Yamaha YXR70FX Service Manual
  1. Manuals
  2. Brands
  3. Yamaha Manuals
  4. Offroad Vehicle
  5. YXR70FX
  6. Service manual

Yamaha YXR70FX Service Manual

Off-road motorcycle
Hide thumbs Also See for YXR70FX:
1
2
3
4
5
6
7
Table Of Contents
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
Table of Contents

Advertisement

Quick Links

Download this manual See also: Owner's Manual
2008
SERVICE MANUAL
YXR70FX
LIT-11616-21-58
5B4-F8197-10

Advertisement

Table of Contents
loading

Related Manuals for Yamaha YXR70FX

Summary of Contents for Yamaha YXR70FX

  • Page 1 2008 SERVICE MANUAL YXR70FX LIT-11616-21-58 5B4-F8197-10...
  • Page 2 EBS00001 YXR70FX SERVICE MANUAL ©2007 by Yamaha Motor Corporation, U.S.A. First edition, September 2007 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-11616-21-58...
  • Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.

  • Page 4: How To Use This Manual

    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 every vehicle. INFO 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 injection system COOL 7 Drive train 8 Chassis...
  • Page 7 EBS00008 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM 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 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 INSTRUMENT FUNCTIONS ..............1-4 IMPORTANT INFORMATION ................. 1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-7 REPLACEMENT PARTS................1-7 GASKETS, OIL SEALS AND O-RINGS ............ 1-7 LOCK WASHERS/PLATES AND COTTER PINS ........
  • Page 9 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-24 LUBRICATION POINTS AND LUBRICANT TYPES ........2-25 ENGINE....................2-25 COOLANT FLOW DIAGRAMS ..............2-27 OIL FLOW DIAGRAMS ................. 2-29 CABLE ROUTING ..................2-32 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION....................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ......................
  • Page 10 CHASSIS ....................... 3-30 ADJUSTING THE BRAKE PEDAL ............3-30 ADJUSTING THE PARKING BRAKE............3-31 CHECKING THE BRAKE FLUID LEVEL..........3-32 CHECKING THE FRONT BRAKE PADS ..........3-33 CHECKING THE REAR BRAKE PADS ..........3-34 CHECKING THE PARKING BRAKE PADS ..........3-34 CHECKING THE BRAKE HOSES AND BRAKE PIPES ......3-35 BLEEDING THE HYDRAULIC BRAKE SYSTEM ........
  • Page 11 CYLINDER HEAD..................4-11 REMOVING THE CYLINDER HEAD............4-14 CHECKING THE CAMSHAFT SPROCKET..........4-15 CHECKING THE TAPPET COVERS ............4-15 CHECKING THE TIMING CHAIN TENSIONER........4-15 CHECKING THE CYLINDER HEAD ............4-16 INSTALLING THE CYLINDER HEAD .............4-17 ROCKER ARMS AND CAMSHAFT ..............4-20 REMOVING THE ROCKER ARMS AND CAMSHAFT......4-22 CHECKING THE CAMSHAFT..............4-22 CHECKING THE DECOMPRESSION SYSTEM........
  • Page 12 PRIMARY AND SECONDARY SHEAVES............4-55 PRIMARY SHEAVE................. 4-57 SECONDARY SHEAVE ................4-58 REMOVING THE PRIMARY AND SECONDARY SHEAVES ....4-59 DISASSEMBLING THE SECONDARY SHEAVE........4-59 CHECKING THE PRIMARY SHEAVE ............4-60 CHECKING THE SECONDARY SHEAVE ..........4-60 ASSEMBLING THE PRIMARY SHEAVE ..........4-61 ASSEMBLING THE SECONDARY SHEAVE..........4-62 INSTALLING THE PRIMARY AND SECONDARY SHEAVES....
  • Page 13 MIDDLE GEAR ....................4-91 MIDDLE DRIVE SHAFT ................4-91 MIDDLE DRIVEN SHAFT................4-92 REMOVING THE MIDDLE DRIVE SHAFT ..........4-94 REMOVING THE MIDDLE DRIVEN SHAFT...........4-95 CHECKING THE PINION GEARS ............4-98 SELECTING MIDDLE DRIVE AND DRIVEN GEAR SHIMS....4-98 INSTALLING THE BEARING AND OIL SEALS ........4-102 INSTALLING THE MIDDLE DRIVEN SHAFT ........4-103 INSTALLING THE MIDDLE DRIVE SHAFT ..........4-105 MEASURING THE MIDDLE GEAR BACKLASH........
  • Page 14 AIR FILTER CASE AND AIR INTAKE DUCT ..........6-28 INSTALLING THE AIR INTAKE DUCT AND AIR FILTER CASE....6-31 FUEL PUMP AND FUEL TANK ..............6-32 REMOVING THE FUEL TANK ..............6-34 REMOVING THE FUEL PUMP ...............6-34 CHECKING THE FUEL PUMP BODY.............6-35 CHECKING THE ROLLOVER VALVE ............6-35 INSTALLING THE FUEL PUMP..............6-35 INSTALLING THE FUEL HOSE ..............6-36...
  • Page 15 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT ....................7-20 DISASSEMBLING THE REAR CONSTANT VELOCITY JOINTS...7-28 ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS....7-29 DISASSEMBLING THE FINAL GEAR CASE..........7-31 REMOVING THE FINAL DRIVE ROLLER BEARINGS......7-32 INSTALLING THE FINAL DRIVE ROLLER BEARINGS ......7-32 POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR .....................
  • Page 16 FRONT AND REAR BRAKES............... 8-21 FRONT BRAKE PADS ................8-21 REAR BRAKE PADS................8-22 REPLACING THE FRONT AND REAR BRAKE PADS......8-23 BRAKE MASTER CYLINDER ..............8-25 CHECKING THE MASTER CYLINDER ..........8-27 ASSEMBLING THE BRAKE MASTER CYLINDER.........8-27 INSTALLING THE BRAKE MASTER CYLINDER ........8-28 FRONT BRAKE CALIPER...............
  • Page 17 REAR KNUCKLE AND STABILIZER ............8-67 CHECKING THE REAR KNUCKLES ............8-68 CHECKING THE STABILIZER..............8-68 REAR ARMS AND REAR SHOCK ABSORBER..........8-69 CHECKING THE REAR ARMS ...............8-71 HANDLING THE REAR SHOCK ABSORBERS AND GAS CYLINDERS (For models equipped with gas-oil damper shock absorbers) ....8-71 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER (For models equipped with gas-oil damper shock absorbers) ....
  • Page 18 LIGHTING SYSTEM ..................9-27 CIRCUIT DIAGRAM ................9-27 TROUBLESHOOTING ................9-28 CHECKING THE LIGHTING SYSTEM............9-30 SIGNALING SYSTEM ...................9-32 CIRCUIT DIAGRAM ................9-32 TROUBLESHOOTING ................9-34 CHECKING THE SIGNALING SYSTEM ..........9-36 COOLING SYSTEM..................9-45 CIRCUIT DIAGRAM ................9-45 TROUBLESHOOTING ................9-46 FUEL PUMP SYSTEM...................9-50 CIRCUIT DIAGRAM ................
  • Page 19 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 OVERCOOLING .................... 10-5 COOLING SYSTEM ................10-5 FAULTY BRAKE ................... 10-5 POOR BRAKING EFFECT..............

  • Page 20: General Information

    VEHICLE IDENTIFICATION INFO EBS00009 GENERAL INFORMATION VEHICLE IDENTIFICATION EBS00010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame. EBS00011 MODEL LABEL The model label 1 is affixed to the frame under the driver seat. Record the information on this label in the space provided.

  • Page 21: Features

    FEATURES INFO EAS20170 FEATURES OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.

  • Page 22: Fi System

    FEATURES INFO FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm , 46.1 psi). Accord- ingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 23: Instrument Functions

    FEATURES INFO INSTRUMENT FUNCTIONS 5B410004 Multi-function meter unit 1 Speedometer 2 Fuel meter 3 “H” button 4 “M” button 5 Clock/Hour meter/Voltage display 6 Odometer/Tripmeter A/Tripmeter B 7 “TRIP/ODO” button 8 Clock/Hour button “ ” The multi-function meter unit is equipped with the following: •...
  • Page 24 FEATURES INFO Clock and voltage display modes 1 Clock/Hour button “ ” 2 “H” button 3 “M” button 4 Clock/Hour meter/Voltage display Pushing the “ ” button switches the dis- play between the clock mode “CLOCK”, the hour meter mode “HOUR”, and the voltage dis- play mode “btry”...
  • Page 25 FEATURES INFO Fuel meter 1 Fuel level warning indicator 2 Fuel meter 3 “E” segment The fuel meter indicates the amount of fuel in the fuel tank. The display segments of the fuel meter disappear from “F” (full) towards “E” (empty) as the fuel level decreases.

  • Page 26: Important Information

    5. Keep all parts away from any source of fire. EBS00014 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 27: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION INFO EBS00016 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EBS00017 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu-...

  • Page 28: Checking The Connections

    IMPORTANT INFORMATION INFO EBS00019 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains →...

  • Page 29: Special Tools

    SPECIAL TOOLS INFO EBS00021 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 30 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Ring nut wrench Spanner wrench 90890-01268 YU-01268 This tool is used to loosen or tighten the front and rear shock absorber locknuts. Crankshaft installer pot 90890-01274 YU-90058 YU-90058/YU-90059 This tool is used to install the crankshaft. Crankshaft installer bolt Bolt 90890-01275...
  • Page 31 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Radiator cap tester Radiator pressure tester 90890-01325 YU-24460-01 YU-24460-01 This tool is used to check the cooling sys- tem. Locknut wrench 90890-01348 YM-01348 This tool is needed when removing or installing the secondary sheave spring.
  • Page 32 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Gear lash measurement tool 90890-01467 YM-01467 This tool is used to measure the gear lash. Ball joint remover 90890-01474 YM-01474 These tools are used to remove or install the ball joints. Gear lash measurement tool Middle drive gear lash tool 90890-01475...
  • Page 33 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Timing light Inductive clamp timing light 90890-03141 YU-03141 This tool is necessary for checking igni- tion timing. Pressure gauge 90890-03153 YU-03153 This tool is used to measure fuel pres- sure. Digital circuit tester Model 88 Multimeter with tachometer 90890-03174...
  • Page 34 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Valve guide installer (ø6) Valve guide installer (6.0 mm) 90890-04065 YM-04065-A This tool is needed to install the valve guides. Valve guide reamer (ø6) Valve guide reamer (6.0 mm) 90890-04066 YM-04066 This tool is needed to rebore the new valve guides.
  • Page 35 This instrument is necessary for checking the ignition system components. Digital tachometer 90890-06760 YU-39951-B This tool is needed for checking engine rpm. Yamaha bond No. 1215 ® (Three bond No.1215 90890-85505 This bond is used on crankcase mating surfaces, etc. 1 - 16...

  • Page 36: Specifications

    SPEC GENERAL SPECIFICATIONS EBS01001 SPECIFICATIONS GENERAL SPECIFICATIONS *1 For models equipped with panel wheels and oil damper shock absorbers *2 For models equipped with cast wheels and oil damper shock absorbers *3 For models equipped with cast wheels and gas-oil damper shock absorbers *4 For models equipped with cast wheels, gas-oil damper shock absorbers, and overfenders Item Standard...
  • Page 37 SPEC GENERAL SPECIFICATIONS Item Standard Oil quantity Engine oil Without oil filter cartridge replacement 2.00 L (1.76 Imp qt, 2.11 US qt) With oil filter cartridge replacement 2.10 L (1.85 Imp qt, 2.22 US qt) Total amount 3.00 L (2.64 Imp qt, 3.17 US qt) Final gear oil Periodic oil change 0.25 L (0.22 Imp qt, 0.26 US qt)
  • Page 38 SPEC GENERAL SPECIFICATIONS Item Standard Tire Type front Tubeless rear Tubeless 25 × 8.00-12NHS Size front 25 × 10.00-12NHS rear Manufacturer/model front MAXXIS/M951Y rear MAXXIS/M952Y Tire pressure (cold tire) Maximum load* 367.0 kg (809 lb) *1, *2 359.0 kg (791 lb) *3, *4 Off-road riding front 63 ~ 77 kPa (0.63 ~ 0.77 kg/cm...
  • Page 39 SPEC GENERAL SPECIFICATIONS Item Standard Bulb voltage/wattage × quantity 12 V 30.0 W/30.0 W × 2 Headlight 12 V 5.0/21.0 W × 2 Tail/brake light Indicator light Neutral indicator light Reverse indicator light Coolant temperature warning light Engine trouble warning light Park indicator light On-command four-wheel drive/differential gear lock indicator...

  • Page 40: Engine Specifications

    SPEC ENGINE SPECIFICATIONS EBS01002 ENGINE SPECIFICATIONS Item Standard Limit Cylinder head Maximum warpage ---- 0.03 mm (0.0012 in) Cylinder Bore 102.000 ~ 102.010 mm 102.080 mm (4.0157 ~ 4.0161 in) (4.0189 in) Measuring point 50.0 mm (1.97 in) ---- Maximum taper 0.05 mm (0.002 in) Out of round...
  • Page 41 SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links 98XRH2010/126 ---- Tensioning system Automatic ---- Rocker arm/rocker arm shaft Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) ---- Shaft outside diameter 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) ---- Rocker-arm-to-rocker-arm-shaft 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in)
  • Page 42 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve-stem-to-valve-guide clearance Intake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.080 mm (0.0031 in) Exhaust 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) 0.100 mm (0.0039 in) Valve stem runout ---- 0.040 mm (0.0016 in) Valve spring Free length...
  • Page 43 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston Piston-to-cylinder clearance 0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in) 0.13 mm (0.0051 in) Diameter “D” 101.955 ~ 101.970 mm ---- (4.0140 ~ 4.0146 in) Height “H” 10.0 mm (0.39 in) ---- Offset 0.50 mm (0.0197 in) ---- Offset direction...
  • Page 44 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil ring Dimensions (B × T) 2.50 × 2.80 mm (0.10 × 0.11 in) ---- End gap (installed) 0.20 ~ 0.70 mm (0.008 ~ 0.028 in) ---- Ring side clearance 0.060 ~ 0.150 mm (0.0024 ~ 0.0059 in) ---- Crankshaft Crank width “A”...
  • Page 45 SPEC ENGINE SPECIFICATIONS Item Standard Limit Throttle body Model/manufacturer × quantity 41EHS/MIKUNI × 1 ---- Engine idle speed 1,550 ~ 1,650 r/min ---- Intake vacuum 40.0 kPa (300 mmHg, 11.8 inHg) ---- Water temperature 80 ~ 90 °C ---- Oil temperature 60 ~ 70 °C ---- Fuel pump...
  • Page 46 SPEC ENGINE SPECIFICATIONS Cylinder head tightening sequence 2 - 11...

  • Page 47: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS EBS01003 CHASSIS SPECIFICATIONS *1 For models equipped with panel wheels and oil damper shock absorbers *2 For models equipped with cast wheels and oil damper shock absorbers *3 For models equipped with cast wheels and gas-oil damper shock absorbers *4 For models equipped with cast wheels, gas-oil damper shock absorbers, and overfenders Item Standard...
  • Page 48 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear wheel Wheel type Panel wheel *1 ---- Cast wheel *2, *3, *4 ---- 12 × 7.5 AT Rim size ---- Rim material Steel *1 ---- Aluminum *2, *3, *4 ---- Max. radial wheel runout ---- 2.0 mm (0.08 in)
  • Page 49 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Parking brake Type Disc ---- Disc outside diameter × thickness 165.0 × 3.5 mm (6.50 × 0.14 in) ---- Brake disc minimum thickness 3.0 mm (0.12 in) ---- Brake disc maximum deflection 0.1 mm (0.004 in) ---- Brake pad lining thickness-inner 3.2 mm (0.13 in)

  • Page 50: Electrical Specifications

    ---- tance/color gray/black ECU (engine control unit) Model/manufacturer F8T83871/MITSUBISHI ---- Ignition coil Model/manufacturer 2JN/YAMAHA ---- Minimum ignition spark gap 6.0 mm (0.24 in) ---- 2.16 ~ 2.64 Ω at 20 °C (68 °F) Primary coil resistance ---- Secondary coil resistance 8.64 ~ 12.96 kΩ...
  • Page 51 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Starter relay Model/manufacturer RC19-080A/MITSUBA ---- Amperage rating 180.0 A ---- 4.18 ~ 4.62 Ω at 20 °C (68 °F) Coil winding resistance ---- Fuel sender 19.00 ~ 21.00 Ω Sender unit resistance (full) ---- 137.00 ~ 143.00 Ω...

