Yamaha 2016 Grizzly yfm700gplg Service Manual
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Yamaha 2016 Grizzly yfm700gplg Service Manual

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Table of Contents

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SERVICE MANUAL
YF70GG
YF70GPG
YF70GPSG
YF70GPLG
YFM70GDXG
YFM70GDHG
YFM70GPXG
YFM70GPHG
YFM70GPSG
YFM70GPLG
YFM700FWAD
2016
2UD-F8197-E0

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Summary of Contents for Yamaha 2016 Grizzly yfm700gplg

  • Page 1 2016 SERVICE MANUAL YF70GG YF70GPG YF70GPSG YF70GPLG YFM70GDXG YFM70GDHG YFM70GPXG YFM70GPHG YFM70GPSG YFM70GPLG YFM700FWAD 2UD-F8197-E0...
  • Page 2 EBS20002 YF70GG/YF70GPG/YF70GPSG/ YF70GPLG/YFM70GDXG/ YFM70GDHG/YFM70GPXG/ YFM70GPHG/YFM70GPSG/ YFM70GPLG/YFM700FWAD SERVICE MANUAL ©2015 by Yamaha Motor Co., Ltd. First edition, July 2015 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
  • Page 4 EBS20004 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 5 EBS20005 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 7: Table Of Contents

    EBS10003 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM DRIVE TRAIN ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-3 OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) ..................1-3 INSTRUMENT FUNCTIONS ..............1-5 IMPORTANT INFORMATION ................. 1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-7 REPLACEMENT PARTS................1-7 GASKETS, OIL SEALS AND O-RINGS ............

  • Page 10: Identification

    IDENTIFICATION EBS20009 IDENTIFICATION EBS30003 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the frame. EBS30004 MODEL LABEL The model label “1” is affixed at the location in the illustration. This information will be needed to order spare parts.
  • Page 11 IDENTIFICATION...

  • Page 12: Features

    FEATURES EBS20010 FEATURES EBS30007 OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
  • Page 13 FEATURES 1. Speed information from speed sensor b. Twists torsion bar 2. Engine RPM information from ECU c. Sends the torque sensor signal 3. Battery d. EPS control unit calculates assist power 4. EPS control unit e. Electricity output switched by EPS control unit 5.

  • Page 14: Instrument Functions

    FEATURES Clock mode EBS30008 INSTRUMENT FUNCTIONS Pushing the “CLOCK” button switches the dis- play between the clock mode “CLOCK” and the Multi-function display hour meter mode “HOUR” in the following order: CLOCK → HOUR → CLOCK To set the clock 1.
  • Page 15 FEATURES Self-diagnosis device 1. Fault code display 2. Engine trouble warning light This model is equipped with a self-diagnosis de- vice for various electrical circuits. If a problem is detected in any of those circuits, the engine trouble warning light will come on or flash and the multi-function display will indicate an fault code.

  • Page 16: Important Information

    5. Keep all parts away from any source of fire. EBS30010 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...

  • Page 17: Bearings And Oil Seals

    IMPORTANT INFORMATION EBS30013 EBS30015 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in- manufacturer’s marks or numbers are visible. spection. Some of the rubber parts are sensitive When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc.

  • Page 18: Basic Service Information

    BASIC SERVICE INFORMATION EBS20012 BASIC SERVICE INFORMATION EBS30016 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.

  • Page 19: Electrical System

    BASIC SERVICE INFORMATION ECB01520 EBS30017 NOTICE ELECTRICAL SYSTEM Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- Electrical parts handling tery lead connections could damage the ECB01460 NOTICE electrical components. Never disconnect a battery lead while the en- gine is running;...
  • Page 20 BASIC SERVICE INFORMATION ECB01480 Checking the electrical system NOTICE Handle electrical components with special Before checking the electrical system, make care, and do not subject them to strong shocks. sure that the battery voltage is at least 12 V. ECB01490 ECB01440 NOTICE NOTICE...
  • Page 21 BASIC SERVICE INFORMATION 2. Check: Checking the connections • Lead Check the leads, couplers, and connectors for • Coupler stains, rust, moisture, etc. • Connector 1. Disconnect: Moisture → Dry with an air blower. • Lead Rust/stains → Connect and disconnect sev- •...
  • Page 22 BASIC SERVICE INFORMATION The resistance values shown were obtained at the standard measuring temperature of 20 °C (68 °F). If the measuring temperature is not 20 °C (68 °F), the specified measuring conditions will be shown. Intake air temperature sensor re- sistance 5.40–6.60 kΩ...

  • Page 23: Special Tools

    9-95, 9-96, 9-96, 9-96, 9-97, 9-97, 9-98, 9-98 Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 Valve lapper 90890-04101 90890-04101 Valve lapping tool YM-A8998 YM-A8998 Yamaha diagnostic tool 3-9, 9-33 90890-03231 Ring nut wrench 3-18, 3-19 90890-01268 Spanner wrench YU-01268 1-14...
  • Page 24 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Belt tension gauge 3-21 90890-03170 Rear drive belt tension gauge YM-03170 Oil filter wrench 3-24 90890-01426 Oil filter wrench YU-38411 Pressure gauge 3-25, 7-7 90890-03153 Pressure gauge YU-03153 Oil pressure adapter H 3-25 90890-03139 Damper rod holder (30 mm)
  • Page 25 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Extension 90890-04136 Compression gauge 90890-03081 90890-03081 Engine compression tester YU-33223 YU-33223 Piston pin puller set 5-22 90890-01304 Piston pin puller YU-01304 YU-01304 Valve spring compressor 5-29, 5-33 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attachment 5-29, 5-33 90890-01243...
  • Page 26 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide remover & installer set (ø5.5) 5-31 90890-04016 Valve guide installer (5.5 mm) YM-04015 Valve guide remover & installer set (ø5.5) 5-31 90890-04016 Valve guide reamer (5.5 mm) YM-01196 Rotor holding tool 5-37, 5-37, 5-38, 90890-04166 5-39, 5-45, 5-46,...
  • Page 27 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Locknut wrench 5-52, 5-56 90890-01348 Locknut wrench YM-01348 Sheave spring compressor 5-52, 5-56 90890-04134 Sheave spring compressor YM-04134 Universal clutch holder 5-61, 5-62 90890-04086 Universal clutch holder YM-91042 Crankcase separating tool 5-67, 5-72 90890-01135 Crankcase separator YU-01135-B...
  • Page 28 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Yamaha bond No. 1215 5-68 90890-85505 (Three bond No.1215®) Crankshaft installer pot 5-74 90890-01274 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt 5-74 90890-01275 Bolt YU-90060 Adapter (M16) 5-74 90890-04130 Adapter #13 YM-04059...
  • Page 29 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Ring nut wrench 5-85, 5-86 90890-01430 Ring nut wrench YM-38404 Final gear backlash band 5-88, 8-29 90890-01511 Middle drive gear lash tool YM-01230 Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter...
  • Page 30 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Test harness– TPS (3P) 90890-03204 Test harness– TPS (3P) YU-03204 Boots band installation tool 8-9, 8-11, 8-21, 90890-01526 8-21, 8-23 Boots band installation tool YM-01526 Ring gear fix bolt (M10) 8-13 90890-01527 Ring gear fix bolt (M10) YM-01527 M10×P1.25...

  • Page 31: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-9 TIGHTENING TORQUES ................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-12 ENGINE TIGHTENING TORQUES............2-13 CHASSIS TIGHTENING TORQUES............2-18 LUBRICATION POINTS AND LUBRICANT TYPES ........2-23 ENGINE....................2-23 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-25 ENGINE OIL LUBRICATION CHART .............2-25 LUBRICATION DIAGRAMS ..............

  • Page 32: General Specifications

    GENERAL SPECIFICATIONS EBS20014 GENERAL SPECIFICATIONS Model Model 2UD2 (YF70GPG) (for CDN) 2UD3 (YFM70GPXG) (for Europe) 2UD4 (YFM70GPXG) (for Oceania) 2UD5 (YFM700FWAD) (for Russia) 2UD7 (YF70GPG) (for CDN) 2UD8 (YFM70GPHG) (for Europe) 2UD9 (YFM70GPHG) (for Oceania) 2UDA (YFM700FWAD) (for Russia) B302 (YF70GG) (for CDN) B303 (YFM70GDXG) (for Europe) B305 (YFM70GDHG) (for Europe) B312 (YF70GPSG) (for CDN)

  • Page 33: Engine Specifications

    2.10 L (2.22 US qt, 1.85 Imp.qt) Quantity (disassembled) 2.60 L (2.75 US qt, 2.29 Imp.qt) Differential gear oil Type Yamaha Friction Modified Plus Shaft Drive Oil (Part No.: ACC-SHFTL-PL-32) or SAE 80 API GL-4 Hypoid gear oil Quantity 0.22 L (0.23 US qt, 0.19 Imp.qt) Quantity (disassembled) 0.23 L (0.24 US qt, 0.20 Imp.qt)
  • Page 34 ENGINE SPECIFICATIONS Oil pump Inner-rotor-to-outer-rotor-tip clearance limit 0.20 mm (0.0079 in) Outer-rotor-to-oil-pump-housing clearance limit 0.240 mm (0.0094 in) Oil pressure (hot) 50.0 kPa/1600 r/min (0.50 kgf/cm²/1600 r/min, 7.3 psi/1600 r/min) Cooling system Coolant quantity Radiator (including all routes) 1.76 L (1.86 US qt, 1.55 Imp.qt) Coolant reservoir (up to the maximum level mark) 0.25 L (0.26 US qt, 0.22 Imp.qt)
  • Page 35 ENGINE SPECIFICATIONS Valve seat contact width (exhaust) limit 1.9 mm (0.07 in) Valve stem diameter (intake) limit 5.420 mm (0.2134 in) Valve stem diameter (exhaust) limit 5.415 mm (0.2132 in) Valve guide inside diameter (intake) limit 5.550 mm (0.2185 in) Valve guide inside diameter (exhaust) limit 5.550 mm (0.2185 in) Valve-stem-to-valve-guide clearance (intake)
  • Page 36 ENGINE SPECIFICATIONS V-belt V-belt width limit 31.3 mm (1.23 in) Transmission type V-belt automatic Operation Left hand operation Low range 31/16 (1.938) High range 27/25 (1.080) 23/14 × 28/23 (2.000) Reverse gear Gear ratio 2.380–0.700 : 1 Drive axle runout limit 0.06 mm (0.0024 in) 43/21 ×...
  • Page 37 ENGINE SPECIFICATIONS Air induction system 18–22 Ω Solenoid resistance...

  • Page 38: Chassis Specifications

    CHASSIS SPECIFICATIONS EBS20016 CHASSIS SPECIFICATIONS Chassis Frame type Steel tube frame Caster angle 4.53° Camber angle 0.3° Kingpin angle 11.3° Kingpin offset 0.0 mm (0.00 in) Trail 26.0 mm (1.02 in) Toe-in (with tires touching the ground) 0.0–10.0 mm (0.00–0.39 in) Tread rear (STD) 975.0 mm (38.39 in) Tread front (STD)
  • Page 39 CHASSIS SPECIFICATIONS Minimum Vehicle load 0 - maximum Front 32.0 kPa (0.320 kgf/cm², 4.6 psi) Rear 27.0 kPa (0.270 kgf/cm², 4.0 psi) Front brake Type Hydraulic disc brake Operation Right hand operation Disc outside diameter × thickness 220.0 × 3.5 mm (8.66 × 0.14 in) Brake disc thickness limit 3.0 mm (0.12 in) Brake disc deflection limit...

  • Page 40: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EBS20017 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Engine control unit Model/manufacturer F8T85873/MITSUBISHI (YF70GPLG, YF70GPSG, YFM70GPLG, YFM70GPSG) F8T85875/MITSUBISHI (YF70GPG, YFM700FWAD, YFM70GPHG, YFM70GPXG) F8T85876/MITSUBISHI (YF70GG, YFM70GDHG, YFM70GDXG) Ignition system Ignition system Advancer type Digital Ignition timing (B.T.D.C.) 7.0°/1600 r/min 152.0–228.0 Ω...
  • Page 41 ELECTRICAL SPECIFICATIONS Coolant temperature warning light Park indicator light Engine trouble warning light High-range indicator light Low-range indicator light Differential gear lock indicator light EPS warning light LED (YF70GPG, YF70GPLG, YF70GPSG, YFM700FWAD, YFM70GPHG, YFM70GPLG, YFM70GPSG, YFM70GPXG) Starter motor Power output 0.80 kW 0.005–0.015 Ω...
  • Page 42 ELECTRICAL SPECIFICATIONS Headlight fuse 10.0 A Signaling system fuse 10.0 A Ignition fuse 10.0 A Radiator fan motor fuse 20.0 A Auxiliary DC jack fuse 10.0 A Fuel injection system fuse 15.0 A Four-wheel-drive motor fuse 10.0 A EPS fuse 40.0 A (YF70GPG, YF70GPLG, YF70GPSG, YFM700FWAD, YFM70GPHG, YFM70GPLG, YFM70GPSG, YFM70GPXG)

  • Page 43: Tightening Torques

    TIGHTENING TORQUES EBS20018 TIGHTENING TORQUES EBS30018 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

  • Page 44: Engine Tightening Torques

    TIGHTENING TORQUES EBS30019 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size V-belt cooling exhaust duct joint 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) clamp screw V-belt cooling intake duct joint clamp 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) screw Exhaust pipe nut 20 Nm (2.0 m·kgf, 14 ft·lbf) Muffler bolt 33 Nm (3.3 m·kgf, 24 ft·lbf)
  • Page 45 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil filter cartridge union bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) Oil hose union bolt (crankcase to 18 Nm (1.8 m·kgf, 13 ft·lbf) cylinder) Oil pipe bolt (crankcase) 35 Nm (3.5 m·kgf, 25 ft·lbf) Oil pipe bolt (AC magneto cover) 18 Nm (1.8 m·kgf, 13 ft·lbf) Oil pump drive sprocket nut...
  • Page 46 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Stake. Middle drive shaft bearing retainer 29 Nm (2.9 m·kgf, 21 ft·lbf) bolt Rear drive shaft coupling gear nut 150 Nm (15 m·kgf, 108 ft·lbf) (middle gear side) Left-hand thread Middle driven shaft bearing retainer 80 Nm (8.0 m·kgf, 58 ft·lbf) Middle driven pinion gear bearing 25 Nm (2.5 m·kgf, 18 ft·lbf)
  • Page 47 TIGHTENING TORQUES Cylinder head bolt and cylinder bolt 1. Temporarily tighten the cylinder head bolts (M6) and cylinder bolts (M6). 2. Tighten the cylinder head bolts (M11) to 30 Nm (3.0 m·kgf, 22 ft·lbf) in the proper tightening se- quence. 3.
  • Page 48 TIGHTENING TORQUES Oil pump bolt Tighten the oil pump bolts to 10 Nm (1.0 m·kgf, 7.2 ft·lbf) in the proper tightening sequence. 2-17...

