1. Manuals
  2. Brands
  3. Yamaha Manuals
  4. Offroad Vehicle
  5. 2004 YXR660
  6. Service manual

Yamaha 2004 YXR660 Service Manual

Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
Table of Contents

Advertisement

Quick Links

Download this manual
EBS00004
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See "symbols")
1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title 2: This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa-
nied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.
2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed
by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
6. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition
to the exploded diagram and the job instruction chart.
HOW TO USE THIS MANUAL

Advertisement

Table of Contents
loading

Related Manuals for Yamaha 2004 YXR660

Summary of Contents for Yamaha 2004 YXR660

  • Page 1 EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section.

  • Page 2: Specifications

    EBS00006 SYMBOLS The following symbols are not relevant to SPEC INFO every vehicle. Symbols 1 to 0 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Fuel system FUEL COOL 7 Drive train...
  • Page 3 EBS00008 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLING SYSTEM COOL FUEL SYSTEM FUEL DRIVE TRAIN DRIV CHASSIS CHAS – ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG...

  • Page 4: Table Of Contents

    CONTENTS CHAPTER 1 GENERAL INFORMATION VEHICLE IDENTIFICATION................1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 SELF-ADJUSTING PARKING BRAKE MECHANISM....... 1-2 IMPORTANT INFORMATION ................. 1-5 PREPARATION FOR REMOVAL PROCEDURES ........1-5 REPLACEMENT PARTS................1-5 GASKETS, OIL SEALS AND O-RINGS ............ 1-5 LOCK WASHERS/PLATES AND COTTER PINS ........1-6 BEARINGS AND OIL SEALS ..............
  • Page 5 LUBRICATION POINTS AND LUBRICANT TYPES ........2-23 ENGINE....................2-23 COOLANT FLOW DIAGRAMS ..............2-24 OIL FLOW DIAGRAMS ................. 2-27 CABLE ROUTING ..................2-32 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION....................3-1 PERIODIC MAINTENANCE/LUBRICATION ..........3-1 ENGINE ......................3-3 ADJUSTING THE VALVE CLEARANCE ..........3-3 ADJUSTING THE TIMING CHAIN ............
  • Page 6 CHANGING THE DIFFERENTIAL GEAR OIL ........3-35 CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS ..3-36 CHECKING THE STEERING SYSTEM ..........3-37 ADJUSTING THE TOE-IN............... 3-37 ADJUSTING THE FRONT SHOCK ABSORBERS .........3-39 ADJUSTING THE REAR SHOCK ABSORBERS........3-39 CHECKING THE TIRES................3-40 CHECKING THE WHEELS ..............
  • Page 7 VALVES AND VALVE SPRINGS..............4-25 REMOVING THE VALVES AND VALVE SPRINGS .......4-26 CHECKING THE VALVES AND VALVE SPRINGS ........4-27 INSTALLING THE VALVES AND VALVE SPRINGS ......4-31 CYLINDER AND PISTON................4-33 REMOVING THE PISTON ..............4-34 CHECKING THE CYLINDER AND PISTON ...........4-34 CHECKING THE PISTON RINGS............
  • Page 8 CRANKCASE ....................4-66 STARTER MOTOR, TIMING CHAIN AND OIL FILTER......4-66 CRANKCASE ..................4-68 CRANKCASE BEARINGS............... 4-69 SEPARATING THE CRANKCASE............4-70 CHECKING THE TIMING CHAIN AND GUIDES ........4-70 CHECKING THE OIL DELIVERY PIPE...........4-70 CHECKING THE RELIEF VALVE ............4-71 CHECKING THE CRANKCASE ..............4-71 CHECKING THE BEARINGS..............
  • Page 9 CHAPTER 5 COOLING SYSTEM RADIATOR AND COOLANT RESERVOIR ............ 5-1 CHECKING THE RADIATOR..............5-3 INSTALLING THE RADIATOR..............5-4 WATER PUMP....................5-5 DISASSEMBLING THE WATER PUMP............ 5-7 CHECKING THE WATER PUMP .............. 5-7 ASSEMBLING THE WATER PUMP............5-8 OIL COOLER....................5-10 CHECKING THE OIL COOLER ..............5-12 CHAPTER 6 FUEL SYSTEM FUEL PUMP AND FUEL TANK ..............
  • Page 10 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT ..................7-18 ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS....7-24 DISASSEMBLING THE FINAL GEAR CASE..........7-24 REMOVING THE FINAL DRIVE ROLLER BEARINGS......7-25 INSTALLING THE FINAL DRIVE ROLLER BEARINGS ......7-26 POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR ... 7-26 CHECKING THE DRIVE SHAFT.............
  • Page 11 REAR BRAKE CALIPER .................8-31 DISASSEMBLING THE FRONT BRAKE CALIPERS......8-35 DISASSEMBLING THE REAR BRAKE CALIPER ........8-35 CHECKING THE FRONT AND REAR BRAKE CALIPERS ....8-36 ASSEMBLING THE FRONT BRAKE CALIPERS........8-37 ASSEMBLING THE REAR BRAKE CALIPER ........8-38 INSTALLING THE FRONT BRAKE CALIPERS ........8-40 INSTALLING THE REAR BRAKE CALIPER...........8-41 PEDAL ASSEMBLY ..................8-43 STEERING SYSTEM ..................8-45...
  • Page 12 CHECKING THE BULBS AND BULB SOCKETS .......... 9-6 TYPES OF BULBS ..................9-6 CHECKING THE CONDITION OF THE BULBS ........9-6 CHECKING THE CONDITION OF THE BULB SOCKETS .......9-8 IGNITION SYSTEM ..................9-9 CIRCUIT DIAGRAM .................. 9-9 TROUBLESHOOTING ................9-10 ELECTRIC STARTING SYSTEM ..............9-15 CIRCUIT DIAGRAM ................
  • Page 13 CHAPTER 10 TROUBLESHOOTING STARTING FAILURE/HARD STARTING .............10-1 FUEL SYSTEM..................10-1 ELECTRICAL SYSTEM................10-1 COMPRESSION SYSTEM..............10-2 POOR IDLE SPEED PERFORMANCE ............10-2 POOR IDLE SPEED PERFORMANCE...........10-2 POOR MEDIUM AND HIGH-SPEED PERFORMANCE........10-2 POOR MEDIUM AND HIGH-SPEED PERFORMANCE ......10-2 FAULTY DRIVE TRAIN ................. 10-3 FAULTY GEAR SHIFTING................10-4 HARD SHIFTING..................10-4 SHIFT LEVER DOES NOT MOVE ............

  • Page 14: General Information

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

  • Page 15: Features

    FEATURES INFO FEATURES SELF-ADJUSTING PARKING BRAKE MECHANISM Usually, for vehicles equipped with a parking brake that must be adjusted manually, it is necessary to adjust the adjusting bolt to achieve the proper clearance between the brake caliper piston and the adjusting bolt.
  • Page 16 FEATURES INFO Parking Brake Operation 1 Parking brake arm 4 Adjusting bolt sleeve 2 Parking brake arm shaft 5 Brake caliper piston 3 Set bolt 6 Brake pad When the parking brake is operated, the parking brake cable turns the parking brake arm 1. The rotation of the parking brake arm is changed to axial thrust in the parking brake arm shaft 2 and the set bolt 3 is pushed against the adjusting bolt sleeve 4.
  • Page 17 FEATURES INFO Parking Brake Adjustment È É Ê 1 Brake caliper piston 3 Adjusting bolt 2 Nut 4 Adjusting bolt sleeve When the brake pedal is operated, the brake fluid pressure in the master cylinder increases and the brake caliper piston 1 and the nut 2 are pushed. When there is proper clearance between the brake caliper piston and the brake pad, no other parts move because the movement of the brake caliper piston and the nut is absorbed by the backlash of the threads of the nut and the adjusting bolt 3.

  • Page 18: Important Information

    5. Keep all parts away from any source of fire. EB101010 REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 19: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION INFO EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1. Replace all lock washers/plates 1 and cot- ter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. EB101040 BEARINGS AND OIL SEALS 1.

  • Page 20: Checking Of Connections

    CHECKING OF CONNECTIONS INFO EB801000 CHECKING OF CONNECTIONS Check the connectors for stains, rust, mois- ture, etc. 1. Disconnect: • connector 2. Check: • connector Moisture → Dry each terminal with an air blower. Stains/rust → Connect and disconnect the terminals several times.

  • Page 21: Special Tools

    SPECIAL TOOLS INFO EB102001 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country.
  • Page 22 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Tappet adjusting tool 90890-01311 YM-08035-A This tool is necessary for adjusting the valve clearance. Fuel level gauge 90890-01312 YM-01312-A This gauge is used to measure the fuel level in the float chamber. Radiator cap tester 90890-01325 YU-24460-01...
  • Page 23 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Ring nut wrench 90890-01430 YM-38404 This tool is needed to removing and installing the middle driven shaft bearing retainer. Gear lash measurement tool 90890-01467 YM-01467 This tool is used to measure the gear lash.
  • Page 24 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Valve spring compressor Compressor Valve spring compressor attachment 90890-04019 YM-04019 Attachment 90890-01243 This tool is needed to remove and install YM-01253-1 the valve assemblies. Middle driven shaft bearing driver Middle driven shaft bearing driver Mechanical seal installer 90890-04058...
  • Page 25 Ignition checker Pulse ignition spark checker 90890-06754 YM-34487 This instrument is necessary for checking the ignition system components. Yamaha bond No. 1215 ® Sealant (Quick Gasket Bond 90890-85505 Sealant ACC-11001-05-01 This sealant (bond) is used on crankcase mating surfaces, etc.

  • Page 26: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code 5UG1 Dimensions Overall length 2,885 mm (113.6 in) Overall width 1,385 mm (54.5 in) Overall height 1,853 mm (73.0 in) Seat height 818 mm (32.2 in) Wheelbase 1,910 mm (75.2 in) Minimum ground clearance 273 mm (10.75 in) Minimum turning radius...
  • Page 27 SPEC GENERAL SPECIFICATIONS Item Standard Differential gear case oil Periodic oil change 0.32 L (0.28 Imp qt, 0.34 US qt) Total amount 0.33 L (0.29 Imp qt, 0.35 US qt) Air filter Wet type element Fuel Type Unleaded gasoline only Fuel tank capacity 30 L (6.60 Imp gal, 7.93 US gal) Carburetor...
  • Page 28 SPEC GENERAL SPECIFICATIONS Item Standard Tire pressure (cold tire) Maximum load* 397 kg (876 lb) Off-road riding front 63 ~ 77 kPa (0.63 ~ 0.77 kg/cm , 9 ~ 11 psi) rear 91 ~ 105 kPa (0.91 ~ 1.05 kg/cm , 13 ~ 15 psi) * Load in total weight of cargo, operator, passenger, accessories and tongue weight...

  • Page 29: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Cylinder head Warp limit ---- 0.03 mm (0.0012 in) Cylinder Bore size 100.005 ~ 100.055 mm 100.10 mm (3.9372 ~ 3.9392 in) (3.9410 in) Measuring point 50 mm (1.97 in) ---- Camshaft Drive method Chain drive (Left) ----...
  • Page 30 SPEC ENGINE SPECIFICATIONS Item Standard Limit Cam chain Cam chain type/No. of links 92RH2010J/126M ---- Cam chain adjustment method Automatic ---- Rocker arm/rocker arm shaft Rocker arm inside diameter 12.000 ~ 12.018 mm ---- (0.4724 ~ 0.4731 in) Shaft outside diameter 11.976 ~ 11.991 mm ---- (0.4715 ~ 0.4721 in)
  • Page 31 SPEC ENGINE SPECIFICATIONS Item Standard Limit Stem-to-guide clearance 0.010 ~ 0.037 mm 0.08 mm (0.0004 ~ 0.0015 in) (0.0031 in) 0.025 ~ 0.052 mm 0.10 mm (0.0010 ~ 0.0020 in) (0.0039 in) Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 0.9 ~ 1.1 mm ----...
  • Page 32 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston Piston to cylinder clearance 0.050 ~ 0.070 mm 0.15 mm (0.0020 ~ 0.0028 in) (0.0059 in) Piston size “D” 99.945 ~ 99.995 mm ---- (3.9348 ~ 3.9368 in) Measuring point “H” 2.5 mm (0.10 in) ---- Piston off-set 1.0 mm (0.0394 in)
  • Page 33 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil ring Dimensions (B × T) 2.5 × 3.4 mm ---- (0.0984 × 0.1339 in) End gap (installed) 0.20 ~ 0.70 mm ---- (0.0079 ~ 0.0276 in) Side clearance 0.06 ~ 0.15 mm ---- (0.0024 ~ 0.0059 in) Crankshaft Crank width “A”...
  • Page 34 ---- 0.06 mm (0.0024 in) Shifter Shifter type Shift drum and guide bar ---- Air filter oil grade Yamaha foam air filter oil or other quality ---- foam air filter oil Carburetor I. D. mark 5UG1 00 ---- Main jet (M.J)
  • Page 35 SPEC ENGINE SPECIFICATIONS Item Standard Limit Cooling system Radiator core Width 380 mm (14.96 in) ---- Height 238 mm (9.37 in) ---- Thickness 24 mm (0.94 in) ---- Radiator cap opening pressure 107.9 ~ 137.3 kPa ---- (1.079 ~ 1.373 kg/cm , 15.35 ~ 19.53 psi) Radiator capacity 2.5 L (2.20 Imp qt, 2.64 US qt)
  • Page 36 SPEC ENGINE SPECIFICATIONS Cylinder head tightening sequence 2 - 11...

  • Page 37: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Steering system Type Rack and pinion ---- Front suspension Shock absorber travel 108 mm (4.25 in) ---- Spring free length 313 mm (12.32 in) ---- Spring fitting length 247.9 mm (9.76 in) ---- Spring rate (K1)
  • Page 38 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front disc brake Type Dual ---- Disc outside diameter × thickness 200 × 3.5 mm (7.87 × 0.14 in) ---- Pad thickness inner 5.2 mm (0.20 in) 1.5 mm (0.06 in) Pad thickness outer 5.2 mm (0.20 in) 1.5 mm (0.06 in)

  • Page 39: Electrical Specifications

    Rotor rotation direction sensing coil ---- resistance/color Red – White/Blue C.D.I. unit model/manufacturer F8T38681/MITSUBISHI ---- Ignition coil Model/manufacturer 2JN/YAMAHA ---- Minimum spark gap 6 mm (0.24 in) ---- 0.18 ~ 0.28 Ω at 20 °C (68 °F) Primary winding resistance ---- Secondary winding resistance 6.32 ~ 9.48 kΩ...
  • Page 40 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Electric starter system Type Constant mesh type ---- Starter motor Model/manufacturer SM-13/MITSUBA ---- Output 0.8 kW ---- 0.025 ~ 0.035 Ω at 20 °C (68 °F) Armature coil resistance ---- Brush overall length 12.5 mm (0.49 in) 5 mm (0.20 in) Spring force...

  • Page 41: Tightening Torques

    SPEC TIGHTENING TORQUES EBS01005 TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Cylinder head Bolt Bolt Spark plug — Cylinder head (exhaust pipe) Stud bolt Cylinder head cover Bolt Tappet cover (exhaust)
  • Page 42 Remarks size Nm m · kg ft · lb Crankcase Bolt Bolt Sealant (Quick ® Gasket Bolt Yamaha bond No.1215 Bearing housing (clutch housing Bolt assembly) Air duct assembly 1 bracket Bolt Oil seal (engine cooling fan pulley) Bolt retainer...
  • Page 43 SPEC TIGHTENING TORQUES Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Primary sheave assembly 12.0 Primary pulley sheave cap Screw Secondary sheave assembly 10.0 Secondary sheave spring retainer Shift lever cover Bolt Shift lever 2 assembly Bolt...

  • Page 44: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES EBS01006 CHASSIS TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks Nm m · kg ft · lb Rubber damper and frame Engine and rubber damper (front) Engine bracket and rubber damper (rear) Rear upper arm and frame Rear lower arm and frame Rear knuckle and rear upper arm Rear knuckle and rear lower arm...
  • Page 45 SPEC TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks Nm m · kg ft · lb Steering knuckle and front lower arm Tie-rod locknut Steering knuckle and tie-rod Front arm protector and front lower arm Seat belt and frame Seat belt and side frame (enclosure) 7/16 Front wheel and front wheel hub...
  • Page 46 SPEC TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks Nm m · kg ft · lb Front bumper and frame Hood stopper and frame Upper instrument panel and frame Side frame (enclosure) and frame Support frame (enclosure) and frame Left support frame (enclosure) and right support frame (enclosure) Support frame (enclosure) and side frame (enclo-...

  • Page 47: How To Use The Conversion Table

    HOW TO USE THE CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EBS00022 EBS00023 HOW TO USE THE CONVERSION GENERAL TIGHTENING TORQUE TABLE SPECIFICATIONS All specification data in this manual are listed This chart specifies tightening torques for stan- in SI and METRIC UNITS. dard fasteners with a standard ISO thread Use this table to convert METRIC unit data to pitch.

  • Page 48: Lubrication Points And Lubricant Types

    Shift drum stopper ball Shift lever 2 assembly Shift lever 1 Shift lever 1 and shift lever 2 assembly mating surface Sealant ® (Quick Gasket Crankcase mating surface Yamaha Bond No.1215 Sealant ® (Quick Gasket A.C. magneto lead grommet Yamaha Bond No.1215...

  • Page 49: Coolant Flow Diagrams

    SPEC COOLANT FLOW DIAGRAMS COOLANT FLOW DIAGRAMS 1 Radiator 2 Thermo switch 3 3 Radiator outlet hose 4 Radiator inlet hose 5 Radiator outlet pipe 6 Radiator inlet pipe 2 - 24...
  • Page 50 SPEC COOLANT FLOW DIAGRAMS 1 Coolant breather hose 2 Coolant breather pipe 3 Radiator outlet pipe 4 Water pump inlet hose 5 Water pump outlet pipe 6 Water pump outlet hose 7 Coolant outlet hose 8 Radiator inlet pipe 2 - 25...
  • Page 51 SPEC COOLANT FLOW DIAGRAMS 1 Coolant outlet hose 2 Radiator inlet pipe 2 - 26...

  • Page 52: Oil Flow Diagrams

    SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 Camshaft 2 Oil delivery pipe 2 3 Oil delivery pipe 3 4 Crankshaft 2 - 27...
  • Page 53 SPEC OIL FLOW DIAGRAMS 1 Oil delivery pipe 1 2 Oil delivery pipe 2 3 Oil delivery pipe 3 4 Oil pump 5 Oil strainer 2 - 28...
  • Page 54 SPEC OIL FLOW DIAGRAMS 1 Oil filter cartridge 2 Oil pipe adapter 3 Oil delivery pipe 2 4 Oil delivery pipe 1 5 Drive axle 6 Relief valve 7 Oil pump 8 Oil strainer 2 - 29...
  • Page 55 SPEC OIL FLOW DIAGRAMS 1 Oil outlet pipe 2 Oil inlet pipe 3 Oil outlet hose 4 Oil inlet hose 5 Oil cooler inlet pipe 2 6 Oil cooler outlet pipe 2 2 - 30...
  • Page 56 SPEC OIL FLOW DIAGRAMS 1 Oil cooler 2 Oil cooler inlet pipe 2 3 Oil cooler outlet pipe 2 4 Oil cooler inlet hose 5 Oil cooler outlet hose 6 Oil cooler inlet pipe 1 7 Oil cooler outlet pipe 1 2 - 31...

