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  4. 2004 YXR660
  5. Service Manual

Yamaha 2004 YXR660 Service Manual

Summary of 2004 YXR660

  • Page 1

    Ebs00004 how to use this manual manual organization this manual consists of chapters for the main categories of subjects. (see “symbols”) 1st title 1: this is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: this title indicates the section of the chapter...

  • Page 2: Gen

    Ebs00006 symbols the following symbols are not relevant to every vehicle. Symbols 1 to 0 indicate the subject of each chapter. 1 general information 2 specifications 3 periodic checks and adjustments 4 engine 5 cooling system 6 fuel system 7 drive train 8 chassis 9 electrical 0 troubleshooting symbo...

  • Page 3: Table of Contents

    Ebs00008 table of contents general information gen info 1 specifications spec 2 periodic checks and adjustments chk adj 3 engine eng 4 cooling system cool 5 fuel system fuel 6 drive train driv 7 chassis chas 8 electrical elec 9 troubleshooting trbl shtg 10 – + www.Midwestmanuals.Com.

  • Page 4: Contents

    Contents chapter 1 general information vehicle identification............................................................................ 1-1 vehicle identification number ..................................................... 1-1 model label..............................................................

  • Page 5: Chapter 3

    Lubrication points and lubricant types .................................... 2-23 engine................................................................................................... 2-23 coolant flow diagrams ..................................................................... 2-24 oil flow di...

  • Page 6: Chapter 4

    Changing the differential gear oil ........................................ 3-35 checking the constant velocity joint dust boots .......... 3-36 checking the steering system .................................................. 3-37 adjusting the toe-in.....................................................

  • Page 7

    Valves and valve springs.................................................................. 4-25 removing the valves and valve springs ............................... 4-26 checking the valves and valve springs ................................ 4-27 installing the valves and valve springs ................

  • Page 8

    Crankcase ................................................................................................ 4-66 starter motor, timing chain and oil filter.......................... 4-66 crankcase .......................................................................................... 4-68 crankcas...

  • Page 9: Chapter 5

    Chapter 5 cooling system radiator and coolant reservoir .................................................... 5-1 checking the radiator.................................................................... 5-3 installing the radiator.................................................................. 5-4...

  • Page 10: Chapter 8

    Rear constant velocity joints, final drive gear and drive shaft ...................................................................................... 7-18 assembling the rear constant velocity joints................. 7-24 disassembling the final gear case.......................................... 7...

  • Page 11: Chapter 9

    Rear brake caliper ......................................................................... 8-31 disassembling the front brake calipers.............................. 8-35 disassembling the rear brake caliper .................................. 8-35 checking the front and rear brake calipers ...........

  • Page 12

    Checking the bulbs and bulb sockets .......................................... 9-6 types of bulbs .................................................................................... 9-6 checking the condition of the bulbs ....................................... 9-6 checking the condition of the bul...

  • Page 13: Chapter 10

    Chapter 10 troubleshooting starting failure/hard starting ..................................................... 10-1 fuel system........................................................................................ 10-1 electrical system................................................................

  • Page 14: Gen

    1 - 1 gen info general information vehicle identification vehicle identification number the vehicle identification number 1 is stamped into the left side of the frame. Model label the model label 1 is affixed to the frame. This information will be needed to order spare parts. Vehicle identification ...

  • Page 15: Gen

    1 - 2 gen info features features self-adjusting parking brake mechanism usually, for vehicles equipped with a parking brake that must be adjusted manually, it is necessary to adjust the adjusting bolt to achieve the proper clearance between the brake caliper piston and the adjusting bolt. This adjus...

  • Page 16: Gen

    1 - 3 gen info features parking brake operation 1 parking brake arm 2 parking brake arm shaft 3 set bolt 4 adjusting bolt sleeve 5 brake caliper piston 6 brake pad when the parking brake is operated, the parking brake cable turns the parking brake arm 1. The rotation of the parking brake arm is chan...

  • Page 17: Gen

    1 - 4 gen info features parking brake adjustment 1 brake caliper piston 2 nut 3 adjusting bolt 4 adjusting bolt sleeve when the brake pedal is operated, the brake fluid pressure in the master cylinder increases and the brake caliper piston 1 and the nut 2 are pushed. When there is proper clearance b...

  • Page 18: Gen

    1 - 5 gen info important information eb101000 important information preparation for removal procedures 1. Remove all dirt, mud, dust and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. Refer to “special tools”. 3. When disassembling the vehicle, always ke...

  • Page 19: Gen

    1 - 6 gen info important information eb101030 lock washers/plates and cotter pins 1. Replace all lock washers/plates 1 and cot- ter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. Eb101040 bearings and oil seals 1. Install bea...

  • Page 20: Gen

    1 - 7 gen info checking of connections eb801000 checking of connections check the connectors for stains, rust, mois- ture, etc. 1. Disconnect: • connector 2. Check: • connector moisture → dry each terminal with an air blower. Stains/rust → connect and disconnect the terminals several times. 3. Check...

  • Page 21: Gen

    1 - 8 gen info special tools eb102001 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may dif...

  • Page 22: Gen

    1 - 9 gen info special tools 90890-01311 ym-08035-a tappet adjusting tool this tool is necessary for adjusting the valve clearance. 90890-01312 ym-01312-a fuel level gauge this gauge is used to measure the fuel level in the float chamber. 90890-01325 yu-24460-01 radiator cap tester this tool is used...

  • Page 23: Gen

    1 - 10 gen info special tools 90890-01430 ym-38404 ring nut wrench this tool is needed to removing and installing the middle driven shaft bearing retainer. 90890-01467 ym-01467 gear lash measurement tool this tool is used to measure the gear lash. 90890-01474 ym-01474 ball joint remover/installer se...

  • Page 24: Gen

    1 - 11 gen info special tools compressor 90890-04019 ym-04019 attachment 90890-01243 ym-01253-1 valve spring compressor valve spring compressor attachment this tool is needed to remove and install the valve assemblies. Middle driven shaft bearing driver 90890-04058 ym-04058-1 mechanical seal install...

  • Page 25: Gen

    1 - 12 gen info special tools 90890-04134 ym-04134 sheave spring compressor this tool is needed when removing or installing the secondary sheave spring. 90890-04135 ym-04135 sheave fixed block this tool is needed when removing or installing the secondary sheave spring. 90890-06754 ym-34487 ignition ...

  • Page 26: Spec

    2 - 1 spec specifications general specifications item standard model code 5ug1 dimensions overall length 2,885 mm (113.6 in) overall width 1,385 mm (54.5 in) overall height 1,853 mm (73.0 in) seat height 818 mm (32.2 in) wheelbase 1,910 mm (75.2 in) minimum ground clearance 273 mm (10.75 in) minimum...

  • Page 27: Spec

    2 - 2 spec general specifications differential gear case oil periodic oil change 0.32 l (0.28 imp qt, 0.34 us qt) total amount 0.33 l (0.29 imp qt, 0.35 us qt) air filter wet type element fuel type unleaded gasoline only fuel tank capacity 30 l (6.60 imp gal, 7.93 us gal) carburetor type/quantity bs...

  • Page 28: Spec

    2 - 3 spec general specifications tire pressure (cold tire) maximum load* 397 kg (876 lb) off-road riding front 63 ~ 77 kpa (0.63 ~ 0.77 kg/cm 2 , 9 ~ 11 psi) rear 91 ~ 105 kpa (0.91 ~ 1.05 kg/cm 2 , 13 ~ 15 psi) * load in total weight of cargo, operator, passenger, accessories and tongue weight bra...

  • Page 29: Spec

    2 - 4 spec engine specifications engine specifications item standard limit cylinder head warp limit ---- 0.03 mm (0.0012 in) cylinder bore size 100.005 ~ 100.055 mm (3.9372 ~ 3.9392 in) 100.10 mm (3.9410 in) measuring point 50 mm (1.97 in) ---- camshaft drive method chain drive (left) ---- cam dimen...

  • Page 30: Spec

    2 - 5 spec engine specifications cam chain cam chain type/no. Of links 92rh2010j/126m ---- cam chain adjustment method automatic ---- rocker arm/rocker arm shaft rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) ---- shaft outside diameter 11.976 ~ 11.991 mm (0.4715 ~ 0.4721 in) ---...

  • Page 31: Spec

    2 - 6 spec engine specifications stem-to-guide clearance in 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.08 mm (0.0031 in) ex 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) 0.10 mm (0.0039 in) stem runout limit ---- 0.01 mm (0.0004 in) valve seat width in 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) ---- ex 0.9 ~ 1.1 mm (0....

  • Page 32: Spec

    2 - 7 spec engine specifications piston piston to cylinder clearance 0.050 ~ 0.070 mm (0.0020 ~ 0.0028 in) 0.15 mm (0.0059 in) piston size “d” 99.945 ~ 99.995 mm (3.9348 ~ 3.9368 in) ---- measuring point “h” 2.5 mm (0.10 in) ---- piston off-set 1.0 mm (0.0394 in) ---- off-set direction intake side -...

  • Page 33: Spec

    2 - 8 spec engine specifications oil ring dimensions (b × t) 2.5 × 3.4 mm (0.0984 × 0.1339 in) ---- end gap (installed) 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in) ---- side clearance 0.06 ~ 0.15 mm (0.0024 ~ 0.0059 in) ---- crankshaft crank width “a” 74.95 ~ 75.00 mm (2.9508 ~ 2.9528 in) ---- runout limit ...

  • Page 34: Spec

    2 - 9 spec engine specifications transmission main axle deflection limit ---- 0.06 mm (0.0024 in) drive axle deflection limit ---- 0.06 mm (0.0024 in) shifter shifter type shift drum and guide bar ---- air filter oil grade yamaha foam air filter oil or other quality foam air filter oil ---- carburet...

  • Page 35: Spec

    2 - 10 spec engine specifications cooling system radiator core width 380 mm (14.96 in) ---- height 238 mm (9.37 in) ---- thickness 24 mm (0.94 in) ---- radiator cap opening pressure 107.9 ~ 137.3 kpa (1.079 ~ 1.373 kg/cm 2 , 15.35 ~ 19.53 psi) ---- radiator capacity (including all routes) 2.5 l (2.2...

  • Page 36: Spec

    2 - 11 spec engine specifications cylinder head tightening sequence www.Midwestmanuals.Com.

  • Page 37: Spec

    2 - 12 spec chassis specifications chassis specifications item standard limit steering system type rack and pinion ---- front suspension shock absorber travel 108 mm (4.25 in) ---- spring free length 313 mm (12.32 in) ---- spring fitting length 247.9 mm (9.76 in) ---- spring rate (k1) 19.4 n/mm (1.9...

  • Page 38: Spec

    2 - 13 spec chassis specifications front disc brake type dual ---- disc outside diameter × thickness 200 × 3.5 mm (7.87 × 0.14 in) ---- pad thickness inner 5.2 mm (0.20 in) 1.5 mm (0.06 in) pad thickness outer 5.2 mm (0.20 in) 1.5 mm (0.06 in) master cylinder inside diameter 17.4 mm (0.69 in) ---- c...

  • Page 39: Spec

    2 - 14 spec electrical specifications electrical specifications item standard limit voltage 12 v ---- ignition system ignition timing (btdc) 12°/ 1,500 r/min ---- advancer type digital type ---- c.D.I. Magneto model/manufacturer f4t46972/mitsubishi ---- pickup coil resistance/color 459 ~ 561 Ω at 20...

  • Page 40: Spec

    2 - 15 spec electrical specifications electric starter system type constant mesh type ---- starter motor model/manufacturer sm-13/mitsuba ---- output 0.8 kw ---- armature coil resistance 0.025 ~ 0.035 Ω at 20 °c (68 °f) ---- brush overall length 12.5 mm (0.49 in) 5 mm (0.20 in) spring force 7.65 ~ 1...

  • Page 41: Spec

    2 - 16 spec tightening torques ebs01005 tightening torques engine tightening torques part to be tightened part name thread size q’ty tightening torque remarks nm m · kg ft · lb cylinder head bolt m6 1 10 1.0 7.2 bolt m9 6 38 3.8 27 spark plug — m12 1 18 1.8 13 cylinder head (exhaust pipe) stud bolt ...

  • Page 42: Spec

    2 - 17 spec tightening torques crankcase bolt m8 3 26 2.6 19 bolt m6 14 10 1.0 7.2 bolt m6 1 10 1.0 7.2 sealant (quick gasket ® ) yamaha bond no.1215 bearing housing (clutch housing assembly) bolt m6 4 10 1.0 7.2 air duct assembly 1 bracket bolt m6 2 14 1.4 10 oil seal (engine cooling fan pulley) re...

  • Page 43: Spec

    2 - 18 spec tightening torques primary sheave assembly nut m16 1 120 12.0 85 primary pulley sheave cap screw m4 8 3 0.3 2.2 secondary sheave assembly nut m16 1 100 10.0 72 secondary sheave spring retainer nut m36 1 90 9.0 65 shift lever cover bolt m6 4 10 1.0 7.2 shift lever 2 assembly bolt m6 1 14 ...

  • Page 44: Spec

    2 - 19 spec tightening torques ebs01006 chassis tightening torques part to be tightened thread size tightening torque remarks nm m · kg ft · lb rubber damper and frame m10 52 5.2 37 engine and rubber damper (front) m10 52 5.2 37 m6 10 1.0 7.2 engine bracket and rubber damper (rear) m8 33 3.3 24 m6 1...

  • Page 45: Spec

    2 - 20 spec tightening torques steering knuckle and front lower arm m12 30 3.0 22 tie-rod locknut m12 40 4.0 29 steering knuckle and tie-rod m12 39 3.9 28 front arm protector and front lower arm m6 7 0.7 5.1 seat belt and frame m10 59 5.9 43 seat belt and side frame (enclosure) 7/16 59 5.9 43 front ...

  • Page 46: Spec

    2 - 21 spec tightening torques front bumper and frame m10 32 3.2 23 m12 59 5.9 43 hood stopper and frame m8 16 1.6 11 upper instrument panel and frame m6 7 0.7 5.1 side frame (enclosure) and frame m10 64 6.4 46 support frame (enclosure) and frame m10 64 6.4 46 left support frame (enclosure) and righ...

  • Page 47: Spec

    2 - 22 spec how to use the conversion table/ general tightening torque specifications ebs00022 how to use the conversion table all specification data in this manual are listed in si and metric units. Use this table to convert metric unit data to imperial unit data. Conversion table ebs00023 general ...

  • Page 48: Spec

    2 - 23 spec lubrication points and lubricant types ebs00024 lubrication points and lubricant types engine lubrication points lubricant oil seal lips ls bearings e o-rings ls piston, piston ring e piston pin e buffer boss and balancer drive gear e crankshaft seal and spacer e valve stem m valve stem ...

  • Page 49: Spec

    2 - 24 spec coolant flow diagrams coolant flow diagrams 1 radiator 2 thermo switch 3 3 radiator outlet hose 4 radiator inlet hose 5 radiator outlet pipe 6 radiator inlet pipe 6 5 a a 4 3 1 2 a-a www.Midwestmanuals.Com.

  • Page 50: Spec

    2 - 25 spec coolant flow diagrams 1 coolant breather hose 2 coolant breather pipe 3 radiator outlet pipe 4 water pump inlet hose 5 water pump outlet pipe 6 water pump outlet hose 7 coolant outlet hose 8 radiator inlet pipe 8 3 a a 7 1 2 3 4 5 6 a-a www.Midwestmanuals.Com.

  • Page 51: Spec

    2 - 26 spec coolant flow diagrams 1 coolant outlet hose 2 radiator inlet pipe 2 1 www.Midwestmanuals.Com.

  • Page 52: Spec

    2 - 27 spec oil flow diagrams oil flow diagrams 1 camshaft 2 oil delivery pipe 2 3 oil delivery pipe 3 4 crankshaft 4 1 2 3 www.Midwestmanuals.Com.

  • Page 53: Spec

    2 - 28 spec oil flow diagrams 1 oil delivery pipe 1 2 oil delivery pipe 2 3 oil delivery pipe 3 4 oil pump 5 oil strainer 4 5 3 2 1 www.Midwestmanuals.Com.

  • Page 54: Spec

    2 - 29 spec oil flow diagrams 1 oil filter cartridge 2 oil pipe adapter 3 oil delivery pipe 2 4 oil delivery pipe 1 5 drive axle 6 relief valve 7 oil pump 8 oil strainer 1 3 4 5 6 7 8 2 www.Midwestmanuals.Com.

  • Page 55: Spec

    2 - 30 spec oil flow diagrams 1 oil outlet pipe 2 oil inlet pipe 3 oil outlet hose 4 oil inlet hose 5 oil cooler inlet pipe 2 6 oil cooler outlet pipe 2 5 6 a a 1 2 4 3 a-a www.Midwestmanuals.Com.

  • Page 56: Spec

    2 - 31 spec oil flow diagrams 1 oil cooler 2 oil cooler inlet pipe 2 3 oil cooler outlet pipe 2 4 oil cooler inlet hose 5 oil cooler outlet hose 6 oil cooler inlet pipe 1 7 oil cooler outlet pipe 1 2 3 2 4 3 5 a a b c 1 6 7 b c a-a www.Midwestmanuals.Com.

  • Page 57: Spec

    2 - 32 spec cable routing cable routing 1 left headlight lead 2 wire harness 3 throttle cable 4 brake light switch lead 5 radiator fan motor breather hose 6 starter cable 7 starter (choke) knob 8 light switch 9 coolant reservoir breather hose 0 parking brake switch lead a parking brake cable b crank...

  • Page 58: Spec

    2 - 33 spec cable routing È 30 ~ 60 mm (1.18 ~ 2.36 in) É 160 ~ 190 mm (6.30 ~ 7.48 in) Ê fasten the wire harness to the frame with the plastic bands. Ë pull the excess of the hoses through the guide in the upper instrument panel so that there is no slack in the hoses. Ì fasten the throttle cable, p...

  • Page 59: Spec

    2 - 34 spec cable routing 1 float chamber breather hose 2 throttle cable 3 parking brake cable 4 thermo switch 1 5 vacuum hose 6 spark plug cap 7 wire harness 8 tail/brake light lead 9 starter motor lead 0 carburetor heater leads a carburetor heater È fasten the parking brake switch lead and park- i...

  • Page 60: Spec

    2 - 35 spec cable routing Í fasten the parking brake cable to the air duct assembly 2 with the plastic band. Î fasten the parking brake cable and float cham- ber breather hose with the plastic clip. Ï 20 ~ 40° Ð fasten the starter motor lead, reverse switch lead, gear position switch lead, thermo sw...

  • Page 61: Spec

    2 - 36 spec cable routing 1 main switch 2 starter (choke) knob 3 starter (choke) cable 4 rectifier/regulator 5 wire harness 6 coolant reservoir breather hose 7 right headlight lead 8 radiator fan motor breather hose 9 radiator fan motor coupler 0 differential gear case breather hose a thermo switch ...

  • Page 62: Spec

    2 - 37 spec cable routing È 70 ~ 80 mm (2.76 ~ 3.15 in) É fasten the wire harness with the plastic bands. Ê fasten the wire harness to the frame with the plastic locking ties. Ë 30 ~ 60 mm (1.18 ~ 2.36 in) Ì 160 ~ 190 mm (6.30 ~ 7.48 in) Í fasten the radiator outlet hose and coolant reservoir hose w...

  • Page 63: Spec

    2 - 38 spec cable routing Ò 70 ~ 90 mm (2.76 ~ 3.54 in) Ó fasten the throttle cable with the plastic band. Ô fasten the radiator inlet pipe with the plastic band. Õ fasten the rear brake pipe with the plastic band. Ö fasten the radiator outlet pipe with the plastic band. × fasten the wire harness, s...

