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Yamaha GRIZZLY 700 FI YFM7FGPW Service Manual - Chapter  9

Other manuals for GRIZZLY 700 FI YFM7FGPW: Owner's Manual, Owner's Manual

Summary of GRIZZLY 700 FI YFM7FGPW

  • Page 1

    Lit-11616-20-11 3b4-28197-10 yfm7fgpw service manual.

  • Page 2

    Ebs00001 yfm7fgpw service manual ©2006 by yamaha motor corporation, u.S.A. First edition, may 2006 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor corporation, u.S.A. Is expressly prohibited. Printed in u.S.A. Lit-11616-20-11.

  • Page 3: Notice

    Ebs00002 notice this manual was produced by the yamaha motor company primarily for use by yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on y...

  • Page 4: How to Use This Manual

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

  • Page 5: 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 injection system 7 drive train 8 chassis 9 electrical 0 troubleshoo...

  • Page 6: 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 injection system fi 6 drive train driv 7 chassis chas 8 electrical elec 9 troubleshooting trbl shtg 10 – +.

  • Page 7: Contents

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

  • Page 8: Chapter  3

    General tightening torque specifications............................... 2-22 lubrication points and lubricant types .................................... 2-23 engine................................................................................................... 2-23 coolant flow diagrams ............

  • Page 9

    Engine ......................................................................................................... 3-16 adjusting the valve clearance ................................................ 3-16 adjusting the engine idling speed ........................................... 3-19 adjusting the t...

  • Page 10: Chapter  4

    Electrical system................................................................................. 3-67 checking and charging the battery ....................................... 3-67 checking the fuses ........................................................................ 3-73 adjusting the headli...

  • Page 11

    Ac magneto............................................................................................... 4-42 removing the ac magneto rotor.............................................. 4-45 checking the stator coil and crankshaft position sensor .......................................................

  • Page 12: Chapter  5

    Crankshaft and oil pump ................................................................... 4-75 oil pump ............................................................................................... 4-76 removing the crankshaft ........................................................... 4-77 chec...

  • Page 13: Chapter  6

    Chapter 6 fuel injection system fuel injection system............................................................................ 6-1 circuit diagram .................................................................................. 6-3 ecu self-diagnostic function......................................

  • Page 14: Chapter  8

    Front constant velocity joints and differential gear........ 7-4 removing the differential gear assembly........................... 7-10 checking the front constant velocity joints................... 7-10 checking the differential gears ............................................. 7-11 checking the...

  • Page 15

    Front and rear brakes......................................................................... 8-8 front brake pads .............................................................................. 8-8 rear brake pads................................................................................. 8-9 ...

  • Page 16: Chapter  9

    Rear arms and rear shock absorber assemblies ................. 8-55 checking the rear arms ............................................................... 8-57 checking the rear shock absorber assemblies ................ 8-57 installing the rear arms and rear shock absorber assemblies .................

  • Page 17: Chapter  10

    Cooling system....................................................................................... 9-45 circuit diagram ................................................................................ 9-45 troubleshooting ..............................................................................

  • Page 18

    Faulty clutch performance ............................................................ 10-4 engine operates but vehicle will not move ........................ 10-4 clutch slipping ................................................................................ 10-4 poor starting performance ...........

  • Page 19: Gen

    1 - 1 gen info ebs00009 general information vehicle identification ebs00010 vehicle identification number the vehicle identification number 1 is stamped into the front left side of the frame. Ebs00011 model label the model label 1 is affixed at the location in the illustration. This information will...

  • Page 20: Gen

    1 - 2 gen info features eas20170 features outline of the fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture. In the conventional carburet...

  • Page 21: Gen

    1 - 3 gen info features fi system the fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kpa (3.24 kg/cm 2 , 46.1 psi). Accord- ingly, when the energizing signal from the ecu energizes ...

  • Page 22: Gen

    1 - 4 gen info features outline of the eps (electric power steering) system caution: to prevent accidental damage to the eps unit, it must not be disassembled. Engine starting rpm information from ecu battery 4. Eps control unit calculates assist power 5. Electricity output switched by eps control u...

  • Page 23: Gen

    1 - 5 gen info features eps (electric power steering) system block diagram eps unit torque sensor eps motor eps control unit battery engine rpm signal meter assembly multifunction display odometer/tripmeter a/tripmeter b/clock/fuel meter/gear position indicator and warning lights eps warning/engine ...

  • Page 24: Gen

    1 - 6 gen info instrument functions ebu27291 multifunction display 1 “clock” button 2 “reset” button 3 “select” button 4 speedometer 5 fuel meter 6 clock/hour meter 7 odometer/tripmeter a/tripmeter b the multifunction display is equipped with the following: • a speedometer (which shows the riding sp...

  • Page 25: Gen

    1 - 7 gen info features clock mode pushing the “clock” button switches the dis- play between the clock mode “clock” and the hour meter mode “hour” in the following order: clock → hour → clock to set the clock 1. Set the display to the clock mode. 2. Push the “select” button and “reset” button togeth...

  • Page 26: Gen

    1 - 8 gen info features self-diagnosis device this model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuits are defective, the multi- function display will indicate a two-digit error code. If the multifunction display indicates such an error code, note...

  • Page 27: Gen

    1 - 9 gen info important information ebs00013 important information preparation for removal and disassembly 1. Before removal and disassembly remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to “special tools”. 3. When disassembling always k...

  • Page 28: Gen

    1 - 10 gen info important information ebs00016 lock washers/plates and cotter pins after removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. Ebs00017 bearings and oil seals install ...

  • Page 29: Gen

    1 - 11 gen info important information ebs00019 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector moisture → dry with an air blower. Rust/stains → connect and disconnec...

  • Page 30: Gen

    1 - 12 gen info special tools ebs00021 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may di...

  • Page 31: Gen

    1 - 13 gen info special tools 90890-01274 yu-90058 yu-90059 crankshaft installer pot installing pot pot installer this tool is used to install the crankshaft. 90890-01275 yu-90060 crankshaft installer bolt bolt this tool is used to install the crankshaft. 90890-01304 yu-01304 piston pin puller set p...