  • Page 57: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Left headlight lead 0 Parking brake switch lead 2 Wire harness A Parking brake cable 3 Throttle cable B Crankcase breather hose 4 Brake light switch lead C Gear position switch 5 Radiator fan motor breather hose D Reverse switch lead 6 Starter cable E Front brake hoses...
  • Page 58 SPEC CABLE ROUTING È 30 ~ 60 mm (1.18 ~ 2.36 in) Í Fasten the throttle cable to the air duct assembly É 160 ~ 190 mm (6.30 ~ 7.48 in) 1 with the plastic band. Ê Fasten the wire harness to the frame with the Î...
  • Page 59 SPEC CABLE ROUTING 1 Float chamber breather hose È Fasten the parking brake switch lead and park- 2 Throttle cable ing brake cable to the air duct assembly 1 with 3 Parking brake cable the plastic band. 4 Thermo switch 1 É...
  • Page 60 SPEC CABLE ROUTING Í Fasten the parking brake cable to the air duct Ò Fasten the tail/brake light lead with the plastic assembly 2 with the plastic band. holders. Î Fasten the parking brake cable and float cham- Ó Push the excess tail/brake light lead into the rear ber breather hose with the plastic clip.
  • Page 61 SPEC CABLE ROUTING 1 Main switch 0 Differential gear case breather J Rear brake pipe 2 Starter (choke) knob K Radiator outlet pipe hose 3 Starter (choke) cable A Thermo switch 3 L Gear motor lead 4 Rectifier/regulator B Gear motor couplers M Brake light switch lead 5 Wire harness C Coolant reservoir hose...
  • Page 62 SPEC CABLE ROUTING È 70 ~ 80 mm (2.76 ~ 3.15 in) Í Fasten the radiator outlet hose Ð Fasten wire harness, É Fasten the wire harness with and coolant reservoir hose with starter motor lead, and ground the plastic bands. the plastic clip.
  • Page 63 SPEC CABLE ROUTING Ò 70 ~ 90 mm (2.76 ~ 3.54 in) × Fasten wire harness, Ó Fasten the throttle cable with starter (choke) cable, starter the plastic band. motor lead, and ground lead Ô Fasten the radiator inlet pipe with the plastic bands.
  • Page 64 SPEC CABLE ROUTING 1 Ignition coil lead B Ignition coil 2 Spark plug lead C Rear brake pipe 3 Final gear case breather hose D Wire harness 4 Vacuum hose E Fuel tank breather hose 5 Fuel hoses F Rollover valve 6 Air vent hoses G Fuel return hose 7 Starter (choke) cable...
  • Page 65 SPEC CABLE ROUTING È Fasten the spark plug lead with the plastic Í Fasten the A.C. magneto leads, reverse switch holder. lead, gear position switch lead, thermo switch 1 É 20 ~ 30 mm (0.79 ~ 1.18 in) lead, carburetor heater lead, and parking brake Ê...
  • Page 66 SPEC CABLE ROUTING Ò Fasten the parking brake cable with the metal Ø Fasten the parking brake cable and final gear holder. case breather hose with the plastic holders. Ó Fasten the wire harness, ignition coil lead, and Ù Fasten the rear brake hose with the plastic rear brake hose with the plastic band.
  • Page 67 SPEC CABLE ROUTING 1 Throttle cable È Pass the throttle cable through the cable guide. 2 Rear brake pipe É Fasten the speed sensor lead, starter (choke) 3 A.C. magneto couplers cable, starter motor lead, and ground lead with 4 Starter (choke) cable the plastic band.
  • Page 68 SPEC CABLE ROUTING Í Fasten the fuel hose and vacuum hose with the Ó Pass the spark plug lead through the cutout in plastic clip. the protective cover as shown. Î Make sure that the spark plug lead does not Ô...
  • Page 69 SPEC CABLE ROUTING 1 Battery 0 Light switch 2 Negative battery lead A Differential gear case breather hose 3 Rectifier/regulator B Radiator fan motor breather hose 4 Starter (choke) cable C Left headlight lead 5 Indicator light assembly couplers D Throttle cable 6 On-Command four-wheel drive switch and differ- E Right headlight lead F Starter motor lead...
  • Page 70 SPEC CABLE ROUTING K Four-wheel drive relay 3 V C.D.I. unit L Differential gear lock indicator light relay M Four-wheel drive indicator light relay È Fasten the wire harness with the plastic bands. N Fuse box É Pass the radiator fan motor breather hose, dif- O Positive battery lead ferential gear case breather hose, coolant reser- P Neutral indicator light...
  • Page 71 SPEC CABLE ROUTING Ë Fasten the throttle cable with the plastic holder. Ñ 4 mm (0.16 in) of clearance or more is required Ì Fasten the left headlight lead, differential gear around the boot. Ò Make sure that the washer is installed on the case breather hose, and radiator fan motor breather hose with the plastic holder.
  • Page 72 SPEC CABLE ROUTING 1 Auxiliary DC jack B Starter relay lead 2 Auxiliary DC jack lead 3 Coolant reservoir breather hose È Fasten the coolant reservoir breather hose with 4 Throttle cable the plastic band. 5 Radiator fan motor breather hose É...
  • Page 73 SPEC CABLE ROUTING Ì Fasten the wire harness and ground lead with the plastic band. Í Fasten the differential gear case breather hose, coolant reservoir hose, radiator fan motor lead, and thermo switch 3 lead with the plastic holder. Í Ì...

  • Page 74: Periodic Checks And Adjustments

    INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 75 Fittings and fasten- • Check all chassis fittings and fasteners. ers* • Correct if necessary. * Since these items require special tools, data and technical skills have a Yamaha dealer perform the ser- vice. NOTE: • Recommended brake fluid: DOT 4 •...

  • Page 76: Engine

    ADJUSTING THE VALVE CLEARANCE ENGINE ADJUSTING THE VALVE CLEARANCE NOTE: • The valve clearance must be adjusted when the engine is cool to the touch. • Adjust the valve clearance when the piston is at the Top Dead Center (TDC) on the com- pression stroke.
  • Page 77 ADJUSTING THE VALVE CLEARANCE 7. Remove: • engine cooling fan 1 8. Remove: • timing plug 1 9. Check: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) Exhaust 0.15 ~ 0.20 mm (0.0059 ~ 0.0079 in) M MMM...
  • Page 78 ADJUSTING THE VALVE CLEARANCE 10.Adjust: • valve clearance M MMM M MMM M MMM M MMM M MMM a. Loosen the locknut 1. b. Insert a thickness gauge 2 between the adjuster end and the valve end. c. Turn the adjuster 3 clockwise or counter- clockwise with the tappet adjusting tool 4 until the proper clearance is obtained.

  • Page 79: Adjusting The Timing Chain

    ADJUSTING THE TIMING CHAIN/ ADJUSTING THE IDLING SPEED ADJUSTING THE TIMING CHAIN Adjustment free. ADJUSTING THE IDLING SPEED 1. Start the engine and let it warm up for sev- eral minutes. 2. Remove: • driver seat • passenger seat • console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED”...

  • Page 80: Adjusting The Throttle Cable

    ADJUSTING THE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE 7. Detach: • tachometer 8. Lower the cargo bed. 9. Install: • console • passenger seat • driver seat Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. ADJUSTING THE THROTTLE CABLE NOTE: Throttle cable free play should be adjusted properly before adjusting the engine idling...

  • Page 81: Adjusting The Starter Cable

    ADJUSTING THE THROTTLE CABLE/ ADJUSTING THE STARTER CABLE 5. Remove: • throttle valve cover 6. Install: • console • passenger seat • driver seat ADJUSTING THE STARTER CABLE 1. Remove: • driver seat • passenger seat • console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED”...

  • Page 82: Checking The Spark Plug

    ADJUSTING THE STARTER CABLE/ CHECKING THE SPARK PLUG 3. Install: • console • passenger seat • driver seat Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. CHECKING THE SPARK PLUG 1. Lift the cargo bed up. 2. Remove: •...

  • Page 83: Checking The Ignition Timing

    CHECKING THE IGNITION TIMING CHECKING THE IGNITION TIMING NOTE: Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing. 1. Remove: • driver seat • passenger seat • console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED”...

  • Page 84: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 6. Check: • ignition timing M MMM M MMM M MMM M MMM M MMM a. Warm up the engine and keep it at the specified speed. Engine speed 1,450 ~ 1,550 r/min b.
  • Page 85 MEASURING THE COMPRESSION PRESSURE 5. Remove: • spark plug 6. Attach: • adapter • compression gauge 1 Compression gauge P/N. YU-33223, 90890-03081 Adapter P/N. YU-33223-4, 90890-04082 7. Measure: • compression pressure Above the maximum pressure: Check the cylinder head, valve surfaces, and piston crown for carbon deposits.

  • Page 86: Checking The Engine Oil Level

    MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL WARNING When cranking the engine, ground the spark plug lead to prevent sparking. L LLL L LLL L LLL L LLL L LLL 8. Install: • spark plug · · 18 Nm (1.8 m kg, 13 ft 9.

  • Page 87: Changing The Engine Oil

    CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL 5. Stop the engine and check the oil level again. NOTE: Wait a few minutes until the oil settles before checking the oil level. WARNING Never remove the dipstick just after high speed operation because the heated oil could spurt out.
  • Page 88 CHANGING THE ENGINE OIL b. Lubricate the O-ring 3 of the new oil filter cartridge with a thin coat of lithium-soap- based grease. CAUTION: Make sure that the O-ring 3 is positioned correctly in the groove of the oil filter car- tridge.

  • Page 89: Cleaning The Air Filter

    CHANGING THE ENGINE OIL/ CLEANING THE AIR FILTER 11.Check: • engine oil pressure M MMM M MMM M MMM M MMM M MMM a. Slightly loosen the oil gallery bolt 1. b. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt.
  • Page 90 CLEANING THE AIR FILTER 2. Remove: • air filter case cover 1 3. Remove: • air filter element assembly 1 • air filter element cap • air filter element 2 Air filter element cap 3 Air filter element CAUTION: Never operate the engine with the air filter element removed.

  • Page 91: Checking The Coolant Level

    CLEANING THE AIR FILTER/ CHECKING THE COOLANT LEVEL c. Apply Yamaha foam air filter oil or other quality foam air filter oil. d. Squeeze out the excess oil. NOTE: The element should be wet but not dripping. L LLL L LLL...

  • Page 92: Changing The Coolant

    CHECKING THE COOLANT LEVEL/ CHANGING THE COOLANT 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check: • coolant level NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled. 6.
  • Page 93 CHANGING THE COOLANT 8. Remove: • radiator cap 1 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause seri- ous injury.

  • Page 94: Cooling System

    CHANGING THE COOLANT 14.Connect: • water pump inlet hose • coolant outlet hose 15.Remove: • air bleed bolt 1 16.Fill: • cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1 : 1 (antifreeze : water)
  • Page 95 CHANGING THE COOLANT CAUTION: • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if necessary, correct the antifreeze concentration of the coolant. • Use only distilled water. However, soft water may be used if distilled water is not available.

  • Page 96: Checking The Coolant Temperature Warning Light

    CHECKING THE COOLANT TEMPERATURE WARNING LIGHT/CHECKING THE V-BELT CHECKING THE COOLANT TEMPERATURE WARNING LIGHT 1 Coolant temperature indicator light Coolant temperature warning light checking method Turn the main switch “ON”. Coolant temperature warning light Coolant temperature warning does not come on. light comes on.

  • Page 97: Checking The V-Belt

    CHECKING THE V-BELT 2. Check: • V-belt 1 Cracks/wear/scaling/chipping → Replace. Oil/grease → Check primary sheave and secondary sheave. 3. Measure: • V-belt width 2 Out of specification → Replace. V-belt width 33.2 mm (1.31 in) <Limit:> 29.9 mm (1.18 in) 4.

  • Page 98: Cleaning The Spark Arrester

    CHECKING THE V-BELT/ CLEANING THE SPARK ARRESTER 5. Remove: • drive belt cover Refer to “PRIMARY AND SECONDARY SHEAVES” in chapter 4. • console • passenger seat • driver seat Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. CLEANING THE SPARK ARRESTER 1.

  • Page 99: Chassis

    ADJUSTING THE BRAKE PEDAL CHASSIS ADJUSTING THE BRAKE PEDAL 1. Check: • brake pedal free play a Out of specification → Adjust. NOTE: The end of the brake rod 1 should lightly con- tact the brake master cylinder 2. Brake pedal free play 0 mm (0.0 in) 2.

  • Page 100: Adjusting The Parking Brake

    ADJUSTING THE PARKING BRAKE ADJUSTING THE PARKING BRAKE 1. Shift the drive select lever into low gear “L”. 2. Remove: • driver seat • passenger seat • console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. 3. Check: •...

  • Page 101: Checking The Brake Fluid Level

    CHECKING THE BRAKE FLUID LEVEL CHECKING THE BRAKE FLUID LEVEL 1. Place the vehicle on a level surface. NOTE: When checking the brake fluid level, make sure that the top of the brake fluid reservoir top is horizontal. 2. Lift the hood up. 3.

  • Page 102: Checking The Front Brake Pads

    CHECKING THE FRONT BRAKE PADS/CHECKING THE REAR BRAKE PADS/CHECKING THE BRAKE HOSES AND BRAKE PIPES CHECKING THE FRONT BRAKE PADS 1. Remove: • front wheels 2. Check: • brake pads Wear indicator groove 1 almost disap- peared → Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKES”...

  • Page 103: Checking The Brake Hoses And Brake Pipes

    CHECKING THE BRAKE HOSES AND BRAKE PIPES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM 2. Lift the hood up. 3. Lift the cargo bed. 4. Check: • front brake hoses 1 • rear brake pipes 2 • rear brake hoses 3 Cracks/wear/damage → Replace. Fluid leakage →...
  • Page 104 BLEEDING THE HYDRAULIC BRAKE SYSTEM È 1. Bleed: • brake system M MMM M MMM M MMM M MMM M MMM a. Add the proper brake fluid to the reservoir. b. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. c.

  • Page 105: Adjusting The Select Lever Shift Rod

    ADJUSTING THE SELECT LEVER SHIFT ROD/ ADJUSTING THE BRAKE LIGHT SWITCH ADJUSTING THE SELECT LEVER SHIFT 1 Neutral 2 High 3 Low 4 Reverse 5 Select lever shift rod CAUTION: Before shifting, you must stop the vehicle and take your foot off the accelerator pedal. Otherwise, the transmission may be dam- aged.

  • Page 106: Checking The Final Gear Oil Level

    ADJUSTING THE BRAKE LIGHT SWITCH/ CHECKING THE FINAL GEAR OIL LEVEL 1. Check: • brake light operation timing Incorrect → Adjust. 2. Adjust: • brake light operation timing M MMM M MMM M MMM M MMM M MMM a. Hold the main body 1 of the brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the brake light comes on at the proper time.

  • Page 107: Changing The Final Gear Oil

    CHANGING THE FINAL GEAR OIL/ CHECKING THE DIFFERENTIAL GEAR OIL CHANGING THE FINAL GEAR OIL 1. Place the vehicle on a level surface. 2. Place a container under the final gear case to collect the used oil. 3. Remove: • oil filler plug 1 •...

  • Page 108: Changing The Differential Gear Oil

    CHECKING THE DIFFERENTIAL GEAR OIL/ CHANGING THE DIFFERENTIAL GEAR OIL 3. Check: • oil level Oil level should be up to the brim of hole. Oil level low → Add oil to proper level. Recommended oil SAE 80 API “GL-4” Hypoid gear CAUTION: Take care not allow foreign material to enter the differential gear case.

  • Page 109: Checking The Constant Velocity Joint Dust Boots

    CHANGING THE DIFFERENTIAL GEAR OIL/CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS 6. Fill: • differential gear case Periodic oil change 0.32 L (0.28 Imp qt, 0.34 US qt) Total amount 0.33 L (0.29 Imp qt, 0.35 US qt) Recommended oil SAE 80 API “GL-4”...

  • Page 110: Checking The Steering System

    CHECKING THE STEERING SYSTEM/ ADJUSTING THE TOE-IN CHECKING THE STEERING SYSTEM 1. Place the vehicle on a level surface. 2. Check: • steering assembly bearings Try to move the steering wheel up and down, and back and forth. Excessive play → Replace the steering shaft assembly.
  • Page 111 ADJUSTING THE TOE-IN c. Measure distance È between the marks. d. Rotate the front tires 180° until the marks are exactly opposite one another. e. Measure distance É between the marks. f. Calculate the toe-in using the formula given below. Toe-in = É...

  • Page 112: Adjusting The Front Shock Absorbers

    ADJUSTING THE FRONT SHOCK ABSORBERS/ ADJUSTING THE REAR SHOCK ABSORBERS ADJUSTING THE FRONT SHOCK ABSORBERS WARNING Always adjust both shock absorber spring preload to the same setting. Uneven adjust- ment can cause poor handling and loss of stability. NOTE: The spring preload of the shock absorbers can be adjusted to suit the operator’s preference, weight, and the operating conditions.

  • Page 113: Checking The Tires

    • TIRE CHARACTERISTICS 1) Tire characteristics influence the han- dling of vehicle’s. The tires listed below have been approved by Yamaha Motor Manufacturing corporation of America for this model. If other tire combinations are used, they can adversely affect your vehicle’s handling characteristics and...
  • Page 114 CHECKING THE TIRES 1. Measure: • tire pressure (cold tire pressure) Out of specification → Adjust. NOTE: • The tire pressure gauge 1 is included as standard equipment. • If dust or the like is stuck to this gauge, it will not provide the correct readings.

  • Page 115: Checking The Wheels

    Damage → Replace. 2. Check: • cable operation Unsmooth operation → Lubricate or replace. Recommended lubricant Yamaha chain and cable lube or engine oil NOTE: Hold the cable end up and apply several drops of lubricant to the cable. 3. Apply: •...

  • Page 116: Lubricating The Pedal, Etc

    LUBRICATING THE PEDAL, ETC. LUBRICATING THE PEDAL, ETC. 1. Lubricate the pivoting parts. Recommended lubricant Lithium-soap-based grease 3 - 43...

  • Page 117: Electrical

    CHECKING AND CHARGING THE BATTERY EB305000 ELECTRICAL CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
  • Page 118 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 119 CHECKING AND CHARGING THE BATTERY 6. Charge: Charging Ambient temperature 20 °C (68 °F) • battery (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit CAUTION: voltage. • Never remove the MF battery sealing caps.
  • Page 120 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger NOTE: Leave the battery unused for more than 30 minutes before measuring Measure the open-circuit its open-circuit voltage. voltage prior to charging. Charger Ammeter NOTE: Set the charging voltage to 16 Connect a charger and 17 V.
  • Page 121 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit volt- Measure the open-circuit age. voltage prior to charging. Connect a charger and ammeter to the battery and start charging.

