5 POOR BRAKING EFFECT 10 5 SHOCK ABSORBER MALFUNCTION 10 6 MALFUNCTION 10 6...

Page 20: ...ON NUMBER The vehicle identification number 1 is stamped into the frame EBS00011 MODEL LABEL The model label 1 is affixed to the frame under the driver seat Record the information on this label in the...

Page 21: ...As the requirements for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned man ner To acco...

Page 22: ...injection timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake air tem perature sensor coolant temper...

Page 23: ...which shows the battery voltage a fuel meter a self diagnosis device 1 2 3 4 5 6 7 8 Odometer and tripmeter modes 1 Odometer Tripmeter A Tripmeter B 2 TRIP ODO button Pushing the TRIP ODO button swit...

Page 24: ...by pushing the M but ton 5 Push the button and then release it to start the clock Voltage display mode This display shows the battery voltage btry appears for 1 second when the voltage display mode is...

Page 25: ...he display segments and fuel level warning indicator will start flashing If this occurs check the electrical circuit 1 2 3 Self diagnosis device 1 Error code display This model is equipped with a self...

Page 26: ...ll of the parts and place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EBS00...

Page 27: ...sible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appro priate 1 Oil seal NOTICE _ Do not spin the be...

Page 28: ...al times 3 Check all connections Loose connection Connect properly TIP _ If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector TIP _ Make sure all connections are tight...

Page 29: ...YK ACC Except for US and CDN P N 90890 Tool No Tool name How to use Illustration 90890 01083 YU 01083 1 Slide hammer bolt Slide hammer bolt 6 mm This tool is used to remove the rocker arm shaft 90890...

Page 30: ...rankshaft installer bolt Bolt This tool is used to install the crankshaft 90890 01304 YU 01304 Piston pin puller set Piston pin puller This tool is used to remove the piston pin 90890 01309 YU 90059 S...

Page 31: ...tester adapter Radiator pressure tester adapter This tool is used to check the cooling sys tem 90890 01362 YU 33270 B Flywheel puller Heavy duty puller This tool is used to remove the AC mag neto roto...

Page 32: ...ball joints 90890 01526 YM 01526 Boot band installing tool This tool is used to remove or install the boot band 90890 01527 YM 01527 Ring gear fix bolt M10 This tool is used to hold the ring gear 908...

Page 33: ...sure 90890 03180 YU 26900 9 Thickness gauge Feeler gauge set This tool is used to measure the valve clearance 90890 04019 YM 04019 Valve spring compressor This tool is used to remove or install the v...

Page 34: ...is tool is used to install the crankshaft 90890 04082 Extension This tool is used to measure engine com pression 90890 04086 YM 91042 Universal clutch holder This tool is needed to hold the clutch car...

Page 35: ...4135 Sheave fixed block Sheave fixed bracket This tool is needed when removing or installing the secondary sheave spring 90890 06754 YM 34487 Ignition checker Opama pet 4000 spark checker This instrum...

Page 36: ...mm 75 2 in Minimum ground clearance 280 mm 11 0 in Minimum turning radius 3 900 mm 154 in Basic weight With oil and fuel 540 0 kg 1 190 lb 1 2 548 0 kg 1 208 lb 3 4 Engine Engine type Liquid cooled 4...

Page 37: ...6 45 Imp gal 7 74 US gal Fuel injector Type quantity E252019 1 Manufacturer NIPPON INJECTOR Spark plug Type manufacturer CPR7EA 9 NGK Spark plug gap 0 8 0 9 mm 0 031 0 035 in Clutch type Wet centrifug...

Page 38: ...ot operation Rear brake type Dual disc brake operation Foot operation Parking brake type Single disc brake operation Right hand operation Suspension Front suspension Double wishbone Rear suspension Do...

Page 39: ...ight Neutral indicator light LED Reverse indicator light LED Coolant temperature warning light LED Engine trouble warning light LED Park indicator light LED On command four wheel drive differential ge...

Page 40: ...n Maximum taper 0 05 mm 0 002 in Out of round 0 05 mm 0 002 in Camshaft Drive system Chain drive Camshaft lobe dimensions Intake measurement A 42 481 42 581 mm 1 6725 1 6764 in 42 381 mm 1 6685 in B 3...

Page 41: ...10 mm 1 4921 1 5000 in Exhaust 31 90 32 10 mm 1 2559 1 2638 in Valve face width B Intake 2 26 mm 0 0890 in Exhaust 2 26 mm 0 0890 in Valve seat width C Intake 1 00 1 20 mm 0 0394 0 0472 in 1 60 mm 0...

Page 42: ...ake 40 38 mm 1 59 in 38 36 mm 1 51 in Exhaust 40 38 mm 1 59 in 38 36 mm 1 51 in Installed length valve closed Intake 35 00 mm 1 38 in Exhaust 35 00 mm 1 38 in Compressed spring force installed Intake...

Page 43: ...0 9052 0 9055 in 22 971 mm 0 9044 in Piston pin to piston pin bore clear ance 0 004 0 024 mm 0 0002 0 0009 in 0 074 mm 0 0029 in Piston rings Top ring Ring type Barrel Dimensions B T 1 20 3 80 mm 0 0...

Page 44: ...ll end free play F 0 16 0 40 mm 0 0063 0 0157 in Balancer Balancer drive method Gear Automatic centrifugal clutch Clutch shoe thickness 1 5 mm 0 06 in 1 0 mm 0 04 in Clutch in revolution 1 850 2 250 r...

Page 45: ...0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 0067 in Oil pressure hot 50 0 kPa at 1 600 r min 0 50 kg cm2 at 1 600 r min 7 1 psi at 1 600 r min Pressure check location Cylinder head Cooling system Radiator...

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

Page 47: ...mm 10 26 in 3 4 Spring rate K1 19 40 N mm 1 98 kgf mm 110 77 lb in Spring stroke K1 0 0 108 0 mm 0 00 4 25 in 1 2 0 0 110 0 mm 0 00 4 33 in 3 4 Optional spring available No Rear suspension Rear shock...

Page 48: ...n Pad thickness inner 5 2 mm 0 20 in 1 5 mm 0 06 in Pad thickness outer 5 2 mm 0 20 in 1 5 mm 0 06 in Master cylinder inside diameter 17 46 mm 0 69 in Caliper cylinder inside diameter 27 00 mm 1 06 in...

Page 49: ...um deflection 0 1 mm 0 004 in Brake pad lining thickness inner 3 2 mm 0 13 in 1 0 mm 0 04 in Brake pad lining thickness outer 3 2 mm 0 13 in 1 0 mm 0 04 in Brake lever and brake pedal Accelerator peda...

Page 50: ...plug cap Material Resin Resistance 10 0 k AC magneto Model manufacturer F004T39372 MITSUBISHI Standard output 14 0 V 33 5 A at 5 000 r min Stator coil resistance color 0 099 0 121 at 20 C 68 F white...

Page 51: ...nce 96 0 Four wheel drive motor relay 3 Model manufacturer ACM33211 MATSUSHITA Coil resistance 96 0 Headlight relay Model manufacturer G8HN 1C4T DJ OMRON Coil resistance 105 0 Four wheel drive motor r...

Page 52: ...0 7 2 LT Timing chain tensioner cap Bolt M16 1 20 2 0 14 Timing chain tensioner Bolt M6 2 10 1 0 7 2 Bearing retainer camshaft Bolt M6 2 10 1 0 7 2 LT Camshaft sprocket cover Bolt M6 2 10 1 0 7 2 Tapp...

Page 53: ...1 0 7 2 Water jacket joint Bolt M6 2 10 1 0 7 2 Crankshaft end accessing screw Bolt M36 1 10 1 0 7 2 Timing mark accessing screw Bolt M14 1 6 0 6 4 3 Drive belt cover Bolt M6 12 10 1 0 7 2 Drive belt...

Page 54: ...9 0 65 Secondary sheave assembly Nut M16 1 100 10 0 72 Shift lever cover Bolt M6 4 10 1 0 7 2 Shift lever 2 assembly Bolt M6 1 14 1 4 10 Shift drum stopper Bolt M14 1 18 1 8 13 Crankcase plug bolt Bol...

Page 55: ...per plate and frame M8 16 1 6 11 Side door bracket and side door M6 7 0 7 5 1 Frame and hinge M8 23 2 3 17 LT Frame and latch M6 8 0 8 5 8 LT Handle latch and side door M5 5 0 5 3 6 Fuel tank and fuel...

Page 56: ...32 Steering knuckle and tie rod M12 39 3 9 28 Steering knuckle and front upper arm M12 30 3 0 22 Steering knuckle and front lower arm M12 30 3 0 22 Steering knuckle and brake disc guard M6 7 0 7 5 1 F...

Page 57: ...7 19 Parking brake lever assembly and parking brake lever assembly bracket M6 13 1 3 9 4 Parking brake lever assembly bracket and frame M10 32 3 2 23 Parking brake cable holder and frame M6 7 0 7 5 1...

Page 58: ...M8 23 2 3 17 Ring gear stopper nut M8 16 1 6 11 Bearing retainer and final gear pinion gear bear ing housing M65 170 17 0 125 Left hand thread LT Drive shaft coupling gear and final drive pinion gear...

Page 59: ...less otherwise specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter Ex METRIC MULTIPLIER IM...

Page 60: ...intake and exhaust M Rocker arm shafts E Camshaft lobes M Decompressor lever pin E Decompressor lever spring E Rocker arms intake and exhaust M Oil pump shaft E O ring oil filter cartridge LS Water p...

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

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

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

Page 64: ...BS00026 OIL FLOW DIAGRAMS 1 Oil delivery pipe 2 2 Oil delivery pipe 3 3 Oil delivery pipe 1 4 Oil filter cartridge 5 Oil strainer 6 Reverse idle gear shaft 7 Drive axle 8 Relief valve assembly 6 7 8 4...

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

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

Page 67: ...6 Thermostat outlet hose 7 Radiator inlet pipe 8 Brake pipe 9 Radiator inlet hose 0 Front brake hose A Radiator fan motor breather hose B Differential gear case breather hose C Coolant reservoir breat...

Page 68: ...Pull the excess of the hoses through the guide in the upper instrument panel so that there is no slack in the hoses Fasten the radiator inlet hose and throttle cable with the plastic band 10 20 mm 0...

Page 69: ...t lead 7 Parking brake cable 8 Thermostat outlet hose 9 Coolant temperature sensor lead 0 Reverse switch lead A Gear position switch lead B Brake pipe Fasten the wire harness to the frame with the pla...

Page 70: ...fender so that there is no slack in the lead Fasten the unused coupler to the wire harness with tape Fasten the tail brake light lead with the plastic holder Fasten the tail brake light lead with the...

Page 71: ...ifferential gear case breather hose 9 Front brake hose 0 Differential gear motor lead A Radiator outlet hose B Water pump inlet hose C Oil inlet hose D Oil outlet hose E Ground lead F Starter motor le...

Page 72: ...asten the wire harness with the plastic band Fasten the left headlight lead right headlight lead and radiator fan motor lead to the frame with a plastic band 30 60 mm 1 18 2 36 in 220 250 mm 8 66 9 84...

Page 73: ...en the radiator inlet pipe with the plastic band Fasten the brake pipe with the plastic band Fasten the radiator outlet pipe with the plastic band Fasten the AC magneto crankshaft position sen sor lea...