  • Page 52: Tightening Torques

    SPEC TIGHTENING TORQUES EBS01005 TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Item Part name Q’ty Remarks size Nm m · kg ft · lb Cylinder head (exhaust pipe) Stud bolt Cylinder head Bolt Cylinder head Bolt Cylinder head Bolt Spark plug —...
  • Page 53 SPEC TIGHTENING TORQUES Tightening torque Thread Item Part name Q’ty Remarks size Nm m · kg ft · lb Air intake duct Bolt Muffler Bolt Muffler bracket Bolt Exhaust pipe Tailpipe Bolt Radiator inlet pipe holder Bolt Radiator outlet pipe holder Bolt Oil cooler inlet pipe 1/oil cooler outlet Bolt...
  • Page 54 SPEC TIGHTENING TORQUES Tightening torque Thread Item Part name Q’ty Remarks size Nm m · kg ft · lb Left-hand Middle driven pinion gear bearing thread 13.0 retainer Universal joint yoke nut (middle gear 15.0 side) Middle driven pinion gear bearing Bolt housing Drive shaft coupling gear nut (middle...

  • Page 55: 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 and front rubber damper Engine and front rubber damper Engine and rear rubber damper Engine and rear rubber damper Rubber damper and frame Front skid plate and frame Rear skid plate and frame...
  • Page 56 SPEC TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks Nm m · kg ft · lb Top frame (enclosure) and side frame (enclosure) Headrest and upper support frame Seat belt and frame Seat belt and side frame (enclosure) Buckle and lower support frame Rectifier/regulator and frame Engine ground lead and crankcase...
  • Page 57 SPEC TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks Nm m · kg ft · lb Stabilizer joint and stabilizer Stabilizer joint and rear lower arm Rear wheel and rear wheel hub Rear wheel hub and constant velocity joint 35.0 250 Stake.
  • Page 58 SPEC TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks Nm m · kg ft · lb Ring gear bearing housing and final gear case Ring gear stopper nut Left-hand Bearing retainer and final gear pinion gear bear- thread.

  • Page 59: 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 60: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EBS00024 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication points Lubricant Oil seal lips Bearings O-ring Cylinder head bolts Crankshaft pin Connecting rod big end thrust surface Crankshaft sprocket Inner race (crankshaft) Buffer boss (crankshaft) Crankshaft seal Piston pin Piston and ring grooves...
  • Page 61 SPEC LUBRICATION POINTS AND LUBRICANT TYPES Lubrication points Lubricant Shift lever 1 Shift lever 1 gear teeth and shift lever 2 gear teeth Yamaha bond No.1215 AC magneto lead grommet ® (Three bond No.1215 Yamaha bond No.1215 Crankcase mating surface ®...

  • Page 62: Coolant Flow Diagrams

    SPEC COOLANT FLOW DIAGRAMS COOLANT FLOW DIAGRAMS 1 Radiator outlet pipe 2 Radiator inlet hose 3 Radiator outlet hose 4 Radiator cap 5 Radiator 6 Radiator inlet pipe 2 - 27...
  • Page 63 SPEC COOLANT FLOW DIAGRAMS 1 Radiator inlet pipe 2 Thermostat outlet hose 3 Thermostat 4 Radiator outlet pipe 5 Water pump inlet hose 6 Water pump 7 Water pump outlet pipe 8 Water pump outlet hose 2 - 28...

  • Page 64: Oil Flow Diagrams

    SPEC OIL FLOW DIAGRAMS EBS00026 OIL FLOW DIAGRAMS 1 Oil delivery pipe 2 2 Oil delivery pipe 3 3 Oil delivery pipe 1 4 Oil filter cartridge 5 Oil strainer 6 Reverse idle gear shaft 7 Drive axle 8 Relief valve assembly 2 - 29...
  • Page 65 SPEC OIL FLOW DIAGRAMS 1 Camshaft 2 Crankshaft 3 Oil strainer 4 Oil pump rotor 5 Oil pump driven gear 2 - 30...
  • Page 66 SPEC OIL FLOW DIAGRAMS 1 Oil delivery pipe 3 2 Oil delivery pipe 2 3 Oil outlet hose 4 Oil inlet hose 5 Oil cooler inlet pipe 2 6 Oil cooler outlet pipe 2 7 Oil cooler outlet hose 8 Oil cooler outlet pipe 1 9 Oil cooler inlet pipe 1 0 Oil cooler A Oil cooler inlet hose...

  • Page 67: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING 1 Left headlight lead 0 Front brake hose 2 Wire harness A Radiator fan motor breather hose 3 Throttle cable B Differential gear case breather hose 4 Light switch lead C Coolant reservoir breather hose 5 Brake light switch lead D Parking brake switch lead 6 Thermostat outlet hose...
  • Page 68 SPEC CABLE ROUTING È 30 ~ 60 mm (1.18 ~ 2.36 in) Í 10 ~ 20 mm (0.39 ~ 0.79 in) É 160 ~ 190 mm (6.30 ~ 7.48 in) Î Route the throttle cable to the inside of the radia- Ê...
  • Page 69 SPEC CABLE ROUTING 1 Throttle cable B Brake pipe 2 Wire harness È Fasten the wire harness to the frame with the 3 Intake air temperature sensor lead 4 ISC (idle speed control) unit lead plastic bands. É 30° 5 Intake air pressure sensor lead Ê...
  • Page 70 SPEC CABLE ROUTING Í Fasten the wire harness with the plastic holder. Ò Fasten the wire harness with the plastic band. Î Push the excess tail/brake light lead into the rear fender so that there is no slack in the lead. Ï...
  • Page 71 SPEC CABLE ROUTING 1 Light switch lead A Radiator outlet hose 2 Main switch lead B Water pump inlet hose 3 Meter assembly lead C Oil inlet hose 4 Auxiliary DC jack lead D Oil outlet hose 5 On-command four-wheel-drive motor switch and E Ground lead F Starter motor lead differential gear lock switch lead...
  • Page 72 SPEC CABLE ROUTING É Fasten the left headlight lead, right headlight L Throttle cable M Radiator inlet pipe lead, and radiator fan motor lead to the frame N Oil cooler inlet pipe 2/oil cooler outlet pipe 2 with a plastic band. Ê...
  • Page 73 SPEC CABLE ROUTING Ï 85 ~ 105 mm (3.35 ~ 4.13 in) Õ Fasten the AC magneto/crankshaft position sen- Ð Fasten the wire harness, starter motor lead, and sor lead and fuel pump/fuel sender lead with the ground lead with the plastic band. plastic band.
  • Page 74 SPEC CABLE ROUTING 1 Final gear case breather hose A Water pump outlet pipe 2 Parking brake cable B Water pump outlet hose 3 Intake air pressure sensor lead C Brake pipe 4 Throttle position sensor lead D Rear brake hose 5 Throttle body breather hose E Wire harness 6 Starter motor lead...
  • Page 75 SPEC CABLE ROUTING È Fasten the throttle position sensor lead with the Ï Fasten the final gear case breather hose with holder. the plastic holder. É Fasten the final gear case breather hose and Ð Fasten the fuel tank breather hose with the plas- brake pipe with the plastic holder.
  • Page 76 SPEC CABLE ROUTING Õ 20 ~ 40° Ö 1 mm (0.04 in) or less × Fasten the brake pipe with the plastic holder. Ø Fasten the fuel pump/fuel sender lead with the plastic holder. Ï Ð Ò Ñ Ë É Ì...
  • Page 77 SPEC CABLE ROUTING 1 Throttle cable B Throttle body breather hose 2 Radiator inlet pipe C Oil delivery pipe 2 3 Oil cooler inlet pipe 2/oil cooler outlet pipe 2 D Oil delivery pipe 3 4 Brake pipe E Fuel hose 5 Radiator outlet pipe F Throttle position sensor lead 6 Wire harness...
  • Page 78 SPEC CABLE ROUTING Ê Fasten the throttle body breather hose and wire M Thermostat outlet hose N ISC (idle speed control) unit lead harness with the plastic band. Ë Fasten the starter motor lead and ground lead O Coolant temperature sensor lead P Intake air temperature sensor lead with the holder.
  • Page 79 SPEC CABLE ROUTING Ð Fasten the parking brake cable with the metal holder. Ñ 20 ~ 40 mm (0.79 ~ 1.57 in) Ò Fasten the ignition coil lead with the plastic band. Ó Fasten the throttle cable at the white mark with the plastic band.
  • Page 80 SPEC CABLE ROUTING 1 Radiator fan motor relay A Coolant reservoir breather hose 2 Fuel injection system relay B Rectifier/regulator lead 3 Headlight relay C Brake light switch lead 4 Four-wheel-drive motor relay 1 D Throttle cable 5 Four-wheel-drive motor relay 2 E Differential gear case breather hose 6 Negative battery lead F Radiator fan motor breather hose...
  • Page 81 SPEC CABLE ROUTING È Fasten the starter motor lead with the plastic L Starter relay M Positive battery lead holder. É Fasten the differential gear case breather hose N Main fuse O Load control relay and coolant reservoir breather hose with the P Four-wheel-drive motor relay 3 plastic holder.
  • Page 82 SPEC CABLE ROUTING Í Fasten the radiator fan motor breather hose, dif- Ð Fasten the throttle cable with the plastic holder. Ñ Fasten the left headlight lead, radiator fan motor ferential gear case breather hose, and coolant reservoir breather hose with the plastic band. breather hose, differential gear case breather Î...
  • Page 83 SPEC CABLE ROUTING Ó Fasten the right headlight lead, differential gear case breather hose, radiator fan motor lead, and coolant reservoir breather hose with the plastic band. Ô Fasten the positive battery lead with the plastic holder. Õ 4 mm (0.16 in) of clearance or more is required around the boot.
  • Page 84 SPEC CABLE ROUTING 1 Auxiliary DC jack lead B Brake pipe 2 Throttle cable C Front brake hose 3 Radiator fan motor breather hose D Oil cooler inlet pipe 2/oil cooler outlet pipe 2 4 Differential gear case breather hose E Starter relay lead 5 Coolant reservoir breather hose È...

  • Page 85: 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 86: General Maintenance And Lubrication Chart

    GENERAL MAINTENANCE AND LUBRICATION CHART GENERAL MAINTENANCE AND LUBRICATION CHART 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 coolant leakage. Cooling system • Repair if necessary. • Replace coolant every 24 months. •...

  • Page 87: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. TIP: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 88 ADJUSTING THE VALVE CLEARANCE 5. Remove: • crankshaft end accessing screw 1 6. Measure: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0.09 ~ 0.13 mm (0.0035 ~ 0.0051 in) Exhaust valve 0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in) M MMM M MMM...
  • Page 89 ADJUSTING THE VALVE CLEARANCE 7. Adjust: • valve clearance M MMM M MMM M MMM M MMM M MMM a. Loosen the locknut 1. b. Insert a thickness gauge 2 between the adjusting screw and the valve tip. c. Turn the adjusting screw 3 with the tappet adjusting tool 4 until the specified valve clearance is obtained.

  • Page 90: Adjusting The Throttle Cable

    ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE THROTTLE CABLE 11.Install: • O-ring • camshaft sprocket cover 10 Nm (1.0 m · kg, 7.2 ft · lb) • O-ring 1 • intake tappet cover 10 Nm (1.0 m · kg, 7.2 ft · lb) •...

  • Page 91: Checking The Spark Plug

    ADJUSTING THE THROTTLE CABLE/ CHECKING THE SPARK PLUG 4. Adjust: • throttle cable M MMM M MMM M MMM M MMM M MMM a. Loosen the locknut 1. b. Turn the adjusting nut 2 in direction a or b until the correct free play is obtained. Direction a Free play is increased.
  • Page 92 CHECKING THE SPARK PLUG 5. Check: • electrode 1 Wear/damage → Replace. • insulator 2 Abnormal color → Replace. Normal color is a medium-to-light tan color. 6. Clean: • spark plug (with a spark plug cleaner or wire brush) 7. Measure: •...

  • Page 93: Checking The Ignition Timing

    CHECKING THE IGNITION TIMING EBS00058 CHECKING THE IGNITION TIMING TIP: Throttle cable free play should be adjusted properly before checking the ignition timing. 1. Remove: • seats • rear console Refer to “SEATS, REAR CONSOLE AND INSTRUMENT PANELS” in chapter 8. •...

  • Page 94: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE c. Visually check the stationary pointer a to verify it is within the required firing range b indicated on the AC magneto rotor. Incorrect firing range → Check the ignition system. TIP: When checking the ignition timing, make sure that the timing light cord does not come in con- tact with the exhaust muffler.
  • Page 95 MEASURING THE COMPRESSION PRESSURE 4. Disconnect: • spark plug cap 5. Remove: • spark plug NOTICE Before removing a spark plug, use com- pressed air to blow away any dirt accumu- lated in the spark plug well to prevent it from falling into the cylinder.
  • Page 96 MEASURING THE COMPRESSION PRESSURE b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. WARNING To prevent sparking, ground the spark plug lead before cranking the engine. c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces and piston crown for carbon deposits.

  • Page 97: Checking The Engine Oil Level

    CHECKING THE ENGINE OIL LEVEL EBS00064 CHECKING THE ENGINE OIL LEVEL 1. Place the vehicle on a level surface. 2. Check the engine oil level on a cold engine. TIP: If the engine was started before the oil level was checked, be sure to warm up the engine sufficiently, and then wait at least 10 minutes until the oil settles for an accurate reading.

  • Page 98: Changing The Engine Oil

    CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL 5. Check the engine oil level again. NOTICE Be sure the engine oil is at the correct level, otherwise engine damage may result. 6. Install: • rear console • seats Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED”...
  • Page 99 CHANGING THE ENGINE OIL 7. If the oil filter cartridge is also to be replaced, perform the following procedure. M MMM M MMM M MMM M MMM M MMM a. Lift the cargo bed up. b. Remove the oil filter cartridge 1 with an oil filter wrench 2.

  • Page 100: Cleaning The Air Filter Element

    CHANGING THE ENGINE OIL/ CLEANING THE AIR FILTER ELEMENT 13.Check: • engine (for engine oil leaks) 14.Check: • engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”. 15.Check: • engine oil pressure M MMM M MMM M MMM M MMM M MMM a.
  • Page 101 CLEANING THE AIR FILTER ELEMENT 2. Remove: • air intake duct shroud 1 3. Remove: • air filter case cover 1 4. Remove: • air filter element 1 • air filter element frame 2 NOTICE The engine should never be run without the air filter;...
  • Page 102 NOTICE 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 to the element. d. Squeeze out the excess oil. TIP: The element should be wet but not dripping.

  • Page 103: Checking The Throttle Body Joint

    CHECKING THE THROTTLE BODY JOINT/ CHECKING THE FUEL HOSE/CHECKING THE BREATHER HOSES EAS00094 CHECKING THE THROTTLE BODY JOINT 1. Remove: • seats • rear console Refer to “SEATS, REAR CONSOLE AND INSTRUMENT PANELS” in chapter 8. 2. Check: • throttle body joint 1 Cracks/damage →...

  • Page 104: Checking The Breather Hoses

    CHECKING THE BREATHER HOSES/ CHECKING THE COOLANT LEVEL 2. Check: • cylinder head breather hose 1 • throttle body breather hose 2 Cracks/damage → Replace. Loose connection → Connect properly. NOTICE Make sure the breather hoses are routed correctly. 3. Install: •...

  • Page 105: Changing The Coolant

    CHANGING THE COOLANT EBS00075 CHANGING THE COOLANT 1. Remove: • seats • rear console Refer to “SEATS, REAR CONSOLE AND INSTRUMENT PANELS” in chapter 8. • fuel tank Refer to “FUEL PUMP AND FUEL TANK” in chapter 6. 2. Remove: •...
  • Page 106 CHANGING THE COOLANT 7. Remove: • coolant drain bolt 1 (along with the copper washer) • air bleeding bolt 2 8. Drain: • coolant (from the engine and radiator) 9. Check: • coolant drain bolt 1 Damage → Replace. 10.Install: •...
  • Page 107 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 108 CHANGING THE COOLANT b. When coolant begins to flow out of the bolt hole, tighten the water pump air bleed bolt to specification. Water pump air bleed bolt 10 Nm (1.0 m · kg, 7.2 ft · lb) c. Loosen the thermostat cover air bleed bolt 2, without removing it, to allow all of the air to escape from the air bleed bolt hole.

  • Page 109: Checking The Cooling System

    CHECKING THE COOLING SYSTEM EAS00104 CHECKING THE COOLING SYSTEM 1. Remove: • seats • rear console • side panels • front console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. • air intake duct Refer to “AIR FILTER CASE AND AIR INTAKE DUCT”...

  • Page 110: Checking The Coolant Temperature Warning Light

    CHECKING THE COOLING SYSTEM/CHECKING THE COOLANT TEMPERATURE WARNING LIGHT 3. Install: • air intake duct Refer to “AIR FILTER CASE AND AIR INTAKE DUCT” in chapter 6. • front console • side panels • rear console • seats Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED”...