  • Page 122: Checking The Fuses

    CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 7. Install: • battery 8. Connect: • battery leads CAUTION: First, connect the positive battery lead 1, and then the negative battery lead 2. 9. Check: • battery terminals Dirt → Clean with a wire brush. Loose connection →...
  • Page 123 CHECKING THE FUSES 4. Replace: • blown fuse M MMM M MMM M MMM M MMM M MMM a. Turn off the ignition. b. Install a new fuse of the proper amperage. c. Turn on switches to verify operation of the related electrical devices.

  • Page 124: Adjusting The Headlight Beam

    ADJUSTING THE HEADLIGHT BEAM/ CHANGING THE HEADLIGHT BULB ADJUSTING THE HEADLIGHT BEAM 1. Adjust: • headlight beam (vertically) Turn the adjuster 1 in or out. Turning in Headlight beam raised. Turning out Headlight beam lowered. CHANGING THE HEADLIGHT BULB 1. Lift the hood up. 2.

  • Page 125: Changing The Tail/Brake Light Bulb

    CHANGING THE HEADLIGHT BULB/ CHANGING THE TAIL/BRAKE LIGHT BULB 5. Install: • headlight bulb holder (with bulb) • headlight bulb holder cover 6. Close the hood. CHANGING THE TAIL/BRAKE LIGHT BULB 1. Remove: • cargo bed panel 1 2. Remove: •...
  • Page 126 CHANGING THE TAIL/BRAKE LIGHT BULB 4. Install: • tail/brake light bulb holder (with bulb) 5. Install: • cargo bed panel · · 7 Nm (0.7 m kg, 5.1 ft 3 - 53...

  • Page 127: Engine

    ENGINE REMOVAL ENGINE ENGINE REMOVAL AIR DUCTS, MUFFLER AND EXHAUST PIPE 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 128 ENGINE REMOVAL 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 20 Nm (2.0 m kg, 14 ft • • 14 Nm (1.4 m kg, 10 ft •...

  • Page 129: Select Lever Unit And Coolant Reservoir

    ENGINE REMOVAL SELECT LEVER UNIT AND COOLANT RESERVOIR 14 Nm (1.4 m kg, 10 ft • • 15 Nm (1.5 m kg, 11 ft • • 15 Nm (1.5 m kg, 11 ft • • 15 Nm (1.5 m kg, 11 ft •...

  • Page 130: Hoses And Leads

    ENGINE REMOVAL HOSES AND LEADS 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the hoses and leads Remove the parts in the order listed. Water pump inlet hose Disconnect. Coolant outlet hose Disconnect. Oil inlet hose Disconnect.
  • Page 131 ENGINE REMOVAL 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Reverse switch lead Green/White Engine ground lead Disconnect. For installation, reverse the removal pro- cedure. 4 - 5...

  • Page 132: Engine Mounting Bolts

    ENGINE REMOVAL ENGINE MOUNTING BOLTS Order Job/Part Q’ty Remarks Removing the engine mounting Remove the parts in the order listed. bolts Front skid plate/center skid plate/rear Refer to “SEATS, ENCLOSURE, HOOD skid plate AND CARGO BED” in chapter 8. Rear wheels Refer to “REAR WHEELS AND BRAKE DISC”...
  • Page 133 ENGINE REMOVAL Order Job/Part Q’ty Remarks Rubber damper nut (rear) NOTE: Engine mounting bolt (front-upper) Remove the engine assembly from the top of the vehicle. Engine mounting bolt (front-lower)/nut Engine assembly Rubber damper nut (front) CAUTION: Rubber damper (front) Install all of the bolts/nuts and then Rubber damper (rear) tighten them to full torque specifica- Engine mounting bolt (rear)

  • Page 134: Installing The Engine

    ENGINE REMOVAL INSTALLING THE ENGINE 1. Install: • engine mounting bolt (rear) 1 • rubber damper (rear) 2 • rubber damper nut (front) 3 • engine assembly 4 • engine mounting bolt (front lower)/nut 5 • engine mounting bolt (front upper) 6 •...

  • Page 135: Cylinder Head Cover

    CYLINDER HEAD COVER CYLINDER HEAD COVER Order Job/Part Q’ty Remarks Removing the cylinder head cover Remove the parts in the order listed. Driver seat/passenger seat/console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. air shroud 1/engine cooling fan/timing Refer to “ADJUSTING THE VALVE plug CLEARANCE”...
  • Page 136 CYLINDER HEAD COVER Order Job/Part Q’ty Remarks Cylinder head cover Refer to “REMOVING THE CYLINDER HEAD COVER” and “INSTALLING THE CYLINDER HEAD COVER”. Dowel pin For installation, reverse the removal pro- cedure. 4 - 10...

  • Page 137: Removing The Cylinder Head Cover

    CYLINDER HEAD COVER REMOVING THE CYLINDER HEAD COVER 1. Align: • “I” mark (with stationary pointer) M MMM M MMM M MMM M MMM M MMM a. Turn the crankshaft counterclockwise with a wrench. b. Align the “I” mark 1 on the rotor with the stationary pointer 2 on the A.C.

  • Page 138: Installing The Cylinder Head Cover

    • sealant (Quick Gasket (to the mating surfaces of the cylinder head and cylinder head cover) ® Sealant (Quick Gasket P/N. ACC-11001-05-01 Yamaha bond No. 1215 P/N. 90890-85505 2. Install: • cylinder head cover • washers 1 • bolts 10 Nm (1.0 m · kg, 7.2 ft · lb)

  • Page 139: Rocker Arms

    ROCKER ARMS ROCKER ARMS Order Job/Part Q’ty Remarks Removing the rocker arms Remove the parts in the order listed. Cylinder head cover Refer to “CYLINDER HEAD COVER”. Plug/O-ring Rocker arm shaft stopper Rocker arm shaft 2 Rocker arm 3 Rocker arm shaft 3/O-ring Refer to “REMOVING THE ROCKER Rocker arm 4 ARMS”...
  • Page 140 ROCKER ARMS Order Job/Part Q’ty Remarks Wave washer Locknut Valve adjuster For installation, reverse the removal pro- cedure. 4 - 14...

  • Page 141: Removing The Rocker Arms

    ROCKER ARMS REMOVING THE ROCKER ARMS 1. Remove: • rocker arm shafts 1 • rocker arms 2 NOTE: Use a slide hammer bolt 3 and weight 4 to remove the rocker arm shafts. Slide hammer set P/N. YU-01083-A Slide hammer bolt (M6) P/N.

  • Page 142: Installing The Rocker Arms

    ROCKER ARMS d. Measure the outside diameter b of the rocker arm shafts. Out of specification → Replace. Rocker arm shaft outside diame- 11.976 ~ 11.991 mm (0.4715 ~ 0.4721 in) e. Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter.

  • Page 143: Camshaft And Cylinder Head

    CAMSHAFT AND CYLINDER HEAD CAMSHAFT AND CYLINDER HEAD Order Job/Part Q’ty Remarks Removing the camshaft and cylin- Remove the parts in the order listed. der head Carburetor Refer to “CARBURETOR” in chapter 6. Coolant outlet joint breather hose Refer to “WATER PUMP” in chapter 5. Muffler/exhaust pipe/thermo switch 1 Refer to “ENGINE REMOVAL”.
  • Page 144 CAMSHAFT AND CYLINDER HEAD Order Job/Part Q’ty Remarks Thermo switch 1 Cylinder head Coolant outlet joint Gasket Cylinder head gasket Dowel pin Intake manifold For installation, reverse the removal pro- cedure. 4 - 18...

  • Page 145: Removing The Camshaft And Cylinder Head

    CAMSHAFT AND CYLINDER HEAD REMOVING THE CAMSHAFT AND CYLINDER HEAD 1. Loosen: • camshaft sprocket bolts 1 2. Loosen: • timing chain tensioner cap bolt 3. Remove: • timing chain tensioner • timing chain guide (exhaust side) • decompressor cam guide plates •...

  • Page 146: Checking The Camshaft Sprocket

    CAMSHAFT AND CYLINDER HEAD CHECKING THE CAMSHAFT SPROCKET 1. Check: • camshaft sprocket Wear/damage → Replace the camshaft sprocket and timing chain as a set. a 1/4 of a tooth b Correct 1 Timing chain 2 Sprocket CHECKING THE DECOMPRESSION SYSTEM 1.

  • Page 147: Checking The Cylinder Head

    CAMSHAFT AND CYLINDER HEAD b. Removing the screwdriver and slowly release the timing chain tensioner rod. c. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. If there is rough move- ment, replace the timing chain tensioner. L LLL L LLL L LLL...

  • Page 148: Installing The Camshaft And Cylinder Head

    CAMSHAFT AND CYLINDER HEAD d. Place a 400 ~ 600 grit wet sandpaper on the surface plate, and resurface the head using a figure-eight sanding pattern. NOTE: To ensure an even surface rotate the cylinder head several times. L LLL L LLL L LLL L LLL...
  • Page 149 CAMSHAFT AND CYLINDER HEAD c. Temporarily install the camshaft sprocket on the camshaft. (Do not install the bolts.) Then, install the timing chain on the cam- shaft sprocket. NOTE: Make sure the small holes 3 on the camshaft face upward. d.
  • Page 150 CAMSHAFT AND CYLINDER HEAD c. With the screwdriver still inserted into the timing chain tensioner, install the timing chain tensioner and gasket onto the cylin- der block. Then, tighten the timing chain tensioner bolts to the specified torque. WARNING Always use a new gasket. NOTE: The “UP”...

  • Page 151: Valves And Valve Springs

    VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Cylinder head Refer to “CAMSHAFT AND CYLINDER HEAD”. Valve cotter Valve spring retainer Intake valve spring Refer to “REMOVING THE VALVES Exhaust valve spring AND VALVE SPRINGS”...

  • Page 152: Removing The Valves And Valve Springs

    VALVES AND VALVE SPRINGS REMOVING THE VALVES AND VALVE SPRINGS 1. Check: • valve sealing Leakage at the valve seat → Check the valve face, valve seat and valve seat width. Refer to “CHECKING THE VALVES AND VALVE SPRINGS”. M MMM M MMM M MMM M MMM...

  • Page 153: Checking The Valves And Valve Springs

    VALVES AND VALVE SPRINGS CHECKING THE VALVES AND VALVE SPRINGS 1. Measure: • stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Out of specification → Replace the valve guide. Stem-to-guide clearance Intake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) <Limit>: 0.08 mm (0.0031 in) Exhaust...
  • Page 154 VALVES AND VALVE SPRINGS 3. Check: • valve face Pitting/wear → Grind the face. • valve stem end Mushroom shape or diameter larger than the body of the stem → Replace. 4. Measure: • margin thickness a Out of specification → Replace. Margin thickness Intake 0.85 ~ 1.15 mm...
  • Page 155 VALVES AND VALVE SPRINGS 8. Measure: • valve seat width a Out of specification → Reface the valve seat. Valve seat width Intake 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) <Limit>: 1.6 mm (0.0630 in) Exhaust 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) <Limit>: 1.6 mm (0.0630 in) M MMM...
  • Page 156 VALVES AND VALVE SPRINGS c. Install the valve into the cylinder head. d. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the compound. NOTE: For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands.

  • Page 157: Installing The Valves And Valve Springs

    VALVES AND VALVE SPRINGS 11.Measure: • compressed spring force a Out of specification → Replace. b Installed length Compressed spring force Intake 100.0 ~ 115.7 N at 27.5 mm (10.20 ~ 11.80 kg, 22.49 ~ 26.01 lb at 1.08 in) Exhaust 120.6 ~ 138.3 N at 31.0 mm (12.30 ~ 14.10 kg,...
  • Page 158 VALVES AND VALVE SPRINGS 3. Install: • valve cotters NOTE: Install the valve cotters while compressing the valve spring with the valve spring compressor 1 and valve spring compressor attachment Valve spring compressor set P/N. YM-04019 Valve spring compressor P/N. 90890-04019 Valve spring compressor attach- ment P/N.

  • Page 159: Cylinder And Piston

    CYLINDER AND PISTON CYLINDER AND PISTON Order Job/Part Q’ty Remarks Removing the cylinder and piston Remove the parts in the order listed. Water pump outlet hose Refer to “WATER PUMP” in chapter 5. Cylinder head Refer to “CAMSHAFT AND CYLINDER HEAD”.

  • Page 160: Removing The Piston

    CYLINDER AND PISTON REMOVING THE PISTON 1. Remove: • piston pin clips 1 • piston pin 2 • piston 3 NOTE: Before removing piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller 4.
  • Page 161 CYLINDER AND PISTON Standard Wear limit 100.005 ~ Cylinder 100.055 mm 100.10 mm bore “C” (3.9372 ~ (3.9410 in) 3.9392 in) X + Y b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set.

  • Page 162: Checking The Piston Rings

    CYLINDER AND PISTON CHECKING THE PISTON RINGS 1. Measure: • ring side clearance Use a thickness gauge. Out of specification → Replace the piston and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. Side clearance Standard Limit...

  • Page 163: Checking The Piston Pin

    CYLINDER AND PISTON CHECKING THE PISTON PIN 1. Check: • piston pin Blue discoloration/grooves → Replace, then check the lubrication system. 2. Measure: • piston pin-to-piston clearance M MMM M MMM M MMM M MMM M MMM a. Measure the piston pin outside diameter a. If out of specification, replace the piston pin.
  • Page 164 CYLINDER AND PISTON 2. Position: • top ring • 2nd ring • oil ring Offset the piston ring end gaps as shown. a Top ring end b Upper oil ring rail end C Oil ring expander end d Lower oil ring rail end e 2nd ring end f 20 mm (0.79 in) 3.

  • Page 165: Installing The Cylinder

    CYLINDER AND PISTON INSTALLING THE CYLINDER 1. Install: • cylinder • O-ring • bolts (M10) 42 Nm (4.2 m · kg, 30 ft · lb) • bolts (M6) 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Install the cylinder with one hand while com- pressing the piston rings with the other hand.

  • Page 166: Engine Cooling Fan And A.c. Magneto

    ENGINE COOLING FAN AND A.C. MAGNETO ENGINE COOLING FAN AND A.C. MAGNETO Order Job/Part Q’ty Remarks Removing the engine cooling fan Remove the parts in the order listed. and A.C. magneto Driver seat/passenger seat/console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. Drive belt cover Refer to “PRIMARY AND SECONDARY SHEAVES”.
  • Page 167 ENGINE COOLING FAN AND A.C. MAGNETO Order Job/Part Q’ty Remarks Engine cooling fan Air shroud 2 A.C. magneto coupler Disconnect. Engine cooling fan pulley base Refer to “REMOVING THE A.C. MAG- A.C. magneto cover/gasket NETO” and “INSTALLING THE A.C. MAGNETO”. Dowel pin Stator lead holder Pickup coil...
  • Page 168 ENGINE COOLING FAN AND A.C. MAGNETO Order Job/Part Q’ty Remarks Starter idle gear For installation, reverse the removal pro- cedure. 4 - 42...

  • Page 169: Removing The A.c. Magneto

    ENGINE COOLING FAN AND A.C. MAGNETO REMOVING THE A.C. MAGNETO 1. Remove: • engine cooling fan pulley 1 NOTE: Use the sheave holder 2 to hold the primary sheave. Primary sheave holder P/N. YS-01880-A Sheave holder P/N. 90890-01701 2. Remove: •...

  • Page 170: Checking The Starter Clutch

    ENGINE COOLING FAN AND A.C. MAGNETO CHECKING THE STARTER CLUTCH 1. Check: • starter clutch 1 Cracks/damage → Replace. • starter clutch bolts 2 Loose → Replace with new ones, and clinch the end of the bolts. NOTE: The arrow mark on the starter clutch must face inward, away from the A.C.

  • Page 171: Checking The Engine Cooling Fan

    1. Apply: ® • sealant (Quick Gasket (into the slit) ® Sealant (Quick Gasket P/N. ACC-11001-05-01 Yamaha bond No. 1215 P/N. 90890-85505 2. Install: • woodruff key • A.C. magneto rotor NOTE: • Before installing the rotor, clean the outside of the crankshaft and the inside of the rotor.
  • Page 172 • Tighten the bolts in stages, using a criss- cross pattern. ® Sealant (Quick Gasket P/N. ACC-11001-05-01 Yamaha bond No. 1215 P/N. 90890-85505 4. Install: • engine cooling fan pulley 1 55 Nm (5.5 m · kg, 40 ft · lb)
  • Page 173 ENGINE COOLING FAN AND A.C. MAGNETO 5. Connect: • A.C. magneto couplers 6. Install: • engine cooling fan 1 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: Install the bolts in the holes in the collar of the engine cooling fan.

  • Page 174: Balancer Gears And Oil Pump Gears

    BALANCER GEARS AND OIL PUMP GEARS BALANCER GEARS AND OIL PUMP GEARS Order Job/Part Q’ty Remarks Removing the balancer gears and oil Remove the parts in the order listed. pump gears Starter wheel gear Refer to “ENGINE COOLING FAN AND A.C.
  • Page 175 BALANCER GEARS AND OIL PUMP GEARS Order Job/Part Q’ty Remarks For installation, reverse the removal pro- cedure. 4 - 49...

  • Page 176: Removing The Balancer Drive Gear And Balancer Driven Gear

    BALANCER GEARS AND OIL PUMP GEARS REMOVING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 1. Straighten the lock washer tabs. 2. Loosen: • balancer driven gear nut 1 NOTE: Place an aluminum plate 2 between the teeth of the balancer drive gear 3 and balancer driven gear 4.

  • Page 177: Installing The Balancer Drive Gear And Balancer Driven Gear

    BALANCER GEARS AND OIL PUMP GEARS INSTALLING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR 1. Install: • pins • springs • balancer drive gear (onto the buffer boss) • plate • circlip NOTE: Align the punch mark a on the balancer drive gear with the hole b to the buffer boss.

  • Page 178: Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES PRIMARY AND SECONDARY SHEAVES 14 Nm (1.4 m kg, 10 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 100 Nm (10.0 m kg, 72 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 179 PRIMARY AND SECONDARY SHEAVES 14 Nm (1.4 m kg, 10 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 100 Nm (10.0 m kg, 72 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (12) 10 Nm (1.0 m kg, 7.2 ft...

  • Page 180: Primary Sheave

    PRIMARY AND SECONDARY SHEAVES PRIMARY SHEAVE Order Job/Part Q’ty Remarks Disassembling the primary sheave Remove the parts in the order listed. Primary pulley sheave cap Primary pulley slider Spacer Primary pulley cam Refer to “ASSEMBLING THE PRIMARY Primary pulley weight SHEAVE”.

  • Page 181: Secondary Sheave

    PRIMARY AND SECONDARY SHEAVES SECONDARY SHEAVE Order Job/Part Q’ty Remarks Disassembling the secondary Remove the parts in the order listed. sheave Spring seat Compression spring Refer to “DISASSEMBLING THE SEC- Spring seat ONDARY SHEAVE” and “ASSEMBLING Guide pin THE SECONDARY SHEAVE”. Secondary sliding sheave O-ring Secondary fixed sheave...

  • Page 182: Removing The Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES REMOVING THE PRIMARY AND SECONDARY SHEAVES 1. Loosen: • secondary sheave nut 1 • primary sheave nut 2 NOTE: • Use the sheave holder 3 to hold the primary sheave. • First, loosen the secondary sheave nut 1, then loosen the primary sheave nut 2.