  • Page 49: Chassis Tightening Torques

    TIGHTENING TORQUES EBS30020 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (front) (M6) 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Engine mounting bolt (front) (M10) 42 Nm (4.2 m·kgf, 30 ft·lbf) Engine mounting bolt (rear) (M6) 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Engine mounting bolt (rear) (M10) 42 Nm (4.2 m·kgf, 30 ft·lbf)
  • Page 50 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Air intake duct clamp screw 0.8 Nm (0.08 m·kgf, 0.58 ft·lbf) Storage compartment bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Front carrier bolt 34 Nm (3.4 m·kgf, 25 ft·lbf) Front carrier bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Front guard bolt 34 Nm (3.4 m·kgf, 25 ft·lbf)
  • Page 51 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Brake caliper retaining pin nut 22 Nm (2.2 m·kgf, 16 ft·lbf) Brake caliper bleed screw 5 Nm (0.5 m·kgf, 3.6 ft·lbf) Steering knuckle and front upper 30 Nm (3.0 m·kgf, 22 ft·lbf) arm nut Steering knuckle and front lower arm 30 Nm (3.0 m·kgf, 22 ft·lbf)
  • Page 52 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front brake lever pivot nut 6 Nm (0.6 m·kgf, 4.3 ft·lbf) Rear brake lever pivot bolt 6 Nm (0.6 m·kgf, 4.3 ft·lbf) Rear brake lever pivot nut 6 Nm (0.6 m·kgf, 4.3 ft·lbf) Steering stem bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) Steering stem bracket bolt...
  • Page 53 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size ECU (engine control unit) screw 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) Intake air temperature sensor screw 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) Rectifier/regulator bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Ignition coil bolt 9 Nm (0.9 m·kgf, 6.5 ft·lbf) Horn bracket bolt (except for CDN) 7 Nm (0.7 m·kgf, 5.1 ft·lbf)

  • Page 54: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES EBS20094 LUBRICATION POINTS AND LUBRICANT TYPES EBS30021 ENGINE Lubrication point Lubricant/Sealant Oil seal lips Bearings O-rings Cylinder head bolt threads and washers Crankshaft seals Piston pin Cylinder inner surface, piston, piston rings and ring grooves Valve stems and stem ends (intake and exhaust) Valve stem seals (intake and exhaust) Valve lifter surfaces...
  • Page 55 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant/Sealant Yamaha bond No.1215 Crankcase mating surface (Three Bond No.1215®) 2-24...

  • Page 56: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EBS20020 LUBRICATION SYSTEM CHART AND DIAGRAMS EBS30022 ENGINE OIL LUBRICATION CHART 2-25...
  • Page 57 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pan 2. Oil strainer 3. Oil pump 4. Relief valve 5. Oil filter cartridge 6. Drive axle 7. Reverse idle gear shaft 8. Oil pipe (crankcase) 9. Oil hose (crankcase to cylinder) 10. Crankshaft 11.

  • Page 58: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EBS30023 LUBRICATION DIAGRAMS 2-27...
  • Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil hose (crankcase to cylinder) 2. Oil pipe (crankcase) 3. Oil filter cartridge 4. Oil strainer 5. Oil pump 6. Oil pipe (AC magneto cover) 7. Reverse idle gear shaft 8. Drive axle 9. Relief valve 2-28...
  • Page 60 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Crankshaft 3. Oil strainer 4. Oil pump 5. Oil pump driven sprocket 2-30...

  • Page 62: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EBS20021 COOLING SYSTEM DIAGRAMS 2-31...
  • Page 63 COOLING SYSTEM DIAGRAMS 1. Coolant reservoir hose 2. Radiator inlet hose 3. Coolant reservoir 4. Water pump 5. Water pump inlet hose 6. Water pump outlet pipe 7. Oil cooler inlet hose 8. Water pump outlet hose 9. Radiator outlet hose 10.

  • Page 64: Cable Routing

    CABLE ROUTING EBS20022 CABLE ROUTING Handlebar (front view 1) 2-33...
  • Page 65 CABLE ROUTING 1. Front brake hose 2. Throttle cable 3. Rear brake cable 4. Shift control cable 5. Rear brake hose 6. Front brake light switch lead 7. On-Command four-wheel-drive motor switch and differential gear lock switch lead 8. Meter assembly lead 9.
  • Page 66 CABLE ROUTING Handlebar (front view 2) 2-35...
  • Page 67 CABLE ROUTING 1. Front brake light switch lead 2. On-Command four-wheel-drive motor switch and differential gear lock switch lead 3. Rear brake light switch lead 4. Handlebar switch lead (left) 5. Differential case breather hose 6. Radiator fan motor breather hose 7.
  • Page 68 CABLE ROUTING Engine (left side view) 2-37...
  • Page 69 CABLE ROUTING 1. Coolant reservoir hose 2. Radiator fan motor breather hose 3. Differential case breather hose 4. Ground lead 5. Coolant reservoir breather hose 6. Throttle body breather hose 7. TPS lead 8. Intake air pressure sensor lead 9. Final drive case breather hose 10.
  • Page 70 CABLE ROUTING Engine (right side view 1) 11 12 13 14 15 2-39...
  • Page 71 CABLE ROUTING 1. AC magneto/crankshaft position sensor lead 2. ISC unit lead 3. Final drive case breather hose 4. Negative battery lead 5. Starter motor lead 6. Throttle body breather hose 7. Coolant temperature sensor lead 8. Throttle cable 9. Wire harness 10.
  • Page 72 CABLE ROUTING Engine (right side view 2) 2-41...
  • Page 73 CABLE ROUTING 1. Tail/brake light lead 2. Fuel tank breather hose 3. Circuit breaker 4. Rectifier/regulator lead 5. AC magneto/crankshaft position sensor lead 6. Wire harness 7. Speed sensor lead 8. Final drive case breather hose 9. Fuel hose 10. Fuel pump lead A.
  • Page 74 CABLE ROUTING Electrical components tray (top view) 2-43...
  • Page 75 CABLE ROUTING 1. Headlight lead (left) L. Pass the coolant reservoir breather hose through the guides on the electrical components tray and 2. Four-wheel-drive motor relay 1 route it under the positive battery lead and starter 3. Four-wheel-drive motor relay 2 motor lead.
  • Page 76 CABLE ROUTING Engine (top view) 2-45...
  • Page 77 CABLE ROUTING 1. Throttle cable 2. Rear brake cable 3. Rear brake hose 4. Shift control cable 5. Front brake hose 6. Negative battery lead 7. Final drive case breather hose 8. Starter motor lead 9. Throttle body breather hose 10.
  • Page 78 CABLE ROUTING Front and rear brake hoses 2-47...
  • Page 79 CABLE ROUTING 1. Front brake pipe 2. Front brake hose 3. Rear brake pipe 4. Rear brake hose A. Face the mark on the front brake pipe upward. B. Route the front brake hose above the frame. C. Pass the front brake hose through the holder. D.
  • Page 80 CABLE ROUTING 2-49...

  • Page 81: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .......3-1 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUG ............... 3-4 ADJUSTING THE VALVE CLEARANCE ..........3-5 CHECKING THE BREATHER HOSES .............3-8 CHECKING THE EXHAUST SYSTEM............3-8 ADJUSTING THE EXHAUST GAS VOLUME ...........3-8...
  • Page 82 LUBRICATING THE LEVERS ..............3-32 LUBRICATING THE PEDAL ..............3-32 ADJUSTING THE DRIVE SELECT LEVER CONTROL CABLE AND SHIFT ROD..................3-32 ADJUSTING THE THROTTLE LEVER FREE PLAY ......3-33 ADJUSTING THE SPEED LIMITER............3-34 REPLACING THE HANDLE MOUNTED LIGHT BULB......3-34 ADJUSTING THE HEADLIGHT AND HANDLE MOUNTED LIGHT BEAMS ....................

  • Page 84: Periodic Maintenance

    However, keep in mind that if the vehicle isn’t used for a long period of time, the month main- tenance intervals should be followed. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 85 PERIODIC MAINTENANCE INITIAL EVERY month CHECK OR MAINTENANCE Whichever ITEM 1300 2500 2500 5000 comes first km (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element • Clean and replace if necessary. dusty areas) •...
  • Page 86 PERIODIC MAINTENANCE INITIAL EVERY month CHECK OR MAINTENANCE Whichever ITEM 1300 2500 2500 5000 comes first km (mi) (200) (800) (1600) (1600) (3200) hours • Check operation. √ √ √ √ √ Throttle lever • Check throttle lever free play, and adjust if necessary. •...

  • Page 87: Checking The Fuel Line

    PERIODIC MAINTENANCE 4. Check: EBS30027 CHECKING THE FUEL LINE • Spark plug type 1. Remove: Incorrect → Change. • Side panel (right) Refer to “GENERAL CHASSIS (1)” on page Manufacturer/model 4-1. NGK/CPR7EA-9 • Rear fender Refer to “GENERAL CHASSIS (3)” on page 5.

  • Page 88: Adjusting The Valve Clearance

    PERIODIC MAINTENANCE EBS30028 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 89 PERIODIC MAINTENANCE b. Calculate the difference between the speci- fied valve clearance and the measured valve clearance. Example: Specified valve clearance = 0.10–0.20 mm (0.0039–0.0079 in) Measured valve clearance = 0.27 mm (0.0106 in) 0.27 mm (0.0106 in)–0.20 mm (0.0079 in) = 0.07 mm (0.0028 in) c.
  • Page 90 PERIODIC MAINTENANCE • Position the holes “a” in the intake camshaft Number “a” Thickness sprocket and exhaust camshaft sprocket 1.900 mm (0.07480 in) above the cylinder head mating surface “b” as 1.925 mm (0.07579 in) shown in the illustration, and align the marks “c”...

  • Page 91: Checking The Breather Hoses

    • Side panel (left) • To adjust the exhaust gas volume, use the CO Refer to “GENERAL CHASSIS (1)” on page adjustment mode of the Yamaha diagnostic 4-1. tool. For more information, refer to the opera- tion manual of the Yamaha diagnostic tool.

  • Page 92: Cleaning The Spark Arrester

    PERIODIC MAINTENANCE 1. Connect the Yamaha diagnostic tool to the Spark arrester bolt coupler. For information about connecting the 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Yamaha diagnostic tool, refer to “YAMAHA DIAGNOSTIC TOOL” on page 9-32. ▲ ▲▲▲ ▲ ▲▲▲...
  • Page 93 PERIODIC MAINTENANCE 5. Disassemble: b. After cleaning, squeeze the air filter element • Air filter element holder “1” to remove the excess solvent. • Air filter element “2” ECB01290 NOTICE • Air filter element frame “3” Do not twist the air filter element when ECB01800 NOTICE squeezing it.

  • Page 94: Checking The Front Brake Pads

    PERIODIC MAINTENANCE g. Place the air filter element into the storage bag and repeatedly squeeze the element un- til the air filter element is saturated with oil. The air filter element should be wet but not drip- ping. 4. Install: •...

  • Page 95: Adjusting The Rear Disc Brake

    PERIODIC MAINTENANCE 3. Adjust: EBS30581 • Brake pedal free play ADJUSTING THE REAR DISC BRAKE ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ EWB03730 a. Remove the front fender inner panel (right). WARNING Refer to “GENERAL CHASSIS (3)”...

  • Page 96: Checking The Front Brake Hoses

    PERIODIC MAINTENANCE 2. Check: h. Adjust the drive select lever control cable. • Brake hose holders Refer to “ADJUSTING THE DRIVE SELECT Loose → Tighten the holder bolt. LEVER CONTROL CABLE AND SHIFT 3. Apply the brake several times. ROD” on page 3-32. 4.

  • Page 97: Checking The Brake Fluid Level

    PERIODIC MAINTENANCE 2. Check: A. Front brake • Brake hose holders B. Rear brake Loose → Tighten the holder bolt. EWB02790 3. Apply the brake several times. WARNING 4. Check: • Use only the designated brake fluid. Other • Brake hoses brake fluids may cause the rubber seals to Brake fluid leakage →...

  • Page 98: Checking The Wheels

    PERIODIC MAINTENANCE • When bleeding the hydraulic brake system, h. Tighten the bleed screw, and then release make sure there is always enough brake fluid the brake lever. before applying the brake. Ignoring this pre- i. Repeat steps (e) to (h) until all of the air bub- caution could allow air to enter the hydraulic bles have disappeared from the brake fluid in brake system, considerably lengthening the...

  • Page 99: Checking The Tires

    Tire characteristics influence the handling of 32.0 kPa (0.320 kgf/cm², 4.6 vehicles. The tires listed below have been psi) approved by Yamaha Motor Co., Ltd. for this Rear model. If other tire combinations are used, 27.0 kPa (0.270 kgf/cm², 4.0 they can adversely affect your vehicle’s han-...

  • Page 100: Checking The V-Belt

    PERIODIC MAINTENANCE • The tire pressure gauge “1” is included as stan- The arrow mark “1” on the tire must point in the dard equipment. direction of wheel rotation. • In order to insure an accurate reading, make sure that the gauge is clean before use. EBS30055 CHECKING THE V-BELT 1.

  • Page 101: Replacing The V-Belt

    PERIODIC MAINTENANCE d. Remove the bolts. EBS30056 REPLACING THE V-BELT ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 1. Remove: • Drive belt cover EBS30069 CHECKING THE FASTENER Refer to “PRIMARY AND SECONDARY 1.

  • Page 102: Checking The Rear Shock Absorber Assemblies

    PERIODIC MAINTENANCE EWB03770 WARNING Direction “a” Spring preload is increased (suspen- Always adjust the spring preload for both sion is harder). rear shock absorber assemblies to the same Direction “b” setting. Uneven adjustment can cause poor Spring preload is decreased (suspen- handling and loss of stability.

  • Page 103: Lubricating The Steering Shaft

    PERIODIC MAINTENANCE Recommended lubricant Lithium-soap-based grease 3. Check: • Tie-rod ends Free play → Replace the tie-rod end. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the handlebar left until it stops. EBS30063 LUBRICATING THE STEERING SHAFT b.

  • Page 104: Adjusting The Toe-In

    PERIODIC MAINTENANCE 6. Measure: (for EPS models) • Steering tension Above specification → Adjust. Steering tension 50 N (5.0 kgf) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Set the main switch to “ ”...
  • Page 105 PERIODIC MAINTENANCE • After setting the toe-in to specification, run Toe-in (with tires touching the the vehicle slowly for some distance with ground) both hands lightly holding the handlebar 0.0–10.0 mm (0.00–0.39 in) and check that the handlebar responds cor- rectly.

  • Page 106: Checking The Engine Mount

    PERIODIC MAINTENANCE EBS30038 CHECKING THE ENGINE OIL LEVEL After adjusting the toe-in, the handlebar should 1. Place the vehicle on a level surface. be centered. 2. Check the engine oil level on a cold engine. Refer to “INSTALLING THE HANDLEBAR” on page 4-50.

  • Page 107: Changing The Engine Oil

    PERIODIC MAINTENANCE 130 ˚F SAE 0W-30 SAE 10W-30 SAE 10W-40 SAE 15W-40 SAE 20W-40 SAE 20W-50 –20 –10 50 ˚C ECB01820 5. Drain: NOTICE • Engine oil • Engine oil also lubricates the clutch and the (completely from the crankcase) wrong oil types or additives could cause 6.

  • Page 108: Measuring The Engine Oil Pressure

    PERIODIC MAINTENANCE 2. Remove: Oil filter cartridge • Side panel (left) 15 Nm (1.5 m·kgf, 11 ft·lbf) Refer to “GENERAL CHASSIS (1)” on page 4-1. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 109: Checking The Differential Gear Oil Level

    (along with the gasket Type Differential gear oil drain bolt Yamaha Friction Modified Plus 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Shaft Drive Oil (Part No.: ACC- SHFTL-PL-32) or SAE 80 API GL-4 Hypoid gear oil...

  • Page 110: Checking The Final Gear Oil Level

    5. Fill: • Differential case (with the specified amount of the recom- mended differential gear oil) Type Yamaha Friction Modified Plus Shaft Drive Oil (Part No.: ACC- SHFTL-PL-32) or SAE 80 API GL-4 Hypoid gear oil Quantity (disassembled) 4. Check: 0.23 L (0.24 US qt, 0.20 Imp.qt)

  • Page 111: Checking The Cooling System

    Cracks/damage → Replace. Coolant leakage → Replace any damaged Type hose and pipe Yamaha Friction Modified Plus Refer to “RADIATOR” on page 6-4 and “WA- Shaft Drive Oil (Part No.: ACC- TER PUMP” on page 6-10. SHFTL-PL-32) or SAE 80 API...