  • Page 111: Checking And Replacing The V-Belt

    CHECKING AND REPLACING THE V-BELT EBS00078 CHECKING AND REPLACING THE V-BELT 1. Remove: • drive belt cover Refer to “PRIMARY AND SECONDARY SHEAVES” in chapter 4. 2. Check: • V-belt 1 Cracks/wear/scaling/chipping → Replace. Oil/grease → Check primary sheave and secondary sheave.

  • Page 112: Checking The Exhaust System

    CHECKING AND REPLACING THE V-BELT/ CHECKING THE EXHAUST SYSTEM c. Install the new V-belt. TIP: Install the V-belt so that its arrow faces the direction shown in the illustration. d. Remove the bolts. L LLL L LLL L LLL L LLL L LLL EAS00099 CHECKING THE EXHAUST SYSTEM...

  • Page 113: Cleaning The Spark Arrester

    CLEANING THE SPARK ARRESTER CLEANING THE SPARK ARRESTER 1. Clean: • spark arrester M MMM M MMM M MMM M MMM M MMM WARNING • Select a well-ventilated area free of com- bustible materials. • Always let the exhaust system cool before performing this operation.

  • Page 114: Chassis

    ADJUSTING THE BRAKE PEDAL CHASSIS ADJUSTING THE BRAKE PEDAL 1. Check: • brake pedal free play a Out of specification → Adjust. TIP: 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 115: Adjusting The Parking Brake

    ADJUSTING THE PARKING BRAKE ADJUSTING THE PARKING BRAKE 1. Shift the drive select lever into low gear “L”. 2. Remove: • seats • rear console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. 3. Check: • parking brake lever free play a The maximum free play is equal to one click of the parking brake lever.

  • Page 116: Checking The Brake Fluid Level

    ADJUSTING THE PARKING BRAKE/ CHECKING THE BRAKE FLUID LEVEL 5. Adjust: • parking brake cable free play M MMM M MMM M MMM M MMM M MMM a. Pull back the adjuster cover 1. b. Loosen the locknut 2. c. Turn the adjusting nut 3 in direction a or b until the correct free play is obtained.

  • Page 117: Checking The Front Brake Pads

    CHECKING THE BRAKE FLUID LEVEL/ CHECKING THE FRONT BRAKE PADS 3. Check: • brake fluid level Fluid level is under “MIN” level line 1 → Fill Recommended brake fluid DOT 4 NOTICE Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately.

  • Page 118: Checking The Rear Brake Pads

    CHECKING THE REAR BRAKE PADS/ CHECKING THE PARKING BRAKE PADS CHECKING THE REAR BRAKE PADS 1. Remove: • rear wheels Refer to “FRONT AND REAR WHEELS” in chapter 8. 2. Check: • brake pads Wear indicator grooves 1 almost disap- peared →...

  • Page 119: Checking The Brake Hoses And Brake Pipes

    CHECKING THE BRAKE HOSES AND BRAKE PIPES CHECKING THE BRAKE HOSES AND BRAKE PIPES 1. Remove: • seats • rear console Refer to “SEATS, ENCLOSURE, HOOD AND CARGO BED” in chapter 8. 2. Lift the hood up. 3. Lift the cargo bed. 4.

  • Page 120: Bleeding The Hydraulic Brake System

    BLEEDING THE HYDRAULIC BRAKE SYSTEM BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the brake system if: • The system has been disassembled. • A brake hose or brake pipe have been loosened or removed. • The brake fluid has been very low. •...

  • Page 121: Adjusting The Select Lever Shift Rod

    BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SELECT LEVER SHIFT ROD k. Add brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”. WARNING Check the operation of the brake after bleeding the brake system. L LLL L LLL L LLL L LLL...

  • Page 122: Adjusting The Brake Light Switch

    ADJUSTING THE BRAKE LIGHT SWITCH/ CHECKING THE FINAL GEAR OIL LEVEL ADJUSTING THE BRAKE LIGHT SWITCH TIP: • The brake light switch is operated by move- ment of the brake pedal. • The brake light switch is properly adjusted when the brake light comes on just before the braking effect starts.

  • Page 123: Changing The Final Gear Oil

    CHECKING THE FINAL GEAR OIL LEVEL/ CHANGING THE FINAL GEAR OIL 4. Install: • oil filler plug · · 23 Nm (2.3 m kg, 17 ft CHANGING THE FINAL GEAR OIL 1. Place the vehicle on a level surface. 2. Remove: •...

  • Page 124: Checking The Differential Gear Oil

    CHANGING THE FINAL GEAR OIL/ CHECKING THE DIFFERENTIAL GEAR OIL 8. Fill: • final gear case Periodic oil change 0.25 L (0.22 Imp qt, 0.26 US qt) Total amount 0.28 L (0.25 Imp qt, 0.30 US qt) Recommended oil SAE 80 API “GL-4” Hypoid gear NOTICE Take care not to allow foreign material to enter the final gear case.

  • Page 125: Changing The Differential Gear Oil

    CHECKING THE DIFFERENTIAL GEAR OIL/ CHANGING THE DIFFERENTIAL GEAR OIL 3. Check: • oil level Oil level should be up to the brim of hole. Oil level low → Add oil to proper level. Recommended oil SAE 80 API “GL-4” Hypoid gear NOTICE Take care not allow foreign material to enter the differential gear case.
  • Page 126 CHANGING THE DIFFERENTIAL GEAR OIL 5. Remove: • drain plug 1 6. Drain: • differential gear oil 7. Install: • drain plug · · 10 Nm (1.0 m kg, 7.2 ft TIP: Check the gasket (drain plug). If it is damaged, replace it with new one.

  • Page 127: Checking The Constant Velocity Joint Dust Boots

    CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS/CHECKING THE STEERING SYSTEM CHECKING THE CONSTANT VELOCITY È JOINT DUST BOOTS 1. Check: • dust boots 1 Damage → Replace. Refer to “FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR DRIVE SHAFT” in chapter 7. È...

  • Page 128: Adjusting The Toe-In

    ADJUSTING THE TOE-IN ADJUSTING THE TOE-IN 1. Place the vehicle on a level surface. 2. Measure: • toe-in Out of specification → Adjust. Toe-in 15 ~ 25 mm (0.59 ~ 0.98 in) (with tires touching the ground) M MMM M MMM M MMM M MMM M MMM...
  • Page 129 ADJUSTING THE TOE-IN/ADJUSTING THE FRONT SHOCK ABSORBERS M MMM M MMM M MMM M MMM M MMM a. Mark both tie-rods ends. This reference point will be needed during adjustment. b. Loosen the locknut (tie-rod end) 1 on each tie-rod. c.

  • Page 130: Adjusting The Front Shock Absorbers

    ADJUSTING THE FRONT SHOCK ABSORBERS For models equipped with gas-oil damper shock absorbers WARNING Always adjust the spring preload, rebound damping force and compression damping force of both front shock absorbers to the same setting. Uneven adjustment can result in poor handling and loss of stability. 1.
  • Page 131 ADJUSTING THE FRONT SHOCK ABSORBERS TIP: Always tighten the locknut against the adjust- ing ring, then torque it to specification. L LLL L LLL L LLL L LLL L LLL 2. Adjust: • rebound damping force M MMM M MMM M MMM M MMM M MMM...

  • Page 132: Adjusting The Rear Shock Absorbers

    ADJUSTING THE FRONT SHOCK ABSORBERS/ ADJUSTING THE REAR SHOCK ABSORBERS NOTICE Do not force the adjusting screw past the minimum or maximum extent of adjust- ment. The adjusting screw may be dam- aged. L LLL L LLL L LLL L LLL L LLL ADJUSTING THE REAR SHOCK ABSORBERS...
  • Page 133 ADJUSTING THE REAR SHOCK ABSORBERS For models equipped with gas-oil damper shock absorbers WARNING Always adjust the spring preload, rebound damping force and compression damping force of both rear shock absorbers to the same setting. Uneven adjustment can result in poor handling and loss of stability. 1.
  • Page 134 ADJUSTING THE REAR SHOCK ABSORBERS TIP: Always tighten the locknut against the adjust- ing ring, then torque it to specification. L LLL L LLL L LLL L LLL L LLL 2. Adjust: • rebound damping force M MMM M MMM M MMM M MMM M MMM...

  • Page 135: Checking The Tires

    CHECKING THE TIRES WARNING • TIRE CHARACTERISTICS 1) Tire characteristics influence the han- dling of the vehicles. The tires listed below have been approved by Yamaha Motor Manufacturing corporation America for this model. If other tire com- binations are used, they can adversely affect your vehicle’s handling character-...
  • Page 136 CHECKING THE TIRES • MAXIMUM LOADING LIMIT 1) Vehicle loading limit (total weight of cargo, operator, passenger and accesso- ries, and tongue weight): For models equipped with oil damper shock absorbers: 367 kg (809 lb) models equipped with gas-oil damper shock absorbers: 359 kg (791 lb) 2) Cargo bed: 181 kg (400 lb) 3) Trailer hitch: Pulling load (total weight of trailer and...

  • Page 137: Checking The Wheels

    CHECKING THE TIRES/ CHECKING THE WHEELS WARNING Uneven or improper tire pressure may adversely affect the handling of this vehicle and may cause loss of control. • Maintain proper tire pressures. • Set tire pressures when the tires are cold. •...

  • Page 138: Checking And Lubricating The Cables

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

  • Page 139: Electrical System

    CHECKING AND CHARGING THE BATTERY EBS00120 ELECTRICAL SYSTEM 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 140 CHECKING AND CHARGING THE BATTERY TIP: 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 141 CHECKING AND CHARGING THE BATTERY b. Check the charge of the battery, as shown Relationship between the open-circuit volt- in the charts and the following example. age and the charging time at 20 °C (68 °F) Example c. Open-circuit voltage = 12.0 V d.
  • Page 142 CHECKING AND CHARGING THE BATTERY • If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode! • As shown in the following illustration, the open-circuit voltage of an MF battery sta- bilizes about 30 minutes after charging has been completed.
  • Page 143 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger TIP: Measure the open-circuit Leave the battery unused for voltage prior to charging. Charger more than 30 minutes before measuring its open-circuit voltage. Ammeter Connect a charger and TIP: Set the charging voltage to 16 ~ ammeter to the battery and...
  • Page 144 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger TIP: Measure the open-circuit Leave the battery unused for voltage prior to charging. more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging.

  • Page 145: Checking The Fuses

    CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) NOTICE First, connect the positive battery lead 1, and then the negative battery lead 2. 8. Check: • battery terminals Dirt →...
  • Page 146 CHECKING THE FUSES 2. Check: • fuse M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester to the fuse and check the continuity. TIP: Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C...
  • Page 147 CHECKING THE FUSES d. If the fuse immediately blows again, check the electrical circuit. Amperage Items Q’ty rating Main fuse 40 A Backup fuse 10 A Fuel injection 10 A system fuse Ignition fuse 10 A Headlight fuse 15 A Four-wheel- 10 A drive motor fuse...

  • Page 148: Adjusting The Headlight Beams

    ADJUSTING THE HEADLIGHT BEAMS/ CHANGING THE HEADLIGHT BULBS EBS00122 ADJUSTING THE HEADLIGHT BEAMS 1. Adjust: • headlight beam (vertically) M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting screw 1 in direction a or b. Headlight beam is Direction a raised.

  • Page 149: Changing The Tail/Brake Light Bulb

    CHANGING THE HEADLIGHT BULBS/ CHANGING THE TAIL/BRAKE LIGHT BULB 4. Remove: • headlight bulb holder 1 • bulb TIP: Remove the headlight bulb holder by pushing it in and turning it counterclockwise. WARNING Keep flammable products and your hands away from the bulb while it is on, since it will be hot.
  • Page 150 CHANGING THE TAIL/BRAKE LIGHT BULB 3. Remove: • tail/brake light bulb holder (with bulb) 1 • bulb TIP: Turn the bulb holder counterclockwise and remove the defective bulb. WARNING Keep flammable products and your hands away from the bulb while it is on, since it will be hot.

  • Page 151: Engine

    ENGINE REMOVAL ENGINE ENGINE REMOVAL V-BELT COOLING DUCTS, MUFFLER AND EXHAUST PIPES 8 Nm (0.8 m kg, 5.8 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 20 Nm (2.0 m kg, 14 ft • • 30 Nm (3.0 m kg, 22 ft •...
  • Page 152 ENGINE REMOVAL 8 Nm (0.8 m kg, 5.8 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 20 Nm (2.0 m kg, 14 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Throttle body assembly...
  • Page 153 ENGINE REMOVAL 8 Nm (0.8 m kg, 5.8 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 20 Nm (2.0 m kg, 14 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Exhaust pipe 1...

  • Page 154: Installing The V-Belt Cooling Ducts

    ENGINE REMOVAL INSTALLING THE V-BELT COOLING DUCTS 1. Install: • V-belt cooling duct 2 1 TIP: Align the projection a on the section b of V- belt cooling duct 2 with the rib on the crank- case and fit the projection c on the section b between the projections on the section d of the duct.

  • Page 155: Shift Arm

    ENGINE REMOVAL SHIFT ARM 14 Nm (1.4 m kg, 10 ft • • 15 Nm (1.5 m kg, 11 ft • • Order Job/Part Q’ty Remarks Removing the shift arm Remove the parts in the order listed. Select lever shift rod Shift arm For installation, reverse the removal pro- cedure.

  • Page 156: Hoses And Leads

    ENGINE REMOVAL HOSES AND LEADS 10 Nm (1.0 m kg, 7.2 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the hoses and leads Remove the parts in the order listed.
  • Page 157 ENGINE REMOVAL 10 Nm (1.0 m kg, 7.2 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks AC magneto coupler Disconnect. Crankshaft position sensor coupler Disconnect.

  • Page 158: Engine Mounting Bolts

    ENGINE REMOVAL EBS00205 ENGINE MOUNTING BOLTS 10 Nm (1.0 m kg, 7.2 ft • • 42 Nm (4.2 m kg, 30 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 159 ENGINE REMOVAL 10 Nm (1.0 m kg, 7.2 ft • • 42 Nm (4.2 m kg, 30 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 42 Nm (4.2 m kg, 30 ft •...

  • Page 160: Installing The Engine

    ENGINE REMOVAL EBS00207 INSTALLING THE ENGINE 1. Install: • rubber dampers (rear side) 1 • engine mounting bolts (rear lower side) 2 • engine mounting bolts (rear upper side) 3 2. Tighten: • engine mounting bolts (rear lower side) 2 42 Nm (4.2 m ·...

  • Page 161: Cylinder Head

    CYLINDER HEAD EBS00218 CYLINDER HEAD 20 Nm (2.0 m kg, 14 ft 20 Nm (2.0 m kg, 14 ft • • • • 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • •...
  • Page 162 CYLINDER HEAD 20 Nm (2.0 m kg, 14 ft 20 Nm (2.0 m kg, 14 ft • • • • 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 13 Nm (1.3 m kg, 9.4 ft •...
  • Page 163 CYLINDER HEAD 20 Nm (2.0 m kg, 14 ft 20 Nm (2.0 m kg, 14 ft • • • • 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 13 Nm (1.3 m kg, 9.4 ft •...

  • Page 164: Removing The Cylinder Head

    CYLINDER HEAD EBS00220 REMOVING THE CYLINDER HEAD 1. Align: • “I” mark on the AC magneto rotor (with the stationary pointer on the AC mag- neto cover) M MMM M MMM M MMM M MMM M MMM a. Turn the crankshaft counterclockwise. b.

  • Page 165: Checking The Camshaft Sprocket

    CYLINDER HEAD 5. Remove: • cylinder head TIP: • Loosen the bolts in the proper sequence as shown. • Loosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them. EBS00224 CHECKING THE CAMSHAFT SPROCKET 1.

  • Page 166: Checking The Cylinder Head

    CYLINDER HEAD EBS00230 CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) TIP: Do not use a sharp instrument to avoid damag- ing or scratching: • spark plug bore threads • valve seats 2. Check: •...

  • Page 167: Installing The Cylinder Head

    CYLINDER HEAD EBS00232 INSTALLING THE CYLINDER HEAD 1. Install: • dowel pins • cylinder head gasket 2. Install: • cylinder head • cylinder head bolts TIP: • Lubricate the threads of the cylinder head bolts 1 and 2 and mating surface with molybdenum disulfide grease.
  • Page 168 CYLINDER HEAD TIP: When installing the camshaft sprocket, keep the timing chain as tense as possible on the exhaust side. NOTICE Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. f. Remove the wire from the timing chain. L LLL L LLL L LLL...
  • Page 169 CYLINDER HEAD 7. Check: • “I” mark a TIP: Check that the “I” mark on the AC magneto rotor is aligned with the stationary pointer b on the AC magneto cover. • “I” mark c TIP: Check that the “I” mark on the camshaft sprocket is aligned with the stationary pointer d on the cylinder head.