  • Page 32: Gen

    1 - 14 gen info special tools 90890-01325 yu-24460-01 radiator cap tester radiator pressure tester this tool is used to check the cooling sys- tem. 90890-01348 ym-01348 locknut wrench this tool is needed when removing or installing the secondary sheave spring. 90890-01352 yu-33984 radiator cap teste...

  • Page 33: Gen

    1 - 15 gen info special tools 90890-01474 ym-01474 ball joint remover these tools are used to removing or installing the ball joints. 90890-01475 ym-01475 gear lash measurement tool middle drive gear lash tool this tool is used to measure the gear lash. 90890-01480 ym-01480 ball joint remover attach...

  • Page 34: Gen

    1 - 16 gen info special tools 90890-03141 yu-03141 timing light inductive clamp timing light this tool is necessary for checking igni- tion timing. 90890-03153 yu-03153 pressure gauge this tool is used to measure fuel pres- sure. 90890-03170 ym-03170 belt tension gauge rear drive belt tension gauge ...

  • Page 35: Gen

    1 - 17 gen info special tools 90890-04066 ym-04066 valve guide reamer (ø6) valve guide reamer (6.0 mm) this tool is needed to rebore the new valve guides. 90890-04081 ym-91044 spacer (crankshaft installer) pot spacer this tool is used to install the crankshaft. 90890-04082 extension this tool is use...

  • Page 36: Gen

    1 - 18 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 sheave fixed bracket this tool is needed when removing or installing the secondary sheave spring. 90890-067...

  • Page 37: Spec

    2 - 1 spec ebs01001 specifications general specifications item standard model code 3b41 3b45 3b48 dimensions overall length 2,065 mm (81.3 in) overall width 1,180 mm (46.5 in) overall height 1,240 mm (48.8 in) seat height 905 mm (35.6 in) wheelbase 1,250 mm (49.2 in) minimum ground clearance 275 mm ...

  • Page 38: Spec

    2 - 2 spec general specifications oil quantity engine oil periodic oil change 2.00 l (1.76 imp qt, 2.11 us qt) with oil filter replacement 2.10 l (1.85 imp qt, 2.22 us qt) total amount 2.40 l (2.11 imp qt, 2.54 us qt) final gear oil periodic oil change 0.20 l (0.18 imp qt, 0.21 us qt) total amount 0...

  • Page 39: Spec

    2 - 3 spec general specifications tire type front tubeless rear tubeless size front at25 × 8-12 rear at25 × 10-12 manufacturer/model front dunlop/kt421 rear dunlop/kt425 tire pressure (cold tire) maximum load* 220.0 kg (485 lb) off-road riding front 32 ~ 38 kpa (0.32 ~ 0.38 kg/cm 2 , 4.6 ~ 5.5 psi) ...

  • Page 40: Spec

    2 - 4 spec general specifications bulb voltage/wattage × quantity headlight 12 v 35.0 w/35.0 w × 2 tail/brake light 12 v 21.0/5.0 w × 1 indicator light neutral indicator light led reverse indicator light led coolant temperature warning light led engine trouble warning light led eps warning light led...

  • Page 41: Spec

    2 - 5 spec engine specifications ebs01002 engine specifications item standard limit cylinder head maximum warpage ---- 0.03 mm (0.0012 in) cylinder bore 102.000 ~ 102.010 mm (4.0157 ~ 4.0161 in) 102.080 mm (4.0189 in) measuring point 50.0 mm (1.97 in) ---- maximum taper 0.05 mm (0.002 in) out of rou...

  • Page 42: Spec

    2 - 6 spec engine specifications timing chain model/number of links 98xrh2010/126 ---- tensioning system automatic ---- rocker arm/rocker arm shaft rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) ---- shaft outside diameter 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) ---- arm-to-shaft...

  • Page 43: Spec

    2 - 7 spec engine specifications valve-stem-to-valve-guide clearance intake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.080 mm (0.0031 in) exhaust 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) 0.100 mm (0.0039 in) valve stem runout ---- 0.040 mm (0.0016 in) valve seat width intake 1.00 ~ 1.20 mm (0.0394 ~ 0.047...

  • Page 44: Spec

    2 - 8 spec engine specifications piston piston-to-cylinder clearance 0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in) 0.13 mm (0.0051 in) diameter “d” 101.955 ~ 101.970 mm (4.0140 ~ 4.0146 in) ---- height “h” 10.0 mm (0.39 in) ---- offset 0.50 mm (0.0197 in) ---- offset direction intake side ---- piston pin bo...

  • Page 45: Spec

    2 - 9 spec engine specifications oil ring dimensions (b × t) 2.50 × 2.80 mm (0.10 × 0.11 in) ---- end gap (installed) 0.20 ~ 0.70 mm (0.008 ~ 0.028 in) ---- ring side clearance 0.060 ~ 0.150 mm (0.0024 ~ 0.0059 in) ---- crankshaft crank width “a” 74.95 ~ 75.00 mm (2.951 ~ 2.953 in) ---- maximum runo...

  • Page 46: Spec

    2 - 10 spec engine specifications fuel pump pump type electrical ---- model/manufacturer 3b4/denso ---- oil filter type cartridge (paper) ---- oil pump oil pump type trochoid ---- inner-rotor-to-outer-rotor-tip clear- ance less than 0.12 mm (0.0047 in) 0.20 mm (0.0079 in) outer-rotor-to-oil-pump-hou...

  • Page 47: Spec

    2 - 11 spec engine specifications cylinder head tightening sequence 3 1 4 2 7 8 5 6.

  • Page 48: Spec

    2 - 12 spec chassis specifications ebs01003 chassis specifications item standard limit steering system steering bearing type ball and race bearing ---- steering tension 50 n (5.0 kgf) ---- front suspension shock absorber travel 90.7 mm (3.57 in) ---- spring free length 292.0 mm (11.50 in) ---- insta...

  • Page 49: Spec

    2 - 13 spec chassis specifications front disc brake type dual ---- disc outside diameter × thickness 220.0 × 3.5 mm (8.66 × 0.14 in) ---- brake disc minimum thickness 3.0 mm (0.12 in) ---- brake disc maximum deflection 0.1 mm (0.004 in) ---- pad thickness inner 4.4 mm (0.17 in) 1.0 mm (0.04 in) pad ...

