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Yamaha Rhino 450 YXR45FAV Service Manual

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YXR45FAV
SERVICE MANUAL
LIT-11616-19-43
2P5-F8197-10

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Summary of Contents for Yamaha Rhino 450 YXR45FAV

  • Page 1 YXR45FAV SERVICE MANUAL LIT-11616-19-43 2P5-F8197-10...
  • Page 2 EBS00001 YXR45FAV SERVICE MANUAL ©2005 by Yamaha Motor Corporation, U.S.A. First Edition, August 2005 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-11616-19-43...

  • Page 3: Specifications

    EBS00002 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle repair.
  • Page 4 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 5: Periodic Checks And

    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 7 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 8: Table Of Contents

    CONTENTS CHAPTER 1 GENERAL INFORMATION VEHICLE IDENTIFICATION................1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 IMPORTANT INFORMATION ................. 1-2 PREPARATION FOR REMOVAL PROCEDURES ........1-2 REPLACEMENT PARTS................1-2 GASKETS, OIL SEALS AND O-RINGS ............ 1-2 LOCK WASHERS/PLATES AND COTTER PINS ........1-3 BEARINGS AND OIL SEALS ..............1-3 CIRCLIPS ....................1-3 CHECKING OF CONNECTIONS ..............
  • Page 9 COOLANT FLOW DIAGRAMS ..............2-26 OIL FLOW DIAGRAMS ................. 2-29 CABLE ROUTING ..................2-34 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 IDLING SPEED............3-5 ADJUSTING THE THROTTLE CABLE .............3-7 ADJUSTING THE STARTER CABLE ............3-8 CHECKING THE SPARK PLUG ...............
  • Page 10 ADJUSTING THE REAR SHOCK ABSORBERS........3-41 CHECKING THE TIRES................3-42 CHECKING THE WHEELS ..............3-44 CHECKING AND LUBRICATING THE CABLES ........3-44 LUBRICATING THE PEDALS, ETC............3-45 ELECTRICAL ....................3-46 CHECKING AND CHARGING THE BATTERY........3-46 CHECKING THE FUSES ................3-51 ADJUSTING THE HEADLIGHT BEAMS..........3-53 CHANGING THE HEADLIGHT BULBS...........3-53 CHANGING THE TAIL/BRAKE LIGHT BULBS........
  • Page 11 ENGINE COOLING FAN AND A.C. MAGNETO...........4-35 REMOVING THE A.C. MAGNETO............4-38 CHECKING THE A.C. MAGNETO ............4-38 CHECKING THE STARTER CLUTCH ............4-39 CHECKING THE ENGINE COOLING FAN..........4-40 INSTALLING THE A.C. MAGNETO ............4-40 PRIMARY AND SECONDARY SHEAVES............4-42 PRIMARY SLIDING SHEAVE ..............4-43 SECONDARY SHEAVE ................4-44 REMOVING THE PRIMARY AND SECONDARY SHEAVES ....
  • Page 12 TRANSMISSION.................... 4-70 CHECKING THE SHIFT FORKS............. 4-72 CHECKING THE SHIFT DRUM ..............4-72 CHECKING THE TRANSMISSION ............4-73 CHECKING THE SECONDARY SHAFT AND DRIVEN SPROCKET..4-73 CHECKING THE CHAIN .................4-73 INSTALLING THE TRANSMISSION ............4-74 MIDDLE GEAR ....................4-75 MIDDLE DRIVE PINION GEAR SHAFT..........4-75 MIDDLE DRIVE SHAFT ................4-76 REMOVING THE MIDDLE DRIVE PINION GEAR SHAFT.....4-78 REMOVING THE MIDDLE DRIVE SHAFT ..........
  • Page 13 CHAPTER 7 DRIVE TRAIN TROUBLESHOOTING..................7-1 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND FRONT DRIVE SHAFT................... 7-4 DISASSEMBLING THE UNIVERSAL JOINT ..........7-9 DISASSEMBLING THE DIFFERENTIAL GEAR ........7-9 CHECKING THE CONSTANT VELOCITY JOINTS ........7-10 CHECKING THE DIFFERENTIAL GEAR..........7-10 CHECKING THE GEAR MOTOR............7-11 ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS ....
  • Page 14 FRONT WHEELS AND BRAKE DISCS............8-10 CHECKING THE FRONT WHEELS............8-12 CHECKING THE FRONT WHEEL HUBS ..........8-12 CHECKING THE FRONT BRAKE DISCS..........8-13 INSTALLING THE FRONT WHEEL HUBS ..........8-13 INSTALLING THE FRONT WHEELS............8-13 REAR WHEELS AND BRAKE DISC ............8-14 REAR WHEELS ..................8-14 REAR BRAKE DISC................
  • Page 15 FRONT ARMS AND FRONT SHOCK ABSORBERS ........8-56 REMOVING THE FRONT ARMS ............8-58 CHECKING THE FRONT ARMS............. 8-58 CHECKING THE FRONT SHOCK ABSORBERS........8-60 INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBERS ..................8-61 REAR KNUCKLES AND STABILIZER ............8-62 CHECKING THE REAR KNUCKLES ............8-63 CHECKING THE STABILIZER..............8-63 INSTALLING THE STABILIZER..............8-64...
  • Page 16 LIGHTING SYSTEM ..................9-27 CIRCUIT DIAGRAM ................9-27 TROUBLESHOOTING ................9-28 CHECKING THE LIGHTING SYSTEM............9-30 SIGNALING SYSTEM ...................9-33 CIRCUIT DIAGRAM ................9-33 TROUBLESHOOTING ................9-35 CHECKING THE SIGNAL SYSTEM ............9-37 COOLING SYSTEM..................9-47 CIRCUIT DIAGRAM ................9-47 TROUBLESHOOTING ................9-48 2WD/4WD SELECTING SYSTEM..............9-52 CIRCUIT DIAGRAM ................9-52 TROUBLESHOOTING ................9-53 CARBURETOR HEATING SYSTEM.............
  • Page 17 FAULTY CLUTCH PERFORMANCE ............10-4 ENGINE OPERATES BUT VEHICLE WILL NOT MOVE ......10-4 CLUTCH SLIPPING ................10-4 POOR STARTING PERFORMANCE............10-4 POOR SPEED PERFORMANCE............10-5 OVERHEATING..................... 10-5 OVERHEATING ..................10-5 FAULTY BRAKE ................... 10-5 POOR BRAKING EFFECT..............10-5 SHOCK ABSORBER MALFUNCTION ............10-5 MALFUNCTION..................

  • Page 18: 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 19: 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 20: 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 21: 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 22: 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 23 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Piston pin puller 90890-01304 YU-01304 This tool is used to remove the piston pin. Tappet adjusting tool Valve adjuster 3 mm & 4 mm 90890-01311 YM-08035-A This tool is necessary for adjusting the valve clearance.
  • Page 24 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 25 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Valve spring compressor 90890-04019 YM-04019 This tool is needed to remove and install the valve assemblies. Middle driven shaft Middle driven shaft bearing driver bearing driver Mechanical seal installer 90890-04058 YM-04058 Mechanical seal installer These tools are used to install the water 90890-04078...
  • Page 26 This instrument is necessary for checking the ignition system components. Digital tachometer 90890-06760 YU-39951-B This instrument is needed for observing engine rpm. Yamaha bond No. 1215 ® (Three Bond No.1215 90890-85505 This bond is used on crankcase mating surfaces, etc. Ball joint remover/installer attachment set...

  • Page 27: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code 2P51 (for USA) 2P52 (for CDN) 2P53 (for Europe) 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)
  • Page 28 SPEC GENERAL SPECIFICATIONS Item Standard Oil type or grade Engine oil For USA and CDN API service SE, SF, SG type or higher 0° 10° 30° 50° 70° 90° 110° 130°F YAMALUBE 4 (20W40) or SAE 20W40 YAMALUBE 4 (10W30) or SAE 10W30 SAE 5W30 -20°...
  • Page 29 SPEC GENERAL SPECIFICATIONS Item Standard Spark plug Type/manufacturer DR8EA/NGK Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) Clutch type Wet, centrifugal automatic Transmission Primary reduction system V-belt Secondary reduction system Shaft drive 43/20 × 24/17 × 33/9 (11.129) Secondary reduction ratio Transmission type V-belt automatic...
  • Page 30 SPEC GENERAL SPECIFICATIONS Item Standard Suspension Front suspension Double wishbone Rear suspension Double wishbone Shock absorber Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/oil damper Wheel travel Front wheel travel 185 mm (7.28 in) Rear wheel travel 185 mm (7.28 in) Electrical Ignition system...