Page 74: ...motor lead 7 Ground lead 8 Water pump inlet hose 9 Oil delivery pipe 2 0 Oil delivery pipe 3 A Water pump outlet pipe B Water pump outlet hose C Brake pipe D Rear brake hose E Wire harness F Fuel tan...

Page 75: ...e mark with the holder Fasten the brake pipe with the plastic band 55 65 mm 2 17 2 56 in Fasten the final gear case breather hose with the plastic holder Fasten the fuel tank breather hose with the pl...

Page 76: ...or less Fasten the brake pipe with the plastic holder Fasten the fuel pump fuel sender lead with the plastic holder E F F G H H 8 9 0 A B C 2 C C C D 1 1 1 1 1 1 2 2 2 3 4 5 6 6 7 7 F F H H I I A A B...

Page 77: ...Oil inlet hose A AC magneto crankshaft position sensor lead B Throttle body breather hose C Oil delivery pipe 2 D Oil delivery pipe 3 E Fuel hose F Throttle position sensor lead G Fuel injector lead H...

Page 78: ...with the plastic band making sure to align the red tape on the leads and harness with the band Fasten the throttle body breather hose and wire harness with the plastic band Fasten the starter motor le...

Page 79: ...ad with the plastic band Fasten the throttle cable at the white mark with the plastic band Fasten the brake pipe with the plastic band Fasten the wire harness and AC magneto crank shaft position senso...

Page 80: ...ferential gear lock switch lead 9 Main switch lead 0 Light switch lead A Coolant reservoir breather hose B Rectifier regulator lead C Brake light switch lead D Throttle cable E Differential gear case...

Page 81: ...ith the plastic holder Fasten the differential gear case breather hose and coolant reservoir breather hose with the plastic holder Fasten the light switch lead with the plastic band Fasten the main sw...

Page 82: ...the radiator fan motor breather hose dif ferential gear case breather hose brake light switch lead and coolant reservoir breather hose through the hose guide Fasten the throttle cable with the plasti...

Page 83: ...diator fan motor lead and coolant reservoir breather hose with the plastic band Fasten the positive battery lead with the plastic holder 4 mm 0 16 in of clearance or more is required around the boot 5...

Page 84: ...switch lead 8 Ground lead 9 Rectifier regulator lead 0 Wire harness A Radiator fan motor lead B Brake pipe C Front brake hose D Oil cooler inlet pipe 2 oil cooler outlet pipe 2 E Starter relay lead F...

Page 85: ...an hour meter follow the km mi or hours mainte nance intervals However keep in mind that if the vehicle isn t used for a long period of time the month maintenance intervals should be followed Items m...

Page 86: ...ke Check operation brake pad wear fluid leakage Correct if necessary Replace pads if worn to the limit Rear brake Check operation brake pad wear fluid leakage Correct if necessary Replace pads if worn...

Page 87: ...ure When the valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compression stroke 1 Remove seats rear console Refer to SEATS REAR CONSOLE AND INSTRUMENT PA...

Page 88: ...t the top dead center TDC on the compression stroke align the I mark a on the camshaft sprocket with the stationary pointer b on the cylinder head Valve clearance cold Intake valve 0 09 0 13 mm 0 0035...

Page 89: ...vent it from moving and tighten the locknut to the speci fied torque e Measure the valve clearance again f If the valve clearance is still out of specifica tion repeat all of the valve clearance adjus...

Page 90: ...ND FRONT CON SOLE in chapter 8 rear console seats Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 New T R 10 Nm 1 0 m kg 7 2 ft lb 1 New New T R 10 Nm 1 0 m kg 7 2 ft lb New T R 10 Nm 1...

Page 91: ...t the throttle valve 3 closes completely after releasing the accelerator pedal Direction a Free play is increased Direction b Free play is decreased a b 2 1 3 5 Install throttle valve cover 6 Install...

Page 92: ...leaner or wire brush 7 Measure spark plug gap a Use a wire gauge or thickness gauge Out of specification Regap 8 Tighten spark plug TIP _ Before installing a spark plug clean the gasket surface and pl...

Page 93: ...REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 fuel tank Refer to FUEL PUMP AND FUEL TANK in chapter 6 2 Attach tachometer timing light to spark plug lead Digital tachometer 90890 06760 YU 39951 B Ti...

Page 94: ...w 4 Detach timing light tachometer 5 Install fuel tank Refer to FUEL PUMP AND FUEL TANK in chapter 6 rear console seats Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 T R Timing mark a...

Page 95: ...ent it from falling into the cylinder 6 Attach extension 1 compression gauge 2 7 Measure compression pressure Out of specification Refer to steps c and d a Set the main switch to ON Compression gauge...

Page 96: ...bon deposits Eliminate d If the compression pressure is below the minimum specification squirt a few drops of oil into the cylinder and measure again Refer to the following table 8 Install spark plug...

Page 97: ...level TIP To obtain an accurate oil level reading the dip stick must be inserted completely into the oil filter hole NOTICE Engine oil also lubricates the clutch and the wrong oil types or additives c...

Page 98: ...er to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 EBS00069 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several min utes and then turn it off 2 Place a container under the engine oil...

Page 99: ...ifi cation with an oil filter wrench e Lower the cargo bed 8 Check engine oil drain bolt gasket Damage Replace 9 Install engine oil drain bolt along with the gasket 10 Fill crankcase with the specifie...

Page 100: ...the engine off so that it will not seize c Check the engine oil passages the oil filter cartridge and the oil pump for damage or leakage Refer to CRANKSHAFT AND OIL PUMP in chapter 4 d Start the engi...

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

Page 102: ...twist or wring out the element This could damage the foam material c Apply Yamaha foam air filter oil or other quality foam air filter oil to the element d Squeeze out the excess oil TIP _ The element...

Page 103: ...6 3 Install rear console seats Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 1 EAS00096 CHECKING THE FUEL HOSE 1 Remove seats rear console Refer to SEATS REAR CONSOLE AND INSTRUMENT P...

Page 104: ...d on a cold engine since the level varies with engine tem perature 2 Check coolant level The coolant level should be between the minimum level mark a and maximum level mark b in the coolant reservoir...

Page 105: ...ir hose 2 1 6 Remove radiator cap 1 WARNING _ A hot radiator is under pressure Therefore do not remove the radiator cap when the engine is hot Scalding hot fluid and steam may be blown out which could...

Page 106: ...R 10 Nm 1 0 m kg 7 2 ft lb 11 Fill cooling system with the specified amount of the recom mended coolant Recommended antifreeze High quality ethylene glycol antifreeze containing corrosion inhibitors...

Page 107: ...wers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis tilled...

Page 108: ...es and then rev the engine five times 16 Pour the recommended coolant into the radiator until it is full 17 Stop the engine and allow it to cool If the coolant level has dropped after the engine has c...

Page 109: ...tor inlet pipe 6 radiator outlet pipe 7 thermostat outlet hose 8 water pump inlet hose 9 water jacket 0 water pump outlet hose A water pump outlet pipe B water pump housing C Cracks damage Replace Ref...

Page 110: ...checking method Turn the main switch ON Coolant temperature warning light does not come on Coolant temperature warning light comes on Turn the main switch to START with the transmission in neutral po...

Page 111: ...heave and secondary sheave 3 Measure V belt width 2 Out of specification Replace V belt width 33 3 mm 1 31 in Limit 30 0 mm 1 18 in 4 Replace V belt a Install the bolts 1 90101 06018 into the secondar...

Page 112: ...SYSTEM The following procedure applies to all of the exhaust pipe gaskets 1 Check exhaust pipe 2 1 exhaust pipe 1 2 muffler 3 muffler brackets 4 springs 5 Cracks damage Replace gaskets 6 Exhaust gas...

Page 113: ...ffler and the gasket c Tap the tailpipe lightly with a soft face ham mer or suitable tool then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and inside...

Page 114: ...rake master cylinder 2 Brake pedal free play 0 mm 0 0 in 2 Adjust brake pedal free play a Loosen the locknut 1 b Turn brake rod 2 in or out until the correct free play is obtained c Tighten the locknu...

Page 115: ...g brake lever free play a The maximum free play is equal to one click of the parking brake lever Incorrect Adjust a 4 Adjust parking brake mechanical a Move the parking brake lever to the released pos...

Page 116: ...btained d Tighten the locknut 2 e Slide the adjuster cover 1 to its original position Direction a Free play is increased Direction b Free play is decreased a b 2 1 3 6 Install rear console seats Refer...

Page 117: ...result in a harmful chemical reaction and lead to poor perfor mance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the flui...

Page 118: ...eplace the brake pads as a set Refer to FRONT AND REAR BRAKES in chapter 8 3 Operate the brake pedal 4 Install rear wheels Refer to FRONT AND REAR WHEELS in chapter 8 Brake pad wear limit a 1 5 mm 0 0...

Page 119: ...brake hoses 1 front brake pipe 2 rear brake pipes 3 rear brake hoses 4 Cracks wear damage Replace Fluid leakage Replace all damaged parts Refer to FRONT AND REAR BRAKES in chapter 8 TIP Hold the vehi...

Page 120: ...c Connect a clear plastic hose 1 tightly to the caliper bleed screw 2 Front Rear d Place the other end of the hose into a con tainer e Slowly apply the brake pedal several times f Push down on the pe...

Page 121: ...Select lever shift rod NOTICE Before shifting you must stop the vehicle and take your foot off the accelerator pedal Otherwise the transmission may be dam aged 1 Adjust select lever shift rod a Make...

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

Page 123: ...GEAR OIL 1 Place the vehicle on a level surface 2 Remove rear skid plate 1 3 Place a container under the final gear case to collect the used oil 1 4 Remove oil filler plug 1 1 5 Remove drain plug 1 6...

Page 124: ...gear case 9 Install oil filler plug 10 Install rear skid plate Periodic oil change 0 25 L 0 22 Imp qt 0 26 US qt Total amount 0 28 L 0 25 Imp qt 0 30 US qt Recommended oil SAE 80 API GL 4 Hypoid gear...

Page 125: ...level NOTICE Take care not allow foreign material to enter the differential gear case 4 Install oil filler plug Recommended oil SAE 80 API GL 4 Hypoid gear oil T R 23 Nm 2 3 m kg 17 ft lb CHANGING TH...

Page 126: ...1 T R 10 Nm 1 0 m kg 7 2 ft lb 8 Fill differential gear case NOTICE Take care not to allow foreign material to enter the differential gear case 9 Install oil filler plug 10 Install front skid plate Pe...

Page 127: ...bearings Try to move the steering wheel up and down and back and forth Excessive play Replace the steering shaft assembly 3 Check tie rod ends Turn the steering wheel to the left and right until it st...

Page 128: ...y opposite one another e Measure distance between the marks f Calculate the toe in using the formula given below g If the toe in is incorrect adjust it 3 Adjust toe in WARNING Be sure that both tie ro...

Page 129: ...R Locknut rod end 40 Nm 4 0 m kg 29 ft lb ADJUSTING THE FRONT SHOCK ABSORBERS For models equipped with oil damper shock absorbers WARNING Always adjust the spring load of both shock absorbers to the...

Page 130: ...he locknut 1 with the ring nut wrench 2 c Turn the adjusting ring 3 in direction a or b TIP _ Be sure to remove all dirt and mud from around the locknut and adjusting ring before adjusting NOTICE _ Ne...