  • Page 112: Checking The Coolant Level

    PERIODIC MAINTENANCE EBS30035 CHECKING THE COOLANT LEVEL 1. Place the vehicle on a level surface. The coolant level must be checked on a cold en- gine since the level varies with engine tempera- ture. 2. Check: • Coolant level The coolant level should be between the maximum level mark “a”...
  • Page 113 PERIODIC MAINTENANCE 6. Remove: Coolant drain bolt • Radiator cap “1” 8 Nm (0.8 m·kgf, 5.8 ft·lbf) EWB02770 WARNING 10.Fill: A hot radiator is under pressure. Therefore, • Cooling system do not remove the radiator cap when the en- (with the specified amount of the recom- gine is hot.

  • Page 114: Checking And Lubricating The Cables

    PERIODIC MAINTENANCE 13.Install: Thermostat cover air bleed bolt • Coolant reservoir cap “1” 10 Nm (1.0 m·kgf, 7.2 ft·lbf) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 15.Start the engine, warm it up for ten minutes, and then rev the engine five times.

  • Page 115: Lubricating The Levers

    PERIODIC MAINTENANCE 2. “H” (high) 3. “L” (low) Hold the cable end upright and pour a few drops 4. “R” (reverse) of lubricant into the cable sheath or use a suit- 5. “P” (park) able lubricating device. 6. Drive select lever shift control cable 3.

  • Page 116: Adjusting The Throttle Lever Free Play

    PERIODIC MAINTENANCE c. Release the brake lever so that “a” is 0 mm (0 EBS30446 ADJUSTING THE THROTTLE LEVER FREE in), and then verify that the drive select lever PLAY cannot be shifted to “R” (reverse) from “N” 1. Check: (neutral), or to “P”...

  • Page 117: Adjusting The Speed Limiter

    PERIODIC MAINTENANCE Speed limiter length If the free play cannot be adjusted here, adjust it 12 mm (0.5 in) at the handlebar side of the cable. 2. Adjust: ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 118: Adjusting The Headlight And Handle Mounted Light Beams

    PERIODIC MAINTENANCE ECB02990 NOTICE Avoid touching the glass part of the handle mounted light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the handle mounted light bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lac- quer thinner.
  • Page 119 PERIODIC MAINTENANCE A. Headlight (left and right) B. Handle mounted light ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3-36...
  • Page 120 PERIODIC MAINTENANCE 3-37...

  • Page 121: Chassis

    CHASSIS GENERAL CHASSIS (1) ................. 4-1 REMOVING THE BATTERY COVER ............4-3 INSTALLING THE BATTERY COVER ............4-3 REMOVING THE TOP COVER..............4-3 INSTALLING THE TOP COVER ............... 4-4 REMOVING THE SIDE PANELS .............. 4-4 INSTALLING THE SIDE PANELS............. 4-5 GENERAL CHASSIS (2) ................. 4-6 REMOVING THE UPPER PANEL.............
  • Page 122 FRONT BRAKE ..................... 4-26 INTRODUCTION ..................4-31 CHECKING THE FRONT BRAKE DISCS..........4-31 REPLACING THE FRONT BRAKE PADS ..........4-32 DISASSEMBLING THE FRONT BRAKE CALIPERS......4-32 CHECKING THE FRONT BRAKE CALIPERS ........4-33 ASSEMBLING THE FRONT BRAKE CALIPERS........4-33 INSTALLING THE FRONT BRAKE CALIPERS ........4-33 CHECKING THE FRONT BRAKE MASTER CYLINDER......
  • Page 123 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES ..... 4-65 CHECKING THE FRONT ARMS............. 4-67 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES ..... 4-67 CHECKING THE FRONT ARM BALL JOINTS ........4-67 INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES ..................4-68 INSTALLING THE FRONT ARM PROTECTORS ........

  • Page 124: General Chassis (1)

    GENERAL CHASSIS (1) EBS20024 GENERAL CHASSIS (1) Removing the skid plates 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • •...
  • Page 125 GENERAL CHASSIS (1) Removing the seat and side panels 0.4 Nm (0.04 m kgf, 0.29 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) •...

  • Page 126: Removing The Battery Cover

    GENERAL CHASSIS (1) EBS30449 REMOVING THE BATTERY COVER 1. Remove: • Battery cover “1” ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EBS30451 REMOVING THE TOP COVER 1. Remove: ▼ ▼▼▼...

  • Page 127: Installing The Top Cover

    GENERAL CHASSIS (1) d. Fit the projections “a” on the top cover into the ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ holes “b” in the side panels and slide the cov- EBS30452 er forward.

  • Page 128: Installing The Side Panels

    GENERAL CHASSIS (1) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the bolt. a.

  • Page 129: General Chassis (2)

    GENERAL CHASSIS (2) EBS20087 GENERAL CHASSIS (2) Removing the front carrier and front guard 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 34 Nm (3.4 m kgf, 25 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 130: Removing The Upper Panel

    GENERAL CHASSIS (2) EBS30455 REMOVING THE UPPER PANEL 1. Remove: • Upper panel “1” b. Install the quick fasteners. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▼ ▼▼▼ ▼ ▼▼▼ ▼...

  • Page 131: General Chassis (3)

    GENERAL CHASSIS (3) EBS20088 GENERAL CHASSIS (3) Removing the front fenders and front grill 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...
  • Page 132 GENERAL CHASSIS (3) Removing the rear carrier and rear fender 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 60 Nm (6.0 m kgf, 43 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 34 Nm (3.4 m kgf, 25 ft Ibf)

  • Page 133: Installing The Rear Fender

    GENERAL CHASSIS (3) EBS30356 INSTALLING THE REAR FENDER 1. Install: • Rear fender Rear fender bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) The bolts may be tightened to the specified torque in any tightening sequence. However, in- stall the front bolts “1” and tighten them tempo- rarily before installing the rear bolts “2”.

  • Page 134: General Chassis (4)

    GENERAL CHASSIS (4) EBS20089 GENERAL CHASSIS (4) Removing the electrical components tray 1/2 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) •...
  • Page 135 GENERAL CHASSIS (4) Removing the electrical components tray 1/2 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) •...
  • Page 136 GENERAL CHASSIS (4) Removing the electrical components tray 2/2 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 3.6 Nm (0.36 m kgf, 2.6 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • ’ Order Job/Parts to remove Remarks...
  • Page 137 GENERAL CHASSIS (4) Removing the electrical components tray 2/2 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 3.6 Nm (0.36 m kgf, 2.6 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • ’ Order Job/Parts to remove Remarks...
  • Page 138 GENERAL CHASSIS (4) Removing the footrest boards 16 Nm (1.6 m kgf, 12 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...

  • Page 139: Installing The Footrest Boards

    GENERAL CHASSIS (4) EBS30357 INSTALLING THE FOOTREST BOARDS The following procedure applies to both of the footrest boards. 1. Install: • Footrest board Footrest board bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Tighten the footrest board bolts to the specified torque in the proper tightening sequence as shown.

  • Page 140: General Chassis (5)

    GENERAL CHASSIS (5) EBS20090 GENERAL CHASSIS (5) Removing the air filter case 0.8 Nm (0.08 m kgf, 0.58 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 141 GENERAL CHASSIS (5) Removing the air filter case 0.8 Nm (0.08 m kgf, 0.58 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) •...

  • Page 142: Installing The Air Filter Case

    GENERAL CHASSIS (5) EBS30457 INSTALLING THE AIR FILTER CASE 1. Install: • Intake air temperature sensor • Air filter case • Air filter case joint “1” (to the air filter case) Intake air temperature sensor screw 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) Air filter case bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Air filter case joint clamp screw...

  • Page 143: Front Wheels

    FRONT WHEELS EBS20095 FRONT WHEELS Removing the front wheels and brake discs 30 Nm (3.0 m kgf, 22 ft Ibf) • • 260 Nm (26 m kgf, 188 ft lbf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...

  • Page 144: Removing The Front Wheels

    FRONT WHEELS EBS30358 REMOVING THE FRONT WHEELS Radial wheel runout limit 1. Place the vehicle on a level surface. 1.2 mm (0.05 in) 2. Elevate: Lateral wheel runout limit • Front wheels 1.2 mm (0.05 in) Place the vehicle on a suitable stand so that the front wheels are elevated.

  • Page 145: Installing The Front Brake Discs

    FRONT WHEELS • Splines (wheel hub) “2” Wear/damage → Replace the wheel hub. 2. Check: • Brake disc Refer to “CHECKING THE FRONT BRAKE EBS30362 INSTALLING THE FRONT BRAKE DISCS DISCS” on page 4-31. The following procedure applies to both of the EBS30364 front brake discs.

  • Page 146: Rear Wheels

    REAR WHEELS EBS20096 REAR WHEELS Removing the rear wheels and brake discs 30 Nm (3.0 m kgf, 22 ft Ibf) • • 260 Nm (26 m kgf, 188 ft lbf) • • 30 Nm (3.0 m kg, 22 ft • •...

  • Page 147: Removing The Rear Wheels

    REAR WHEELS 3. Check: EBS30365 REMOVING THE REAR WHEELS • Wheel balance 1. Place the vehicle on a level surface. Refer to “CHECKING THE FRONT 2. Elevate: WHEELS” on page 4-21. • Rear wheels EBS30368 CHECKING THE REAR WHEEL HUBS Place the vehicle on a suitable stand so that the The following procedure applies to both of the rear wheels are elevated.

  • Page 148: Installing The Rear Wheels

    REAR WHEELS 1. Install: • Wheel axle nut Rear wheel axle nut 260 Nm (26 m·kgf, 188 ft·lbf) • Do not apply oil to the threads of the nut. • After tightening the nut, stake the collar of the nut into the notch of the shaft. EBS30371 INSTALLING THE REAR WHEELS The following procedure applies to both of the...

  • Page 149: Front Brake

    FRONT BRAKE EBS20097 FRONT BRAKE Removing the front brake pads 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf)
  • Page 150 FRONT BRAKE Removing the front brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) •...
  • Page 151 FRONT BRAKE Disassembling the front brake master cylinder ’ Order Job/Parts to remove Remarks Dust boot Circlip Brake master cylinder kit Brake master cylinder body 4-28...
  • Page 152 FRONT BRAKE Removing the front brake calipers 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...
  • Page 153 FRONT BRAKE Disassembling the front brake calipers 17 Nm (1.7 m kgf, 12 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 22 Nm (2.2 m kgf, 16 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) •...

  • Page 154: Introduction

    FRONT BRAKE EBS30372 INTRODUCTION EWB02930 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake ▲...

  • Page 155: Replacing The Front Brake Pads

    FRONT BRAKE d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f. If the brake disc deflection cannot be brought within specification, replace the brake disc. ▲...

  • Page 156: Checking The Front Brake Calipers

    FRONT BRAKE 1. Remove: 1. Check: • Brake caliper piston “1” • Brake caliper piston “1” Rust/scratches/wear → Replace the brake • Brake caliper dust seal “2” • Brake caliper piston seal “3” caliper piston. • Brake caliper cylinder “2” Scratches/wear →...

  • Page 157: Checking The Front Brake Master Cylinder

    FRONT BRAKE 1. Install: • When refilling, be careful that water does • Brake caliper assembly not enter the brake fluid reservoir. Water • Brake caliper bolts “1” will significantly lower the boiling point of • Brake hose “2” the brake fluid and could cause vapor lock. •...

  • Page 158: Assembling The Front Brake Master Cylinder

    FRONT BRAKE EBS30379 EWB02870 ASSEMBLING THE FRONT BRAKE MASTER WARNING CYLINDER Proper brake hose routing is essential to in- EWB03590 sure safe vehicle operation. WARNING Refer to “CABLE ROUTING” on page 2-33. • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid.
  • Page 159 FRONT BRAKE 4. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-14. 5. Check: • Brake fluid level Below the minimum level mark → Add the specified brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...

  • Page 160: Rear Brake

    REAR BRAKE EBS20098 REAR BRAKE Removing the brake pedal 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove ’ Remarks Refer to “GENERAL CHASSIS (1)” on page Seat/Top cover/Side panels 4-1.
  • Page 161 REAR BRAKE Removing the rear brake pads 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) •...
  • Page 162 REAR BRAKE Removing the rear brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 1.2 Nm (0.12 m kgf, 0.87 ft Ibf) •...
  • Page 163 REAR BRAKE Disassembling the rear brake master cylinder ’ Order Job/Parts to remove Remarks Dust boot Circlip Brake master cylinder kit Brake master cylinder body 4-40...
  • Page 164 REAR BRAKE Removing the rear brake calipers 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) •...
  • Page 165 REAR BRAKE Disassembling the rear brake calipers 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 22 Nm (2.2 m kgf, 16 ft Ibf) •...

  • Page 166: Introduction

    REAR BRAKE Refer to “CHECKING THE FRONT BRAKE EBS30382 INTRODUCTION DISCS” on page 4-31. EWB02930 WARNING Brake disc thickness limit Disc brake components rarely require disas- 3.0 mm (0.12 in) sembly. Therefore, always follow these pre- ventive measures: 5. Adjust: •...

  • Page 167: Removing The Rear Brake Master Cylinder

    REAR BRAKE ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ • Brake lever bracket a. Connect a clear plastic hose “1” tightly to ECB02880 NOTICE the bleed screw “2”. Put the other end of the hose into an open container.

  • Page 168: Checking The Rear Brake Calipers

    REAR BRAKE • Never use solvents on internal brake com- EBS30387 CHECKING THE REAR BRAKE CALIPERS ponents as they will cause the brake caliper The following procedure applies to both of the piston dust seals and brake caliper piston brake calipers. seals to swell and distort.

  • Page 169: Checking The Rear Brake Master Cylinder

    REAR BRAKE 3. Check: Specified brake fluid • Brake master cylinder reservoir DOT 4 Cracks/damage → Replace. • Brake master cylinder reservoir diaphragm EWB02790 Cracks/damage → Replace. WARNING 4. Check: • Use only the designated brake fluid. Other • Brake hoses brake fluids may cause the rubber seals to Cracks/damage/wear →...
  • Page 170 REAR BRAKE EWB02880 • Copper washers WARNING • Brake hose union bolt • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to Brake hose union bolt deteriorate, causing leakage and poor 27 Nm (2.7 m·kgf, 20 ft·lbf) brake performance.

  • Page 171: Handlebar

    HANDLEBAR EBS20099 HANDLEBAR Removing the handlebar 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 0.5 Nm (0.05 m kgf, 0.36 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...
  • Page 172 HANDLEBAR Removing the handlebar 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 0.5 Nm (0.05 m kgf, 0.36 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...

  • Page 173: Removing The Handlebar

    HANDLEBAR EBS30393 REMOVING THE HANDLEBAR 1. Place the vehicle on a level surface. 2. Remove: • Handlebar grips “1” Blow compressed air between the handlebar end and the handlebar grip, and gradually push the grip off the handlebar. EBS30394 CHECKING THE HANDLEBAR 1.
  • Page 174 HANDLEBAR d. Wipe off any excess rubber adhesive with a clean rag. Be sure to fit the projection “a” on the handlebar EWB03690 “2” between the ends of the horn switch. WARNING Do not touch the handlebar grip until the rub- ber adhesive has fully dried.
  • Page 175 HANDLEBAR 8. Connect: • Throttle cable Lubricate the end of the throttle cable with a thin coat of lithium-soap-based grease. Throttle lever assembly cover bolt 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) 9. Adjust: • Rear brake lever free play Refer to “ADJUSTING THE REAR DISC BRAKE”...

  • Page 176: Steering Stem

    STEERING STEM EBS20101 STEERING STEM Removing the steering stem (except for EPS models) 51 Nm (5.1 m kgf, 37 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 34 Nm (3.4 m kgf, 25 ft Ibf) •...
  • Page 177 STEERING STEM Removing the steering stem (except for EPS models) 51 Nm (5.1 m kgf, 37 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 34 Nm (3.4 m kgf, 25 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf)
  • Page 178 STEERING STEM Removing the steering stem (for EPS models) 51 Nm (5.1 m kgf, 37 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...
  • Page 179 STEERING STEM Removing the steering stem (for EPS models) 51 Nm (5.1 m kgf, 37 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...