  • Page 31: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Cylinder head Warp limit ---- 0.03 mm (0.0012 in) Cylinder Bore size 84.500 ~ 84.510 mm ---- (3.3268 ~ 3.3272 in) Out-of-round limit ---- 0.01 mm (0.0004 in) Taper limit ---- 0.05 mm (0.0020 in) Camshaft Drive method...
  • Page 32 SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links DID SCR-0409 SV/116 ---- Timing chain adjustment method Automatic ---- Rocker arm/rocker arm shaft Rocker arm inside diameter 12.000 ~ 12.018 mm 12.078 mm (0.4724 ~ 0.4731 in) (0.4755 in) Shaft outside diameter 11.981 ~ 11.991 mm 11.951 mm...
  • Page 33 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) 0.030 ~ 0.057 mm 0.10 mm (0.0012 ~ 0.0022 in) (0.0039 in) Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 1.2 ~ 1.4 mm 1.6 mm...
  • Page 34 SPEC ENGINE SPECIFICATIONS Item Standard Limit Outer spring Free length 43.27 mm (1.70 in) 41.1 mm (1.62 in) 43.27 mm (1.70 in) 41.1 mm (1.62 in) Set length (valve closed) IN 36.6 mm (1.44 in) ---- 36.6 mm (1.44 in) ---- Compressed pressure (installed)
  • Page 35 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston rings Top ring Type Barrel ---- Dimensions (B × T) 1.0 × 3.1 mm ---- (0.0394 × 0.1220 in) End gap (installed) 0.20 ~ 0.40 mm 0.65 mm (0.0079 ~ 0.0157 in) (0.0256 in) Side clearance (installed) 0.03 ~ 0.07 mm 0.12 mm...
  • Page 36 ---- 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 2P51 00 ---- Main jet (M.J)

  • Page 37: Cooling System

    SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil pump Oil filter type Foam ---- Oil pump type Trochoid ---- Inner-rotor-to-outer-rotor-tip clear- Less than 0.15 mm (0.0059 in) 0.23 mm ance (0.0091 in) Outer-rotor-to-oil-pump-housing 0.010 ~ 0.034 mm 0.104 mm clearance (0.0004 ~ 0.0013 in) (0.0041 in) Oil-pump-housing-to-inner-rotor-and- 0.04 ~ 0.09 mm...
  • Page 38 SPEC ENGINE SPECIFICATIONS Lubrication chart Pressure feed Splashed scavenge Camshaft Rocker arm Valve Crank pin Oil filter Piston Piston pin Transmission Bypass valve Oil cooler Clutch Timing chain area Oil pump Oil strainer Cylinder head tightening sequence 2 - 12...

  • Page 39: 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 40 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front disc brake Type Dual ---- Disc outside diameter × thickness 200.0 × 3.5 mm (7.87 × 0.14 in) 3.0 mm (0.12 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)

  • Page 41: Electrical Specifications

    Rotor rotation direction detection coil ---- resistance/color Red – White/Blue C.D.I. unit model/manufacturer F8T40378/MITSUBISHI ---- Ignition coil Model/manufacturer 2JN/YAMAHA ---- Minimum spark gap 6.0 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 42 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 43 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Four-wheel drive relay 3 Model/manufacturer ACA12115-1/MATSUSHITA ---- 72 ~ 88 Ω at 20 °C (68 °F) Coil resistance ---- Thermo switch Thermo switch 1 Model/manufacturer 4BA/DENSO (for USA) ---- 5KM/DENSO (for CDN and Europe) ---- Thermo switch 2 Model/manufacturer...

  • Page 44: 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 Oil gallery bolt — Cylinder head (exhaust pipe) Stud bolt Cylinder head Bolt Bolt Camshaft sprocket cover baffle plate...
  • Page 45 SPEC TIGHTENING TORQUES Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Oil cooler inlet pipe 2/oil cooler outlet Bolt pipe 2 holder Oil cooler Bolt Intake manifold Bolt Bearing cover (crankshaft) Screw Oil seal retainer (A.C.
  • Page 46 SPEC TIGHTENING TORQUES Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Shift drum stopper Bolt Shift arm Bolt Shift lever cover Bolt Low-range switch — High-range switch — Neutral switch —...

  • Page 47: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES EBS01006 CHASSIS TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks Nm m · kg ft · lb Engine bracket nut Engine mounting bolt (front) Engine mounting bolt (rear) Rear upper arm and frame Rear lower arm and frame Rear knuckle and rear upper arm Rear knuckle and rear lower arm Rear shock absorber and frame...
  • Page 48 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 end locknut Rack gear-pinion gear backlash adjuster — 0.39 Steering knuckle and tie-rod end Front arm protector and front lower arm Seat belt and frame Seat belt and side frame (enclosure)
  • Page 49 SPEC TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks Nm m · kg ft · lb Cargo bed release lever and cargo bed Gas spring assembly and gas spring assembly bracket Gas spring assembly and frame Gas spring assembly bracket and cargo bed assembly Front guard protector and front guard Front guard and frame...

  • Page 50: Lubrication Points And Lubricant Types

    Damper cam Gear coupling Shift drum Shift fork guide bar Shift drum stopper ball Shift lever 1 Shift lever 2 assembly Yamaha Bond No.1215 Crankcase mating surfaces ® (Three Bond No.1215 Yamaha Bond No.1215 A.C. magneto lead grommet ® (Three Bond No.1215...

  • Page 51: 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 52: 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 - 26...
  • Page 53 SPEC COOLANT FLOW DIAGRAMS 1 Coolant outlet hose 2 Water pump outlet hose 3 Water pump outlet pipe 4 Radiator outlet pipe 5 Water pump inlet hose 6 Radiator inlet pipe 2 - 27...
  • Page 54 SPEC COOLANT FLOW DIAGRAMS 1 Coolant outlet hose 2 Radiator inlet pipe 3 Radiator inlet hose 2 - 28...

  • Page 55: Oil Flow Diagrams

    SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 Camshaft 2 Crankshaft 3 Drive axle 4 Middle drive pinion gear shaft 2 - 29...
  • Page 56 SPEC OIL FLOW DIAGRAMS 1 Oil filter cartridge 2 Oil pipe adapter 3 Oil delivery pipe 2 - 30...
  • Page 57 SPEC OIL FLOW DIAGRAMS 1 Oil delivery pipe 2 Oil pump 3 Oil strainer 2 - 31...
  • Page 58 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 - 32...
  • Page 59 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 - 33...