  • Page 183: Checking The Primary Sheave

    PRIMARY AND SECONDARY SHEAVES CHECKING THE PRIMARY SHEAVE 1. Check: • weight outside diameter a Out of specification → Replace the weight. Weight outside diameter 30 mm (1.18 in) <Limit>: 29.5 mm (1.16 in) 2. Check: • primary pulley slider •...

  • Page 184: Assembling The Primary Sheave

    NOTE: Remove any excess grease. 2. Install: • weights 1 NOTE: • Apply Yamaha Grizzly grease (90 g) to the whole outer surface of the weights and install. • Apply Yamaha Grizzly grease to the inner surface of the collar.
  • Page 185 PRIMARY AND SECONDARY SHEAVES 3. Apply: ® • BEL-RAY assembly lube (to the guide pin sliding grooves 1, and O- rings 2 4. Install: • spring seat • compression spring • spring seat • nut M MMM M MMM M MMM M MMM M MMM a.

  • Page 186: Installing The Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES INSTALLING THE PRIMARY AND SECONDARY SHEAVES 1. Install: • secondary sheave assembly • V-belt • primary sheave assembly NOTE: • Tightening the bolts 1 will push the second- ary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen.

  • Page 187: Clutch

    CLUTCH CLUTCH Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Primary and secondary sheaves Refer to “PRIMARY AND SECONDARY SHEAVES”. Clutch housing assembly Gasket/dowel pin Refer to “REMOVING THE CLUTCH” and “INSTALLING THE CLUTCH”. One-way clutch bearing Clutch carrier assembly For installation, reverse the removal pro-...
  • Page 188 CLUTCH Order Job/Part Q’ty Remarks Disassembling the clutch housing Remove the parts in the order listed. Oil seal Circlip Bearing housing Circlip Bearing Circlip Bearing Clutch housing For assembly, reverse the disassembly procedure. 4 - 62...

  • Page 189: Removing The Clutch

    CLUTCH REMOVING THE CLUTCH 1. Remove: • clutch housing assembly • gasket • dowel pins NOTE: Working in crisscross pattern, loosen each bolt 1/4 of a turn. Remove them after all of them are loosened. 2. Straighten: • punched portion of the nut 1 3.

  • Page 190: Installing The Clutch

    CLUTCH b. When turning the clutch housing clockwise È, the clutch housing should turn freely. If not, the one-way clutch assembly is faulty. Replace it. c. When turning the clutch housing counter- clockwise É, the clutch housing and crank- shaft should be engaged. If not, the one-way clutch assembly is faulty.
  • Page 191 CLUTCH 3. Install: • one-way clutch bearing NOTE: The one-way clutch bearing should be installed in the clutch carrier assembly with the arrow mark a facing toward the clutch hous- ing. 4. Install: • dowel pins • gasket • clutch housing assembly 10 Nm (1.0 m ·...

  • Page 192: Crankcase

    CRANKCASE CRANKCASE STARTER MOTOR, TIMING CHAIN AND OIL FILTER Order Job/Part Q’ty Remarks Remove the starter motor, timing Remove the parts in the order listed. chain and oil filter Engine assembly Refer to “ENGINE REMOVAL”. Cylinder head Refer to “CAMSHAFT AND CYLINDER HEAD”.

  • Page 193: Crankcase

    CRANKCASE Order Job/Part Q’ty Remarks Oil pipe assembly/O-ring Oil pipe adapter/O-ring Relief valve assembly Speed sensor Shift drum stopper Gear position switch Reverse switch Oil filler cap Oil delivery pipe 1 Drain plug For installation, reverse the removal pro- cedure. 4 - 67...
  • Page 194 CRANKCASE CRANKCASE Order Job/Part Q’ty Remarks Separating the crankcase Remove the parts in the order listed. Shift lever cover/gasket Dowel pin Refer to “INSTALLING THE SHIFT LEVERS”. Shift lever 1 Shift lever 2 assembly Right crankcase Refer to “SEPARATING THE CRANK- Dowel pin CASE”...

  • Page 195: Crankcase Bearings

    CRANKCASE CRANKCASE BEARINGS 10 Nm (1.0 m kg, 7.2 ft Ib) Order Job/Part Q’ty Remarks Removing the crankcase bearings Remove the parts in the order listed. Crankshaft and oil pump Refer to “CRANKSHAFT AND OIL PUMP”. Transmission Refer to “TRANSMISSION”. Middle drive/driven shaft Refer to “MIDDLE GEAR”.

  • Page 196: Separating The Crankcase

    CRANKCASE È SEPARATING THE CRANKCASE 1. Separate: • right crankcase • left crankcase M MMM M MMM M MMM M MMM M MMM a. Remove the crankcase bolts. NOTE: • Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them.

  • Page 197: Checking The Relief Valve

    Roughness → Replace. ASSEMBLING THE CRANKCASE 1. Apply: ® • sealant (Quick Gasket (to the mating surfaces of both case halves) ® Sealant (Quick Gasket P/N. ACC-11001-05-01 Yamaha bond No. 1215 P/N. 90890-85505 2. Install: • dowel pins 2 4 - 71...

  • Page 198: Installing The Shift Levers

    • Apply sealant (Quick Gasket thread of the bolt 2 shown in the illustration. ® Sealant (Quick Gasket P/N. ACC-11001-05-01 Yamaha bond No. 1215 P/N. 90890-85505 5. Apply: • 4-stroke engine oil (to the crank pin, bearing and oil delivery hole) 6.

  • Page 199: Crankshaft And Oil Pump

    CRANKSHAFT AND OIL PUMP CRANKSHAFT AND OIL PUMP Order Job/Part Q’ty Remarks Removing the crankshaft and oil Remove the parts in the order listed. pump Crankcase separation Refer to “CRANKCASE”. Oil strainer/O-ring Oil pump assembly/gasket Balancer Refer to “REMOVING THE CRANK- Plate SHAFT”...

  • Page 200: Oil Pump

    CRANKSHAFT AND OIL PUMP OIL PUMP Order Job/Part Q’ty Remarks Disassembling the oil pump Remove the parts in the order listed. Rotor cover Shaft Inner rotor Outer rotor Oil pump housing For assembly, reverse the disassembly procedure. 4 - 74...

  • Page 201: Removing The Crankshaft

    CRANKSHAFT AND OIL PUMP REMOVING THE CRANKSHAFT 1. Remove: • crankshaft Use a crankcase separating tool 1. Crankcase separating tool P/N. YU-01135-A, 90890-01135 CHECKING THE OIL PUMP 1. Check: • rotor housing • rotor cover Cracks/wear/damage → Replace. 2. Measure: •...

  • Page 202: Checking The Relief Valve

    CRANKSHAFT AND OIL PUMP CHECKING THE RELIEF VALVE 1. Check: • relief valve body 1 • relief valve 2 • spring 3 • O-ring 4 Damage/wear → Replace the defective part(s). CHECKING THE OIL STRAINER 1. Check: • oil strainer 1 •...

  • Page 203: Checking The Crankshaft

    CRANKSHAFT AND OIL PUMP CHECKING THE CRANKSHAFT 1. Measure: • crank width A Out of specification → Replace the crank- shaft. Crank width 74.95 ~ 75.00 mm (2.9508 ~ 2.9528 in) • side clearance D Out of specification → Replace the crank- shaft.

  • Page 204: Installing The Crankshaft And Balancer

    CRANKSHAFT AND OIL PUMP INSTALLING THE CRANKSHAFT AND BALANCER 1. Install: • crankshaft Crankshaft installer pot 1 P/N. 90890-01274 Crankshaft installer bolt 2 P/N. 90890-01275 Crankshaft installer set 3 P/N. YU-90050 Adapter 4 P/N. YM-01383, 90890-01383 Spacer (crankshaft installer) 5 P/N.

  • Page 205: Transmission

    TRANSMISSION TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission Remove the parts in the order listed. Crankcase separation Refer to “CRANKCASE”. Middle driven gear Refer to “MIDDLE GEAR”. Low wheel gear Shift drum Shift fork assembly Short spring White painting Refer to “REMOVING Shift fork 1 THE TRANSMISSION”...

  • Page 206: Drive Axle Assembly

    TRANSMISSION DRIVE AXLE ASSEMBLY Order Job/Part Q’ty Remarks Disassembling the drive axle Remove the parts in the order listed. assembly Clutch dog High wheel gear Middle drive gear Driven sprocket Drive axle For assembly, reverse the disassembly procedure. 4 - 80...

  • Page 207: Removing The Transmission

    TRANSMISSION REMOVING THE TRANSMISSION 1. Remove: • shift drum 1 • shift fork assembly 2 M MMM M MMM M MMM M MMM M MMM a. Pull out the guide bar from the right crank- case. b. Slide the shift fork assembly and remove the shift fork followers from the shift drum grooves.

  • Page 208: Checking The Shift Drum

    TRANSMISSION 3. Check: • shift fork movement (on the guide bar) Unsmooth operation → Replace the shift fork and the guide bar. 4. Check: • springs Cracks/damage → Replace. CHECKING THE SHIFT DRUM 1. Check: • shift drum grooves Scratches/wear/damage → Replace. CHECKING THE DRIVE AXLE 1.

  • Page 209: Checking The Secondary Shaft And Driven Sprocket

    TRANSMISSION 2. Check: • gear movement Unsmooth → Repeat steps #1 or replace the defective parts. 3. Check: • circlip Bends/looseness/damage → Replace. CHECKING THE SECONDARY SHAFT AND DRIVEN SPROCKET 1. Check: • gear teeth Blue discoloration/pitting/wear → Replace. 2. Check: •...

  • Page 210: Assembling The Shift Fork Assembly

    TRANSMISSION ASSEMBLING THE SHIFT FORK ASSEMBLY 1. Install: • guide bar 1 • shift fork 2 2 • long spring 3 • shift fork 1 4 • short spring 5 INSTALLING THE TRANSMISSION 1. Install: • chain 1 • drive axle assembly 2 •...

  • Page 211: Middle Gear

    MIDDLE GEAR MIDDLE GEAR MIDDLE DRIVE SHAFT Order Job/Part Q’ty Remarks Removing the middle drive shaft Remove the parts in the order listed. Crankcase separation Refer to “CRANKCASE”. Bearing housing Middle driven gear Refer to “REMOVING THE MIDDLE DRIVE SHAFT” and “INSTALLING THE Middle drive pinion gear MIDDLE DRIVE SHAFT”.

  • Page 212: Middle Driven Shaft

    MIDDLE GEAR MIDDLE DRIVEN SHAFT Order Job/Part Q’ty Remarks Removing the middle driven shaft Remove the parts in the order listed. Crankcase separation Refer to “CRANKCASE”. Drive shaft coupling Circlip Refer to “REMOVING THE MIDDLE Bearing DRIVEN SHAFT” and “INSTALLING Universal joint THE MIDDLE DRIVEN SHAFT”.
  • Page 213 MIDDLE GEAR Order Job/Part Q’ty Remarks Bearing retainer Middle driven shaft For installation, reverse the removal pro- cedure. 4 - 87...

  • Page 214: Removing The Middle Drive Shaft

    MIDDLE GEAR REMOVING THE MIDDLE DRIVE SHAFT 1. Straighten: • punched portion of the nut (middle drive pinion gear) 2. Loosen: • middle drive pinion gear nut 1 NOTE: Secure the middle drive shaft in the vise with a clean rag. 3.
  • Page 215 MIDDLE GEAR 2. Remove: • universal joint M MMM M MMM M MMM M MMM M MMM a. Remove the circlips 1. b. Place the universal joint in a press. c. With a suitable diameter pipe 2 beneath the yoke 3, press the bearing 4 into the pipe as shown.
  • Page 216 MIDDLE GEAR 4. Remove: • bearing housing assembly 1 M MMM M MMM M MMM M MMM M MMM a. Clean the outside of the bearing housing assembly. b. Place the bearing housing assembly onto a hydraulic press. CAUTION: • Never directly press the middle driven pinion gear end with a hydraulic press, this will result in damage to the middle driven pinion gear thread.

  • Page 217: Checking The Pinion Gears

    MIDDLE GEAR 6. Remove: • drive shaft coupling • oil seal 1 • bearing retainer 2 • bearing NOTE: Attach the ring nut wrench 3. Ring nut wrench P/N. YM-38404, 90890-01430 CAUTION: The middle driven shaft bearing retainer has left-handed threads. To loosen the retainer, turn it clockwise.

  • Page 218: Selecting The Middle Drive And Driven Gear Shims

    MIDDLE GEAR SELECTING THE MIDDLE DRIVE AND DRIVEN GEAR SHIMS When the drive and driven gear, bearing hous- ing assembly and/or crankcase replaced, be sure to adjust the gear shims 1 and 2. 1. Select: • middle drive gear shim 1 •...
  • Page 219 MIDDLE GEAR Example: 1) If the bearing housing is marked “+02”, ..a is 7.52, 2) b is 17 3) c is 55 4) If the crankcase (left) is marked “64.98”, ..d is 64.98. 5) Therefore, the shim thickness is 0.50 mm. A = 7.52 + 64.98 –...
  • Page 220 MIDDLE GEAR g = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or subtracted from “80.5”. h = a numeral (usually a decimal number) on the right crankcase specifies a thickness of “97.26”. i = a numeral (usually a decimal number) on the left crankcase specifies a thickness of “1.66”.

  • Page 221: Installing The Middle Driven Shaft

    MIDDLE GEAR INSTALLING THE MIDDLE DRIVEN SHAFT 1. Install: • bearing retainer 1 Bearing retainer 80 Nm (8.0 m · kg, 58 ft · lb) ® LOCTITE NOTE: Attach the ring nut wrench 2. Ring nut wrench P/N. YM-38404, 90890-01430 CAUTION: The middle driven shaft bearing retainer has left-handed threads.
  • Page 222 MIDDLE GEAR 3. Install: • shims 1 • bearing housing NOTE: Install the shims so that the tabs are positioned as shown in the illustration. 4. Install: • universal joint yoke • washer • nut 1 NOTE: Use the universal joint holder 2 to hold the yoke.

  • Page 223: Installing The Middle Drive Shaft

    MIDDLE GEAR d. Press each bearing into the universal joint using a suitable socket. NOTE: The bearing must be inserted far enough into the universal joint so that the circlip can be installed. e. Install the circlips 2 into the groove of each bearing.

  • Page 224: Measuring The Middle Gear Backlash

    MIDDLE GEAR MEASURING THE MIDDLE GEAR BACKLASH 1. Measure: • gear lash Middle gear lash 0.1 ~ 0.3 mm (0.004 ~ 0.012 in) M MMM M MMM M MMM M MMM M MMM a. Temporary install the left crankcase. b. Wrap a rag 1 around a screwdriver 2, and then insert it into the installation hole 3 of the right crankcase speed sensor to hold the middle driven gear.

  • Page 225: Cooling System

    COOL RADIATOR AND COOLANT RESERVOIR COOLING SYSTEM RADIATOR AND COOLANT RESERVOIR 7 Nm (0.7 m kg, 5.1 ft • • 28 Nm (2.8 m kg, 20 ft • • Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Oil cooler Refer to “OIL COOLER”.
  • Page 226 COOL RADIATOR AND COOLANT RESERVOIR 7 Nm (0.7 m kg, 5.1 ft • • 28 Nm (2.8 m kg, 20 ft • • Order Job/Part Q’ty Remarks Coolant reservoir Coolant reservoir breather hose Disconnect. For installation, reverse the removal pro- cedure.

  • Page 227: Checking The Radiator

    COOL RADIATOR AND COOLANT RESERVOIR CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction → Clean. Apply compressed air to the rear of the radi- ator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver.

  • Page 228: Installing The Radiator

    COOL RADIATOR AND COOLANT RESERVOIR INSTALLING THE RADIATOR 1. Fill: • cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: • cooling system Leaks → Repair or replace any faulty part. 5 - 4...

  • Page 229: Water Pump

    COOL WATER PUMP WATER PUMP 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the water pump Remove the parts in the order listed. Driver seat/passenger seat/console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. Coolant outlet joint breather hose Water pump inlet hose Water pump outlet hose...
  • Page 230 COOL WATER PUMP Order Job/Part Q’ty Remarks Disassembling the water pump Remove the parts in the order listed. Water pump housing cover Gasket Circlip Impeller Rubber damper holder Rubber damper Water pump seal Oil seal Bearing Water pump housing For assembly, reverse the disassembly procedure.

  • Page 231: Disassembling The Water Pump

    COOL WATER PUMP DISASSEMBLING THE WATER PUMP 1. Remove: • rubber damper holder 1 • rubber damper 2 (from the impeller, with a thin, flathead screwdriver) NOTE: Do not scratch the impeller shaft. 2. Remove: • water pump seal 1 NOTE: Tap out the water pump seal from the inside of the water pump housing.

  • Page 232: Assembling The Water Pump

    COOL WATER PUMP 3. Measure: • impeller shaft tilt Out of specification → Replace. Max. impeller shaft tilt 0.15 mm (0.006 in) 1 Straightedge 2 Impeller ASSEMBLING THE WATER PUMP 1. Install: • oil seal 1 (into the water pump housing 2) NOTE: •...
  • Page 233 COOL WATER PUMP 3. Install: • rubber damper 1 • rubber damper holder 2 NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface. CAUTION: Make sure that the rubber damper and rub- ber damper holder are flush with the impel- ler.

  • Page 234: Oil Cooler

    COOL OIL COOLER OIL COOLER 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the oil cooler Remove the parts in the order listed. Driver seat/passenger seat/console/left Refer to “SEATS, ENCLOSURE, HOOD support side panel/right support side AND CARGO BED”...
  • Page 235 COOL OIL COOLER 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Oil cooler inlet pipe 2/oil cooler outlet pipe 2 For installation, reverse the removal pro- cedure.

  • Page 236: Checking The Oil Cooler

    COOL OIL COOLER CHECKING THE OIL COOLER 1. Check: • oil cooler Obstruction → Clean. Apply compressed air to the rear of the oil cooler. Damage → Repair or replace the oil cooler. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver.

  • Page 237: Fuel System

    FUEL FUEL PUMP AND FUEL TANK FUEL SYSTEM FUEL PUMP AND FUEL TANK 30 Nm (3.0 m kg, 22 ft 7 Nm (0.7 m kg, 5.1 ft • • • • Order Job/Part Q’ty Remarks Removing the fuel pump and fuel Remove the parts in the order listed.
  • Page 238 FUEL FUEL PUMP AND FUEL TANK 30 Nm (3.0 m kg, 22 ft 7 Nm (0.7 m kg, 5.1 ft • • • • Order Job/Part Q’ty Remarks Fuel tank cap Fuel tank For installation, reverse the removal pro- cedure. 6 - 2...

  • Page 239: Checking The Fuel Pump Operation

    FUEL FUEL PUMP AND FUEL TANK EAS00506 CHECKING THE FUEL PUMP OPERATION 1. Remove: • driver seat • passenger seat • console • right protector Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. 2. Place a container under the end of the fuel hose 1.