  • Page 64: Spec

    2 - 39 spec cable routing 1 ignition coil lead 2 spark plug lead 3 final gear case breather hose 4 vacuum hose 5 fuel hoses 6 air vent hoses 7 starter (choke) cable 8 crankcase breather hose 9 ground lead 0 rear brake hose a parking brake cable b ignition coil c rear brake pipe d wire harness e fuel...

  • Page 65: Spec

    2 - 40 spec cable routing È fasten the spark plug lead with the plastic holder. É 20 ~ 30 mm (0.79 ~ 1.18 in) Ê pass the final gear case breather hose through the grommet. Ë 10° Ì fasten the starter (choke) cable, starter motor lead, reverse switch lead, gear position switch lead, thermo switch 1 le...

  • Page 66: Spec

    2 - 41 spec cable routing Ò fasten the parking brake cable with the metal holder. Ó fasten the wire harness, ignition coil lead, and rear brake hose with the plastic band. Ô fasten the final gear case breather hose and fuel hose with the plastic clip. Õ fasten the fuel filter with the plastic band. ...

  • Page 67: Spec

    2 - 42 spec cable routing 1 throttle cable 2 rear brake pipe 3 a.C. Magneto couplers 4 starter (choke) cable 5 rear brake hose 6 fuel hose 7 vacuum hose 8 spark plug lead 9 parking brake cable È pass the throttle cable through the cable guide. É fasten the speed sensor lead, starter (choke) cable, s...

  • Page 68: Spec

    2 - 43 spec cable routing Í fasten the fuel hose and vacuum hose with the plastic clip. Î make sure that the spark plug lead does not contact the frame. Ï fasten the final gear case breather hose with the plastic holder. Ð 105 ~ 115 mm (4.13 ~ 4.53 in) Ñ fasten the wire harness with the plastic band...

  • Page 69: Spec

    2 - 44 spec cable routing 1 battery 2 negative battery lead 3 rectifier/regulator 4 starter (choke) cable 5 indicator light assembly couplers 6 on-command four-wheel drive switch and differ- ential gear lock switch leads 7 on-command four-wheel drive switch and differ- ential gear lock switch 8 main...

  • Page 70: Spec

    2 - 45 spec cable routing k four-wheel drive relay 3 l differential gear lock indicator light relay m four-wheel drive indicator light relay n fuse box o positive battery lead p neutral indicator light q reverse indicator light r parking brake indicator light s four-wheel drive indicator light t dif...

  • Page 71: Spec

    2 - 46 spec cable routing Ë fasten the throttle cable with the plastic holder. Ì fasten the left headlight lead, differential gear case breather hose, and radiator fan motor breather hose with the plastic holder. Í fasten the left headlight lead and differential gear case breather hose with the plas...

  • Page 72: Spec

    2 - 47 spec cable routing 1 auxiliary dc jack 2 auxiliary dc jack lead 3 coolant reservoir breather hose 4 throttle cable 5 radiator fan motor breather hose 6 differential gear case breather hose 7 starter (choke) cable 8 wire harness 9 front brake hoses 0 coolant reservoir hose a ground lead b star...

  • Page 73: Spec

    2 - 48 spec cable routing Ì fasten the wire harness and ground lead with the plastic band. Í fasten the differential gear case breather hose, coolant reservoir hose, radiator fan motor lead, and thermo switch 3 lead with the plastic holder. A c b-b b c b a Ì Í È É Ê Ë a b 1 2 3 4 5 6 7 8 9 9 0 3 È w...

  • Page 74: Chk

    3 - 1 chk adj eb300000 periodic checks and adjustments introduction this chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for...

  • Page 75: Chk

    3 - 2 chk adj periodic maintenance/lubrication * since these items require special tools, data and technical skills have a yamaha dealer perform the ser- vice. Note: • recommended brake fluid: dot 4 • brake fluid replacement: • when disassembling the master cylinder or caliper, replace the brake flu...

  • Page 76: Chk

    3 - 3 chk adj adjusting the valve clearance engine adjusting the valve clearance note: • the valve clearance must be adjusted when the engine is cool to the touch. • adjust the valve clearance when the piston is at the top dead center (tdc) on the com- pression stroke. 1. Remove: • driver seat • pas...

  • Page 77: Chk

    3 - 4 chk adj adjusting the valve clearance 7. Remove: • engine cooling fan 1 1 8. Remove: • timing plug 1 9. Check: • valve clearance out of specification → adjust. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft counterclockwise with a wrench. B. Align the “i” mark 1 on th...

  • Page 78: Chk

    3 - 5 chk adj adjusting the valve clearance 10.Adjust: • valve clearance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen the locknut 1. B. Insert a thickness gauge 2 between the adjuster end and the valve end. C. Turn the adjuster 3 clockwise or counter- clockwise with the tappet adjusti...

  • Page 79: Chk

    3 - 6 chk adj adjusting the timing chain adjustment free. Adjusting the idling speed 1. Start the engine and let it warm up for sev- eral minutes. 2. Remove: • driver seat • passenger seat • console refer to “seats, enclosure, hood and cargo bed” in chapter 8. 3. Lift the cargo bed up. 4. Attach: • ...

  • Page 80: Chk

    3 - 7 chk adj adjusting the idling speed/ adjusting the throttle cable 7. Detach: • tachometer 8. Lower the cargo bed. 9. Install: • console • passenger seat • driver seat refer to “seats, enclosure, hood and cargo bed” in chapter 8. Adjusting the throttle cable note: _ throttle cable free play shou...

  • Page 81: Chk

    3 - 8 chk adj adjusting the throttle cable/ adjusting the starter cable 5. Remove: • throttle valve cover 6. Install: • console • passenger seat • driver seat adjusting the starter cable 1. Remove: • driver seat • passenger seat • console refer to “seats, enclosure, hood and cargo bed” in chapter 8....

  • Page 82: Chk

    3 - 9 chk adj adjusting the starter cable/ checking the spark plug 3. Install: • console • passenger seat • driver seat refer to “seats, enclosure, hood and cargo bed” in chapter 8. Checking the spark plug 1. Lift the cargo bed up. 2. Remove: • spark plug 3. Check: • spark plug type incorrect → repl...

  • Page 83: Chk

    3 - 10 chk adj checking the ignition timing checking the ignition timing note: engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing. 1. Remove: • driver seat • passenger seat • console refer to “seats, enclosure, hood and cargo bed” in chap...

  • Page 84: Chk

    3 - 11 chk adj checking the ignition timing/ measuring the compression pressure 6. Check: • ignition timing ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Warm up the engine and keep it at the specified speed. B. Remove the timing plug 1. C. Visually check the stationary pointer 2 to verify it...

  • Page 85: Chk

    3 - 12 chk adj measuring the compression pressure 5. Remove: • spark plug 6. Attach: • adapter • compression gauge 1 7. Measure: • compression pressure above the maximum pressure: check the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure: squirt a few ...

  • Page 86: Chk

    3 - 13 chk adj measuring the compression pressure/ checking the engine oil level warning when cranking the engine, ground the spark plug lead to prevent sparking. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 8. Install: • spark plug 9. Lower the cargo bed. T r . . 18 nm (1.8 m · kg, 13 ft · lb)...

  • Page 87: Chk

    3 - 14 chk adj checking the engine oil level/ changing the engine oil 5. Stop the engine and check the oil level again. Note: wait a few minutes until the oil settles before checking the oil level. Warning never remove the dipstick just after high speed operation because the heated oil could spurt o...

  • Page 88: Chk

    3 - 15 chk adj changing the engine oil b. Lubricate the o-ring 3 of the new oil filter cartridge with a thin coat of lithium-soap- based grease. Caution: make sure that the o-ring 3 is positioned correctly in the groove of the oil filter car- tridge. C. Tighten the new oil filter cartridge to specif...

  • Page 89: Chk

    3 - 16 chk adj changing the engine oil/ cleaning the air filter 11.Check: • engine oil pressure ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Slightly loosen the oil gallery bolt 1. B. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine ...

  • Page 90: Chk

    3 - 17 chk adj cleaning the air filter 2. Remove: • air filter case cover 1 3. Remove: • air filter element assembly 1 • air filter element cap • air filter element 2 air filter element cap 3 air filter element caution: never operate the engine with the air filter element removed. This will allow un...

  • Page 91: Chk

    3 - 18 chk adj cleaning the air filter/ checking the coolant level c. Apply yamaha foam air filter oil or other quality foam air filter oil. D. Squeeze out the excess oil. Note: the element should be wet but not dripping. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 6. Install: • air filter ele...

  • Page 92: Chk

    3 - 19 chk adj checking the coolant level/ changing the coolant 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check: • coolant level note: before checking the coolant level, wait a few minutes until the coolant has settled. 6. Close the hood. Changing the coolant 1....

  • Page 93: Chk

    3 - 20 chk adj changing the coolant 8. Remove: • radiator cap 1 warning a hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause seri- ous injury. When the engine has cooled, open the radiator...

  • Page 94: Chk

    3 - 21 chk adj changing the coolant 14.Connect: • water pump inlet hose • coolant outlet hose 15.Remove: • air bleed bolt 1 16.Fill: • cooling system (with the specified amount of the recom- mended coolant) note: the specified amount of coolant is a standard amount. Fill the cooling system with cool...

  • Page 95: Chk

    3 - 22 chk adj changing the coolant caution: • adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if necessary, correct the antifreeze concentration of the coolant. • use only distilled water. However, soft water may be used ...

  • Page 96: Chk

    3 - 23 chk adj checking the coolant temperature warning light/checking the v-belt checking the coolant temperature warning light 1 coolant temperature indicator light coolant temperature warning light checking method turn the main switch “on”. Coolant temperature warning light does not come on. Turn...

  • Page 97: Chk

    3 - 24 chk adj checking the v-belt 2. Check: • v-belt 1 cracks/wear/scaling/chipping → replace. Oil/grease → check primary sheave and secondary sheave. 3. Measure: • v-belt width 2 out of specification → replace. V-belt width 33.2 mm (1.31 in) 29.9 mm (1.18 in) 4. Replace: • v-belt ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼...

  • Page 98: Chk

    3 - 25 chk adj checking the v-belt/ cleaning the spark arrester 5. Remove: • drive belt cover refer to “primary and secondary sheaves” in chapter 4. • console • passenger seat • driver seat refer to “seats, enclosure, hood and cargo bed” in chapter 8. Cleaning the spark arrester 1. Clean: • spark ar...

  • Page 99: Chk

    3 - 26 chk adj adjusting the brake pedal chassis adjusting the brake pedal 1. Check: • brake pedal free play a out of specification → adjust. Note: _ the end of the brake rod 1 should lightly con- tact the brake master cylinder 2. Brake pedal free play 0 mm (0.0 in) 2. Adjust: • brake pedal free pla...

  • Page 100: Chk

    3 - 27 chk adj adjusting the parking brake adjusting the parking brake 1. Shift the drive select lever into low gear “l”. 2. Remove: • driver seat • passenger seat • console refer to “seats, enclosure, hood and cargo bed” in chapter 8. 3. Check: • parking brake cable free play a out of specification...

  • Page 101: Chk

    3 - 28 chk adj checking the brake fluid level checking the brake fluid level 1. Place the vehicle on a level surface. Note: when checking the brake fluid level, make sure that the top of the brake fluid reservoir top is horizontal. 2. Lift the hood up. 3. Check: • brake fluid level fluid level is un...

  • Page 102: Chk

    3 - 29 chk adj checking the front brake pads/checking the rear brake pads/checking the brake hoses and brake pipes checking the front brake pads 1. Remove: • front wheels 2. Check: • brake pads wear indicator groove 1 almost disap- peared → replace the brake pads as a set. Refer to “front and rear b...

  • Page 103: Chk

    3 - 30 chk adj checking the brake hoses and brake pipes/ bleeding the hydraulic brake system 2. Lift the hood up. 3. Lift the cargo bed. 4. Check: • front brake hoses 1 • rear brake pipes 2 • rear brake hoses 3 cracks/wear/damage → replace. Fluid leakage → replace all damaged parts. Refer to “front ...

  • Page 104: Chk

    3 - 31 chk adj bleeding the hydraulic brake system 1. Bleed: • brake system ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Add the proper brake fluid to the reservoir. B. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. C. Connect the clear plastic h...

  • Page 105: Chk

    3 - 32 chk adj adjusting the select lever shift rod/ adjusting the brake light switch adjusting the select lever shift rod 1 neutral 2 high 3 low 4 reverse 5 select lever shift rod caution: before shifting, you must stop the vehicle and take your foot off the accelerator pedal. Otherwise, the transm...

  • Page 106: Chk

    3 - 33 chk adj adjusting the brake light switch/ checking the final gear oil level 1. Check: • brake light operation timing incorrect → adjust. 2. Adjust: • brake light operation timing ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Hold the main body 1 of the brake light switch so that it doe...

  • Page 107: Chk

    3 - 34 chk adj changing the final gear oil/ checking the differential gear oil changing the final gear oil 1. Place the vehicle on a level surface. 2. Place a container under the final gear case to collect the used oil. 3. Remove: • oil filler plug 1 • drain plug 2 4. Drain: • final gear oil 5. Inst...

  • Page 108: Chk

    3 - 35 chk adj 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. Caution: take care not allow foreign material to enter the differential gear case. 4. Install: • oil filler...

  • Page 109: Chk

    3 - 36 chk adj changing the differential gear oil/checking the constant velocity joint dust boots 6. Fill: • differential gear case note: if gear oil is filled to the brim of the oil filler hole, oil may start leaking from the differential gear case breather hose. Therefore, check the quantity of th...

  • Page 110: Chk

    3 - 37 chk adj checking the steering system/ adjusting the toe-in checking the steering system 1. Place the vehicle on a level surface. 2. Check: • steering assembly bearings try to move the steering wheel up and down, and back and forth. Excessive play → replace the steering shaft assembly. 3. Chec...

  • Page 111: Chk

    3 - 38 chk adj adjusting the toe-in c. Measure distance È between the marks. D. Rotate the front tires 180° until the marks are exactly opposite one another. E. Measure distance É between the marks. F. Calculate the toe-in using the formula given below. G. If the toe-in is incorrect, adjust it. ▲▲▲ ...

  • Page 112: Chk

    3 - 39 chk adj adjusting the front shock absorbers/ adjusting the rear shock absorbers adjusting the front shock absorbers warning always adjust both shock absorber spring preload to the same setting. Uneven adjust- ment can cause poor handling and loss of stability. Note: the spring preload of the ...

  • Page 113: Chk

    3 - 40 chk adj checking the tires checking the tires warning • tire characteristics 1) tire characteristics influence the han- dling of vehicle’s. The tires listed below have been approved by yamaha motor manufacturing corporation of america for this model. If other tire combinations are used, they ...

  • Page 114: Chk

    3 - 41 chk adj checking the tires 1. Measure: • tire pressure (cold tire pressure) out of specification → adjust. Note: • the tire pressure gauge 1 is included as standard equipment. • if dust or the like is stuck to this gauge, it will not provide the correct readings. Therefore, take two measureme...

  • Page 115: Chk

    3 - 42 chk adj checking the wheels/ checking and lubricating the cables checking the wheels 1. Check: • wheels 1 damage/bends → replace. Note: always balance the wheel when a tire or wheel has been changed or replaced. Warning • never attempt even small repairs to the wheel. • ride conservatively af...

  • Page 116: Chk

    3 - 43 chk adj lubricating the pedal, etc. Lubricating the pedal, etc. 1. Lubricate the pivoting parts. Recommended lubricant lithium-soap-based grease www.Midwestmanuals.Com.

  • Page 117: Chk

    3 - 44 chk adj checking and charging the battery eb305000 electrical checking and charging the battery warning _ batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • wear p...

  • Page 118: Chk

    3 - 45 chk adj checking and charging the battery note: _ since mf batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery...

  • Page 119: Chk

    3 - 46 chk adj 6. Charge: • battery (refer to the appropriate charging method illustration) warning _ do not quick charge a battery. Caution: _ • never remove the mf battery sealing caps. • do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and ca...

  • Page 120: Chk

    3 - 47 chk adj checking and charging the battery charging method using a variable-current (voltage) charger measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the b...

  • Page 121: Chk

    3 - 48 chk adj checking and charging the battery charging method using a constant voltage charger measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the battery? Ch...

  • Page 122: Chk

    3 - 49 chk adj checking and charging the battery/ checking the fuses 7. Install: • battery 8. Connect: • battery leads caution: _ first, connect the positive battery lead 1, and then the negative battery lead 2. 9. Check: • battery terminals dirt → clean with a wire brush. Loose connection → connect...

  • Page 123: Chk

    3 - 50 chk adj checking the fuses 4. Replace: • blown fuse ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn off the ignition. B. Install a new fuse of the proper amperage. C. Turn on switches to verify operation of the related electrical devices. D. If the fuse immediately blows again, chec...

  • Page 124: Chk

    3 - 51 chk adj adjusting the headlight beam/ changing the headlight bulb adjusting the headlight beam 1. Adjust: • headlight beam (vertically) turn the adjuster 1 in or out. Turning in headlight beam raised. Turning out headlight beam lowered. Changing the headlight bulb 1. Lift the hood up. 2. Remo...

  • Page 125: Chk

    3 - 52 chk adj changing the headlight bulb/ changing the tail/brake light bulb 5. Install: • headlight bulb holder (with bulb) • headlight bulb holder cover 6. Close the hood. Changing the tail/brake light bulb 1. Remove: • cargo bed panel 1 2. Remove: • tail/brake light bulb holder (with bulb) 1 • ...

  • Page 126: Chk

    3 - 53 chk adj changing the tail/brake light bulb 4. Install: • tail/brake light bulb holder (with bulb) 5. Install: • cargo bed panel t r . . 7 nm (0.7 m · kg, 5.1 ft · lb) www.Midwestmanuals.Com.

  • Page 127: Eng

    4 - 1 eng engine engine removal air ducts, muffler and exhaust pipe t r . . 11 nm (1.1 m • kg, 8.0 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) 8 6 6 5 3 7 4 new t r . . 7 nm (0....

  • Page 128: Eng

    4 - 2 eng engine removal t r . . 11 nm (1.1 m • kg, 8.0 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) 8 6 6 5 3 7 4 new t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) 5 new 2 (6) 1 order ...

  • Page 129: Eng

    4 - 3 eng engine removal select lever unit and coolant reservoir t r . . 15 nm (1.5 m • kg, 11 ft • ib) t r . . 15 nm (1.5 m • kg, 11 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) 2 1 3 t r . . 15 nm (1.5 m • kg, 11 ft • ib) order job/part q’ty remarks removing the select lever unit and coolant re...

  • Page 130: Eng

    4 - 4 eng engine removal hoses and leads r . . 10 nm (1.0 m • kg, 7.2 ft • ib) 12 1 2 4 3 6 5 7 8 9 14 13 10 11 order job/part q’ty remarks removing the hoses and leads remove the parts in the order listed. 1 water pump inlet hose 1 disconnect. 2 coolant outlet hose 1 disconnect. 3 oil inlet hose 1 ...

  • Page 131: Eng

    4 - 5 eng r . . 10 nm (1.0 m • kg, 7.2 ft • ib) 12 1 2 4 3 6 5 7 8 9 14 13 10 11 order job/part q’ty remarks 13 reverse switch lead 1 green/white 14 engine ground lead 1 disconnect. For installation, reverse the removal pro- cedure. Engine removal www.Midwestmanuals.Com.

  • Page 132: Eng

    4 - 6 eng engine removal engine mounting bolts order job/part q’ty remarks removing the engine mounting bolts remove the parts in the order listed. Front skid plate/center skid plate/rear skid plate refer to “seats, enclosure, hood and cargo bed” in chapter 8. Rear wheels refer to “rear wheels and b...

  • Page 133: Eng

    4 - 7 eng engine removal order job/part q’ty remarks 1 rubber damper nut (rear) 2 note: remove the engine assembly from the top of the vehicle. Caution: install all of the bolts/nuts and then tighten them to full torque specifica- tions. Refer to “installing the engine”. 2 engine mounting bolt (fron...