  • Page 50: Spec

    2 - 14 spec electrical specifications ebs01004 electrical specifications item standard limit system voltage 12 v ---- ignition system ignition timing (b.T.D.C.) 12°/1,400 r/min ---- advancer type digital ---- transistorized coil ignition crankshaft position sensor resis- tance/color 459 ~ 561 Ω at 2...

  • Page 51: Spec

    2 - 15 spec electrical specifications starter relay model/manufacturer 2768113-a/jideco ---- amperage rating 180.0 a ---- coil winding resistance 4.18 ~ 4.62 Ω at 20 °c (68 °f) ---- fuel gauge sender unit resistance (full) 19.00 ~ 21.00 Ω ---- sender unit resistance (empty) 139.00 ~ 141.00 Ω ---- st...

  • Page 52: Spec

    2 - 16 spec tightening torques ebs01005 tightening torques engine tightening torques item part name thread size q’ty tightening torque remarks nm m · kg ft · lb cylinder head (exhaust pipe) stud bolt m8 4 15 1.5 11 cylinder head bolt m9 4 35 3.5 25 m cylinder head bolt m9 2 38 3.8 27 e cylinder head...

  • Page 53: Spec

    2 - 17 spec tightening torques water pump outlet pipe bolt m6 1 10 1.0 7.2 water jacket joint bolt m6 2 10 1.0 7.2 timing chain guide bolt m6 2 10 1.0 7.2 lt crankshaft end accessing screw — m36 1 10 1.0 7.2 timing mark accessing screw — m14 1 6 0.6 4.3 drive belt cover bolt m6 12 10 1.0 7.2 bearing...

  • Page 54: Spec

    2 - 18 spec tightening torques note: temporarily tighten the cylinder bolts to 15 nm (1.5 m · kg, 11 ft · lb) and then tighten them to 50 nm (5.0 m · kg, 36 ft · lb)..

  • Page 55: Spec

    2 - 19 spec tightening torques ebs01006 chassis tightening torques part to be tightened thread size tightening torque remarks nm m · kg ft · lb engine and front rubber damper m10 42 4.2 30 engine and front rubber damper m6 10 1.0 7.2 lt engine and rear rubber damper m10 42 4.2 30 engine and rear rub...

  • Page 56: Spec

    2 - 20 spec tightening torques pitman arm nut m16 210 21.0 150 eps motor cover m6 7 0.7 5.1 pitman arm and tie-rod m10 25 2.5 18 steering knuckle and tie-rod m10 25 2.5 18 steering knuckle and front lower arm m12 30 3.0 22 front arm protector and front lower arm m6 7 0.7 5.1 fuel tank and fuel pump ...

  • Page 57: Spec

    2 - 21 spec tightening torques rear carrier and rear fender m6 7 0.7 5.1 engine skid plates m6 7 0.7 5.1 trailer hitch and frame m10 55 5.5 40 battery holding bracket m6 7 0.7 5.1 battery bracket and fitting screw m6 7 0.7 5.1 fitting screw and frame m6 7 0.7 5.1 electrical components tray and frame...

  • Page 58: 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 59: Spec

    2 - 23 spec lubrication points and lubricant types ebs00024 lubrication points and lubricant types engine lubrication point lubricant oil seal lips ls bearings e o-ring ls cylinder head bolts m crankshaft pin e connecting rod big end thrust surface e crankshaft sprocket m inner race (crankshaft) e b...

  • Page 60: Spec

    2 - 24 spec lubrication points and lubricant types shift lever 2 inner surface ls shift lever 1 e shift lever 1 gear teeth and shift lever 2 gear teeth e stopper lever stopper e bearing (final drive pinion gear assembly) g bearing (final gear) g ac magneto lead grommet yamaha bond no.1215 (three bon...

  • Page 61: Spec

    2 - 25 spec coolant flow diagrams ebs00025 coolant flow diagrams 1 coolant reservoir hose 2 radiator inlet hose 3 fast idle plunger outlet hose 4 coolant reservoir 5 water pump 6 water pump outlet pipe 7 water pump outlet hose 8 radiator outlet hose 9 radiator 0 fast idle plunger inlet hose a a 3 0 ...

  • Page 62: Spec

    2 - 26 spec oil flow diagrams ebs00026 oil flow diagrams 1 oil delivery pipe 2 oil filter cartridge 3 oil strainer 4 drive axle 5 relief valve assembly 6 reverse idle gear shaft b b b-b 1 2 3 4 2 6 5.

  • Page 63: Spec

    2 - 27 spec oil flow diagrams 1 camshaft 2 crankshaft 3 oil strainer 4 oil pump rotor 5 oil pump driven gear 1 2 4 5 3.

  • Page 64: Spec

    2 - 28 spec cable routing ebs00028 cable routing 1 front brake light switch lead 2 on-command four-wheel-drive motor switch and differential gear lock switch lead 3 front brake hose 4 throttle cable 5 rear brake cable 6 shift control cable 7 rear brake hose 8 left handlebar switch lead 9 rear brake ...

  • Page 65: Spec

    2 - 29 spec cable routing È pass the front brake hose and throttle cable through the guide on the handlebar cover. É pass the rear brake cable, shift control cable, and rear brake hose through the guide on the handlebar cover. Ê route the rear brake cable, shift control cable, and rear brake hose in...

  • Page 66: Spec

    2 - 30 spec cable routing Ï route the front brake light switch lead, on-com- mand four-wheel-drive motor switch and differ- ential gear lock switch lead, left handlebar switch lead, and rear brake light switch lead over the throttle cable, rear brake cable, and shift control cable, then to the front...

  • Page 67: Spec

    2 - 31 spec cable routing Ó pass the eps motor breather hose through the guide on the meter bracket, making sure to face the end of the hose downward. Ô route the radiator fan motor breather hose and differential gear case breather hose in front of the frame. Õ fasten the differential gear case brea...

  • Page 68: Spec

    2 - 32 spec cable routing Ù fasten the front brake light switch lead and on- command four-wheel-drive motor switch and dif- ferential gear lock switch lead with the plastic bands at the bends in the handlebar, making sure to route the leads under the handlebar and to face the ends of the bands forwa...

  • Page 69: Spec

    2 - 33 spec cable routing 1 coolant reservoir hose 2 radiator fan motor breather hose 3 differential gear case breather hose 4 eps motor breather hose 5 ground lead 6 coolant reservoir breather hose 7 throttle cable 8 fuel injector lead 9 final gear case breather hose 0 speed sensor lead a crankshaf...