  • Page 240: Carburetor

    FUEL CARBURETOR CARBURETOR Order Job/Part Q’ty Remarks Removing the carburetor Remove the parts in the order listed. Driver seat/passenger seat/console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. Crankcase breather hose Disconnect. Air filter case Carburetor joint (air filter case) Vacuum chamber breather hose Air vent hose Starter cable/starter plunger...
  • Page 241 FUEL CARBURETOR Order Job/Part Q’ty Remarks Throttle cable end Throttle cable Carburetor joint (intake manifold) For installation, reverse the removal pro- cedure. 6 - 5...
  • Page 242 FUEL CARBURETOR Order Job/Part Q’ty Remarks Disassembling the carburetor Remove the parts in the order listed. NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. Throttle stop screw Vacuum chamber cover Spring...
  • Page 243 FUEL CARBURETOR Order Job/Part Q’ty Remarks Pilot air jet Drain screw Float chamber Float Refer to “ASSEMBLING THE CARBURE- TOR”. Needle valve set Main jet Needle jet Refer to “ASSEMBLING THE CARBURE- TOR”. Pilot jet Starter jet Carburetor heater For assembly, reverse the disassembly procedure.

  • Page 244: Disassembling The Carburetor

    FUEL CARBURETOR DISASSEMBLING THE CARBURETOR NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. CHECKING THE CARBURETOR 1. Check: • carburetor body •...
  • Page 245 FUEL CARBURETOR 4. Check: • piston valve 1 Scratches/wear/damage → Replace. • rubber diaphragm 2 Tears → Replace. 5. Check: • vacuum chamber cover 1 • spring 2 Cracks/damage → Replace. 6. Check: • diaphragm (coasting enricher) 1 • spring 2 •...

  • Page 246: Assembling The Carburetor

    FUEL CARBURETOR 8. Check: • free movement (piston valve) Sticks → Replace the piston valve guide and the piston valve. Insert the piston valve into the carburetor body, and check for free movement. 9. Check: • free movement (throttle valve) Sticks →...

  • Page 247: Adjusting The Fuel Level

    FUEL CARBURETOR ADJUSTING THE FUEL LEVEL 1. Measure: • fuel level a Out of specification → Adjust. Fuel level 4.0 ~ 5.0 mm (0.16 ~ 0.20 in) Above the float chamber mating surface M MMM M MMM M MMM M MMM M MMM a.

  • Page 248: Drive Train

    DRIV TROUBLESHOOTING DRIVE TRAIN TROUBLESHOOTING The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1. A pronounced hesitation or “jerky” move- A. Bearing damage. ment during acceleration, deceleration, or B. Improper gear lash. sustained speed. (This must not be con- C.
  • Page 249 DRIV TROUBLESHOOTING CAUTION: Too little gear lash is extremely destructive to the gear teeth. If a test ride following reassembly indicates this condition, stop riding immediately to minimize gear dam- age. c. A slight “thunk” evident at low speed opera- tion.
  • Page 250 DRIV TROUBLESHOOTING Troubleshooting chart When basic condition “a” and “b” exist, check the following points: YES Replace the wheel bearing. Elevate and spin both wheels. Feel for wheel bearing damage. (Refer to “STEERING SYSTEM” and “REAR KNUCKLE AND STABILIZER” in chapter 8.) NO Torque to specification.

  • Page 251: Front Constant Velocity Joints, Differential Gear And Drive Shaft

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT 55 Nm (5.5 m kg, 40 ft • • 55 Nm (5.5 m kg, 40 ft • • Order Job/Part Q’ty Remarks Removing the front constant veloc- Remove the parts in the order listed.
  • Page 252 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT 55 Nm (5.5 m kg, 40 ft • • 55 Nm (5.5 m kg, 40 ft • • Order Job/Part Q’ty Remarks Differential gear assembly Drive shaft Compression spring For installation, reverse the removal pro- cedure.
  • Page 253 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT Order Job/Part Q’ty Remarks Disassembling the constant velocity Remove the parts in the order listed. joint Circlip Boot band Boot band Dust boot Circlip Refer to “ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS”. Double off-set joint Circlip Ball bearing...
  • Page 254 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT Order Job/Part Q’ty Remarks Disassembling the differential gear Remove the parts in the order listed. Gear motor/O-ring NOTE: Do not disassemble the gear motor or remove the pinion gear. Circlip Refer to “DISASSEMBLING THE UNI- Bearing VERSAL JOINT”...
  • Page 255 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT Order Job/Part Q’ty Remarks Shim (right) Differential gear assembly Shim (left) Bearing Bearing Circlip/bearing Drive pinion gear Differential gear case Bearing For assembly, reverse the disassembly procedure. 7 - 8...

  • Page 256: Disassembling The Universal Joint

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT DISASSEMBLING THE UNIVERSAL JOINT 1. Remove: • universal joint M MMM M MMM M MMM M MMM M MMM a. Remove the circlips 1. b. Place the universal joint in a press. c.

  • Page 257: Checking The Constant Velocity Joints

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT CHECKING THE CONSTANT VELOCITY JOINTS 1. Check: • double off-set joint spline • ball joint spline • shaft spline Wear/damage → Replace. 2. Check: • dust boots Cracks/damage → Replace. CAUTION: Always use a new boot band.

  • Page 258: Checking The Gear Motor

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT 3. Check: • front drive shaft Bends → Replace. • torque limiter Loose → Replace the front drive shaft. WARNING Do not attempt to straighten a bent shaft; this may dangerously weaken the shaft. È...

  • Page 259: Assembling The Differential Gear

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT 2. Install: • dust boots 1 • boot bands 2, 3 M MMM M MMM M MMM M MMM M MMM a. Apply molybdenum disulfide grease into the dust boots. Molybdenum disulfide grease 40 g (1.4 oz) per dust boot (front wheel side)
  • Page 260 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT b. Connect two C size batteries to the gear motor terminal 2 to operate the pinion gear 3. Operate the pinion gear until the paint mark 4 on the gear is aligned with the paint mark 5 on the gear motor case.

  • Page 261: Assembling The Universal Joint

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT 4. Check: • differential gear operation Unsmooth operation → Replace the differ- ential gear assembly. Insert the double off-set joint into the differ- ential gear, and turn the gear back and forth.
  • Page 262 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT 3. Install: • a bolt of the specified size 1 (into the drain plug hole) CAUTION: Finger tighten the bolt until it holds the ring gear. Otherwise, the ring gear will be dam- aged.

  • Page 263: Checking The Differential Gear Operation

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT 2. Adjust: • gear lash M MMM M MMM M MMM M MMM M MMM a. Select the suitable shims using the following chart. Too little gear Reduce right shim lash thickness.
  • Page 264 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT 3. Measure the starting torque of the front wheel (i.e., differential gear preload) with a torque wrench. NOTE: • Repeat this step several times to obtain an average figure. • During this test, the other front wheel will turn in the opposite direction.

  • Page 265: Rear Constant Velocity Joints, Final Drive Gear And Drive Shaft

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT 70 Nm (7.0m kg, 51 ft • • Order Job/Part Q’ty Remarks Removing the rear constant velocity Remove the parts in the order listed. joints, final drive gear and drive shaft Rear skid plate...
  • Page 266 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT 70 Nm (7.0m kg, 51 ft • • Order Job/Part Q’ty Remarks Rear constant velocity joint NOTE: Remove the constant velocity joint on the right side of the vehicle, rotate the final gear assembly slightly so that the con- stant velocity joint on the left side clears the frame, and then remove it.
  • Page 267 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT Order Job/Part Q’ty Remarks Disassembling the rear constant Remove the parts in the order listed. velocity joint Circlip Boot band Boot band Dust boot Circlip Refer to “ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS”.
  • Page 268 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT Order Job/Part Q’ty Remarks Disassembling the final gear case Remove the parts in the order listed. Rear brake disc Refer to “REAR WHEELS AND BRAKE DISC” in chapter 8. Bolt Final drive pinion gear shim Drive shaft coupling...
  • Page 269 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT Order Job/Part Q’ty Remarks Bolt NOTE: Working in a crisscross pattern, loosen Bolt each bolt 1/4 of a turn. After all the bolts are loosened, remove them. Oil seal Bearing O-ring Ring gear bearing housing...
  • Page 270 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT Order Job/Part Q’ty Remarks Bearing Refer to “REMOVING THE FINAL DRIVE ROLLER BEARINGS” and Bearing “INSTALLING THE FINAL DRIVE ROLLER BEARINGS”. For assembly, reverse the disassembly procedure. 7 - 23...

  • Page 271: Assembling The Rear Constant Velocity Joints

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS 1. Apply: • molybdenum disulfide grease (into the ball joint assembly) 2. Install: • dust boots 1 • boot bands 2, 3 M MMM M MMM M MMM M MMM...

  • Page 272: Removing The Final Drive Roller Bearings

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT 2. Remove: • final drive pinion gear bearing housing assembly 1 M MMM M MMM M MMM M MMM M MMM a. Clean the outside surface of the final drive pinion gear.

  • Page 273: Installing The Final Drive Roller Bearings

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT 2. Remove: • roller bearing (final drive pinion gear) 1 M MMM M MMM M MMM M MMM M MMM a. Heat the main housing only to 150 °C (302 °F).
  • Page 274 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT Selecting the final drive pinion gear shim 1. Select: • final drive pinion gear shim(s) 1 M MMM M MMM M MMM M MMM M MMM a. To find the final drive pinion gear shim thick- “A”...
  • Page 275 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT Shims are supplied in the following thick- nesses. Final drive pinion gear shim 0.25 0.30 0.35 Thickness (mm) 0.40 0.45 0.50 L LLL L LLL L LLL L LLL L LLL Selecting the ring gear shim 1.
  • Page 276 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT 6) Round off the hundredth digit and select the appropriate shim(s). In the example above, the calculated num- ber is 0.48. The chart instructs you to round off 8 to 10 at the hundredth place. Thus, the shim thickness is 0.50 mm.
  • Page 277 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT c. Remove the final gear assembly. d. Measure the thrust clearance. Calculate the ® width of the flattened Plastigauge Ring gear thrust clearance 0.1 ~ 0.2 mm (0.004 ~ 0.008 in) e.

  • Page 278: Checking The Drive Shaft

    Damage → Replace. NOTE: • Reusing roller bearings is acceptable, but Yamaha recommends installing new ones. Do not reuse the oil seal. • When the final drive pinion gear and/or ring gear are replaced, be sure to adjust the shim of the final drive pinion gear and/or ring gear.

  • Page 279: Measuring And Adjusting The Final Gear Lash

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT MEASURING AND ADJUSTING THE FINAL GEAR LASH Measuring the final gear lash 1. Secure the gear case in a vise or another supporting device. 2. Remove: • drain plug •...

  • Page 280: Assembling The Final Gear Case

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT Adjusting the final gear lash 1. Remove: • ring gear bearing housing 1 • ring gear shim(s) 2 • ring gear 3 • thrust washer 4 2. Adjust: • gear lash M MMM M MMM M MMM...
  • Page 281 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT 2. Install: • ring gear bearing housing • M8 bolts (ring gear bearing housing) 1 23 Nm (2.3 m · kg, 17 ft · lb) • M10 bolts (ring gear bearing housing) 2 40 Nm (4.0 m ·...
  • Page 282 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT 4. Install: • drive shaft coupling nut M MMM M MMM M MMM M MMM M MMM a. Place a folded rag 1. b. Secure the drive shaft coupling edge in the vise.

  • Page 283: Seats, Enclosure, Hood And Cargo Bed

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED CHASSIS SEATS, ENCLOSURE, HOOD AND CARGO BED FRONT BUMPER AND HOOD 16 Nm (1.6 m kg, 11 ft • • 32 Nm (3.2 m kg, 23 ft • • 59 Nm (5.9 m kg, 43 ft •...

  • Page 284: Seats, Console And Instrument Panels

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED SEATS, CONSOLE AND INSTRUMENT PANELS 7 Nm (0.7 m kg, 5.1 ft • • (16) 35 Nm (3.5 m kg, 25 ft • • Order Job/Part Q’ty Remarks Removing the seats, console and Remove the parts in the order listed.
  • Page 285 CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED 7 Nm (0.7 m kg, 5.1 ft • • (16) 35 Nm (3.5 m kg, 25 ft • • Order Job/Part Q’ty Remarks Auxiliary DC jack connector Disconnect. Nut/starter cable Upper instrument panel Lower instrument panel For installation, reverse the removal pro- cedure.

  • Page 286: Panels And Footrest Cover

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED PANELS AND FOOTREST COVER 7 Nm (0.7 m kg, 5.1 ft • • 16 Nm (1.6 m kg, 11 ft • • (12) 32 Nm (3.2 m kg, 23 ft • • Order Job/Part Q’ty Remarks...
  • Page 287 CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED 7 Nm (0.7 m kg, 5.1 ft • • 16 Nm (1.6 m kg, 11 ft • • (12) 32 Nm (3.2 m kg, 23 ft • • Order Job/Part Q’ty Remarks Passenger seat support For installation, reverse the removal pro- cedure.

  • Page 288: Cargo Bed

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED CARGO BED 16 Nm (1.6 m kg, 11 ft • • 16 Nm (1.6 m kg, 11 ft • • Order Job/Part Q’ty Remarks Removing the cargo bed Remove the parts in the order listed. Tail/brake light connector Disconnect.
  • Page 289 CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED 7 Nm (0.7 m kg, 5.1 ft • • (12) 7 Nm (0.7 m kg, 5.1 ft • • (12) 7 Nm (0.7 m kg, 5.1 ft • • 26 Nm (2.6 m kg, 19 ft •...

  • Page 290: Skid Plates

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED SKID PLATES 7 Nm (0.7 m kg, 5.1 ft • • (11) (11) (11) (11) 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the engine skid plates Remove the parts in the order listed.

  • Page 291: Enclosure And Seat Belts

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED ENCLOSURE AND SEAT BELTS 64 Nm (6.4 m kg, 46 ft • • 64 Nm (6.4 m kg, 46 ft • • 64 Nm (6.4 m kg, 46 ft • • 59 Nm (5.9 m kg, 43 ft •...

  • Page 292: Front Wheels And Brake Discs

    CHAS FRONT WHEELS AND BRAKE DISCS FRONT WHEELS AND BRAKE DISCS 260 Nm (26.0 m kg, 190 ft • • 30 Nm (3.0 m kg, 22 ft • • 48 Nm (4.8 m kg, 35 ft • • 55 Nm (5.5 m kg, 40 ft •...
  • Page 293 CHAS FRONT WHEELS AND BRAKE DISCS 260 Nm (26.0 m kg, 190 ft • • 30 Nm (3.0 m kg, 22 ft • • 48 Nm (4.8 m kg, 35 ft • • 55 Nm (5.5 m kg, 40 ft •...

  • Page 294: Checking The Front Wheel

    CHAS FRONT WHEELS AND BRAKE DISCS CHECKING THE FRONT WHEEL 1. Check: • wheel 2. Measure: • wheel runout Over the specified limit → Replace the wheel or check the wheel bearing play 1. Wheel runout limit Radial 2: 2.0 mm (0.08 in) Lateral 3: 2.0 mm (0.08 in) 3.

  • Page 295: Checking The Front Brake Disc

    CHAS FRONT WHEELS AND BRAKE DISCS CHECKING THE FRONT BRAKE DISC 1. Check: • brake disc Galling/damage → Replace. 2. Measure: • brake disc deflection Out of specification → Check the wheel runout. If wheel runout is within the limits, replace the brake disc.

  • Page 296: Rear Wheels And Brake Disc

    CHAS REAR WHEELS AND BRAKE DISC REAR WHEELS AND BRAKE DISC REAR WHEELS 260 Nm (26.0 m kg, 190 ft • • 55 Nm (5.5 m kg, 40 ft • • Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed. Place the vehicle on a level surface.

  • Page 297: Rear Brake Disc

    CHAS REAR WHEELS AND BRAKE DISC REAR BRAKE DISC 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the rear brake disc Remove the parts in the order listed. Brake caliper assembly Refer to “FRONT AND REAR BRAKES”. Final drive gear Refer to “REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND...

  • Page 298: Checking The Rear Wheel

    CHAS REAR WHEELS AND BRAKE DISC CHECKING THE REAR WHEEL 1. Check: • wheel Refer “CHECKING FRONT WHEEL”. 2. Measure: • wheel runout Refer “CHECKING FRONT WHEEL”. Over the specified limit → Replace. Wheel runout limit Radial: 2.0 mm (0.08 in) Lateral: 2.0 mm (0.08 in) 3.

  • Page 299: Installing The Rear Wheel Hub

    CHAS REAR WHEELS AND BRAKE DISC INSTALLING THE REAR WHEEL HUB 1. Install: • axle nut Refer “INSTALLING FRONT WHEEL HUB”. INSTALLING THE REAR WHEEL 1. Install: • wheel Refer “INSTALLING FRONT WHEEL”. 2. Tighten: • wheel nuts Refer “INSTALLING FRONT WHEEL”.

  • Page 300: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES FRONT AND REAR BRAKES FRONT BRAKE PADS 18 Nm (1.8 m kg, 13 ft • • 48 Nm (4.8 m kg, 35 ft • • Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. Front wheel Refer to “FRONT WHEELS AND BRAKE DISCS”.

  • Page 301: Rear Brake Pads

    CHAS FRONT AND REAR BRAKES REAR BRAKE PADS 40Nm (4.0 m kg, 29 ft • • 17 Nm (1.7 m kg, 12 ft • • Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Rear skid plate Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED”.

  • Page 302: Replacing The Front Brake Pads

    CHAS FRONT AND REAR BRAKES CAUTION: Disc brake components rarely require dis- assembly. DO NOT: • disassemble components unless abso- lutely necessary; • use solvents on internal brake compo- nents; • use spent brake fluid for cleaning; (use only clean brake fluid) •...

  • Page 303: Replacing The Rear Brake Pads

    CHAS FRONT AND REAR BRAKES 2. Install: • brake pads • brake pad spring NOTE: Always install new brake pads and brake pad spring as a set. M MMM M MMM M MMM M MMM M MMM a. Connect a suitable hose 1 tightly to the brake caliper bleed screw 2.
  • Page 304 CHAS FRONT AND REAR BRAKES 1. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 1.5 mm (0.06 in) 2. Install: • brake pads • brake pad spring NOTE: Always install new brake pads, new brake pad shims, new insulators, and a new brake pad...
  • Page 305 CHAS FRONT AND REAR BRAKES e. Install the brake pad holding bolts, the brake caliper, and the brake caliper mounting bolts. Brake pad holding bolt 17 Nm (1.7 m · kg, 12 ft · lb) Brake caliper mounting bolt 40 Nm (4.0 m · kg, 29 ft · lb) L LLL L LLL L LLL...

  • Page 306: Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES BRAKE MASTER CYLINDER 19 Nm (1.9 m kg, 13 ft • • 16 Nm (1.6 m kg, 11 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Part Q’ty Remarks Removing the brake master cylinder Remove the parts in the order listed.
  • Page 307 CHAS FRONT AND REAR BRAKES 9 Nm (0.9 m kg, 6.5 ft • • Order Job/Part Q’ty Remarks Disassembling the brake master cyl- Remove the parts in the order listed. inder Dust boot Circlip Primary brake master cylinder kit Refer to “ASSEMBLING THE BRAKE Secondary brake master cylinder kit MASTER CYLINDER”.

  • Page 308: Checking The Master Cylinder

    CHAS FRONT AND REAR BRAKES CHECKING THE MASTER CYLINDER 1. Check: • brake master cylinder 1 Wear/scratches → Replace the brake mas- ter cylinder assembly. • brake master cylinder body Cracks/damage → Replace. • brake fluid delivery passage (brake master cylinder body) Blockage →...