Page 131: ...usting screw may be dam aged Direction a Rebound damping force is increased Direction b Rebound damping force is decreased From the fully turned in position Standard 10 clicks out Minimum 12 clicks ou...

Page 132: ...orbers WARNING Always adjust the spring load of both shock absorbers to the same setting Uneven adjustment can cause poor han dling and loss of stability TIP The spring preload of the shock absorbers...

Page 133: ...ocknut 1 with the ring nut wrench 2 c Turn the adjusting ring 3 in direction a or b TIP _ Be sure to remove all dirt and mud from around the locknut and adjusting ring before adjusting NOTICE _ Never...

Page 134: ...usting screw may be dam aged Direction a Rebound damping force is increased Direction b Rebound damping force is decreased From the fully turned in position Standard 12 clicks out Minimum 20 clicks ou...

Page 135: ...character istics and are therefore not recom mended TIRE PRESSURE 1 Recommended tire pressure Front 70 kPa 0 70 kg cm2 10 psi Rear 98 kPa 0 98 kg cm2 14 psi 2 Tire pressure below the minimum speci fi...

Page 136: ...on trailer hitch point 50 kg 110 lb Be extra careful of the vehicle balance and stability when towing a trailer 1 Measure tire pressure cold tire pressure Out of specification Adjust TIP A tire press...

Page 137: ...both rear tires 2 Check tire surfaces Wear damage Replace WARNING It is dangerous to ride with a worn out tire When tire wear is out of specification replace the tire immediately Tire wear limit a Fro...

Page 138: ...ce a damaged cable as soon as possi ble 1 Check cable sheath Damage Replace 2 Check cable operation Unsmooth operation Lubricate or replace TIP Hold the cable end up and apply several drops of lubrica...

Page 139: ...lectrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attenti...

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

Page 141: ...to regulate the charging current on the battery charger be careful not to overcharge the battery When charging a battery be sure to remove it from the vehicle If charging has to be done with the batt...

Page 142: ...t the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of an MF battery sta bilizes about 30 mi...

Page 143: ...THE BATTERY If the amperage does not exceed the standard charging amperage after 5 minutes replace the battery If the required charging time exceeds 5 hours it is advisable to check the charging amper...

Page 144: ...rge the battery until the charging voltage reaches 15 V This type of battery charger cannot charge an MF battery A variable voltage charger is recommended Leave the battery unused for more than 30 min...

Page 145: ...tery lead 2 8 Check battery terminals Dirt Clean with a wire brush Loose connection Connect properly 9 Lubricate battery terminals 10 Install battery cover Recommended lubricant Dielectric grease 1 2...

Page 146: ..._ Set the pocket tester selector to 1 b If the pocket tester indicates replace the fuse 3 Replace blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage c Set on the swit...

Page 147: ...tensive damage to the electrical system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install battery cover Items Amperage rating Q ty Main fuse 40 A 1 Backu...

Page 148: ...GHT BEAMS 1 Adjust headlight beam vertically a Turn the adjusting screw 1 in direction a or b Direction a Headlight beam is raised Direction b Headlight beam is lowered CHANGING THE HEADLIGHT BULBS 1...

Page 149: ...e headlight bulb holder NOTICE Avoid touching the glass part of the bulb Keep it free from oil otherwise the trans parency of the glass life of the bulb and luminous flux will be adversely affected If...

Page 150: ...uch the bulb until it cools down 4 Install bulb Secure the new bulb with the tail brake light bulb holder NOTICE Avoid touching the glass part of the bulb Keep it free from oil otherwise the trans par...

Page 151: ...belt cooling ducts muffler and exhaust pipes Remove the parts in the order listed Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter...

Page 152: ...rottle body assembly Refer to THROTTLE BODY in chapter 6 Fuel tank Refer to FUEL PUMP AND FUEL TANK in chapter 6 Front drive shaft Refer to FRONT CONSTANT VELOC ITY JOINTS DIFFERENTIAL GEAR AND DRIVE...

Page 153: ...kg 5 1 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib Order Job Part Q ty Remarks 7 Exhaust pipe 1 1 8 Gasket 2 9 V belt cooling duct 1 1 10 V belt cooling d...

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

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

Page 156: ...sted 1 Cylinder head breather hose 1 2 Water pump inlet hose 1 Disconnect 3 Water pump outlet pipe hose 1 1 4 Water pump breather hose 1 5 Thermostat outlet hose 1 Disconnect 6 Oil outlet hose 1 Disco...

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

Page 158: ...ob Part Q ty Remarks Removing the engine mounting bolts Remove the parts in the order listed Primary and secondary sheave assem bly drive belt case Refer to PRIMARY AND SECONDARY SHEAVES 1 Rubber damp...

Page 159: ...Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT LT LT LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 42 Nm 4 2 m kg 30 ft Ib T R 42 Nm 4 2 m kg 30 ft Ib 7 8 9 9 7 8 3 2 6 6 3 2 5 1 1 5 4 Order Job Part Q ty Remarks 9 R...

Page 160: ...engine 6 engine mounting bolts front lower side 7 engine mounting bolts front upper side 8 rubber damper nuts rear side 9 TIP _ Do not fully tighten the bolts and nuts 4 Tighten rubber damper nuts fro...

Page 161: ...4 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 38 Nm 3 8 m kg 27 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib Order Job Part Q ty Remarks Removing the cylinder h...

Page 162: ...25 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 38 Nm 3 8 m kg 27 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib Order Job Part Q ty Remarks Thermostat coolant temperature sen sor Refer to THE...

Page 163: ...b T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 35 Nm 3 5 m kg 25 ft I...

Page 164: ...at top dead center TDC on the compression stroke align the I mark c on the camshaft sprocket with the stationary pointer d on the cylinder head as shown in the illustration a b d c 2 Loosen camshaft s...

Page 165: ...camshaft sprocket and timing chain as a set a 1 4 of a tooth b Correct 1 Roller 2 Sprocket EBS00227 CHECKING THE TAPPET COVERS 1 Check tappet covers camshaft sprocket cover Cracks damage Replace EBS0...

Page 166: ...eposits rust Eliminate 3 Measure cylinder head warpage Out of specification Resurface the cylin der head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage...

Page 167: ...rque them in two stages New 3 1 4 2 7 8 5 6 4 2 3 4 3 1 T R 35 Nm 3 5 m kg 25 ft lb T R 35 Nm 3 5 m kg 25 ft lb T R 38 Nm 3 8 m kg 27 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 4 Install decompressor assembly...

Page 168: ...washer 2 and spring 3 b Release the timing chain tensioner one way cam 4 and push the timing chain tensioner rod 5 all the way into the timing chain ten sioner housing c Install the timing chain tens...

Page 169: ...1 decompressor assembly bolts 2 TIP While holding the AC magneto rotor nut with a wrench tighten the camshaft sprocket bolts and decompressor assembly bolts After tightening the decompressor assembly...

Page 170: ...y Remarks Removing the rocker arms and cam shaft Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Bearing retainer 1 Refer to REMOVING THE ROCKER ARMS AND CAMSHAFT and INSTA...

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

Page 172: ...HAFT 1 Check cam lobes Pitting scratches blue discoloration Replace 2 Measure cam lobe dimensions a and b Out of specification Replace Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 W...

Page 173: ...ck that the decompressor lever pin 1 projects from the camshaft c Check that the decompressor cam 2 moves smoothly 2 1 EBS00239 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure a...

Page 174: ...the rocker arm inside diameter Out of specification Replace the defective part s Rocker arm shaft outside diame ter 11 981 11 991 mm 0 4717 0 4721 in Rocker arm to rocker arm shaft clearance 0 009 0...

Page 175: ...nt Engine oil 3 Install decompressor lever pin 1 decompressor lever 2 TIP _ Install the decompressor lever pin 1 and decompressor lever 2 in the camshaft 3 as shown in the illustration 3 1 2 4 Install...

Page 176: ...shaft 2 intake rocker arm intake rocker arm shaft TIP _ Use a slide hammer bolt 3 to install the rocker arm shafts Make sure the rocker arm shafts intake and exhaust are completely pushed into the cy...

Page 177: ...inder head Refer to CYLINDER HEAD Rocker arms rocker arm shafts cam shaft Refer to ROCKER ARMS AND CAM SHAFT 1 Valve cotter 8 Refer to REMOVING THE VALVES AND VALVE SPRINGS and INSTALL ING THE VALVES...

Page 178: ...the valve face valve seat and valve seat width Refer to CHECKING THE VALVES AND VALVE SPRINGS a Pour a clean solvent a into the intake and exhaust ports b Check that the valve seals properly There sh...

Page 179: ...EBS00240 CHECKING THE VALVES AND VALVE SPRINGS The following procedure applies to all of the valves and valve guides 1 Measure valve stem to valve guide clearance Out of specification Replace the val...

Page 180: ...guide bore the valve guide using a valve guide reamer 3 to obtain proper stem to guide clearance TIP _ After replacing the valve guide reface the valve seat 3 Check valve face Pitting wear Grind the...

Page 181: ...m the valve face and valve seat 7 Check valve seats Pitting wear Reface the valve seat Runout limit 0 040 mm 0 0016 in 8 Measure valve seat width a Out of specification Reface the valve seat a Apply M...

Page 182: ...alve guide b Apply molybdenum disulfide oil to the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of...

Page 183: ...lve spring free length 40 38 mm 1 59 in Limit 38 36 mm 1 51 in 11 Measure compressed spring force a Out of specification Replace b Installed length Compressed spring force 171 0 197 0 N at 35 00 mm 17...

Page 184: ...rings 4 valve spring retainers 5 TIP _ Install the valve springs with the larger pitch a facing upwards b Smaller pitch 4 Install valve cotters TIP _ Install the valve cotters while compressing the va...

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

Page 186: ...Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD Water jacket joint Refer to WATER PUMP in chapter 5 1 Timing chain guide exhaust side 1 2 Cylinder 1 Refer to INSTALLING THE P...

Page 187: ...s are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 4 NOTICE _ Do not use a hammer to drive the piston pin out Piston pin puller set 90890 01304 Pis...

Page 188: ...0 39 in from the bottom edge of the pis ton d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula Cylinder bor...

Page 189: ...from the piston ring grooves and piston rings Piston ring side clearance Top ring 0 030 0 070 mm 0 0012 0 0028 in Limit 0 12 mm 0 0047 in 2nd ring 0 030 0 070 mm 0 0012 0 0028 in Limit 0 13 mm 0 0051...

Page 190: ...piston pin Blue discoloration grooves Replace the piston pin and then check the lubrication system 2 Measure piston pin outside diameter a Out of specification Replace the piston pin Piston pin outsid...

Page 191: ...nce Piston pin bore diameter b Piston pin outside diameter a Piston pin to piston clearance 0 004 0 024 mm 0 0002 0 0009 in Limit 0 074 mm 0 0029 in EBS00252 INSTALLING THE PISTON AND CYLINDER 1 Insta...

Page 192: ...lips cover the crankcase opening with a clean rag to prevent the clips from falling into the crank case 3 Install cylinder gasket dowel pins 4 Lubricate piston piston rings cylinder with the recommend...

Page 193: ...the timing chain and timing chain guide exhaust side through the timing chain cav ity 1 7 Install cylinder bolts TIP Lubricate the threads of the cylinder bolts 1 and mating surface with engine oil 8...