  • Page 70: Spec

    2 - 34 spec cable routing É route the ground lead, radiator fan motor breather hose, differential gear case breather hose, and eps motor breather hose to the inside of the fast idle plunger outlet hose. Ê pass the radiator fan motor breather hose through the larger diameter guide. Ë route the coolan...

  • Page 71: Spec

    2 - 35 spec cable routing Ñ fasten the differential gear case breather hose to the frame with the plastic band, making sure to face the end of the band inward. Ò attach the ground lead terminal to the frame using the bolt. Ó route the radiator fan motor breather hose and differential gear case breat...

  • Page 72: Spec

    2 - 36 spec cable routing Ú route the shift control cable under the gear posi- tion switch lead, speed sensor lead, and crank- shaft position sensor lead. Ó Ò Ñ Ð Ï Ô Õ Õ Ú × Ø Ø Ù Ö Î Í È É Ê Ë Ì 1 d c b d 5 e f 0 9 a g 5 i h 1 4 c 1 4 e a 2 3 5 6 7 8 9 0 a 4 e e a a b b c c d a-a e-e b-b c-c d.

  • Page 73: Spec

    2 - 37 spec cable routing 1 wire harness 2 fuel injector lead 3 fuel hose 4 intake air temperature sensor lead 5 final gear case breather hose 6 ground lead 7 starter motor lead 8 air filter case breather hose 9 main switch lead 0 auxiliary dc jack lead a eps motor lead b differential gear motor lea...

  • Page 74: Spec

    2 - 38 spec cable routing m speed sensor lead n coolant temperature sensor lead o eps motor lead coupler p eps torque sensor lead coupler È route the fuel hose between the wire harness and the fuel tank drain hose. É route the coolant temperature sensor lead above the fast idle plunger inlet hose. Ê...

  • Page 75: Spec

    2 - 39 spec cable routing Î fasten the final gear case breather hose, ground lead, starter motor lead, fuel injector lead, coolant temperature sensor lead, ac mag- neto lead, and wire harness with the plastic band, making sure to position the band near the split in the wire harness. Ï route the fuel...

  • Page 76: Spec

    2 - 40 spec cable routing 1 tail/brake light lead 2 rectifier/regulator lead 3 ac magneto lead 4 speed sensor lead 5 final gear case breather hose 6 fuel hose 7 fuel pump lead 8 wire harness È to tail/brake light É fasten the tail/brake light lead to the frame with a plastic locking tie, making sure...

  • Page 77: Spec

    2 - 41 spec cable routing 1 left headlight lead 2 negative battery lead 3 right headlight lead 4 radiator fan motor lead 5 eps control unit lead 6 auxiliary dc jack lead 7 main switch lead 8 final gear case breather hose 9 starter motor lead 0 differential gear motor lead a ignition coil lead b mete...

  • Page 78: Spec

    2 - 42 spec cable routing m joint coupler lead È to left headlight É connect the headlight lead coupler, and then fasten the coupler with the holder on the electri- cal components tray. Ê route the negative battery lead along the guide on the electrical components tray. Ë to right headlight Ì place ...

  • Page 79: Spec

    2 - 43 spec cable routing Ñ route the hoses under the positive battery lead, and then route them upward, to the inside of the coolant reservoir breather hose. Ò fasten the coolant reservoir breather hose with the holder on the electrical components tray. Ó fasten the coolant reservoir hose with the ...

  • Page 80: Spec

    2 - 44 spec cable routing 1 throttle cable 2 rear brake hose 3 rear brake cable 4 front brake hose 5 negative battery lead 6 final gear case breather hose 7 starter motor lead 8 intake air pressure sensor lead 9 tps lead 0 intake air temperature sensor lead a fuel injector lead b coolant temperature...

  • Page 81: Spec

    2 - 45 spec cable routing É to engine Ê to air filter case Ë route the fuel injector lead and coolant temper- ature sensor lead to the outside of the frame. Ì pass the tail/brake light lead through the hole in the rear fender. Í fasten the tail/brake light lead with the holder, making sure that the ...

  • Page 82: Chk

    3 - 1 chk adj ebs00029 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 83: Chk

    3 - 2 chk adj general maintenance and lubrication chart ebu21863 general maintenance and lubrication chart no. Item check or mainte- nance job whichever comes first initial every month 1 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 1 air filter el...

  • Page 84: Chk

    3 - 3 chk adj general maintenance and lubrication chart ebu23070 note: • the air filter needs more frequent service if you are riding in unusually wet or dusty areas. • hydraulic brake service • regularly check and, if necessary, correct the brake fluid level. • every two years replace the internal ...

  • Page 85: Chk

    3 - 4 chk adj engine skid plates, seat, carriers and fenders engine skid plates 1 2 3 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks removing the engine skid plates remove the parts in the order listed. 1 front engine skid plate 1 2 center engine skid plate 1 3 rear engine skid p...

  • Page 86: Chk

    3 - 5 chk adj seat and side panels 6 4 1 3 2 5 order job/part q’ty remarks removing the seat and side panels remove the parts in the order listed. 1 seat 1 note: pull up the seat lock lever, then pull up on the rear of the seat. 2 battery cover 1 3 fuel tank cover 1 4 left side panel 1 5 right side ...

  • Page 87: Chk

    3 - 6 chk adj engine skid plates, seat, carriers and fenders ebs00037 front carrier and front guard 3 4 4 5 6 1 2 2 7 8 (4) (4) t r . . 26 nm (2.6 m • kg, 19 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 . . 26 nm (2.6 m • kg, 19 ft • ib) order job/part q...

  • Page 88: Chk

    3 - 7 chk adj 3 4 4 5 6 1 2 2 7 8 (4) (4) t r . . 26 nm (2.6 m • kg, 19 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 . . 26 nm (2.6 m • kg, 19 ft • ib) order job/part q’ty remarks 7 front guard 1 8 front guard cover 2 for installation, reverse the remova...

  • Page 89: Chk

    3 - 8 chk adj engine skid plates, seat, carriers and fenders front fenders and front grill 6 5 1 (3) (3) 2 3 4 4 1 5 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) order job/part q’ty remarks removing the front fenders and front g...