  • Page 170: Rocker Arms And Camshaft

    ROCKER ARMS AND CAMSHAFT EBS00235 ROCKER ARMS AND CAMSHAFT 14 Nm (1.4 m kg, 10 ft • • 14 Nm (1.4 m kg, 10 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the rocker arms and cam- Remove the parts in the order listed.
  • Page 171 ROCKER ARMS AND CAMSHAFT 14 Nm (1.4 m kg, 10 ft • • 14 Nm (1.4 m kg, 10 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Decompressor lever pin Refer to “REMOVING THE ROCKER ARMS AND CAMSHAFT”...

  • Page 172: Removing The Rocker Arms And Camshaft

    ROCKER ARMS AND CAMSHAFT EBS00237 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Loosen: • locknuts • valve adjusting screws 2. Remove: • intake rocker arm shaft • exhaust rocker arm shaft • intake rocker arm • exhaust rocker arm TIP: Remove the rocker arm shafts with the slide hammer bolt 1 and weight 2.

  • Page 173: Checking The Decompression System

    ROCKER ARMS AND CAMSHAFT 3. Measure: • camshaft runout Out of specification → Replace. Camshaft runout limit 0.015 mm (0.0006 in) EBS00225 CHECKING THE DECOMPRESSION SYSTEM 1. Check: • decompression system M MMM M MMM M MMM M MMM M MMM a.

  • Page 174: Installing The Camshaft And Rocker Arms

    ROCKER ARMS AND CAMSHAFT 4. Measure: • rocker arm shaft outside diameter Out of specification → Replace. Rocker arm shaft outside diame- 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) 5. Calculate: • rocker-arm-to-rocker-arm-shaft clearance TIP: Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter.
  • Page 175 ROCKER ARMS AND CAMSHAFT 2. Lubricate: • camshaft Recommended lubricant Molybdenum disulfide oil • decompressor lever pin • decompressor lever Recommended lubricant Engine oil 3. Install: • decompressor lever pin 1 • decompressor lever 2 TIP: Install the decompressor lever pin 1 and decompressor lever 2 in the camshaft 3 as shown in the illustration.
  • Page 176 ROCKER ARMS AND CAMSHAFT 6. Install: • exhaust rocker arm 1 • exhaust rocker arm shaft 2 • intake rocker arm • intake rocker arm shaft TIP: • Use a slide hammer bolt 3 to install the rocker arm shafts. •...

  • Page 177: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EBS00234 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Cylinder head Refer to “CYLINDER HEAD”. Rocker arms/rocker arm shafts/cam- Refer to “ROCKER ARMS AND CAM- shaft SHAFT”.

  • Page 178: Removing The Valves And Valve Springs

    VALVES AND VALVE SPRINGS EBS00238 REMOVING THE VALVES AND VALVE SPRINGS The following procedure applies to all of the valves and related components. TIP: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.

  • Page 179: Checking The Valves And Valve Springs

    VALVES AND VALVE SPRINGS 3. Remove: • valve spring retainer 1 • valve spring 2 • valve 3 • valve stem seal 4 • valve spring seat 5 TIP: Identify the position of each part very carefully so that it can be reinstalled in its original place. EBS00240 CHECKING THE VALVES AND VALVE SPRINGS...
  • Page 180 VALVES AND VALVE SPRINGS 2. Replace: • valve guide TIP: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. M MMM M MMM M MMM M MMM M MMM a.
  • Page 181 VALVES AND VALVE SPRINGS 4. Measure: • margin thickness a Out of specification → Replace. Margin thickness 0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in) 5. Measure: • valve stem runout Out of specification → Replace. Runout limit 0.040 mm (0.0016 in) TIP: •...
  • Page 182 VALVES AND VALVE SPRINGS e. If the valve seat is too wide, too narrow, or the seat is not centered, the valve seat must be refaced. L LLL L LLL L LLL L LLL L LLL 9. Lap: • valve face •...

  • Page 183: Installing The Valves And Valve Springs

    VALVES AND VALVE SPRINGS h. Press the valve through the valve guide and onto the valve seat to make a clear pattern. i. Measure the valve seat width again. If the valve seat width is out of specification, reface and relap the valve seat. L LLL L LLL L LLL...
  • Page 184 VALVES AND VALVE SPRINGS 2. Lubricate: • valve stem 1 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. Install: • valve spring seats 1 • valve stem seals 2 • valves 3 • valve springs 4 • valve spring retainers 5 TIP: Install the valve springs with the larger pitch a facing upwards.
  • Page 185 VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a mallet. NOTICE Hitting the valve tip with excessive force could damage the valve. 4 - 35...

  • Page 186: Cylinder And Piston

    CYLINDER AND PISTON EBS00245 CYLINDER AND PISTON 1st 15 Nm (1.5 m kg, 11 ft • • 2nd 50 Nm (5.0 m kg, 36 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the cylinder and piston Remove the parts in the order listed.

  • Page 187: Removing The Piston

    CYLINDER AND PISTON EBS00247 REMOVING THE PISTON 1. Remove: • piston pin clips 1 • piston pin 2 • piston 3 TIP: • Before removing the piston pin clips, cover the crankcase opening with a clean rag to prevent the piston pin clips from falling into the crankcase.
  • Page 188 CYLINDER AND PISTON 2. Measure: • piston-to-cylinder clearance M MMM M MMM M MMM M MMM M MMM a. Measure the cylinder bore “C” with a cylin- der bore gauge. TIP: Measure the cylinder bore “C” in parallel to and at right angles to the crankshaft.

  • Page 189: Checking The Piston Rings

    CYLINDER AND PISTON f. If out of specification, replace the cylinder, and the piston and piston rings as a set. L LLL L LLL L LLL L LLL L LLL EBS00250 CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specification →...

  • Page 190: Checking The Piston Pin

    CYLINDER AND PISTON Piston ring end gap Top ring 0.20 ~ 0.35 mm (0.008 ~ 0.014 in) <Limit>: 0.60 mm (0.024 in) 2nd ring 0.75 ~ 0.90 mm (0.030 ~ 0.035 in) <Limit>: 1.25 mm (0.049 in) Oil ring 0.20 ~ 0.70 mm (0.008 ~ 0.028 in) EBS00251 CHECKING THE PISTON PIN...

  • Page 191: Installing The Piston And Cylinder

    CYLINDER AND PISTON 4. Calculate: • piston-pin-to-piston-pin-bore clearance Out of specification → Replace the piston pin and piston as a set. Piston-pin-to-piston-pin-bore clearance = Piston pin bore diameter b – Piston pin outside diameter a Piston-pin-to-piston clearance 0.004 ~ 0.024 mm (0.0002 ~ 0.0009 in) <Limit>: 0.074 mm (0.0029 in) EBS00252...
  • Page 192 CYLINDER AND PISTON 2. Install: • piston 1 • piston pin 2 • piston pin clips 3 TIP: • Apply engine oil to the piston pin. • Make sure the punch mark a on the piston points towards the exhaust side of the cylin- der.
  • Page 193 CYLINDER AND PISTON 6. Install: • cylinder 1 • timing chain guide (exhaust side) TIP: • While compressing the piston rings with one hand, install the cylinder with the other hand. • Pass the timing chain and timing chain guide (exhaust side) through the timing chain cav- ity.

  • Page 194: Ac Magneto

    AC MAGNETO EBS00256 AC MAGNETO 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 • • 7 Nm (0.7 m kg, 5.1 ft • •...
  • Page 195 AC MAGNETO 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 • • 7 Nm (0.7 m kg, 5.1 ft • • 60 Nm (6.0 m kg, 43 ft •...
  • Page 196 AC MAGNETO 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 • • 7 Nm (0.7 m kg, 5.1 ft • • 60 Nm (6.0 m kg, 43 ft •...

  • Page 197: Removing The Ac Magneto Rotor

    AC MAGNETO EBS00259 REMOVING THE AC MAGNETO ROTOR 1. Remove: • pipe holder 1 • AC magneto cover TIP: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.

  • Page 198: Checking The Stator Coil And Crankshaft Position Sensor

    AC MAGNETO Flywheel puller 90890-01362 Heavy duty puller YU-33270-B EBS00262 CHECKING THE STATOR COIL AND CRANKSHAFT POSITION SENSOR 1. Check: • stator coil 1 • crankshaft position sensor 2 Damage → Replace the crankshaft position sensor/stator assembly. EBS00263 CHECKING THE STARTER CLUTCH 1.

  • Page 199: Checking The Torque Limiter

    ® LOCTITE TIP: Align the projection a on the stator coil with the slot b in the AC magneto cover. 2. Apply: • sealant 1 (into the slit) Yamaha bond No. 1215 90890-85505 ® (Three bond No.1215 4 - 49...
  • Page 200 AC MAGNETO 3. Install: • woodruff key • AC magneto rotor TIP: • Before installing the rotor, clean the outside of the crankshaft and the inside of the rotor. • After installing the rotor, check that the rotor rotates smoothly. If not, reinstall the key and rotor.

  • Page 201: Balancer Gears And Oil Pump Gears

    BALANCER GEARS AND OIL PUMP GEARS BALANCER GEARS AND OIL PUMP GEARS Order Job/Part Q’ty Remarks Removing the balancer gears and oil Remove the parts in the order listed. pump gears Starter wheel gear Refer to “AC MAGNETO”. Lock washer Refer to “REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP Balancer driven gear...
  • Page 202 BALANCER GEARS AND OIL PUMP GEARS Order Job/Part Q’ty Remarks Lock washer Refer to “REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR” and “INSTALLING THE BAL- ANCER DRIVE GEAR, BALANCER DRIVEN GEAR, AND OIL PUMP DRIVEN GEAR”. Oil pump driven gear Plate Spring Refer to “REMOVING THE BALANCER...

  • Page 203: Removing The Balancer Driven Gear And Oil Pump Driven Gear

    BALANCER GEARS AND OIL PUMP GEARS REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR 1. Straighten the lock washer tabs. 2. Loosen: • balancer driven gear nut 1 • oil pump driven gear nut 2 TIP: Place an aluminum plate 3 between the teeth of the balancer drive gear 4 and balancer driven gear 5, then loosen the nuts.

  • Page 204: Installing The Balancer Drive Gear, Balancer Driven Gear, And Oil Pump Driven Gear

    BALANCER GEARS AND OIL PUMP GEARS INSTALLING THE BALANCER DRIVE GEAR, BALANCER DRIVEN GEAR, AND OIL PUMP DRIVEN GEAR 1. Install: • pin • spring • balancer drive gear (onto the buffer boss) TIP: Align the punch mark a on the balancer drive gear with the hole b to the buffer boss.

  • Page 205: Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES EBS00269 PRIMARY AND SECONDARY SHEAVES 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 100 Nm (10.0 m kg, 72 ft • • 140 Nm (14.0 m kg, 100 ft •...
  • Page 206 PRIMARY AND SECONDARY SHEAVES 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 100 Nm (10.0 m kg, 72 ft • • 140 Nm (14.0 m kg, 100 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 207: Primary Sheave

    PRIMARY AND SECONDARY SHEAVES EBS00270 PRIMARY SHEAVE Order Job/Part Q’ty Remarks Disassembling the primary sheave Remove the parts in the order listed. Primary pulley sheave cap Primary pulley slider Primary pulley cam Primary pulley weight Refer to “ASSEMBLING THE PRIMARY SHEAVE”.

  • Page 208: Secondary Sheave

    PRIMARY AND SECONDARY SHEAVES EBS00271 SECONDARY SHEAVE Order Job/Part Q’ty Remarks Disassembling the secondary Remove the parts in the order listed. sheave Spring seat Compression spring Refer to “DISASSEMBLING THE SEC- Spring seat ONDARY SHEAVE” and “ASSEMBLING Guide pin THE SECONDARY SHEAVE”. Secondary sliding sheave O-ring Secondary fixed sheave...

  • Page 209: Removing The Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES EBS00272 REMOVING THE PRIMARY AND SECONDARY SHEAVES 1. Loosen: • secondary sheave nut 1 • primary sheave nut 2 TIP: • 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 210: Checking The Primary Sheave

    PRIMARY AND SECONDARY SHEAVES EBS00274 CHECKING THE PRIMARY SHEAVE 1. Check: • weight outside diameter a Out of specification → Replace the weight. Weight outside diameter 30 mm (1.18 in) <Limit>: 29.5 mm (1.16 in) 2. Check: • primary pulley slider •...

  • Page 211: Assembling The Primary Sheave

    Remove any excess grease. 2. Install: • weights 1 TIP: • Apply Yamaha Grizzly grease (90 g) to the whole outer surface of the weights and install. • Apply Yamaha Grizzly grease (2.5 g) to the inner surface of the collar.

  • Page 212: Assembling The Secondary Sheave

    PRIMARY AND SECONDARY SHEAVES 3. Install: • slider 1 • cam 2 • primary sliding sheave cap 3 Nm (0.3 m · kg, 2.2 ft · lb) EBS00277 ASSEMBLING THE SECONDARY SHEAVE 1. Apply: ® • BEL-RAY assembly lube (to the secondary sliding sheave 1 inner surface and oil seals) ®...
  • Page 213 PRIMARY AND SECONDARY SHEAVES 4. Install: • spring seat • compression spring • spring seat • nut M MMM M MMM M MMM M MMM M MMM a. Attach the sheave fixed block, locknut wrench and sheave spring compressor to the secondary sheave.

  • Page 214: Installing The Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES EBS00279 INSTALLING THE PRIMARY AND SECONDARY SHEAVES 1. Install: • secondary sheave • V-belt fan • V-belt • primary sheave TIP: • Be sure to push in the primary pulley cam 1 when installing the primary sheave so that the primary pulley weights 2 will be properly position a.

  • Page 215: Clutch

    CLUTCH EBS00291 CLUTCH Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Primary sheave/secondary sheave Refer to “PRIMARY AND SECONDARY SHEAVES”. Clutch housing assembly Gasket Dowel pin Refer to “REMOVING THE CLUTCH” and “INSTALLING THE CLUTCH”. One-way clutch bearing Clutch carrier assembly For installation, reverse the removal pro-...
  • Page 216 CLUTCH EBS00292 Order Job/Part Q’ty Remarks Disassembling the clutch housing Remove the parts in the order listed. assembly Oil seal Circlip Bearing housing Circlip Bearing Circlip Bearing Clutch housing For assembly, reverse the disassembly procedure. 4 - 66...

  • Page 217: Removing The Clutch

    CLUTCH EBS00296 REMOVING THE CLUTCH 1. Remove: • clutch housing assembly • gasket • dowel pins TIP: 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 218: Checking The Clutch

    CLUTCH EBS00299 CHECKING THE CLUTCH 1. Check: • clutch housing Heat damage/wear/damage → Replace. • one-way clutch bearing Chafing/wear/damage → Replace. TIP: • Replace the one-way clutch assembly and clutch housing as a set. • The one-way clutch bearing must be installed with the flange side facing in.

  • Page 219: Installing The Clutch

    CLUTCH EBS00309 INSTALLING THE CLUTCH 1. Install: • clutch carrier assembly • nut 1 190 Nm (19.0 m · kg, 140 ft · lb) NOTICE The clutch carrier assembly nut has left- handed threads. To tighten the clutch car- rier assembly nut turn it counterclockwise. TIP: Use a clutch holding tool 2 to hold the clutch carrier assembly.

  • Page 220: Crankcase

    CRANKCASE EBS00319 CRANKCASE TIMING CHAIN AND OIL FILTER 7 Nm (0.7 m kg, 5.1 ft • • 17 Nm (1.7 m kg, 12 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 68 Nm (6.8 m kg, 49 ft •...

  • Page 221: Crankcase

    CRANKCASE 7 Nm (0.7 m kg, 5.1 ft • • 17 Nm (1.7 m kg, 12 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 68 Nm (6.8 m kg, 49 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 222 CRANKCASE EBS00320 CRANKCASE 10 Nm (1.0 m kg, 7.2 ft • • 18 Nm (1.8 m kg, 13 ft • • 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 223: Crankcase Bearings

    CRANKCASE EBS00321 CRANKCASE BEARINGS 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the crankcase bearings Remove the parts in the order listed. Crankshaft/oil pump Refer to “CRANKSHAFT AND OIL PUMP”. Transmission Refer to “TRANSMISSION”. Middle drive shaft/middle driven shaft Refer to “MIDDLE GEAR”.

  • Page 224: Separating The Crankcase

    CRANKCASE EBS00332 SEPARATING THE CRANKCASE 1. Separate: • left crankcase • right crankcase M MMM M MMM M MMM M MMM M MMM a. Remove the crankcase bolts. TIP: • Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them.

  • Page 225: Checking The Bearings

    Clogged → Blow out with compressed air. EBS00342 ASSEMBLING THE CRANKCASE 1. Apply: • sealant 1 (to the mating surfaces of both case halves) Yamaha bond No. 1215 90890-85505 ® (Three bond No.1215 TIP: Apply two coats of sealant to the area a shown in the illustration.