  • Page 180: Removing The Bearing Retainer (Except For Eps Models)

    STEERING STEM EBS30396 EBS30109 REMOVING THE BEARING RETAINER INSTALLING THE STEERING STEM (except (except for EPS models) for EPS models) 1. Remove: • Bearing retainer “1” Remove the bearing retainer with the damper rod holder “2”. Damper rod holder (30 mm) 90890-01327 Damper rod holder (30 mm) YM-01327...

  • Page 181: Installing The Steering Stem (For Eps Models)

    STEERING STEM • Steering stem bolts “12” EBS30398 INSTALLING THE STEERING STEM (for EPS (temporarily tighten) models) Apply lithium-soap-based grease to the steering stem bushings. 5. Install: • Steering stem bracket “13” 1 2 3 • Steering stem bracket bolts “14” (temporarily tighten) 6.

  • Page 182: Installing The Pitman Arm (Except For Eps Models)

    STEERING STEM EBS30399 INSTALLING THE PITMAN ARM (except for EPS models) 1. Install: • Pitman arm “1” • Washer • Pitman arm nut • Cotter pin Pitman arm nut (except for EPS models) 4. Install: 190 Nm (19 m·kgf, 137 ft·lbf) •...
  • Page 183 STEERING STEM Align the punch mark “a” on the EPS unit with the groove “b” in the pitman arm. 4-60...

  • Page 184: Tie-Rods And Steering Knuckles

    TIE-RODS AND STEERING KNUCKLES EBS20100 TIE-RODS AND STEERING KNUCKLES Removing the tie-rods and steering knuckles 25 Nm (2.5 m kgf, 18 ft Ibf) • • 15 Nm (1.5 m kgf, 11 ft Ibf) • • 25 Nm (2.5 m kgf, 18 ft Ibf) •...

  • Page 185: Removing The Steering Knuckles

    TIE-RODS AND STEERING KNUCKLES 2. Check: EBS30401 REMOVING THE STEERING KNUCKLES • Front wheel bearing “1” The following procedure applies to both of the Rough movement/excessive free play → Re- steering knuckles. place. 1. Remove: ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼...
  • Page 186 TIE-RODS AND STEERING KNUCKLES ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Clean the surface of the steering knuckle. Ball joint remover 90890-01474 b. Remove the circlip “1”. Ball joint remover YM-01474 Ball joint remover attachment set 90890-01480...

  • Page 187: Installing The Tie-Rods

    TIE-RODS AND STEERING KNUCKLES h. Install a new circlip. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EBS30405 INSTALLING THE TIE-RODS The following procedure applies to both of the tie-rods. 1.

  • Page 188: Front Arms And Front Shock Absorber Assemblies

    FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES EBS20031 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Removing the front arms and front shock absorber assemblies 45 Nm (4.5 m kgf, 33 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 189 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Removing the front arms and front shock absorber assemblies 45 Nm (4.5 m kgf, 33 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 55 Nm (5.5 m kgf, 40 ft Ibf) •...

  • Page 190: Checking The Front Arms

    FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES • Front shock absorber rod EBS30113 CHECKING THE FRONT ARMS Bends/damage → Replace the front shock The following procedure applies to both of the absorber assembly. front upper arms and front lower arms. •...

  • Page 191: Installing The Front Arms And Front Shock Absorber Assemblies

    FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES d. Attach the special tools and new ball joint “5” e. Hold the base “12” in place while turning in to the front upper arm “4”. the long bolt “6” to install the new ball joint “5” into the front upper arm “4”.

  • Page 192: Installing The Front Arm Protectors

    FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES b. Tighten the bolt “b”. Steering knuckle and front upper arm nut 30 Nm (3.0 m·kgf, 22 ft·lbf) Steering knuckle and front lower arm nut 30 Nm (3.0 m·kgf, 22 ft·lbf) d. Install the new cotter pins. e.

  • Page 193: Rear Knuckles And Stabilizer

    REAR KNUCKLES AND STABILIZER EBS20032 REAR KNUCKLES AND STABILIZER Removing the rear knuckles and stabilizer 56 Nm (5.6 m kgf, 41 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 194: Checking The Rear Knuckles And Rear Wheel Bearings

    REAR KNUCKLES AND STABILIZER EBS30119 CHECKING THE REAR KNUCKLES AND Rear arm protector bolt REAR WHEEL BEARINGS 7 Nm (0.7 m·kgf, 5.1 ft·lbf) The following procedure applies to both of the Rear arm protector nut rear knuckles and rear wheel bearings. 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 1.

  • Page 195: Rear Arms And Rear Shock Absorber Assemblies

    REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES EBS20033 REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES Removing the rear arms and rear shock absorber assemblies 55 Nm (5.5 m kgf, 40 ft Ibf) • • 45 Nm (4.5 m kgf, 33 ft Ibf) •...

  • Page 196: Checking The Rear Arms

    REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES • Rear shock absorber rod EBS30122 CHECKING THE REAR ARMS Bends/damage → Replace the rear shock The following procedure applies to both of the absorber assembly. rear upper arms and rear lower arms. •...
  • Page 197 REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4-74...
  • Page 198 REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES 4-75...

  • Page 199: Engine

    ENGINE ENGINE INSPECTION ..................5-1 MEASURING THE COMPRESSION PRESSURE........5-1 ENGINE REMOVAL (1) ................... 5-3 INSTALLING THE EXHAUST PIPE AND MUFFLER........5-4 INSTALLING THE V-BELT COOLING DUCTS......... 5-4 ENGINE REMOVAL (2) ................... 5-6 INSTALLING THE DRIVE SELECT LEVER UNIT ........5-7 ENGINE REMOVAL (3) ................... 5-8 INSTALLING THE ENGINE..............
  • Page 200 ELECTRIC STARTER ...................5-40 CHECKING THE STARTER MOTOR .............5-42 ASSEMBLING THE STARTER MOTOR..........5-42 OIL PUMP SPROCKETS ................5-44 REMOVING THE OIL PUMP DRIVE SPROCKET AND OIL PUMP DRIVEN SPROCKET...........5-45 CHECKING THE OIL PUMP SPROCKETS ..........5-45 INSTALLING THE OIL PUMP DRIVE SPROCKET AND OIL PUMP DRIVEN SPROCKET...........5-45 SHIFT LEVER....................5-47 CHECKING THE STOPPER LEVER ............5-48...
  • Page 201 CRANKSHAFT AND OIL PUMP ..............5-70 REMOVING THE CRANKSHAFT ............5-72 CHECKING THE OIL PUMP ..............5-72 CHECKING THE OIL STRAINER ............5-72 CHECKING THE RELIEF VALVE ............5-72 CHECKING THE CRANKSHAFT ............5-73 ASSEMBLING THE OIL PUMP...............5-73 INSTALLING THE CRANKSHAFT ............5-73 INSTALLING THE OIL PUMP ..............5-74 TRANSMISSION....................

  • Page 202: Engine Inspection

    ENGINE INSPECTION 7. Measure: EBS20105 ENGINE INSPECTION • Compression pressure Out of specification → Refer to steps (b) and EBS30135 (c). MEASURING THE COMPRESSION PRESSURE Standard compression pressure (at sea level) Insufficient compression pressure will result in a 650–1000 kPa (6.5–10.0 kgf/cm², loss of performance.
  • Page 203 ENGINE INSPECTION • Top cover Refer to “GENERAL CHASSIS (2)” on page 4-6.

  • Page 204: Engine Removal (1)

    ENGINE REMOVAL (1) EBS20034 ENGINE REMOVAL (1) Removing the V-belt cooling ducts, muffler and exhaust pipe 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 33 Nm (3.3 m kgf, 24 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...

  • Page 205: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL (1) EBS30127 INSTALLING THE EXHAUST PIPE AND MUFFLER 1. Install: • Gasket “1” • Exhaust pipe “2” • Exhaust pipe nuts “3” Exhaust pipe nut 20 Nm (2.0 m·kgf, 14 ft·lbf) 2. Install: • Muffler bracket “4” • Muffler bracket bolts “5” Muffler bracket bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) 3.

  • Page 206: Engine Removal (2)

    ENGINE REMOVAL (1) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Install: •...
  • Page 207 ENGINE REMOVAL (2) EBS20093 ENGINE REMOVAL (2) Removing the drive select lever unit 7 Nm (0.7 m kgf, 5.1 ft Ibf) 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 208: Installing The Drive Select Lever Unit

    ENGINE REMOVAL (2) EBS30553 INSTALLING THE DRIVE SELECT LEVER UNIT 1. Install: • Shift arm “1” • Drive select lever unit “2” • Drive select lever shift rod “3” Shift arm bolt 14 Nm (1.4 m·kgf, 10 ft·lbf) LOCTITE® Drive select lever unit bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Drive select lever shift rod lock- nut (select lever unit side)

  • Page 209: Engine Removal (3)

    ENGINE REMOVAL (3) EBS20120 ENGINE REMOVAL (3) Disconnecting the leads, cables and hoses 17 Nm (1.7 m kgf, 12 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (4)” on page Footrest board 4-11. Refer to “GENERAL CHASSIS (5)” on page Air filter case 4-17.
  • Page 210 ENGINE REMOVAL (3) Disconnecting the leads, cables and hoses 17 Nm (1.7 m kgf, 12 ft Ibf) • • ’ Order Job/Parts to remove Remarks Cylinder head breather hose Coolant temperature sensor coupler Disconnect. Spark plug cap Shift control cable Disconnect.
  • Page 211 ENGINE REMOVAL (3) Removing the engine 42 Nm (4.2 m kgf, 30 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 212: Installing The Engine

    ENGINE REMOVAL (3) EBS30351 INSTALLING THE ENGINE Engine mounting bolt (front) 1. Install: (M10) • Rubber dampers (front side) “1” 42 Nm (4.2 m·kgf, 30 ft·lbf) • Engine mounting bolts (front) (M10) “2” Engine mounting bolt (front) (M6) 10 Nm (1.0 m·kgf, 7.2 ft·lbf) •...

  • Page 213: Camshafts

    CAMSHAFTS EBS20106 CAMSHAFTS Removing the cylinder head cover 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 11 Nm (1.1 m kgf, 8.0 ft Ibf)* • • Specified angle 30–45˚* 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •...
  • Page 214 CAMSHAFTS Removing the camshafts 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) •...

  • Page 215: Removing The Camshafts

    CAMSHAFTS EBS30432 REMOVING THE CAMSHAFTS 1. Remove: • Crankshaft end accessing screw “1” • Timing mark accessing screw “2” ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Remove: • Timing chain tensioner •...

  • Page 216: Checking The Camshafts

    CAMSHAFTS 3. Measure: • Camshaft-journal-to-camshaft-cap clearance Out of specification → Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance 0.037–0.075 mm (0.0015–0.0030 ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the camshafts into the cylinder head EBS30433 CHECKING THE CAMSHAFTS (without the camshaft cap).

  • Page 217: Checking The Camshaft Sprockets

    CAMSHAFTS EBS30435 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • Timing chain tensioner Cracks/damage/rough movement → Re- place. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand.
  • Page 218 CAMSHAFTS 3. Install: • Bearing stoppers • Camshaft cap “1” Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) ECB02450 NOTICE • The camshaft cap bolts must be tightened evenly or damage to the cylinder head, b. Position the mark “a” on the AC magneto ro- camshaft cap, and camshafts will result.

  • Page 219: Installing The Breather Plate

    CAMSHAFTS c. Install a new gasket and the timing chain ten- 7. Measure: sioner cap bolt. • Valve clearance Out of specification → Adjust. Timing chain tensioner cap bolt Refer to “ADJUSTING THE VALVE CLEAR- 5 Nm (0.5 m·kgf, 3.6 ft·lbf) ANCE”...

  • Page 220: Cylinder Head, Cylinder, And Piston

    CYLINDER HEAD, CYLINDER, AND PISTON EBS20107 CYLINDER HEAD, CYLINDER, AND PISTON Removing the cylinder head 30 Nm (3.0 m kgf, 22 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) • • Loosen 360˚ 30 Nm (3.0 m kgf, 22 ft Ibf) •...
  • Page 221 CYLINDER HEAD, CYLINDER, AND PISTON Removing the cylinder head 30 Nm (3.0 m kgf, 22 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) • • Loosen 360˚ 30 Nm (3.0 m kgf, 22 ft Ibf) • •...
  • Page 222 CYLINDER HEAD, CYLINDER, AND PISTON Removing the cylinder and piston ’ Order Job/Parts to remove Remarks Timing chain guide (exhaust side) Cylinder Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Top ring 2nd ring Oil ring 5-21...

  • Page 223: Removing The Cylinder Head

    CYLINDER HEAD, CYLINDER, AND PISTON • Before removing the piston pin, deburr the pis- EBS30438 REMOVING THE CYLINDER HEAD ton pin clip grooves and the piston pin bore ar- 1. Remove: ea. If both areas are deburred and the piston •...

  • Page 224: Checking The Cylinder Head

    CYLINDER HEAD, CYLINDER, AND PISTON EBS30439 CHECKING THE CYLINDER HEAD To ensure an even surface, rotate the cylinder 1. Eliminate: head several times. • Combustion chamber carbon deposits (with a rounded scraper) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...

  • Page 225: Checking The Piston Rings

    CYLINDER HEAD, CYLINDER, AND PISTON b. If out of specification, replace the cylinder, Top ring and replace the piston and piston rings as a Ring side clearance limit set. 0.12 mm (0.0047 in) c. Measure piston skirt diameter “P” with a mi- 2nd ring crometer.

  • Page 226: Checking The Piston Pin

    CYLINDER HEAD, CYLINDER, AND PISTON EBS30150 INSTALLING THE PISTON AND CYLINDER Top ring 1. Install: End gap (installed) limit • Oil ring expander “1” 0.50 mm (0.0197 in) 2nd ring • Lower oil ring rail “2” End gap (installed) limit •...

  • Page 227: Installing The Cylinder Head

    CYLINDER HEAD, CYLINDER, AND PISTON Recommended lubricant Engine oil 5. Install: ×4 • Cylinder “1” • Timing chain guide (exhaust side) ×4 • While compressing the piston rings with one hand, install the cylinder with the other hand. • Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity.
  • Page 228 CYLINDER HEAD, CYLINDER, AND PISTON Oil hose union bolt (crankcase to cylinder) 18 Nm (1.8 m·kgf, 13 ft·lbf) Tighten the clamp screw of each clamp “2” until 6 slots are visible in the area “a” of the clamp as shown in the illustration. 5-27...
  • Page 229 VALVES AND VALVE SPRINGS EBS20037 VALVES AND VALVE SPRINGS Removing the valves and valve springs 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • Order Job/Parts to remove ’ Remarks Refer to “CYLINDER HEAD, CYLINDER, Cylinder head AND PISTON” on page 5-19. Valve lifter Valve pad Valve cotter...

  • Page 230: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EBS30141 REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “1” and the valve spring compressor attachment “2”.
  • Page 231 VALVES AND VALVE SPRINGS 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) limit b. Install the new valve guide with the valve 0.080 mm (0.0032 in) guide installer “2”...

  • Page 232: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 1. Eliminate: Valve guide remover & installer • Carbon deposits set (ø5.5) (from the valve face and valve seat) 90890-04016 2. Check: Valve guide remover (5.5 mm) • Valve seat YM-01122 Pitting/wear → Replace the cylinder head. Valve guide remover &...

  • Page 233: Checking The Valve Springs

    VALVES AND VALVE SPRINGS After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 234: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS EBS30441 CHECKING THE VALVE LIFTERS • Make sure each valve is installed in its original The following procedure applies to all of the place. valve lifters. • Install the valve springs with the larger pitch “a” 1.
  • Page 235 VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECB01370 NOTICE Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Valve pad •...

  • Page 236: Ac Magneto And Starter Clutch

    AC MAGNETO AND STARTER CLUTCH EBS20039 AC MAGNETO AND STARTER CLUTCH Removing the AC magneto and starter clutch 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) •...
  • Page 237 AC MAGNETO AND STARTER CLUTCH Removing the AC magneto and starter clutch 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) •...