  • Page 60: 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 Rear brake pipe 4 Brake light switch lead C Radiator inlet hose 5 Rectifier/regulator D Front brake hoses 6 Starter cable E Radiator fan motor breather hose 7 Starter (choke) knob...
  • Page 61 SPEC CABLE ROUTING È 30 ~ 60 mm (1.18 ~ 2.36 in) Í Fasten the throttle cable with the metal holder. É 160 ~ 190 mm (6.30 ~ 7.48 in) Î Fasten the throttle cable to the radiator inlet Ê Fasten the wire harness to the frame with the hose with the plastic bands.
  • Page 62 SPEC CABLE ROUTING È Fasten the parking brake cable with the metal 1 Parking brake cable 2 Spark plug lead holder. É Fasten the spark plug lead to the air duct 3 Coolant outlet hose 4 Wire harness assembly 1 with a plastic band. Ê...
  • Page 63 SPEC CABLE ROUTING Í Fasten the wire harness with the plastic holders. Ò Fasten the wire harness with the plastic bands. Î Push the excess tail/brake light lead into the rear fender so that there is no slack in the lead (left and right).
  • Page 64 SPEC CABLE ROUTING 1 Main switch 0 Radiator fan motor coupler J Parking brake switch lead 2 Starter (choke) knob A Thermo switch 3 K Reverse switch 3 Auxiliary DC jack B Differential gear case breather L Neutral switch 4 Starter (choke) cable M High-range switch hose 5 Auxiliary DC jack lead...
  • Page 65 SPEC CABLE ROUTING T Brake light switch lead É Fasten the wire harness, radia- Î Fasten wire harness, U Indicator light assembly leads tor fan motor lead, and thermo starter motor lead, ground lead, V On-command four-wheel drive switch 3 lead to the frame with and starter (choke) cable to the switch and differential gear lock a plastic band.
  • Page 66 SPEC CABLE ROUTING Ð Fasten the wire harness, speed Ò Fasten the thermo switch 1 Õ Fasten the sub-wire harness sensor lead, starter motor lead, lead, carburetor heater leads, with the metal holder. Ö Fasten and ground lead with a plastic starter motor lead, parking A.C.
  • Page 67 SPEC CABLE ROUTING Ø Fasten the radiator inlet pipe Ü Fasten the wire harness, brake with a plastic band. light switch lead, and starter Ù Fasten the rear brake pipe with (choke) cable with a plastic a plastic band. band. Ú...
  • Page 68 SPEC CABLE ROUTING 1 Final gear case breather hose B Rear brake pipe 2 Vacuum hose C Starter motor lead 3 Fuel hose (fuel pump to carburetor) D Fuel tank breather hose 4 Cylinder head breather hose E Rollover valve 5 Starter (choke) cable 6 Air vent hose 7 Rear brake hose...
  • Page 69 SPEC CABLE ROUTING È 20 ~ 30 mm (0.79 ~ 1.18 in) Î Fasten the wire harness with a plastic band. É Pass the final gear case breather hose through Ï Fasten the parking brake cable and wire har- the grommet. ness with the plastic clip.
  • Page 70 SPEC CABLE ROUTING Ô Fasten the fuel hose (fuel tank to fuel pump) with Ù Fasten the starter motor lead, carburetor heater the plastic holders. leads, thermo switch 1 lead, and parking brake Õ Fasten the parking brake cable and final gear switch lead with a plastic band.
  • Page 71 SPEC CABLE ROUTING È Pass the throttle cable through the cable guide. 1 Throttle cable É Fasten the speed sensor lead, starter motor 2 Rear brake pipe 3 Wire harness lead, and ground lead with a plastic band. Ê Fasten the wire harness and A.C. magneto 4 A.C.
  • Page 72 SPEC CABLE ROUTING Í Fasten the rear brake pipe with a plastic band. Î Fasten the wire harness, speed sensor lead, starter (choke) cable, starter motor lead, and ground lead with a plastic band. È É Ê Ë Î Ì Í...
  • Page 73 SPEC CABLE ROUTING 1 Battery 0 Rectifier/regulator 2 Negative battery lead A Differential gear case breather hose 3 Starter (choke) cable B Radiator fan motor breather hose 4 Indicator light assembly couplers C Left headlight lead 5 On-Command four-wheel drive switch and differ- D Throttle cable E Right headlight lead ential gear lock switch leads...
  • Page 74 SPEC CABLE ROUTING K Four-wheel drive relay 3 V Coolant temperature indicator light L Four-wheel drive indicator light relay W C.D.I. unit M Headlight relay È Fasten the wire harness with the plastic bands. N Differential gear lock indicator light relay É...
  • Page 75 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 76 SPEC CABLE ROUTING 1 Auxiliary DC jack B Starter relay lead 2 Auxiliary DC jack lead È Fasten the coolant reservoir breather hose with 3 Coolant reservoir breather hose 4 Throttle cable the plastic holders. É Fasten the front brake hose bushing with the 5 Radiator fan motor breather hose 6 Differential gear case breather hose plastic bands.

  • Page 77: Periodic Checks And Adjustments

    However, keep in mind that if the vehicle isn’t used for a long period of time, the month maintenance intervals should be followed. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

  • Page 78: Brake Fluid Replacement

    PERIODIC MAINTENANCE/LUBRICATION INITIAL EVERY month Whichever ITEM ROUTINE comes first 1,200 2,400 2,400 4,800 (mi) (200) (750) (1,500) (1,500) (3,000) hours • Check operation/brake pad wear/fluid leakage/see Rear brake* NOTE page 3-2. • Correct if necessary. Replace pads if worn to the limit. Accelerator pedal* •...

  • Page 79: 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 80 ADJUSTING THE VALVE CLEARANCE 7. Check: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake 0.06 ~ 0.10 mm (0.0024 ~ 0.0039 in) Exhaust 0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in) M MMM M MMM M MMM M MMM M MMM a.

  • Page 81: Adjusting The Idling Speed

    ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE IDLING SPEED d. Hold the adjusting screw to prevent it from moving and then tighten the locknut. Locknut 20 Nm (2.0 m · kg, 14 ft · lb) e. Measure the valve clearance. f. If the clearance is incorrect, repeat the above steps until the proper clearance is obtained.
  • Page 82 ADJUSTING THE IDLING SPEED 3. Attach: • tachometer (to the spark plug lead) Digital tachometer P/N. YU-39951-B, 90890-06760 4. Check: • engine idling speed Out of specification → Adjust. Engine idling speed 1,450 ~ 1,550 r/min 5. Adjust: • engine idling speed M MMM M MMM M MMM...

  • Page 83: Adjusting The Throttle Cable

    ADJUSTING THE THROTTLE CABLE ADJUSTING THE THROTTLE CABLE NOTE: Throttle cable free play should be adjusted properly before adjusting the engine idling speed. 1. Remove: • driver seat • passenger seat • console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. 2.

  • Page 84: Adjusting The Starter Cable

    ADJUSTING THE STARTER CABLE ADJUSTING THE STARTER CABLE 1. Remove: • driver seat • passenger seat • console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. 2. Adjust: • starter cable M MMM M MMM M MMM M MMM M MMM a.

  • Page 85: Checking The Spark Plug

    CHECKING THE SPARK PLUG CHECKING THE SPARK PLUG 1. Remove: • driver seat • passenger seat • console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. 2. Remove: • spark plug 3. Check: • spark plug type Incorrect →...

  • Page 86: 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 87: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 5. 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 88 MEASURING THE COMPRESSION PRESSURE 4. Remove: • spark plug 5. Attach: • adapter • compression gauge 1 Engine compression tester P/N. YU-33223 Compression gauge P/N. 90890-03081 Extension P/N. 90890-04082 6. Measure: • compression pressure Above the maximum pressure: Check the cylinder head, valve surfaces, and piston crown for carbon deposits.

  • Page 89: 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 7. Install: • spark plug · · 18 Nm (1.8 m kg, 13 ft 8.

  • Page 90: 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 91 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 92: Cleaning The Air Filter Elements

    CHANGING THE ENGINE OIL/ CLEANING THE AIR FILTER ELEMENTS 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 93 CLEANING THE AIR FILTER ELEMENTS 3. Clean: • air filter element 1 NOTE: Remove any large particles from the air filter element by hand, tap the air filter element to remove most of the dust and dirt, and then blow the remaining dirt out with compressed air.
  • Page 94 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 95: Checking The Coolant Level

    CLEANING THE AIR FILTER ELEMENTS/ CHECKING THE COOLANT LEVEL 6. Install: • air filter element assembly • air filter case cover NOTE: To prevent air leaks make sure that the sealing surface of the element matches the sealing surface of the case. 7.

  • Page 96: Changing The Coolant

    CHANGING THE COOLANT CHANGING THE COOLANT 1. Remove: • driver seat • passenger seat • console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. 2. Lift the hood up. 3. Remove: • coolant reservoir cap 1 4. Disconnect: •...
  • Page 97 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 98 CHANGING THE COOLANT 13.Install: • coolant drain bolt (water pump) (along with the copper washer) · · 10 Nm (1.0 m kg, 7.2 ft • coolant drain bolt (cylinder) (along with the copper washer) · · 10 Nm (1.0 m kg, 7.2 ft 14.Connect: •...
  • Page 99 CHANGING THE COOLANT Handling notes for coolant Coolant is potentially harmful and should be handled with special care. WARNING • If coolant splashes in your eyes, thor- oughly wash them with water and consult a doctor. • If coolant splashes on your clothes, quickly wash it away with water and then with soap and water.
  • Page 100 CHANGING THE COOLANT 22.Check: • coolant level Refer to “CHECKING THE COOLANT LEVEL”. NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled. 23.Close the hood. 24.Install: • console • passenger seat • driver seat Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED”...

  • Page 101: 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 warning 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 102: 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 30.7 mm (1.21 in) <Limit:> 27.6 mm (1.09 in) 4.

  • Page 103: Cleaning The Spark Arrester

    CHECKING THE V-BELT/ CLEANING THE SPARK ARRESTER 5. Install: • 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 104: 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 105: Adjusting The Parking Brake

    ADJUSTING THE PARKING BRAKE ADJUSTING THE PARKING BRAKE 1. Shift the drive select lever into low gear “L”. 2. Check: • parking brake lever free play a The maximum free play is equal to one click of the parking brake lever. If necessary, adjust the free play as follows.