  • Page 134: Eng

    4 - 8 eng engine removal installing the engine 1. Install: • engine mounting bolt (rear) 1 • rubber damper (rear) 2 • rubber damper nut (front) 3 • engine assembly 4 • engine mounting bolt (front lower)/nut 5 • engine mounting bolt (front upper) 6 • rubber damper nut (rear) 7 note: do not fully tigh...

  • Page 135: Eng

    4 - 9 eng cylinder head cover cylinder head cover order job/part q’ty remarks removing the cylinder head cover remove the parts in the order listed. Driver seat/passenger seat/console refer to “seats, enclosure, hood and cargo bed” in chapter 8. Air shroud 1/engine cooling fan/timing plug refer to “...

  • Page 136: Eng

    4 - 10 eng cylinder head cover order job/part q’ty remarks 8 cylinder head cover 1 refer to “removing the cylinder head cover” and “installing the cylinder head cover”. 9 dowel pin 2 for installation, reverse the removal pro- cedure. Www.Midwestmanuals.Com.

  • Page 137: Eng

    4 - 11 eng cylinder head cover removing the cylinder head cover 1. Align: • “i” mark (with stationary pointer) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft counterclockwise with a wrench. B. Align the “i” mark 1 on the rotor with the stationary pointer 2 on the a.C. Magne...

  • Page 138: Eng

    4 - 12 eng cylinder head cover installing the cylinder head cover 1. Apply: • sealant (quick gasket ® ) 1 (to the mating surfaces of the cylinder head and cylinder head cover) 2. Install: • cylinder head cover • washers 1 • bolts 2 bolt: = 25 mm 3 bolt: = 40 mm 4 bolt: = 55 mm 5 bolt: = 55 mm 6 bolt...

  • Page 139: Eng

    4 - 13 eng rocker arms rocker arms order job/part q’ty remarks removing the rocker arms remove the parts in the order listed. Cylinder head cover refer to “cylinder head cover”. 1 plug/o-ring 1/1 2 rocker arm shaft stopper 2 3 rocker arm shaft 2 1 refer to “removing the rocker arms” and “installing ...

  • Page 140: Eng

    4 - 14 eng rocker arms order job/part q’ty remarks 10 wave washer 4 11 locknut 5 12 valve adjuster 5 for installation, reverse the removal pro- cedure. Www.Midwestmanuals.Com.

  • Page 141: Eng

    4 - 15 eng rocker arms removing the rocker arms 1. Remove: • rocker arm shafts 1 • rocker arms 2 note: use a slide hammer bolt 3 and weight 4 to remove the rocker arm shafts. Slide hammer set p/n. Yu-01083-a slide hammer bolt (m6) p/n. 90890-01083 weight p/n. 90890-01084 checking the rocker arms 1. ...

  • Page 142: Eng

    4 - 16 eng rocker arms d. Measure the outside diameter b of the rocker arm shafts. Out of specification → replace. E. Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Out of specification → replace the defec- tive part(s). ▲▲▲ ▲ ▲ ▲▲▲ ...

  • Page 143: Eng

    4 - 17 eng camshaft and cylinder head camshaft and cylinder head order job/part q’ty remarks removing the camshaft and cylin- der head remove the parts in the order listed. Carburetor refer to “carburetor” in chapter 6. Coolant outlet joint breather hose refer to “water pump” in chapter 5. Muffler/e...

  • Page 144: Eng

    4 - 18 eng camshaft and cylinder head order job/part q’ty remarks 7 thermo switch 1 1 8 cylinder head 1 9 coolant outlet joint 1 10 gasket 1 11 cylinder head gasket 1 12 dowel pin 2 13 intake manifold 1 for installation, reverse the removal pro- cedure. Www.Midwestmanuals.Com.

  • Page 145: Eng

    4 - 19 eng camshaft and cylinder head removing the camshaft and cylinder head 1. Loosen: • camshaft sprocket bolts 1 2. Loosen: • timing chain tensioner cap bolt 3. Remove: • timing chain tensioner • timing chain guide (exhaust side) • decompressor cam guide plates • camshaft sprocket • camshaft not...

  • Page 146: Eng

    4 - 20 eng camshaft and cylinder head checking the camshaft sprocket 1. Check: • camshaft sprocket wear/damage → replace the camshaft sprocket and timing chain as a set. A 1/4 of a tooth b correct 1 timing chain 2 sprocket checking the decompression system 1. Check: • decompression system ▼▼▼ ▼ ▼ ▼▼...

  • Page 147: Eng

    4 - 21 eng camshaft and cylinder head b. Removing the screwdriver and slowly release the timing chain tensioner rod. C. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. If there is rough move- ment, replace the timing chain tensioner. ▲▲▲ ▲ ▲ ▲▲...

  • Page 148: Eng

    4 - 22 eng camshaft and cylinder head d. Place a 400 ~ 600 grit wet sandpaper on the surface plate, and resurface the head using a figure-eight sanding pattern. Note: to ensure an even surface rotate the cylinder head several times. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ installing the ca...

  • Page 149: Eng

    4 - 23 eng camshaft and cylinder head c. Temporarily install the camshaft sprocket on the camshaft. (do not install the bolts.) then, install the timing chain on the cam- shaft sprocket. Note: make sure the small holes 3 on the camshaft face upward. D. Align the notches 4 on the decompressor cams wi...

  • Page 150: Eng

    4 - 24 eng camshaft and cylinder head c. With the screwdriver still inserted into the timing chain tensioner, install the timing chain tensioner and gasket onto the cylin- der block. Then, tighten the timing chain tensioner bolts to the specified torque. Warning always use a new gasket. Note: the “u...

  • Page 151: Eng

    4 - 25 eng valves and valve springs valves and valve springs order job/part q’ty remarks removing the valves and valve springs remove the parts in the order listed. Cylinder head refer to “camshaft and cylinder head”. 1 valve cotter 10 refer to “removing the valves and valve springs” and “install- i...

  • Page 152: Eng

    4 - 26 eng valves and valve springs removing the valves and valve springs 1. Check: • valve sealing leakage at the valve seat → check the valve face, valve seat and valve seat width. Refer to “checking the valves and valve springs”. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Pour a clean s...

  • Page 153: Eng

    4 - 27 eng valves and valve springs checking the valves and valve springs 1. Measure: • stem-to-guide clearance out of specification → replace the valve guide. Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b stem-to-guide clearance intake 0.010 ~ 0.037 mm (0.0004 ~ 0....

  • Page 154: Eng

    4 - 28 eng valves and valve springs 3. Check: • valve face pitting/wear → grind the face. • valve stem end mushroom shape or diameter larger than the body of the stem → replace. 4. Measure: • margin thickness a out of specification → replace. Margin thickness intake 0.85 ~ 1.15 mm (0.0335 ~ 0.0453 i...

  • Page 155: Eng

    4 - 29 eng valves and valve springs 8. Measure: • valve seat width a out of specification → reface the valve seat. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply mechanic’s blueing dye (dykem) b to the valve face. B. Install the valve into the cylinder head. C. Press the valve through th...

  • Page 156: Eng

    4 - 30 eng valves and valve springs c. Install the valve into the cylinder head. D. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the compound. Note: for best lapping results, lightly tap the valve seat while rotating the valve back and forth between y...

  • Page 157: Eng

    4 - 31 eng valves and valve springs 11.Measure: • compressed spring force a out of specification → replace. B installed length 12.Measure: • spring tilt a out of specification → replace. Compressed spring force intake 100.0 ~ 115.7 n at 27.5 mm (10.20 ~ 11.80 kg, 22.49 ~ 26.01 lb at 1.08 in) exhaust...

  • Page 158: Eng

    4 - 32 eng valves and valve springs 3. Install: • valve cotters note: install the valve cotters while compressing the valve spring with the valve spring compressor 1 and valve spring compressor attachment 2. Valve spring compressor set p/n. Ym-04019 valve spring compressor p/n. 90890-04019 valve spr...

  • Page 159: Eng

    4 - 33 eng cylinder and piston cylinder and piston order job/part q’ty remarks removing the cylinder and piston remove the parts in the order listed. Water pump outlet hose refer to “water pump” in chapter 5. Cylinder head refer to “camshaft and cylinder head”. 1 coolant inlet joint 1 2 cylinder/o-r...

  • Page 160: Eng

    4 - 34 eng cylinder and piston removing the piston 1. Remove: • piston pin clips 1 • piston pin 2 • piston 3 note: before removing piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller 4. ...

  • Page 161: Eng

    4 - 35 eng cylinder and piston b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. Standard wear limit cylinder bore “c” 100.005 ~ 100.055 mm (3.9372 ~ 3.9392 in) 100.10 mm (3.9410 in) c = x + y 2 2nd step: a. Measure piston skirt diameter “p...

  • Page 162: Eng

    4 - 36 eng cylinder and piston checking the piston rings 1. Measure: • ring side clearance use a thickness gauge. Out of specification → replace the piston and rings as a set. Note: clean carbon from the piston ring grooves and rings before measuring the side clearance. Side clearance standard limit...

  • Page 163: Eng

    4 - 37 eng cylinder and piston checking the piston pin 1. Check: • piston pin blue discoloration/grooves → replace, then check the lubrication system. 2. Measure: • piston pin-to-piston clearance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure the piston pin outside diameter a. If out o...

  • Page 164: Eng

    4 - 38 eng cylinder and piston 2. Position: • top ring • 2nd ring • oil ring offset the piston ring end gaps as shown. A top ring end b upper oil ring rail end c oil ring expander end d lower oil ring rail end e 2nd ring end f 20 mm (0.79 in) 3. Install: • piston 1 • piston pin 2 • piston pin clips ...

  • Page 165: Eng

    4 - 39 eng cylinder and piston installing the cylinder 1. Install: • cylinder • o-ring • bolts (m10) • bolts (m6) note: install the cylinder with one hand while com- pressing the piston rings with the other hand. Caution: • be careful not to damage the timing chain guide during installation. • pass ...

  • Page 166: Eng

    4 - 40 eng engine cooling fan and a.C. Magneto engine cooling fan and a.C. Magneto order job/part q’ty remarks removing the engine cooling fan and a.C. Magneto remove the parts in the order listed. Driver seat/passenger seat/console refer to “seats, enclosure, hood and cargo bed” in chapter 8. Drive...

  • Page 167: Eng

    4 - 41 eng engine cooling fan and a.C. Magneto order job/part q’ty remarks 3 engine cooling fan 1 4 air shroud 2 1 5 a.C. Magneto coupler 2 disconnect. 6 engine cooling fan pulley base 1 refer to “removing the a.C. Mag- neto” and “installing the a.C. Magneto”. 7 a.C. Magneto cover/gasket 1/1 8 dowel...

  • Page 168: Eng

    4 - 42 eng order job/part q’ty remarks 18 starter idle gear 1 for installation, reverse the removal pro- cedure. Engine cooling fan and a.C. Magneto www.Midwestmanuals.Com.

  • Page 169: Eng

    4 - 43 eng engine cooling fan and a.C. Magneto removing the a.C. Magneto 1. Remove: • engine cooling fan pulley 1 note: use the sheave holder 2 to hold the primary sheave. Primary sheave holder p/n. Ys-01880-a sheave holder p/n. 90890-01701 2. Remove: • a.C. Magneto cover • gasket • dowel pins note:...

  • Page 170: Eng

    4 - 44 eng engine cooling fan and a.C. Magneto checking the starter clutch 1. Check: • starter clutch 1 cracks/damage → replace. • starter clutch bolts 2 loose → replace with new ones, and clinch the end of the bolts. Note: the arrow mark on the starter clutch must face inward, away from the a.C. Ma...

  • Page 171: Eng

    4 - 45 eng checking the engine cooling fan 1. Check: • engine cooling fan • air shroud 1 • air shroud 2 cracks/damage → replace. Installing the a.C. Magneto 1. Apply: • sealant (quick gasket ® ) 1 (into the slit) 2. Install: • woodruff key • a.C. Magneto rotor note: • before installing the rotor, cl...

  • Page 172: Eng

    4 - 46 eng engine cooling fan and a.C. Magneto 3. Install: • dowel pins • gasket • a.C. Magneto cover note: • when installing the a.C. Magneto cover, use a long rod to hold the a.C. Magneto rotor in position from the outside. This will make assembly easier. Be careful not to damage the oil seal. • a...

  • Page 173: Eng

    4 - 47 eng 5. Connect: • a.C. Magneto couplers 6. Install: • engine cooling fan 1 note: install the bolts in the holes in the collar of the engine cooling fan. T r . . 7 nm (0.7 m · kg, 5.1 ft · lb) 7. Install: • air shroud 1 • engine cooling fan air duct assembly 1 note: install the engine cooling ...

  • Page 174: Eng

    4 - 48 eng balancer gears and oil pump gears balancer gears and oil pump gears order job/part q’ty remarks removing the balancer gears and oil pump gears remove the parts in the order listed. Starter wheel gear refer to “engine cooling fan and a.C. Magneto”. 1 nut/lock washer 1/1 2 balancer driven/o...

  • Page 175: Eng

    4 - 49 eng order job/part q’ty remarks 9 pin 4 for installation, reverse the removal pro- cedure. Balancer gears and oil pump gears www.Midwestmanuals.Com.

  • Page 176: Eng

    4 - 50 eng balancer gears and oil pump gears removing the balancer drive gear and balancer driven gear 1. Straighten the lock washer tabs. 2. Loosen: • balancer driven gear nut 1 note: place an aluminum plate 2 between the teeth of the balancer drive gear 3 and balancer driven gear 4. 3. Remove: • c...

  • Page 177: Eng

    4 - 51 eng balancer gears and oil pump gears installing the balancer drive gear and balancer driven gear 1. Install: • pins • springs • balancer drive gear (onto the buffer boss) • plate • circlip note: align the punch mark a on the balancer drive gear with the hole b to the buffer boss. 2. Install:...

  • Page 178: Eng

    4 - 52 eng primary and secondary sheaves primary and secondary sheaves t r . . 100 nm (10.0 m • kg, 72 ft • lb) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 120 nm (12.0 m • kg, 85 ft • lb) 10 10 9 7 6 8 5 4 3 2 1 (12...

  • Page 179: Eng

    4 - 53 eng primary and secondary sheaves t r . . 100 nm (10.0 m • kg, 72 ft • lb) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 120 nm (12.0 m • kg, 85 ft • lb) 10 10 9 7 6 8 5 4 3 2 1 (12) (7) t r . . 10 nm (1.0 m • k...

  • Page 180: Eng

    4 - 54 eng primary and secondary sheaves primary sheave order job/part q’ty remarks disassembling the primary sheave remove the parts in the order listed. 1 primary pulley sheave cap 1 refer to “assembling the primary sheave”. 2 primary pulley slider 4 3 spacer 4 4 primary pulley cam 1 5 primary pul...

  • Page 181: Eng

    4 - 55 eng primary and secondary sheaves secondary sheave order job/part q’ty remarks disassembling the secondary sheave remove the parts in the order listed. 1 nut 1 refer to “disassembling the sec- ondary sheave” and “assembling the secondary sheave”. 2 spring seat 1 3 compression spring 1 4 sprin...

  • Page 182: Eng

    4 - 56 eng primary and secondary sheaves removing the primary and secondary sheaves 1. Loosen: • secondary sheave nut 1 • primary sheave nut 2 note: • use the sheave holder 3 to hold the primary sheave. • first, loosen the secondary sheave nut 1, then loosen the primary sheave nut 2. Primary sheave ...

  • Page 183: Eng

    4 - 57 eng primary and secondary sheaves checking the primary sheave 1. Check: • weight outside diameter a out of specification → replace the weight. Weight outside diameter 30 mm (1.18 in) : 29.5 mm (1.16 in) 2. Check: • primary pulley slider • primary sliding sheave splines wear/cracks/damage → re...

  • Page 184: Eng

    4 - 58 eng primary and secondary sheaves assembling the primary sheave 1. Clean: • primary sliding sheave face 1 • primary fixed sheave face 2 • collar 3 • weights 4 • primary sliding sheave cam face note: remove any excess grease. 2. Install: • weights 1 note: • apply yamaha grizzly grease (90 g) t...

  • Page 185: Eng

    4 - 59 eng primary and secondary sheaves 3. Apply: • bel-ray assembly lube ® (to the guide pin sliding grooves 1, and o- rings 2 ) new 4. Install: • spring seat • compression spring • spring seat • nut ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Attach the sheave fixed block, locknut wrench...

  • Page 186: Eng

    4 - 60 eng primary and secondary sheaves installing the primary and secondary sheaves 1. Install: • secondary sheave assembly • v-belt • primary sheave assembly note: • tightening the bolts 1 will push the second- ary sliding sheave away, causing the gap between the secondary fixed and sliding sheav...

  • Page 187: Eng

    4 - 61 eng clutch clutch order job/part q’ty remarks removing the clutch remove the parts in the order listed. Primary and secondary sheaves refer to “primary and secondary sheaves”. 1 clutch housing assembly 1 refer to “removing the clutch” and “installing the clutch”. 2 gasket/dowel pin 1/2 3 one-...

  • Page 188: Eng

    4 - 62 eng clutch order job/part q’ty remarks disassembling the clutch housing remove the parts in the order listed. 1 oil seal 1 2 circlip 1 3 bearing housing 1 4 circlip 1 5 bearing 1 6 circlip 1 7 bearing 1 8 clutch housing 1 for assembly, reverse the disassembly procedure. Www.Midwestmanuals.Com.

  • Page 189: Eng

    4 - 63 eng clutch removing the clutch 1. Remove: • clutch housing assembly • gasket • dowel pins note: working in crisscross pattern, loosen each bolt 1/4 of a turn. Remove them after all of them are loosened. 2. Straighten: • punched portion of the nut 1 3. Remove: • nut 1 note: use a universal clu...

  • Page 190: Eng

    4 - 64 eng clutch b. When turning the clutch housing clockwise È, the clutch housing should turn freely. If not, the one-way clutch assembly is faulty. Replace it. C. When turning the clutch housing counter- clockwise É, the clutch housing and crank- shaft should be engaged. If not, the one-way clut...

  • Page 191: Eng

    4 - 65 eng clutch 3. Install: • one-way clutch bearing note: the one-way clutch bearing should be installed in the clutch carrier assembly with the arrow mark a facing toward the clutch hous- ing. 4. Install: • dowel pins • gasket • clutch housing assembly note: • tighten the bolts in stages, using ...

  • Page 192: Eng

    4 - 66 eng crankcase crankcase starter motor, timing chain and oil filter order job/part q’ty remarks remove the starter motor, timing chain and oil filter remove the parts in the order listed. Engine assembly refer to “engine removal”. Cylinder head refer to “camshaft and cylinder head”. Cylinder a...

  • Page 193: Eng

    4 - 67 eng crankcase order job/part q’ty remarks 5 oil pipe assembly/o-ring 1/2 6 oil pipe adapter/o-ring 1/1 7 relief valve assembly 1 8 speed sensor 1 9 shift drum stopper 1 10 gear position switch 1 11 reverse switch 1 12 oil filler cap 1 13 oil delivery pipe 1 1 14 drain plug 1 for installation,...

  • Page 194: Eng

    4 - 68 eng crankcase crankcase order job/part q’ty remarks separating the crankcase remove the parts in the order listed. 1 shift lever cover/gasket 1/1 refer to “installing the shift levers”. 2 dowel pin 1 3 shift lever 1 1 4 shift lever 2 assembly 1 5 right crankcase 1 refer to “separating the cra...

  • Page 195: Eng

    4 - 69 eng crankcase crankcase bearings t r . . 10 nm (1.0 m kg, 7.2 ft ib) ls e e e e 4 4 4 4 3 1 2 4 4 4 new e 4 e 4 order job/part q’ty remarks removing the crankcase bearings remove the parts in the order listed. Crankshaft and oil pump refer to “crankshaft and oil pump”. Transmission refer to “...