  • Page 238: Removing The Ac Magneto Rotor

    AC MAGNETO AND STARTER CLUTCH • Make sure the flywheel puller is centered over EBS30151 REMOVING THE AC MAGNETO ROTOR the AC magneto rotor. 1. Remove: • AC magneto cover Flywheel puller (M38 X P1.5) 90890-04178 Loosen each bolt 1/4 of a turn at a time, in stag- Flywheel puller (M38 X P1.5) es and in a crisscross pattern.

  • Page 239: Installing The Starter Clutch

    AC MAGNETO AND STARTER CLUTCH 3. Check: Starter clutch bolt • Starter clutch gear contact surfaces 14 Nm (1.4 m·kgf, 10 ft·lbf) Damage/pitting/wear → Replace the defec- tive part(s). 4. Check: While holding the AC magneto rotor “2” with the •...
  • Page 240 AC MAGNETO AND STARTER CLUTCH 2. Tighten: • AC magneto rotor nut “1” AC magneto rotor nut 160 Nm (16 m·kgf, 116 ft·lbf) Hold the AC magneto rotor “2” with the rotor holding tool “3” while tightening the AC magneto rotor nut.

  • Page 241: Electric Starter

    ELECTRIC STARTER EBS20040 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “ENGINE REMOVAL (1)” on page Muffler 5-3.
  • Page 242 ELECTRIC STARTER Disassembling the starter motor 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • ’ Order Job/Parts to remove Remarks Starter motor front cover Starter motor rear cover Brush set Armature assembly Starter motor yoke...

  • Page 243: Checking The Starter Motor

    ELECTRIC STARTER EBS30157 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt → Clean with 600-grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification → Cut the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. ▲...
  • Page 244 ELECTRIC STARTER 5-43...

  • Page 245: Oil Pump Sprockets

    OIL PUMP SPROCKETS EBS20114 OIL PUMP SPROCKETS Removing the oil pump sprockets 25 Nm (2.5 m kgf, 18 ft Ibf) • • 25 Nm (2.5 m kgf, 18 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 246: Removing The Oil Pump Drive Sprocket And Oil Pump Driven Sprocket

    OIL PUMP SPROCKETS EBS30524 REMOVING THE OIL PUMP DRIVE Install the oil pump drive sprocket so that the SPROCKET AND OIL PUMP DRIVEN protruding portion “a” of the sprocket is facing to- SPROCKET ward the crankcase. 1. Loosen: • Oil pump driven sprocket nut “1” •...
  • Page 247 OIL PUMP SPROCKETS Oil pump drive sprocket nut 25 Nm (2.5 m·kgf, 18 ft·lbf) LOCTITE® Oil pump driven sprocket nut 25 Nm (2.5 m·kgf, 18 ft·lbf) LOCTITE® ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 248: Shift Lever

    SHIFT LEVER EBS20042 SHIFT LEVER Removing the shift levers and stopper lever 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) •...

  • Page 249: Checking The Stopper Lever

    SHIFT LEVER EBS30163 CHECKING THE STOPPER LEVER 1. Check: • Stopper lever Damage/wear → Replace. • Stopper lever spring Damage/wear → Replace. EBS30164 CHECKING THE SHIFT LEVERS 1. Check: • Shift lever 1 3. Install: • Shift lever 2 • Shift lever 1 “1” Damage/wear →...

  • Page 250: Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES EBS20043 PRIMARY AND SECONDARY SHEAVES Removing the primary and secondary sheaves 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 100 Nm (10.0 m kgf, 72 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 251 PRIMARY AND SECONDARY SHEAVES Disassembling the primary sheave * Apply Yamaha Grizzly grease or Yamaha grease F. ’ Order Job/Parts to remove Remarks Primary sheave cap Primary sheave slider Primary sheave cam Primary sheave weight Spacer Oil seal Primary sliding sheave...
  • Page 252 PRIMARY AND SECONDARY SHEAVES Disassembling the secondary sheave ® * Apply Yamaha grease H or POLYREX EM ’ Order Job/Parts to remove Remarks Secondary sheave spring retaining nut Upper spring seat Compression spring Lower spring seat Guide pin Secondary sliding sheave...

  • Page 253: Removing The Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES EBS30167 REMOVING THE PRIMARY AND Sheave fixed block SECONDARY SHEAVES 90890-04135 1. Loosen: Sheave fixed bracket • Primary sheave assembly nut “1” YM-04135 Locknut wrench 90890-01348 Use the rotor holding tool “2” to hold the primary Locknut wrench sheave.

  • Page 254: Checking The V-Belt

    PRIMARY AND SECONDARY SHEAVES 2. Check: • Primary sliding sheave • Primary fixed sheave Cracks/damage → Replace. EBS30171 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the pri- mary sheave weights. 1. Check: • Primary sheave weight ▲...

  • Page 255: Assembling The Primary Sheave

    • Spacer inner surface • Primary sliding sheave inner surface Recommended lubricant Yamaha Grizzly grease or Yamaha grease F • Apply Yamaha Grizzly grease or Yamaha grease F (2.5 g) to the inner surface of the EBS30174 ASSEMBLING THE PRIMARY SHEAVE spacer.

  • Page 256: Assembling The Secondary Sheave

    • Guide pin grooves “1” (with the recommended lubricant) Recommended lubricant Yamaha grease H or POLYREX EM® Apply Yamaha grease H or POLYREX EM® (5.0 g) to the guide pin grooves. 2. Lubricate: • Secondary sliding sheave “1” • Secondary fixed sheave “2”...

  • Page 257: Installing The Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Attach the sheave fixed block “5”, locknut wrench “6” and sheave spring compressor “7” to the secondary sheave. Sheave fixed block 90890-04135 Sheave fixed bracket...
  • Page 258 PRIMARY AND SECONDARY SHEAVES A. Correct position B. Incorrect position 3. Tighten: • Primary sheave assembly nut “1” Primary sheave assembly nut 140 Nm (14 m·kgf, 100 ft·lbf) Use the rotor holding tool “2” to hold the primary sheave. 2. Check: •...
  • Page 259 PRIMARY AND SECONDARY SHEAVES Shift the transmission into “L” (low) or “H” (high), set the parking brake, and then tighten the sec- ondary sheave assembly nut. 5. Lubricate: • Bearing housing bearing inner surface and ball (with the recommended lubricant) Recommended lubricant Shell Sunlight Grease 3®...

  • Page 260: Clutch

    CLUTCH EBS20044 CLUTCH Removing the clutch 190 Nm (19 m kgf, 137 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove ’ Remarks Refer to “PRIMARY AND SECONDARY Drive belt case SHEAVES”...
  • Page 261 CLUTCH Disassembling the clutch housing assembly ’ Order Job/Parts to remove Remarks Oil seal Circlip Bearing housing Circlip Bearing Seal ring One-way clutch bearing Bearing Clutch housing 5-60...

  • Page 262: Removing The Clutch

    CLUTCH • One-way clutch bearing EBS30177 REMOVING THE CLUTCH Chafing/wear/damage → Replace. 1. Remove: • Clutch housing assembly • Replace the one-way clutch bearing and clutch housing as a set. Working in crisscross pattern, loosen each bolt • The one-way clutch bearing must be installed 1/4 of a turn.

  • Page 263: Assembling The Clutch Housing

    CLUTCH a. Clutch shoe wear limit EBS30181 INSTALLING THE CLUTCH EBS30180 1. Install: ASSEMBLING THE CLUTCH HOUSING • Clutch carrier assembly 1. Install: • Clutch carrier assembly nut “1” • Bearing “1” (into the clutch housing “2”) Clutch carrier assembly nut 190 Nm (19 m·kgf, 137 ft·lbf) Installed depth “a”...
  • Page 264 CLUTCH • Tighten the bolts in stages, using a crisscross pattern. • After tightening the bolts, check that the clutch housing assembly rotates smoothly. 5-63...

  • Page 265: Crankcase

    CRANKCASE EBS20045 CRANKCASE Separating the crankcase 7 Nm (0.7 m kgf, 5.1 ft Ibf) 17 Nm (1.7 m kgf, 12 ft Ibf) 18 Nm (1.8 m kgf, 13 ft Ibf) • • • • • • 35 Nm (3.5 m kgf, 25 ft Ibf) •...
  • Page 266 CRANKCASE Separating the crankcase 7 Nm (0.7 m kgf, 5.1 ft Ibf) 17 Nm (1.7 m kgf, 12 ft Ibf) 18 Nm (1.8 m kgf, 13 ft Ibf) • • • • • • 35 Nm (3.5 m kgf, 25 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft...
  • Page 267 CRANKCASE Removing the crankcase bearings 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “CRANKSHAFT AND OIL PUMP” Crankshaft/Oil pump on page 5-70. Middle drive shaft/Middle driven shaft Refer to “MIDDLE GEAR” on page 5-81. Transmission Refer to “TRANSMISSION”...

  • Page 268: Separating The Crankcase

    CRANKCASE EBS30182 SEPARATING THE CRANKCASE 1. Remove: • Crankcase bolts Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. EBS30183 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1.

  • Page 269: Checking The Crankcase

    2. Thoroughly clean the crankcase mating sur- faces. 3. Apply: • Sealant “1” ×3 ×2 ×1 (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) Do not allow any sealant to come into contact with the oil gallery. 5-68...
  • Page 270 CRANKCASE ×3 ×2 ×6 A. Crankcase (right) B. Crankcase (left) 7. Apply: • 4-stroke engine oil (onto the crankshaft pin, bearings and oil de- livery hole) 8. Check: • Crankshaft and transmission operation Rough operation → Repair. 9. Install: • Gasket •...

  • Page 271: Crankshaft And Oil Pump

    CRANKSHAFT AND OIL PUMP EBS20046 CRANKSHAFT AND OIL PUMP Removing the crankshaft and oil pump 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove ’ Remarks Separate.
  • Page 272 CRANKSHAFT AND OIL PUMP Disassembling the oil pump 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • ’ Order Job/Parts to remove Remarks Oil pump housing cover Oil pump shaft Oil pump inner rotor Oil pump outer rotor Oil pump housing 5-71...

  • Page 273: Removing The Crankshaft

    CRANKSHAFT AND OIL PUMP EBS30188 REMOVING THE CRANKSHAFT 1. Remove: • Crankshaft “1” • Balancer “2” • Remove the crankshaft with the crankcase separating tool “3”. • Make sure the crankcase separating tool is centered over the crankshaft. • Remove the crankshaft “1” and balancer “2” at 1.

  • Page 274: Checking The Crankshaft

    CRANKSHAFT AND OIL PUMP EBS30191 CHECKING THE CRANKSHAFT Recommended lubricant 1. Measure: Engine oil • Crankshaft width “a” Out of specification → Replace the crank- 2. Install: shaft. • Oil pump housing “1” • Oil pump outer rotor “2” Crank assembly width •...

  • Page 275: Installing The Oil Pump

    CRANKSHAFT AND OIL PUMP Crankshaft installer pot 90890-01274 Installing pot YU-90058 Crankshaft installer bolt 90890-01275 Bolt YU-90060 Adapter (M16) 90890-04130 Adapter #13 YM-04059 Spacer (crankshaft installer) 90890-04081 Pot spacer YM-91044 EBS30445 INSTALLING THE OIL PUMP 1. Install: • Oil pump Oil pump bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tighten the bolts to specification in the proper...

  • Page 276: Transmission

    TRANSMISSION EBS20047 TRANSMISSION Removing the transmission, shift drum and shift forks 18 Nm (1.8 m kgf, 13 ft Ibf) • • Order Job/Parts to remove ’ Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-64. Middle driven gear Refer to “MIDDLE GEAR” on page 5-81. Shift drum stopper bolt Spring Ball...
  • Page 277 TRANSMISSION Removing the transmission, shift drum and shift forks 18 Nm (1.8 m kgf, 13 ft Ibf) • • ’ Order Job/Parts to remove Remarks Secondary shaft Drive axle assembly Collar Reverse idle gear Bearing Reverse idle gear shaft Stopper lever Stopper lever shaft 5-76...
  • Page 278 TRANSMISSION Disassembling the drive axle assembly ’ Order Job/Parts to remove Remarks Washer Collar High wheel gear Washer Clutch dog Circlip Washer Collar Low wheel gear Washer Circlip Middle drive gear Circlip Washer Bearing Reverse wheel gear Stopper wheel Drive axle 5-77...

  • Page 279: Removing The Transmission

    TRANSMISSION EBS30194 REMOVING THE TRANSMISSION 1. Remove: • Shift drum “1” • Shift fork assembly “2” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Pull out the guide bar from the left crankcase, and then remove the shift fork cam followers.

  • Page 280: Checking The Transmission

    TRANSMISSION EBS30199 CHECKING THE SECONDARY SHAFT 1. Check: • Gear teeth Blue discoloration/pitting/wear → Replace. EBS30555 CHECKING THE STOPPER LEVER AND STOPPER WHEEL 1. Check: • Stopper lever pawl “1” EBS30198 Bends/damage/wear → Replace the stopper CHECKING THE TRANSMISSION 1. Measure: lever and stopper wheel as a set.

  • Page 281: Installing The Shift Forks And Shift Drum

    TRANSMISSION • Shift fork “L” “2” 2. Check: • Spring “3” • Shift operation Rough operation → Repair. • Shift fork “R” “4” • Circlips “5” • Oil each gear and bearing thoroughly. • Before assembling the crankcase, make sure Install the shift forks with the “R”...

  • Page 282: Middle Gear

    MIDDLE GEAR EBS20048 MIDDLE GEAR Removing the middle drive shaft 190 Nm (19 m kgf, 137 ft lbf) • • 38 Nm (3.8 m kgf, 27 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • Order Job/Parts to remove ’...
  • Page 283 MIDDLE GEAR Removing the middle driven shaft 115 Nm (11.5 m kgf, 83 ft lbf) • • 25 Nm (2.5 m kgf, 18 ft Ibf) • • 80 Nm (8.0 m kgf, 58 ft Ibf) • • 130 Nm (13 m kgf, 94 ft lbf) •...
  • Page 284 MIDDLE GEAR Removing the middle driven shaft 115 Nm (11.5 m kgf, 83 ft lbf) • • 25 Nm (2.5 m kgf, 18 ft Ibf) • • 80 Nm (8.0 m kgf, 58 ft Ibf) • • 130 Nm (13 m kgf, 94 ft lbf) •...

  • Page 285: Removing The Middle Drive Shaft

    MIDDLE GEAR EBS30203 REMOVING THE MIDDLE DRIVE SHAFT Coupling gear/middle shaft tool 1. Straighten: 90890-01229 • Punched portion of the middle drive pinion Gear holder gear nut YM-01229 2. Loosen: • Middle drive pinion gear nut “1” Wrap the middle drive shaft in a folded rag, and then secure it in a vise.

  • Page 286: Checking The Pinion Gears

    MIDDLE GEAR • Install a suitable socket “2” on the middle Ring nut wrench driven pinion gear end to protect the thread 90890-01430 from damage. Ring nut wrench c. Press the middle driven pinion gear end and YM-38404 remove the bearing housing. ECB01750 NOTICE The middle driven shaft bearing retainer has...

  • Page 287: Installing The Bearing And Oil Seals

    MIDDLE GEAR EBS30206 INSTALLING THE BEARING AND OIL SEALS Ring nut wrench 1. Install: 90890-01430 • Bearing “1” Ring nut wrench YM-38404 • Oil seal “2” (into the bearing housing “3”) ECB01760 NOTICE Installed depth “a” of bearing The middle driven shaft bearing retainer has 0.9–1.4 mm (0.035–0.055 in) left-hand threads.

  • Page 288: Installing The Middle Drive Shaft

    MIDDLE GEAR ECB01770 NOTICE The middle driven pinion gear bearing retain- er has left-hand threads. To tighten the re- tainer turn it counterclockwise. 5. Install: • Front drive shaft coupling gear “1” • Washer • Front drive shaft coupling gear nut “2” Front drive shaft coupling gear ▲...