  • Page 226: Installing The Shift Lever

    CRANKCASE 3. Fit the left crankcase onto the right crank- case. Tap lightly on the case with a soft hammer. NOTICE Before installing and torquing the crank- case holding bolts, be sure to check whether the transmission is functioning properly by manually rotating the shift drum in both directions.

  • Page 227: Crankshaft And Oil Pump

    CRANKSHAFT AND OIL PUMP EBS00326 CRANKSHAFT AND OIL PUMP 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the crankshaft and oil Remove the parts in the order listed. pump Crankcase Separate.

  • Page 228: Oil Pump

    CRANKSHAFT AND OIL PUMP EBS00327 OIL PUMP 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Part Q’ty Remarks Disassembling the oil pump Remove the parts in the order listed. Oil pump housing cover Oil pump shaft Oil pump inner rotor Oil pump outer rotor Oil pump housing For assembly, reverse the disassembly...

  • Page 229: Removing The Crankshaft

    CRANKSHAFT AND OIL PUMP EBS00336 REMOVING THE CRANKSHAFT 1. Remove: • crankshaft 1 Use a crankcase separating tool 2. Crankcase separating tool 90890-01135 Crankcase separator YU-01135-B EBS00331 CHECKING THE OIL PUMP 1. Check: • oil pump housing • oil pump housing cover Cracks/wear/damage →...

  • Page 230: Checking The Oil Strainer

    CRANKSHAFT AND OIL PUMP CHECKING THE OIL STRAINER 1. Check: • oil strainer Damage → Replace. Contaminants → Clean with engine oil. EBS00360 CHECKING THE CRANKSHAFT 1. Measure: • crank width a Out of specification → Replace the crank- shaft. Crank width 74.95 ~ 75.00 mm (2.951 ~ 2.953 in)

  • Page 231: Assembling The Oil Pump

    CRANKSHAFT AND OIL PUMP EBS00318 ASSEMBLING THE OIL PUMP 1. Install: • oil pump housing 1 • oil pump outer rotor 2 • oil pump inner rotor 3 • oil pump shaft 4 • pin 5 TIP: When installing the oil pump shaft 4 align the pin 5 with the groove a in the inner rotor 3.
  • Page 232 CRANKSHAFT AND OIL PUMP TIP: Hold the connecting rod at the Top Dead Cen- ter (TDC) with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against the bearing. NOTICE Apply engine oil to each bearing to protect the crankshaft against scratches and to...

  • Page 233: Transmission

    TRANSMISSION EBS00345 TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. Middle driven gear Refer to “MIDDLE GEAR”. Shift drum Shift fork assembly Shift fork “R” Refer to “REMOV- Spring Refer to “ASSEM- ING THE TRANS-...
  • Page 234 TRANSMISSION Order Job/Part Q’ty Remarks Reverse idle gear shaft Refer to “REMOVING THE TRANSMIS- SION” and “INSTALLING THE TRANS- MISSION”. For installation, reverse the removal pro- cedure. 4 - 84...

  • Page 235: Drive Axle

    TRANSMISSION EBS00348 DRIVE AXLE Order Job/Part Q’ty Remarks Disassembling the drive axle Remove the parts in the order listed. assembly Washer Collar High wheel gear Washer Clutch dog Circlip Washer Collar Low wheel gear Washer Circlip Middle drive gear Circlip 4 - 85...
  • Page 236 TRANSMISSION Order Job/Part Q’ty Remarks Washer Bearing Reverse wheel gear Stopper wheel Drive axle For assembly, reverse the disassembly procedure. 4 - 86...

  • Page 237: Removing The Transmission

    TRANSMISSION REMOVING THE TRANSMISSION 1. Remove: • shift drum 1 • shift fork assembly 2 M MMM M MMM M MMM M MMM M MMM a. Pull out the guide bar from the left crank- case. b. Push down on the drive shaft, and then slide the shift fork assembly to remove the shift fork cam followers.

  • Page 238: Checking The Shift Drum

    TRANSMISSION EBS00351 CHECKING THE SHIFT DRUM 1. Check: • shift drum grooves Scratches/wear/damage → Replace. EBS00354 CHECKING THE TRANSMISSION 1. Measure: • drive axle runout (with a centering device and dial gauge 1) Out of specification → Replace the drive axle.

  • Page 239: Checking The Secondary Shaft

    TRANSMISSION CHECKING THE SECONDARY SHAFT 1. Check: • gear teeth Blue discoloration/pitting/wear → Replace. ASSEMBLING THE SHIFT FORK ASSEMBLY 1. Install: • shift fork guide bar 1 • shift fork “L” 2 • spring 3 • shift fork “R” 4 •...
  • Page 240 TRANSMISSION 2. Check: • shift operation Unsmooth operation → Repair. TIP: • Oil each gear and bearing thoroughly. • Before assembling the crankcase, make sure that the transmission is in neutral and that the gears turn freely. 4 - 90...

  • Page 241: Middle Gear

    MIDDLE GEAR EBS00363 MIDDLE GEAR MIDDLE DRIVE SHAFT Order Job/Part Q’ty Remarks Removing the middle drive shaft Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. Bearing housing Middle drive pinion gear nut Middle drive pinion gear Middle drive gear shim Middle drive shaft Refer to “REMOVING THE MIDDLE...

  • Page 242: Middle Driven Shaft

    MIDDLE GEAR EBS00364 MIDDLE DRIVEN SHAFT Order Job/Part Q’ty Remarks Removing the middle driven shaft Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. Drive shaft coupling gear nut (middle gear side) Drive shaft coupling gear (middle gear side) Circlip Refer to “REMOVING THE MIDDLE...
  • Page 243 MIDDLE GEAR Order Job/Part Q’ty Remarks O-ring Middle driven gear shim Middle driven pinion gear Bearing Refer to “REMOVING THE MIDDLE Middle driven pinion gear bearing DRIVEN SHAFT” and “INSTALLING retainer THE MIDDLE DRIVEN SHAFT”. Bearing Middle driven shaft bearing retainer Bearing Middle driven shaft For installation, reverse the removal pro-...

  • Page 244: Removing The Middle Drive Shaft

    MIDDLE GEAR EBS00365 REMOVING THE MIDDLE DRIVE SHAFT 1. Straighten: • punched portion of the middle drive pinion gear nut 2. Loosen: • middle drive pinion gear nut 1 TIP: Secure the middle drive shaft in the vise with a clean rag.

  • Page 245: Removing The Middle Driven Shaft

    MIDDLE GEAR EBS01020 REMOVING THE MIDDLE DRIVEN SHAFT 1. Remove: • drive shaft coupling gear nut (middle gear side) 1 • washer • drive shaft coupling gear (middle gear side) TIP: Use the coupling gear/middle shaft tool 3 to hold the coupling gear. Coupling gear/middle shaft tool 90890-01229 Gear holder...
  • Page 246 MIDDLE GEAR 3. Remove: • universal joint yoke nut (middle gear side) • washer • universal joint yoke (middle gear side) TIP: Use the universal joint holder 2 to hold the universal joint yoke. Universal joint holder 90890-04062, YM-04062 4. Remove: •...
  • Page 247 MIDDLE GEAR 5. Remove: • middle driven pinion gear bearing retainer • bearing M MMM M MMM M MMM M MMM M MMM a. Fold a rag around the bearing housing 1. b. Secure the bearing housing edge in the vise.

  • Page 248: Checking The Pinion Gears

    MIDDLE GEAR 7. Remove: • middle driven shaft 1 (with bearing) EBS01021 CHECKING THE PINION GEARS 1. Check: • drive pinion gear teeth • driven pinion gear teeth Pitting/galling/wear → Replace. 2. Check: • O-ring Damage → Replace. • bearings Pitting/damage →...
  • Page 249 MIDDLE GEAR M MMM M MMM M MMM M MMM M MMM a. Position middle drive and driven gear by using shims 1 and 2 with their respective thickness calculated from information “A” marked on crankcase, bearing housing and drive gear end. 1 Shim thickness “A”...
  • Page 250 MIDDLE GEAR 8) Round off the hundredth digit and select the appropriate shim(s). In the example above, the calculated num- ber is 1.38. The chart instructs you to round off 8 to 10 at the hundredth place. Thus, the shim thickness is 1.40 mm (0.055 in). Hundredths Round value 0, 1, 2...
  • Page 251 MIDDLE GEAR g = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or subtracted from “49.0” h = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or subtracted from “80.5”...

  • Page 252: Installing The Bearing And Oil Seals

    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 BEARING AND OIL SEALS 1. Install: •...

  • Page 253: Installing The Middle Driven Shaft

    MIDDLE GEAR EBS00373 INSTALLING THE MIDDLE DRIVEN SHAFT 1. Install: • middle driven shaft bearing retainer 1 80 Nm (8.0 m · kg, 58 ft · lb) TIP: Attach the ring nut wrench 2. Ring nut wrench 90890-01430, YM-38404 NOTICE The middle driven shaft bearing retainer has left-handed threads.
  • Page 254 MIDDLE GEAR 3. Install: • middle driven gear shim(s) 1 • bearing housing TIP: Install the shim(s) so that the tabs are posi- tioned as shown in the illustration. 4. Install: • universal joint yoke (middle gear side) • washer •...

  • Page 255: Installing The Middle Drive Shaft

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

  • Page 256: Measuring The Middle Gear Backlash

    MIDDLE GEAR 2. Tighten: • middle drive pinion gear nut 1 190 Nm (19.0 m · kg, 140 ft · lb) TIP: Secure the middle drive shaft in the vise with a clean rag. 3. Lock the threads with a drift punch. EBS01022 MEASURING THE MIDDLE GEAR BACKLASH...

  • Page 257: Cooling System

    COOL RADIATOR AND COOLANT RESERVOIR COOLING SYSTEM RADIATOR AND COOLANT RESERVOIR 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 radiator and coolant Remove the parts in the order listed. reservoir Oil cooler Refer to “OIL COOLER”.
  • Page 258 COOL RADIATOR AND COOLANT RESERVOIR 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Radiator outlet pipe Thermostat outlet hose Water pump inlet hose Oil cooler bracket Radiator Radiator fan For installation, reverse the removal pro-...

  • Page 259: 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. TIP: Straighten any flattened fins with a thin, flat- head screwdriver.

  • Page 260: Installing The Radiator

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

  • Page 261: Thermostat

    COOL THERMOSTAT EBS00129 THERMOSTAT 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 18 Nm (1.8 m kg, 13 ft • • Order Job/Part Q’ty Remarks Removing the thermostat Remove the parts in the order listed. Seats/rear console Refer to “SEATS, REAR CONSOLE AND INSTRUMENT PANELS”...

  • Page 262: Checking The Thermostat

    COOL THERMOSTAT EBS00132 CHECKING THE THERMOSTAT 1. Check: • thermostat 1 Does not open at 50 ~ 54 °C (122 ~ 129.2 °F) → Replace. M MMM M MMM M MMM M MMM M MMM a. Suspend the thermostat in a container filled with water.

  • Page 263: Water Pump

    COOL WATER PUMP EBS00134 WATER PUMP 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • Order Job/Part Q’ty Remarks Removing the water pump Remove the parts in the order listed.
  • Page 264 COOL WATER PUMP 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • Order Job/Part Q’ty Remarks Gasket Circlip Impeller shaft Water pump seal Refer to “DISASSEMBLING THE Bearing WATER PUMP”...

  • Page 265: Disassembling The Water Pump

    COOL WATER PUMP EBS00138 DISASSEMBLING THE WATER PUMP 1. Remove: • water pump seal 1 TIP: Tap out the water pump seal from the inside of the AC magneto cover 2. 2. Remove: • bearing 1 • oil seal 2 TIP: Tap out the bearing and oil seal from the out- side of the AC magneto cover 3.

  • Page 266: Assembling The Water Pump

    COOL WATER PUMP EBS00140 ASSEMBLING THE WATER PUMP 1. Install: • oil seal 1 (into the AC magneto cover 2) TIP: • Before installing the oil seal, apply tap water or coolant onto its outer surface. • Install the oil seal with a socket 3 that matches its outside diameter.
  • Page 267 COOL WATER PUMP 3. Measure: • impeller shaft tilt Out of specification → Replace. NOTICE Make sure the rubber damper and rubber damper holder are flush with the impeller. Impeller shaft tilt limit 0.15 mm (0.006 in) 1 Straightedge 2 Impeller shaft 5 - 11...

  • Page 268: Oil Cooler

    COOL OIL COOLER OIL COOLER 21 Nm (2.1 m kg, 15 ft • • 7 Nm (0.7 m kg, 5.1 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 7 Nm (0.7 m kg, 5.1 ft • •...
  • Page 269 COOL OIL COOLER 21 Nm (2.1 m kg, 15 ft • • 7 Nm (0.7 m kg, 5.1 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 270: 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. TIP: Straighten any flattened fins with a thin, flat- head screwdriver.

  • Page 271: Fuel Injection System

    FUEL INJECTION SYSTEM EAS00894 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 Fuel injection system relay 8 Spark plug E Speed sensor 2 ECU (engine control unit) 9 Coolant temperature sensor 3 Lean angle sensor 0 Fuel injector 4 Engine trouble warning light A ISC (idle speed control) unit 5 Intake air temperature sensor B Fuel pump...

  • Page 272: Circuit Diagram

    FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 6 - 2...
  • Page 273 FUEL INJECTION SYSTEM 1 Crankshaft position sensor 4 Main fuse 5 Frame ground 6 Ignition fuse 7 Main switch 8 Battery 9 Fuel injection system fuse B Backup fuse D Fuel injection system relay F ISC (idle speed control) unit G ECU (engine control unit) H Ignition coil I Spark plug...

  • Page 274: Ecu Self-Diagnostic Function

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

  • Page 275: Self-Diagnostic Function Table

    FUEL INJECTION SYSTEM EAS27380 SELF-DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for the type of malfunction.

  • Page 276: Troubleshooting Chart

    FUEL INJECTION SYSTEM EAS00904 TROUBLESHOOTING CHART Engine operation is not normal or the engine trouble warning light is on. * Engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light comes on. The engine trouble warning light does not come on.

  • Page 277: Diagnostic Mode

    FUEL INJECTION SYSTEM EAS00905 DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators without connecting the measurement equipment by simply switching the meter indication from the normal mode to the diagnostic monitoring mode.
  • Page 278 FUEL INJECTION SYSTEM 6. Verify the operation of the sensor or actua- tor. • Sensor operation The data representing the operating condi- tions of the sensor appears on the LCD meter. • Actuator operation Set the differential gear lock switch to “LOCK”...
  • Page 279 FUEL INJECTION SYSTEM Diagnostic code table Fault Symptom Probable cause of malfunction Diagnostic code No. code No. • Open or short circuit in wire harness. • Defective crankshaft position sensor. No normal signals are received from • Malfunction in pickup rotor. —...
  • Page 280 FUEL INJECTION SYSTEM Fault Symptom Probable cause of malfunction Diagnostic code No. code No. Faulty ECU memory. (When this mal- function is detected in the ECU, the • Malfunction in ECU. (The program and data are not — fault code number might not appear properly written on or read from the internal memory.) on the LCD of the meter.) Sensor operation table...

  • Page 281: Troubleshooting Details

    FUEL INJECTION SYSTEM Actuator operation table • Actuator operation Set the differential gear lock switch to “4WD” and then to “LOCK”. Diagnos- tic code Item Actuation Checking method Actuates the ignition coil five times in one-second intervals. Check the spark five times. Ignition coil The engine trouble warning light also flashes five •...
  • Page 282 FUEL INJECTION SYSTEM Fault code No. 12 Symptom No normal signals are received from the crankshaft posi- tion sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of crankshaft Check for looseness or pinching. Cranking the position sensor.
  • Page 283 FUEL INJECTION SYSTEM Fault code No. 13 Symptom Intake air pressure sensor: open or short circuit detected. Diagnostic code No. d03 Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 284 FUEL INJECTION SYSTEM Fault code No. 14 Symptom Intake air pressure sensor: hose system malfunction (clogged or detached hose). Diagnostic code No. d03 Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Intake air pressure sensor hose •...
  • Page 285 FUEL INJECTION SYSTEM Fault code No. 15 Symptom Throttle position sensor: open or short circuit detected. Diagnostic code No. d01 Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle posi- • Check for looseness or pinching. Turning the tion sensor.
  • Page 286 FUEL INJECTION SYSTEM Fault code No. 16 Symptom Stuck throttle position sensor detected. Diagnostic code No. d01 Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle posi- • Check the installed area for Reinstated by tion sensor.
  • Page 287 FUEL INJECTION SYSTEM Fault code No. 22 Symptom Intake air temperature sensor: open or short circuit detected. Diagnostic code No. d05 Intake air temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of air tempera- Check for looseness or pinching.
  • Page 288 FUEL INJECTION SYSTEM Fault code No. 30 Symptom The vehicle has overturned. Diagnostic code No. d08 Lean angle sensor Order Item/components and probable Check or maintenance job Reinstatement cause method The vehicle has overturned. Raise the vehicle upright. Turning the main switch to Installed condition of the lean Check for looseness or pinching.
  • Page 289 FUEL INJECTION SYSTEM Fault code No. 33 Symptom Malfunction detected in the primary lead of the ignition coil. Diagnostic code No. d30 Ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the connector and cou- Starting the •...
  • Page 290 FUEL INJECTION SYSTEM Fault code No. 37 Symptom Engine speed is high when the engine is idling. Diagnostic code No. d54 ISC valve Order Item/components and probable Check or maintenance job Reinstatement cause method Backup fuse is blown. • Check the backup fuse. ISC valve Refer to “CHECKING THE returns to its...
  • Page 291 FUEL INJECTION SYSTEM Fault code No. 39 Symptom Open circuit detected in a injector. Diagnostic code No. d36 Injector Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the couplers for any pins Cranking the •...
  • Page 292 FUEL INJECTION SYSTEM Fault code No. 41 Symptom Lean angle sensor: open or short circuit detected. Diagnostic code No. d08 Lean angle sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 293 FUEL INJECTION SYSTEM Fault code No. 42 Symptom No normal signals are received from the speed sensor. Diagnostic code No. d07 Speed sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the •...
  • Page 294 FUEL INJECTION SYSTEM Fault code No. 43 Symptom Power supply to the injector and fuel pump is not normal. Diagnostic code No. d09 Fuel system voltage Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the •...
  • Page 295 FUEL INJECTION SYSTEM Fault code No. 46 Symptom Power supply is not normal. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the • Main wire harness-ECU coupler that may be pulled out.