  • Page 196: Eng

    4 - 70 eng crankcase separating the crankcase 1. Separate: • right crankcase • left crankcase ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the crankcase bolts. Note: • loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. • loosen the bolts in sta...

  • Page 197: Eng

    4 - 71 eng crankcase checking the relief valve 1. Check: • relief valve 1 • spring 2 damage/wear → replace the defective part(s). Checking the crankcase 1. Thoroughly wash the case halves in a mild solvent. 2. Clean all the gasket mating surfaces and crankcase mating surfaces thoroughly. 3. Check: •...

  • Page 198: Eng

    4 - 72 eng crankcase 3. Fit the left crankcase onto the right case. Tap lightly on the case with a soft hammer. Caution: 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 directi...

  • Page 199: Eng

    4 - 73 eng crankshaft and oil pump crankshaft and oil pump order job/part q’ty remarks removing the crankshaft and oil pump remove the parts in the order listed. Crankcase separation refer to “crankcase”. 1 oil strainer/o-ring 1/1 2 oil pump assembly/gasket 1/1 3 balancer 1 refer to “removing the cr...

  • Page 200: Eng

    4 - 74 eng crankshaft and oil pump oil pump order job/part q’ty remarks disassembling the oil pump remove the parts in the order listed. 1 rotor cover 1 2 pin 2 3 shaft 1 4 pin 1 5 inner rotor 1 6 outer rotor 1 7 oil pump housing 1 for assembly, reverse the disassembly procedure. Www.Midwestmanuals....

  • Page 201: Eng

    4 - 75 eng crankshaft and oil pump removing the crankshaft 1. Remove: • crankshaft use a crankcase separating tool 1. Crankcase separating tool p/n. Yu-01135-a, 90890-01135 checking the oil pump 1. Check: • rotor housing • rotor cover cracks/wear/damage → replace. 2. Measure: • tip clearance a (betw...

  • Page 202: Eng

    4 - 76 eng crankshaft and oil pump checking the relief valve 1. Check: • relief valve body 1 • relief valve 2 • spring 3 • o-ring 4 damage/wear → replace the defective part(s). Checking the oil strainer 1. Check: • oil strainer 1 • o-ring 2 damage → replace. Contaminants → clean with engine oil. Ass...

  • Page 203: Eng

    4 - 77 eng crankshaft and oil pump checking the crankshaft 1. Measure: • crank width a out of specification → replace the crank- shaft. • side clearance d out of specification → replace the crank- shaft. • runout c out of specification → replace the crank- shaft. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ...

  • Page 204: Eng

    4 - 78 eng crankshaft and oil pump installing the crankshaft and balancer 1. Install: • crankshaft note: 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 ...

  • Page 205: Eng

    4 - 79 eng transmission transmission order job/part q’ty remarks removing the transmission remove the parts in the order listed. Crankcase separation refer to “crankcase”. Middle driven gear refer to “middle gear”. 1 low wheel gear 1 refer to “removing the transmission” and “installing the transmiss...

  • Page 206: Eng

    4 - 80 eng transmission drive axle assembly order job/part q’ty remarks disassembling the drive axle assembly remove the parts in the order listed. 1 clutch dog 1 2 high wheel gear 1 3 middle drive gear 1 4 driven sprocket 1 5 drive axle 1 for assembly, reverse the disassembly procedure. Www.Midwest...

  • Page 207: Eng

    4 - 81 eng transmission removing the transmission 1. Remove: • shift drum 1 • shift fork assembly 2 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Pull out the guide bar from the right crank- case. B. Slide the shift fork assembly and remove the shift fork followers from the shift drum grooves...

  • Page 208: Eng

    4 - 82 eng transmission 3. Check: • shift fork movement (on the guide bar) unsmooth operation → replace the shift fork and the guide bar. 4. Check: • springs cracks/damage → replace. Checking the shift drum 1. Check: • shift drum grooves scratches/wear/damage → replace. Checking the drive axle 1. Me...

  • Page 209: Eng

    4 - 83 eng transmission 2. Check: • gear movement unsmooth → repeat steps #1 or replace the defective parts. 3. Check: • circlip bends/looseness/damage → replace. Checking the secondary shaft and driven sprocket 1. Check: • gear teeth blue discoloration/pitting/wear → replace. 2. Check: • gear movem...

  • Page 210: Eng

    4 - 84 eng transmission assembling the shift fork assembly 1. Install: • guide bar 1 • shift fork 2 2 • long spring 3 • shift fork 1 4 • short spring 5 installing the transmission 1. Install: • chain 1 • drive axle assembly 2 • secondary shaft 3 • shift fork assembly 4 • shift drum 5 • low wheel gea...

  • Page 211: Eng

    4 - 85 eng middle gear middle gear middle drive shaft order job/part q’ty remarks removing the middle drive shaft remove the parts in the order listed. Crankcase separation refer to “crankcase”. 1 bearing housing 1 2 middle driven gear 1 3 nut 1 refer to “removing the middle drive shaft” and “instal...

  • Page 212: Eng

    4 - 86 eng middle gear middle driven shaft order job/part q’ty remarks removing the middle driven shaft remove the parts in the order listed. Crankcase separation refer to “crankcase”. 1 drive shaft coupling 1 refer to “removing the middle driven shaft” and “installing the middle driven shaft”. 2 ci...

  • Page 213: Eng

    4 - 87 eng middle gear order job/part q’ty remarks 10 bearing retainer 1 11 middle driven shaft 1 for installation, reverse the removal pro- cedure. Www.Midwestmanuals.Com.

  • Page 214: Eng

    4 - 88 eng middle gear removing the middle drive shaft 1. Straighten: • punched portion of the nut (middle drive pinion gear) 2. Loosen: • middle drive pinion gear nut 1 note: secure the middle drive shaft in the vise with a clean rag. 3. Remove: • middle drive pinion gear nut • middle drive pinion ...

  • Page 215: Eng

    4 - 89 eng 2. Remove: • universal joint ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the circlips 1. B. Place the universal joint in a press. C. With a suitable diameter pipe 2 beneath the yoke 3, press the bearing 4 into the pipe as shown. Note: it may be necessary to lightly tap the...

  • Page 216: Eng

    4 - 90 eng middle gear 4. Remove: • bearing housing assembly 1 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Clean the outside of the bearing housing assembly. B. Place the bearing housing assembly onto a hydraulic press. Caution: • never directly press the middle driven pinion gear end with ...

  • Page 217: Eng

    4 - 91 eng middle gear 6. Remove: • drive shaft coupling • oil seal 1 • bearing retainer 2 • bearing note: attach the ring nut wrench 3. Caution: the middle driven shaft bearing retainer has left-handed threads. To loosen the retainer, turn it clockwise. Ring nut wrench p/n. Ym-38404, 90890-01430 7....

  • Page 218: Eng

    4 - 92 eng middle gear selecting the middle drive and driven gear shims when the drive and driven gear, bearing hous- ing assembly and/or crankcase replaced, be sure to adjust the gear shims 1 and 2. 1. Select: • middle drive gear shim 1 • middle driven gear shim 2 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼...

  • Page 219: Eng

    4 - 93 eng middle gear example: 1) if the bearing housing is marked “+02”, ...... A is 7.52, 2) b is 17 3) c is 55 4) if the crankcase (left) is marked “64.98”, ...... D is 64.98. 5) therefore, the shim thickness is 0.50 mm. A = 7.52 + 64.98 – 17 – 55 = 0.50 6) round off hundredths digit and select ...

  • Page 220: Eng

    4 - 94 eng middle gear g = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or subtracted from “80.5”. H = a numeral (usually a decimal number) on the right crankcase specifies a thickness of “97.26”. I = a numeral (usually a decimal number) on the left crankc...

  • Page 221: Eng

    4 - 95 eng middle gear installing the middle driven shaft 1. Install: • bearing retainer 1 note: attach the ring nut wrench 2. Caution: the middle driven shaft bearing retainer has left-handed threads. To tighten the retainer, turn it counterclockwise. T r . . Bearing retainer 80 nm (8.0 m · kg, 58 ...

  • Page 222: Eng

    4 - 96 eng middle gear 3. Install: • shims 1 • bearing housing note: install the shims so that the tabs are positioned as shown in the illustration. 4. Install: • universal joint yoke • washer • nut 1 note: use the universal joint holder 2 to hold the yoke. T r . . Universal joint yoke nut 150 nm (1...

  • Page 223: Eng

    4 - 97 eng middle gear d. Press each bearing into the universal joint using a suitable socket. Note: the bearing must be inserted far enough into the universal joint so that the circlip can be installed. E. Install the circlips 2 into the groove of each bearing. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 224: Eng

    4 - 98 eng middle gear measuring the middle gear backlash 1. Measure: • gear lash ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Temporary install the left crankcase. B. Wrap a rag 1 around a screwdriver 2, and then insert it into the installation hole 3 of the right crankcase speed sensor to ...

  • Page 225: Cool

    5 - 1 cool cooling system radiator and coolant reservoir 9 8 10 5 3 2 1 4 6 7 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 28 nm (2.8 m • kg, 20 ft • ib) 12 11 order job/part q’ty remarks removing the radiator remove the parts in the order listed. Oil cooler refer to “oil cooler”. Coolant drain. R...

  • Page 226: Cool

    5 - 2 cool 9 8 10 5 3 2 1 4 6 7 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 28 nm (2.8 m • kg, 20 ft • ib) 12 11 order job/part q’ty remarks 11 coolant reservoir 1 12 coolant reservoir breather hose 1 disconnect. For installation, reverse the removal pro- cedure. Radiator and coolant reservoir ww...

  • Page 227: Cool

    5 - 3 cool radiator and coolant reservoir checking the radiator 1. Check: • radiator fins obstruction → clean. Apply compressed air to the rear of the radi- ator. Damage → repair or replace. Note: straighten any flattened fins with a thin, flat- head screwdriver. 2. Check: • radiator hoses cracks/da...

  • Page 228: Cool

    5 - 4 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. Www.Midwestmanuals.Com.

  • Page 229: Cool

    5 - 5 cool water pump water pump 6 7 new ls 8 1 ls 5 new t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) 2 4 3 new order job/part q’ty remarks removing the water pump remove the parts in the order listed. Driver seat/passenger seat/console refer to “seats, enclosure, hood and cargo bed” in chapter 8. 1 cool...

  • Page 230: Cool

    5 - 6 cool water pump order job/part q’ty remarks disassembling the water pump remove the parts in the order listed. 1 water pump housing cover 1 2 gasket 1 3 circlip 1 4 impeller 1 5 rubber damper holder 1 6 rubber damper 1 7 water pump seal 1 8 oil seal 1 9 bearing 1 0 water pump housing 1 for ass...

  • Page 231: Cool

    5 - 7 cool water pump disassembling the water pump 1. Remove: • rubber damper holder 1 • rubber damper 2 (from the impeller, with a thin, flathead screwdriver) note: do not scratch the impeller shaft. 2. Remove: • water pump seal 1 note: tap out the water pump seal from the inside of the water pump ...

  • Page 232: Cool

    5 - 8 cool water pump 3. Measure: • impeller shaft tilt out of specification → replace. 1 straightedge 2 impeller max. Impeller shaft tilt 0.15 mm (0.006 in) assembling the water pump 1. Install: • oil seal 1 (into the water pump housing 2) note: • before installing the oil seal, apply tap water or ...

  • Page 233: Cool

    5 - 9 cool water pump 3. Install: • rubber damper 1 • rubber damper holder 2 note: before installing the rubber damper, apply tap water or coolant onto its outer surface. Caution: make sure that the rubber damper and rub- ber damper holder are flush with the impel- ler. New new www.Midwestmanuals.Co...

  • Page 234: Cool

    5 - 10 cool oil cooler oil cooler ls ls new new r . . 7 nm (0.7 m • kg, 5.1 ft • ib) r . . 7 nm (0.7 m • kg, 5.1 ft • ib) 1 2 2 3 (4) 7 6 8 4 5 order job/part q’ty remarks removing the oil cooler remove the parts in the order listed. Driver seat/passenger seat/console/left support side panel/right s...

  • Page 235: Cool

    5 - 11 cool oil cooler ls ls new new r . . 7 nm (0.7 m • kg, 5.1 ft • ib) r . . 7 nm (0.7 m • kg, 5.1 ft • ib) 1 2 2 3 (4) 7 6 8 4 5 order job/part q’ty remarks 8 oil cooler inlet pipe 2/oil cooler outlet pipe 2 1/1 for installation, reverse the removal pro- cedure. Www.Midwestmanuals.Com.

  • Page 236: Cool

    5 - 12 cool oil cooler checking the oil cooler 1. Check: • oil cooler obstruction → clean. Apply compressed air to the rear of the oil cooler. Damage → repair or replace the oil cooler. Note: straighten any flattened fins with a thin, flat- head screwdriver. 2. Check: • oil hoses cracks/damage → rep...

  • Page 237: Fuel

    6 - 1 fuel fuel system fuel pump and fuel tank 4 5 3 6 2 9 1 11 t r . . 30 nm (3.0 m • kg, 22 ft • ib) 7 8 7 10 2 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks removing the fuel pump and fuel tank remove the parts in the order listed. Driver seat/passenger seat/console/ right si...

  • Page 238: Fuel

    6 - 2 fuel 4 5 3 6 2 9 1 11 t r . . 30 nm (3.0 m • kg, 22 ft • ib) 7 8 7 10 2 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks 10 fuel tank cap 1 11 fuel tank 1 for installation, reverse the removal pro- cedure. Fuel pump and fuel tank www.Midwestmanuals.Com.

  • Page 239: Fuel

    6 - 3 fuel eas00506 checking the fuel pump operation 1. Remove: • driver seat • passenger seat • console • right protector refer to “seats, enclosure, hood and cargo bed” in chapter 8. 2. Place a container under the end of the fuel hose 1. 1 3. Check: • fuel pump operation ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼...

  • Page 240: Fuel

    6 - 4 fuel carburetor carburetor 4 3 14 12 11 8 13 6 2 9 1 7 10 5 order job/part q’ty remarks removing the carburetor remove the parts in the order listed. Driver seat/passenger seat/console 1 refer to “seats, enclosure, hood and cargo bed” in chapter 8. 1 crankcase breather hose 1 disconnect. 2 air...

  • Page 241: Fuel

    6 - 5 fuel 4 3 14 12 11 8 13 6 2 9 1 7 10 5 order job/part q’ty remarks 12 throttle cable end 1 13 throttle cable 1 14 carburetor joint (intake manifold) 1 for installation, reverse the removal pro- cedure. Carburetor www.Midwestmanuals.Com.

  • Page 242: Fuel

    6 - 6 fuel carburetor order job/part q’ty remarks disassembling the carburetor remove the parts in the order listed. Note: before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. 1 throttle stop screw 1 2 ...

  • Page 243: Fuel

    6 - 7 fuel carburetor order job/part q’ty remarks 9 pilot air jet 1 0 drain screw 1 a float chamber 1 b float 1 refer to “assembling the carbure- tor”. C needle valve set 1 d main jet 1 e needle jet 1 refer to “assembling the carbure- tor”. F pilot jet 1 g starter jet 1 h carburetor heater 1 for ass...

  • Page 244: Fuel

    6 - 8 fuel carburetor disassembling the carburetor note: before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. Checking the carburetor 1. Check: • carburetor body • float chamber cracks/damage → replace....

  • Page 245: Fuel

    6 - 9 fuel carburetor 4. Check: • piston valve 1 scratches/wear/damage → replace. • rubber diaphragm 2 tears → replace. 5. Check: • vacuum chamber cover 1 • spring 2 cracks/damage → replace. 6. Check: • diaphragm (coasting enricher) 1 • spring 2 • cover 3 tears (diaphragm) /damage → replace. 7. Chec...

  • Page 246: Fuel

    6 - 10 fuel carburetor 8. Check: • free movement (piston valve) sticks → replace the piston valve guide and the piston valve. Insert the piston valve into the carburetor body, and check for free movement. 9. Check: • free movement (throttle valve) sticks → replace. Assembling the carburetor note: be...

  • Page 247: Fuel

    6 - 11 fuel carburetor adjusting the fuel level 1. Measure: • fuel level a out of specification → adjust. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Place the vehicle on a level surface. B. Connect the fuel level gauge 1 to the drain pipe 2. C. Loosen the drain screw 3. D. Hold the gauge v...

  • Page 248: Driv

    7 - 1 driv drive train troubleshooting the following conditions may indicate damaged shaft drive components: note: areas a, b, and c above may be extremely difficult to diagnose. The symptoms are quite subtle and difficult to distinguish from normal vehicle operating noise. If there is reason to bel...

  • Page 249: Driv

    7 - 2 driv troubleshooting caution: too little gear lash is extremely destructive to the gear teeth. If a test ride following reassembly indicates this condition, stop riding immediately to minimize gear dam- age. C. A slight “thunk” evident at low speed opera- tion. This noise must be distinguished...

  • Page 250: Driv

    7 - 3 driv troubleshooting troubleshooting chart when basic condition “a” and “b” exist, check the following points: elevate and spin both wheels. Feel for wheel bearing damage. Yes replace the wheel bearing. (refer to “steering system” and “rear knuckle and stabilizer” in chapter 8.) no check the w...

  • Page 251: Driv

    7 - 4 driv front constant velocity joints, differential gear and drive shaft front constant velocity joints, differential gear and drive shaft ls ls 6 5 3 2 4 t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 55 nm (5.5 m • kg, 40 ft • ib) 1 1 ls ls order job/part q’ty remarks removing the front consta...

  • Page 252: Driv

    7 - 5 driv front constant velocity joints, differential gear and drive shaft ls ls 6 5 3 2 4 t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 55 nm (5.5 m • kg, 40 ft • ib) 1 1 ls ls order job/part q’ty remarks 4 differential gear assembly 1 5 drive shaft 1 6 compression spring 1 for installation, rev...

  • Page 253: Driv

    7 - 6 driv front constant velocity joints, differential gear and drive shaft order job/part q’ty remarks disassembling the constant velocity joint remove the parts in the order listed. 1 circlip 1 2 boot band 2 refer to “assembling the front constant velocity joints”. 3 boot band 2 4 dust boot 2 5 c...

  • Page 254: Driv

    7 - 7 driv front constant velocity joints, differential gear and drive shaft order job/part q’ty remarks disassembling the differential gear remove the parts in the order listed. 1 gear motor/o-ring 1/1 note: do not disassemble the gear motor or remove the pinion gear. 2 circlip 2 refer to “disassem...

  • Page 255: Driv

    7 - 8 driv front constant velocity joints, differential gear and drive shaft order job/part q’ty remarks b shim (right) c differential gear assembly 1 d shim (left) e bearing 1 f bearing 1 g circlip/bearing 1/1 h drive pinion gear 1 i differential gear case 1 j bearing 1 for assembly, reverse the di...

  • Page 256: Driv

    7 - 9 driv front constant velocity joints, differential gear and drive shaft disassembling the universal joint 1. Remove: • universal joint ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the circlips 1. B. Place the universal joint in a press. C. With a suitable diameter pipe 2 beneath ...

  • Page 257: Driv

    7 - 10 driv front constant velocity joints, differential gear and drive shaft checking the constant velocity joints 1. Check: • double off-set joint spline • ball joint spline • shaft spline wear/damage → replace. 2. Check: • dust boots cracks/damage → replace. Caution: always use a new boot band. 3...

  • Page 258: Driv

    7 - 11 driv front constant velocity joints, differential gear and drive shaft 3. Check: • front drive shaft bends → replace. • torque limiter loose → replace the front drive shaft. Warning do not attempt to straighten a bent shaft; this may dangerously weaken the shaft. 1 checking the gear motor 1. ...