Page 194: ...marks Removing the AC magneto Remove the parts in the order listed Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Seats rear co...

Page 195: ...Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 60 Nm 6 0 m kg 43 ft Ib Order Job Part Q ty Remarks 5 AC magneto cover gasket 1 6 Dowel pin 2 7 Lead holder 1 8 Crankshaft position sens...

Page 196: ...T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T...

Page 197: ...osen the AC mag neto rotor nut Do not allow the sheave holder to touch the projection on the rotor Sheave holder 90890 01701 Primary clutch holder YS 01880 A 3 2 1 3 Remove AC magneto rotor 1 with the...

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

Page 199: ...E TORQUE LIMITER 1 Check torque limiter Damage wear Replace TIP Do not disassemble the torque limiter EBS00268 INSTALLING THE AC MAGNETO ROTOR 1 Install stator coil 1 TIP Align the projection a on the...

Page 200: ...reinstall the key and rotor 4 Tighten AC magneto rotor nut 1 TIP _ While holding the AC magneto rotor 2 with the sheave holder 3 tighten the AC magneto rotor nut Sheave holder 90890 01701 Primary clu...

Page 201: ...oil pump gears Remove the parts in the order listed Starter wheel gear Refer to AC MAGNETO 1 Lock washer 1 Refer to REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR and INSTALLING THE BALAN...

Page 202: ...STALLING THE BAL ANCER DRIVE GEAR BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR 7 Oil pump driven gear 1 8 Plate 1 9 Spring 8 Refer to REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR and IN...

Page 203: ...of the balancer drive gear 4 and balancer driven gear 5 then loosen the nuts 5 4 3 1 2 CHECKING THE OIL PUMP DRIVE 1 Check oil pump drive gear oil pump driven gear Cracks wear damage Replace CHECKING...

Page 204: ...a on the balancer drive gear with the punch mark b on the bal ancer driven gear Install the oil pump driven gear with the 3B4 mark c facing out 2 3 c a b 1 3 Install lock washers oil pump driven gear...

Page 205: ...0 m kg 7 2 ft Ib T R 100 Nm 10 0 m kg 72 ft lb Order Job Part Q ty Remarks Removing the primary and second ary sheaves Remove the parts in the order listed Seats rear console Refer to SEATS REAR CONS...

Page 206: ...b T R 10 Nm 1 0 m kg 7 2 ft Ib T R 100 Nm 10 0 m kg 72 ft lb Order Job Part Q ty Remarks 5 Primary sheave assembly 1 Refer to REMOVING THE PRIMARY AND SECONDARY SHEAVES and INSTALLING THE PRIMARY AND...

Page 207: ...e primary sheave Remove the parts in the order listed 1 Primary pulley sheave cap 1 Refer to ASSEMBLING THE PRIMARY SHEAVE 2 Primary pulley slider 4 3 Primary pulley cam 1 4 Primary pulley weight 8 5...

Page 208: ...ve Remove the parts in the order listed 1 Nut 1 Refer to DISASSEMBLING THE SEC ONDARY SHEAVE and ASSEMBLING THE SECONDARY SHEAVE 2 Spring seat 1 3 Compression spring 1 4 Spring seat 1 5 Guide pin 4 6...

Page 209: ...ASSEMBLING THE SECONDARY SHEAVE 1 Remove nut 1 a Attach the sheave fixed block 2 locknut wrench 3 and sheave spring compressor 4 to the secondary sheave assembly b Place the sheave fixed block in a vi...

Page 210: ...sheave splines Wear cracks damage Replace primary pulley cam Cracks damage Replace 3 Check primary sliding sheave primary fixed sheave Cracks damage Replace EBS00275 CHECKING THE SECONDARY SHEAVE 1 Ch...

Page 211: ...ARY SHEAVE 1 Clean primary sliding sheave face 1 primary fixed sheave face 2 collar 3 weights 4 primary sliding sheave cam face TIP _ Remove any excess grease 2 Install weights 1 TIP _ Apply Yamaha Gr...

Page 212: ...SSEMBLING THE SECONDARY SHEAVE 1 Apply BEL RAY assembly lube to the secondary sliding sheave 1 inner surface and oil seals BEL RAY assembly lube to the bearings oil seals and inner surface of the seco...

Page 213: ...n a vise and secure it c Tighten the sheave spring compressor nut 1 and compress the spring d Install the nut 2 and tighten it to the speci fied torque using the locknut wrench e Remove the sheave spr...

Page 214: ...tward Tightening the bolts 3 will push the second ary sliding sheave away causing the gap between the secondary fixed and sliding sheaves to widen Install the V belt so that its arrow faces the direct...

Page 215: ...order listed Primary sheave secondary sheave Refer to PRIMARY AND SECONDARY SHEAVES 1 Clutch housing assembly 1 Refer to REMOVING THE CLUTCH and INSTALLING THE CLUTCH 2 Gasket 1 3 Dowel pin 2 4 One w...

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

Page 217: ...4 of a turn Remove them after all of them are loosened 2 Straighten punched portion of the nut 1 3 Remove nut 1 NOTICE The clutch carrier assembly nut has left handed threads To loosen the clutch car...

Page 218: ...and clutch carrier assembly to the clutch hous ing and hold the clutch carrier assembly b When turning the clutch housing clockwise the clutch housing should turn freely If not the one way clutch ass...

Page 219: ...with a drift punch Universal clutch holder 90890 04086 YM 91042 New T R 190 Nm 19 0 m kg 140 ft lb 3 Install one way clutch bearing TIP _ The one way clutch bearing should be installed in the clutch...

Page 220: ...9 1 8 4 5 3 Order Job Part Q ty Remarks Removing the timing chain and oil filter Remove the parts in the order listed Engine Refer to ENGINE REMOVAL Cylinder head Refer to CYLINDER HEAD Cylinder pist...

Page 221: ...49 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib New New New New New New New New New LS LS LS LS LT E E LT LT LT LT LS LS 2 6 7 10 9 1 8 4 5 3 Order Job Part Q ty Remarks 4 Oil filter...

Page 222: ...ew New LS LS E E E 1 4 2 3 3 5 6 8 8 9 7 Order Job Part Q ty Remarks Separating the crankcase Remove the parts in the order listed 1 Shift lever cover 1 Refer to INSTALLING THE SHIFT LEVER 2 Gasket 1...

Page 223: ...arks Removing the crankcase bearings Remove the parts in the order listed Crankshaft oil pump Refer to CRANKSHAFT AND OIL PUMP Transmission Refer to TRANSMISSION Middle drive shaft middle driven shaft...

Page 224: ...mer to tap on one side of the crankcase Tap only on reinforced portions of the crankcase Do not tap on the crank case mating surfaces Work slowly and carefully Make sure that the crankcase halves sepa...

Page 225: ...t 2 Clean all the gasket mating surfaces and crankcase mating surfaces thoroughly 3 Check crankcase Cracks damage Replace oil delivery passages Clogged Blow out with compressed air EBS00342 ASSEMBLING...

Page 226: ...bolts follow the proper tightening sequence Left crankcase Right crankcase TIP _ Tighten the bolts in stages using a crisscross pattern 6 Apply 4 stroke engine oil to the crankshaft pin bearing and oi...

Page 227: ...g 7 2 ft Ib New Order Job Part Q ty Remarks Removing the crankshaft and oil pump Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Oil pump 1 2 Gasket 1 3 Balancer 1 4 Crank...

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

Page 229: ...pump housing clearance b oil pump housing to inner rotor and outer rotor clearance c Out of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing 3 Check oil pump operation...

Page 230: ...1 Measure crank width a Out of specification Replace the crank shaft 2 Measure side clearance d Out of specification Replace the crank shaft 3 Measure runout c Out of specification Replace the crank s...

Page 231: ...shaft 4 align the pin 5 with the groove a in the inner rotor 3 1 2 3 5 4 a a EBS00362 INSTALLING THE CRANKSHAFT 1 Install crankshaft 1 Crankshaft installer pot 2 90890 01274 YU 90058 Crankshaft insta...

Page 232: ...en ter TDC with one hand while turning the nut of the installing tool with the other Operate the installing tool until the crankshaft bottoms against the bearing NOTICE _ Apply engine oil to each bear...

Page 233: ...listed Crankcase Separate Refer to CRANKCASE Middle driven gear Refer to MIDDLE GEAR 1 Shift drum 1 Refer to REMOV ING THE TRANS MISSION and INSTALLING THE TRANSMISSION 2 Shift fork assembly 1 3 Shift...

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

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

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

Page 237: ...m d Remove the shift fork assembly EBS00349 CHECKING THE SHIFT FORKS The following procedure applies to each shift fork 1 Check shift fork cam follower 1 shift fork pawl 2 Scoring bends wear damage Re...

Page 238: ...transmission gears Blue discoloration pitting wear Replace the defective gear s transmission gear dogs Cracks damage rounded edges Replace the defective gear s 3 Check transmission gear engagement ea...

Page 239: ...TIP Install the shift forks with the 3B4 mark a and 5B4 mark b facing each other 3B4 New New a b 4 2 1 5 3 5 New EBS00356 INSTALLING THE TRANSMISSION 1 Install reverse idle gear 1 drive axle assembly...

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

Page 241: ...e Separate Refer to CRANKCASE 1 Bearing housing 1 2 Middle drive pinion gear nut 1 Refer to REMOVING THE MIDDLE DRIVE SHAFT and INSTALLING THE MIDDLE DRIVE SHAFT 3 Middle drive pinion gear 1 4 Middle...

Page 242: ...1 Drive shaft coupling gear nut middle gear side 1 Refer to REMOVING THE MIDDLE DRIVEN SHAFT and INSTALLING THE MIDDLE DRIVEN SHAFT 2 Drive shaft coupling gear middle gear side 1 3 Circlip 2 4 Bearing...

Page 243: ...T and INSTALLING THE MIDDLE DRIVEN SHAFT 11 Middle driven gear shim 12 Middle driven pinion gear 1 13 Bearing 1 14 Middle driven pinion gear bearing retainer 1 15 Bearing 1 16 Middle driven shaft bear...

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

Page 245: ...ling gear middle shaft tool 90890 01229 Gear holder YM 01229 1 3 2 2 Remove universal joint middle gear side a Remove the circlips 1 b Place the universal joint in a press c With a suitable diameter p...

Page 246: ...using assembly 1 a Clean the outside of the bearing housing assembly b Place the bearing housing assembly onto a hydraulic press NOTICE Never directly press the middle driven pinion gear end with a hy...

Page 247: ...ring retainer has left handed threads To loosen the retainer turn it clockwise d Remove the bearing retainer and bearing Bearing retainer wrench 90890 04128 Middle gear bearing retainer YM 04128 2 1 6...

Page 248: ...pinion gear teeth Pitting galling wear Replace 2 Check O ring Damage Replace bearings Pitting damage Replace EBS00370 SELECTING MIDDLE DRIVE AND DRIVEN GEAR SHIMS When the drive and driven gear bearin...

Page 249: ...ed to or subtracted from 0 9 b 17 0 c 55 0 d a numeral usually a decimal number on the left crankcase specifies a thickness of 65 0 e a numeral usually a decimal number on the right crankcase specifie...