  • Page 90: Chk

    3 - 9 chk adj engine skid plates, seat, carriers and fenders ebs00040 rear carrier and rear fender 4 1 2 (4) 2 5 3 6 (6) (6) 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 . . 48 nm (4.8 m • kg, 35 ft • ib) t r . . 48 nm (4.8 m • kg, 35 ft • ib) t r . . 34 nm (3.4 ...

  • Page 91: Chk

    3 - 10 chk adj electrical components tray electrical components tray 1/2 2 2 3 5 1 6 6 6 6 7 8 9 10 11 12 15 13 14 4 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks removing the electrical compo- nents tray remove the parts in the order listed. Front fender/front grill refer to “f...

  • Page 92: Chk

    3 - 11 chk adj electrical components tray 2 2 3 5 1 6 6 6 6 7 8 9 10 11 12 15 13 14 4 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks 7 eps (electric power steering) control unit 1 8 four-wheel-drive motor relay 3 1 9 rear brake relay 1 10 four-wheel-drive motor relay 2 1 11 four-...

  • Page 93: Chk

    3 - 12 chk adj electrical components tray electrical components tray 2/2 4 3 2 18 1 5 6 12 17 13 20 16 15 (4) 19 14 7 8 9 10 11 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks removing the electrical compo- nents tray remove the parts in the ...

  • Page 94: Chk

    3 - 13 chk adj electrical components tray 4 3 2 18 1 5 6 12 17 13 20 16 15 (4) 19 14 7 8 9 10 11 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks 12 front brake light switch connector 2 disconnect. 13 rear brake light switch connector 2 discon...

  • Page 95: Chk

    3 - 14 chk adj footrest boards ebs00045 footrest boards (4) (5) (4) (5) (5) (5) 1 (4) 1 2 3 2 3 (4) 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 . . 53 nm (5.3 m • kg, 38 ft • ib) t r . . 53 nm (5.3 m • kg, 38 ft • ib) order...

  • Page 96: Chk

    3 - 15 chk adj air filter case new new 1 2 3 9 10 4 8 7 6 5 order job/part q’ty remarks removing the air filter case remove the parts in the order listed. Seat/side panels refer to “seat and side panels”. 1 air filter case cover 1 2 air filter element 1 3 air filter element frame 1 4 air filter case...

  • Page 97: Chk

    3 - 16 chk adj eas00049 engine adjusting the valve clearance the following procedure applies to all of the valves. Note: • valve clearance adjustment should be made on a cold engine, at room temperature. • when the valve clearance is to be measured or adjusted, the piston must be at top dead center ...

  • Page 98: Chk

    3 - 17 chk adj adjusting the valve clearance 4. Disconnect: • spark plug cap 1 5. Remove: • spark plug 2 1 2 6. Remove: • timing mark accessing screw 1 • crankshaft end accessing screw 2 1 2 7. Measure: • valve clearance out of specification → adjust. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼...

  • Page 99: Chk

    3 - 18 chk adj adjusting the valve clearance c. Measure the valve clearance with a thick- ness gauge 1. Out of specification → adjust. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ thickness gauge 90890-03079 narrow gauge set ym-34483 1 8. Adjust: • valve clearance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ...

  • Page 100: Chk

    3 - 19 chk adj adjusting the valve clearance/ adjusting the engine idling speed 12.Install: • o-ring • camshaft sprocket cover • o-ring 1 • intake tappet cover • o-ring • exhaust tappet cover 13.Install: • fast idle plunger unit 14.Install: • air filter case refer to “air filter case”. • footrest bo...

  • Page 101: Chk

    3 - 20 chk adj adjusting the engine idling speed/ adjusting the throttle lever free play 5. Adjust: • engine idling speed ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the idle speed adjusting screw 1 in direction a or b until the specified idling speed is obtained. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 102: Chk

    3 - 21 chk adj adjusting the throttle lever free play 3. Adjust: • throttle lever free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ first step: a. Slide back the rubber cover 1. B. Loosen the locknut 2 on the throttle body side. C. Turn the adjusting nut 3 in direction a or b until the cor...

  • Page 103: Chk

    3 - 22 chk adj adjusting the speed limiter ebs00053 adjusting the speed limiter the speed limiter keeps the throttle from becoming fully-opened even when the throttle lever is applied to the maximum position. Screwing in the adjusting screw stops the engine speed from increasing. 1. Measure: • speed...

  • Page 104: Chk

    3 - 23 chk adj checking the spark plug ebs00057 checking the spark plug 1. Remove: • right side panel refer to “seat and side panels”. 2. Disconnect: • spark plug cap 3. Remove: • spark plug 4. Check: • spark plug type incorrect → change. Standard spark plug cr8e/ngk 5. Check: • electrode 1 wear/dam...

  • Page 105: Chk

    3 - 24 chk adj checking the ignition timing ebs00058 checking the ignition timing note: _ engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing. 1. Remove: • left side panel • right side panel refer to “seat and side panels”. • footrest boar...

  • Page 106: Chk

    3 - 25 chk adj checking the ignition timing/ measuring the compression pressure c. Visually check the stationary pointer a to verify it is within the required firing range b indicated on the ac magneto rotor. Incorrect firing range → check the pulser coil assembly. Note: when checking the ignition t...

  • Page 107: Chk

    3 - 26 chk adj measuring the compression pressure 4. Disconnect: • spark plug cap 5. Remove: • spark plug caution: _ before removing a spark plug, use com- pressed air to blow away any dirt accumu- lated in the spark plug well to prevent it from falling into the cylinder. 6. Attach: • extension 1 • ...

  • Page 108: Chk

    3 - 27 chk adj measuring the compression pressure b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. Warning _ to prevent sparking, ground the spark plug lead before cranking the engine. C. If the compression pressure is above the maximum specific...

  • Page 109: Chk

    3 - 28 chk adj checking the engine oil level ebs00064 checking the engine oil level 1. Place the vehicle on a level surface. 2. Check the engine oil level on a cold engine. Note: _ if the engine was started before checking the oil level, be sure to warm up the engine suffi- ciently, and then wait at...

  • Page 110: Chk

    3 - 29 chk adj checking the engine oil level/ changing the engine oil 6. Install: • dipstick accessing panel refer to “seat and side panels”. Ebs00069 changing the engine oil 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain ...