  • Page 259: Driv

    7 - 12 driv front constant velocity joints, differential gear and drive shaft 2. Install: • dust boots 1 • boot bands 2, 3 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply molybdenum disulfide grease into the dust boots. B. Install the dust boots. C. Install the dust boot bands. Note: • th...

  • Page 260: Driv

    7 - 13 driv front constant velocity joints, differential gear and drive shaft b. Connect two c size batteries to the gear motor terminal 2 to operate the pinion gear 3. Operate the pinion gear until the paint mark 4 on the gear is aligned with the paint mark 5 on the gear motor case. Caution: do not...

  • Page 261: Driv

    7 - 14 driv front constant velocity joints, differential 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. Assembling the universa...

  • Page 262: Driv

    7 - 15 driv front constant velocity joints, differential gear and drive shaft 3. Install: • a bolt of the specified size 1 (into the drain plug hole) caution: finger tighten the bolt until it holds the ring gear. Otherwise, the ring gear will be dam- aged. 4. Attach: • gear lash measurement tool 1 •...

  • Page 263: Driv

    7 - 16 driv front constant velocity joints, differential gear and drive shaft 2. Adjust: • gear lash ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Select the suitable shims using the following chart. * right shim only note: • use a combination of shims (left and right) so that the differentia...

  • Page 264: Driv

    7 - 17 driv 3. Measure the starting torque of the front wheel (i.E., differential gear preload) with a torque wrench. Note: • repeat this step several times to obtain an average figure. • during this test, the other front wheel will turn in the opposite direction. 4. Out of specification → replace t...

  • Page 265: Driv

    7 - 18 driv rear constant velocity joints, final drive gear and drive shaft rear constant velocity joints, final drive gear and drive shaft 3 1 4 6 5 1 2 t r . . 70 nm (7.0m • kg, 51 ft • ib) ls ls ls order job/part q’ty remarks removing the rear constant velocity joints, final drive gear and drive ...

  • Page 266: Driv

    7 - 19 driv 3 1 4 6 5 1 2 t r . . 70 nm (7.0m • kg, 51 ft • ib) ls ls ls order job/part q’ty remarks 1 rear constant velocity joint 2 note: remove the constant velocity joint on the right side of the vehicle, rotate the final gear assembly slightly so that the con- stant velocity joint on the left s...

  • Page 267: Driv

    7 - 20 driv rear constant velocity joints, final drive gear and drive shaft order job/part q’ty remarks disassembling the rear constant velocity joint remove the parts in the order listed. 1 circlip 1 2 boot band 2 refer to “assembling the rear constant velocity joints”. 3 boot band 2 4 dust boot 2 ...

  • Page 268: Driv

    7 - 21 driv rear constant velocity joints, final drive gear and drive shaft order job/part q’ty remarks disassembling the final gear case remove the parts in the order listed. Rear brake disc refer to “rear wheels and brake disc” in chapter 8. 1 bolt 4 2 final drive pinion gear shim * 3 drive shaft ...

  • Page 269: Driv

    7 - 22 driv rear constant velocity joints, final drive gear and drive shaft order job/part q’ty remarks b bolt 2 note: working in a crisscross pattern, loosen each bolt 1/4 of a turn. After all the bolts are loosened, remove them. C bolt 6 d oil seal 1 e bearing 1 f o-ring 1 g ring gear bearing hous...

  • Page 270: Driv

    7 - 23 driv rear constant velocity joints, final drive gear and drive shaft order job/part q’ty remarks m bearing 1 refer to “removing the final drive roller bearings” and “installing the final drive roller bearings”. N bearing 1 for assembly, reverse the disassembly procedure. Www.Midwestmanuals.Co...

  • Page 271: Driv

    7 - 24 driv rear constant velocity joints, final drive gear and drive shaft assembling the rear constant velocity joints 1. Apply: • molybdenum disulfide grease (into the ball joint assembly) 2. Install: • dust boots 1 • boot bands 2, 3 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply moly...

  • Page 272: Driv

    7 - 25 driv rear constant velocity joints, final drive gear and drive shaft 2. Remove: • final drive pinion gear bearing housing assembly 1 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Clean the outside surface of the final drive pinion gear. B. Place the final drive pinion gear in a hydrau-...

  • Page 273: Driv

    7 - 26 driv 2. Remove: • roller bearing (final drive pinion gear) 1 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Heat the main housing only to 150 °c (302 °f). B. Remove the roller bearing outer race with an appropriately shaped punch 2. C. Remove the inner race from the final drive pinion g...

  • Page 274: Driv

    7 - 27 driv selecting the final drive pinion gear shim 1. Select: • final drive pinion gear shim(s) 1 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. To find the final drive pinion gear shim thick- ness “a”, use the following formula. A = 92.5 mm b = a numeral (usually a decimal number) on the ...

  • Page 275: Driv

    7 - 28 driv rear constant velocity joints, final drive gear and drive shaft shims are supplied in the following thick- nesses. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ final drive pinion gear shim thickness (mm) 0.25 0.30 0.35 0.40 0.45 0.50 selecting the ring gear shim 1. Select: • ring ge...

  • Page 276: Driv

    7 - 29 driv rear constant velocity joints, final drive gear and drive shaft 6) round off the hundredth digit and select the appropriate shim(s). In the example above, the calculated num- ber is 0.48. The chart instructs you to round off 8 to 10 at the hundredth place. Thus, the shim thickness is 0.5...

  • Page 277: Driv

    7 - 30 driv rear constant velocity joints, final drive gear and drive shaft c. Remove the final gear assembly. D. Measure the thrust clearance. Calculate the width of the flattened plastigauge ® 1. E. If out of specification, select the correct washer. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...

  • Page 278: Driv

    7 - 31 driv rear constant velocity joints, final drive gear and drive shaft checking the drive shaft 1. Check: • drive shaft (splines) 1 • coupling gear (splines) 2 wear/damage → replace. 1 2 checking the final gear case 1. Check: • final gear case 1 • ring gear bearing housing 2 cracks/damage → rep...

  • Page 279: Driv

    7 - 32 driv rear constant velocity joints, final drive gear and drive shaft measuring and adjusting the final gear lash measuring the final gear lash 1. Secure the gear case in a vise or another supporting device. 2. Remove: • drain plug • gasket 3. Install: • a bolt of the specified size 1 (into th...

  • Page 280: Driv

    7 - 33 driv rear constant velocity joints, final drive 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 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Select a suitable shim(...

  • Page 281: Driv

    7 - 34 driv rear constant velocity joints, final drive gear and drive shaft 2. Install: • ring gear bearing housing • m8 bolts (ring gear bearing housing) 1 • m10 bolts (ring gear bearing housing) 2 note: apply quick gasket ® to the bolts 1 and 2 threads. T r . . 23 nm (2.3 m · kg, 17 ft · lb) t r ....

  • Page 282: Driv

    7 - 35 driv rear constant velocity joints, final drive gear and drive shaft 4. Install: • drive shaft coupling nut ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Place a folded rag 1. B. Secure the drive shaft coupling edge in the vise. C. Tighten the drive shaft coupling nut. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ...

  • Page 283: Chas

    8 - 1 chas chassis seats, enclosure, hood and cargo bed front bumper and hood 4 3 2 1 t r . . 32 nm (3.2 m • kg, 23 ft • ib) t r . . 59 nm (5.9 m • kg, 43 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 16 nm (1.6 m • kg, 11 ft • ib) order job/part q’ty remarks removing the front bumper and ...

  • Page 284: Chas

    8 - 2 chas seats, enclosure, hood and cargo bed seats, console and instrument panels (16) (5) (9) (7) 1 2 3 4 5 6 14 13 12 12 9 10 8 7 11 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 35 nm (3.5 m • kg, 25 ft • ib) order job/part q’ty remarks removing the seats, console and instrument panels remove...

  • Page 285: Chas

    8 - 3 chas (16) (5) (9) (7) 1 2 3 4 5 6 14 13 12 12 9 10 8 7 11 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 35 nm (3.5 m • kg, 25 ft • ib) order job/part q’ty remarks 11 auxiliary dc jack connector 2 disconnect. 12 nut/starter cable 1/1 13 upper instrument panel 1 14 lower instrument panel 1 for ...

  • Page 286: Chas

    8 - 4 chas seats, enclosure, hood and cargo bed panels and footrest cover 1 (12) 5 6 8 10 3 2 4 13 11 12 (8) (8) (4) (6) (4) (6) (4) (4) 6 7 9 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 16 nm (1.6 m • kg, 11 ft • ib) t r . . 32 nm (3.2 m • kg, 23 ft • ib) order job/part q’ty remarks removing the...

  • Page 287: Chas

    8 - 5 chas 1 (12) 5 6 8 10 3 2 4 13 11 12 (8) (8) (4) (6) (4) (6) (4) (4) 6 7 9 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 16 nm (1.6 m • kg, 11 ft • ib) t r . . 32 nm (3.2 m • kg, 23 ft • ib) order job/part q’ty remarks 13 passenger seat support 1 for installation, reverse the removal pro- cedu...

  • Page 288: Chas

    8 - 6 chas seats, enclosure, hood and cargo bed cargo bed 4 2 3 new new 1 1 2 3 t r . . 16 nm (1.6 m • kg, 11 ft • ib) t r . . 16 nm (1.6 m • kg, 11 ft • ib) order job/part q’ty remarks removing the cargo bed remove the parts in the order listed. 1 tail/brake light connector 6 disconnect. 2 damper 2...

  • Page 289: Chas

    8 - 7 chas 5 5 4 2 1 4 3 6 7 3 (9) (12) (12) (9) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 11 nm (1.1 m • kg, 8.0 ft • ib) t r . . 26 nm (2.6 m • kg, 19 ft • ib) order job/part q’ty remarks disassembling the cargo bed...

  • Page 290: Chas

    8 - 8 chas seats, enclosure, hood and cargo bed skid plates t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) 3 1 2 (11) (7) (4) (4) (7) (11) (11) (11) order job/part q’ty remarks removing the engine skid plates remove the parts in the order listed. 1 front skid plate 1 2...

  • Page 291: Chas

    8 - 9 chas seats, enclosure, hood and cargo bed enclosure and seat belts t r . . 64 nm (6.4 m • kg, 46 ft • ib) t r . . 64 nm (6.4 m • kg, 46 ft • ib) t r . . 64 nm (6.4 m • kg, 46 ft • ib) t r . . 59 nm (5.9 m • kg, 43 ft • ib) t r . . 59 nm (5.9 m • kg, 43 ft • ib) 6 1 2 3 5 7 (4) (8) (4) (8) 4 8 ...

  • Page 292: Chas

    8 - 10 chas front wheels and brake discs front wheels and brake discs 4 6 5 3 new lt lt 2 1 t r . . 48 nm (4.8 m • kg, 35 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 260 nm (26.0 m • kg, 190 ft • lb) order job/part q’ty remarks removing the front wh...

  • Page 293: Chas

    8 - 11 chas front wheels and brake discs 4 6 5 3 new lt lt 2 1 t r . . 48 nm (4.8 m • kg, 35 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 260 nm (26.0 m • kg, 190 ft • lb) order job/part q’ty remarks 4 brake caliper assembly 1 note: do not depress th...

  • Page 294: Chas

    8 - 12 chas front wheels and brake discs checking the front wheel 1. Check: • wheel 2. Measure: • wheel runout over the specified limit → replace the wheel or check the wheel bearing play 1. 3. Check: • wheel balance out of balance → adjust. Warning after replacing the tire, ride conservatively to a...

  • Page 295: Chas

    8 - 13 chas front wheels and brake discs checking the front brake disc 1. Check: • brake disc galling/damage → replace. 2. Measure: • brake disc deflection out of specification → check the wheel runout. If wheel runout is within the limits, replace the brake disc. • brake disc thickness a out of spe...

  • Page 296: Chas

    8 - 14 chas rear wheels and brake disc rear wheels and brake disc rear wheels new 1 3 4 2 t r . . 260 nm (26.0 m • kg, 190 ft • lb) t r . . 55 nm (5.5 m • kg, 40 ft • ib) order job/part q’ty remarks removing the rear wheel remove the parts in the order listed. Place the vehicle on a level surface. W...

  • Page 297: Chas

    8 - 15 chas rear wheels and brake disc rear brake disc (6) 1 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks removing the rear brake disc remove the parts in the order listed. Brake caliper assembly refer to “front and rear brakes”. Final drive gear refer to “rear constant veloci...

  • Page 298: Chas

    8 - 16 chas rear wheels and brake disc checking the rear wheel 1. Check: • wheel refer to “checking the front wheel”. 2. Measure: • wheel runout refer to “checking the front wheel”. Over the specified limit → replace. 3. Check: • wheel balance refer to “checking the front wheel”. Out of balance → ad...

  • Page 299: Chas

    8 - 17 chas rear wheels and brake disc installing the rear wheel hub 1. Install: • axle nut refer to “installing the front wheel hub”. New installing the rear wheel 1. Install: • wheel refer to “installing the front wheel”. 2. Tighten: • wheel nuts refer to “installing the front wheel”. Www.Midwestm...

  • Page 300: Chas

    8 - 18 chas front and rear brakes front and rear brakes front brake pads 3 4 2 1 t r . . 48 nm (4.8 m • kg, 35 ft • ib) t r . . 18 nm (1.8 m • kg, 13 ft • ib) order job/part q’ty remarks removing the front brake pads remove the parts in the order listed. Front wheel refer to “front wheels and brake ...

  • Page 301: Chas

    8 - 19 chas front and rear brakes rear brake pads t r . . 17 nm (1.7 m • kg, 12 ft • ib) 4 7 6 5 7 8 1 2 3 t r . . 40nm (4.0 m • kg, 29 ft • ib) order job/part q’ty remarks removing the rear brake pads remove the parts in the order listed. Rear skid plate refer to “seats, enclosure, hood and cargo b...

  • Page 302: Chas

    8 - 20 chas front and rear brakes caution: disc brake components rarely require dis- assembly. Do not: • disassemble components unless abso- lutely necessary; • use solvents on internal brake compo- nents; • use spent brake fluid for cleaning; (use only clean brake fluid) • allow brake fluid to come...

  • Page 303: Chas

    8 - 21 chas front and rear brakes 2. Install: • brake pads • brake pad spring note: always install new brake pads and brake pad spring as a set. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a suitable hose 1 tightly to the brake caliper bleed screw 2. Put the other end of this hose i...

  • Page 304: Chas

    8 - 22 chas front and rear brakes 1. Measure: • brake pad wear limit a out of specification → replace the brake pads as a set. Brake pad wear limit 1.5 mm (0.06 in) 2. Install: • brake pads • brake pad spring note: always install new brake pads, new brake pad shims, new insulators, and a new brake p...

  • Page 305: Chas

    8 - 23 chas e. Install the brake pad holding bolts, the brake caliper, and the brake caliper mounting bolts. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Check: • brake fluid level refer to “checking the brake fluid level” in chapter 3. 4. Check: • brake pedal operation soft or spongy feelin...

  • Page 306: Chas

    8 - 24 chas front and rear brakes brake master cylinder 7 4 5 6 5 t r . . 19 nm (1.9 m • kg, 13 ft • ib) t r . . 16 nm (1.6 m • kg, 11 ft • ib) t r . . 27 nm (2.7 m • kg, 19 ft • ib) new new 8 1 2 3 order job/part q’ty remarks removing the brake master cylinder remove the parts in the order listed. ...

  • Page 307: Chas

    8 - 25 chas front and rear brakes 3 6 2 1 4 t r . . 9 nm (0.9 m • kg, 6.5 ft • ib) new new 5 new order job/part q’ty remarks disassembling the brake master cyl- inder remove the parts in the order listed. 1 dust boot 1 refer to “assembling the brake master cylinder”. 2 circlip 1 3 primary brake mast...

  • Page 308: Chas

    8 - 26 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 → blow out with...

  • Page 309: Chas

    8 - 27 chas front and rear brakes installing the brake master cylinder 1. Install: • brake master cylinder 2. Install: • brake pipe • copper washers • brake hose • union bolt note: tighten the union bolt while holding the brake hose as shown. Warning proper brake hose routing is essential to insure ...

  • Page 310: Chas

    8 - 28 chas front and rear brakes 4. Air bleed: • brake system refer to “bleeding the hydraulic brake system” in chapter 3. 5. Check: • brake fluid level brake fluid level is under the “min” level line → fill up. Refer to “checking the brake fluid level” in chapter 3. 6. Adjust: • brake pedal free p...

  • Page 311: Chas

    8 - 29 chas front and rear brakes front brake caliper order job/part q’ty remarks removing the front brake caliper remove the parts in the order listed. Brake fluid drain. Front wheel refer to “front wheels and brake discs”. 1 union bolt 1 refer to “installing the front brake calipers”. 2 copper was...

  • Page 312: Chas

    8 - 30 chas front and rear brakes new new 5 6 6 7 7 4 1 t r . . 18 nm (1.8 m • kg, 13 ft • ib) 3 8 t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) 2 order job/part q’ty remarks disassembling the front brake cali- per remove the parts in the order listed. 1 brake pad holding bolt 2 2 brake pad 2 3 pad spring ...

  • Page 313: Chas

    8 - 31 chas front and rear brakes rear brake caliper t r . . 27 nm (2.7 m • kg, 19 ft • ib) t r . . 40 nm (4.0m • kg, 29 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) 1 2 3 4 5 6 7 8 9 10 new order job/part q’ty remarks removing the rear brake caliper remove the parts in the order listed. Rear ski...

  • Page 314: Chas

    8 - 32 chas t r . . 27 nm (2.7 m • kg, 19 ft • ib) t r . . 40 nm (4.0m • kg, 29 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) 1 2 3 4 5 6 7 8 9 10 new order job/part q’ty remarks 6 union bolt 1 refer to “installing the rear brake cali- per”. 7 copper washer 2 8 brake hose 1 disconnect. 9 brake cal...

  • Page 315: Chas

    8 - 33 chas front and rear brakes t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) t r . . 17 nm (1.7 m • kg, 12 ft • ib) t r . . 22 nm (2.2 m • kg, 16 ft • ib) ls ls 1 2 3 4 5 6 7 8 9 0 a b c d e f g a 4 new new order job/part q’ty remarks disassembling the rear brake cali- per remove the parts in the order ...

  • Page 316: Chas

    8 - 34 chas t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) t r . . 17 nm (1.7 m • kg, 12 ft • ib) t r . . 22 nm (2.2 m • kg, 16 ft • ib) ls ls 1 2 3 4 5 6 7 8 9 0 a b c d e f g a 4 new new order job/part q’ty remarks b parking brake case 1 refer to “assembling the rear brake caliper”. C gasket 1 d brake cal...

  • Page 317: Chas

    8 - 35 chas front and rear brakes ebs00427 disassembling the front brake calipers 1. Remove: • brake caliper pistons • dust seals 1 • caliper piston seals 2 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Blow compressed air into the hose joint opening to force out the caliper piston from the b...

  • Page 318: Chas

    8 - 36 chas front and rear brakes eb702040 checking the front and rear brake calipers warning all internal brake components should be cleaned in new brake fluid only. Do not use solvents as they will cause seals to swell and distort. 1. Check: • brake caliper pistons 1 scratches/rust/wear → replace ...

  • Page 319: Chas

    8 - 37 chas front and rear brakes ebs00431 assembling the front brake calipers the following procedure applies to both of the front brake calipers. Warning _ • all internal brake components should be cleaned and lubricated with new brake fluid only before installation. • replace the caliper piston s...

  • Page 320: Chas

    8 - 38 chas ebs00432 assembling the rear brake caliper warning _ • all internal brake components should be cleaned and lubricated with new brake fluid only before installation. • replace the caliper piston seal and dust seal whenever a brake caliper is disas- sembled. 1. Install: • caliper piston se...

  • Page 321: Chas

    8 - 39 chas front and rear brakes 4. Install: • parking brake arm shaft 1 • parking brake arm 2 • set bolt 3 • parking brake arm nut 4 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ note: apply lithium-soap-based grease to the park- ing brake arm shaft and set bolt. A. Screw in the parking brake ...