  • Page 106: 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 107: 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 Refer to “FRONT WHEELS AND BRAKE DISCS” in chapter 8. 2. Check: • brake pads Wear indicator grooves 1 almost disap- peared →...

  • Page 108: 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 hose 3 Cracks/wear/damage → Replace. Fluid leakage →...
  • Page 109 BLEEDING THE HYDRAULIC BRAKE SYSTEM 1. Bleed: È • 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 110: Adjusting The Select Lever Shift Rod

    ADJUSTING THE SELECT LEVER SHIFT ROD/ ADJUSTING THE BRAKE LIGHT SWITCH ADJUSTING THE SELECT LEVER SHIFT ROD 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 111: 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 112: 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 113: 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 filler hole. Oil level low → Add oil to proper level. Recommended oil SAE 80 API “GL-4” Hypoid gear CAUTION: Take care not to allow foreign material to enter the differential gear case.

  • Page 114: 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 115: 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 shaft assembly bearings Try to move the steering wheel up and down, and back and forth. Excessive play → Replace the steering shaft assembly.
  • Page 116 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 117: Adjusting The Front Shock Absorbers

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

  • Page 118: Checking The Tires

    • TIRE CHARACTERISTICS 1) Tire characteristics influence the han- dling of the vehicles. The tires listed below have been approved by Yamaha Motor Manufacturing Corporation of America for this model. If other tire com- binations are used, they can adversely affect your vehicle’s handling character-...
  • Page 119 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 120: 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 121: Lubricating The Pedals, Etc

    LUBRICATING THE PEDALS, ETC. LUBRICATING THE PEDALS, ETC. 1. Lubricate the pivoting parts. Recommended lubricant Lithium-soap-based grease 3 - 45...

  • Page 122: 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 123 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 124 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 125 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger NOTE: Leave the battery unused for more Measure the open-circuit than 30 minutes before measuring voltage prior to charging. Charger its open-circuit voltage. Ammeter NOTE: Connect a charger and Set the charging voltage to 16 ammeter to the battery and 17 V.
  • Page 126 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger NOTE: Leave the battery unused for more than 30 minutes before Measure the open-circuit measuring its open-circuit volt- voltage prior to charging. age. Connect a charger and ammeter to the battery and start charging.

  • Page 127: 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 128 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 129: Adjusting The Headlight Beams

    ADJUSTING THE HEADLIGHT BEAMS/ CHANGING THE HEADLIGHT BULBS ADJUSTING THE HEADLIGHT BEAMS 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 BULBS 1. Lift the hood up. 2.

  • Page 130: Changing The Tail/Brake Light Bulbs

    CHANGING THE HEADLIGHT BULBS/ CHANGING THE TAIL/BRAKE LIGHT BULBS 5. Install: • headlight bulb holder assembly CAUTION: Avoid touching the glass part of the bulb. Keep it free from oil; otherwise, the trans- parency of the glass, life of the bulb, and luminous flux will be adversely affected.
  • Page 131 CHANGING THE TAIL/BRAKE LIGHT BULBS 3. Install: • bulb Secure the new bulb in the tail/brake light bulb holder. CAUTION: Avoid touching the glass part of the bulb. Keep it free from oil; otherwise, the trans- parency of the glass, life of the bulb, and luminous flux will be adversely affected.

  • Page 132: 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 • • 30 Nm (3.0 m kg, 22 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 133 ENGINE REMOVAL 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 14 Nm (1.4 m kg, 10 ft •...

  • Page 134: 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 135: Hoses And Leads

    ENGINE REMOVAL HOSES AND LEADS 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. Oil outlet hose Disconnect. Vacuum hose Disconnect.
  • Page 136 ENGINE REMOVAL Order Job/Part Q’ty Remarks Reverse switch connector Disconnect. Green/White Engine ground lead Disconnect. For installation, reverse the removal pro- cedure. 4 - 5...

  • Page 137: Engine Mounting Bolts

    ENGINE REMOVAL ENGINE MOUNTING BOLTS 56 Nm (5.6 m kg, 40 ft • • 42 Nm (4.2 m kg, 30 ft • • 33 Nm (3.3 m kg, 24 ft • • 42 Nm (4.2 m kg, 30 ft • •...
  • Page 138 ENGINE REMOVAL 56 Nm (5.6 m kg, 40 ft • • 42 Nm (4.2 m kg, 30 ft • • 33 Nm (3.3 m kg, 24 ft • • 42 Nm (4.2 m kg, 30 ft • • Order Job/Part Q’ty Remarks Engine bracket nut...

  • Page 139: Installing The Engine

    ENGINE REMOVAL INSTALLING THE ENGINE 1. Install: • engine bracket 1 • engine bracket nut 2 • engine assembly 3 • engine mounting bolt (rear) 4 • engine mounting bolt/nut (front) 5 NOTE: Do not fully tighten the bolts and nuts. 2.

  • Page 140: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. Engine assembly Refer to “ENGINE REMOVAL”. Timing plug Refer to “ADJUSTING THE VALVE CLEARANCE” in chapter 3. Spark plug Camshaft sprocket cover/O-ring Air duct assembly 2 bracket Tappet cover/O-ring Timing chain tensioner cap bolt...
  • Page 141 CYLINDER HEAD Order Job/Part Q’ty Remarks Coolant outlet joint Coolant outlet joint gasket For installation, reverse the removal pro- cedure. 4 - 10...

  • Page 142: Removing The Cylinder Head

    CYLINDER HEAD REMOVING THE CYLINDER HEAD 1. Align: • “T” 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 “T” mark 1 on the rotor with the stationary pointer 2 on the A.C.

  • Page 143: Checking The Tappet Covers

    CYLINDER HEAD 5. Remove: • cylinder head NOTE: • Loosen the 6-mm bolts first. • Working in a crisscross pattern, loosen each 10-mm bolt 1/4 of a turn. After all the bolts are loosened, remove them. CHECKING THE TAPPET COVERS 1.

  • Page 144: Checking The Cylinder Head

    CYLINDER HEAD CHECKING THE CYLINDER HEAD 1. Eliminate: • carbon deposits (from the combustion chamber) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damag- ing or scratching: • Spark plug threads • Valve seats 2. Check: •...

  • Page 145: Installing The Cylinder Head

    CYLINDER HEAD INSTALLING THE CYLINDER HEAD 1. Install: • cylinder head • cylinder head bolts (M10) 40 Nm (4.0 m · kg, 29 ft · lb) • cylinder head bolts (M6) 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: •...
  • Page 146 CYLINDER HEAD NOTE: Be sure the “I” mark 5 on the camshaft sprocket is aligned with the match mark 2 on the cylinder head. f. Force the camshaft clockwise and counter- clockwise to remove timing chain slack. g. Insert a screwdriver into the timing chain tensioner hole and push the timing chain guide inward.
  • Page 147 CYLINDER HEAD 4. Tighten: • camshaft sprocket bolt 1 60 Nm (6.0 m · kg, 43 ft · lb) 5. Check: • camshaft sprocket “I” mark • rotor “T” mark Out of alignment → Adjust. 4 - 16...

  • Page 148: Camshaft, Rocker Arms And Valves

    CAMSHAFT, ROCKER ARMS AND VALVES CAMSHAFT, ROCKER ARMS AND VALVES Order Job/Part Q’ty Remarks Removing the camshaft, rocker Remove the parts in the order listed. arms and valves Intake manifold/O-ring Thermo switch 1 Oil gallery bolt Lock washer/bearing retainer Camshaft Refer to “REMOVING THE CAMSHAFT AND ROCKER ARMS”...
  • Page 149 CAMSHAFT, ROCKER ARMS AND VALVES Order Job/Part Q’ty Remarks Inner valve spring Refer to “REMOVING THE VALVES Intake valve AND VALVE SPRINGS” and “INSTALL- Exhaust valve ING THE VALVES AND VALVE Valve stem seal SPRINGS”. Valve spring seat For installation, reverse the removal pro- cedure.

  • Page 150: Removing The Camshaft And Rocker Arms

    CAMSHAFT, ROCKER ARMS AND VALVES REMOVING THE CAMSHAFT AND ROCKER ARMS 1. Remove: • camshaft 1 NOTE: Screw in a M10 bolt 2 into the thread hole on the camshaft, and pull out the camshaft. 2. Remove: • rocker arm shafts (intake and exhaust) 1 •...