Page 250: ...7 5 8 9 10 Middle drive pinion gear shim Thickness mm 0 50 0 70 1 00 0 55 0 80 0 60 0 90 c To find shim thickness B use the following formula Where f a numeral usually a decimal number on the bearing...

Page 251: ...s of 8 12 Example 1 If the bearing housing is marked 03 f is 77 53 2 If the driven pinion gear is marked 02 g is 49 02 3 If the driven pinion gear is marked 02 h is 80 52 4 If the right crankcase is m...

Page 252: ...EARING AND OIL SEALS 1 Install bearing 1 oil seal 2 oil seal 3 4 Middle drive pinion gear bearing retainer 5 Bearing housing 6 Middle driven shaft bearing retainer 7 Crankcase Installed depth of beari...

Page 253: ...430 YM 38404 LT T R 80 Nm 8 0 m kg 58 ft lb 1 2 2 Install middle driven pinion gear bearing retainer 1 a Secure the bearing housing edge in the vise with a clean rag b Attach the bearing retainer wren...

Page 254: ...der 2 to hold the yoke T R Universal joint yoke nut 150 Nm 15 0 m kg 110 ft lb LOCTITE Universal joint holder 90890 04062 YM 04062 5 Install universal joint middle gear side a Install the yoke into th...

Page 255: ...nstall drive shaft coupling gear middle gear side 1 washer drive shaft coupling gear nut middle gear side 2 TIP Use the coupling gear middle shaft tool 3 to hold the coupling gear Coupling gear middle...

Page 256: ...nto the installation hole a of the right crankcase speed sensor to hold the middle driven gear c Attach the gear lash measurement tool 3 and dial gauge 4 b 12 3 mm 0 48 in d Measure the gear lash whil...

Page 257: ...ve the parts in the order listed Oil cooler Refer to OIL COOLER Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Radiator fan motor coupler 1 Disconnect 2 Radiator fan motor breather hose 1...

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

Page 259: ...cified pressure Replace the radiator cap a Install the radiator cap tester 1 and adapter 2 onto the radiator cap 3 b Apply the specified pressure for ten sec onds and make sure that there is no drop i...

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

Page 261: ...the parts in the order listed Seats rear console Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Thermostat outlet hose 1 Dis...

Page 262: ...closed Fully open TIP _ If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause seri ous overheating or overcooling 2 Check thermostat cover thermostat housing cylind...

Page 263: ...move the parts in the order listed Seats rear console Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Coolant Drain Refer...

Page 264: ...g 7 2 ft Ib R T 10 Nm 1 0 m kg 7 2 ft Ib R T 10 Nm 1 0 m kg 7 2 ft Ib LS Order Job Part Q ty Remarks 7 Gasket 1 8 Circlip 1 9 Impeller shaft 1 10 Water pump seal 1 Refer to DISASSEMBLING THE WATER PUM...

Page 265: ...r 2 2 1 2 Remove bearing 1 oil seal 2 TIP _ Tap out the bearing and oil seal from the out side of the AC magneto cover 3 1 2 3 EBS00139 CHECKING THE WATER PUMP 1 Check water pump housing impeller shaf...

Page 266: ...ide diameter Installed depth of oil seal a 8 1 8 7 mm 0 32 0 34 in 3 1 2 New a New 2 Install water pump seal 1 into the AC magneto cover 2 NOTICE _ Never lubricate the water pump seal sur face with oi...

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

Page 268: ...g the oil cooler Remove the parts in the order listed Seats rear console support side pan els front console Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Engine oil Drain Refer to CHANGING...

Page 269: ...Nm 2 1 m kg 15 ft Ib New New New 4 2 3 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib 4 4 New LS Order Job Part Q ty Remarks 5 Oil outlet hose 1 6 Oil inlet hose 1 7 Oil cooler inlet pipe...

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

Page 271: ...4 Engine trouble warning light 5 Intake air temperature sensor 6 TPS throttle position sensor 7 Intake air pressure sensor 8 Spark plug 9 Coolant temperature sensor 0 Fuel injector A ISC idle speed co...

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

Page 273: ...rol unit H Ignition coil I Spark plug J Fuel injector K Intake air temperature sensor L Coolant temperature sensor M Speed sensor N TPS throttle position sensor O Intake air pressure sensor P Lean ang...

Page 274: ...teristic operation and alerts the rider of the detected malfunction by illuminating the engine trou ble warning light After the engine has been stopped the low est fault code number appears on the odo...

Page 275: ...ature sensor open or short circuit detected Able Able 30 Lean angle sensor latch up detected The vehicle has overturned Unable Unable 33 Ignition coil faulty ignition Malfunction detected in the prima...

Page 276: ...Refer to Rein statement method in TROUBLESHOOTING DETAILS Turn the main switch to OFF turn the main switch back to ON and then check if the fault code number is still displayed Repairs completed No fa...

Page 277: ...e TIP All displays on the meter disappear dIAG appears on the LCD meter 4 Simultaneously press the and TRIP ODO buttons for 2 seconds or more to execute the selection 5 Select the diagnostic code numb...

Page 278: ...r Actuator operation Set the differential gear lock switch to LOCK to operate the actuator If the differential gear lock switch is set to LOCK set it to 4WD and then set it to LOCK again 7 Turn the ma...

Page 279: ...30 The vehicle has overturned Overturned Malfunction in ECU d08 33 Malfunction detected in the primary lead of the ignition coil Open or short circuit in wire harness Malfunction in ignition coil Mal...

Page 280: ...meter d07 Vehicle speed pulse 0 999 Check that the number increases when the rear wheel is rotated The number is cumulative and does not reset each time the wheel is stopped d08 Lean angle sensor Remo...

Page 281: ...ashes five times Check the spark five times Connect an ignition checker d36 Injector Actuates the injector five times in one second inter vals Check the operating sound of the injector five times d50...

Page 282: ...Connections Crankshaft position sensor cou pler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction...

Page 283: ...he coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Turning the main switch to ON 2 Open or s...

Page 284: ...arting the engine and operating it at idle 2 Intake air pressure sensor mal function at intermediate electrical potential Check and repair the connec tion Replace it if there is a malfunc tion 3 Conne...

Page 285: ...U coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 3 Open or short circuit...

Page 286: ...21 Symptom Coolant temperature sensor open or short circuit detected Diagnostic code No d06 Coolant temperature sensor Order Item components and probable cause Check or maintenance job Reinstatement...

Page 287: ...take air temperature sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it a...

Page 288: ...ne can not be restarted unless the main switch is first turned OFF 2 Installed condition of the lean angle sensor Check for looseness or pinching 3 Connections Lean angle sensor coupler Main wire harn...

Page 289: ...Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler or con nector securely Starting the engine and operating it at idle 2 Open or short...

Page 290: ...THE THROTTLE CABLE in chapter 3 3 ISC valve is stuck fully open due to disconnected ISC unit hose or cou pler High engine idle speed is detected with the ISC valve stuck fully open even though signals...

Page 291: ...Check the couplers for any pins that may be pulled out Check the locking condition of the couplers If there is a malfunction repair it and connect the coupler securely Cranking the engine Con nect the...

Page 292: ...upler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely Turning the main switch to ON 2 Open or short...

Page 293: ...r If there is a malfunction repair it and connect the coupler securely Starting the engine and activating the vehicle speed sensor by oper ating the vehi cle at 20 to 30 km h 2 Open or short circuit i...

Page 294: ...air or replace if there is an open or short circuit Between fuel injection system relay coupler and ECU coupler red blue red blue Between fuel injection system relay coupler and starter relay coupler...

Page 295: ...ulator Replace if defective Refer to CHARGING SYSTEM in chapter 9 4 Open or short circuit in wire har ness Repair or replace if there is an open or short circuit Between battery lead and main fuse cou...

Page 296: ...5 4 25 V Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe pink terminal 1 Negative tester probe black blue terminal 2 L P B L 2 1 CHECKING THE INTAKE AIR TEMPERATURE SEN...

Page 297: ...ster probe brown white 1 Negative tester probe black blue 2 Br W B L 2 1 b Immerse the air temperature sensor 3 in a container filled with water 4 TIP Make sure that the air temperature sensor ter min...

Page 298: ...ving the air filter case and air intake duct Remove the parts in the order listed Seats rear console Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 Side panels corner panels front con...

Page 299: ...ector coupler 1 Disconnect 11 Throttle position sensor coupler 1 Disconnect 12 Intake air pressure sensor coupler 1 Disconnect 13 ISC idle speed control unit coupler 1 Disconnect 14 Coolant temperatur...

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

Page 301: ...a 2 Install air intake duct joint clamp 1 throttle body side TIP Align the projection a on the air intake duct joint with the gap b in the air intake duct joint clamp 1 a b 3 Install air filter case j...

Page 302: ...rear console Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 Right side panel right corner panel right protector passenger seat support Refer to PANELS AND FRONT CON SOLE in chapter 8...

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

Page 304: ...ay be fuel remaining in it TIP To remove the fuel hose from the throttle body and the fuel tank slide the fuel hose connector cover 1 on the end of the hose in direction of the arrow shown press the b...

Page 305: ...l fuel pump gasket fuel pump fuel pump bracket TIP Do not damage the installation surface of the fuel tank when installing the fuel pump Always use a new fuel pump gasket Install the fuel pump in the...

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

Page 307: ...listed Seats rear console Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS in chapter 8 1 Intake air pressure sensor coupler 1 Disconnect 2 Throttle position sensor coupler 1 Disconnect 3 Throttle b...

Page 308: ...r to REMOVING THE THROTTLE BODY ASSEMBLY and INSTALLING THE THROTTLE BODY ASSEMBLY 9 Air intake duct joint clamp 2 10 Air intake duct joint 1 11 Throttle body joint clamp 2 Refer to INSTALLING THE THR...

Page 309: ...assembly Remove the parts in the order listed 1 Intake air pressure sensor 1 2 Intake air pressure sensor hose 1 3 Throttle position sensor 1 4 Injector fuel rail 1 5 Fuel injector 1 6 Throttle body...

Page 310: ...isconnect the fuel hose from the throttle body slide the fuel hose connector cover 1 on the end of the hose in direction of the arrow shown press the button 2 on either side of the connector and then...

Page 311: ...er head with the slot b in the throttle body joint 1 a b 2 Install throttle body joint clamps 1 TIP Align the projections on the throttle body joint with the gap in each throttle body joint clamp 1 3...

Page 312: ...will not be properly connected TIP To connect the fuel hose onto the throttle body slide the fuel hose connector cover 1 on the end of the hose in direction of the arrow shown 6 Install throttle cabl...

Page 313: ...from the fuel pump TIP Before removing the hose place a few rags in the area under where it will be removed c Connect the pressure gauge 2 and adapter 3 to the fuel pump and fuel hose d Start the eng...

Page 314: ...of specification Replace the throttle position sensor 2 Adjust throttle position sensor angle a Connect the throttle position sensor coupler to the throttle position sensor b Connect the digital circu...

Page 315: ...st the throttle position sensor angle so that the voltage is within the specified range e After adjusting the throttle position sensor angle tighten the throttle position sensor screws 3 Throttle posi...

Page 316: ...ion and deceleration Diagnosis Possible incorrect reassembly too little gear lash NOTICE _ Too little gear lash is extremely destructive to the gear teeth If a test ride following reassembly indicates...