  • Page 322: Chas

    8 - 40 chas front and rear brakes 6. Install: • brake pad holding bolts t r . . 17 nm (1.7 m · kg, 12 ft · lb) ebs00434 installing the front brake calipers the following procedure applies to both of the front brake calipers. 1. Install: • brake caliper assembly • brake caliper mounting bolts • brake...

  • Page 323: Chas

    8 - 41 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 ...

  • Page 324: Chas

    8 - 42 chas 2. Fill: • brake reservoir caution: _ brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. Warning _ • use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake pe...

  • Page 325: Chas

    8 - 43 chas pedal assembly 5 6 new t r . . 16 nm (1.6 m • kg, 11 ft • ib) 2 3 7 4 1 order job/part q’ty remarks removing the pedal assembly remove the parts in the order listed. Steering wheel cover/steering wheel/ pedal cover/upper instrument panel/ lower instrument panel refer to “seats, enclosure...

  • Page 326: Chas

    8 - 44 chas 2 3 4 3 9 5 1 7 7 6 8 ls order job/part q’ty remarks disassembling the pedal assembly remove the parts in the order listed. 1 spring 1 2 circlip 1 3 washer 2 4 brake pedal 1 5 spring 1 6 circlip 1 7 washer 2 8 accelerator pedal 1 9 pedal assembly bracket 1 for assembly, reverse the disas...

  • Page 327: Chas

    8 - 45 chas steering system steering system steering column and steering assembly 1 2 3 t r . . 48 nm (4.8 m • kg, 35 ft • ib) t r . . 21 nm (2.1 m • kg, 15 ft • ib) t r . . 22 nm (2.2 m • kg, 16 ft • ib) t r . . 39 nm (3.9 m • kg, 28 ft • ib) order job/part q’ty remarks removing the steering column...

  • Page 328: Chas

    8 - 46 chas steering system 2 4 3 1 8 9 a b 7 6 5 c 2 4 1 3 new new new t r . . 40 nm (4.0 m • kg, 29 ft • ib) 0 order job/part q’ty remarks disassembling the steering assem- bly remove the parts in the order listed. 1 tie-rod end locknut 2 refer to “assembling the steer- ing assembly”. 2 tie-rod en...

  • Page 329: Chas

    8 - 47 chas 2 4 3 1 8 9 a b 7 6 5 c 2 4 1 3 new new new t r . . 40 nm (4.0 m • kg, 29 ft • ib) 0 order job/part q’ty remarks c steering assembly 1 refer to “assembling the steering assembly”. For assembly, reverse the disassembly procedure. Steering system www.Midwestmanuals.Com.

  • Page 330: Chas

    8 - 48 chas steering system disassembling the steering assembly 1. Remove: • oil seal • circlip • pinion gear with bearing 1 note: lightly tap on the steering housing with a soft hammer to remove the pinion gear easily. Checking the steering joint 1. Check: • steering joint rough movement → replace....

  • Page 331: Chas

    8 - 49 chas steering system 3. Check: • rack gear teeth 1 • pinion gear teeth 2 wear/damage → replace the steering assembly. Note: the wear pattern on the rack and pinion gear teeth should be uniform. An uneven wear pat- tern may indicate improper adjustment or lack of lubrication. 1 2 4. Check: • p...

  • Page 332: Chas

    8 - 50 chas steering system 2. Install: • steering assembly • bearing • circlips • pinion gear • oil seal note: after centering the rack gear, make two align- ment marks a on the pinion gear and the steering housing to mark the position of the pinion gear. This is necessary to install the steering j...

  • Page 333: Chas

    8 - 51 chas steering system tie-rod and steering knuckle 3 6 8 9 7 4 2 5 new 3 new new ls 1 t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 39 nm (3.9 m • kg, 28 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks removing the tie-rod and...

  • Page 334: Chas

    8 - 52 chas steering system removing the steering knuckles 1. Remove: • steering knuckle 1 note: use a general puller to separate the ball joints 2 from the steering knuckle 1 or the front lower arm 3. Checking the tie-rods 1. Check: • tie-rod free play and movement free play → replace the tie-rod e...

  • Page 335: Chas

    8 - 53 chas steering system d. Install the body 3, short bolt 5, remover washer 6 and remover spacer 7 onto the ball joint. Note: • remover washer 6 must be aligned with the projection on the head of the ball joint. • surface a of the remover spacer 7 must be aligned with the surface b of the steeri...

  • Page 336: Chas

    8 - 54 chas steering system h. Attach the assembled ball joint remover/ installer, new ball joint b and installer attachment 8 to the steering knuckle c. Note: do not tap or damage the top of the ball joint. I. Hold the body 3 in place while turning in the long bolt 4 to install the new ball joint b...

  • Page 337: Chas

    8 - 55 chas steering system h. Install the new oil seals. Note: when installing the oil seals, the “seal side” of the oil seal faces out. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ www.Midwestmanuals.Com.

  • Page 338: Chas

    8 - 56 chas front arms and front shock absorber front arms and front shock absorber 6 8 8 4 3 4 4 5 5 1 6 9 6 10 11 9 7 6 new ls new 4 ls 8 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r ...

  • Page 339: Chas

    8 - 57 chas 6 8 8 4 3 4 4 5 5 1 6 9 6 10 11 9 7 6 new ls new 4 ls 8 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) 3 2 ls ls 8 order job/part q’ty remar...

  • Page 340: Chas

    8 - 58 chas front arms and front shock absorber removing the front arms 1. Check: • front arm free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Check the front arm side play È by moving it from side to side. If side play is noticeable, check the bush- ings. B. Check the front arm vertic...

  • Page 341: Chas

    8 - 59 chas front arms and front shock absorber c. Install the body 3, long bolt 4, remover washer 5 and remover spacer 6 onto ball joint. Note: remover washer 5 must be aligned with the projection on the head of the ball joint. D. Hold the body 3 in place while turning in the long bolt 4 to remove ...

  • Page 342: Chas

    8 - 60 chas front arms and front shock absorber j. Apply lithium-soap base grease to the new ball joint a. K. Install a new rubber boot and new circlip. Note: always use a new ball joint set. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ checking the front shock absorber 1. Check: • shock absorb...

  • Page 343: Chas

    8 - 61 chas front arms and front shock absorber installing the front arms and front shock absorber 1. Install: • front arms • front shock absorber ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the front upper arm 1 and front lower arm 2. Note: • lubricate the bolts 3 with lithium-soap...

  • Page 344: Chas

    8 - 62 chas rear knuckle and stabilizer rear knuckle and stabilizer 6 7 5 6 7 8 5 3 3 1 2 4 3 3 4 ls t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 56 nm (5.6 m • kg, 40 ft • ib) t r . . 56 nm (5.6 m • kg, 40 ft • ib) t r . . 32 nm (3.2m • kg, 23 ft • ib) ls order job/part q’ty remarks removing the ...

  • Page 345: Chas

    8 - 63 chas rear knuckle and stabilizer checking the rear knuckle 1. Check: • rear knuckle damage/pitting → replace. 2. Check: • rear wheel bearings bearings allow play in the wheel hubs or the wheel turns roughly → replace. • oil seals damage → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 346: Chas

    8 - 64 chas rear arms and rear shock absorber rear arms and rear shock absorber 3 5 5 2 2 4 3 6 3 6 5 5 t r . . 45 nm (4.5 m • kg, 32 ft • ib) 1 1 t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) 1 t r . . 45 nm (4.5 m • kg, 32 ft • ib) ls ls ls order job/part q’ty remar...

  • Page 347: Chas

    8 - 65 chas rear arms and rear shock absorber checking the rear arms 1. Check: • rear arms 1 bends/damage → replace. 2. Check: • bushings 2 wear/damage → replace. 1 2 2 checking the rear shock absorber 1. Check: • shock absorber rod bends/damage → replace the shock absorber assembly. • shock absorbe...

  • Page 348: Chas

    8 - 66 chas rear arms and rear shock absorber installing the rear arms and rear shock absorber 1. Install: • rear arms • rear shock absorber ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the rear upper arm 1 and rear lower arm 2. Note: • lubricate the bolts 3 with lithium-soap- based ...

  • Page 349: Elec

    9 - 1 – + elec eb800000 electrical electrical components 1 diode 1 2 thermo switch 2 3 diode 2 4 circuit breaker (radiator fan motor) 5 carburetor heater 6 thermo switch 1 7 ignition coil 8 gear position switch 9 reverse switch 0 brake light switch a parking brake switch b pickup coil/stator assembl...

  • Page 350: Elec

    9 - 2 – + elec electrical components 1 rectifier/regulator 2 auxiliary dc jack 3 indicator light assembly 1 4 indicator light assembly 2 5 on-command four-wheel drive switch and differ- ential gear lock switch 6 main switch 7 light switch 8 four-wheel drive relay 1 9 four-wheel drive relay 2 0 start...

  • Page 351: Elec

    9 - 3 – + elec checking the switch checking the switch checking the switch use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. Note: • set the pocket tester to “0” before starting the test. • the pocket tester should be set to the ...

  • Page 352: Elec

    9 - 4 – + elec checking the switch checking the switch continuity refer to “checking the switch” and check for continuity between lead terminals. Poor connection, no continuity → correct or replace. The coupler locations are circled. * 4 3 1 2 r b l/b l/g l/r sb br gy g/r b 2wd 4wd lock l/g l/b l/b ...

  • Page 353: Elec

    9 - 5 – + elec checking the switch 1 fuse 2 brake light switch 3 on-command four-wheel drive switch and differential gear lock switch 4 main switch 5 light switch 6 parking brake switch 7 gear position switch 8 reverse switch 9 four-wheel drive switch www.Midwestmanuals.Com.

  • Page 354: Elec

    9 - 6 – + elec checking the bulbs and bulb sockets eb801020 checking the bulbs and bulb sockets check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or both. Improperly connected...

  • Page 355: Elec

    9 - 7 – + elec checking the bulbs and bulb sockets warning since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. Caution: • be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pu...

  • Page 356: Elec

    9 - 8 – + elec checking the bulbs and bulb sockets checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) no continuity → replace. Note: check each bulb socket for continuity in the same...

  • Page 357: Elec

    9 - 9 – + elec ignition system eb802000 ignition system circuit diagram (black) br ww w 2wd 4wd lock on off off start r y /ll /b sb g /w w /b g /r (black) (black) (black) (gray) (gray) (black) (black) (black) r w /g w /lw /r (black) br /l r bl b w /g r w /rw /g l/ g l/ b l/ r sb l/ g l/ b l/ r sb gy...

  • Page 358: Elec

    9 - 10 – + elec ignition system eb802010 troubleshooting procedure check: 1. Fuses (main, ignition) 2. Battery 3. Spark plug 4. Ignition spark gap 5. Spark plug cap resistance 6. Ignition coil resistance 7. Main switch 8. Pickup coil resistance 9. Rotor rotation direction detection coil resis- tance...

  • Page 359: Elec

    9 - 11 – + elec ignition system correct 3. Spark plug • check the spark plug condition. • check the spark plug type. • check the spark plug gap. Refer to “checking the spark plug” in chapter 3. Spark plug gap 0.8 ~ 0.9 mm (0.031 ~ 0.035 in) * incorrect standard spark plug dpr8ea-9/ngk repair or repl...

  • Page 360: Elec

    9 - 12 – + elec ignition system 6. Ignition coil resistance • disconnect the ignition coil connector from the wire harness. • connect the pocket tester ( Ω × 1) to the ignition coil. Tester (+) lead → orange lead terminal tester (–) lead → ignition coil base • check that the primary coil has the spe...

  • Page 361: Elec

    9 - 13 – + elec ignition system meets specification 8. Pickup coil resistance • disconnect the a.C. Magneto coupler from the wire harness. • connect the pocket tester ( Ω × 100) to the pickup coil terminal. Tester (+) lead → white/red terminal 1 tester (–) lead → white/green terminal 2 • check the p...

  • Page 362: Elec

    9 - 14 – + elec ignition system correct 10.Wiring connection • check the connections of the entire igni- tion system. Refer to “circuit diagram”. Replace the c.D.I. Unit. * poor connection properly connect the ignition system. Www.Midwestmanuals.Com.

  • Page 363: Elec

    9 - 15 – + elec electric starting system eb803000 electric starting system circuit diagram (black) br ww w 2wd 4wd lock on off off start r y /ll /b sb g /w w /b g /r (black) (black) (black) (gray) (gray) (black) (black) (black) r w /g w /lw /r (black) br /l r bl b w /g r w /rw /g l/ g l/ b l/ r sb l...

  • Page 364: Elec

    9 - 16 – + elec electric starting system starting circuit operation the starting circuit on this model consists of the starter motor, starter relay, brake light switch, c.D.I. Unit and gear position switch. If the main switch is “start” position, the starter motor can be operated only if: 1 main fus...

  • Page 365: Elec

    9 - 17 – + elec electric starting system eb803020 troubleshooting procedure check: 1. Fuses (main, ignition, signaling system) 2. Battery 3. Starter motor 4. Starter relay 5. Main switch 6. Gear position switch 7. Brake light switch 8. Diode 1 9. Wiring connection (the entire starting sys- tem) if t...

  • Page 366: Elec

    9 - 18 – + elec electric starting system turns 3. Starter motor • connect the battery (+) terminal 1 and starter motor cable 2 using a jumper lead 3 . • check the operation of the starter motor. * * warning • a wire that is used as a jumper lead must have the equivalent capacity or more as that of t...

  • Page 367: Elec

    9 - 19 – + elec electric starting system correct 6. Gear position switch refer to “checking the switch”. * incorrect replace the gear position switch. Correct 7. Brake light switch refer to “checking the switch”. Incorrect replace the brake light switch. Correct 8. Diode 1 • remove the diode from th...

  • Page 368: Elec

    9 - 20 – + elec electric starting system starter motor order job/part q’ty remarks removing the starter motor remove the parts in the order listed. 1 starter motor lead 1 2 starter motor/o-ring 1/1 for installation, reverse the removal pro- cedure. Disassembling the starter motor remove the parts in...

  • Page 369: Elec

    9 - 21 – + elec electric starting system checking the starter motor 1. Check: • commutator dirty → clean it with #600 grit sandpaper. 2. Measure: • commutator diameter a out of specification → replace the starter motor. 3. Measure: • mica undercut b out of specification → scrape the mica using a hac...

  • Page 370: Elec

    9 - 22 – + elec electric starting system 5. Measure: • brush length a (each) out of specification → replace the brush. 6. Measure: • brush spring force fatigue/out of specification → replace as a set. 7. Check: • oil seal • bushing • o-rings wear/damage → replace. Brush length 12.5 mm (0.49 in) : 5 ...

  • Page 371: Elec

    9 - 23 – + elec charging system eb804000 charging system circuit diagram (black) br ww w 2wd 4wd lock on off off start r y /ll /b sb g /w w /b g /r (black) (black) (black) (gray) (gray) (black) (black) (black) r w /g w /lw /r (black) br /l r bl b w /g r w /rw /g l/ g l/ b l/ r sb l/ g l/ b l/ r sb g...

  • Page 372: Elec

    9 - 24 – + elec charging system eb804010 troubleshooting procedure check: 1. Fuse (main) 2. Battery 3. Charging voltage 4. Charging coil resistance 5. Wiring connections (the entire charging system) if the battery is not charged: note: • remove the following part(s) before trouble- shooting: 1) cons...

  • Page 373: Elec

    9 - 25 – + elec charging system out of specification • start the engine and accelerate to about 1,000 r/min. Charging voltage 14 v at 1,000 r/min note: use a fully charged battery. Meets specification the charging circuit is not faulty. Eb804012 meets specification 4. Charging coil resistance • disc...

  • Page 374: Elec

    9 - 26 – + elec lighting system eb805000 lighting system circuit diagram (black) br ww w 2wd 4wd lock on off off start r y /ll /b sb g /w w /b g /r (black) (black) (black) (gray) (gray) (black) (black) (black) r w /g w /lw /r (black) br /l r bl b w /g r w /rw /g l/ g l/ b l/ r sb l/ g l/ b l/ r sb g...

  • Page 375: Elec

    9 - 27 – + elec lighting system eb805010 troubleshooting procedure check: 1. Fuses (main, lighting system) 2. Battery 3. Main switch 4. Light switch 5. Wiring connections (the entire lighting system) if the headlight and/or taillight fail to come on: note: • remove the following part(s) before troub...

  • Page 376: Elec

    9 - 28 – + elec lighting system correct 4. Light switch refer to “checking the switch”. * incorrect replace the light switch. Eb805013 correct 5. Wiring connection • check the connections of the entire light- ing system. Refer to “circuit diagram”. Check the condition of each of the lighting system’...

  • Page 377: Elec

    9 - 29 – + elec lighting system eb805020 checking the lighting system 1. If the headlights fail to come on: continuity 1. Bulb and bulb socket • check the bulb and bulb socket for conti- nuity. No continuity replace the bulb and/or bulb socket. Meets specification 2. Voltage • connect the pocket tes...

  • Page 378: Elec

    9 - 30 – + elec lighting system eb805021 2. If the taillights fail to come on: continuity 1. Bulb and bulb socket • check the bulb and bulb socket for conti- nuity. No continuity replace the bulb and/or bulb socket. 2. Voltage • connect the pocket tester (dc 20 v) to the tail/brake light connectors....

  • Page 379: Elec

    9 - 32 – + elec signaling system eb806000 signaling system circuit diagram (black) br ww w 2wd 4wd lock on off off start r y /ll /b sb g /w w /b g /r (black) (black) (black) (gray) (gray) (black) (black) (black) r w /g w /lw /r (black) br /l r bl b w /g r w /rw /g l/ g l/ b l/ r sb l/ g l/ b l/ r sb...

  • Page 380: Elec

    9 - 33 – + elec signaling system 3 main switch 6 battery 7 main fuse 0 brake light switch b reverse switch c c.D.I. Unit p gear position switch q parking brake switch r thermo switch 1 z gear motor [ diode 2 ] four-wheel drive indicator light _ differential gear lock indicator light a coolant temper...

  • Page 381: Elec

    9 - 34 – + elec signaling system eb806010 troubleshooting procedure check: 1. Fuses (main, signaling system) 2. Battery 3. Main switch 4. Wiring connections (the entire signal system) if a brake light, an indicator light, or the warning light fails to come on: note: • remove the following part(s) be...

  • Page 382: Elec

    9 - 35 – + elec signaling system eb806011 correct 4. Wiring connections • check the connections of the entire signal system. Refer to “circuit diagram”. Check the condition of each of the signal sys- tem’s circuits. Refer to “checking the signal sys- tem”. * poor connection properly connect the sign...

  • Page 383: Elec

    9 - 36 – + elec signaling system checking the signal system 1. If the brake lights fail to come on: continuity 1. Bulb and bulb socket • check the bulb and bulb socket for conti- nuity. No continuity replace the bulb and/or bulb socket. Continuity 2. Brake light switch refer to “checking the switch”...

  • Page 384: Elec

    9 - 37 – + elec signaling system eb806024 2. If the neutral indicator light fails to come on: continuity 1. Bulb and bulb socket • check the bulb and bulb socket for conti- nuity. No continuity replace the bulb and/or bulb socket. Continuity 2. Gear position switch refer to “checking the switch”. No...

  • Page 385: Elec

    9 - 38 – + elec signaling system 3. If the parking brake indicator light fails to come on: continuity 1. Bulb and bulb socket • check the bulb and bulb socket for conti- nuity. No continuity replace the bulb and/or bulb socket. Continuity 2. Parking brake switch refer to “checking the switch”. No co...

  • Page 386: Elec

    9 - 39 – + elec signaling system 4. If the reverse indicator light fails to come on: continuity 1. Bulb and bulb socket • check the bulb and bulb socket for conti- nuity. No continuity replace the bulb and/or bulb socket. Continuity 2. Reverse switch refer to “checking the switch”. No continuity rep...