  • Page 151: Checking The Camshaft

    CAMSHAFT, ROCKER ARMS AND VALVES 2. Remove: • valve cotters NOTE: Attach a valve spring compressor 1 between the valve spring retainer and the cylinder head to remove the valve cotters. Valve spring compressor P/N. YM-04019, 90890-04019 CHECKING THE CAMSHAFT 1.
  • Page 152 CAMSHAFT, ROCKER ARMS AND VALVES 2. Check: • rocker arms • rocker arm shafts Damage/wear → Replace. M MMM M MMM M MMM M MMM M MMM a. Check the two contact areas on the rocker arms for signs of abnormal wear. 1) Rocker arm shaft hole 2) Camshaft lobe contact surface Excessive wear →...

  • Page 153: Checking The Valves And Valve Springs

    CAMSHAFT, ROCKER ARMS AND VALVES 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. Clearance (stem to guide) Intake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in)
  • Page 154 CAMSHAFT, ROCKER ARMS AND VALVES 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 1.0 ~ 1.4 mm (0.0394 ~ 0.0551 in)
  • Page 155 CAMSHAFT, ROCKER ARMS AND VALVES M MMM M MMM M MMM M MMM M MMM a. Apply Mechanic’s blueing dye (Dykem) b to the valve face. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear pattern.
  • Page 156 CAMSHAFT, ROCKER ARMS AND VALVES e. Apply a fine lapping compound to the valve face and repeat the above steps. NOTE: After every lapping operation be sure to clean off all of the compound from the valve face and valve seat. f.

  • Page 157: Installing The Valves And Valve Springs

    CAMSHAFT, ROCKER ARMS AND VALVES 12.Measure: • spring tilt a Out of specification → Replace. Spring tilt limit Inner 2.5°/1.7 mm (2.5°/0.067 in) Outer 2.5°/1.9 mm (2.5°/0.075 in) INSTALLING THE VALVES AND VALVE SPRINGS 1. Apply: • molybdenum disulfide oil (onto the valve stem and valve stem seal) 2.

  • Page 158: Installing The Camshaft And Rocker Arms

    CAMSHAFT, ROCKER ARMS AND VALVES INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Apply: • engine oil (onto the rocker arm shafts) 2. Install: • rocker arms 1 • rocker arm shafts (intake and exhaust) 2 NOTE: Use a slide hammer bolt 3 to install the rocker arm shafts.

  • 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. Cylinder head Refer to “CYLINDER HEAD”. Water pump outlet hose/pipe Refer to “WATER PUMP” in chapter 5. Coolant inlet joint Timing chain guide (exhaust) Cylinder/O-ring Refer to “INSTALLING THE CYLINDER”.

  • 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 the 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 2. Measure: • piston-to-cylinder clearance M MMM M MMM M MMM M MMM M MMM 1st step: a. Measure the cylinder bore “C” with the cyl- inder bore gauge. NOTE: Measure cylinder bore “C” by taking side-to- side and front-to-back measurements of the cylinder.

  • Page 162: Checking The Piston Rings

    CYLINDER AND PISTON 3rd step: a. Find the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance 0.040 ~ 0.065 mm (0.0016 ~ 0.0026 in) <Limit>: 0.15 mm (0.0059 in) b.

  • Page 163: Checking The Piston Pin

    CYLINDER AND PISTON 3. Measure: • ring end gap Out of specification → Replace. NOTE: You cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings.

  • Page 164: Installing The Piston

    CYLINDER AND PISTON d. If out of specification, replace the piston. Piston pin-to-piston clearance 0.004 ~ 0.024 mm (0.00016 ~ 0.00094 in) <Limit>: 0.074 mm (0.0029 in) L LLL L LLL L LLL L LLL L LLL INSTALLING THE PISTON 1.

  • Page 165: Installing The Cylinder

    CYLINDER AND PISTON 4. Lubricate: • piston • piston rings • cylinder NOTE: Apply a liberal coating of engine oil. INSTALLING THE CYLINDER 1. Install: • cylinder NOTE: Install the cylinder with one hand while com- pressing the piston rings with the other hand. CAUTION: •...

  • 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 - 37...

  • 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 base 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 a new one, and clinch the end of the bolt. NOTE: The arrow mark on the starter clutch must face inward, away from the rotor.

  • Page 171: Checking The Engine Cooling Fan

    • air shroud 1 • air shroud 2 Cracks/damage → Replace. INSTALLING THE A.C. MAGNETO 1. Apply: • sealant 1 (into the slit) Yamaha bond No. 1215 ® (Three Bond No. 1215 P/N. 90890-85505 2. Install: • woodruff key • A.C. magneto rotor NOTE: •...
  • Page 172 ENGINE COOLING FAN AND A.C. MAGNETO 4. Install: • engine cooling fan pulley base 1 50 Nm (5.0 m · kg, 36 ft · lb) NOTE: Use a sheave holder 2 to hold the primary sheave. Primary sheave holder P/N. YS-01880-A Sheave holder P/N.

  • Page 173: Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES PRIMARY AND SECONDARY SHEAVES Order Job/Part Q’ty Remarks Removing the primary and second- Remove the parts in the order listed. ary sheaves Engine assembly Refer to “ENGINE REMOVAL”. Drive belt cover Rubber gasket Bearing housing Dowel pin Primary sliding sheave assembly V-belt Refer to “REMOVING THE PRIMARY...

  • Page 174: Primary Sliding Sheave

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

  • Page 175: 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 Spring seat Refer to “DISASSEMBLING THE SEC- Guide pin ONDARY SHEAVE” and “ASSEMBLING THE SECONDARY SHEAVE”. Secondary sliding sheave O-ring Secondary fixed sheave...

  • Page 176: 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 2, then loosen the primary sheave nut 1.

  • Page 177: 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 sliders •...

  • Page 178: Checking The V-Belt Case Cooling Fan

    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 spacer.
  • Page 179 PRIMARY AND SECONDARY SHEAVES 2. Install: • guide pins 1 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 • primary sheave spring retainer nut M MMM M MMM M MMM...

  • Page 180: Installing The Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES Primary sheave spring retainer 90 Nm (9.0 m · kg, 65 ft · lb) e. Remove the sheave spring compressor, locknut wrench, and sheave fixed block. L LLL L LLL L LLL L LLL L LLL INSTALLING THE PRIMARY AND SECONDARY SHEAVES 1.

  • Page 181: 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 Refer to “REMOVING THE CLUTCH” Gasket/dowel pin and “INSTALLING THE CLUTCH”. One-way clutch bearing Clutch carrier assembly For installation, reverse the removal pro-...
  • Page 182 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 - 51...

  • Page 183: 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 184: Installing The Clutch

    CLUTCH b. When turning the clutch housing clockwise È, the clutch carrier assembly 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 clutch carrier assembly should be engaged.
  • Page 185 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 186: Crankcase

    CRANKCASE CRANKCASE STARTER MOTOR, TIMING CHAIN AND OIL FILTER Order Job/Part Q’ty Remarks Removing 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 “CYLINDER HEAD”. Cylinder and piston Refer to “CYLINDER AND PISTON”.

  • Page 187: Crankcase

    CRANKCASE Order Job/Part Q’ty Remarks Oil pump drive gear/straight key Refer to “REMOVING THE OIL PUMP DRIVE GEAR” and “INSTALLING THE OIL PUMP DRIVE GEAR”. Oil pump driven gear Timing chain guide (intake) Timing chain Starter motor/O-ring Speed sensor Shift drum stopper Low-range switch High-range switch Neutral switch...
  • Page 188 CRANKCASE Order Job/Part Q’ty Remarks Oil delivery pipe Oil strainer cover/O-ring Compression spring Oil strainer For installation, reverse the removal procedure. 4 - 57...
  • Page 189 CRANKCASE CRANKCASE Order Job/Part Q’ty Remarks Separating the crankcase Remove the parts in the order listed. Shift lever cover/gasket Refer to “INSTALLING THE SHIFT Shift lever 1/O-ring LEVER”. Shift lever 2 assembly Right crankcase Refer to “SEPARATING THE CRANK- Dowel pin CASE”...

  • Page 190: Crankcase Bearings

    CRANKCASE CRANKCASE BEARINGS 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”. Oil seal Bearing retainer Bearing For installation, reverse the removal pro-...