Page 317: ...etal particles Check the bearing for seizure TIP _ A small amount of metal particles in the oil is normal 3 Check oil leakage a Clean the entire vehicle thoroughly then dry it b Apply a leak localizin...

Page 318: ...chapter 8 YES Check the front constant velocity joints Feel for bearing damage NO Constant velocity joint bearings and differ ential gear bearings are probably not dam aged Repeat the test or remove t...

Page 319: ...the front constant veloc ity joints differential gear and drive shaft Remove the parts in the order listed Front skid plate Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Differential gear...

Page 320: ...9 8 3 2 4 T R 55 Nm 5 5 m kg 40 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib 1 1 LS LS LS New New New Order Job Part Q ty Remarks 4 Differential gear case assembly 1 5 Compression spring 1 6 Washer 1 7 Dust sea...

Page 321: ...n the order listed The following procedure applies to both of the front constant velocity joints 1 Clip 1 2 Boot band 1 Refer to DISASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS and ASSEMBLING THE FRO...

Page 322: ...EAR AND DRIVE SHAFT Wheel side Gear case side Order Job Part Q ty Remarks C Clip 1 Refer to DISASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS and ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS D Joint s...

Page 323: ...Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks Disassembling the differential gear case assembly Remove the parts in the order listed 1 Differential gear motor 1 Refer to ASSEMBLING THE DIFFER ENTI...

Page 324: ...R 24 Nm 2 4 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 62 Nm 6 2 m kg 45 ft Ib New New New New New New LT LS LS New LS LS New 8 T R 10 Nm 1 0 m kg 7 2 ft Ib Order Job Part Q ty Remarks C Oil seal...

Page 325: ...f set joint 2 circlip 3 ball bearing 4 dust boot 5 TIP Before removing the clip 1 slide the dust boot away from the double off set joint 5 1 2 4 3 2 Remove boot band 1 Use a boot band installing tool...

Page 326: ...the opposite bearing e Remove the yoke 2 Remove universal joint yoke Use a universal joint holder 1 Universal joint holder 90890 04062 YM 04062 1 EBS00163 REMOVING THE DIFFERENTIAL GEAR ASSEMBLY 1 Re...

Page 327: ...balls and ball races inner surface of double off set joint Pitting wear damage Replace EBS00166 CHECKING THE DIFFERENTIAL GEARS 1 Check gear teeth Pitting galling wear Replace bearing Pitting damage R...

Page 328: ...from the differential gear case assembly Do not use a 12 V battery to operate the pinion gear Check that the pinion gear 2 turns counter clockwise Check that the pinion gear 2 turns clockwise TIP Be...

Page 329: ...TIP Securely install the circlip into the groove in the joint shaft Securely install the clip into the groove in the double off set joint 1 2 New New New 3 4 New 3 Apply molybdenum disulfide grease in...

Page 330: ...ed with the boot bands 3 and 5 at the grooves in the joint shaft Boot band installing tool 90890 01526 YM 01526 6 4 5 Check thrust movement free play Excessive play Replace the joint assem bly EBS0100...

Page 331: ...l gear assembly making sure that the shift fork sliding gear remains in the 2WD mode position NOTICE _ If the position of the shift fork sliding gear is moved the position of the differential gear and...

Page 332: ...ngs c Install the bearing 1 onto the yoke NOTICE Check each bearing The needles can eas ily fall out of their races Slide the yoke back and forth on the bearings the yoke will not go all the way onto...

Page 333: ...easuring point is 22 5 mm 0 86 in 5 Measure gear lash Gently rotate the coupling gear from engagement to engagement TIP _ Measure the gear lash at four positions Rotate the shaft 90 each time Ring gea...

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

Page 335: ...move the parts in the order listed Rear skid plate Refer to SEATS ENCLOSURE HOOD AND CARGO BED in chapter 8 Muffler exhaust pipes Refer to ENGINE REMOVAL in chapter 4 Final gear oil Drain Rear knuckle...

Page 336: ...nstant velocity joint 2 TIP Remove the constant velocity joint on the right side of the vehicle rotate the final gear assembly slightly so that the con stant velocity joint on the left side clears the...

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

Page 338: ...he order listed The following procedure applies to both of the rear constant velocity joints 1 Dust cover 1 2 Clip 1 3 Boot band 1 Refer to DISASSEMBLING THE REAR CONSTANT VELOCITY JOINTS and ASSEMBLI...

Page 339: ...DRIVE SHAFT Wheel side Gear case side Order Job Part Q ty Remarks C Off set joint 1 Refer to DISASSEMBLING THE REAR CONSTANT VELOCITY JOINTS and ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS D Clip 1 E...

Page 340: ...in the order listed 1 Final drive pinion gear assembly 1 2 Final drive pinion gear shim 3 Drive shaft coupling gear 1 Refer to DISASSEMBLING THE FINAL GEAR CASE and ASSEM BLING THE FINAL GEAR CASE 4 F...

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

Page 342: ...Apply Yamaha bond No 1215 90890 85505 Three bond No 1215 Order Job Part Q ty Remarks H Bearing 1 Refer to REMOVING THE FINAL DRIVE ROLLER BEARINGS and INSTALLING THE FINAL DRIVE ROLLER BEARINGS I Bear...

Page 343: ...set joint 2 circlip 3 ball bearing 4 dust boot 5 TIP Before removing the clip 1 slide the dust boot away from the double off set joint 5 1 2 4 3 2 Remove boot band 1 Use a boot band installing tool 2...

Page 344: ...set joint 2 TIP Install the clip 1 into the groove in the joint shaft as shown Secure the off set joint in a vise and then fit the joint shaft into the off set joint using a hammer New 3 1 New 3 2 1 N...

Page 345: ...s b Install the dust boots c Install the dust boot bands 4 5 Use a boot band installing tool 6 TIP The new boot bands may differ from the orig inal ones The dust boots should be fastened with the boot...

Page 346: ...a hydrau lic press NOTICE _ Never directly press the gear end with a hydraulic press this will result in damage to the gear thread Install a suitable socket 2 on the gear end to protect the thread fr...

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

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

Page 349: ...2 0 3 4 5 6 7 5 8 9 10 Final drive pinion gear shim Thickness mm 0 25 0 30 0 35 0 40 0 45 0 50 Selecting ring gear shims 1 Select ring gear shim s 1 a To find the ring gear shim thickness B use the fo...

Page 350: ...14 00 5 Therefore shim thickness B is 0 48 B 50 98 1 55 34 95 14 00 49 43 48 95 0 48 6 Round off the hundredth digit and select the appropriate shim s In the example above the calculated num ber is 0...

Page 351: ...ten the bolts to specification TIP Do not turn the drive pinion gear and ring gear when measuring the clearance with Plasti gauge T R M8 bolts ring gear bearing hous ing 23 Nm 2 3 m kg 17 ft lb M10 bo...

Page 352: ...er Thickness mm 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 Adjusting the ring gear stopper 1 Install ring gear stopper nut TIP Apply sealant to the ring gear stopper threads 2 Adjust ring gear st...

Page 353: ...e pinion gear and or ring gear 2 Check gear teeth Pitting galling wear Replace the drive pinion gear and ring gear as a set oil seals O rings Damage Replace 3 Check bearings Damage Replace TIP Roller...

Page 354: ...ring gear will be dam aged Ring gear fix bolt M10 90890 01527 YM 01527 4 Attach gear lash measurement tool 1 dial gauge 2 a Measuring point is 31 1 mm 1 22 in Gear lash measurement tool 90890 01467 Y...

Page 355: ...kness by 0 2 mm 0 008 in for every 0 2 mm of ring gear shim increase c If reduced by more than 0 2 mm 0 008 in Increase the thrust washer thickness by 0 2 mm 0 008 in for every 0 2 mm that the ring ge...

Page 356: ...3 Install bearing retainer a Place a folded rag 1 b Secure the final drive pinion gear bearing housing edge in the vise TIP Apply locking agent LOCTITE to the threads of bearing retainer c Attach the...

Page 357: ...1 b Secure the drive shaft coupling gear edge in the vise c Tighten the drive shaft coupling gear nut 5 Check final drive gear operation Unsmooth operation Replace the final gear assembly Insert the...

Page 358: ...kg 23 ft Ib T R 59 Nm 5 9 m kg 43 ft Ib Order Job Part Q ty Remarks Removing the front guard and hood Remove the parts in the order listed 1 Front guard 1 2 Radiator mesh 1 3 Headlight coupler 2 Disc...

Page 359: ...Order Job Part Q ty Remarks Removing the seats rear console and instrument panels Remove the parts in the order listed 1 Driver seat 1 2 Passenger seat 1 3 Passenger handhold strap 1 4 Passenger handh...

Page 360: ...5 m kg 25 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib Order Job Part Q ty Remarks 12 On Command four wheel drive motor switch and differential gear lock switch 2 Disconnect 13 Meter assembly coupler 1 Disconnec...

Page 361: ...the steering wheel cover from the steering wheel a 1 INSTALLING THE STEERING WHEEL 1 Install steering wheel 1 TIP Install the steering wheel onto the steering col umn so that it is straight as shown i...

Page 362: ...Nm 2 3 m kg 17 ft Ib Order Job Part Q ty Remarks Removing the side doors Remove the parts in the order listed The following procedure applies to both of the side doors 1 Rubber protector 2 2 Side doo...

Page 363: ...g 11 ft Ib Order Job Part Q ty Remarks Removing the panels and front con sole Remove the parts in the order listed 1 Left side panel 1 Refer to REMOVING THE SIDE PAN ELS and INSTALLING THE SIDE PANELS...

Page 364: ...12 11 8 T R 16 Nm 1 6 m kg 11 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib Order Job Part Q ty Remarks 12 Seat rail 1 For installation reverse the removal...

Page 365: ...panel and corner panel together from the vehicle making sure not to break the projections a Unhook the projections a on the side panel from the corner panel INSTALL THE SIDE PANELS 1 Install quick fas...

Page 366: ...Ib 16 Nm 1 6 m kg 11 ft Ib T R T R 7 Nm 0 7 m kg 5 1 ft Ib T R Order Job Part Q ty Remarks Removing the cargo bed Remove the parts in the order listed 1 Tail brake light connector 6 Disconnect 2 Gas...

Page 367: ...7 m kg 5 1 ft Ib 16 Nm 1 6 m kg 11 ft Ib T R T R T R T R T R T R Order Job Part Q ty Remarks Disassembling the cargo bed Remove the parts in the order listed 1 Cargo bed mat 1 2 Tailgate cable 2 3 Hi...

Page 368: ...ARGO BED SKID PLATES T R 7 Nm 0 7 m kg 5 1 ft Ib 2 1 7 7 Order Job Part Q ty Remarks Removing the skid plates Remove the parts in the order listed 1 Front skid plate 1 2 Rear skid plate 1 For installa...

Page 369: ...ENCLOSURE HOOD AND CARGO BED INSTALLING THE REAR SKID PLATE 1 Install rear skid plate 1 TIP Make sure that the hole a in the rear skid plate 1 is towards the left side of the vehicle Forward Left side...

Page 370: ...6 ft Ib T R 22 Nm 2 2 m kg 16 ft Ib T R 65 Nm 6 5 m kg 47 ft Ib T R T R T R T R T R Order Job Part Q ty Remarks Removing the enclosure and seat belts Remove the parts in the order listed 1 Roof 1 For...