  • Page 296: Checking The Intake Air Pressure Sensor

    FUEL INJECTION SYSTEM EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR 1. Check: • intake air pressure sensor output voltage Out of specification → Replace. Intake air pressure sensor output voltage 3.75 ~ 4.25 V M MMM M MMM M MMM M MMM M MMM a.
  • Page 297 FUEL INJECTION SYSTEM M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 100) to the intake air temperature sensor terminal as shown. Br/W B/L Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe → brown/white 1 Negative tester probe →...
  • Page 298 AIR FILTER CASE AND AIR INTAKE DUCT AIR FILTER CASE AND AIR INTAKE DUCT 15 Nm (1.5 m kg, 11 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 32 Nm (3.2 m kg, 23 ft • •...
  • Page 299 AIR FILTER CASE AND AIR INTAKE DUCT 15 Nm (1.5 m kg, 11 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 32 Nm (3.2 m kg, 23 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 300 AIR FILTER CASE AND AIR INTAKE DUCT 15 Nm (1.5 m kg, 11 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 32 Nm (3.2 m kg, 23 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 301: Installing The Air Intake Duct And Air Filter Case

    AIR FILTER CASE AND AIR INTAKE DUCT INSTALLING THE AIR INTAKE DUCT AND AIR FILTER CASE 1. Install: • air intake duct joint 1 TIP: Fit the projection a on the air intake duct joint between the projections on the air intake duct. 2.

  • Page 302: Fuel Pump And Fuel Tank

    FUEL PUMP AND FUEL TANK FUEL PUMP AND FUEL TANK 8 Nm (0.8 m kg, 5.8 ft • • 30 Nm (3.0 m kg, 22 ft 16 Nm (1.6 m kg, 11 ft • • • • Order Job/Part Q’ty Remarks Removing the fuel pump and fuel Remove the parts in the order listed.
  • Page 303 FUEL PUMP AND FUEL TANK 8 Nm (0.8 m kg, 5.8 ft • • 30 Nm (3.0 m kg, 22 ft 16 Nm (1.6 m kg, 11 ft • • • • Order Job/Part Q’ty Remarks Fuel tank holder Fuel tank cap Fuel tank For installation, reverse the removal pro- cedure.

  • Page 304: Removing The Fuel Tank

    FUEL PUMP AND FUEL TANK REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel hose NOTICE • Be sure to disconnect the fuel hose by hand.

  • Page 305: Checking The Fuel Pump Body

    FUEL PUMP AND FUEL TANK CHECKING THE FUEL PUMP BODY 1. Check: • fuel pump body Obstruction → Clean. Cracks/damage → Replace the fuel pump assembly. CHECKING THE ROLLOVER VALVE 1. Check: • rollover valve Damage/faulty → Replace. INSTALLING THE FUEL PUMP 1.

  • Page 306: Installing The Fuel Hose

    FUEL PUMP AND FUEL TANK INSTALLING THE FUEL HOSE 1. Install: • fuel hose • fuel pump coupler TIP: To install the fuel hose onto the throttle body and the fuel tank, slide the fuel hose connector cover 1 on the end of the hose in direction of the arrow shown.

  • Page 307: Throttle Body

    THROTTLE BODY EAS00909 THROTTLE BODY Order Job/Part Q’ty Remarks Removing the throttle body Remove the parts in the order listed. Seats/rear console Refer to “SEATS, REAR CONSOLE AND INSTRUMENT PANELS” in chapter 8. Intake air pressure sensor coupler Disconnect. Throttle position sensor coupler Disconnect.
  • Page 308 THROTTLE BODY Order Job/Part Q’ty Remarks Fuel hose Disconnect. Refer to “REMOVING THE THROTTLE BODY ASSEMBLY” and “INSTALLING THE THROTTLE BODY ASSEMBLY”. Air intake duct joint clamp Air intake duct joint Throttle body joint clamp Refer to “INSTALLING THE THROT- Throttle body assembly TLE BODY ASSEMBLY”.
  • Page 309 THROTTLE BODY Order Job/Part Q’ty Remarks Disassembling the throttle body Remove the parts in the order listed. assembly Intake air pressure sensor Intake air pressure sensor hose Throttle position sensor Injector fuel rail Fuel injector Throttle body NOTICE The throttle body should not be disas- sembled.

  • Page 310: Removing The Throttle Body Assembly

    THROTTLE BODY REMOVING THE THROTTLE BODY ASSEMBLY 1. Disconnect: • fuel hose NOTICE • Be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. • Although the fuel has been removed from the fuel tank be careful when disconnect- ing the fuel hose, since there may be fuel remaining in it.

  • Page 311: Installing The Throttle Body Assembly

    THROTTLE BODY M MMM M MMM M MMM M MMM M MMM a. Wash the throttle body in a petroleum- based solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages with com- pressed air. L LLL L LLL L LLL...
  • Page 312 THROTTLE BODY 5. Connect: • fuel hose NOTICE When connecting the fuel hose, make sure that it is securely connected, and that the fuel hose connector cover is in the correct position, otherwise the fuel hose will not be properly connected. TIP: To connect the fuel hose onto the throttle body, slide the fuel hose connector cover 1 on...

  • Page 313: Checking The Fuel Pump And Pressure Regulator Operation

    THROTTLE BODY EAS00915 CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Check: • pressure regulator operation M MMM M MMM M MMM M MMM M MMM a. Remove the seat. Refer to “SEATS, REAR CONSOLE AND INSTRUMENT PANELS” in chapter 8. b.

  • Page 314: Checking And Adjusting The Throttle Position Sensor

    THROTTLE BODY EAS00916 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 1. Check: • throttle position sensor M MMM M MMM M MMM M MMM M MMM a. Disconnect the throttle position sensor cou- pler from the throttle position sensor. b. Remove the throttle position sensor from the throttle body.
  • Page 315 THROTTLE BODY c. Measure the throttle position sensor volt- age. d. Adjust the throttle position sensor angle so that the voltage is within the specified range. Throttle position sensor voltage 0.68 V (yellow-black/blue) e. After adjusting the throttle position sensor angle, tighten the throttle position sensor screws 3.

  • Page 316: Drive Train

    DRIV TROUBLESHOOTING EBS00155 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 317 DRIV TROUBLESHOOTING (c).A slight “thunk” evident at low speed opera- tion. This noise must be distinguished from normal vehicle operation. Diagnosis: Possible broken gear teeth. WARNING Stop riding immediately if broken gear teeth are suspected. This condition could result in the shaft drive assembly locking up, causing loss of control of the vehicle and possible injury to the rider.

  • Page 318: Troubleshooting Chart

    DRIV TROUBLESHOOTING EBS00157 TROUBLESHOOTING CHART When basic conditions “(a)” and “(b)” exist, check the following points: YES Replace the wheel bearing. Elevate and spin both wheels. Feel for wheel bearing damage. (Refer to “STEERING SYSTEM” and “REAR KNUCKLE AND STABILIZER” in chapter 8.) Check the wheel nuts and hub nuts for tight- Torque to specification.

  • Page 319: Front Constant Velocity Joints, Differential Gear And Drive Shaft

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT 55 Nm (5.5 m kg, 40 ft • • 55 Nm (5.5 m kg, 40 ft • • Order Job/Part Q’ty Remarks Removing the front constant veloc- Remove the parts in the order listed.
  • Page 320 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT 55 Nm (5.5 m kg, 40 ft • • 55 Nm (5.5 m kg, 40 ft • • Order Job/Part Q’ty Remarks Differential gear case assembly Compression spring Washer Dust seal Dust seal Drive shaft For installation, reverse the removal pro-...
  • Page 321 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT EBS00159 Order Job/Part Q’ty Remarks Disassembling the front constant Remove the parts in the order listed. velocity joints The following procedure applies to both of the front constant velocity joints. Clip Boot band Boot band...
  • Page 322 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT Order Job/Part Q’ty Remarks Clip Refer to “DISASSEMBLING THE FRONT CONSTANT VELOCITY Joint shaft JOINTS” and “ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS”. For assembly, reverse the disassembly procedure. È Wheel side É...
  • Page 323 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT EBS00160 62 Nm (6.2 m kg, 45 ft • • 11 Nm (1.1 m kg, 8.0 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft 23 Nm (2.3 m kg, 17 ft...
  • Page 324 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT 62 Nm (6.2 m kg, 45 ft • • 11 Nm (1.1 m kg, 8.0 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft 23 Nm (2.3 m kg, 17 ft...

  • Page 325: Disassembling The Front Constant Velocity Joints

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT DISASSEMBLING THE FRONT CONSTANT È VELOCITY JOINTS È Gear case side É Wheel side 1. Remove: • clip 1 • double off-set joint 2 • circlip 3 • ball bearing 4 •...

  • Page 326: Disassembling The Universal Joint

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

  • Page 327: Checking The Front Constant Velocity Joints

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT EBS00165 CHECKING THE FRONT 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. NOTICE Always use a new boot band.

  • Page 328: Checking The Differential Gear Motor

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT CHECKING THE DIFFERENTIAL GEAR È MOTOR 1. Check: • differential gear motor M MMM M MMM M MMM M MMM M MMM a. Connect two C size batteries to the gear motor terminals 1 (as shown in illustration).
  • Page 329 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT È TIP: • Install the clip 1 into the groove in the joint shaft as shown. • Secure the off-set joint in a vise, and then fit the joint shaft into the off-set joint using a hammer.

  • Page 330: Assembling The Differential Gears

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT b. Install the dust boots 1. È c. Install the dust boot bands 4, 5. Use a boot band installing tool 6. Boot band installing tool 90890-01526, YM-01526 TIP: • The new boot bands may differ from the orig- inal ones.
  • Page 331 FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT b. Connect two C-size batteries to the gear motor terminal 2 to operate the pinion gear 3, and operate it until the mark 4 on the gear is aligned with the mark 5 on the gear motor case.

  • Page 332: Assembling The Universal Joint

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT 4. Check: • differential gear operation Unsmooth operation → Replace the differ- ential gear assembly. Insert the double off-set joint into the differ- ential gear, and turn the gear back and forth.

  • Page 333: Adjusting The Differential Gear Lash

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT 3. Install: • ring gear fix bolt (M10) 1 (into the drain plug hole) Ring gear fix bolt (M10) 90890-01527, YM-01527 NOTICE Finger tighten the bolt until it holds the ring gear.

  • Page 334: Checking The Differential Gear Operation

    FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL DRIV GEAR AND DRIVE SHAFT 2. Adjust: • gear lash M MMM M MMM M MMM M MMM M MMM a. Select the suitable shims using the following chart. Too little gear Reduce shim thickness. lash Too large Increase shim thickness.

  • Page 335: Rear Constant Velocity Joints, Final Drive Gear And Drive Shaft

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE GEAR AND DRIVE SHAFT 70 Nm (7.0 m kg, 51 ft • • Order Job/Part Q’ty Remarks Removing the rear constant velocity Remove the parts in the order listed. joints, final drive gear and drive shaft Rear skid plate...
  • Page 336 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT 70 Nm (7.0 m kg, 51 ft • • Order Job/Part Q’ty Remarks Rear constant velocity joint TIP: Remove the constant velocity joint on the right side of the vehicle, rotate the final gear assembly slightly so that the con- stant velocity joint on the left side clears the frame, and then remove it.
  • Page 337 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT 70 Nm (7.0 m kg, 51 ft • • Order Job/Part Q’ty Remarks Drive shaft For installation, reverse the removal pro- cedure. 7 - 22...
  • Page 338 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT Order Job/Part Q’ty Remarks Disassembling the rear constant Remove the parts in the order listed. velocity joints The following procedure applies to both of the rear constant velocity joints. Dust cover Clip Boot band...
  • Page 339 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT Order Job/Part Q’ty Remarks Off-set joint Refer to “DISASSEMBLING THE REAR CONSTANT VELOCITY JOINTS” and Clip “ASSEMBLING THE REAR CONSTANT Joint shaft VELOCITY JOINTS”. For assembly, reverse the disassembly procedure.
  • Page 340 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT Order Job/Part Q’ty Remarks Disassembling the final gear case Remove the parts in the order listed. Final drive pinion gear assembly Final drive pinion gear shim Drive shaft coupling gear Final drive pinion gear Refer to “DISASSEMBLING THE Inner race...
  • Page 341 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT Order Job/Part Q’ty Remarks Ring gear bearing housing TIP: Working in a crisscross pattern, loosen each bolt 1/4 of a turn. After all the bolts are loosened, remove them. Oil seal Bearing Ring gear shim...
  • Page 342 Remarks Bearing Refer to “REMOVING THE FINAL DRIVE ROLLER BEARINGS” and Bearing “INSTALLING THE FINAL DRIVE ROLLER BEARINGS”. Final gear case For assembly, reverse the disassembly procedure. * Apply Yamaha bond No.1215 90890-85505 ® (Three bond No.1215 7 - 27...

  • Page 343: Disassembling The Rear Constant Velocity Joints

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT DISASSEMBLING THE REAR CONSTANT È VELOCITY JOINTS È Gear case side É Wheel side 1. Remove: • clip 1 • double off-set joint 2 • circlip 3 • ball bearing 4 •...

  • Page 344: Assembling The Rear Constant Velocity Joints

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT ASSEMBLING THE REAR CONSTANT È VELOCITY JOINTS È Wheel side É Gear case side 1. Install: • dust boot • clip 1 • off-set joint 2 • joint shaft 3 M MMM M MMM M MMM...
  • Page 345 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT 3. Apply: • molybdenum disulfide grease (into the ball joint assembly) TIP: Molybdenum disulfide grease is included in the repair kit. 4. Install: • dust boots 1 • boot bands 2, 3, 4, 5 M MMM M MMM M MMM...

  • Page 346: Disassembling The Final Gear Case

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT DISASSEMBLING THE FINAL GEAR CASE 1. Remove: • drive shaft coupling gear nut M MMM M MMM M MMM M MMM M MMM a. Place a folded rag 1. b.

  • Page 347: Removing The Final Drive Roller Bearings

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT REMOVING THE FINAL DRIVE ROLLER BEARINGS 1. Remove: • roller bearing (ring gear) 1 Use a suitable press tool 2 and an appro- priate support for the main housing. 2.

  • Page 348: Positioning The Final Drive Pinion Gear And Ring Gear

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR When the final drive pinion gear, ring gear, final gear case and/or ring gear bearing hous- ing are replaced, be sure to adjust the posi- tions of the final drive pinion gear and ring gear using the shim(s).
  • Page 349 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT 6) Round off the hundredth digit and select the appropriate shim(s). In the example above, the calculated num- ber is 0.97. The chart instructs you to round off 7 to 5 at the hundredth place. Thus, the shim thickness is 0.95 mm.
  • Page 350 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT h = bearing thickness (considered constant) Bearing thickness h 14.00 mm (0.55 in) Example: 1) If “98” is stamped on the final gear case, e = 50 + 0.98 = 50.98 2) If “55”...
  • Page 351 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT Selecting thrust washer 1. Measure: • ring gear thrust clearance “C” M MMM M MMM M MMM M MMM M MMM ® a. Place four pieces of Plastigauge between the originally fitted thrust washer and the ring gear.
  • Page 352 L LLL Adjusting the ring gear stopper 1. Install: • ring gear stopper • nut TIP: Apply sealant to the ring gear stopper threads. Yamaha bond No.1215 90890-85505 ® (Three bond No.1215 2. Adjust: • ring gear stopper clearance M MMM...