  • Page 289: Measuring The Middle Gear Backlash

    MIDDLE GEAR 2. Install: EBS30209 MEASURING THE MIDDLE GEAR • Bearing BACKLASH • Bearing retainers “1” 1. Measure: • Bearing retainer bolts “2” • Middle gear backlash Out of specification → Adjust. Middle drive shaft bearing retain- er bolt Refer to “ALIGNING THE MIDDLE GEAR” on 29 Nm (2.9 m·kgf, 21 ft·lbf) page 5-89.

  • Page 290: Aligning The Middle Gear

    MIDDLE GEAR a. 44.9 mm (1.77 in) b. 19.7 mm (0.78 in) d. Measure the gear lash while rotating the mid- dle driven shaft back and forth. Measure the gear lash at 4 positions. Rotate the middle driven gear 90° each time. e.
  • Page 291 MIDDLE GEAR Middle drive pinion gear shim Thickness (mm) 0.50 0.55 0.60 0.70 0.80 0.90 1.00 c. To find middle driven pinion gear shim thick- ness “B”, use the following formula. Middle driven pinion gear shim thickness “B” = “f” - “g” + “h” - “i” - “j” “f”...
  • Page 292 MIDDLE GEAR If the driven pinion gear is marked “+02”, Therefore, “B” is 0.81. “g” is 49.02 “B” = 77.53 - 49.02 + 80.40 - 99.98 - 8.12 = 0.81 Round off hundredth digit and select appro- priate shim(s). In the above example, the calculated shim thickness is 0.81 mm.

  • Page 293: Cooling System

    COOLING SYSTEM OIL COOLER....................6-1 CHECKING THE OIL COOLER ..............6-3 INSTALLING THE OIL COOLER .............. 6-3 RADIATOR ...................... 6-4 CHECKING THE RADIATOR..............6-6 INSTALLING THE RADIATOR..............6-6 THERMOSTAT ....................6-7 CHECKING THE THERMOSTAT.............. 6-8 INSTALLING THE THERMOSTAT............6-8 WATER PUMP....................6-10 DISASSEMBLING THE WATER PUMP..........6-12 CHECKING THE WATER PUMP ............

  • Page 294: Oil Cooler

    OIL COOLER EBS20050 OIL COOLER Removing the oil cooler 18 Nm (1.8 m kgf, 13 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...
  • Page 295 OIL COOLER Removing the oil cooler 18 Nm (1.8 m kgf, 13 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...

  • Page 296: Checking The Oil Cooler

    OIL COOLER Refer to “CHANGING THE COOLANT” on EBS30211 CHECKING THE OIL COOLER page 3-29. 1. Check: • Crankcase • Oil cooler (with the specified amount of the recom- Cracks/damage → Replace. mended engine oil) 2. Check: Refer to “CHANGING THE ENGINE OIL” on •...

  • Page 297: Radiator

    RADIATOR EBS20051 RADIATOR Removing the radiator 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • Order Job/Parts to remove ’ Remarks Front skid plate/Center skid plate/Top cov- Refer to “GENERAL CHASSIS (1)” on page er/Side panels 4-1.
  • Page 298 RADIATOR Removing the radiator 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • ’ Order Job/Parts to remove Remarks Coolant reservoir Radiator outlet hose Radiator inlet hose Radiator Radiator fan...

  • Page 299: Checking The Radiator

    RADIATOR EBS30213 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.

  • Page 300: Thermostat

    THERMOSTAT EBS20052 THERMOSTAT Removing the thermostat 20 Nm (2.0 m kgf, 14 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove ’ Remarks Refer to “GENERAL CHASSIS (1)” on page Top cover/Side panel (right) 4-1.

  • Page 301: Checking The Thermostat

    THERMOSTAT 2. Check: EBS30215 CHECKING THE THERMOSTAT • Thermostat housing cover 1. Check: • Thermostat housing (cylinder head) • Thermostat Cracks/damage → Replace. Does not open at 69–73 °C (156.2–163.4 °F) → Replace. EBS30216 INSTALLING THE THERMOSTAT 1. Install: • Copper washer •...
  • Page 302 THERMOSTAT 5. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-6.

  • Page 303: Water Pump

    WATER PUMP EBS20053 WATER PUMP Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...
  • Page 304 WATER PUMP Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...

  • Page 305: Disassembling The Water Pump

    WATER PUMP EBS30217 DISASSEMBLING THE WATER PUMP Install the oil seal with a socket that matches its 1. Remove: outside diameter. • Mechanical seal “1” Installed depth of oil seal “a” Remove the mechanical seal from the inside of 0 mm (0 in) the AC magneto cover.

  • Page 306: Installing The Water Pump Housing

    WATER PUMP 3. Install: • Water pump outlet hose “2” (onto the water • Impeller “1” jacket joint) • Water jacket joint “3” Impeller 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tighten the clamp screw of each clamp “1” until 4 slots remain in the area “a” of the clamp as shown in the illustration.

  • Page 307: Fuel System

    FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP ..............7-2 CHECKING THE FUEL PUMP BODY............7-2 CHECKING THE FUEL TANK BREATHER HOSE JOINT .......7-2 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL TANK..............7-3 THROTTLE BODY................... 7-4 REMOVING THE THROTTLE BODY ASSEMBLY ........7-6 CHECKING THE INJECTOR ..............

  • Page 308: Fuel Tank

    FUEL TANK EBS20054 FUEL TANK Removing the fuel tank 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove ’...

  • Page 309: Removing The Fuel Tank

    FUEL TANK EBS30221 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose connector holder • Fuel hose EWB03050 WARNING Cover fuel hose connections with a cloth when disconnecting them.

  • Page 310: Installing The Fuel Tank

    FUEL TANK ECB02010 NOTICE • Do not damage the installation surfaces of the When installing the fuel hose, make sure that fuel tank when installing the fuel pump. it is securely connected, and that the fuel • Always use a new fuel pump gasket. hose holder is in the correct position, other- •...

  • Page 311: Throttle Body

    THROTTLE BODY EBS20056 THROTTLE BODY Removing the throttle body 0.8 Nm (0.08 m kgf, 0.58 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • 2.8 Nm (0.28 m kgf, 2.0 ft Ibf) •...
  • Page 312 THROTTLE BODY Disassembling the throttle body assembly 3.6 Nm (0.36 m kgf, 2.6 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • ’ Order Job/Parts to remove Remarks Intake air pressure sensor Intake air pressure sensor hose...

  • Page 313: Removing The Throttle Body Assembly

    THROTTLE BODY 2. Check: EBS30229 REMOVING THE THROTTLE BODY • Fuel passages ASSEMBLY Obstructions → Clean. 1. Disconnect: ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ • Fuel hose a. Wash the throttle body in a petroleum- based EWB03050 solvent.

  • Page 314: Checking The Fuel Pressure

    THROTTLE BODY d. Connect the pressure gauge “3” and adapter ECB02370 NOTICE “4” to the fuel pump and fuel hose. When connecting the fuel hose, make sure Pressure gauge that it is securely connected, and that the 90890-03153 fuel hose connector cover is in the correct Pressure gauge position, otherwise the fuel hose will not be YU-03153...
  • Page 315 THROTTLE BODY • Positive tester probe yellow (wire harness color) • Negative tester probe black/blue (wire harness color) Test harness– TPS (3P) 90890-03204 Test harness– TPS (3P) YU-03204 Digital circuit tester 90890-03174 Model 88 Multimeter with ta- chometer YU-A1927 c. Turn the main switch to “ ”...

  • Page 316: Air Induction System

    AIR INDUCTION SYSTEM EBS20057 AIR INDUCTION SYSTEM...
  • Page 317 AIR INDUCTION SYSTEM 1. Air induction system hose (air filter case to air cut-off valve) 2. Air cut-off valve 3. Air induction system hose (air cut-off valve to reed valve assembly) 4. Reed valve assembly 7-10...
  • Page 318 AIR INDUCTION SYSTEM Removing the air cut-off valve 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)” on page Seat/Side panels 4-1. Air cut-off valve coupler Disconnect. Air induction system hose (air filter case to air cut-off valve) Air induction system hose (air cut-off valve to reed valve assembly)
  • Page 319 AIR INDUCTION SYSTEM Removing the reed valve 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Reed valve cover Reed valve assembly Reed valve plate 7-12...

  • Page 320: Checking The Air Induction System

    AIR INDUCTION SYSTEM 2. Check: EBS30235 CHECKING THE AIR INDUCTION SYSTEM • Reed valve • Reed valve stopper Air injection • Reed valve seat The air induction system burns unburned ex- Cracks/damage → Replace the reed valve haust gases by injecting fresh air (secondary air) assembly.

  • Page 321: Drive Train

    DRIVE TRAIN TROUBLESHOOTING..................8-1 CHECKING NOISES ................. 8-2 TROUBLESHOOTING CHART ..............8-3 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT ......8-4 DISASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES ................... 8-9 CHECKING THE FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES ................... 8-9 ASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES ..................

  • Page 322: Troubleshooting

    TROUBLESHOOTING EBS20058 TROUBLESHOOTING The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1. A pronounced hesitation or “jerky” movement A. Bearing damage. during acceleration, deceleration, or sustained B. Improper gear backlash. speed. (This must not be confused with engine C.

  • Page 323: Checking Noises

    TROUBLESHOOTING b. Apply a leak-localizing compound or dry pow- EBS30237 CHECKING NOISES der spray to the shaft drive. 1. Investigate any unusual noises. c. Road test the vehicle for the distance neces- sary to locate the leak. ▼ ▼▼▼ ▼ ▼▼▼ ▼...

  • Page 324: Troubleshooting Chart

    TROUBLESHOOTING EBS30238 TROUBLESHOOTING CHART When basic conditions (a) and (b) exist, check the following points: YES → Replace the wheel bearing. (Refer to “TIE- 1. Elevate and spin both wheels. Feel RODS AND STEERING KNUCKLES” on for wheel bearing damage. page 4-61 and “REAR KNUCKLES AND STABILIZER”...

  • Page 325: Front Constant Velocity Shaft Assemblies, Differential Assembly And Front Drive Shaft

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT EBS20059 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT Removing the front constant velocity shaft assemblies, differential assembly and front drive shaft 55 Nm (5.5 m kgf, 40 ft Ibf) 55 Nm (5.5 m...
  • Page 326 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT Removing the front constant velocity shaft assemblies, differential assembly and front drive shaft 55 Nm (5.5 m kgf, 40 ft Ibf) 55 Nm (5.5 m kgf, 40 ft Ibf) •...
  • Page 327 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT Disassembling the front constant velocity shaft assemblies A: Wheel side B: Differential side ’ Order Job/Parts to remove Remarks The following procedure applies to both of the front constant velocity shaft assemblies. Clip Boot band Boot band...
  • Page 328 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT Disassembling the differential assembly 24 Nm (2.4 m kgf, 17 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 62 Nm (6.2 m kgf, 45 ft Ibf) •...
  • Page 329 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT Disassembling the differential assembly 24 Nm (2.4 m kgf, 17 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 62 Nm (6.2 m kgf, 45 ft Ibf) •...

  • Page 330: Disassembling The Front Constant Velocity Shaft Assemblies

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT EBS30240 DISASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES The following procedure applies to both of the front constant velocity shaft assemblies. 1. Remove: • Boot bands • Clip “1” •...

  • Page 331: Assembling The Front Constant Velocity Shaft Assemblies

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT 2. Install: EBS30242 ASSEMBLING THE FRONT CONSTANT • Dust boot VELOCITY SHAFT ASSEMBLIES • Ball bearing “1” The following procedure applies to both of the • Circlip “2” front constant velocity shaft assemblies.

  • Page 332: Removing The Differential Gear Assembly

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT EBS30244 REMOVING THE DIFFERENTIAL GEAR • The new boot bands may differ from the origi- ASSEMBLY nal ones. 1. Remove: • The dust boots should be fastened with the •...

  • Page 333: Assembling The Differential Assembly

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ ECB01930 NOTICE a. Slide the shift fork sliding gear “1”, which is in- stalled to the differential case cover, to the left Do not disassemble the differential motor or as shown in the illustration to put it into the...

  • Page 334: Measuring The Differential Gear Backlash

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT ECB01250 NOTICE Finger tighten the bolt until it holds the ring gear. Otherwise, the ring gear will be dam- aged. 4. Attach: • Gear lash measurement tool “2” •...
  • Page 335 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFT 2. Adjust: • Gear backlash ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Select the suitable shims using the following chart.

  • Page 336: Rear Constant Velocity Shaft Assemblies, Final Drive Assembly And Rear Drive Shaft

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT EBS20060 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Removing the rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 55 Nm (5.5 m kgf, 40 ft Ibf) •...
  • Page 337 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Removing the rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 55 Nm (5.5 m kgf, 40 ft Ibf) • • 66 Nm (6.6 m kgf, 48 ft Ibf) •...
  • Page 338 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Disassembling the rear constant velocity shaft assemblies A: Wheel side B: Final drive side ’ Order Job/Parts to remove Remarks The following procedure applies to both of the rear constant velocity shaft assemblies. Clip Boot band Boot band...
  • Page 339 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Disassembling the final drive assembly 23 Nm (2.3 m kgf, 17 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...
  • Page 340 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Disassembling the final drive assembly 23 Nm (2.3 m kgf, 17 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...
  • Page 341 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Disassembling the final drive assembly 23 Nm (2.3 m kgf, 17 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...

  • Page 342: Disassembling The Rear Constant Velocity Shaft Assemblies

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT EBS30253 DISASSEMBLING THE REAR CONSTANT VELOCITY SHAFT ASSEMBLIES The following procedure applies to both of the rear constant velocity shaft assemblies. 1. Remove: • Boot band “1” Use the boot band installation tool “2”. Boots band installation tool 90890-01526 Boots band installation tool...

  • Page 343: Checking The Rear Constant Velocity Shaft Assemblies

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT EBS30254 CHECKING THE REAR CONSTANT VELOCITY SHAFT ASSEMBLIES The following procedure applies to both of the rear constant velocity shaft assemblies. 1. Check: • Double offset joint splines •...

  • Page 344: Disassembling The Final Drive Pinion Gear Assembly

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Boots band installation tool 90890-01526 Boots band installation tool YM-01526 B. Final drive side 3. Apply: • Molybdenum disulfide grease (into the double offset joint, constant velocity joint, and dust boots) ▲...

  • Page 345: Checking The Rear Drive Shaft

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT EBS30257 EBS30262 CHECKING THE REAR DRIVE SHAFT ASSEMBLING THE FINAL DRIVE PINION 1. Check: GEAR ASSEMBLY • Drive shaft splines 1. Install: • Coupling sleeve splines • Rear drive shaft yoke nut “1” Wear/damage →...

  • Page 346: Selecting The Final Drive Pinion Gear Shim(S)

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Check: • Final drive assembly operation Unsmooth operation → Replace the final drive assembly.

  • Page 347: Selecting The Final Driven Pinion Gear Shim (Final Drive Case Side) And Thrust Washer

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT If “-01” is stamped on the final drive case, “e” = a numeral (usually a decimal number) “d” = 100 - 0.01 on the final drive case either added to or sub- = 99.99 tracted from “71.6”...

  • Page 348: Selecting The Final Driven Pinion Gear Shim (Final Drive Case Cover Side)

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Hundredth Rounded value 3, 4, 5, 6, 7 8, 9 Shim and thrust washer are supplied in the following thicknesses. Final driven pinion gear shims (fi- nal drive case side) “1” Thickness (mm) If “-12”...

  • Page 349: Selecting The Wheel Gear Shim(S)

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Place four pieces of Plastigauge® between Measure the thickness of the originally fitted the originally fitted shim(s) and the final driv- shim(s), and then calculate the required new en pinion gear assembly.