  • Page 309: Installing The Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES INSTALLING THE BRAKE MASTER CYLINDER 1. Install: • brake master cylinder 16 Nm (1.6 m · kg, 11 ft · lb) 2. Install: • brake pipe 19 Nm (1.9 m · kg, 13 ft · lb) •...
  • Page 310 CHAS FRONT AND REAR BRAKES 4. Air bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5. Check: • brake fluid level Brake fluid level is under the “MIN” level line → Fill up. Refer to “CHECKING THE BRAKE FLUID LEVEL”...

  • Page 311: Front Brake Caliper

    CHAS FRONT AND REAR BRAKES FRONT BRAKE CALIPER Order Job/Part Q’ty Remarks Removing the front brake caliper Remove the parts in the order listed. Brake fluid Drain. Front wheel Refer to “FRONT WHEELS AND BRAKE DISCS”. Union bolt Copper washer Refer to “INSTALLING Brake hose Disconnect.
  • Page 312 CHAS FRONT AND REAR BRAKES 6 Nm (0.6 m kg, 4.3 ft • • 18 Nm (1.8 m kg, 13 ft • • Order Job/Part Q’ty Remarks Disassembling the front brake cali- Remove the parts in the order listed. Brake pad holding bolt Brake pad Pad spring Caliper bracket...

  • Page 313: Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES REAR BRAKE CALIPER 40 Nm (4.0m kg, 29 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed.
  • Page 314 CHAS FRONT AND REAR BRAKES 40 Nm (4.0m kg, 29 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Part Q’ty Remarks Union bolt Copper washer Refer to “INSTALLING Brake hose Disconnect.
  • Page 315 CHAS FRONT AND REAR BRAKES 5 Nm (0.5 m kg, 3.6 ft 17 Nm (1.7 m kg, 12 ft • • • • 22 Nm (2.2 m kg, 16 ft • • Order Job/Part Q’ty Remarks Disassembling the rear brake cali- Remove the parts in the order listed.
  • Page 316 CHAS FRONT AND REAR BRAKES 5 Nm (0.5 m kg, 3.6 ft 17 Nm (1.7 m kg, 12 ft • • • • 22 Nm (2.2 m kg, 16 ft • • Order Job/Part Q’ty Remarks Parking brake case Refer to “ASSEMBLING THE REAR Gasket BRAKE CALIPER”.

  • Page 317: Disassembling The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EBS00427 DISASSEMBLING THE FRONT BRAKE CALIPERS 1. Remove: • brake caliper pistons • dust seals 1 • caliper piston seals 2 M MMM M MMM M MMM M MMM M MMM a. Blow compressed air into the hose joint opening to force out the caliper piston from the brake caliper body.

  • Page 318: Checking The Front And Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES EB702040 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule: Brake pads As required Piston seals, dust Every two years seals Brake hoses Every two years Replace when Brake fluid brakes are disassembled.

  • Page 319: Assembling The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EBS00431 ASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the front brake calipers. WARNING • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid DOT 4 •...

  • Page 320: Assembling The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EBS00432 ASSEMBLING THE REAR BRAKE CALIPER WARNING • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid DOT 4 • Replace the caliper piston seal and dust seal whenever a brake caliper is disas- sembled.
  • Page 321 CHAS FRONT AND REAR BRAKES 4. Install: • parking brake arm shaft 1 • parking brake arm 2 • set bolt 3 • parking brake arm nut 4 M MMM M MMM M MMM M MMM M MMM NOTE: Apply lithium-soap-based grease to the park- ing brake arm shaft and set bolt.

  • Page 322: Installing The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES 6. Install: • brake pad holding bolts 17 Nm (1.7 m · kg, 12 ft · lb) EBS00434 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the front brake calipers. 1. Install: •...

  • Page 323: Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES WARNING • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. • Refill with the same type of brake fluid: mixing brake fluids may result in a harm- ful chemical reaction and lead to poor brake performance.
  • Page 324 CHAS FRONT AND REAR BRAKES 2. Fill: • brake reservoir Recommended brake fluid DOT 4 CAUTION: Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. WARNING • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance.

  • Page 325: Pedal Assembly

    CHAS PEDAL ASSEMBLY PEDAL ASSEMBLY 16 Nm (1.6 m kg, 11 ft • • Order Job/Part Q’ty Remarks Removing the pedal assembly Remove the parts in the order listed. Steering wheel cover/steering wheel/ Refer to “SEATS, ENCLOSURE, HOOD pedal cover/upper instrument panel/ AND CARGO BED”.
  • Page 326 CHAS PEDAL ASSEMBLY Order Job/Part Q’ty Remarks Disassembling the pedal assembly Remove the parts in the order listed. Spring Circlip Washer Brake pedal Spring Circlip Washer Accelerator pedal Pedal assembly bracket For assembly, reverse the disassembly procedure. 8 - 44...

  • Page 327: Steering System

    CHAS STEERING SYSTEM STEERING SYSTEM STEERING COLUMN AND STEERING ASSEMBLY 21 Nm (2.1 m kg, 15 ft • • 22 Nm (2.2 m kg, 16 ft • • 39 Nm (3.9 m kg, 28 ft • • 48 Nm (4.8 m kg, 35 ft •...
  • Page 328 CHAS STEERING SYSTEM 40 Nm (4.0 m kg, 29 ft • • Order Job/Part Q’ty Remarks Disassembling the steering assem- Remove the parts in the order listed. Tie-rod end locknut Tie-rod end Plastic locking tie Dust boot Refer to “ASSEMBLING THE STEER- Adjuster ING ASSEMBLY”.
  • Page 329 CHAS STEERING SYSTEM 40 Nm (4.0 m kg, 29 ft • • Order Job/Part Q’ty Remarks Steering assembly Refer to “ASSEMBLING THE STEERING ASSEMBLY”. For assembly, reverse the disassembly procedure. 8 - 47...

  • Page 330: Disassembling The Steering Assembly

    CHAS STEERING SYSTEM DISASSEMBLING THE STEERING ASSEMBLY 1. Remove: • oil seal • circlip • pinion gear with bearing 1 NOTE: Lightly tap on the steering housing with a soft hammer to remove the pinion gear easily. CHECKING THE STEERING JOINT 1.

  • Page 331: Assembling The Steering Assembly

    CHAS STEERING SYSTEM 3. Check: • rack gear teeth 1 • pinion gear teeth 2 Wear/damage → Replace the steering assembly. NOTE: The wear pattern on the rack and pinion gear teeth should be uniform. An uneven wear pat- tern may indicate improper adjustment or lack of lubrication.

  • Page 332: Installing The Steering System

    CHAS STEERING SYSTEM 2. Install: • steering assembly • bearing • circlips • pinion gear • oil seal NOTE: After centering the rack gear, make two align- ment marks a on the pinion gear and the steering housing to mark the position of the pinion gear.

  • Page 333: Tie-Rod And Steering Knuckle

    CHAS STEERING SYSTEM TIE-ROD AND STEERING KNUCKLE 7 Nm (0.7 m kg, 5.1 ft • • 39 Nm (3.9 m kg, 28 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft •...

  • Page 334: Removing The Steering Knuckles

    CHAS STEERING SYSTEM REMOVING THE STEERING KNUCKLES 1. Remove: • steering knuckle 1 NOTE: Use a general puller to separate the ball joints 2 from the steering knuckle 1 or the front lower arm 3. CHECKING THE TIE-RODS 1. Check: •...
  • Page 335 CHAS STEERING SYSTEM Ball joint remover/installer set P/N. 90890-01474 Ball joint adapter set P/N. YM-01474 Ball joint remover/installer attach- ment set P/N. YM-01477 YM-01474 Body 90890-01474 YM-01474 Long bolt 90890-01474 Short bolt YM-01477 Remover washer YM-01477 Remover spacer YM-01477 Installer YM-01477 attachment Installer spacer...
  • Page 336 CHAS STEERING SYSTEM h. Attach the assembled ball joint remover/ installer, new ball joint B and installer attachment 8 to the steering knuckle C. NOTE: Do not tap or damage the top of the ball joint. i. Hold the body 3 in place while turning in the long bolt 4 to install the new ball joint B into the steering knuckle C.
  • Page 337 CHAS STEERING SYSTEM h. Install the new oil seals. NOTE: When installing the oil seals, the “seal side” of the oil seal faces out. L LLL L LLL L LLL L LLL L LLL 8 - 55...

  • Page 338: Front Arms And Front Shock Absorber

    CHAS FRONT ARMS AND FRONT SHOCK ABSORBER FRONT ARMS AND FRONT SHOCK ABSORBER 45 Nm (4.5 m kg, 32 ft 45 Nm (4.5 m kg, 32 ft • • • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 339 CHAS FRONT ARMS AND FRONT SHOCK ABSORBER 45 Nm (4.5 m kg, 32 ft 45 Nm (4.5 m kg, 32 ft • • • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 340: Removing The Front Arms

    CHAS FRONT ARMS AND FRONT SHOCK ABSORBER REMOVING THE FRONT ARMS 1. Check: • front arm free play M MMM M MMM M MMM M MMM M MMM a. Check the front arm side play È by moving it from side to side. If side play is noticeable, check the bush- ings.
  • Page 341 CHAS FRONT ARMS AND FRONT SHOCK ABSORBER Ball joint remover/installer set P/N. 90890-01474 Ball joint adapter set P/N. YM-01474 Ball joint remover/installer attach- ment set P/N. YM-01477 YM-01474 Body 90890-01474 YM-01474 Long bolt 90890-01474 Remover washer YM-01477 Remover spacer YM-01477 Installer YM-01477 attachment...

  • Page 342: Checking The Front Shock Absorber

    CHAS FRONT ARMS AND FRONT SHOCK ABSORBER j. Apply lithium-soap base grease to the new ball joint A. k. Install a new rubber boot and new circlip. NOTE: Always use a new ball joint set. L LLL L LLL L LLL L LLL L LLL CHECKING THE FRONT SHOCK...

  • Page 343: Installing The Front Arms And Front Shock Absorber

    CHAS FRONT ARMS AND FRONT SHOCK ABSORBER INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 1. Install: • front arms • front shock absorber M MMM M MMM M MMM M MMM M MMM a. Install the front upper arm 1 and front lower arm 2.

  • Page 344: Rear Knuckle And Stabilizer

    CHAS REAR KNUCKLE AND STABILIZER REAR KNUCKLE AND STABILIZER 32 Nm (3.2m kg, 23 ft • • 56 Nm (5.6 m kg, 40 ft • • 56 Nm (5.6 m kg, 40 ft • • 45 Nm (4.5 m kg, 32 ft •...

  • Page 345: Checking The Rear Knuckle

    CHAS REAR KNUCKLE AND STABILIZER CHECKING THE REAR KNUCKLE 1. Check: • rear knuckle Damage/pitting → Replace. 2. Check: • rear wheel bearings Bearings allow play in the wheel hubs or the wheel turns roughly → Replace. • oil seals Damage →...

  • Page 346: Rear Arms And Rear Shock Absorber

    CHAS REAR ARMS AND REAR SHOCK ABSORBER REAR ARMS AND REAR SHOCK ABSORBER 45 Nm (4.5 m kg, 32 ft • • 45 Nm (4.5 m kg, 32 ft • • 45 Nm (4.5 m kg, 32 ft • • 45 Nm (4.5 m kg, 32 ft •...

  • Page 347: Checking The Rear Arms

    CHAS REAR ARMS AND REAR SHOCK ABSORBER CHECKING THE REAR ARMS 1. Check: • rear arms 1 Bends/damage → Replace. 2. Check: • bushings 2 Wear/damage → Replace. CHECKING THE REAR SHOCK ABSORBER 1. Check: • shock absorber rod Bends/damage → Replace the shock absorber assembly.

  • Page 348: Installing The Rear Arms And Rear Shock Absorber

    CHAS REAR ARMS AND REAR SHOCK ABSORBER INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER 1. Install: • rear arms • rear shock absorber M MMM M MMM M MMM M MMM M MMM a. Install the rear upper arm 1 and rear lower arm 2.

  • Page 349: Electrical

    – ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Diode 1 7 Ignition coil D Gear motor 2 Thermo switch 2 8 Gear position switch E Radiator fan 3 Diode 2 9 Reverse switch F Thermo switch 3 4 Circuit breaker 0 Brake light switch A Parking brake switch (radiator fan motor)

  • Page 350: Electrical Components

    – ELEC ELECTRICAL COMPONENTS 1 Rectifier/regulator A Main fuse 2 Auxiliary DC jack B Four-wheel drive relay 3 3 Indicator light assembly 1 C Differential gear lock indicator light relay 4 Indicator light assembly 2 D Four-wheel drive indicator light relay 5 On-Command four-wheel drive switch and differ- E Fuse box F C.D.I.

  • Page 351: Checking The Switch

    – ELEC CHECKING THE SWITCH CHECKING THE SWITCH CHECKING THE SWITCH Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. Pocket tester P/N. YU-03112-C, 90890-03112 NOTE: • Set the pocket tester to “0” before starting the test.

  • Page 352: Checking The Switch Continuity

    – ELEC CHECKING THE SWITCH CHECKING THE SWITCH CONTINUITY Refer to “CHECKING THE SWITCH” and check for continuity between lead terminals. Poor connection, no continuity → Correct or replace. The coupler locations are circled. L/B L/G L/R Sb Br Gy G/R B (BLACK) (GRAY) LOCK...
  • Page 353 – ELEC CHECKING THE SWITCH 1 Fuse 2 Brake light switch 3 On-Command four-wheel drive switch and differential gear lock switch 4 Main switch 5 Light switch 6 Parking brake switch 7 Gear position switch 8 Reverse switch 9 Four-wheel drive switch 9 - 5...

  • Page 354: Checking The Bulbs And Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS EB801020 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.
  • Page 355 – ELEC CHECKING THE BULBS AND BULB SOCKETS WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: • Be sure to hold the socket firmly when removing the bulb.

  • Page 356: Checking The Condition Of The Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • Bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester P/N.

  • Page 357: Ignition System

    – ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM 9 - 9...

  • Page 358: Troubleshooting

    – ELEC IGNITION SYSTEM EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1. Fuses (main, ignition) 7. Main switch 2. Battery 8. Pickup coil resistance 3. Spark plug 9. Rotor rotation direction detection coil resis- 4.
  • Page 359 – ELEC IGNITION SYSTEM 3. Spark plug Standard spark plug DPR8EA-9/NGK • Check the spark plug condition. • Check the spark plug type. • Check the spark plug gap. Refer to “CHECKING THE SPARK PLUG” in chapter 3. INCORRECT Spark plug gap 0.8 ~ 0.9 mm (0.031 ~ 0.035 in) CORRECT Repair or replace the spark plug.
  • Page 360 – ELEC IGNITION SYSTEM 5. Spark plug cap resistance • Remove the spark plug cap. • Connect the pocket tester (Ω × 1k) to the spark plug cap. • Check that the spark plug cap has the specified resistance. OUT OF SPECIFICATION Spark plug cap resistance 10 kΩ...
  • Page 361 – ELEC IGNITION SYSTEM INCORRECT 7. Main switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the main switch. 8. Pickup coil resistance • Disconnect the A.C. magneto coupler from the wire harness. • Connect the pocket tester (Ω × 100) to the pickup coil terminal.
  • Page 362 – ELEC IGNITION SYSTEM POOR CONNECTION 10.Wiring connection • Check the connections of the entire igni- tion system. Refer to “CIRCUIT DIAGRAM”. Properly connect the ignition system. CORRECT Replace the C.D.I. unit. 9 - 14...

  • Page 363: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 9 - 15...

  • Page 364: Starting Circuit Operation

    – ELEC ELECTRIC STARTING SYSTEM STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, brake light switch, C.D.I. unit and gear position switch. If the main switch is “START” position, the starter motor can be operated only if: •...

  • Page 365: Troubleshooting

    – ELEC ELECTRIC STARTING SYSTEM EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 1. Fuses (main, ignition, signaling system) 6. Gear position switch 2. Battery 7. Brake light switch 3. Starter motor 8. Diode 1 4. Starter relay 9.
  • Page 366 – ELEC ELECTRIC STARTING SYSTEM 3. Starter motor WARNING • Connect the battery (+) terminal 1 and • A wire that is used as a jumper lead must starter motor cable 2 using a jumper lead have the equivalent capacity or more as that of the battery lead, otherwise the jumper lead may burn.
  • Page 367 – ELEC ELECTRIC STARTING SYSTEM INCORRECT 6. Gear position switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the gear position switch. INCORRECT 7. Brake light switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the brake light switch. 8. Diode 1 •...

  • Page 368: Starter Motor

    – ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Starter motor lead Starter motor/O-ring For installation, reverse the removal pro- cedure. Disassembling the starter motor Remove the parts in the order listed. Bracket 1 Washer kit Bracket 2...

  • Page 369: Checking The Starter Motor

    – ELEC ELECTRIC STARTING SYSTEM CHECKING THE STARTER MOTOR 1. Check: • commutator Dirty → Clean it with #600 grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Outside diameter 28 mm (1.10 in) <Wear limit>: 27 mm (1.06 in) 3.

  • Page 370: Assembling The Starter Motor

    – ELEC ELECTRIC STARTING SYSTEM 5. Measure: • brush length a (each) Out of specification → Replace the brush. Brush length 12.5 mm (0.49 in) <Wear limit>: 5 mm (0.20 in) 6. Measure: • brush spring force Fatigue/out of specification → Replace as a set.

  • Page 371: Charging System

    – ELEC CHARGING SYSTEM EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM 9 - 23...

  • Page 372: Troubleshooting

    – ELEC CHARGING SYSTEM EB804010 TROUBLESHOOTING IF THE BATTERY IS NOT CHARGED: Procedure Check: 1. Fuse (main) 4. Charging coil resistance 2. Battery 5. Wiring connections 3. Charging voltage (the entire charging system) NOTE: Digital engine test tachometer • Remove the following part(s) before trouble- P/N.
  • Page 373 – ELEC CHARGING SYSTEM • Start the engine and accelerate to about 1,000 r/min. Charging voltage 14 V at 1,000 r/min MEETS SPECIFICATION NOTE: Use a fully charged battery. The charging circuit is not faulty. OUT OF SPECIFICATION EB804012 4. Charging coil resistance •...

  • Page 374: Lighting System

    – ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM 9 - 26...

  • Page 375: Troubleshooting

    – ELEC LIGHTING SYSTEM EB805010 TROUBLESHOOTING IF THE HEADLIGHT AND/OR TAILLIGHT FAIL TO COME ON: Procedure Check: 1. Fuses (main, lighting system) 4. Light switch 2. Battery 5. Wiring connections 3. Main switch (the entire lighting system) NOTE: Pocket tester •...
  • Page 376 – ELEC LIGHTING SYSTEM INCORRECT 4. Light switch Refer to “CHECKING THE SWITCH”. CORRECT Replace the light switch. EB805013 5. Wiring connection • Check the connections of the entire light- POOR CONNECTION ing system. Refer to “CIRCUIT DIAGRAM”. CORRECT Properly connect the lighting system. Check the condition of each of the lighting system’s circuits.