  • Page 191: Removing The Oil Pump Drive Gear

    CRANKCASE REMOVING THE OIL PUMP DRIVE GEAR 1. Straighten: • lock washer tab 2. Remove: • oil pump drive gear nut M MMM M MMM M MMM M MMM M MMM a. Temporary install the clutch carrier assem- bly 1. b.

  • Page 192: Checking The Timing Chain And Guide

    CRANKCASE b. Remove the right crankcase. CAUTION: Use a soft hammer to tap on one side of the crankcase. Tap only on reinforced portions of the crankcase. Do not tap on the crank- case mating surfaces. Work slowly and carefully. Make sure that the crankcase halves separate evenly.

  • Page 193: Checking The Relief Valve

    CRANKCASE CHECKING THE RELIEF VALVE 1. Check: • relief valve 1 • spring 2 Damage/wear → Replace the defective part(s). CHECKING THE CRANKCASE 1. Thoroughly wash the case halves in a mild solvent. 2. Clean all the gasket mating surfaces and crankcase mating surfaces thoroughly.

  • Page 194: Assembling The Crankcase

    CRANKCASE ASSEMBLING THE CRANKCASE 1. Apply: • sealant 1 (to the mating surfaces of both case halves) Yamaha bond No. 1215 ® (Three Bond No. 1215 P/N. 90890-85505 2. Install: • dowel pins 2 3. Fit the right crankcase onto the left crank- case.

  • Page 195: Installing The Shift Lever

    CRANKCASE INSTALLING THE SHIFT LEVER 1. Install: • shift lever 2 assembly 1 14 Nm (1.4 m · kg, 10 ft · lb) • shift lever 1 2 NOTE: When installing the shift lever 1, align the punch mark a on the shift lever 1 with the punch marks b on the shift lever 2.

  • Page 196: 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”. Washer/circlip Oil pump assembly/gasket Balancer Refer to “REMOVING THE CRANK- Crankshaft seal SHAFT”...

  • Page 197: 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 - 66...

  • Page 198: Removing The Crankshaft

    CRANKSHAFT AND OIL PUMP REMOVING THE CRANKSHAFT 1. Remove: • crankshaft seals 1 NOTE: Mark a note of the position of each crankshaft seal so that they can be installed in the correct place and in the correct direction. 2. Remove: •...

  • Page 199: Checking The Crankshaft

    CRANKSHAFT AND OIL PUMP 3. Check: • oil pump operation Unsmooth → Repeat steps #1 and #2 or replace the defective parts. CHECKING THE CRANKSHAFT 1. Measure: • crank width A Out of specification → Replace the crank- shaft. Crank width 62.95 ~ 63.00 mm (2.4783 ~ 2.4803 in) •...

  • Page 200: Installing The Crankshaft And Balancer

    CRANKSHAFT AND OIL PUMP INSTALLING THE CRANKSHAFT AND BALANCER 1. Install: • crankshaft Crankshaft installer bolt 1 P/N. YU-90060, 90890-01275 Crankshaft installer set P/N. YU-90050 Buffer boss installer set 2 P/N. 90890-04088 Adapter #11 P/N. YM-33279 Spacer (crankshaft) 3 P/N. YM-90070-A, 90890-04060 NOTE: Hold the connecting rod at the Top Dead Cen- ter (TDC) with one hand while turning the nut...

  • Page 201: Transmission

    TRANSMISSION TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission Remove the parts in the order listed. Crankcase separation Refer to “CRANKCASE”. Driven sprocket Chain Clutch dog 2 Shift fork “L” Spring Low wheel gear Secondary shaft Middle driven gear Drive axle Guide bar 4 - 70...
  • Page 202 TRANSMISSION Order Job/Part Q’ty Remarks Shift fork “R” Spring Shift drum Clutch dog 1 High wheel gear Middle drive gear Spacer/O-ring For installation, reverse the removal pro- cedure. 4 - 71...

  • Page 203: Checking The Shift Forks

    TRANSMISSION CHECKING THE SHIFT FORKS 1. Check: • shift fork cam follower 1 • shift fork pawl 2 Scoring/bends/wear/damage → Replace. 2. Check: • guide bar Roll the guide bar on a flat surface. Bends → Replace. WARNING Do not attempt to straighten a bent guide bar.

  • Page 204: Checking The Transmission

    TRANSMISSION CHECKING THE TRANSMISSION 1. Measure: • axle runout Use a centering device and a dial gauge. Out of specification → Replace the bent axle. Runout limit (drive axle) 0.06 mm (0.0024 in) 2. Check: • gear teeth Blue discoloration/pitting/wear → Replace. •...

  • Page 205: Installing The Transmission

    TRANSMISSION INSTALLING THE TRANSMISSION 1. Install: • shift drum • washer • spring (short) • shift fork “R” 1 • drive axle assembly 2 • guide bar 3 • clutch dog 2 4 • spring (long) 5 • shift fork “L” 6 NOTE: Be sure to install the shift forks “R”...

  • Page 206: Middle Gear

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

  • Page 207: Middle Drive Shaft

    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”. Drive shaft coupling Circlip Bearing Refer to “REMOVING THE MIDDLE Universal joint DRIVE SHAFT” and “INSTALLING THE MIDDLE DRIVE SHAFT”.
  • Page 208 MIDDLE GEAR Order Job/Part Q’ty Remarks Damper cam Spring Gear coupling Bearing retainer Middle drive shaft For installation, reverse the removal pro- cedure. 4 - 77...

  • Page 209: Removing The Middle Drive Pinion Gear Shaft

    MIDDLE GEAR REMOVING THE MIDDLE DRIVE PINION GEAR SHAFT 1. Straighten: • punched portion of the middle drive pinion gear nut 2. Loosen: • middle drive pinion gear nut 1 NOTE: Secure the middle drive pinion gear shaft in the vise with a clean rag. 3.
  • Page 210 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 211 MIDDLE GEAR c. Press the middle driven pinion gear end and remove the bearing housing. L LLL L LLL L LLL L LLL L LLL 5. Remove: • bearing retainer • bearing M MMM M MMM M MMM M MMM M MMM a.

  • Page 212: Checking The Pinion Gears

    MIDDLE GEAR CHECKING THE PINION GEARS 1. Check: • damper cam surface Wear/scratches → Replace damper cam and driven pinion gear as a set. 2. Check: • damper spring Damage/cracks → Replace. 3. Check: • drive pinion gear teeth 1 •...
  • Page 213 MIDDLE GEAR b. To find shim thickness “A” use following for- mula: Middle drive pinion gear shim thickness “A” = c – a – b Where: a = a numeral (usually a decimal number) on the bearing housing is either added to or subtracted from “10.5”.
  • Page 214 MIDDLE GEAR c. To find shim thickness “B” use the following formula: Middle driven pinion gear shim thick- ness: “B” = d – e + f – g – 0.05 Where: d = a numeral (usually a decimal number) on the bearing housing is either added to or subtracted from “76”.

  • Page 215: Installing The Middle Drive Shaft

    MIDDLE GEAR Shims are supplied in the following thickness. Middle drive pinion gear shim 0.10 0.40 0.15 0.50 Thickness (mm) 0.20 0.60 0.30 L LLL L LLL L LLL L LLL L LLL INSTALLING THE MIDDLE DRIVE SHAFT 1. Install: •...
  • Page 216 MIDDLE GEAR 2. Install: • bearing retainer M MMM M MMM M MMM M MMM M MMM a. Attach the folded rag 1. b. Secure the bearing housing edge in the vise. c. Attach the bearing retainer wrench 2. Middle gear bearing retainer P/N.
  • Page 217 MIDDLE GEAR 5. Install: • universal joint M MMM M MMM M MMM M MMM M MMM a. Install the opposite yoke into the universal joint. b. Apply wheel bearing grease to the bearings. c. Install the bearing 1 onto the yoke. CAUTION: Check each bearing.

  • Page 218: Installing The Middle Drive Pinion Gear Shaft

    MIDDLE GEAR INSTALLING THE MIDDLE DRIVE PINION GEAR SHAFT 1. Tighten: • middle drive pinion gear nut 1 145 Nm (14.5 m · kg, 105 ft · lb) NOTE: Secure the middle drive shaft in the vise with a clean rag. 2.

  • Page 219: Cooling System

    COOL RADIATOR AND COOLANT RESERVOIR COOLING SYSTEM RADIATOR AND COOLANT RESERVOIR Order Job/Part Q’ty Remarks Removing the radiator and coolant Remove the parts in the order listed. reservoir Oil cooler Refer to “OIL COOLER”. Coolant Drain. Refer to “CHANGING THE COOLANT” in chapter 3.
  • Page 220 COOL RADIATOR AND COOLANT RESERVOIR Order Job/Part Q’ty Remarks Thermo switch 3 Coolant reservoir Coolant reservoir breather hose Disconnect. For installation, reverse the removal pro- cedure. 5 - 2...