  • Page 350: Measuring The Final Gear Backlash

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT ECB01250 NOTICE Wheel gear thrust clearance 0.03–0.07 mm (0.0012–0.0028 in) Finger tighten the bolt until it holds the ring gear. Otherwise, the ring gear will be dam- aged. 4.
  • Page 351 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Final driven pinion gear shims (fi- nal drive case cover side) “4” Thickness (mm) 0.25 0.30 0.35 0.40 0.45 0.50 ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...
  • Page 352 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT 8-31...

  • Page 353: Electrical System

    CIRCUIT DIAGRAM ................9-25 TROUBLESHOOTING ................9-27 FUEL INJECTION SYSTEM................9-29 CIRCUIT DIAGRAM ................9-29 ECU SELF-DIAGNOSTIC FUNCTION............9-31 TROUBLESHOOTING METHOD............9-32 YAMAHA DIAGNOSTIC TOOL ...............9-32 TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM) ....9-35 FUEL PUMP SYSTEM...................9-59 CIRCUIT DIAGRAM ................9-59 TROUBLESHOOTING ................9-61 2WD/4WD SELECTING SYSTEM..............9-63 CIRCUIT DIAGRAM ................
  • Page 354 EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)...9-67 CIRCUIT DIAGRAM ................9-67 EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION .....9-69 EPS WARNING LIGHT DURING NORMAL OPERATION......9-69 DIAGNOSTIC MODE ................9-70 SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)......9-72 TROUBLESHOOTING DETAILS (EPS SYSTEM) ........9-73 ELECTRICAL COMPONENTS..............9-77 CHECKING THE SWITCHES ..............9-81 CHECKING THE BULBS AND BULB SOCKETS ........

  • Page 356: Ignition System

    IGNITION SYSTEM EBS20074 IGNITION SYSTEM EBS30264 CIRCUIT DIAGRAM...
  • Page 357 IGNITION SYSTEM 1. Crankshaft position sensor 4. Main switch 5. Main fuse 6. Battery 9. Engine ground 11.Joint coupler 16.ECU (Engine Control Unit) 17.Ignition coil 18.Spark plug 25.Lean angle sensor 46.Engine stop switch 61.Ignition fuse 66.Frame ground 1 A. Wire harness B.

  • Page 358: Troubleshooting

    IGNITION SYSTEM EBS30265 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Top cover 4. Side panels (left and right) 5. Storage compartment 6. V-belt cooling exhaust duct NG →...
  • Page 359 IGNITION SYSTEM NG → 8. Check the engine stop switch. The engine stop switch is faulty. Replace Refer to “CHECKING THE the handlebar switch (left). SWITCHES” on page 9-81. OK ↓ NG → 9. Check the lean angle sensor. Refer to “CHECKING THE LEAN Replace the lean angle sensor.

  • Page 360: Electric Starting System

    ELECTRIC STARTING SYSTEM EBS20075 ELECTRIC STARTING SYSTEM EBS30266 CIRCUIT DIAGRAM...
  • Page 361 ELECTRIC STARTING SYSTEM 4. Main switch 5. Main fuse 6. Battery 8. Starter relay 9. Engine ground 10.Starter motor 11.Joint coupler 16.ECU (Engine Control Unit) 27.Gear position switch 45.Start switch 46.Engine stop switch 54.Rear brake light switch 60.Signaling system fuse 61.Ignition fuse 66.Frame ground 1 A.

  • Page 362: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EBS30267 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ ” (on) (both switch circuits are closed), the starter motor can only operate if at least one of the following conditions is met: •...

  • Page 363: Troubleshooting

    ELECTRIC STARTING SYSTEM EBS30268 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Top cover 4. Side panels (left and right) 5. V-belt cooling exhaust duct NG → 1. Check the fuses. (Main, ignition and signaling sys- tem) Replace the fuse(s).
  • Page 364 ELECTRIC STARTING SYSTEM NG → 8. Check the start switch. The start switch is faulty. Replace the han- Refer to “CHECKING THE dlebar switch (left). SWITCHES” on page 9-81. OK ↓ NG → 9. Check the rear brake light switch. Refer to “CHECKING THE Replace the rear brake light switch.
  • Page 365 ELECTRIC STARTING SYSTEM 9-10...

  • Page 366: Charging System

    CHARGING SYSTEM EBS20076 CHARGING SYSTEM EBS30269 CIRCUIT DIAGRAM R/L R/L R/W R/W R/L R/W R/W R/L R/W R/W Gy B (Gy) Br Br/L (Gy) Br/B Br/B Br/B R/W Br/B R Br/L Br Br/L Br/B R/W L/Y R/Y Br/L Br/Y Br Br Br/L L L/Y R/Y Y...
  • Page 367 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 5. Main fuse 6. Battery 9. Engine ground 66.Frame ground 1 67.Frame ground 2 A. Wire harness B. Negative battery sub-wire harness 9-12...

  • Page 368: Troubleshooting

    CHARGING SYSTEM EBS30270 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Top cover 4. Side panel (right) 5. V-belt cooling exhaust duct NG → 1. Check the fuse. (Main) Replace the fuse.
  • Page 369 CHARGING SYSTEM 9-14...

  • Page 370: Lighting System

    LIGHTING SYSTEM EBS20077 LIGHTING SYSTEM EBS30271 CIRCUIT DIAGRAM 9-15...
  • Page 371 LIGHTING SYSTEM 4. Main switch 5. Main fuse 6. Battery 9. Engine ground 11.Joint coupler 47.Light switch 48.Handle mounted light 49.Headlight 50.Headlight relay 2 51.Headlight relay 1 52.Tail/brake light 59.Headlight fuse 66.Frame ground 1 A. Wire harness B. Negative battery sub-wire harness 9-16...

  • Page 372: Troubleshooting

    LIGHTING SYSTEM EBS30272 TROUBLESHOOTING Any of the following fail to light: Handle mounted light, headlight or taillight. • Before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Handle mounted light cover NG → 1. Check the condition of handle mounted light bulb and bulb socket.
  • Page 373 LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM” on tem wiring. page 9-15. OK ↓ Replace the headlight unit or tail/brake light unit. 9-18...

  • Page 374: Signaling System

    SIGNALING SYSTEM EBS20078 SIGNALING SYSTEM EBS30352 CIRCUIT DIAGRAM 9-19...
  • Page 375 SIGNALING SYSTEM 4. Main switch 5. Main fuse 6. Battery 9. Engine ground 11.Joint coupler 14.Reverse switch 16.ECU (Engine Control Unit) 21.Coolant temperature sensor 22.Speed sensor 27.Gear position switch 29.Multi-function meter 31.Coolant temperature warning light 32.Park indicator light 33.Reverse indicator light 34.Neutral indicator light 35.High-range indicator light 36.Low-range indicator light...

  • Page 376: Troubleshooting

    SIGNALING SYSTEM EBS30274 TROUBLESHOOTING • Any of the following fail to light: warning light, brake light or an indicator light. • The fuel meter fails to come on. • The speedometer fails to operate. • The horn fails to sound. (except for CDN) •...
  • Page 377 SIGNALING SYSTEM NG → 2. Check the rear brake light switch. Refer to “CHECKING THE Replace the rear brake light switch. SWITCHES” on page 9-81. OK ↓ NG → 3. Check the diode. Refer to “CHECKING THE DIODE” Replace the diode. on page 9-90.
  • Page 378 SIGNALING SYSTEM The differential gear lock indicator light and /or four-wheel-drive indicator light fails to come on. NG → 1. Check the four-wheel-drive motor switch (differential motor). Replace the differential motor. Refer to “CHECKING THE SWITCHES” on page 9-81. OK ↓ NG →...
  • Page 379 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 9-19. OK ↓ Replace the meter assembly or ECU. The fuel level indicator fails to come on. NG →...

  • Page 380: Cooling System

    COOLING SYSTEM EBS20079 COOLING SYSTEM EBS30275 CIRCUIT DIAGRAM 9-25...
  • Page 381 COOLING SYSTEM 4. Main switch 5. Main fuse 6. Battery 9. Engine ground 11.Joint coupler 16.ECU (Engine Control Unit) 21.Coolant temperature sensor 56.Radiator fan motor 57.Radiator fan motor circuit breaker 58.Radiator fan motor relay 61.Ignition fuse 64.Radiator fan motor fuse 66.Frame ground 1 A.

  • Page 382: Troubleshooting

    COOLING SYSTEM EBS30276 TROUBLESHOOTING The radiator fan motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Top cover 4. Side panels (left and right) 5. Front fenders NG → 1. Check the fuses. (Main, ignition and radiator fan mo- tor) Replace the fuse(s).
  • Page 383 COOLING SYSTEM NG → 8. Check the entire cooling system wiring. Properly connect or repair the cooling sys- Refer to “CIRCUIT DIAGRAM” on tem wiring. page 9-25. OK ↓ Replace the ECU. 9-28...

  • Page 384: Fuel Injection System

    FUEL INJECTION SYSTEM EBS20080 FUEL INJECTION SYSTEM EBS30353 CIRCUIT DIAGRAM 9-29...
  • Page 385 5. Main fuse 6. Battery 7. Fuel injection system fuse 9. Engine ground 11.Joint coupler 12.Fuel injection system relay 13.Yamaha diagnostic tool coupler 15.ISC (Idle Speed Control) unit 16.ECU (Engine Control Unit) 17.Ignition coil 18.Spark plug 19.Fuel injector 20.Intake air temperature sensor 21.Coolant temperature sensor...

  • Page 386: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EBS30278 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 387: Troubleshooting Method

    ▼ ▼ ▼▼▼ ▼ ▼▼▼▼ ▼▼ ▼ a. Check the fault code number displayed on the meter or Yamaha diagnostic tool. b. Identify the faulty system with the fault code. c. Identify the probable cause of the malfunction. ▲ ▲▲▲...
  • Page 388 FUEL INJECTION SYSTEM For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool 90890-03231 Features of the Yamaha diagnostic tool You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional meth- ods.
  • Page 389 FUEL INJECTION SYSTEM Operation of the Yamaha diagnostic tool (Malfunction mode) Malfunction results are displayed in the top part of the window area. 1. Recovered The item list of the malfunction detected in the past (already recovered) are displayed. 2. Detected The item list of the malfunction currently occurred are displayed.

  • Page 390: Troubleshooting Details (Fuel Injection System)

    Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part has been completed, reset the Yamaha diagnos- tic tool or multi-function meter display according to the “Confirmation of service completion”.
  • Page 391 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received from the Item crankshaft position sensor. Improperly connected → Con- Connection of crankshaft posi- Crank the engine. tion sensor coupler. nect the coupler securely or re- Fault code number is not dis- played →...
  • Page 392 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Indicated Displays the intake air pressure. Set the engine stop switch to “ ”, and then operate the throttle while Procedure pushing the start switch “ ”.
  • Page 393 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Defective intake air pressure Execute the diagnostic mode. Turn the main switch to “ ” sensor. (Code No. 03) (on). When engine is stopped: Fault code number is not dis- played →...
  • Page 394 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged or de- Item tached hose). Clogged or detached hose → Condition of intake air pressure Start the engine and let it idle sensor hose. Repair or replace the sensor for approximately 5 seconds.
  • Page 395 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Improperly connected → Con- Connection of throttle position Turn the main switch to “ ” sensor coupler. nect the coupler securely or re- (on). Check the locking condition of place the wire harness.
  • Page 396 FUEL INJECTION SYSTEM Fault code No. 16 • If fault code numbers “15” and “16” are both indicated, take the actions specified for fault code number “15” first. • If fault code numbers “16” and “37” are both indicated, take the actions specified for fault code number “16”...
  • Page 397 FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Improperly connected → Con- Connection of coolant tempera- Turn the main switch to “ ” ture sensor coupler. nect the coupler securely or re- (on). Check the locking condition of place the wire harness.
  • Page 398 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Indicated Displays the intake air temperature. Compare the actually measured intake air temperature with the indicated Procedure value.
  • Page 399 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Defective intake air temperature Execute the diagnostic mode. Turn the main switch to “ ” sensor. (Code No. 05) (on). When engine is cold: Fault code number is not dis- played →...
  • Page 400 Actuates the ignition coil five times at one-second intervals. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on each time the ignition coil is actuated. Check that a spark is generated five times. Procedure •...
  • Page 401 Fully closes the ISC valve, and then opens the valve. This operation takes approximately 3 seconds. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on during the operation. Procedure The operating sound can be heard when ISC valve operates.
  • Page 402 Fully closes the ISC valve, and then opens the valve. This operation takes approximately 3 seconds. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on during the operation. Procedure The operating sound can be heard when ISC valve operates.
  • Page 403 Diagnostic code No. Actuates fuel injector five times at one-second intervals. The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen Actuation come on each time the fuel injector is actuated. Disconnect the fuel pump coupler, and then check that fuel injector is ac- Procedure tuated five times by listening for the operating sound.
  • Page 404 FUEL INJECTION SYSTEM Fault code No. Item Fuel injector: open or short circuit detected. Improperly connected → Con- Connection of fuel injector cou- Execute the diagnostic mode. pler. nect the coupler securely or re- (Code No. 36) Operating sound → Go to item Check the locking condition of place the wire harness.
  • Page 405 FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Improperly connected → Con- Connection of lean angle sen- Turn the main switch to “ ” sor coupler. nect the coupler securely or re- (on), then to “ ”...
  • Page 406 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sen- Item sor. Check that the number increases when the rear wheels are rotated. The Procedure number is cumulative and does not reset each time the wheel is stopped. Probable cause of malfunc- Confirmation of service com- Item...
  • Page 407 ” on the Yamaha di- agnostic tool screen go off. When the relay is off, the “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on.) Check that the fuel injection system relay is actuated five times by listen- Procedure ing for the operating sound.
  • Page 408 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel injector Item and fuel pump. Open or short circuit → Replace Wire harness continuity. Start the engine and let it idle the wire harness. for approximately 5 seconds. Between fuel injection system Fault code number is not dis- played →...
  • Page 409 FUEL INJECTION SYSTEM Fault code No. 46 If fault code numbers “37” and “46” are both indicated, take the actions specified for fault code number “46” first. Fault code No. Item Charging voltage is abnormal. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 410 FUEL INJECTION SYSTEM Fault code No. Er-1 ECU (Engine Control Unit) internal malfunction (output signal error): Item signals cannot be transmitted between the ECU and the multi-func- tion meter. Indicated — Procedure — Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check...
  • Page 411 FUEL INJECTION SYSTEM Fault code No. Er-2 ECU (Engine Control Unit) internal malfunction (output signal error): Item no signals are received from the ECU within the specified duration. Improperly connected → Con- Connection of meter assembly Turn the main switch to “ ”...
  • Page 412 FUEL INJECTION SYSTEM Fault code No. Er-3 ECU (Engine Control Unit) internal malfunction (output signal error): Item data from the ECU cannot be received correctly. Improperly connected → Con- Connection of ECU coupler. Turn the main switch to “ ” Check the locking condition of nect the coupler securely or re- (on).
  • Page 413 FUEL INJECTION SYSTEM Fault code No. Er-4 ECU (Engine Control Unit) internal malfunction (input signal error): Item non-registered data has been received from the meter assembly. Open or short circuit → Replace Wire harness continuity. Turn the main switch to “ ”...

  • Page 414: Fuel Pump System

    FUEL PUMP SYSTEM EBS20081 FUEL PUMP SYSTEM EBS30282 CIRCUIT DIAGRAM 9-59...
  • Page 415 FUEL PUMP SYSTEM 4. Main switch 5. Main fuse 6. Battery 7. Fuel injection system fuse 9. Engine ground 11.Joint coupler 12.Fuel injection system relay 16.ECU (Engine Control Unit) 40.Fuel pump 46.Engine stop switch 61.Ignition fuse 66.Frame ground 1 A. Wire harness B.

  • Page 416: Troubleshooting

    FUEL PUMP SYSTEM EBS30283 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Top cover 4. Side panels (left and right) 5. Rear fender NG → 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).
  • Page 417 FUEL PUMP SYSTEM 9-62...