  • Page 377: Checking The Lighting System

    – ELEC LIGHTING SYSTEM EB805020 CHECKING THE LIGHTING SYSTEM 1. If the headlights fail to come on: 1. Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for conti- nuity. CONTINUITY Replace the bulb and/or bulb socket. 2.
  • Page 378 – ELEC LIGHTING SYSTEM EB805021 2. If the taillights fail to come on: 1. Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for conti- nuity. CONTINUITY Replace the bulb and/or bulb socket. 2. Voltage • Connect the pocket tester (DC 20 V) to the tail/brake light connectors.

  • Page 379: Signaling System

    – ELEC SIGNALING SYSTEM EB806000 SIGNALING SYSTEM CIRCUIT DIAGRAM 9 - 32...
  • Page 380 – ELEC SIGNALING SYSTEM 3 Main switch 6 Battery 7 Main fuse 0 Brake light switch B Reverse switch C C.D.I. unit P Gear position switch Q Parking brake switch R Thermo switch 1 Z Gear motor [ Diode 2 ] Four-wheel drive indicator light _ Differential gear lock indicator light a Coolant temperature warning light...

  • Page 381: Troubleshooting

    – ELEC SIGNALING SYSTEM EB806010 TROUBLESHOOTING IF A BRAKE LIGHT, AN INDICATOR LIGHT, OR THE WARNING LIGHT FAILS TO COME ON: Procedure Check: 1. Fuses (main, signaling system) 2. Battery 3. Main switch 4. Wiring connections (the entire signal system) NOTE: •...

  • Page 382: Circuit Diagram

    – ELEC SIGNALING SYSTEM EB806011 4. Wiring connections • Check the connections of the entire signal POOR CONNECTION system. Refer to “CIRCUIT DIAGRAM”. CORRECT Properly connect the signal system. Check the condition of each of the signal sys- tem’s circuits. Refer to “CHECKING THE SIGNAL SYS- TEM”.

  • Page 383: Checking The Signal System

    – ELEC SIGNALING SYSTEM CHECKING THE SIGNAL SYSTEM 1. If the brake lights fail to come on: 1. Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for conti- nuity. CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2.
  • Page 384 – ELEC SIGNALING SYSTEM EB806024 2. If the neutral indicator light fails to come on: 1. Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for conti- nuity. CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2.
  • Page 385 – ELEC SIGNALING SYSTEM 3. If the parking brake indicator light fails to come on: 1. Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for conti- nuity. CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2.
  • Page 386 – ELEC SIGNALING SYSTEM 4. If the reverse indicator light fails to come on: 1. Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for conti- nuity. CONTINUITY Replace the bulb and/or bulb socket. NO CONTINUITY 2.
  • Page 387 – ELEC SIGNALING SYSTEM 5. If the coolant temperature warning light does not come on when the main switch to “ON”, or if the coolant temperature warning light does not come on when the temperature is high (more than 117 ~ 123 °C (242.6 ~ 253.4 °F)): 1.
  • Page 388 – ELEC SIGNALING SYSTEM 3. Voltage • Connect the pocket tester (DC 20 V) to the indicator light assembly 1 coupler. Br W/Y Tester (+) lead → Brown terminal 1 Br B/G Tester (–) lead → White/Blue terminal 2 Br W/L OUT OF SPECIFICATION •...
  • Page 389 – ELEC SIGNALING SYSTEM 6. If the differential gear lock indicator light fails to come on: 1. Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for conti- nuity. CONTINUITY Replace the bulb and/or bulb socket. 2.
  • Page 390 – ELEC SIGNALING SYSTEM 4. Voltage • Connect the pocket tester (DC 20 V) to the indicator light assembly 1 coupler. Br W/Y Tester (+) lead → Brown terminal 1 Br B/G Tester (–) lead → Br W/L Black/Green terminal 2 OUT OF SPECIFICATION •...
  • Page 391 – ELEC SIGNALING SYSTEM 7. If the four-wheel drive indicator light fails to come on: 1. Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for conti- nuity. CONTINUITY Replace the bulb and bulb socket. 2. Four-wheel drive indicator light relay •...
  • Page 392 – ELEC SIGNALING SYSTEM 4. Voltage • Connect the pocket tester (DC 20 V) to the indicator light assembly 1 coupler. Br W/Y Tester (+) lead → Brown terminal 1 Br B/G Tester (–) lead → Br W/L White/Yellow terminal 2 OUT OF SPECIFICATION •...

  • Page 393: Cooling System

    – ELEC COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM 9 - 46...

  • Page 394: Troubleshooting

    – ELEC COOLING SYSTEM TROUBLESHOOTING IF THE FAN MOTOR DOES NOT MOVE: Procedure Check: 1. Fuse (main) 5. Circuit breaker (radiator fan motor) 2. Battery 6. Thermo switch 3 3. Main switch 7. Wiring connection 4. Radiator fan motor (the entire cooling system) NOTE: •...
  • Page 395 – ELEC COOLING SYSTEM 4. Radiator fan motor • Disconnect the radiator fan motor coupler. • Connect the battery (12 V) as shown. Battery (+) lead → Blue terminal 1 Battery (–) lead → Black terminal 2 DOES NOT TURN •...
  • Page 396 – ELEC COOLING SYSTEM 6. Thermo switch 3 • Remove the thermo switch 3 from the radi- ator. • Connect the pocket tester (Ω × 1) to the thermo switch 3 1. • Immerse the thermo switch 3 in coolant 2. •...

  • Page 397: Circuit Diagram

    – ELEC COOLING SYSTEM EB803028 7. Wiring connection • Check the connections of the entire cool- POOR CONNECTION ing system. Refer to “CIRCUIT DIAGRAM”. CORRECT Properly connect the cooling system. This circuit is not faulty. 9 - 50...

  • Page 398: 2Wd/4Wd Selecting System

    – ELEC 2WD/4WD SELECTING SYSTEM 2WD/4WD SELECTING SYSTEM CIRCUIT DIAGRAM 9 - 51...

  • Page 399: Troubleshooting

    – ELEC 2WD/4WD SELECTING SYSTEM EB803020 TROUBLESHOOTING IF THE FOUR-WHEEL DRIVE INDICATOR FAILS TO COME ON: Procedure Check: 1. Fuses (main, four-wheel drive) 7. On-Command four-wheel drive switch and 2. Battery differential gear lock switch 3. Main switch 8. Gear motor 4.
  • Page 400 – ELEC 2WD/4WD SELECTING SYSTEM 4. Four-wheel drive relay 1 • Remove the four-wheel drive relay 1 from the wire harness. • Connect the pocket tester (Ω × 1) and the battery (12 V) to the four-wheel drive relay 1 terminals. Tester (+) lead →...
  • Page 401 – ELEC 2WD/4WD SELECTING SYSTEM 6. Four-wheel drive relay 3 • Remove the four-wheel drive relay 3 from the wire harness. • Connect the pocket tester (Ω × 1) and the battery (12 V) to the four-wheel drive relay 3 terminals. Battery (+) terminal →...

  • Page 402: Circuit Diagram

    – ELEC 2WD/4WD SELECTING SYSTEM È 8. Gear motor • Disconnect the gear motor coupler. • Remove the gear motor from the differen- tial gear case. Refer to “FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT” in chapter 7. •...

  • Page 403: Carburetor Heating System

    – ELEC CARBURETOR HEATING SYSTEM CARBURETOR HEATING SYSTEM CIRCUIT DIAGRAM 9 - 56...

  • Page 404: Troubleshooting

    – ELEC CARBURETOR HEATING SYSTEM TROUBLESHOOTING IF THE CARBURETOR HEATING SYSTEM FAILS TO OPERATE: Procedure Check: 1. Fuses (main, carburetor heater) 5. Carburetor heater 2. Battery 6. Wiring connection 3. Main switch (the entire carburetor warming system) 4. Thermo switch 2 NOTE: Pocket tester •...
  • Page 405 – ELEC CARBURETOR HEATING SYSTEM 4. Thermo switch 2 • Remove the thermo switch 2 from the wire Ω × 1 harness. • Connect the pocket tester (Ω × 1) to the thermo switch 2 1. • Immerse the thermo switch 2 in a con- tainer filled with water 2.

  • Page 406: Circuit Diagram

    – ELEC CARBURETOR HEATING SYSTEM 5. Carburetor heater • Remove the carburetor heater from the carburetor. • Connect the pocket tester (Ω × 1) to the carburetor heater. Tester (+) lead → Carburetor heater terminal 1 Tester (–) lead → Carburetor heater body 2 •...

  • Page 407: Troubleshooting

    TRBL STARTING FAILURE/HARD STARTING SHTG EBS00537 TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for check, adjustment and replacement of parts.

  • Page 408: Compression System

    TRBL STARTING FAILURE/HARD STARTING/POOR IDLE SPEED PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE SHTG COMPRESSION SYSTEM Cylinder and cylinder head Piston and piston rings • Loose spark plug • Improperly installed piston ring • Loose cylinder head or cylinder • Worn, fatigued or broken piston ring •...

  • Page 409: Faulty Drive Train

    TRBL FAULTY DRIVE TRAIN SHTG EBS00540 FAULTY DRIVE TRAIN The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1. A pronounced hesitation or “jerky” move- A. Bearing damage. ment during acceleration, deceleration, or B. Improper gear lash. sustained speed.

  • Page 410: Faulty Gear Shifting

    FAULTY GEAR SHIFTING/ TRBL FAULTY CLUTCH PERFORMANCE SHTG EBS00542 FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH SLIPPING”. SHIFT LEVER DOES NOT MOVE Shift drum, shift forks Transmission • Groove jammed with impurities • Seized transmission gear • Seized shift fork •...

  • Page 411: Poor Speed Performance

    TRBL FAULTY CLUTCH PERFORMANCE/OVERHEATING/ SHTG FAULTY BRAKE/SHOCK ABSORBER MALFUNCTION POOR SPEED PERFORMANCE V-belt Primary sliding sheave • Oil or grease on the V-belt • Worn primary sliding sheave Primary pulley weight Secondary fixed sheave • Faulty operation • Worn secondary fixed sheave •...

  • Page 412: Unstable Handling

    UNSTABLE HANDLING/ TRBL LIGHTING SYSTEM SHTG EBS00552 UNSTABLE HANDLING UNSTABLE HANDLING Steering wheel Wheels • Improperly installed or bent • Deformed wheel Steering • Loose bearing • Incorrect toe-in • Bent or loose wheel axle • Bent steering shaft • Excessive wheel runout Frame •...
  • Page 413 YXR660FAS WIRING DIAGRAM 1 A.C. magneto R/W L/W W L/Y G/W W/B 2 Rectifier/regulator (BLACK) (BLACK) (BLACK) 3 Main switch 4 Backup fuse 5 Carburetor heater fuse W/G R R W/G 6 Battery (GRAY) W/R W/G W/L W/R (GRAY) 7 Main fuse WIRE HARNESS IGNITION COIL LEAD 8 Starter relay 9 Starter motor...
  • Page 414 EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section.
  • Page 415 EBS00006 SYMBOLS The following symbols are not relevant to SPEC INFO every vehicle. Symbols 1 to 0 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system FUEL COOL 6 Fuel system 7 Drive train 8 Chassis...
  • Page 416 CONTENTS SPECIFICATIONS .....................1 GENERAL SPECIFICATIONS ..............1 ENGINE SPECIFICATIONS ................2 CHASSIS SPECIFICATIONS ..............2 ELECTRICAL SPECIFICATIONS ...............2 TIGHTENING TORQUES ................3 ENGINE TIGHTENING TORQUES ............3 CHASSIS TIGHTENING TORQUES ............3 CABLE ROUTING ..................4 PERIODIC CHECKS AND ADJUSTMENTS ...........20 INTRODUCTION ..................20 PERIODIC MAINTENANCE/LUBRICATION ..........20 ENGINE .....................22 CLEANING THE AIR FILTER ELEMENTS .........22 CHASSIS ....................25 ADJUSTING THE PARKING BRAKE ..........25...

  • Page 417: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code 5UG4 5UG8 Basic weight With oil and full fuel tank 509 kg (1,122 lb) Transmission Primary reduction system V-belt Secondary reduction system Shaft drive 41/21 × 24/18 × 33/9 (9.544) Secondary reduction ratio Transmission type V-belt automatic...

  • Page 418: Engine Specifications

    ENGINE SPECIFICATIONS/CHASSIS SPECIFICATIONS/ SPEC ELECTRICAL SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Carburetor I. D. mark 5UG4 10 ---- Main jet (M.J) #145 ---- Main air jet (M.A.J) ---- Jet needle (J.N) 6JPH10 ---- Needle jet (N.J) O-0M (922) ---- Pilot air jet (P.A.J.1) ---- Pilot air jet...

  • Page 419: Tightening Torques

    SPEC TIGHTENING TORQUES EBS01005 TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Engine cooling fan Bolt EBS01006 CHASSIS TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks Nm m ·...

  • Page 420: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Left headlight lead 0 Parking brake switch lead 2 Wire harness A Parking brake cable 3 Throttle cable B Crankcase breather hose 4 Brake light switch lead C Gear position switch 5 Radiator fan motor breather hose D Reverse switch lead 6 Starter cable E Front brake hoses...
  • Page 421 SPEC CABLE ROUTING È 30 ~ 60 mm (1.18 ~ 2.36 in) Í Fasten the throttle cable to the air duct assembly É 160 ~ 190 mm (6.30 ~ 7.48 in) 1 with the plastic band. Ê Fasten the wire harness to the frame with the Î...
  • Page 422 SPEC CABLE ROUTING 1 Float chamber breather hose È Fasten the parking brake switch lead and park- 2 Throttle cable ing brake cable to the air duct assembly 1 with 3 Parking brake cable the plastic band. 4 Thermo switch 1 É...
  • Page 423 SPEC CABLE ROUTING Ì Fasten the parking brake cable and float cham- Ñ Fasten the starter motor lead, reverse switch ber breather hose with the plastic clip. lead, gear position switch lead, thermo switch 1 Í Fasten the wire harness with the plastic band. lead, carburetor heater lead, and parking brake Face the end of the plastic band down.
  • Page 424 SPEC CABLE ROUTING 1 Main switch 0 Differential gear case breather J Rear brake pipe 2 Starter (choke) knob K Radiator outlet pipe hose 3 Starter (choke) cable A Thermo switch 3 L Gear motor lead 4 Rectifier/regulator B Gear motor couplers M Brake light switch lead 5 Wire harness C Coolant reservoir hose...
  • Page 425 SPEC CABLE ROUTING È Fasten the wire harness with Í Fasten the radiator outlet hose Ð Fasten wire harness, the plastic band. and coolant reservoir hose with starter motor lead, and ground É Fasten the wire harness, radia- the plastic clip. lead to the frame with the plas- Î...
  • Page 426 SPEC CABLE ROUTING Ò 70 ~ 90 mm (2.76 ~ 3.54 in) × Fasten wire harness, Ó Fasten the throttle cable with starter (choke) cable, starter the plastic band. motor lead, and ground lead Ô Fasten the radiator inlet pipe with the plastic band.
  • Page 427 SPEC CABLE ROUTING 1 Ignition coil lead B Ignition coil 2 Spark plug lead C Rear brake pipe 3 Final gear case breather hose D Wire harness 4 Vacuum hose E Fuel tank breather hose 5 Fuel hoses F Rollover valve 6 Air vent hoses G Fuel return hose 7 Starter (choke) cable...
  • Page 428 SPEC CABLE ROUTING È Fasten the spark plug lead with the plastic Í Fasten the A.C. magneto leads, reverse switch holder. lead, gear position switch lead, thermo switch 1 É 20 ~ 30 mm (0.79 ~ 1.18 in) lead, carburetor heater lead, and parking brake Ê...
  • Page 429 SPEC CABLE ROUTING Ò Fasten the wire harness, ignition coil lead, and Ø Fasten the rear brake hose with the plastic rear brake hose with the plastic band. bands. Ó Fasten the final gear case breather hose and Ù Less than 1 mm (0.04 in) Ú...
  • Page 430 SPEC CABLE ROUTING 1 Throttle cable È Pass the throttle cable through the cable guide. 2 Rear brake pipe É Fasten the speed sensor lead, starter (choke) 3 A.C. magneto couplers cable, starter motor lead, and ground lead with 4 Starter (choke) cable the plastic band.
  • Page 431 SPEC CABLE ROUTING Í Fasten the fuel hose and vacuum hose with the Ò Make sure that the plastic band is not fastened plastic clip. too tightly around the wire harness. Î Make sure that the spark plug lead does not Ó...
  • Page 432 SPEC CABLE ROUTING 1 Battery 0 Light switch 2 Negative battery lead A Differential gear case breather hose 3 Rectifier/regulator B Radiator fan motor breather hose 4 Starter (choke) cable C Left headlight lead 5 Indicator light assembly couplers D Throttle cable 6 On-Command four-wheel drive switch and differ- E Right headlight lead F Starter motor lead...
  • Page 433 SPEC CABLE ROUTING K Four-wheel drive relay 3 V C.D.I. unit L Differential gear lock indicator light relay M Four-wheel drive indicator light relay È Fasten the wire harness with the plastic bands. N Fuse box É Pass the radiator fan motor breather hose, dif- O Positive battery lead ferential gear case breather hose, coolant reser- P Neutral indicator light...
  • Page 434 SPEC CABLE ROUTING Ë Pass the radiator fan motor breather hose and Ð Fasten the positive battery lead with the plastic differential gear case breather hose through the holder. Ñ 59 ~ 61 mm (2.32 ~ 2.40 in) guide. Ì Fasten the throttle cable with the plastic holder. Ò...
  • Page 435 SPEC CABLE ROUTING 1 Auxiliary DC jack B Starter relay lead 2 Auxiliary DC jack lead 3 Coolant reservoir breather hose È Fasten the coolant reservoir breather hose with 4 Throttle cable the plastic band. 5 Radiator fan motor breather hose É...

  • Page 436: Periodic Checks And Adjustments

    INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 437 Fittings and fasten- • Check all chassis fittings and fasteners. ers* • Correct if necessary. * Since these items require special tools, data and technical skills have a Yamaha dealer perform the ser- vice. NOTE: • Recommended brake fluid: DOT 4 •...

  • Page 438: Engine

    CLEANING THE AIR FILTER ELEMENTS ENGINE CLEANING THE AIR FILTER ELEMENTS Cleaning the intake duct air filter element 1. Remove: • air intake duct grill 1 2. Remove: • air filter element 1 (from the air intake duct grill 2) 3.
  • Page 439 CLEANING THE AIR FILTER ELEMENTS 1. Remove: • driver seat • passenger seat • console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED”. 2. Remove: • air filter case cover 1 3. Remove: • air filter element assembly 1 • air filter element cap 2 •...
  • Page 440 CAUTION: Do not twist or wring out the element. This could damage the foam material. c. Apply Yamaha foam air filter oil or other quality foam air filter oil (not spray type). d. Squeeze out the excess oil. NOTE: The element should be wet but not dripping.

  • Page 441: Chassis

    ADJUSTING THE PARKING BRAKE CHASSIS ADJUSTING THE PARKING BRAKE 1. Shift the drive select lever into low gear “L”. 2. Remove: • driver seat • passenger seat • console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED”. 3. Check: • parking brake lever free play a The maximum free play is equal to one click of the parking brake lever.

  • Page 442: Engine

    ENGINE REMOVAL ENGINE ENGINE REMOVAL AIR DUCTS, MUFFLER AND EXHAUST PIPE 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 443 ENGINE REMOVAL 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 20 Nm (2.0 m kg, 14 ft • • 14 Nm (1.4 m kg, 10 ft •...