  • Page 221: 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 222: Water Pump

    COOL WATER PUMP WATER PUMP 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 Drain. Refer to “CHANGING THE COOLANT” in chapter 3.
  • Page 223 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 224: 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 outside of the water pump housing.

  • Page 225: Assembling The Water Pump

    COOL WATER PUMP 3. Measure: • impeller shaft tilt Out of specification → Replace. Maximum 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: Install the oil seal with a socket 3 that matches its outside diameter.
  • Page 226 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 227: 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 • • 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.
  • Page 228 COOL OIL COOLER 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 • • Order Job/Part Q’ty Remarks Oil cooler inlet pipe 2/oil cooler outlet pipe 2 For installation, reverse the removal pro- cedure.

  • Page 229: 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 230: 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 231 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 232: 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 233: Carburetor

    FUEL CARBURETOR 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” in chapter 8. Cylinder head breather hose Disconnect. Air filter case joint Air filter case Carburetor joint (air filter case) Air vent hose...
  • Page 234 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 235 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 in from the set position to its seated position. Throttle stop screw Vacuum chamber cover Spring...
  • Page 236 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 237: 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 in from the set position to its seated position. CHECKING THE CARBURETOR 1. Check: • carburetor body •...
  • Page 238 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 239: 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 240: 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 241: Installing The Carburetor

    FUEL CARBURETOR INSTALLING THE CARBURETOR 1. Install: • carburetor assembly NOTE: Align the tab a on the carburetor body with the slot b in the carburetor joint (intake mani- fold). 2. 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.

  • Page 242: 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 243 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 244 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 KNUCKLES AND STABILIZER” in chapter NO Torque to specification.

  • Page 245: Front Constant Velocity Joints, Differential Gear And Front Drive Shaft

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND FRONT DRIVE SHAFT FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND FRONT DRIVE SHAFT 55 Nm (5.5 m kg, 40 ft • • 55 Nm (5.5 m kg, 40 ft • • Order Job/Part Q’ty Remarks...
  • Page 246 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND FRONT DRIVE SHAFT 55 Nm (5.5 m kg, 40 ft • • 55 Nm (5.5 m kg, 40 ft • • Order Job/Part Q’ty Remarks Front drive shaft Compression spring For installation, reverse the removal pro- cedure.
  • Page 247 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND FRONT DRIVE SHAFT Order Job/Part Q’ty Remarks Disassembling the constant velocity Remove the parts in the order listed. joints Circlip Boot band Boot band Dust boot Circlip Refer to “ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS”.
  • Page 248 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND FRONT 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. Circlip Refer to “DISASSEMBLING THE UNI- Bearing VERSAL JOINT”...
  • Page 249 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND FRONT DRIVE SHAFT Order Job/Part Q’ty Remarks Shim (right) Refer to “MEASURING AND ADJUST- ING THE DIFFERENTIAL GEAR LASH”. Differential gear unit Shim (left) Refer to “MEASURING AND ADJUST- ING THE DIFFERENTIAL GEAR LASH”. Bearing Bearing Circlip/bearing...

  • Page 250: Disassembling The Universal Joint

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND FRONT 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 251: Checking The Constant Velocity Joints

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND FRONT 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 252: Checking The Gear Motor

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND FRONT DRIVE SHAFT 3. Check: • front drive shaft Bends → Replace. • torque limiter 1 Loose → Replace the front drive shaft. WARNING Do not attempt to straighten a bent shaft; this may dangerously weaken the shaft.

  • Page 253: Assembling The Differential Gear

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND FRONT 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 70 g (2.5 oz) per dust boot (front wheel side)
  • Page 254 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND FRONT 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 255: Assembling The Universal Joint

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND FRONT 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 256 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND FRONT 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 257: Checking The Differential Operation

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND FRONT 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 258 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND FRONT 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. •...

  • Page 259: Rear Constant Velocity Joints, Final Drive Gear And Rear Drive Shaft

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND REAR DRIVE SHAFT REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND REAR DRIVE SHAFT 70 Nm (7.0m kg, 50 ft • • Order Job/Part Q’ty Remarks Removing the rear constant velocity Remove the parts in the order listed.
  • Page 260 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND REAR DRIVE SHAFT 70 Nm (7.0m kg, 50 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 261 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND REAR DRIVE SHAFT Order Job/Part Q’ty Remarks Disassembling the rear constant Remove the parts in the order listed. velocity joints Circlip Boot band Boot band Dust boot Circlip Refer to “ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS”.
  • Page 262 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND REAR DRIVE SHAFT Order Job/Part Q’ty Remarks Disassembling the final drive gear 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 Refer to “POSITIONING THE FINAL...
  • Page 263 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND REAR DRIVE SHAFT Order Job/Part Q’ty Remarks Ring gear stopper 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...
  • Page 264 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND REAR 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 265: Assembling The Rear Constant Velocity Joints

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND REAR 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...

  • Page 266: Removing The Final Drive Roller Bearings

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND REAR 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 267: Installing The Final Drive Roller Bearings

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND REAR 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 268 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND REAR DRIVE SHAFT Selecting the final drive pinion gear shims 1. Select: • final drive pinion gear shim(s) 1 M MMM M MMM M MMM M MMM M MMM To find the final drive pinion gear shim thick- “A”...
  • Page 269 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND REAR 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 shims 1.
  • Page 270 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND REAR 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 271 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND REAR 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 272: Checking The Rear 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 273: Measuring And Adjusting The Final Gear Lash

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND REAR 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 274: Assembling The Final Drive Gear Assembly

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND REAR 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: •...
  • Page 275 • ring gear bearing housing bolts (M10) 2 40 Nm (4.0 m · kg, 29 ft · lb) NOTE: Apply sealant to the bolts 1 and 2 threads. Yamaha bond No. 1215 ® (Three Bond No. 1215 P/N. 90890-85505 3. Install: •...
  • Page 276 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND REAR 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 277: Seats, Enclosure, Hood And Cargo Bed

    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 278: 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 279 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 280: 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 • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks...

  • Page 281: 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 282 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 283: 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 skid plates Remove the parts in the order listed. Front skid plate Rear skid plate For installation, reverse the removal pro- cedure.

  • Page 284: 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 is towards the left side of the vehicle. È...

  • Page 285: 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 286: 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 287 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 288: Checking The Front Wheels

    CHAS FRONT WHEELS AND BRAKE DISCS CHECKING THE FRONT WHEELS 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 289: Checking The Front Brake Discs

    CHAS FRONT WHEELS AND BRAKE DISCS CHECKING THE FRONT BRAKE DISCS 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 290: 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 wheels Remove the parts in the order listed. Place the vehicle on a level surface.

  • Page 291: 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 292: Checking The Rear Wheels

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

  • Page 293: Installing The Rear Wheel Hubs

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

  • Page 294: 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 295: 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 296: 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 297: 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 298 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 299 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 300: 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 301 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 302: 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 303: 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 304 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 305: Front Brake Calipers

    CHAS FRONT AND REAR BRAKES FRONT BRAKE CALIPERS Order Job/Part Q’ty Remarks Removing the front brake calipers 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 306 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. pers Brake pad holding bolt Brake pad Pad spring...

  • Page 307: 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 308 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 309 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 • • 9 Nm (0.9 m kg, 6.5 ft • •...
  • Page 310 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 • • 9 Nm (0.9 m kg, 6.5 ft • •...

  • Page 311: Removing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES REMOVING THE REAR BRAKE CALIPER NOTE: If the rear brake caliper cannot be removed easily, first remove the brake pads, and then remove the caliper. EBS00427 DISASSEMBLING THE FRONT BRAKE CALIPERS 1. Remove: • brake caliper pistons •...