  • Page 111: Chk

    3 - 30 chk adj changing the engine oil b. Lubricate the o-ring 3 of the new oil filter cartridge with a thin coat of engine oil. Caution: _ make sure the o-ring 3 is positioned cor- rectly in the groove of the oil filter car- tridge. C. Tighten the new oil filter cartridge to specifi- cation with an...

  • Page 112: Chk

    3 - 31 chk adj changing the engine oil/ cleaning the air filter element 15.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...

  • Page 113: Chk

    3 - 32 chk adj cleaning the air filter element 2. Remove: • air filter case cover 1 1 3. Remove: • air filter element 1 • air filter element frame 2 caution: _ the engine should never be run without the air filter; excessive piston and/or cylinder wear may result. 4. Check: • air filter element • ai...

  • Page 114: Chk

    3 - 33 chk adj cleaning the air filter element/ checking the throttle body joint d. Squeeze out the excess oil. Note: _ the element should be wet but not dripping. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 6. Install: • air filter element frame • air filter element note: _ make sure its seal...

  • Page 115: Chk

    3 - 34 chk adj checking the fuel hose/ checking the breather hoses eas00096 checking the fuel hose 1. Remove: • seat • right side panel refer to “seat and side panels”. • rear fender refer to “rear carrier and rear fender”. • v-belt cooling duct 2 refer to “engine removal” in chapter 4. 2. Check: • ...

  • Page 116: Chk

    3 - 35 chk adj checking the coolant level/ changing the coolant ebs00076 checking the coolant level 1. Place the vehicle on a level surface. Note: the coolant level must be checked on a cold engine since the level varies with engine tem- perature. 2. Check: • coolant level the coolant level should b...

  • Page 117: Chk

    3 - 36 chk adj changing the coolant 2. Remove: • coolant reservoir cap 1 3. Disconnect: • coolant reservoir hose 2 4. Drain: • coolant (from the coolant reservoir) 5. Connect: • coolant reservoir hose 1 2 6. Remove: • radiator cap 1 warning _ a hot radiator is under pressure. Therefore, do not remov...

  • Page 118: Chk

    3 - 37 chk adj changing the coolant 11.Fill: • cooling system (with the specified amount of the recom- mended coolant) handling notes for coolant coolant is potentially harmful and should be handled with special care. Warning _ • if coolant splashes in your eyes, thor- oughly wash them with water an...

  • Page 119: Chk

    3 - 38 chk adj changing the coolant 12.Fill: • coolant reservoir (with the recommended coolant to the maxi- mum level mark a) 13.Install: • coolant reservoir cap 1 full low 1 a 14.Bleed: • coolant system ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the v-belt cooling duct 2 1. B. Loos...

  • Page 120: Chk

    3 - 39 chk adj changing the coolant/ checking the cooling system 19.Install: • upper panel • front carrier refer to “front carrier and front guard”. • left side panel • right side panel refer to “seat and side panels”. Eas00104 checking the cooling system 1. Remove: • front fenders refer to “front f...

  • Page 121: Chk

    3 - 40 chk adj checking the coolant temperature warning light ebs00077 checking the coolant temperature warning light 1 coolant temperature warning light 1 coolant temperature warning light checking method turn the main switch “on” and the engine stop switch to “run”. Coolant temperature warning lig...

  • Page 122: Chk

    3 - 41 chk adj checking the v-belt ebs00078 checking the v-belt 1. Remove: • drive belt cover refer to “primary and secondary sheaves” in chapter 4. 2. Check: • v-belt 1 cracks/wear/scaling/chipping → replace. Oil/grease → check primary sheave and secondary sheave. 3. Measure: • v-belt width 2 out o...

  • Page 123: Chk

    3 - 42 chk adj checking the v-belt/ checking the exhaust system c. Install the v-belt. Note: _ install the v-belt so that its arrow faces the direction shown in the illustration. D. Remove the bolts. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas00099 checking the exhaust system the following...

  • Page 124: Chk

    3 - 43 chk adj cleaning the spark arrester cleaning the spark arrester 1. Clean: • spark arrester ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ warning • select a well-ventilated area free of com- bustible materials. • always let the exhaust system cool before performing this operation. • do not...

  • Page 125: Chk

    3 - 44 chk adj adjusting the front brake/ adjusting the rear brake ebs00080 chassis adjusting the front brake 1. Measure: • front brake lever free play a out of specification → bleed the front brake system. Refer to “bleeding the hydraulic brake system”. Front brake lever free play (at the end of th...

  • Page 126: Chk

    3 - 45 chk adj adjusting the rear brake 3. Measure: • brake pedal height c out of specification → adjust. D measuring points brake pedal height 56.7 mm (2.23 in) 4. Adjust: • brake pedal free play • brake pedal height 5. Remove: • front fender inner panel refer to “front fenders and front grill”. ▼▼...

  • Page 127: Chk

    3 - 46 chk adj adjusting the rear brake/ checking the brake fluid level g. Adjust the shift control cable. Refer to “adjusting the select lever control cable and shift rod”. Warning _ after this adjustment is performed, lift the front and rear wheels off the ground by placing a block under the engin...

  • Page 128: Chk

    3 - 47 chk adj checking the brake fluid level/ checking the front brake pads • refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. • when refilling, be careful that water does not en...

  • Page 129: Chk

    3 - 48 chk adj checking the rear brake pads/ checking the rear brake hose protectors ebs00089 checking the rear brake pads 1. Remove: • rear wheels refer to “front and rear wheels” in chapter 8. 2. Check: • brake pads wear indicator groove a almost disap- peared → replace the brake pads as a set. Re...

  • Page 130: Chk

    3 - 49 chk adj checking the brake hoses/ bleeding the hydraulic brake system ebs00092 checking the brake hoses 1. Check: • front brake hoses 1 • rear brake hoses 2 cracks/wear/damage → replace. 2. Check: • brake hose holders loosen → tighten. 3. Hold the vehicle in an upright position and apply the ...

  • Page 131: Chk

    3 - 50 chk adj bleeding the hydraulic brake system • when bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake. Ignoring this precaution could allow air to enter the hydraulic brake system, considerably length- ening the bleeding procedure. • if...