  • Page 387: Elec

    9 - 40 – + elec signaling system 5. If the coolant temperature warning light does not come on when the main switch to “on”, or if the coolant temperature warning light does not come on when the temperature is high (more than 117 ~ 123 °c (242.6 ~ 253.4 °f)): continuity 1. Bulb and bulb socket • chec...

  • Page 388: Elec

    9 - 41 – + elec signaling system 3. Voltage • connect the pocket tester (dc 20 v) to the indicator light assembly 1 coupler. Tester (+) lead → brown terminal 1 tester (–) lead → white/blue terminal 2 * br b/g br w/l br w/y br b/g br w/y br w/l 1 2 meets specification • turn the main switch to “on”. ...

  • Page 389: Elec

    9 - 42 – + elec signaling system 6. If the differential gear lock indicator light fails to come on: continuity 1. Bulb and bulb socket • check the bulb and bulb socket for conti- nuity. No continuity replace the bulb and/or bulb socket. Continuity 2. Differential gear lock indicator light relay • re...

  • Page 390: Elec

    9 - 43 – + elec signaling system 4. Voltage • connect the pocket tester (dc 20 v) to the indicator light assembly 1 coupler. Tester (+) lead → brown terminal 1 tester (–) lead → black/green terminal 2 * br b/g br w/l br w/y br b/g br w/y br w/l 1 2 meets specification • turn the main switch to “on”....

  • Page 391: Elec

    9 - 44 – + elec signaling system 7. If the four-wheel drive indicator light fails to come on: continuity 1. Bulb and bulb socket • check the bulb and bulb socket for conti- nuity. No continuity replace the bulb and bulb socket. Continuity 2. Four-wheel drive indicator light relay • remove the four-w...

  • Page 392: Elec

    9 - 45 – + elec signaling system 4. Voltage • connect the pocket tester (dc 20 v) to the indicator light assembly 1 coupler. Tester (+) lead → brown terminal 1 tester (–) lead → white/yellow terminal 2 * br b/g br w/l br w/y br b/g br w/y br w/l 1 2 meets specification • turn the main switch to “on”...

  • Page 393: Elec

    9 - 46 – + elec cooling system cooling system circuit diagram (black) br ww w 2wd 4wd lock on off off start r y /ll /b sb g /w w /b g /r (black) (black) (black) (gray) (gray) (black) (black) (black) r w /g w /lw /r (black) br /l r bl b w /g r w /rw /g l/ g l/ b l/ r sb l/ g l/ b l/ r sb gy br g /r b...

  • Page 394: Elec

    9 - 47 – + elec cooling system troubleshooting procedure check: 1. Fuse (main) 2. Battery 3. Main switch 4. Radiator fan motor 5. Circuit breaker (radiator fan motor) 6. Thermo switch 3 7. Wiring connection (the entire cooling system) if the fan motor does not move: note: • remove the following part...

  • Page 395: Elec

    9 - 48 – + elec cooling system turns 4. Radiator fan motor • disconnect the radiator fan motor coupler. • connect the battery (12 v) as shown. Battery (+) lead → blue terminal 1 battery (–) lead → black terminal 2 • check the operation of the radiator fan motor. * does not turn replace the radiator ...

  • Page 396: Elec

    9 - 49 – + elec cooling system good condition 6. Thermo switch 3 • remove the thermo switch 3 from the radi- ator. • connect the pocket tester ( Ω × 1) to the thermo switch 3 1. • immerse the thermo switch 3 in coolant 2. • check the thermo switch 3 for continuity. While heating the coolant use a th...

  • Page 397: Elec

    9 - 50 – + elec cooling system eb803028 correct 7. Wiring connection • check the connections of the entire cool- ing system. Refer to “circuit diagram”. This circuit is not faulty. * poor connection properly connect the cooling system. Www.Midwestmanuals.Com.

  • Page 398: Elec

    9 - 51 – + elec 2wd/4wd selecting system 2wd/4wd selecting system circuit diagram (black) br ww w 2wd 4wd lock on off off start r y /ll /b sb g /w w /b g /r (black) (black) (black) (gray) (gray) (black) (black) (black) r w /g w /lw /r (black) br /l r bl b w /g r w /rw /g l/ g l/ b l/ r sb l/ g l/ b ...

  • Page 399: Elec

    9 - 52 – + elec 2wd/4wd selecting system eb803020 troubleshooting procedure check: 1. Fuses (main, four-wheel drive) 2. Battery 3. Main switch 4. Four-wheel drive relay 1 5. Four-wheel drive relay 2 6. Four-wheel drive relay 3 7. On-command four-wheel drive switch and differential gear lock switch 8...

  • Page 400: Elec

    9 - 53 – + elec 2wd/4wd selecting system continuity 4. Four-wheel drive relay 1 • remove the four-wheel drive relay 1 from the wire harness. • connect the pocket tester ( Ω × 1) and the battery (12 v) to the four-wheel drive relay 1 terminals. Tester (+) lead → black/yellow terminal 1 tester (–) lea...

  • Page 401: Elec

    9 - 54 – + elec 2wd/4wd selecting system continuity 6. Four-wheel drive relay 3 • remove the four-wheel drive relay 3 from the wire harness. • connect the pocket tester ( Ω × 1) and the battery (12 v) to the four-wheel drive relay 3 terminals. Battery (+) terminal → brown/red terminal 1 battery (–) ...

  • Page 402: Elec

    9 - 55 – + elec 2wd/4wd selecting system correct 8. Gear motor • disconnect the gear motor coupler. • remove the gear motor from the differen- tial gear case. Refer to “front constant velocity joints, differential gear and drive shaft” in chapter 7. • connect two c size batteries to the gear motor t...

  • Page 403: Elec

    9 - 56 – + elec carburetor heating system carburetor heating system circuit diagram (black) br ww w 2wd 4wd lock on off off start r y /ll /b sb g /w w /b g /r (black) (black) (black) (gray) (gray) (black) (black) (black) r w /g w /lw /r (black) br /l r bl b w /g r w /rw /g l/ g l/ b l/ r sb l/ g l/ ...

  • Page 404: Elec

    9 - 57 – + elec carburetor heating system troubleshooting procedure check: 1. Fuses (main, carburetor heater) 2. Battery 3. Main switch 4. Thermo switch 2 5. Carburetor heater 6. Wiring connection (the entire carburetor warming system) if the carburetor heating system fails to operate: note: • remov...

  • Page 405: Elec

    9 - 58 – + elec carburetor heating system good condition 4. Thermo switch 2 • remove the thermo switch 2 from the wire harness. • connect the pocket tester ( Ω × 1) to the thermo switch 2 1. • immerse the thermo switch 2 in a con- tainer filled with water 2. • place a thermometer 3 in the water. • s...

  • Page 406: Elec

    9 - 59 – + elec carburetor heating system correct 5. Carburetor heater • remove the carburetor heater from the carburetor. • connect the pocket tester ( Ω × 1) to the carburetor heater. Tester (+) lead → carburetor heater terminal 1 tester (–) lead → carburetor heater body 2 • measure the carburetor...

  • Page 407: Trbl

    10 - 1 trbl shtg ebs00537 troubleshooting note: _ the following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for check, adjustment and replacement of parts. Starting fai...

  • Page 408: Trbl

    10 - 2 trbl shtg starting failure/hard starting/poor idle speed performance/poor medium and high-speed performance compression system cylinder and cylinder head • loose spark plug • loose cylinder head or cylinder • broken cylinder head gasket • broken cylinder gasket • worn, damaged or seized cylin...

  • Page 409: Trbl

    10 - 3 trbl shtg faulty drive train ebs00540 faulty drive train the following conditions may indicate damaged shaft drive components: note: _ areas a, b, and c above may be extremely difficult to diagnose. The symptoms are quite subtle and difficult to distinguish from normal vehicle operating noise...

  • Page 410: Trbl

    10 - 4 trbl shtg faulty gear shifting/ faulty clutch performance ebs00542 faulty gear shifting hard shifting refer to “clutch slipping”. Shift lever does not move shift drum, shift forks • groove jammed with impurities • seized shift fork • bent shift fork guide bar transmission • seized transmissio...

  • Page 411: Trbl

    10 - 5 trbl shtg faulty clutch performance/overheating/ faulty brake/shock absorber malfunction poor speed performance v-belt • oil or grease on the v-belt primary pulley weight • faulty operation • worn primary pulley weight primary fixed sheave • worn primary fixed sheave primary sliding sheave • ...

  • Page 412: Trbl

    10 - 6 trbl shtg unstable handling/ lighting system ebs00552 unstable handling unstable handling steering wheel • improperly installed or bent steering • incorrect toe-in • bent steering shaft • improperly installed steering shaft • damaged bearing • bent tie-rods • deformed steering knuckles tires ...

  • Page 413

    Yxr660fas wiring diagram (black) b r w w w 2wd 4wd lock on off off start r y/l l/b sb g/w w/b g/r (black) (black) (black) (gray) (gray) (black) (black) (black) r w/g w/l w/r (black) br/l r b lb w/g r w/r w/g l/g l/b l/r sb l/g l/b l/r sb gy br g/r b r/y l y g gy br g/r b sb w l/w b/r w/l g/l sb l/w ...

  • Page 414: 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...

  • Page 415: Gen

    Ebs00006 symbols the following symbols are not relevant to every vehicle. Symbols 1 to 0 indicate the subject of each chapter. 1 general information 2 specifications 3 periodic checks and adjustments 4 engine 5 cooling system 6 fuel system 7 drive train 8 chassis 9 electrical 0 troubleshooting symbo...

  • Page 416: Contents

    Contents specifications .............................................................................................1 general specifications ....................................................................1 engine specifications .....................................................................

  • Page 417: Spec

    – 1 – spec specifications general specifications item standard model code 5ug4 5ug8 basic weight with oil and full fuel tank 509 kg (1,122 lb) transmission primary reduction system v-belt secondary reduction system shaft drive secondary reduction ratio 41/21 × 24/18 × 33/9 (9.544) transmission type ...

  • Page 418: Spec

    – 2 – spec engine specifications/chassis specifications/ electrical specifications engine specifications chassis specifications electrical specifications item standard limit carburetor i. D. Mark 5ug4 10 ---- main jet (m.J) #145 ---- main air jet (m.A.J) #70 ---- jet needle (j.N) 6jph10 ---- needle ...

  • Page 419: Spec

    – 3 – spec tightening torques ebs01005 tightening torques engine tightening torques ebs01006 chassis tightening torques part to be tightened part name thread size q’ty tightening torque remarks nm m · kg ft · lb engine cooling fan bolt m6 2 9 0.9 6.5 part to be tightened thread size tightening torqu...

  • Page 420: Spec

    – 4 – spec cable routing cable routing 1 left headlight lead 2 wire harness 3 throttle cable 4 brake light switch lead 5 radiator fan motor breather hose 6 starter cable 7 starter (choke) knob 8 light switch 9 coolant reservoir breather hose 0 parking brake switch lead a parking brake cable b crankc...

  • Page 421: Spec

    – 5 – spec cable routing È 30 ~ 60 mm (1.18 ~ 2.36 in) É 160 ~ 190 mm (6.30 ~ 7.48 in) Ê fasten the wire harness to the frame with the plastic bands. Ë pull the excess of the hoses through the guide in the upper instrument panel so that there is no slack in the hoses. Ì fasten the throttle cable, pa...

  • Page 422: Spec

    – 6 – spec cable routing 1 float chamber breather hose 2 throttle cable 3 parking brake cable 4 thermo switch 1 5 vacuum hose 6 spark plug cap 7 wire harness 8 tail/brake light lead 9 starter motor lead 0 carburetor heater leads a carburetor heater È fasten the parking brake switch lead and park- in...

  • Page 423: Spec

    – 7 – spec cable routing Ì fasten the parking brake cable and float cham- ber breather hose with the plastic clip. Í fasten the wire harness with the plastic band. Face the end of the plastic band down. Î push the excess tail/brake light lead into the rear fender so that there is no slack in the lea...

  • Page 424: Spec

    – 8 – spec cable routing 1 main switch 2 starter (choke) knob 3 starter (choke) cable 4 rectifier/regulator 5 wire harness 6 coolant reservoir breather hose 7 right headlight lead 8 radiator fan motor breather hose 9 radiator fan motor coupler 0 differential gear case breather hose a thermo switch 3...

  • Page 425: Spec

    – 9 – spec cable routing È fasten the wire harness with the plastic band. É fasten the wire harness, radia- tor fan motor lead, and thermo switch 3 lead to the frame with the plastic locking tie. Ê fasten the wire harness to the frame with the plastic locking ties. Ë 30 ~ 60 mm (1.18 ~ 2.36 in) Ì 16...

  • Page 426: Spec

    – 10 – spec cable routing Ò 70 ~ 90 mm (2.76 ~ 3.54 in) Ó fasten the throttle cable with the plastic band. Ô fasten the radiator inlet pipe with the plastic band. Õ fasten the rear brake pipe with the plastic band. Ö fasten the radiator outlet pipe with the plastic band. × fasten the wire harness, s...

  • Page 427: Spec

    – 11 – spec cable routing 1 ignition coil lead 2 spark plug lead 3 final gear case breather hose 4 vacuum hose 5 fuel hoses 6 air vent hoses 7 starter (choke) cable 8 crankcase breather hose 9 ground lead 0 rear brake hose a parking brake cable b ignition coil c rear brake pipe d wire harness e fuel...

  • Page 428: Spec

    – 12 – spec cable routing È fasten the spark plug lead with the plastic holder. É 20 ~ 30 mm (0.79 ~ 1.18 in) Ê pass the final gear case breather hose through the grommet. Ë 10° Ì fasten the starter (choke) cable, starter motor lead, reverse switch lead, gear position switch lead, thermo switch 1 le...

  • Page 429: Spec

    – 13 – spec cable routing Ò fasten the wire harness, ignition coil lead, and rear brake hose with the plastic band. Ó fasten the final gear case breather hose and fuel hose with the plastic clip. Ô fasten the fuel filter with the plastic band. Õ fasten the fuel hose with the plastic holders. Ö faste...

  • Page 430: Spec

    – 14 – spec cable routing 1 throttle cable 2 rear brake pipe 3 a.C. Magneto couplers 4 starter (choke) cable 5 air vent hose 6 rear brake hose 7 fuel hose 8 vacuum hose 9 spark plug lead 0 parking brake cable È pass the throttle cable through the cable guide. É fasten the speed sensor lead, starter ...

  • Page 431: Spec

    – 15 – spec cable routing Í fasten the fuel hose and vacuum hose with the plastic clip. Î make sure that the spark plug lead does not contact the frame. Ï the end of the spark plug cap boot must face towards the passenger side of the vehicle. Ð fasten the final gear case breather hose with the plast...

  • Page 432: Spec

    – 16 – spec cable routing 1 battery 2 negative battery lead 3 rectifier/regulator 4 starter (choke) cable 5 indicator light assembly couplers 6 on-command four-wheel drive switch and differ- ential gear lock switch leads 7 on-command four-wheel drive switch and differ- ential gear lock switch 8 main...

  • Page 433: Spec

    – 17 – spec cable routing k four-wheel drive relay 3 l differential gear lock indicator light relay m four-wheel drive indicator light relay n fuse box o positive battery lead p neutral indicator light q reverse indicator light r parking brake indicator light s four-wheel drive indicator light t dif...

  • Page 434: Spec

    – 18 – spec cable routing Ë pass the radiator fan motor breather hose and differential gear case breather hose through the guide. Ì fasten the throttle cable with the plastic holder. Í fasten the left headlight lead, differential gear case breather hose, and radiator fan motor breather hose with the...

  • Page 435: Spec

    – 19 – spec cable routing 1 auxiliary dc jack 2 auxiliary dc jack lead 3 coolant reservoir breather hose 4 throttle cable 5 radiator fan motor breather hose 6 differential gear case breather hose 7 starter (choke) cable 8 wire harness 9 front brake hoses 0 coolant reservoir hose a ground lead b star...

  • Page 436: Chk

    – 20 – chk adj eb300000 periodic checks and adjustments introduction this chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need fo...

  • Page 437: Chk

    – 21 – chk adj periodic maintenance/lubrication * since these items require special tools, data and technical skills have a yamaha dealer perform the ser- vice. Note: • recommended brake fluid: dot 4 • brake fluid replacement: • when disassembling the master cylinder or caliper, replace the brake fl...

  • Page 438: Chk

    – 22 – chk adj cleaning the air filter elements engine cleaning the air filter elements cleaning the intake duct air filter element 1. Remove: • air intake duct grill 1 2. Remove: • air filter element 1 (from the air intake duct grill 2) 3. Clean: • air filter element 1 note: remove any large partic...

  • Page 439: Chk

    – 23 – chk adj cleaning the air filter elements 1. Remove: • driver seat • passenger seat • console refer to “seats, enclosure, hood and cargo bed”. 2. Remove: • air filter case cover 1 3. Remove: • air filter element assembly 1 • air filter element cap 2 • air filter element 3 caution: never operat...

  • Page 440: Chk

    – 24 – chk adj cleaning the air filter elements 5. Clean: • air filter element ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Wash the element gently, but thoroughly in solvent. Warning use a cleaning solvent which is designed to clean parts only. Never use gasoline or low flash point solvents...

  • Page 441: Chk

    – 25 – chk adj adjusting the parking brake chassis adjusting the parking brake 1. Shift the drive select lever into low gear “l”. 2. Remove: • driver seat • passenger seat • console refer to “seats, enclosure, hood and cargo bed”. 3. Check: • parking brake lever free play a the maximum free play is ...

  • Page 442: Eng

    – 26 – eng engine engine removal air ducts, muffler and exhaust pipe t r . . 11 nm (1.1 m • kg, 8.0 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) 8 6 6 5 3 7 4 new t r . . 7 nm (0...

  • Page 443: Eng

    – 27 – eng engine removal t r . . 11 nm (1.1 m • kg, 8.0 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) 8 6 6 5 3 7 4 new t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) 5 new 2 (6) 1 order...

  • Page 444: Fuel

    – 28 – fuel fuel system carburetor 3 4 6 2 15 13 12 9 7 10 1 8 11 14 5 order job/part q’ty remarks removing the carburetor remove the parts in the order listed. Driver seat/passenger seat/air intake duct/console 1 refer to “seats, enclosure, hood and cargo bed”. 1 crankcase breather hose 1 disconnec...

  • Page 445: Fuel

    – 29 – fuel carburetor 3 4 6 2 15 13 12 9 7 10 1 8 11 14 5 order job/part q’ty remarks 13 throttle cable end 1 14 throttle cable 1 15 carburetor joint (intake manifold) 1 for installation, reverse the removal pro- cedure. Www.Midwestmanuals.Com.

  • Page 446: Fuel

    – 30 – fuel carburetor installing the air filter case joint 1. Install: • air filter case joint note: align the tab a on the air filter case joint with the slot b in the air filter case. B a www.Midwestmanuals.Com.

  • Page 447: Chas

    – 31 – chas chassis seats, enclosure, hood and cargo bed seats, console and instrument panels (16) (5) (9) (4) (8) 1 2 4 5 6 7 17 14 13 13 10 11 9 8 12 15 16 15 3 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 35 nm (3.5 m • kg, 25 ft • ib) order job/part q’ty remarks removing the seats, console and...

  • Page 448: Chas

    – 32 – chas seats, enclosure, hood and cargo bed (16) (5) (9) (4) (8) 1 2 4 5 6 7 17 14 13 13 10 11 9 8 12 15 16 15 3 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 35 nm (3.5 m • kg, 25 ft • ib) order job/part q’ty remarks 12 auxiliary dc jack connector 2 disconnect. 13 nut/starter cable 1/1 14 upp...