  • Page 312: 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 313: 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 314: 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 the brake caliper is disas- sembled.
  • Page 315 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 316: 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 317: 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 318 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 319: 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 320 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 321: 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 322 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 323 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 324: 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 325: 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 326: 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 327: Tie-Rods And Steering Knuckles

    CHAS STEERING SYSTEM TIE-RODS AND STEERING KNUCKLES 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 328: 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 329 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 330 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 331 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 332: 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 333 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 334: Removing The Front Arms

    CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS 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 335 CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS 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 336: Checking The Front Shock Absorbers

    CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS 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 337: Installing The Front Arms And Front Shock Absorbers

    CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBERS 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 338: Rear Knuckles And Stabilizer

    CHAS REAR KNUCKLES AND STABILIZER REAR KNUCKLES 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 339: Checking The Rear Knuckles

    CHAS REAR KNUCKLES AND STABILIZER CHECKING THE REAR KNUCKLES 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 340: Installing The Stabilizer

    CHAS REAR KNUCKLES AND STABILIZER INSTALLING THE STABILIZER 1. Install: • stabilizer 1 È • bushing 2 • stabilizer holder 3 32 Nm (3.2 m · kg, 23 ft · lb) NOTE: Install the bushing with its slit a facing rear- ward.

  • Page 341: Rear Arms And Rear Shock Absorbers

    CHAS REAR ARMS AND REAR SHOCK ABSORBERS REAR ARMS AND REAR SHOCK ABSORBERS 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 342: Checking The Rear Arms

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

  • Page 343: Installing The Rear Arms And Rear Shock Absorbers

    CHAS REAR ARMS AND REAR SHOCK ABSORBERS INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBERS 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 344: Electrical

    – ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Diode 1 7 Ignition coil D Pickup coil/stator assembly 2 Thermo switch 2 8 Low-range switch E Speed sensor 3 Diode 2 9 High-range switch F Gear motor 4 Circuit breaker 0 Neutral switch G Radiator fan A Reverse switch...

  • Page 345: 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 Four-wheel drive indicator light relay 4 Indicator light assembly 2 D Headlight relay 5 On-Command four-wheel drive switch and differ- E Differential gear lock indicator light relay F Fuse box ential gear lock switch...

  • Page 346: Checking The Switches

    – ELEC CHECKING THE SWITCHES CHECKING THE SWITCHES CHECKING THE SWITCHES 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 347 – ELEC CHECKING THE SWITCHES 9 - 4...

  • Page 348: Checking The Switch Continuity

    – ELEC CHECKING THE SWITCHES CHECKING THE SWITCH CONTINUITY Refer to “CHECKING THE SWITCHES” and check for continuity between lead terminals. Poor connection, no continuity → Correct or replace. The coupler locations are circled. 9 - 5...
  • Page 349 – ELEC CHECKING THE SWITCHES 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 Reverse switch 8 Neutral switch 9 High-range switch 0 Low-range switch A Four-wheel drive switch 9 - 6...

  • Page 350: 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 351 – 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 352: 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 353: Ignition System

    – ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM 9 - 10...

  • Page 354: 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 355 – ELEC IGNITION SYSTEM 3. Spark plug Standard spark plug DR8EA/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 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) CORRECT Repair or replace the spark plug.
  • Page 356 – 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 357 – ELEC IGNITION SYSTEM INCORRECT 7. Main switch Refer to “CHECKING THE SWITCHES”. 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 358 – 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 - 15...

  • Page 359: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 9 - 16...

  • Page 360: 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 neutral switch. If the main switch is “START” position, the starter motor can be operated only if: •...

  • Page 361: Troubleshooting

    – ELEC ELECTRIC STARTING SYSTEM EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 1. Fuses (main, ignition, signaling system) 6. Neutral switch 2. Battery 7. Brake light switch 3. Starter motor 8. Diode 1 4. Starter relay 9.
  • Page 362 – ELEC ELECTRIC STARTING SYSTEM WARNING 3. Starter motor • A wire that is used as a jumper lead must • Connect the battery (+) terminal 1 and have the equivalent capacity or more as starter motor lead 2 using a jumper lead that of the battery lead, otherwise the jumper lead may burn.
  • Page 363 – ELEC ELECTRIC STARTING SYSTEM INCORRECT 6. Neutral switch Refer to “CHECKING THE SWITCHES”. CORRECT Replace the neutral switch. INCORRECT 7. Brake light switch Refer to “CHECKING THE SWITCHES”. CORRECT Replace the brake light switch. 8. Diode 1 • Remove the diode from the coupler. •...

  • Page 364: 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 Shims...

  • Page 365: 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 366: 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 367: Charging System

    – ELEC CHARGING SYSTEM EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM 9 - 24...

  • Page 368: 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 tachometer • Remove the following part(s) before trouble- P/N.
  • Page 369 – 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 370: Circuit Diagram

    – ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM 9 - 27...

  • Page 371: Troubleshooting

    – ELEC LIGHTING SYSTEM EB805010 TROUBLESHOOTING IF THE HEADLIGHTS AND/OR TAILLIGHTS 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: •...
  • Page 372 – ELEC LIGHTING SYSTEM INCORRECT 4. Light switch Refer to “CHECKING THE SWITCHES”. 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 373: Checking The Lighting System

    – ELEC LIGHTING SYSTEM EB805020 CHECKING THE LIGHTING SYSTEM 1. If the headlights fail to come on: 1. Headlight bulb holder • Check the headlight bulb holder for conti- nuity. NOTE: The headlight bulb cannot be removed from the headlight bulb holder. To replace the headlight bulb, replace the headlight bulb NO CONTINUITY holder assembly.
  • Page 374 – 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 375 – ELEC LIGHTING SYSTEM 9 - 32...

  • Page 376: Signaling System

    – ELEC SIGNALING SYSTEM EB806000 SIGNALING SYSTEM CIRCUIT DIAGRAM 9 - 33...
  • Page 377 – ELEC SIGNALING SYSTEM 3 Main switch 6 Battery 7 Main fuse 0 Brake light switch B Reverse switch C C.D.I. unit R Neutral switch S Parking brake switch T Thermo switch 1 \ Gear motor ] Diode 2 a Four-wheel drive indicator light b Differential gear lock indicator light c Coolant temperature warning light d Four-wheel drive indicator light relay...

  • Page 378: 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 379 – 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 380: 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 381 – 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 382 – 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 383 – 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 384 – ELEC SIGNALING SYSTEM 5. If the coolant temperature warning light does not come on when the main switch is turned 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 385 – 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 → Frame ground Br W/L OUT OF SPECIFICATION •...
  • Page 386 – 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 387 – 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 •...
  • Page 388 – 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/or bulb socket. 2. Four-wheel drive indicator light relay •...
  • Page 389 – 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 390: Cooling System

    – ELEC COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM 9 - 47...

  • Page 391: 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 392 – 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 393 – 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 394 – 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 - 51...

  • Page 395: 2Wd/4Wd Selecting System

    – ELEC 2WD/4WD SELECTING SYSTEM 2WD/4WD SELECTING SYSTEM CIRCUIT DIAGRAM 9 - 52...

  • Page 396: 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 397 – ELEC 2WD/4WD SELECTING SYSTEM 4. Four-wheel drive relay 2 • Remove the four-wheel drive relay 2 from the wire harness. • Connect the pocket tester (Ω × 1) and the battery (12 V) to the four-wheel drive relay 2 terminals. Tester (+) lead →...
  • Page 398 – 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 399 – 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 FRONT DRIVE SHAFT” in chapter 7. •...

  • Page 400: Carburetor Heating System

    – ELEC CARBURETOR HEATING SYSTEM CARBURETOR HEATING SYSTEM CIRCUIT DIAGRAM 9 - 57...
  • Page 401 – 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 heating system) 4. Thermo switch 2 NOTE: •...
  • Page 402 – 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 403 – 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 404: 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 405: 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 406: 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 407: 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 and shift forks Transmission • Groove jammed with impurities • Seized transmission gear • Seized shift fork •...

  • Page 408: Poor Speed Performance

    FAULTY CLUTCH PERFORMANCE/OVERHEATING/ TRBL FAULTY BRAKE/SHOCK ABSORBER MALFUNCTION SHTG 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 409: Unstable Handling

    TRBL UNSTABLE HANDLING/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 •...
  • Page 410 YXR45FAV 2006 WIRING DIAGRAM 1 A.C. magneto h Reverse indicator light COLOR CODE 2 Rectifier/regulator i Parking brake indicator light B.... Black 3 Main switch j Signaling system fuse Br ..Brown 4 Backup fuse (odometer and k Ignition fuse G ...
  • Page 412 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
  • Page 413 YXR45FAV 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 Y/L L/B (BLACK) P O/R L/Y W (BLACK) (BLACK) WIRE HARNESS SUB-WIRE HARNESS B/Y L/W (BLACK)

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