  • Page 418: 2Wd/4Wd Selecting System

    2WD/4WD SELECTING SYSTEM EBS20082 2WD/4WD SELECTING SYSTEM EBS30448 CIRCUIT DIAGRAM 9-63...
  • Page 419 2WD/4WD SELECTING SYSTEM 4. Main switch 5. Main fuse 6. Battery 9. Engine ground 11.Joint coupler 16.ECU (Engine Control Unit) 37.On-Command four-wheel-drive motor switch and differential lock switch 38.Differential motor 41.Four-wheel-drive motor relay 1 42.Four-wheel-drive motor relay 2 61.Ignition fuse 62.Four-wheel-drive motor fuse 66.Frame ground 1 A.

  • Page 420: Troubleshooting

    2WD/4WD SELECTING SYSTEM EBS30285 TROUBLESHOOTING The four-wheel-drive motor indicator light fails to come on. • Before troubleshooting, remove the following part(s): 1. Battery cover NG → 1. Check the fuses. (Main, Ignition and four-wheel-drive motor) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 421 2WD/4WD SELECTING SYSTEM NG → 8. Check the entire 2WD/4WD select- ing system wiring. Properly connect or repair the 2WD/4WD Refer to “CIRCUIT DIAGRAM” on selecting system wiring. page 9-63. OK ↓ Replace the ECU. 9-66...

  • Page 422: Eps (Electric Power Steering) System (For Eps Models)

    EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) EBS20083 EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) EBS30286 CIRCUIT DIAGRAM 9-67...
  • Page 423 EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) 4. Main switch 5. EPS fuse 6. Main fuse 7. Battery 10.Engine ground 12.Joint coupler 13.EPS torque sensor 14.EPS motor 15.EPS (electric power steering) control unit 16.EPS self-diagnosis signal connector 21.ECU (Engine Control Unit) 27.Speed sensor 42.EPS warning light 67.Ignition fuse...

  • Page 424: Eps Control Unit's Self-Diagnostic Function

    EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) EBS30287 EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION The EPS control unit is equipped with a self-diagnostic function. If this function detects a malfunction in the EPS system, it lights the EPS warning light to alert the rider that a malfunction has occurred in the system.

  • Page 425: Diagnostic Mode

    EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) e. “ ” (on) f. Off g. Comes on. h. Initial lighting: 2 seconds i. Goes off. EBS30289 DIAGNOSTIC MODE Setting the diagnostic mode (present and past malfunctions) 1. Disconnect the EPS self-diagnosis signal connector “1”. 2.
  • Page 426 EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) Example 1: Fault code No. 23 0.5 × 3 0.5 × 5 a. EPS self-diagnosis signal connector B. Display of the present malfunctions stops when the past malfunction display mode is b. Diagnostic mode selected.

  • Page 427: Self-Diagnostic Function Table (Eps System)

    EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) After the mode selection judgment is completed (present display or past malfunction mode), the current fault code signaling stops immediately, and then the EPS warning light starts flashing at 1.5-second in- tervals. Deleting fault codes To delete fault codes, ground the EPS self-diagnosis signal connector 3 or more times within 5 seconds while the present or past malfunction mode is activated.

  • Page 428: Troubleshooting Details (Eps System)

    EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) Fault code Probable cause of mal- Item Symptom function • Faulty battery. • Malfunction in the charging system. EPS control unit Battery voltage has dropped. Refer to “CHARGING SYSTEM” on page 9-11. •...
  • Page 429 EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) Fault code No. 21 Fault code No. Symptom Speed sensor: no normal signals are received from the speed sensor. Order Item/components and probable cause Check or maintenance job Reinstatement method Connections • Check the locking condition of the Starting the en- •...
  • Page 430 EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) Fault code No. 41, 42, 43, 45 Fault code No. 41, 42, Symptom EPS motor: no normal signals are received from the EPS motor. 43, 45 Order Item/components and probable cause Check or maintenance job Reinstatement method Connections...
  • Page 431 EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) Fault code No. 54 Fault code No. Symptom Relay contacts in the EPS control unit are welded together. Order Item/components and probable cause Check or maintenance job Reinstatement method Malfunction in EPS control unit. Replace the EPS control unit.

  • Page 432: Electrical Components

    ELECTRICAL COMPONENTS EBS20084 ELECTRICAL COMPONENTS 9-77...
  • Page 433 ELECTRICAL COMPONENTS 1. Four-wheel-drive motor relay 1 2. Four-wheel-drive motor relay 2 3. Headlight relay 1 4. Fuel injection system fuse 5. Starter relay 6. EPS fuse (for EPS models) 7. Main fuse 8. Fuse box (ignition, headlights, four-wheel- drive motor, radiator fan motor, signaling system, auxiliary DC jack) 9.
  • Page 434 ELECTRICAL COMPONENTS 9-79...
  • Page 435 ELECTRICAL COMPONENTS 1. Lean angle sensor 2. Radiator fan motor relay 3. Fuel injection system relay 4. Headlight relay 2 5. Front brake light switch 6. Rear brake light switch 7. Intake air temperature sensor 8. Intake air pressure sensor 9.

  • Page 436: Checking The Switches

    ELECTRICAL COMPONENTS EBS30292 CHECKING THE SWITCHES Br/Y Br/Y R Br/L Br ( BLACK ) R Br/L Br R/Y L Y R/Y Y (GRAY) PUSH L/W G/R LOCK Gy W 1. Main switch 8. Gear position switch 2. Light switch 9. Reverse switch 3.
  • Page 437 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECB02380 NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

  • Page 438: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS • Avoid touching the glass part of a handle EBS30293 CHECKING THE BULBS AND BULB mounted light bulb to keep it free from oil, SOCKETS otherwise the transparency of the glass, the life of the bulb, and the luminous flux Do not check any of the lights that use LEDs.

  • Page 439: Checking The Fuses

    ELECTRICAL COMPONENTS Pocket tester Pocket tester 90890-03112 90890-03112 Analog pocket tester Analog pocket tester YU-03112-C YU-03112-C Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. ▼ ▼▼▼ ▼ ▼▼▼ ▼...

  • Page 440: Checking And Charging The Battery

    ELECTRICAL COMPONENTS cal system, cause the lighting and ignition be charged as explained in the charging systems to malfunction and could possibly method. If the battery is overcharged, the cause a fire. electrolyte level will drop considerably. Therefore, take special care when charging ▲...
  • Page 441 ELECTRICAL COMPONENTS EWB03650 WARNING • The charge state of a VRLA (Valve Regulated Do not quick charge a battery. Lead Acid) battery can be checked by measur- ing its open-circuit voltage (i.e., the voltage ECB02580 NOTICE when the positive battery terminal is discon- •...
  • Page 442 ELECTRICAL COMPONENTS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ B. Time (minutes) Charging method using a constant volt- C. Charging age charger D. Ambient temperature 20 °C (68 °F) a.

  • Page 443: Checking The Relays

    ELECTRICAL COMPONENTS 8. Check: Result • Battery terminals Continuity Dirt → Clean with a wire brush. (between “3” and “4”) Loose connection → Connect properly. 9. Lubricate: Headlight relay 1 • Battery terminals Recommended lubricant Dielectric grease 10.Install: • Battery holding bracket •...
  • Page 444 ELECTRICAL COMPONENTS Radiator fan motor relay Four-wheel-drive motor relay 1 First step: Br/B 1. Positive battery terminal 2. Negative battery terminal 1. Positive tester probe 3. Positive tester probe 2. Negative tester probe 4. Negative tester probe 3. Negative tester probe Result Result Continuity...

  • Page 445: Checking The Diode

    ELECTRICAL COMPONENTS Four-wheel-drive motor relay 2 Pocket tester First step: 90890-03112 Analog pocket tester YU-03112-C The pocket tester or the analog pocket tester readings are shown in the following table. No continuity Positive tester probe → black/yellow “1” 1. Positive tester probe Negative tester probe →...

  • Page 446: Checking The Ignition Coil

    ELECTRICAL COMPONENTS 2. Check: Pocket tester • Secondary coil resistance 90890-03112 Out of specification → Replace. Analog pocket tester YU-03112-C Secondary coil resistance 8.64–12.96 kΩ ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 447: Checking The Lean Angle Sensor

    ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester 65˚ 65˚ YU-03112-C • Positive tester probe L Y/G B/L gray “1” • Negative tester probe black “2” c. Set the main switch to “ ” (on). d. Tilt the lean angle sensor to 65°. e.

  • Page 448: Checking The Stator Coil

    ELECTRICAL COMPONENTS EBS30305 CHECKING THE STATOR COIL Charging voltage 1. Disconnect: above 14 V at 5000 r/min • AC magneto coupler (from the wire harness) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 449: Checking The Speed Sensor

    ELECTRICAL COMPONENTS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ Pocket tester a. Connect the pocket tester (DC 20 V) to the 90890-03112 speed sensor coupler as shown. Analog pocket tester Pocket tester YU-03112-C 90890-03112...

  • Page 450: Checking The Radiator Fan Motor Circuit Breaker

    ELECTRICAL COMPONENTS c. Measure the radiator fan motor movement. EBS30312 CHECKING THE COOLANT TEMPERATURE ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ SENSOR 1. Remove: EBS30311 CHECKING THE RADIATOR FAN MOTOR •...

  • Page 451: Checking The Throttle Position Sensor

    ELECTRICAL COMPONENTS EBS30313 CHECKING THE THROTTLE POSITION Resistance 12.0 Ω SENSOR 1. Remove: • Throttle position sensor ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the fuel injector coupler from wire (from the throttle body) harness.

  • Page 452: Checking The Intake Air Pressure Sensor

    ELECTRICAL COMPONENTS c. Measure the intake air pressure sensor out- • Positive tester probe → put voltage. Air induction system solenoid terminal “1” • Negative tester probe → ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 453: Checking The Eps Motor (For Eps Models)

    ELECTRICAL COMPONENTS e. Measure the intake air temperature sensor EBS30320 CHECKING THE EPS TORQUE SENSOR (for resistance. EPS models) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 1. Remove: EBS30319 •...
  • Page 454 ELECTRICAL COMPONENTS 9-99...

  • Page 455: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING...................10-1 GENERAL INFORMATION ..............10-1 STARTING FAILURES................10-1 INCORRECT ENGINE IDLING SPEED ..........10-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......10-2 FAULTY DRIVE TRAIN ................10-3 FAULTY GEAR SHIFTING..............10-4 SHIFT LEVER DOES NOT MOVE ............10-4 JUMPS OUT OF GEAR................10-4 FAULTY CLUTCH ...................10-4 OVERHEATING ..................10-4 OVERCOOLING..................10-5 POOR BRAKING PERFORMANCE............

  • Page 456: Troubleshooting

    TROUBLESHOOTING • Sucked-in air EBS20085 TROUBLESHOOTING Electrical system EBS30321 1. Battery GENERAL INFORMATION • Discharged battery • Faulty battery The following guide for troubleshooting does not 2. Fuse(s) cover all the possible causes of trouble. It should • Blown, damaged or incorrect fuse be helpful, however, as a guide to basic trouble- •...

  • Page 457: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING Electrical system 1. Battery • Discharged battery • Faulty battery 2. Spark plug • Incorrect spark plug gap • Incorrect spark plug heat range • Fouled spark plug • Worn or damaged electrode • Worn or damaged insulator • Faulty spark plug cap 3.

  • Page 458: Faulty Drive Train

    TROUBLESHOOTING EBS30325 FAULTY DRIVE TRAIN The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1. A pronounced hesitation or “jerky” movement A. Bearing damage. during acceleration, deceleration, or sustained B. Improper gear backlash. speed. (This must not be confused with engine C.

  • Page 459: Faulty Gear Shifting

    TROUBLESHOOTING Poor starting performance EBS30326 FAULTY GEAR SHIFTING 1. V-belt • V-belt slips Shifting is difficult • Oil or grease on the V-belt Refer to “FAULTY CLUTCH” on page 10-4. 2. Primary sliding sheave • Faulty operation EBS30327 SHIFT LEVER DOES NOT MOVE •...

  • Page 460: Overcooling

    TROUBLESHOOTING Fuel system EBS30334 UNSTABLE HANDLING 1. Throttle body 1. Handlebar • Damaged or loose throttle body joint • Bent or improperly installed handlebar 2. Air filter 2. Steering • Clogged air filter element • Incorrect toe-in • Bent steering stem Chassis •...
  • Page 461 TROUBLESHOOTING • Too many electrical accessories • Incorrect connection • Faulty tail/brake light assembly 10-6...

  • Page 462: Self-Diagnostic Function And Diagnostic Code Table

    ECU (Engine Control Unit) internal malfunction (input signal error): non-registered data has Er-4 been received from the meter assembly. EBS30338 DIAGNOSTIC CODE: SENSOR OPERATION TABLE The diagnostic code numbers cannot be displayed on the multi-function meter. To display the diagnos- tic code numbers, use the Yamaha diagnostic tool. 10-7...
  • Page 463 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Display Procedure code No. Throttle angle Check with throttle valve fully closed. • Fully closed position 14–20 Pressure difference Displays the intake air pres- Set the engine stop switch to (atmospheric pressure and sure.

  • Page 464: Diagnostic Code: Actuator Operation Table

    Check that a spark is generat- The “CHECK” indicator and Ignition coil ed five times. “ ” on the Yamaha diagnostic • Connect an ignition checker. tool screen come on each time the ignition coil is actuated. Actuates the fuel injector five Disconnect the fuel pump times at one-second intervals.
  • Page 465 (2 seconds on, 3 sec- onds off) The “CHECK” indicator and “ ” on the Yamaha diagnostic Check that the radiator fan tool screen come on each time motor relay is actuated five Radiator fan motor relay the relay is actuated.

  • Page 466: Wiring Diagram

    68. Horn switch (except for CDN) 12. Joint coupler 12. Fuel injection system relay 69. Horn (except for CDN) 13. EPS torque sensor 13. Yamaha diagnostic tool coupler A. Wire harness 14. EPS motor 14. Reverse switch B. Negative battery sub-wire har- 15.
  • Page 467 52. Engine stop switch EBS30002 COLOR CODE 53. Light switch Black 54. Handle mounted light Brown 55. Headlight Green 56. Headlight relay 2 Gray 57. Headlight relay 1 Blue 58. Tail/brake light Light green 59. Diode Orange 60. Rear brake light switch Pink 61.
  • Page 471 YF70GG/YFM70GDXG/YFM70GDHG 2016 WIRING DIAGRAM Br Br Br Br R/L R/L R/W R/W R/W R/W R/L R/W R/W R/L R/W R/W Br/Y L/B R/G G/R Br/L Br/W W Gy P Y/G P/W Sb O/L Y/W B/G Gy/GW/B Gy B G/Y R/L G/WB/Y L/Y Y/L Y W/R B/R R/L R/B...
  • Page 472 YF70GG/YFM70GDXG/YFM70GDHG 2016 WIRING DIAGRAM (Gy) (Gy) (Gy) (Gy) (Gy) PUSH (Gy) (Gy) (Gy) LOCK...
  • Page 473 YF70GPG/YF70GPSG/YF70GPLG/YFM70GPXG/YFM70GPHG/YFM70GPSG/YFM70GPLG/YFM700FWAD 2016 WIRING DIAGRAM Br Br Br Br Br Br R/L R/L R/W R/W R/W R/W W W W R/L R/W R/W R/L R/W R/W W Br/Y L/B R/G G/R Br/L 13 14 Br/W W Gy P Y/G P/W Sb O/L Y/W B/G Gy/GW/B Gy B G/Y R/L G/WB/Y L/Y Y/L Y...
  • Page 474 YF70GPG/YF70GPSG/YF70GPLG/YFM70GPXG/YFM70GPHG/YFM70GPSG/YFM70GPLG/YFM700FWAD 2016 WIRING DIAGRAM 13 14 (Gy) (Gy) (Gy) (Gy) (Gy) (Gy) ( B ) ( B ) (Gy) (Gy) (Gy) PUSH (Gy) (Gy) (Gy) LOCK...

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