  • Page 449: Chas

    – 33 – chas seats, enclosure, hood and cargo bed panels and footrest cover 1 (12) 5 7 3 2 4 10 8 9 (8) (8) (4) (6) (4) (4) (4) 6 t r . . 16 nm (1.6 m • kg, 11 ft • ib) t r . . 32 nm (3.2 m • kg, 23 ft • ib) order job/part q’ty remarks removing the panels and footrest cover remove the parts in the or...

  • Page 450: Chas

    – 34 – chas seats, enclosure, hood and cargo bed cargo bed 6 6 5 8 8 8 8 3 1 1 2 5 4 7 9 4 (8) (7) (7) (8) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 11 nm (1.1 m • kg, 8.0 ft • i...

  • Page 451: Chas

    – 35 – chas seats, enclosure, hood and cargo bed enclosure and seat belts t r . . 64 nm (6.4 m • kg, 46 ft • ib) t r . . 64 nm (6.4 m • kg, 46 ft • ib) t r . . 64 nm (6.4 m • kg, 46 ft • ib) t r . . 59 nm (5.9 m • kg, 43 ft • ib) t r . . 59 nm (5.9 m • kg, 43 ft • ib) 6 1 2 3 5 7 (4) (8) (4) (8) 4 8...

  • Page 452

    Yxr660fat wiring diagram (black) b r w w w 2wd 4wd lock off on off start r y/l l/b sb g/w w/b g/r (black) (black) (black) (gray) (gray) (black) (black) (black) r w/g w/l w/r (black) br/l r b l/b w/g r w/r w/g l/g l/b l/r sb l/g l/b l/r sb gy br g/r b r/y l y g gy br g/r b sb w l/w b/r w/l g/l sb l/w...

  • Page 453: 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...

  • Page 454: Gen

    Ebs00006 symbols the following symbols are not relevant to every vehicle. Symbols 1 to 0 indicate the subject of each chapter. 1 general information 2 specifications 3 periodic checks and adjustments 4 engine 5 cooling system 6 fuel system 7 drive train 8 chassis 9 electrical 0 troubleshooting symbo...

  • Page 455: Contents

    Contents specifications .............................................................................................. 1 general specifications ..................................................................... 1 chassis specifications.................................................................

  • Page 456: Spec

    – 1 – spec specifications general specifications item standard model code 5ug9, 5ugb, 5ugf (for usa) 5uga, 5ugc, 5ugg (for cdn) 5ugd, 5ugh (for europe) 5uge (for oceania) dimensions overall length 2,885 mm (113.6 in) overall width 1,385 mm (54.5 in) overall height 1,853 mm (73.0 in) seat height 818 ...

  • Page 457: Spec

    – 2 – spec general specifications/ chassis specifications chassis specifications bulb wattage × quantity headlight 12 v 30 w/30 w × 2 tail/brake light 12 v 5 w/21 w × 2 indicator lights except for special edition models neutral indicator light 12 v 1.7 w × 1 reverse indicator light 12 v 1.7 w × 1 co...

  • Page 458: Spec

    – 3 – spec electrical specifications/ tightening torques electrical specifications tightening torques chassis tightening torques item standard limit headlight relay model/manufacturer g8hn-1c4t-dj-y52/omron ---- coil resistance 94.5 ~ 115.5 Ω at 20°c (68 °f) ---- part to be tightened thread size tig...

  • Page 459: Spec

    – 4 – spec cable routing cable routing 1 left headlight lead 2 wire harness 3 throttle cable 4 brake light switch lead 5 radiator fan motor breather hose 6 rectifier/regulator 7 starter cable 8 starter (choke) knob 9 light switch 0 coolant reservoir breather hose a parking brake switch lead b parkin...

  • Page 460: Spec

    – 5 – spec cable routing È 30 ~ 60 mm (1.18 ~ 2.36 in) É 160 ~ 190 mm (6.30 ~ 7.48 in) Ê fasten the wire harness to the frame with the plastic bands. Ë pull the excess of the hoses through the guide in the upper instrument panel so that there is no slack in the hoses. Ì fasten the throttle cable, pa...

  • Page 461: Spec

    – 6 – spec cable routing 1 float chamber breather hose 2 throttle cable 3 parking brake cable 4 thermo switch 1 5 vacuum hose 6 spark plug cap 7 wire harness 8 tail/brake light lead 9 starter motor lead 0 carburetor heater leads a carburetor heater È fasten the parking brake switch lead and park- in...

  • Page 462: Spec

    – 7 – spec cable routing Í 20 ~ 40° Î fasten the starter motor lead, reverse switch lead, gear position switch lead, thermo switch 1 lead, carburetor heater lead, and parking brake switch lead with a plastic band. Ï push the excess tail/brake light lead into the rear fender so that there is no slack...

  • Page 463: Spec

    – 8 – spec cable routing 1 main switch 2 starter (choke) knob 3 starter (choke) cable 4 wire harness 5 coolant reservoir breather hose 6 right headlight lead 7 radiator fan motor breather hose 8 radiator fan motor coupler 9 differential gear case breather hose 0 thermo switch 3 a gear motor couplers...

  • Page 464: Spec

    – 9 – spec cable routing È fasten the wire harness with the plastic bands. É fasten the wire harness, radia- tor fan motor lead, and thermo switch 3 lead to the frame with a plastic band. Ê fasten the wire harness to the frame with the plastic bands. Ë 30 ~ 60 mm (1.18 ~ 2.36 in) Ì 160 ~ 190 mm (6.3...

  • Page 465: Spec

    – 10 – spec cable routing Ò 70 ~ 90 mm (2.76 ~ 3.54 in) Ó fasten the throttle cable with a plastic band. Ô fasten the radiator inlet pipe with a plastic band. Õ fasten the rear brake pipe with a plastic band. Ö fasten the radiator outlet pipe with a plastic band. × fasten the wire harness, starter (...

  • Page 466: Spec

    – 11 – spec cable routing 1 ignition coil lead 2 spark plug lead 3 final gear case breather hose 4 vacuum hose 5 fuel hoses 6 air vent hoses 7 starter (choke) cable 8 crankcase breather hose 9 ground lead 0 rear brake hose a parking brake cable b ignition coil c rear brake pipe d wire harness e fuel...

  • Page 467: Spec

    – 12 – spec cable routing È fasten the spark plug lead with the plastic holder. É 20 ~ 30 mm (0.79 ~ 1.18 in) Ê pass the final gear case breather hose through the grommet. Ë 10° Ì fasten the starter (choke) cable, starter motor lead, reverse switch lead, gear position switch lead, thermo switch 1 le...

  • Page 468: Spec

    – 13 – spec cable routing Ó fasten the parking brake cable with the metal holder. Ô fasten the wire harness and rear brake hose with a plastic band. Õ fasten the final gear case breather hose and fuel hose with the plastic clip. Ö fasten the fuel filter with a plastic band. × fasten the fuel hose wi...

  • Page 469: Spec

    – 14 – spec cable routing 1 throttle cable 2 rear brake pipe 3 a.C. Magneto couplers 4 starter (choke) cable 5 air vent hose 6 rear brake hose 7 fuel hose 8 vacuum hose 9 spark plug lead 0 parking brake cable a wire harness È pass the throttle cable through the cable guide. É fasten the speed sensor...

  • Page 470: Spec

    – 15 – spec cable routing Í fasten the fuel hose and vacuum hose with the plastic clip. Î make sure that the spark plug lead does not contact the frame. Ï fasten the vacuum hose with the plastic holder. Ð the end of the spark plug cap boot must face towards the passenger side of the vehicle. Ñ faste...

  • Page 471: Spec

    – 16 – spec cable routing 1 battery 2 negative battery lead 3 starter (choke) cable 4 meter assembly couplers (for special edition models) 5 indicator light assembly couplers (except for special edition models) 6 on-command four-wheel drive switch and differ- ential gear lock switch leads 7 on-comma...

  • Page 472: Spec

    – 17 – spec cable routing i four-wheel drive relay 1 j four-wheel drive relay 2 k starter relay l four-wheel drive relay 3 m four-wheel drive indicator light relay (except for special edition models) n headlight relay o differential gear lock indicator light relay (except for special edition models)...

  • Page 473: Spec

    – 18 – spec cable routing w coolant temperature indicator light (except for special edition models) x c.D.I. Unit È fasten the wire harness and the leads of the unused couplers with a plastic band. (for special edition models) É fasten the wire harness with the plastic bands. Ê pass the radiator fan...

  • Page 474: Spec

    – 19 – spec cable routing Í fasten the throttle cable with the plastic holder. Î fasten the left headlight lead, differential gear case breather hose, and radiator fan motor breather hose with the plastic holder. Ï fasten the left headlight lead and differential gear case breather hose with the plas...

  • Page 475: Spec

    – 20 – spec cable routing 1 auxiliary dc jack 2 auxiliary dc jack lead 3 coolant reservoir breather hose 4 throttle cable 5 radiator fan motor breather hose 6 differential gear case breather hose 7 starter (choke) cable 8 rectifier/regulator 9 wire harness 0 front brake hoses a coolant reservoir hos...

  • Page 476: Chk

    – 21 – chk adj periodic checks and adjustments electrical changing a headlight bulb 1. Lift the hood up. 2. Remove: • headlight bulb holder cover 1 3. Disconnect: • headlight coupler 1 4. Remove: • headlight bulb holder assembly 1 note: the headlight bulb cannot be removed from the headlight bulb ho...

  • Page 477: Chk

    – 22 – chk adj changing a headlight bulb 6. Connect: • headlight coupler 7. Install: • headlight bulb holder cover 8. Close the hood. Www.Midwestmanuals.Com.

  • Page 478: Eng

    – 23 – eng engine engine cooling fan and a.C. Magneto order job/part q’ty remarks removing the engine cooling fan and a.C. Magneto remove the parts in the order listed. Driver seat/passenger seat/console refer to “seats, enclosure, hood and cargo bed”. (manual no.: 5ug-f8197-11) drive belt cover ref...

  • Page 479: Eng

    – 24 – eng engine cooling fan and a.C. Magneto order job/part q’ty remarks water pump assembly refer to “water pump” in chapter 5. (manual no.: 5ug-f8197-10) 1 engine cooling fan air duct assembly 1 2 air shroud 1 1 3 engine cooling fan 1 4 air shroud 2 1 5 a.C. Magneto coupler 2 disconnect. 6 engin...

  • Page 480: Eng

    – 25 – eng engine cooling fan and a.C. Magneto order job/part q’ty remarks 12 a.C. Magneto rotor 1 refer to “removing the a.C. Mag- neto” and “installing the a.C. Magneto” in chapter 4. (manual no.: 5ug-f8197-10) 13 woodruff key 1 14 starter wheel gear 1 15 washer 1 16 starter idle gear shaft 1 17 b...

  • Page 481: Cool

    – 26 – cool cooling system oil cooler ls ls new new r . . 7 nm (0.7 m • kg, 5.1 ft • ib) r . . 7 nm (0.7 m • kg, 5.1 ft • ib) 1 2 2 3 (4) 7 6 8 4 5 order job/part q’ty remarks removing the oil cooler remove the parts in the order listed. Driver seat/passenger seat/console refer to “seats, enclosure,...

  • Page 482: Cool

    – 27 – cool oil cooler ls ls new new r . . 7 nm (0.7 m • kg, 5.1 ft • ib) r . . 7 nm (0.7 m • kg, 5.1 ft • ib) 1 2 2 3 (4) 7 6 8 4 5 order job/part q’ty remarks 6 oil outlet hose 1 7 oil inlet hose 1 8 oil cooler inlet pipe 2/oil cooler outlet pipe 2 1/1 for installation, reverse the removal pro- ce...

  • Page 483: Chas

    – 28 – chas chassis seats, enclosure, hood and cargo bed front guard and hood 4 3 2 1 t r . . 32 nm (3.2 m • kg, 23 ft • ib) t r . . 59 nm (5.9 m • kg, 43 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks removing the front guard and the hood remove the parts in the order l...

  • Page 484: Chas

    – 29 – chas seats, enclosure, hood and cargo bed panels and footrest cover 1 (12) 6 3 2 4 9 7 8 (8) (8) (4) (6) (4) (4) 5 t r . . 16 nm (1.6 m • kg, 11 ft • ib) t r . . 32 nm (3.2 m • kg, 23 ft • ib) order job/part q’ty remarks removing the panels and footrest cover remove the parts in the order lis...

  • Page 485: Chas

    – 30 – chas seats, enclosure, hood and cargo bed cargo bed 4 2 3 new new 1 2 3 1 r . . 16 nm (1.6 m • kg, 11 ft • ib) r . . 16 nm (1.6 m • kg, 11 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks removing the cargo bed remove the parts in the order listed. 1 tail/brake ligh...

  • Page 486: Chas

    – 31 – chas seats, enclosure, hood and cargo bed 6 8 8 8 8 4 1 2 2 3 6 5 7 9 5 (8) (8) r . . 7 nm (0.7 m • kg, 5.1 ft • ib) r . . 7 nm (0.7 m • kg, 5.1 ft • ib) r . . 7 nm (0.7 m • kg, 5.1 ft • ib) r . . 7 nm (0.7 m • kg, 5.1 ft • ib) r . . 26 nm (2.6 m • kg, 19 ft • ib) r . . 7 nm (0.7 m • kg, 5.1 ...

  • Page 487: Chas

    – 32 – chas seats, enclosure, hood and cargo bed skid plates t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) 2 1 (7) (7) (7) (7) (4) order job/part q’ty remarks removing the engine skid plates remove the parts in the order listed. 1 front skid plate 1 2 rear skid plate 1 for installation, reverse the removal...

  • Page 488: Chas

    – 33 – chas seats, enclosure, hood and cargo bed installing the rear skid plate 1. Install: • rear skid plate 1 note: make sure that the hole a in the rear skid plate 1 is towards the left side of the vehicle. È forward É left side Ê right side È É Ê 1 a www.Midwestmanuals.Com.

  • Page 489: Chas

    – 34 – chas seats, enclosure, hood and cargo bed enclosure and seat belts r . . 64 nm (6.4 m • kg, 46 ft • ib) r . . 64 nm (6.4 m • kg, 46 ft • ib) r . . 64 nm (6.4 m • kg, 46 ft • ib) r . . 59 nm (5.9 m • kg, 43 ft • ib) 6 1 2 3 5 7 (4) (8) (4) (8) 4 8 r . . 59 nm (5.9 m • kg, 43 ft • ib) 7 order j...

  • Page 490: Chas

    – 35 – chas front wheels and brake discs front wheels and brake discs 4 6 5 3 new lt lt 2 1 t r . . 48 nm (4.8 m • kg, 35 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 350 nm (35.0 m • kg, 255 ft • lb) order job/part q’ty remarks removing the front wh...

  • Page 491: Chas

    – 36 – chas front wheels and brake discs 4 6 5 3 new lt lt 2 1 t r . . 48 nm (4.8 m • kg, 35 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 350 nm (35.0 m • kg, 255 ft • lb) order job/part q’ty remarks 4 brake caliper assembly 1 note: do not depress th...

  • Page 492: Chas

    – 37 – chas rear wheels and brake disc rear wheels and brake disc rear wheels new 1 3 4 2 t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 350 nm (35.0 m • kg, 255 ft • lb) order job/part q’ty remarks removing the rear wheel remove the parts in the order listed. Place the vehicle on a level surface. W...

  • Page 493: Chas

    – 38 – chas front arms and front shock absorbers front arms and front shock absorbers 6 8 8 4 3 4 4 5 5 1 6 9 6 10 11 9 7 6 new ls new 4 ls 8 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t ...

  • Page 494: Chas

    – 39 – chas front arms and front shock absorbers 6 8 8 4 3 4 4 5 5 1 6 9 6 10 11 9 7 6 new ls new 4 ls 8 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) ...

  • Page 495: Chas

    – 40 – chas rear knuckle and stabilizer rear knuckle and stabilizer 7 8 6 7 8 9 6 4 4 2 3 5 4 4 5 ls t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 56 nm (5.6 m • kg, 40 ft • ib) t r . . 56 nm (5.6 m • kg, 40 ft • ib) t r . . 32 nm (3.2m • kg, 23 ft • ib) ls 1 r . . 7 nm (0.7 m • kg, 5.1 ft • ib) or...

  • Page 496: Elec

    – 41 – – + elec eb800000 electrical electrical components 1 diode 1 2 thermo switch 2 3 diode 2 4 circuit breaker (radiator fan motor) 5 carburetor heater 6 thermo switch 1 7 ignition coil 8 gear position switch 9 reverse switch 0 brake light switch a parking brake switch b pickup coil/stator assemb...

  • Page 497: Elec

    – 42 – – + elec electrical components 1 rectifier/regulator 2 auxiliary dc jack 3 indicator light assembly 1 (except for special edition mod- els) 4 indicator light assembly 2 (except for special edition mod- els) 5 on-command four-wheel drive switch and differential gear lock switch 6 main switch 7...

  • Page 498: Elec

    – 43 – – + elec lighting system eb805000 lighting system circuit diagram (black) br ww w 2wd 4wd lock off on off start r y /ll /b sb g /w w /b g /r (black) (black) (black) (gray) (gray) (black) (black) (black) r w /g w /lw /r (black) br /l r bl /b w /g r w /rw /g l/ g l/ b l/ r sb l/ g l/ b l/ r sb ...

  • Page 499: Elec

    – 44 – – + elec lighting system eb805010 troubleshooting procedure check: 1. Fuses (main, lighting system) 2. Battery 3. Main switch 4. Light switch 5. Headlight relay 6. Wiring connections (the entire lighting system) if the headlights and/or taillight fail to come on: note: • remove the following ...

  • Page 500: Elec

    – 45 – – + elec lighting system correct 4. Light switch refer to “checking the switch” in chap- ter 9. (manual no.: 5ug-f8197-10) * incorrect replace the light switch. Continuity 5. Headlight relay • remove the headlight relay from the wire harness. • connect the pocket tester ( Ω × 1) and the batte...

  • Page 501: Elec

    – 46 – – + elec signaling system (for special edition models) eb806000 signaling system (for special edition models) circuit diagram (black) br ww w 2wd 4wd lock off on off start r y /ll /b sb g /w w /b g /r (black) (black) (black) (gray) (gray) (black) (black) (black) r w /g w /lw /r (black) br /l ...

  • Page 502: Elec

    – 47 – – + elec signaling system (for special edition models) 3 main switch 4 backup fuse 6 battery 7 main fuse 0 brake light switch b reverse switch c c.D.I. Unit h multi-function meter i differential gear lock indicator light j coolant temperature warning light k reverse indicator light l neutral ...

  • Page 503: Elec

    – 48 – – + elec signaling system (for special edition models) checking the signaling system with multi-function meter 1. If the coolant temperature warning light does not come on when the main switch to “on”, or if the coolant temperature warning light does not come on when the temperature is high (...

  • Page 504: Elec

    – 49 – – + elec signaling system (for special edition models) 2. Diode 2 • remove the diode from the coupler. • connect the pocket tester ( Ω × 1) to the diode terminals as shown. • check the diode for continuity as follows. * correct tester (+) lead → blue/black terminal 1 tester (–) lead → white/b...

  • Page 505

    Yxr66fav 2006 wiring diagram (black) b r w w w 2wd 4wd lock off on off start r y/l l/b sb g/w w/b g/r (black) (black) (black) (gray) (gray) (black) (black) (black) r w/g w/l w/r (black) br/l r b l/b w/g r w/r w/g l/g l/b l/r sb l/g l/b l/r sb gy br g/r b r/y l y gy br g/r b sb w l/w b/r w/l g/l sb l...

  • Page 506

    Yxr66fav 2006 wiring diagram 1 a.C. Magneto 2 rectifier/regulator 3 main switch 4 backup fuse 5 carburetor heater fuse 6 battery 7 main fuse 8 starter relay 9 starter motor 0 brake light switch a diode 1 b reverse switch c c.D.I. Unit d ignition coil e spark plug f speed sensor g meter assembly h mu...