  • Page 353: Checking The Drive Shaft

    3. Check: • bearings Damage → Replace. TIP: • Roller bearings may be reused, but Yamaha recommends installing new ones. Do not reuse the oil seals. • 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 354 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT 3. Install: • ring gear fix bolt (M10) 1 (into the drain plug hole) Ring gear fix bolt (M10) 90890-01527, YM-01527 NOTICE Finger tighten the bolt until it holds the ring gear.

  • Page 355: Assembling The Final Gear Case

    REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT Adjusting the final gear lash 1. Remove: • ring gear bearing housing 1 • ring gear shim(s) 2 • ring gear 3 • thrust washer 4 2. Adjust: • gear lash M MMM M MMM M MMM...
  • Page 356 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT 2. Install: • ring gear bearing housing • M8 bolts (ring gear bearing housing) 1 23 Nm (2.3 m · kg, 17 ft · lb) • M10 bolts (ring gear bearing housing) 2 40 Nm (4.0 m ·...
  • Page 357 REAR CONSTANT VELOCITY JOINTS, FINAL DRIVE DRIV GEAR AND DRIVE SHAFT 4. Install: • drive shaft coupling gear nut M MMM M MMM M MMM M MMM M MMM a. Place a folded rag 1. b. Secure the drive shaft coupling gear edge in the vise.

  • Page 358: 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 • • Order Job/Part Q’ty Remarks Removing the front guard and hood Remove the parts in the order listed.

  • Page 359: Seats, Rear Console And Instrument Panels

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED SEATS, REAR CONSOLE AND INSTRUMENT PANELS 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft • • • • (16) 8 Nm (0.8 m kg, 5.8 ft • •...
  • Page 360 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 • • • • (16) 8 Nm (0.8 m kg, 5.8 ft • • 35 Nm (3.5 m kg, 25 ft •...

  • Page 361: Removing The Steering Wheel

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED REMOVING THE STEERING WHEEL 1. Turn the steering wheel so that it is straight and the front wheels are pointing straight ahead. 2. Remove: • steering wheel cover 1 • steering wheel TIP: While pushing the ends of the projections a together, remove the steering wheel cover from the steering wheel.

  • Page 362: Side Doors

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED SIDE DOORS 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 5 Nm (0.5 m kg, 3.6 ft •...

  • Page 363: Panels And Front Console

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED PANELS AND FRONT CONSOLE 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 • • 32 Nm (3.2 m kg, 23 ft •...
  • Page 364 CHAS SEATS, ENCLOSURE, HOOD AND 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 • • 32 Nm (3.2 m kg, 23 ft •...

  • Page 365: Removing The Side Panels

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED REMOVING THE SIDE PANELS The following procedure applies to both of the side panels. 1. Remove: • quick fastener 1 TIP: To remove the quick fastener, push its center with a screwdriver 2, then pull the fastener out.

  • Page 366: 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 367 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 368: 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 369: Installing The Rear Skid Plate

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

  • Page 370: Enclosure And Seat Belts

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED ENCLOSURE AND SEAT BELTS 65 Nm (6.5 m kg, 47 ft • • 22 Nm (2.2 m kg, 16 ft • • 7 Nm (0.7 m kg, 5.1 ft • • (14) 59 Nm (5.9 m kg, 43 ft •...

  • Page 371: Installing The Enclosure

    CHAS SEATS, ENCLOSURE, HOOD AND CARGO BED INSTALLING THE ENCLOSURE 1. Install: • lower support frame 1 64 Nm (6.4 m · kg, 46 ft · lb) 2. Install: • left side frame 2 • right side frame 3 • upper support frame 4 •...

  • Page 372: Front And Rear Wheels

    CHAS FRONT AND REAR WHEELS EBS00378 FRONT AND REAR WHEELS FRONT WHEELS 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 373 CHAS FRONT AND REAR WHEELS 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 374: Rear Wheels

    CHAS FRONT AND REAR WHEELS EBS00379 REAR WHEELS 30 Nm (3.0 m kg, 22 ft • • 350 Nm (35.0 m kg, 255 ft • • 55 Nm (5.5 m kg, 40 ft • • 48 Nm (4.8 m kg, 35 ft •...
  • Page 375 CHAS FRONT AND REAR WHEELS 30 Nm (3.0 m kg, 22 ft • • 350 Nm (35.0 m kg, 255 ft • • 55 Nm (5.5 m kg, 40 ft • • 48 Nm (4.8 m kg, 35 ft • •...

  • Page 376: Checking The Wheels

    CHAS FRONT AND REAR WHEELS EBS00383 CHECKING THE WHEELS 1. Check: • wheels 2. Measure: • wheel runout Over the specified limit → Replace the wheel or check the wheel bearing play 1. Wheel runout limit Front Radial 2: 2.0 mm (0.08 in) Lateral 3: 2.0 mm (0.08 in) Rear Radial 2: 2.0 mm (0.08 in)

  • Page 377: Checking The Brake Discs

    CHAS FRONT AND REAR WHEELS EBS00389 CHECKING THE BRAKE DISCS 1. Check: • brake discs Galling/damage → Replace. 2. Measure: • brake disc deflection Out of specification → Check the wheel runout. Brake disc maximum deflection Front: 0.1 mm (0.004 in) Rear: 0.1 mm (0.004 in) •...

  • Page 378: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES FRONT AND REAR BRAKES FRONT BRAKE PADS 17 Nm (1.7 m kg, 12 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. The following procedure applies to both of the front brake calipers.

  • Page 379: Rear Brake Pads

    CHAS FRONT AND REAR BRAKES EBS00401 REAR BRAKE PADS 17 Nm (1.7 m kg, 12 ft 48 Nm (4.8 m kg, 35 ft • • • • Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. The following procedure applies to both of the rear brake calipers.

  • Page 380: Replacing The Front And Rear Brake Pads

    CHAS FRONT AND REAR BRAKES NOTICE 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 381 CHAS FRONT AND REAR BRAKES 2. Install: • brake pads • brake pad spring TIP: 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 382: 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 • • 19 Nm (1.9 m kg, 13 ft • • Order Job/Part Q’ty Remarks Removing the brake master cylinder Remove the parts in the order listed.
  • Page 383 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 Secondary brake master cylinder kit stopper Gasket Secondary brake master cylinder kit...

  • Page 384: 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 385: 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 pipes 19 Nm (1.9 m · kg, 13 ft · lb) WARNING Proper brake pipe routing is essential to insure safe vehicle operation.
  • Page 386 CHAS FRONT AND REAR BRAKES 5. Check: • brake fluid level Brake fluid level is under the “MIN” level line → Fill up. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 6. Adjust: • brake pedal free play Refer “ADJUSTING BRAKE...

  • Page 387: Front Brake Caliper

    CHAS FRONT AND REAR BRAKES FRONT BRAKE CALIPER Order Job/Part Q’ty Remarks Removing the front brake caliper Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Brake fluid Drain. Front wheel Refer to “FRONT AND REAR WHEELS”.
  • Page 388 CHAS FRONT AND REAR BRAKES 5 Nm (0.5 m kg, 3.6 ft • • 17 Nm (1.7 m kg, 12 ft • • Order Job/Part Q’ty Remarks Disassembling the front brake cali- Remove the parts in the order listed. The following procedure applies to both of the front brake calipers.

  • Page 389: Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES EBS00424 REAR BRAKE CALIPERS 27 Nm (2.7 m kg, 19 ft • • 17 Nm (1.7 m kg, 12 ft • • 48 Nm (4.8 m kg, 35 ft • • Order Job/Part Q’ty Remarks Removing the rear brake calipers Remove the parts in the order listed.
  • Page 390 CHAS FRONT AND REAR BRAKES EBS00425 5 Nm (0.5 m kg, 3.6 ft • • 17 Nm (1.7 m kg, 12 ft • • Order Job/Part Q’ty Remarks Disassembling the rear brake cali- Remove the parts in the order listed. pers The following procedure applies to both of the rear brake calipers.

  • Page 391: Checking The Front And Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES EBS00427 DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERS 1. Remove: • brake caliper pistons • brake caliper dust seals 1 • brake caliper piston seals 2 M MMM M MMM M MMM M MMM M MMM a.

  • Page 392: Assembling The Front And Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES 1. Check: • brake caliper pistons 1 Scratches/rust/wear → Replace the brake caliper assembly. • brake caliper cylinders 2 Wear/scratches → Replace the brake cali- per assembly. • brake caliper body 3 Cracks/damage → Replace. •...

  • Page 393: Installing The Front And Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES EBS00434 È INSTALLING THE FRONT AND REAR BRAKE CALIPERS 1. Install: • brake caliper assembly • brake caliper bolts 48 Nm (4.8 m · kg, 35 ft · lb) • brake hose 1 • copper washers 2 •...
  • Page 394 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 395: Parking Brake

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

  • Page 396: Replacing The Parking Brake Pads

    CHAS PARKING BRAKE REPLACING THE PARKING BRAKE PADS 1. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 1.0 mm (0.04 in) 2. Install: • brake pad spring •...

  • Page 397: Parking Brake

    CHAS PARKING BRAKE PARKING BRAKE 40 Nm (4.0m kg, 29 ft • • 13 Nm (1.3 m kg, 9.4 ft • • Order Job/Part Q’ty Remarks Removing the parking brake Remove the parts in the order listed. Seats/rear console Refer to “SEATS, REAR CONSOLE AND INSTRUMENT PANELS”.
  • Page 398 CHAS PARKING BRAKE 40 Nm (4.0m kg, 29 ft • • 13 Nm (1.3 m kg, 9.4 ft • • Order Job/Part Q’ty Remarks Parking brake cable (parking brake Disconnect. side) Refer to “ASSEMBLING THE PARKING BRAKE”. For installation, reverse the removal pro- cedure.
  • Page 399 CHAS PARKING BRAKE 17 Nm (1.7 m kg, 12 ft • • 12 Nm (1.2 m kg, 8.7 ft 17 Nm (1.7 m kg, 12 ft • • • • Order Job/Part Q’ty Remarks Disassembling the parking brake Remove the parts in the order listed. Parking brake pad holding bolt Parking brake pad Brake pad spring...

  • Page 400: Parking Brake Disc

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

  • Page 401: Checking The Parking Brake

    CHAS PARKING BRAKE EB702040 CHECKING THE PARKING BRAKE 1. Check: • parking brake piston Scratches/rust/wear → Replace the parking brake assembly. • parking brake body Cracks/damage → Replace. CHECKING THE PARKING BRAKE DISC 1. Check: • brake disc Galling/damage → Replace. 2.
  • Page 402 CHAS PARKING BRAKE 2. Install: • push rod 1 • wave washers • retainer • O-ring • parking brake piston 2 • circlip TIP: Turn in the push rod until it protrudes a from the end of the parking brake arm shaft 3. a 5 ~ 6 mm (0.20 ~ 0.24 in) 3.
  • Page 403 CHAS PARKING BRAKE 7. Install: • parking brake cable 1 • parking brake assembly 2 • parking brake bolts 40 Nm (4.0 m · kg, 29 ft · lb) TIP: Turn the parking brake lever 3 to the position shown in the illustration so that there is enough space between the parking brake pads, and then install the parking brake assembly.

  • Page 404: 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 405 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 - 48...

  • Page 406: Steering System

    CHAS STEERING SYSTEM STEERING SYSTEM STEERING SHAFT 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 407 CHAS STEERING SYSTEM 40 Nm (4.0 m kg, 29 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 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...
  • Page 408 CHAS STEERING SYSTEM 40 Nm (4.0 m kg, 29 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Part Q’ty Remarks Steering rack assembly Refer to “ASSEMBLING THE STEERING ASSEMBLY”.

  • Page 409: Disassembling The Steering Assembly

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

  • Page 410: Assembling The Steering Assembly

    CHAS STEERING SYSTEM 3. Check: • rack gear teeth 1 • pinion gear teeth 2 Wear/damage → Replace the steering rack assembly. TIP: 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 411: Installing The Steering System

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

  • Page 412: Tie-Rod And Steering Knuckle

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

  • Page 413: Removing The Steering Knuckles

    CHAS STEERING SYSTEM REMOVING THE STEERING KNUCKLES 1. Remove: • steering knuckle 1 TIP: 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 414 CHAS STEERING SYSTEM Ball joint remover 90890-01474, YM-01474 Ball joint remover adapter set 90890-01477, YM-01477 90890-01474 Body YM-01474 90890-01474 Long bolt YM-01474 90890-01477 Short bolt YM-01477 90890-01477 Remover washer YM-01477 90890-01477 Remover spacer YM-01477 Installer 90890-01477 attachment YM-01477 90890-01477 Installer spacer YM-01477 90890-01477 Installer guide...
  • Page 415 CHAS STEERING SYSTEM h. Attach the assembled ball joint remover, new ball joint B and installer attachment 8 to the steering knuckle C. TIP: 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 416 CHAS STEERING SYSTEM h. Install the new oil seals. TIP: 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 - 59...

  • Page 417: 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 • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 45 Nm (4.5 m kg, 32 ft •...
  • Page 418 CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS 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 • • 45 Nm (4.5 m kg, 32 ft •...

  • Page 419: 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 420 CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS Ball joint remover 90890-01474, YM-01474 Ball joint remover adapter set 90890-01477, YM-01477 90890-01474 Body YM-01474 90890-01474 Long bolt YM-01474 90890-01477 Remover washer YM-01477 90890-01477 Remover spacer YM-01477 Installer 90890-01477 attachment YM-01477 90890-01477 Installer spacer YM-01477 90890-01477 Installer guide...

  • Page 421: Handling The Front Shock Absorbers And Gas Cylinders

    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. TIP: Always use a new ball joint set. L LLL L LLL L LLL L LLL L LLL HANDLING THE FRONT SHOCK...

  • Page 422: (For Models Equipped With Gas-Oil Damper Shock Absorbers)

    CHAS FRONT ARMS AND FRONT SHOCK ABSORBERS EBS00486 DISPOSING OF A FRONT SHOCK ABSORBER AND GAS CYLINDER (For models equipped with gas-oil damper shock absorbers) Gas pressure must be released before dispos- ing of a front shock absorber and gas cylinder. To release the gas pressure, press on the gas valve needle with a suitable tool as shown, until all of the gas is released (the hissing has...

  • Page 423: Installing The Front Arms And Front Shock Absorber

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

  • Page 424: Rear Knuckle And Stabilizer

    CHAS REAR KNUCKLE AND STABILIZER REAR KNUCKLE AND STABILIZER 42 Nm (4.2 m kg, 30 ft • • 60 Nm (6.0 m kg, 43 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 60 Nm (6.0 m kg, 43 ft •...

  • Page 425: Checking The Rear Knuckles

    CHAS REAR KNUCKLE 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 426: Rear Arms And Rear Shock Absorber

    CHAS REAR ARMS AND REAR SHOCK ABSORBER REAR ARMS AND REAR SHOCK ABSORBER 45 Nm (4.5 m kg, 32 ft • • 45 Nm (4.5 m kg, 32 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 45 Nm (4.5 m kg, 32 ft •...
  • Page 427 CHAS REAR ARMS AND REAR SHOCK ABSORBER 45 Nm (4.5 m kg, 32 ft • • 45 Nm (4.5 m kg, 32 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 45 Nm (4.5 m kg, 32 ft •...

  • Page 428: Checking The Rear Arms

    CHAS REAR ARMS AND REAR SHOCK ABSORBER CHECKING THE REAR ARMS 1. Check: • rear arms Bends/damage → Replace. 2. Check: • bushings Wear/damage → Replace. EBS00485 HANDLING THE REAR SHOCK ABSORBERS AND GAS CYLINDERS (For models equipped with gas-oil damper shock absorbers) WARNING This rear shock absorber and gas cylinder...

  • Page 429: Disposing Of A Rear Shock Absorber And Gas Cylinder (For Models Equipped With Gas-Oil Damper Shock Absorbers)

    CHAS REAR ARMS AND REAR SHOCK ABSORBER EBS00486 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER (For models equipped with gas-oil damper shock absorbers) Gas pressure must be released before dispos- ing of a rear shock absorber and gas cylinder. To release the gas pressure, press on the gas valve needle with a suitable tool as shown, until all of the gas is released (the hissing has...

  • Page 430: Installing The Rear Arms And Rear Shock Absorber

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

  • Page 431: Electrical

    – ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Diode 8 TPS (throttle position sensor) E Brake light switch 2 Lean angle sensor 9 ISC (idle speed control) unit F Differential gear motor 3 Gear position switch 0 Coolant temperature sensor G Radiator fan motor 4 Reverse switch A Crankshaft position sensor...
  • Page 432 – ELEC ELECTRICAL COMPONENTS 1 Auxiliary DC jack A Fuel injection system relay 2 On-Command four-wheel-drive motor switch B Main fuse and differential gear lock switch C Radiator fan motor relay 3 Main switch D Load control relay 4 Light switch E Four-wheel-drive motor relay 3 5 Rectifier/regulator F Fuse box...