Page 371: ...the bolts and nuts 3 Tighten upper support frame and side frame bolts 7 top frame and side frame bolts 8 side frame and frame nuts front side 9 lower support frame and upper support frame nuts 0 side...

Page 372: ...g 255 ft lb Order Job Part Q ty Remarks Removing the front wheels Remove the parts in the order listed The following procedure applies to both of the front wheels Place the vehicle on a level surface...

Page 373: ...5 m kg 40 ft Ib T R 350 Nm 35 0 m kg 255 ft lb Order Job Part Q ty Remarks 4 Front brake caliper assembly 1 TIP _ Do not depress the brake pedal when the brake caliper is off of the brake disc as the...

Page 374: ...4 Order Job Part Q ty Remarks Removing the rear wheels Remove the parts in the order listed The following procedure applies to both of the rear wheels Place the vehicle on a level surface WARNING _ Se...

Page 375: ...m 3 0 m kg 22 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib 4 Order Job Part Q ty Remarks 4 Rear brake caliper assembly 1 TIP Do not depress the brake pedal when the brake caliper is off of the brake disc as the...

Page 376: ...0 08 in Rear Radial 2 2 0 mm 0 08 in Lateral 3 2 0 mm 0 08 in 3 Check wheel balance Out of balance Adjust WARNING _ After replacing the tire ride conservatively to allow the tire to be properly seated...

Page 377: ...12 in Rear 3 0 mm 0 12 in INSTALLING THE WHEEL HUBS 1 Install wheel axle nut TIP Do not apply oil to the seat of the nut After tightening the nut stake the collar of the nut into the notch of the shaf...

Page 378: ...ving the front brake pads Remove the parts in the order listed The following procedure applies to both of the front brake calipers Front wheel Refer to FRONT AND REAR WHEELS 1 Front brake caliper bolt...

Page 379: ...the rear brake pads Remove the parts in the order listed The following procedure applies to both of the rear brake calipers Rear wheel Refer to FRONT AND REAR WHEELS 1 Rear brake caliper bolt 2 Refer...

Page 380: ...y splash brake fluid onto painted surfaces or plastic parts as this may cause dam age disconnect any hydraulic connection as this would require the entire brake sys tem to be disassembled drained clea...

Page 381: ...to the brake caliper c Tighten the brake caliper bleed screw d Install the new brake pads and a new brake pad spring e Tighten the brake pad holding bolts and brake caliper bolts 3 Check brake fluid l...

Page 382: ...Remarks Removing the brake master cylinder Remove the parts in the order listed Brake fluid Drain 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm 1 3 Brake fluid reservoir float 1 4 B...

Page 383: ...t Q ty Remarks Disassembling the brake master cyl inder Remove the parts in the order listed 1 Dust boot 1 2 Circlip 1 3 Primary brake master cylinder kit 1 4 Secondary brake master cylinder kit stopp...

Page 384: ...rake master cylinder kit Scratches wear damage Replace as a set Primary brake master cylinder kit Secondary brake master cylinder kit 1 3 Check brake fluid reservoir 1 brake fluid reservoir diaphragm...

Page 385: ...designated quality brake fluid other brake fluids may deteriorate the rubber seals causing leakage and poor brake performance Refill with the same type of brake fluid mixing brake fluids may result i...

Page 386: ...AR BRAKES 5 Check brake fluid level Brake fluid level is under the MIN level line Fill up Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 6 Adjust brake pedal free play Refer to ADJUSTING THE BRA...

Page 387: ...re applies to both of the front brake calipers Brake fluid Drain Front wheel Refer to FRONT AND REAR WHEELS 1 Union bolt 1 Refer to INSTALLING THE FRONT AND REAR BRAKE CALIPERS 2 Copper washer 2 3 Fro...

Page 388: ...e the parts in the order listed The following procedure applies to both of the front brake calipers 1 Brake pad holding bolt 2 2 Front brake pad 2 3 Brake pad spring 1 4 Brake caliper bracket 1 5 Brak...

Page 389: ...Remove the parts in the order listed The following procedure applies to both of the rear brake calipers Brake fluid Drain Rear wheel Refer to FRONT AND REAR WHEELS 1 Union bolt 1 Refer to INSTALLING T...

Page 390: ...rs Remove the parts in the order listed The following procedure applies to both of the rear brake calipers 1 Brake pad holding bolt 2 2 Rear brake pad 2 3 Brake pad spring 1 4 Brake caliper bracket 1...

Page 391: ...caliper piston with a rag Be careful not to get injured when the piston is expelled from the caliper cylinder b Remove the dust seals and piston seals 1 2 EB702040 CHECKING THE FRONT AND REAR BRAKE C...

Page 392: ...sage brake caliper body Blockage Blow out with compressed air WARNING Replace the caliper piston seals and dust seals whenever the brake caliper is disas sembled 1 2 3 1 2 EBS00431 ASSEMBLING THE FRON...

Page 393: ...the brake pipe touches the projection a on the brake caliper WARNING _ Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING in chapter 2 Front Rear 1 2 3 a N...

Page 394: ...l reaction and lead to poor brake performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result...

Page 395: ...move the parts in the order listed Rear skid plate Refer to SEATS ENCLOSURE HOOD AND CARGO BED Right rear wheel Refer to REAR WHEELS 1 Spring 1 Refer to REPLACING THE PARKING BRAKE PADS 2 Parking brak...

Page 396: ...ds and a new brake pad spring as a set T R Parking brake pad holding bolt 17 Nm 1 7 m kg 12 ft lb LOCTITE 3 Install parking brake cable 1 parking brake assembly 2 parking brake bolts TIP Turn the park...

Page 397: ...eats rear console Refer to SEATS REAR CONSOLE AND INSTRUMENT PANELS Rear skid plate Refer to SEATS ENCLOSURE HOOD AND CARGO BED Right rear wheel Refer to REAR WHEELS 1 Parking brake switch coupler 1 D...

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

Page 399: ...e parking brake Remove the parts in the order listed 1 Parking brake pad holding bolt 2 Refer to ASSEMBLING THE PARKING BRAKE 2 Parking brake pad 2 3 Brake pad spring 1 4 Parking brake arm nut 1 5 Par...

Page 400: ...Removing the parking brake disc Remove the parts in the order listed Parking brake assembly Refer to FRONT AND REAR BRAKES Final drive gear assembly Refer to REAR CONSTANT VELOCITY JOINTS FINAL DRIVE...

Page 401: ...THE PARKING BRAKE DISC 1 Check brake disc Galling damage Replace 2 Measure brake disc deflection Out of specification Replace brake disc thickness a Out of specification Replace Brake disc maximum def...

Page 402: ...1 TIP Install the parking brake arm onto the parking brake arm shaft and then rotate the arm until it contacts the stopper a If the parking brake arm shaft does not rotate repeat steps 1 and 2 1 a 4 I...

Page 403: ...P Turn the parking brake lever 3 to the position shown in the illustration so that there is enough space between the parking brake pads and then install the parking brake assembly 8 Adjust parking bra...

Page 404: ...ring wheel pedal cover upper instrument panel lower instrument panel Refer to SEATS ENCLOSURE HOOD AND CARGO BED Steering joint Refer to STEERING SYSTEM Brake master cylinder Refer to FRONT AND REAR B...

Page 405: ...Part Q ty Remarks Disassembling the pedal assembly Remove the parts in the order listed 1 Spring 1 2 Circlip 1 3 Washer 2 4 Brake pedal 1 5 Spring 1 6 Circlip 1 7 Washer 2 8 Accelerator pedal 1 9 Peda...

Page 406: ...m 3 9 m kg 28 ft Ib New New Order Job Part Q ty Remarks Removing the steering shaft and steering assembly Remove the parts in the order listed Steering wheel cover steering wheel upper instrument pane...

Page 407: ...Part Q ty Remarks Disassembling the steering assem bly Remove the parts in the order listed 1 Tie rod end locknut 2 Refer to ASSEMBLING THE STEER ING ASSEMBLY 2 Tie rod end 2 3 Plastic locking tie 2 4...

Page 408: ...ew T R 40 Nm 4 0 m kg 29 ft Ib 0 New New LT LS LS LS LS LS LS M M T R 4 Nm 0 4 m kg 2 9 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib M Order Job Part Q ty Remarks C Steering rack assembly 1 Refer to ASSEMBLING T...

Page 409: ...Check steering joint Rough movement Replace CHECKING THE STEERING ASSEMBLY 1 Check pinion gear bearing Check the bearing movement on the pinion gear by rotating with the fingers Roughness Replace 2 Ch...

Page 410: ...rn may indicate improper adjustment or lack of lubrication 1 2 4 Check pressure pad Wear damage Replace dust boots Damage Replace 5 Check tie rod free play and movement Free play Replace the tie rod e...

Page 411: ...ly lithium soap based grease to the gear surface of the rack gear Lithium soap based grease 5 10 g 0 2 0 4 oz New New a 4 Adjust rack gear pinion gear backlash a Install the pressure pad spring and ad...

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

Page 413: ...ay Replace the tie rod end Turns roughly Replace the tie rod end 2 Check tie rods Bends damage Replace CHECKING THE STEERING KNUCKLES 1 Check steering knuckles Damage pitting Replace 2 Check ball join...

Page 414: ...5 to remove the ball joint A from the steering knuckle f Remove the ball joint remover Ball joint remover 90890 01474 YM 01474 Ball joint remover adapter set 90890 01477 YM 01477 3 Body 90890 01474 Y...

Page 415: ...e a new ball joint set m Install a steering knuckle oil seal 3 Check front wheel bearings Bearings allow play in the wheel hubs or the wheel turns roughly Replace oil seals Damage Replace a Clean the...

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

Page 417: ...ty Remarks Removing the front arms and front shock absorbers Remove the parts in the order listed Front wheel brake disc Refer to FRONT AND REAR WHEELS 1 Brake disc guard 1 2 Front arm protector 1 3...

Page 418: ...30 Nm 3 0 m kg 22 ft Ib 3 2 LS LS 9 10 8 T R 45 Nm 4 5 m kg 32 ft Ib New Order Job Part Q ty Remarks 8 Front shock absorber 1 For models equipped with gas oil damper shock absorbers Refer to REMOVING...

Page 419: ...it up and down If the vertical movement is tight or rough or if there is binding check the bushings 2 Remove front arms CHECKING THE FRONT ARMS 1 Check front arms Bends damage Replace 2 Check bushings...

Page 420: ...the assembled ball joint remover new ball joint A and installer attachment 7 to the front lower arm B TIP Do not tap or damage the top of the ball joint h Hold the body 3 in place while turning in th...

Page 421: ...r read and make sure you understand the following information The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the front sho...

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

Page 423: ...TIP Lubricate the bolts 3 with lithium soap based grease Be sure to position the bolts 3 so that the bolt head faces outward Temporarily tighten the nuts 4 b Install the front shock absorber 5 c Inst...

Page 424: ...Ib New LS LS T R 42 Nm 4 2 m kg 30 ft Ib Order Job Part Q ty Remarks Removing the rear knuckle and sta bilizer Remove the parts in the order listed Rear wheel hubs Refer to FRONT AND REAR WHEELS 1 Bra...

Page 425: ...Eye protection is recommended when using striking tools d Remove the spacer 3 e Apply lithium base grease to the new bear ings and oil seals f Install the spacer to the rear knuckle g Install the new...