  • Page 132: Chk

    3 - 51 chk adj bleeding the hydraulic brake system/adjusting the select lever control cable and shift rod k. Fill the brake master cylinder reservoir to the proper level with the recommended brake fluid. Refer to “checking the brake fluid level”. Warning _ after bleeding the hydraulic brake system, ...

  • Page 133: Chk

    3 - 52 chk adj adjusting the select lever control cable and shift rod 3. Adjust: • shift control cable • shift rod ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ shift control cable: a. Make sure that the select lever is in neu- tral. B. Squeeze the brake lever 30 mm (1.18 in) a, loosen the lockn...

  • Page 134: Chk

    3 - 53 chk adj checking the final gear oil level/ changing the final gear oil ebs00101 checking the final gear oil level 1. Place the vehicle on a level place. 2. Remove: • final gear oil level check bolt 1 3. Check: • oil level oil level should be up to the bottom brim 2 of the hole. Oil level low ...

  • Page 135: Chk

    3 - 54 chk adj 6. Install: • final gear oil drain bolt note: _ check the gasket (drain bolt). If it is damaged, replace it with a new one. 7. Fill: • final gear case caution: _ take care not to allow foreign material to enter the final gear case. 8. Check: • oil level refer to “checking the final ge...

  • Page 136: Chk

    3 - 55 chk adj checking the differential gear oil level/ changing the differential gear oil ebs00103 checking the differential gear oil level 1. Place the vehicle on a level surface. 2. Remove: • differential gear oil filler bolt 1 3. Check: • oil level oil level should be up to the brim 2 of hole. ...

  • Page 137: Chk

    3 - 56 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 ...

  • Page 138: Chk

    3 - 57 chk adj checking the steering system ebs00106 checking the steering system 1. Place the vehicle on a level surface. 2. Check: • steering assembly bushings move the handlebar up and down, and/or back and forth. Excessive play → replace the steering stem bushings. 3. Check: • tie-rod ends turn ...

  • Page 139: Chk

    3 - 58 chk adj checking the steering system ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ belt tension gauge 90890-03170 rear drive belt tension gauge ym-03170 7. Adjust: • steering tension ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the electrical components tray. Refer to “elec...

  • Page 140: Chk

    3 - 59 chk adj adjusting the toe-in ebs00108 adjusting the toe-in 1. Place the vehicle on a level surface. 2. Measure: • toe-in out of specification → adjust. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ note: _ before measuring the toe-in, make sure that the tire pressure is correct. A. Mark b...

  • Page 141: Chk

    3 - 60 chk adj adjusting the toe-in/checking the front and rear shock absorbers b. Loosen the locknuts (tie-rod end) 1 of both tie-rods. C. The same number of turns should be given to both the right and left tie-rods 2 until the specified toe-in is obtained. This is to keep the length of the rods th...

  • Page 142: Chk

    3 - 61 chk adj checking the front and rear shock absorbers/ adjusting the front shock absorbers 3. Check: • operation pump the shock absorbers up and down for several times. Unsmooth operation → replace front/rear shock absorber. Refer to “front arms and front shock absorber assemblies” and “rear ar...

  • Page 143: Chk

    3 - 62 chk adj adjusting the rear shock absorbers/ checking the tires ebs00112 adjusting the rear shock absorbers warning _ always adjust the spring load for both rear shock absorber spring preload to the same setting. Uneven adjustment can cause poor handling and loss of stability. 1. Adjust: • spr...

  • Page 144: Chk

    3 - 63 chk adj checking the tires • tire pressure 1) recommended tire pressure front 35 kpa (0.35 kg/cm 2 , 5.0 psi) rear 30 kpa (0.30 kg/cm 2 , 4.3 psi) 2) tire pressure below the minimum speci- fication could cause the tire to dislodge from the rim under severe riding condi- tions. The following a...

  • Page 145: Chk

    3 - 64 chk adj checking the tires 1. Measure: • tire pressure out of specification → adjust. Note: _ • the low-pressure tire 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 measurements of the tire...

  • Page 146: Chk

    3 - 65 chk adj checking the wheels/ checking and lubricating the cables ebs00116 checking the wheels 1. Check: • wheel 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 conse...

  • Page 147: Chk

    3 - 66 chk adj lubricating the levers and pedals ebs00118 lubricating the levers and pedals lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant lithium-soap-based grease.

  • Page 148: Chk

    3 - 67 chk adj ebs00120 electrical system checking and charging the battery warning _ batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • wear protective eye gear when han...

  • Page 149: Chk

    3 - 68 chk adj note: _ since mf batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: • battery c...

  • Page 150: Chk

    3 - 69 chk adj checking and charging the battery b. Check the charge of the battery, as shown in the charts and the following example. Example c. Open-circuit voltage = 12.0 v d. Charging time = 6.5 hours e. Charge of the battery = 20 ~ 30% ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ op en-cir...

  • Page 151: Chk

    3 - 70 chk adj checking and charging the battery • if the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode! • as shown in the following illustration, the open-circuit vo...

  • Page 152: Chk

    3 - 71 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 153: Chk

    3 - 72 chk adj checking and charging the battery charging method using a constant voltage charger measure the open-circuit voltage prior to charging. Note: set the charging time to a maxi- mum of 20 hours. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than t...

  • Page 154: Chk

    3 - 73 chk adj checking and charging the battery/ checking the fuses 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) caution: _ first, connect the positive battery lead 1, and then the negative battery lead 2. 8. Check: • battery terminals dirt → clean with a wire brush....

  • Page 155: Chk

    3 - 74 chk adj checking the fuses 2. Check: • fuse ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester to the fuse and check the continuity. Note: _ set the pocket tester selector to “ Ω × 1”. B. If the pocket tester indicates “ ∞”, replace the fuse. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ...

  • Page 156: Chk

    3 - 75 chk adj checking the fuses d. If the fuse immediately blows again, check the electrical circuit. Warning _ never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive damage to the electrical system, caus...

  • Page 157: Chk

    3 - 76 chk adj adjusting the headlight beams/ replacing the headlight bulbs ebs00122 adjusting the headlight beams 1. Adjust: • headlight beam (vertically) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw 1 in direction a or b. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲...