  • Page 433: Checking Switch Continuity

    – ELEC CHECKING SWITCH CONTINUITY EBS01028 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. NOTICE Never insert the tester probes into the cou- pler terminal slots 1.

  • Page 434: Checking The Switches

    – ELEC CHECKING THE SWITCHES EBS01029 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading →...
  • Page 435 – ELEC CHECKING THE SWITCHES 1 Brake light switch 2 Main switch 3 On-command four-wheel-drive motor switch and differential gear lock switch 4 Light switch 5 Parking brake switch 6 Gear position switch 7 Reverse switch 8 Four-wheel-drive motor switch (differential gear motor) 9 - 5...

  • Page 436: Checking The Bulbs And Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS EBS01030 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 437: Checking The Condition Of The Bulbs

    – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: • bulb WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

  • Page 438: Checking The Condition Of The Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS M MMM M MMM M MMM M MMM M MMM a. Connect the positive tester probe to termi- nal 1 and the negative tester probe to ter- minal 2, and check the continuity. b.

  • Page 439: Ignition System

    – ELEC IGNITION SYSTEM EBS00503 IGNITION SYSTEM CIRCUIT DIAGRAM 9 - 9...

  • Page 440: Troubleshooting

    – ELEC IGNITION SYSTEM EBS01045 EBS01043 TROUBLESHOOTING 1. Main, ignition and backup fuses The ignition system fails to operate (no • Check the main, ignition and backup fuses spark or intermittent spark). for continuity. Refer to “CHECKING THE FUSES” in Check: chapter 3.
  • Page 441 – ELEC IGNITION SYSTEM EBS01032 EBS01034 3. Spark plug 4. Ignition spark gap • Check the condition of the spark plug. • Disconnect the spark plug cap from the • Check the spark plug type. spark plug. • Connect the ignition checker 1 as shown. •...
  • Page 442 – ELEC IGNITION SYSTEM EBS01036 EBS01038 5. Spark plug cap resistance 6. Ignition coil resistance • Remove the spark plug cap from the spark • Disconnect the ignition coil connectors plug lead. from the ignition coil terminals. • Connect the pocket tester (Ω × 1k) to the •...
  • Page 443 – ELEC IGNITION SYSTEM EBS01041 9. Lean angle sensor 7. Main switch • Remove the lean angle sensor. • Check the main switch for continuity. • Connect the pocket tester (DC 20 V) to the Refer to “CHECKING THE SWITCHES”. lean angle sensor coupler as shown.

  • Page 444: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM EBS00506 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 9 - 14...

  • Page 445: Starting Circuit Operation

    – ELEC ELECTRIC STARTING SYSTEM EBS00507 STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, load control relay, brake light switch, ECU (engine control unit) and gear position switch. If the main switch is “START” position, the starter motor can be operated only if: •...

  • Page 446: Troubleshooting

    – ELEC ELECTRIC STARTING SYSTEM EBS01048 EBS01044 TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main, ignition, backup and signaling system fuses Minimum open-circuit voltage 2.
  • Page 447 – ELEC ELECTRIC STARTING SYSTEM EBS01054 EBS01054 4. Starter relay 5. Load control relay • Remove the starter relay from the wire • Remove the load control relay from the harness. wire harness. • Connect the pocket tester (Ω × 1) and bat- •...
  • Page 448 – ELEC ELECTRIC STARTING SYSTEM EBS01041 EBS01059 6. Main switch 9. Wiring • Check the main switch for continuity. • Check the entire starting system wiring. Refer to “CHECKING THE SWITCHES”. Refer to “CIRCUIT DIAGRAM”. • Is the main switch OK? •...

  • Page 449: Starter Motor

    – ELEC STARTER MOTOR EBS01061 STARTER MOTOR Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Air intake duct Refer to “AIR FILTER CASE AND AIR INTAKE DUCT” in chapter 6. Starter motor lead Disconnect.
  • Page 450 – ELEC STARTER MOTOR Order Job/Part Q’ty Remarks Bushing Shim Refer to “ASSEMBLING THE STARTER Brush holder set MOTOR”. Armature assembly Starter motor yoke For assembly, reverse the disassembly procedure. 9 - 20...

  • Page 451: Checking The Starter Motor

    – ELEC STARTER MOTOR EBS01064 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600-grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 27 mm (1.06 in) 3.
  • Page 452 – ELEC STARTER MOTOR M MMM M MMM M MMM M MMM M MMM a. Measure the armature assembly resis- tances with the pocket tester. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Armature coil Commutator resistance 1 0.0250 ~ 0.0350 Ω at 20 °C (68 °F) Insulation resistance 2 Above 1 MΩ...

  • Page 453: Assembling The Starter Motor

    – ELEC STARTER MOTOR EBS00515 ASSEMBLING THE STARTER MOTOR 1. Install: • brush holder set 1 TIP: Align the projection a on the brush holder set with the slot b in the starter motor yoke. 2. Install: • starter motor yoke 1 •...

  • Page 454: Charging System

    – ELEC CHARGING SYSTEM EBS00516 CHARGING SYSTEM CIRCUIT DIAGRAM B/L Gy (BLACK) Gy B (GRAY) (GRAY) (GRAY) (GRAY) (GRAY) Br/B Br/B (BLACK) R/B Br/R START Br/R Br/R R/B Br/R (BLACK) Br/R R Br/R Br/L Br/R Br/R R/L Y/R Br/L B Br/L 2 AC magneto 3 Rectifier/regulator...

  • Page 455: Troubleshooting

    – ELEC CHARGING SYSTEM EBS01065 EBS01044 TROUBLESHOOTING 2. Battery The battery is not being charged. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main fuse 2. battery Minimum open-circuit voltage 3.
  • Page 456 – ELEC CHARGING SYSTEM EBS01066 EBS01100 3. Charging voltage 4. Stator coil resistance • Connect the engine tachometer to the • Disconnect the AC magneto couplers from spark plug lead. the wire harness. • Connect the pocket tester (Ω × 1) to the •...

  • Page 457: Lighting System

    – ELEC LIGHTING SYSTEM EBS00518 LIGHTING SYSTEM CIRCUIT DIAGRAM 4 Main fuse 5 Frame ground B G/W 6 Ignition fuse 7 Main switch 8 Battery G/W B (BLACK) B G/W i Headlight fuse B G/W j Light switch B G/W (BLACK) B/L Gy k Headlight relay...

  • Page 458: Troubleshooting

    – ELEC LIGHTING SYSTEM EBS01067 EBS01044 TROUBLESHOOTING 2. Battery Any of the following fail to light: head- • Check the condition of the battery. light, tail/brake light. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main, ignition and headlight fuses Minimum open-circuit voltage 2.
  • Page 459 – ELEC LIGHTING SYSTEM EBS01054 EBS01069 5. Load control relay 6. Wiring • Remove the load control relay from the • Check the entire lighting system wiring. wire harness. Refer to “CIRCUIT DIAGRAM”. • Connect the pocket tester (Ω × 1) and bat- •...

  • Page 460: Checking The Lighting System

    – ELEC LIGHTING SYSTEM EBS01070 2. Headlight relay CHECKING THE LIGHTING SYSTEM 1. The headlights fail to come on. • Remove the headlight relay. • Connect the pocket tester (Ω × 1) and bat- 1. Headlight bulb and socket tery (12 V) to the headlight relay as shown. •...
  • Page 461 – ELEC LIGHTING SYSTEM 3. Voltage 2. Voltage • Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the headlight couplers as shown. tail/brake light connectors as shown. È When the light switch is set to “HI”. Tail/brake light connectors (wire harness É...

  • Page 462: Signaling System

    – ELEC SIGNALING SYSTEM EBS00521 SIGNALING SYSTEM CIRCUIT DIAGRAM 9 - 32...
  • Page 463 – ELEC SIGNALING SYSTEM 4 Main fuse 5 Frame ground 6 Ignition fuse 7 Main switch 8 Battery B Backup fuse E Reverse switch G ECU (engine control unit) L Coolant temperature sensor M Speed sensor Q Gear position switch R Parking brake switch T Multifunction meter V Coolant temperature warning light...

  • Page 464: Troubleshooting

    – ELEC SIGNALING SYSTEM EBS01073 EBS01044 TROUBLESHOOTING 2. Battery Any of the following fail to light: warning • Check the condition of the battery. light, brake light or an indicator light. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1.
  • Page 465 – ELEC SIGNALING SYSTEM EBS01054 EBS01074 4. Load control relay 5. Wiring • Remove the load control relay from the • Check the entire signaling system wiring. wire harness. Refer to “CIRCUIT DIAGRAM”. • Connect the pocket tester (Ω × 1) and bat- •...

  • Page 466: Checking The Signaling System

    – ELEC SIGNALING SYSTEM EBS01075 3. Voltage CHECKING THE SIGNALING SYSTEM EBS01076 • Connect the pocket tester (DC 20 V) to the 1. The brake light fails to come on. tail/brake light connectors (wire harness side) as shown. 1. Brake light bulb and bulb socket Positive tester probe →...
  • Page 467 – ELEC SIGNALING SYSTEM EBS01078 3. Voltage 2. The neutral, high-range, and/or low-range indicator light fails to come on. • Connect the pocket tester (DC 20 V) to the meter assembly coupler as shown. 1. Gear position switch Positive tester probe → brown/yellow 1 •...
  • Page 468 – ELEC SIGNALING SYSTEM EBS01079 3. Voltage 3. The reverse indicator light fails to come on. • Connect the pocket tester (DC 20 V) to the 1. Reverse switch meter assembly coupler as shown. • Check the reverse switch for continuity. Positive tester probe →...
  • Page 469 – ELEC SIGNALING SYSTEM EBS01081 3. Voltage 4. The park indicator light fails to come on. • Connect the pocket tester (DC 20 V) to the 1. Parking brake switch meter assembly coupler as shown. • Check the parking brake switch for conti- Positive tester probe →...
  • Page 470 – ELEC SIGNALING SYSTEM EBS01081 3. Voltage 5. The differential gear lock indicator light and/ or four-wheel-drive motor indicator light fails • Connect the pocket tester (DC 20 V) to the to come on. meter assembly coupler as shown. Positive tester probe → brown/yellow 1 1.
  • Page 471 – ELEC SIGNALING SYSTEM EBS01083 6. The coolant temperature warning light does not come on when the main switch is set to “ON”, or if the coolant temperature warning light does not come on when the tempera- ture is high (more than 122 °C (251.6 °F)). EBS00812 1.
  • Page 472 – ELEC SIGNALING SYSTEM 7. The fuel meter fails to come on. 3. Voltage 1. Fuel sender • Connect the pocket tester (DC 20 V) to the meter assembly coupler as shown. • Drain the fuel from the fuel tank and then Positive tester probe →...
  • Page 473 – ELEC SIGNALING SYSTEM 8. The speedometer fails to come on. 2. Wiring 1. Speed sensor • Check the wiring circuit from the fuel pump to ECU (brown/white) and fuel pump to • Connect the pocket tester (DC 20 V) to the meter assembly (orange/black).
  • Page 474 – ELEC SIGNALING SYSTEM 3. Voltage • Connect the pocket tester (DC 20 V) to the meter assembly coupler as shown. Positive tester probe → brown/yellow 1 Negative tester probe → black/white 2 Y/L Br/Y B/W Y/L Br/Y B/W • Set the main switch to “ON”. •...

  • Page 475: Cooling System

    – ELEC COOLING SYSTEM EBS00532 COOLING SYSTEM CIRCUIT DIAGRAM 9 - 45...

  • Page 476: Troubleshooting

    – ELEC COOLING SYSTEM EBS01085 EBS01044 TROUBLESHOOTING 2. Battery The radiator fan motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main, ignition, and radiator fan motor fuses 2.
  • Page 477 – ELEC COOLING SYSTEM EBS01086 5. Radiator fan motor relay 4. Radiator fan motor • Remove the radiator fan motor relay from • Disconnect the radiator fan motor coupler the wire harness. • Connect the pocket tester (Ω × 1) and bat- from the wire harness.
  • Page 478 – ELEC COOLING SYSTEM 6. Radiator fan motor circuit breaker • Remove the radiator fan motor circuit breaker from the wire harness. • Connect the pocket tester (Ω × 1) to the radiator fan motor circuit breaker. Radiator fan motor circuit breaker resistance 0 ~ 0.05 Ω...
  • Page 479 – ELEC COOLING SYSTEM EBS00812 7. Coolant temperature sensor • Remove the coolant temperature sensor from the cylinder head. • Connect the pocket tester (Ω × 100) to the coolant temperature sensor 1 as shown. • Immerse the coolant temperature sensor in a container filled with coolant 2.

  • Page 480: Fuel Pump System

    – ELEC FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM 9 - 50...

  • Page 481: Troubleshooting

    – ELEC FUEL PUMP SYSTEM TROUBLESHOOTING EBS01044 2. Battery The fuel pump fails to operate. • Check the condition of the battery. Check: Refer to “CHECKING AND CHARGING 1. main, ignition, and fuel injection system THE BATTERY” in chapter 3. fuses Minimum open-circuit voltage 2.
  • Page 482 – ELEC FUEL PUMP SYSTEM 4. Fuel injection system relay 5. Fuel pump • Remove the fuel injection system relay • Check the condition of the fuel pump. from the wire harness. Refer to “CHECKING THE FUEL PUMP • Connect the pocket tester (Ω × 1) and bat- BODY”...

  • Page 483: 2Wd/4Wd Selecting System

    – ELEC 2WD/4WD SELECTING SYSTEM EBS00535 2WD/4WD SELECTING SYSTEM CIRCUIT DIAGRAM 9 - 53...
  • Page 484 – ELEC 2WD/4WD SELECTING SYSTEM EBS01095 EBS01043 TROUBLESHOOTING 1. Main, ignition and four-wheel-drive motor fuses The four-wheel-drive motor indicator light fails to come on. • Check the main, ignition and four-wheel- drive motor fuses for continuity. Check: Refer to “CHECKING THE FUSES” in 1.
  • Page 485 – ELEC 2WD/4WD SELECTING SYSTEM EBS01096 EBS01097 4. Four-wheel-drive motor relay 1 5. Four-wheel-drive motor relay 2 • Remove the four-wheel-drive motor relay • Remove the four-wheel-drive motor relay 1 from the wire harness. 2 from the wire harness. • Connect the pocket tester (Ω × 1) and the •...
  • Page 486 – ELEC 2WD/4WD SELECTING SYSTEM EBS01098 EBS01092 6. Four-wheel-drive motor relay 3 7. On-command four-wheel-drive motor switch and differential gear lock switch • Remove the four-wheel-drive motor relay 3 from the wire harness. • Check the on-command four-wheel-drive • Connect the pocket tester (Ω × 1) and the motor switch and differential gear lock battery (12 V) to the four-wheel-drive switch for continuity.
  • Page 487 – ELEC 2WD/4WD SELECTING SYSTEM EBS01094 8. Differential gear motor 9. Wiring connection • Disconnect the differential gear motor cou- • Check the connections of the entire 2WD/ pler. 4WD selecting system. • Remove the differential gear motor from Refer to “CIRCUIT DIAGRAM”. the differential gear case.

  • Page 488: Troubleshooting

    TRBL STARTING FAILURE/HARD STARTING SHTG EBS00537 TROUBLESHOOTING TIP: 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 489: 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 490: 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 491: Faulty Gear Shifting

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

  • Page 492: Faulty Brake

    FAULTY CLUTCH PERFORMANCE/ TRBL OVERHEATING/OVERCOOLING/FAULTY BRAKE 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 493: Unstable Handling

    SHOCK ABSORBER MALFUNCTION/ TRBL UNSTABLE HANDLING/LIGHTING SYSTEM SHTG EBS00551 SHOCK ABSORBER MALFUNCTION MALFUNCTION • Bent or damaged damper rod • Damaged oil seal lip • Fatigued shock absorber spring EBS00552 UNSTABLE HANDLING UNSTABLE HANDLING Steering wheel Wheels • Improperly installed or bent •...
  • Page 494 YXR70FX 2008 WIRING DIAGRAM 1 Crankshaft position sensor n Tail/brake light COLOR CODE 2 AC magneto o Radiator fan motor B.... Black 3 Rectifier/regulator p Radiator fan motor circuit Br ..Brown 4 Main fuse breaker G ... Green 5 Frame ground q Load control relay Gy ..
  • Page 496 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
  • Page 497 YXR70FX 2008 WIRING DIAGRAM Br/W W Y/G B/Y Sb R/L L/B R/W R/Y Gy/G W/B R/G Y/W G/Y Y G/W G/R L/Y Y/L Br/R Y/W B/L L/R Y/B W/R B/R P/L Br/L (BLACK) B G/W (BLACK) (BLACK) G/W B Br/R...

This manual is also suitable for:

Rhino 700 2008Rhino 700fi 2008Rhino yxr70fx 2008

Table of Contents