  • Page 444: Fuel System

    FUEL CARBURETOR FUEL SYSTEM CARBURETOR Order Job/Part Q’ty Remarks Removing the carburetor Remove the parts in the order listed. Driver seat/passenger seat/air intake Refer to “SEATS, ENCLOSURE, HOOD duct/console AND CARGO BED”. Crankcase breather hose Disconnect. Air filter case joint Air filter case Carburetor joint (air filter case) Vacuum chamber breather hose...
  • Page 445 FUEL CARBURETOR Order Job/Part Q’ty Remarks Throttle cable end Throttle cable Carburetor joint (intake manifold) For installation, reverse the removal pro- cedure. – 29 –...

  • Page 446: Installing The Air Filter Case Joint

    FUEL CARBURETOR INSTALLING THE AIR FILTER CASE JOINT 1. Install: • air filter case joint NOTE: Align the tab a on the air filter case joint with the slot b in the air filter case. – 30 –...

  • Page 447: Chassis

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED CHASSIS SEATS, ENCLOSURE, HOOD AND CARGO BED SEATS, CONSOLE AND INSTRUMENT PANELS 7 Nm (0.7 m kg, 5.1 ft • • (16) 35 Nm (3.5 m kg, 25 ft • • Order Job/Part Q’ty Remarks Removing the seats, console and...
  • Page 448 CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED 7 Nm (0.7 m kg, 5.1 ft • • (16) 35 Nm (3.5 m kg, 25 ft • • Order Job/Part Q’ty Remarks Auxiliary DC jack connector Disconnect. Nut/starter cable Upper instrument panel Hinge Glove box lid Lower instrument panel...

  • Page 449: Panels And Footrest Cover

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED PANELS AND FOOTREST COVER 16 Nm (1.6 m kg, 11 ft • • (12) 32 Nm (3.2 m kg, 23 ft • • Order Job/Part Q’ty Remarks Removing the panels and footrest Remove the parts in the order listed. cover Left side panel Right side panel...

  • Page 450: Cargo Bed

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED CARGO BED 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 451: Enclosure And Seat Belts

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED ENCLOSURE AND SEAT BELTS 64 Nm (6.4 m kg, 46 ft • • 64 Nm (6.4 m kg, 46 ft • • 64 Nm (6.4 m kg, 46 ft • • 59 Nm (5.9 m kg, 43 ft •...

  • Page 452: Yxr660Fat Wiring Diagram

    YXR660FAT WIRING DIAGRAM 1 A.C. magneto j Lighting system fuse 2 Rectifier/regulator k Auxiliary DC jack fuse 3 Main switch l Circuit breaker (radiator Br/B B B G/W R/W L/W W L/Y G/W W/B 4 Backup fuse fan motor) 5 Carburetor heater fuse m Light switch (BLACK) (BLACK)
  • Page 453 EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section.
  • Page 454 EBS00006 SYMBOLS The following symbols are not relevant to SPEC INFO every vehicle. Symbols 1 to 0 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system FUEL COOL 6 Fuel system 7 Drive train 8 Chassis...
  • Page 455 CONTENTS SPECIFICATIONS ....................1 GENERAL SPECIFICATIONS ..............1 CHASSIS SPECIFICATIONS............... 2 ELECTRICAL SPECIFICATIONS ..............3 TIGHTENING TORQUES................3 CHASSIS TIGHTENING TORQUES ............. 3 CABLE ROUTING ..................4 PERIODIC CHECKS AND ADJUSTMENTS............ 21 ELECTRICAL ..................... 21 CHANGING A HEADLIGHT BULB ............21 ENGINE ......................

  • Page 456: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code 5UG9, 5UGB, 5UGF (for USA) 5UGA, 5UGC, 5UGG (for CDN) 5UGD, 5UGH (for Europe) 5UGE (for Oceania) Dimensions Overall length 2,885 mm (113.6 in) Overall width 1,385 mm (54.5 in) Overall height 1,853 mm (73.0 in) Seat height...

  • Page 457: Chassis Specifications

    GENERAL SPECIFICATIONS/ SPEC CHASSIS SPECIFICATIONS Item Standard Bulb wattage × quantity 12 V 30 W/30 W × 2 Headlight 12 V 5 W/21 W × 2 Tail/brake light Indicator lights Except for special edition models 12 V 1.7 W × 1 Neutral indicator light 12 V 1.7 W ×...

  • Page 458: Electrical Specifications

    ELECTRICAL SPECIFICATIONS/ SPEC TIGHTENING TORQUES ELECTRICAL SPECIFICATIONS Item Standard Limit Headlight relay Model/manufacturer G8HN-1C4T-DJ-Y52/OMRON ---- 94.5 ~ 115.5 Ω at 20°C (68 °F) Coil resistance ---- TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks Nm m ·...

  • Page 459: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Left headlight lead A Parking brake switch lead 2 Wire harness B Parking brake cable 3 Throttle cable C Crankcase breather hose 4 Brake light switch lead D Gear position switch 5 Radiator fan motor breather hose E Reverse switch lead 6 Rectifier/regulator F Front brake hoses...
  • Page 460 SPEC CABLE ROUTING È 30 ~ 60 mm (1.18 ~ 2.36 in) Í Fasten the throttle cable to the air duct assembly É 160 ~ 190 mm (6.30 ~ 7.48 in) 1 with a plastic band. Ê Fasten the wire harness to the frame with the Î...
  • Page 461 SPEC CABLE ROUTING 1 Float chamber breather hose È Fasten the parking brake switch lead and park- 2 Throttle cable ing brake cable to the air duct assembly 1 with a 3 Parking brake cable plastic band. 4 Thermo switch 1 É...
  • Page 462 SPEC CABLE ROUTING Í 20 ~ 40° Ò Fasten the tail/brake light lead with the plastic Î Fasten the starter motor lead, reverse switch bands. Ó Fasten the wire harness with the plastic bands. lead, gear position switch lead, thermo switch 1 lead, carburetor heater lead, and parking brake switch lead with a plastic band.
  • Page 463 SPEC CABLE ROUTING 1 Main switch 9 Differential gear case breather I Rear brake pipe 2 Starter (choke) knob J Radiator outlet pipe hose 3 Starter (choke) cable 0 Thermo switch 3 K Gear motor lead 4 Wire harness A Gear motor couplers L Brake light switch lead 5 Coolant reservoir breather B Coolant reservoir hose...
  • Page 464 SPEC CABLE ROUTING È Fasten the wire harness with Í Fasten the radiator outlet hose Ð Fasten wire harness, the plastic bands. and coolant reservoir hose with starter motor lead, and ground É Fasten the wire harness, radia- the plastic clip. lead to the frame with a plastic Î...
  • Page 465 SPEC CABLE ROUTING Ò 70 ~ 90 mm (2.76 ~ 3.54 in) × Fasten wire harness, Ó Fasten the throttle cable with a starter (choke) cable, starter plastic band. motor lead, and ground lead Ô Fasten the radiator inlet pipe with the plastic bands.
  • Page 466 SPEC CABLE ROUTING 1 Ignition coil lead B Ignition coil 2 Spark plug lead C Rear brake pipe 3 Final gear case breather hose D Wire harness 4 Vacuum hose E Fuel tank breather hose 5 Fuel hoses F Rollover valve 6 Air vent hoses G Fuel return hose 7 Starter (choke) cable...
  • Page 467 SPEC CABLE ROUTING È Fasten the spark plug lead with the plastic Í Fasten the A.C. magneto leads, reverse switch holder. lead, gear position switch lead, thermo switch 1 É 20 ~ 30 mm (0.79 ~ 1.18 in) lead, carburetor heater lead, and parking brake Ê...
  • Page 468 SPEC CABLE ROUTING Ó Fasten the parking brake cable with the metal Ù Fasten the rear brake hose with the plastic holder. bands. Ô Fasten the wire harness and rear brake hose Ú Less than 1 mm (0.04 in) Û Fasten the rear brake pipe and wire harness with a plastic band.
  • Page 469 SPEC CABLE ROUTING 1 Throttle cable È Pass the throttle cable through the cable guide. 2 Rear brake pipe É Fasten the speed sensor lead, starter (choke) 3 A.C. magneto couplers cable, starter motor lead, and ground lead with a 4 Starter (choke) cable plastic band.
  • Page 470 SPEC CABLE ROUTING Í Fasten the fuel hose and vacuum hose with the Ó Pass the spark plug lead through the cutout in plastic clip. the protective cover as shown. Î Make sure that the spark plug lead does not Ô...
  • Page 471 SPEC CABLE ROUTING 1 Battery 8 Main switch 2 Negative battery lead 9 Starter (choke) knob 3 Starter (choke) cable 0 Light switch 4 Meter assembly couplers (for special edition A Rectifier/regulator B Differential gear case breather hose models) 5 Indicator light assembly couplers (except for C Radiator fan motor breather hose D Left headlight lead special edition models)
  • Page 472 SPEC CABLE ROUTING I Four-wheel drive relay 1 R Neutral indicator light (except for special edition J Four-wheel drive relay 2 models) K Starter relay S Reverse indicator light (except for special edition L Four-wheel drive relay 3 models) M Four-wheel drive indicator light relay (except for T Parking brake indicator light (except for special special edition models) edition models)
  • Page 473 SPEC CABLE ROUTING W Coolant temperature indicator light (except for Ê Pass the radiator fan motor breather hose, dif- special edition models) ferential gear case breather hose, coolant reser- X C.D.I. unit voir breather hose, and brake light switch lead through the guide.
  • Page 474 SPEC CABLE ROUTING Í Fasten the throttle cable with the plastic holder. Ò 59 ~ 61 mm (2.32 ~ 2.40 in) Î Fasten the left headlight lead, differential gear Ó 4 mm (0.16 in) of clearance or more is required case breather hose, and radiator fan motor around the boot.
  • Page 475 SPEC CABLE ROUTING 1 Auxiliary DC jack 9 Wire harness Ê Fasten the wire harness and 2 Auxiliary DC jack lead 0 Front brake hoses ground lead with a plastic 3 Coolant A Coolant reservoir hose reservoir breather band. B Ground lead Ë...

  • Page 476: Periodic Checks And Adjustments

    CHANGING A HEADLIGHT BULB PERIODIC CHECKS AND ADJUSTMENTS ELECTRICAL CHANGING A HEADLIGHT BULB 1. Lift the hood up. 2. Remove: • headlight bulb holder cover 1 3. Disconnect: • headlight coupler 1 4. Remove: • headlight bulb holder assembly 1 NOTE: The headlight bulb cannot be removed from the headlight bulb holder.
  • Page 477 CHANGING A HEADLIGHT BULB 6. Connect: • headlight coupler 7. Install: • headlight bulb holder cover 8. Close the hood. – 22 –...

  • Page 478: Engine

    ENGINE COOLING FAN AND A.C. MAGNETO ENGINE ENGINE COOLING FAN AND A.C. MAGNETO Order Job/Part Q’ty Remarks Removing the engine cooling fan Remove the parts in the order listed. and A.C. magneto Driver seat/passenger seat/console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED”.
  • Page 479 ENGINE COOLING FAN AND A.C. MAGNETO Order Job/Part Q’ty Remarks Water pump assembly Refer to “WATER PUMP” in chapter 5. (Manual No.: 5UG-F8197-10) Engine cooling fan air duct assembly Air shroud 1 Engine cooling fan Air shroud 2 A.C. magneto coupler Disconnect.
  • Page 480 ENGINE COOLING FAN AND A.C. MAGNETO Order Job/Part Q’ty Remarks A.C. magneto rotor Refer to “REMOVING THE A.C. MAG- NETO” and “INSTALLING THE A.C. Woodruff key MAGNETO” in chapter 4. Starter wheel gear (Manual No.: 5UG-F8197-10) Washer Starter idle gear shaft Bearing Starter idle gear For installation, reverse the removal pro-...

  • Page 481: Cooling System

    COOL OIL COOLER COOLING SYSTEM OIL COOLER 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the oil cooler Remove the parts in the order listed. Driver seat/passenger seat/console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED”.
  • Page 482 COOL OIL COOLER 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Oil outlet hose Oil inlet hose Oil cooler inlet pipe 2/oil cooler outlet pipe 2 For installation, reverse the removal pro- cedure.

  • Page 483: Chassis

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED CHASSIS SEATS, ENCLOSURE, HOOD AND CARGO BED FRONT GUARD AND HOOD 32 Nm (3.2 m kg, 23 ft • • 59 Nm (5.9 m kg, 43 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 484: Panels And Footrest Cover

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED PANELS AND FOOTREST COVER 16 Nm (1.6 m kg, 11 ft • • (12) 32 Nm (3.2 m kg, 23 ft • • Order Job/Part Q’ty Remarks Removing the panels and footrest Remove the parts in the order listed. cover Left side panel Right side panel...

  • Page 485: Cargo Bed

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED CARGO BED 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 16 Nm (1.6 m kg, 11 ft • • Order Job/Part Q’ty Remarks Removing the cargo bed Remove the parts in the order listed.
  • Page 486 CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 487: Skid Plates

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED SKID PLATES 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the engine skid plates Remove the parts in the order listed. Front skid plate Rear skid plate For installation, reverse the removal pro- cedure.

  • Page 488: Installing The Rear Skid Plate

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED INSTALLING THE REAR SKID PLATE Ê 1. Install: • rear skid plate 1 NOTE: Make sure that the hole a in the rear skid È plate 1 is towards the left side of the vehicle. È...

  • Page 489: Enclosure And Seat Belts

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED ENCLOSURE AND SEAT BELTS 64 Nm (6.4 m kg, 46 ft • • 64 Nm (6.4 m kg, 46 ft • • 64 Nm (6.4 m kg, 46 ft • • 59 Nm (5.9 m kg, 43 ft •...

  • Page 490: Front Wheels And Brake Discs

    CHAS FRONT WHEELS AND BRAKE DISCS FRONT WHEELS AND BRAKE DISCS 350 Nm (35.0 m kg, 255 ft • • 30 Nm (3.0 m kg, 22 ft • • 48 Nm (4.8 m kg, 35 ft • • 55 Nm (5.5 m kg, 40 ft •...
  • Page 491 CHAS FRONT WHEELS AND BRAKE DISCS 350 Nm (35.0 m kg, 255 ft • • 30 Nm (3.0 m kg, 22 ft • • 48 Nm (4.8 m kg, 35 ft • • 55 Nm (5.5 m kg, 40 ft •...

  • Page 492: Rear Wheels And Brake Disc

    CHAS REAR WHEELS AND BRAKE DISC REAR WHEELS AND BRAKE DISC REAR WHEELS 350 Nm (35.0 m kg, 255 ft • • 55 Nm (5.5 m kg, 40 ft • • Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed. Place the vehicle on a level surface.

  • Page 493: Front Arms And Front Shock Absorbers

    CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS FRONT ARMS AND FRONT SHOCK ABSORBERS 45 Nm (4.5 m kg, 32 ft • • 45 Nm (4.5 m kg, 32 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 494 CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS 45 Nm (4.5 m kg, 32 ft • • 45 Nm (4.5 m kg, 32 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 495: Rear Knuckle And Stabilizer

    CHAS REAR KNUCKLE AND STABILIZER REAR KNUCKLE AND STABILIZER 32 Nm (3.2m kg, 23 ft • • 56 Nm (5.6 m kg, 40 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 56 Nm (5.6 m kg, 40 ft •...

  • Page 496: Electrical

    – ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Diode 1 7 Ignition coil D Gear motor 2 Thermo switch 2 8 Gear position switch E Radiator fan 3 Diode 2 9 Reverse switch F Thermo switch 3 4 Circuit breaker 0 Brake light switch A Parking brake switch (radiator fan motor)
  • Page 497 – ELEC ELECTRICAL COMPONENTS 1 Rectifier/regulator 6 Main switch E Differential gear lock indicator 2 Auxiliary DC jack 7 Light switch light relay (except for special 3 Indicator light assembly 1 8 Four-wheel drive relay 1 edition models) 9 Four-wheel drive relay 2 F Fuse box (except for special edition mod- 0 Starter relay...

  • Page 498: Lighting System

    – ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM – 43 –...

  • Page 499: Troubleshooting

    – ELEC LIGHTING SYSTEM EB805010 TROUBLESHOOTING IF THE HEADLIGHTS AND/OR TAILLIGHT FAIL TO COME ON: Procedure Check: 1. Fuses (main, lighting system) 5. Headlight relay 2. Battery 6. Wiring connections 3. Main switch (the entire lighting system) 4. Light switch NOTE: Pocket tester •...
  • Page 500 – ELEC LIGHTING SYSTEM 4. Light switch INCORRECT Refer to “CHECKING THE SWITCH” in chap- ter 9. (Manual No.: 5UG-F8197-10) CORRECT Replace the light switch. 5. Headlight relay • Remove the headlight relay from the wire harness. • Connect the pocket tester (Ω × 1) and the battery (12 V) to the headlight relay termi- nals.

  • Page 501: Signaling System (For Special Edition Models)

    – ELEC SIGNALING SYSTEM (for special edition models) EB806000 SIGNALING SYSTEM (for special edition models) CIRCUIT DIAGRAM – 46 –...
  • Page 502 – ELEC SIGNALING SYSTEM (for special edition models) 3 Main switch 4 Backup fuse 6 Battery 7 Main fuse 0 Brake light switch B Reverse switch C C.D.I. unit H Multi-function meter I Differential gear lock indicator light J Coolant temperature warning light K Reverse indicator light L Neutral indicator light M Parking brake indicator light...

  • Page 503: Checking The Signal System

    – ELEC SIGNALING SYSTEM (for special edition models) CHECKING THE SIGNALING SYSTEM With multi-function meter 1. If the coolant temperature warning light does not come on when the main switch to “ON”, or if the coolant temperature warning light does not come on when the temperature is high (more than 117 ~ 123 °C (242.6 ~ 253.4 °F)): 1.
  • Page 504 – ELEC SIGNALING SYSTEM (for special edition models) 2. Diode 2 • Remove the diode from the coupler. • Connect the pocket tester (Ω × 1) to the diode terminals as shown. • Check the diode for continuity as follows. NOTE: Tester (+) lead →...
  • Page 505 YXR66FAV 2006 WIRING DIAGRAM (GRAY) (GRAY) R/W L/W W L/Y G/W W/B WIRE HARNESS IGNITION COIL LEAD (BLACK) (BLACK) (BLACK) (BLACK) B G/W W/G R R W/G W/R W/G W/L W/R WIRE HARNESS Y/L L/B (BLACK) W L/Y L/Y W B/Y L/W (BLACK) É...

  • Page 506: Yxr66Fav 2006 Wiring Diagram

    YXR66FAV 2006 WIRING DIAGRAM 1 A.C. magneto i Ignition fuse COLOR CODE 2 Rectifier/regulator j Lighting system fuse B.... Black 3 Main switch k Auxiliary DC jack fuse Br ..Brown 4 Backup fuse l Circuit breaker (radiator fan G ... Green 5 Carburetor heater fuse motor) Gy ..

This manual is also suitable for:

Rhino 2004Rhino 2005Rhino 2006Rhino 2007Yxr660fas

Table of Contents