Page 426: ...Part Q ty Remarks Removing the rear arms and rear shock absorber Remove the parts in the order listed Rear knuckle stabilizer Refer to REAR KNUCKLE AND STABI LIZER 1 Rear arm protector 1 Refer to INS...

Page 427: ...S LS LS 6 T R 7 Nm 0 7 m kg 5 1 ft Ib 1 Order Job Part Q ty Remarks 6 Rear shock absorber 1 For models equipped with gas oil damper shock absorbers Refer to INSTALLING THE REAR ARMS AND REAR SHOCK ABS...

Page 428: ...sure you understand the following information The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber and...

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

Page 430: ...r lower arm 2 TIP Lubricate the bolts 3 with lithium soap based grease Be sure to position the bolts 3 so that the bolt head faces inward Temporarily tighten the nuts 4 b Install the rear shock absorb...

Page 431: ...ntake air temperature sensor 7 Intake air pressure sensor 8 TPS throttle position sensor 9 ISC idle speed control unit 0 Coolant temperature sensor A Crankshaft position sensor B Speed sensor C Fuel p...

Page 432: ...or 6 Four wheel drive motor relay 2 7 Four wheel drive motor relay 1 8 Starter relay 9 Fuel injection system fuse 0 Headlight relay A Fuel injection system relay B Main fuse C Radiator fan motor relay...

Page 433: ...n checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch are shown in an illustration simi lar to the one on the l...

Page 434: ...tween the ter minals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch 2 3 1 R B L Y Br R Br Br R...

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

Page 436: ...The bulbs used on this vehicle are shown in the illustration on the left Bulbs a and b are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The maj...

Page 437: ...herwise it may be pulled out of the ter minal in the coupler Avoid touching the glass part of the head light bulb to keep it free from oil other wise the transparency of the glass the life of the bulb...

Page 438: ...TION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets 1 Check bulb socket for continuity with the pocket tester No continuity Replace TIP _ Check each bulb socket for con...

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

Page 440: ...BS01043 YES NO EBS01044 YES NO The ignition system fails to operate no spark or intermittent spark Ignition checker 90890 06754 Opama pet 4000 spark checker YM 34487 Pocket tester 90890 03112 Analog p...

Page 441: ...condition is it of the correct type and is its gap within spec ification Re gap or replace the spark plug 4 Ignition spark gap Disconnect the spark plug cap from the spark plug Connect the ignition c...

Page 442: ...nition coil connectors from the ignition coil terminals Connect the pocket tester 1 to the ignition coil as shown Positive tester probe brown red lead terminal 1 Negative tester probe orange lead term...

Page 443: ...he crankshaft position sensor OK Replace the crank shaft position sensor stator assembly Gy B 2 1 9 Lean angle sensor Remove the lean angle sensor Connect the pocket tester DC 20 V to the lean angle s...

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

Page 445: ...position the starter motor can be operated only if 1 Battery 2 Main fuse 3 Backup fuse 4 Ignition fuse 5 Main switch 6 Load control relay 7 Signaling system fuse 8 Brake light switch 9 ECU engine cont...

Page 446: ...ckup and sig naling system fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition backup and signal ing system fuses OK Replace the fuse s 2 Battery Check the condition of...

Page 447: ...black 4 Does the starter relay have continuity between red and black Replace the starter relay R Y L Y Br B R B 1 4 3 2 5 Load control relay Remove the load control relay from the wire harness Connec...

Page 448: ...y Refer to CHECKING THE SWITCHES Is the brake light switch OK Replace the brake light switch 8 Gear position switch Check the gear position switch for continu ity Refer to CHECKING THE SWITCHES Is the...

Page 449: ...SE AND AIR INTAKE DUCT in chapter 6 1 Starter motor lead 1 Disconnect 2 Starter motor 1 For installation reverse the removal pro cedure Disassembling the starter motor Remove the parts in the order li...

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

Page 451: ...it 27 mm 1 06 in a 3 Measure mica undercut a Out of specification Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator TIP _ The mica of the comm...

Page 452: ...nce 1 0 0250 0 0350 at 20 C 68 F Insulation resistance 2 Above 1 M at 20 C 68 F 5 Measure brush length a Out of specification Replace the brushes as a set Brush length wear limit 5 00 mm 0 20 in 6 Mea...

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

Page 454: ...R Y R R Br L Br R B L Y BLACK Br R Br R R B Br B R Y BLACK L Y OFF ON START Br B R R Br L P R R W Br L Br Y R R R R B B B B B B B B W W W W R W W L Y R Y B R B Br R Br R L Y R P B B L Gy R LY R R R R...

Page 455: ...al tool s EBS01043 YES NO EBS01044 YES NO The battery is not being charged Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Main fuse Check the main fuse for continuity Refer to CHECKING TH...

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

Page 457: ...OFF ON START Br B R L R W R R Br L P R R W Br R Br L Br L Br Y Br L Br R R R R B B B B B B B B W W W W R W W L Y R Y B R B Br R Br R L Y R P B L Y B L Gy R Y Y G Y B B L Y Y Y Br Br Y B L Y B G Br R...

Page 458: ...112 C 1 Main ignition and headlight fuses Check the main ignition and headlight fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and headlight fuses OK Replace the f...

Page 459: ...Positive tester probe red 3 Negative tester probe brown blue 4 Does the load control relay have continuity between red and brown blue Replace the load control relay R Br L Br R B 1 2 3 4 6 Wiring Chec...

Page 460: ...t bulb socket or both 2 Headlight relay Remove the headlight relay Connect the pocket tester 1 and bat tery 12 V to the headlight relay as shown high beam low beam Positive battery terminal yellow 1 N...

Page 461: ...ch to the headlight cou pler is faulty and must be repaired 1 Taillight bulb and socket Check the taillight bulb and socket for con tinuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the taillig...

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

Page 463: ...sor M Speed sensor Q Gear position switch R Parking brake switch T Multifunction meter V Coolant temperature warning light W Park indicator light X Reverse indicator light Y Neutral indicator light Z...

Page 464: ...t tester 90890 03112 Analog pocket tester YU 03112 C 1 Main backup signaling system and igni tion fuses Check the main backup signaling system and ignition fuses for continuity Refer to CHECKING THE F...

Page 465: ...sitive tester probe red 3 Negative tester probe brown blue 4 Does the load control relay have continuity between red and brown blue Replace the load control relay R Br L Br R B 1 2 3 4 5 Wiring Check...

Page 466: ...ake light switch for continuity Refer to CHECKING THE SWITCHES Is the brake light switch OK Replace the brake light switch 3 Voltage Connect the pocket tester DC 20 V to the tail brake light connector...

Page 467: ...lue Is the wiring circuit properly connected and without defects Properly connect or repair the wiring cir cuit 3 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler as shown Posit...

Page 468: ...t properly connect and without defects Properly connect or repair the wiring cir cuit 3 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler as shown Positive tester probe brown yel...

Page 469: ...wiring circuit properly connect and without defects Properly connect or repair the wiring cir cuit 3 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler as shown Positive tester p...

Page 470: ...switch to ECU and ECU to meter assembly yellow blue Is the wiring circuit properly connect and without defects Properly connect or repair the wiring cir cuit 3 Voltage Connect the pocket tester DC 20...

Page 471: ...lant Slowly heat the coolant and then let it cool to the specified temperature indicated in the table Measure the coolant temperature sensor resistance Coolant temperature sensor resistance 290 354 at...

Page 472: ...n switch to the meter assem bly coupler is faulty and must be repaired Y L Br Y B W Y L Br Y B W O B R W O B R W 2 1 1 Fuel sender Drain the fuel from the fuel tank and then remove the fuel pump assem...

Page 473: ...er assembly The wiring circuit from the main switch to the meter assem bly coupler is faulty and must be repaired Y L Br Y B W Y L Br Y B W O B R W O B R W 2 1 1 Speed sensor Connect the pocket tester...

Page 474: ...tester probe black white 2 Set the main switch to ON Measure the voltage 12 V of brown yel low 1 and black white 2 at the meter assembly coupler Is the voltage within specification Replace the meter a...

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

Page 476: ...motor fails to turn Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Main ignition and radiator fan motor fuses Check the main ignition and radiator fan motor fuses for continuity Refer to...

Page 477: ...nd must be replaced 5 Radiator fan motor relay Remove the radiator fan motor relay from the wire harness Connect the pocket tester 1 and bat tery 12 V to the radiator fan motor relay terminal as shown...

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

Page 479: ...re indicated in the table Measure the coolant temperature sensor resistance Coolant temperature sensor resistance 290 354 at 80 C 176 F WARNING _ Handle the coolant temperature sensor with special car...

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

Page 481: ...2 Analog pocket tester YU 03112 C 1 Main ignition and fuel injection system fuses Check the main ignition and fuel injection system fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are th...

Page 482: ...e red 2 Positive tester probe brown black 3 Negative tester probe red blue 4 Does the fuel injection system relay have continuity between brown black and red blue Replace the fuel injection system rel...

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

Page 484: ...S NO EBS01041 YES NO The four wheel drive motor indicator light fails to come on Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Main ignition and four wheel drive motor fuses Check the ma...

Page 485: ...Negative tester probe brown red 5 Check the four wheel drive motor relay 1 for continuity Replace the four wheel drive motor relay 1 5 Four wheel drive motor relay 2 Remove the four wheel drive motor...

Page 486: ...Positive tester probe brown 3 Negative tester probe gray 4 Check the four wheel drive motor relay 3 for continuity Replace the four wheel drive motor relay 3 7 On command four wheel drive motor switc...

Page 487: ...pinion gear 2 turns counter clockwise Check that the pinion gear 2 turns clockwise Make sure that the drive gear shift fork sliding gear operates correctly TIP When installing the differential gear m...

Page 488: ...aminated fuel Sucked in air Air filter Clogged air filter element ELECTRICAL SYSTEM Spark plug Improper plug gap Worn electrodes Wire between terminals broken Improper heat range Faulty spark plug cap...

Page 489: ...ton ring Seized or damaged piston Crankcase and crankshaft Improperly seated crankcase Seized crankshaft Valve train Improperly adjusted valve clearance Improperly adjusted valve timing EBS00538 POOR...

Page 490: ...Causes 1 A pronounced hesitation or jerky move ment during acceleration deceleration or sustained speed This must not be con fused with engine surging or transmission characteristics 2 A rolling rumb...

Page 491: ...ft drum groove Transmission Worn gear dog EBS00543 FAULTY CLUTCH PERFORMANCE ENGINE OPERATES BUT VEHICLE WILL NOT MOVE V belt Bent damaged or worn V belt V belt slips Primary pulley cam and primary pu...

Page 492: ...lty throttle body Damaged or loose throttle body joint Clogged air filter element Compression system Heavy carbon build up Engine oil Improper oil level Improper oil viscosity Inferior oil quality Bra...

Page 493: ...s Deformed steering knuckles Tires Uneven tire pressures on both sides Incorrect tire pressure Uneven tire wear Wheels Deformed wheel Loose bearing Bent or loose wheel axle Excessive wheel runout Fram...

Page 494: ...heel drive motor relay 2 c Four wheel drive motor relay 3 d On command four wheel drive motor switch and differential gear lock switch e Differential gear motor f Auxiliary DC jack g Auxiliary DC jack...

Page 495: ......

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

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

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