  • Page 158: Chk

    3 - 77 chk adj replacing the headlight bulbs 4. Remove: • headlight bulb holder 1 • headlight bulb 2 note: _ unhook the headlight bulb holder, and then remove the defective bulb. Warning _ keep flammable products and your hands away from the bulb while it is on, as it will be hot. Do not touch the b...

  • Page 159: Eng

    4 - 1 eng ebs00200 engine engine removal air ducts, muffler and exhaust pipe 4 9 4 1 7 6 5 3 8 2 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) new new order job/part q’ty remarks removing the air ducts, muffler and exhaust pipe r...

  • Page 160: Eng

    4 - 2 eng 4 9 4 1 7 6 5 3 8 2 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) new new order job/part q’ty remarks 6 gasket 1 7 muffler bracket 1 8 exhaust pipe 1 9 gasket 2 for installation, reverse the removal pro- cedure. Engine ...

  • Page 161: Eng

    4 - 3 eng engine removal ebs00202 select lever unit 3 1 2 ls t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 15 nm (1.5 m • kg, 11 ft • ib) t r . . 15 nm (1.5 m • kg, 11 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) order job/part q’ty remarks removing the sel...

  • Page 162: Eng

    4 - 4 eng engine removal ebs00204 leads, cables and hoses 7 8 2 5 6 1 4 10 3 9 order job/part q’ty remarks removing the leads, cables and hoses remove the parts in the order listed. Footrest board refer to “footrest boards” in chap- ter 3. Air filter case refer to “air filter case” in chapter 3. Thr...

  • Page 163: Eng

    4 - 5 eng 7 8 2 5 6 1 4 10 3 9 order job/part q’ty remarks starter motor refer to “starter motor” in chapter 9. Drive belt case refer to “primary and secondary sheaves”. 1 cylinder head breather hose 1 2 fast idle plunger inlet hose 1 3 coolant temperature sensor coupler 1 disconnect. 4 spark plug c...

  • Page 164: Eng

    4 - 6 eng engine removal ebs00205 engine mounting bolts t r . . 42 nm (4.2 m • kg, 30 ft • ib) t r . . 42 nm (4.2 m • kg, 30 ft • ib) t r . . 42 nm (4.2 m • kg, 30 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 . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . ....

  • Page 165: Eng

    4 - 7 eng t r . . 42 nm (4.2 m • kg, 30 ft • ib) t r . . 42 nm (4.2 m • kg, 30 ft • ib) t r . . 42 nm (4.2 m • kg, 30 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 . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) lt lt lt lt l...

  • Page 166: Eng

    4 - 8 eng engine removal ebs00207 installing the engine 1. Install: • rubber dampers (front side) 1 • engine mounting bolts (front lower side) 2 • engine mounting bolts (front upper side) 3 • rubber dampers (rear side) 4 • rubber damper nuts (rear side) 5 • engine 6 • engine mounting bolts (rear low...

  • Page 167: Eng

    4 - 9 eng installing the select lever unit 1. Install: • shift arm 1 • select lever unit 2 • select lever shift rod 3 note: • make sure that the select lever and transmis- sion are in neutral. • the installed length a of the shift rod is 413 mm (16.3 in). 2 1 3 a n n t r . . 14 nm (1.4 m · kg, 10 ft...

  • Page 168: Eng

    4 - 10 eng cylinder head ebs00218 cylinder head new t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 38 nm (3.8 m • kg, 27 ft • ib) new new t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) ls ls e t r . . 10 nm (1.0 m • kg, 7.2 ft •...

  • Page 169: Eng

    4 - 11 eng new t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 38 nm (3.8 m • kg, 27 ft • ib) new new t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) ls ls e t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) ls new t r . . 20 nm (2.0 m • kg...

  • Page 170: Eng

    4 - 12 eng cylinder head ebs00220 removing the cylinder head 1. Align: • “i” mark on the ac magneto rotor (with the stationary pointer on the ac mag- neto cover) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft counterclockwise. B. When the piston is at the top dead center (t...

  • Page 171: Eng

    4 - 13 eng cylinder head 5. Remove: • cylinder head note: _ • loosen the bolts in the proper sequence as shown. • loosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them. 6 8 5 7 2 1 4 3 ebs00224 checking the camshaft sprocket 1. Check: • camshaft sprocket we...

  • Page 172: Eng

    4 - 14 eng cylinder head ebs00230 checking the cylinder head 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) note: _ do not use a sharp instrument to avoid damag- ing or scratching: • spark plug bore threads • valve seats 2. Check: • cylinder head damage/scratches → repla...

  • Page 173: Eng

    4 - 15 eng cylinder head ebs00232 installing the cylinder head 1. Install: • dowel pins • cylinder head gasket 2. Install: • cylinder head • cylinder head bolts note: _ • lubricate the cylinder head bolt 1 and 2 threads and mating surface with molybde- num disulfide grease. • lubricate the cylinder ...

  • Page 174: Eng

    4 - 16 eng cylinder head note: _ when installing the camshaft sprocket, keep the timing chain as tense as possible on the exhaust side. Caution: _ do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. F. Remove the wire from the timing chain. ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 175: Eng

    4 - 17 eng cylinder head 7. Check: • “i” mark a note: check that the “i” mark on the ac magneto rotor is aligned with the stationary pointer b on the ac magneto cover. • “i” mark c note: check that the “i” mark on the camshaft sprocket is aligned with the stationary pointer d on the cylinder head. O...

  • Page 176: Eng

    4 - 18 eng rocker arms and camshaft ebs00235 rocker arms and camshaft e e e lt 1 7 9 8 2 e 10 4 2 3 5 5 5 5 e e 6 6 6 6 e t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) order job/part q’ty remarks removing the rocker arms and cam...

  • Page 177: Eng

    4 - 19 eng e e e lt 1 7 9 8 2 e 10 4 2 3 5 5 5 5 e e 6 6 6 6 e t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) order job/part q’ty remarks 9 decompressor lever pin 1 refer to “removing the rocker arms and camshaft” and “installing...

  • Page 178: Eng

    4 - 20 eng rocker arms and camshaft ebs00237 removing the rocker arms and camshaft 1. Loosen: • locknuts • valve adjusting screws 2. Remove: • intake rocker arm shaft • exhaust rocker arm shaft • intake rocker arm • exhaust rocker arm note: _ remove the rocker arm shafts with the slide hammer bolt 1...

  • Page 179: Eng

    4 - 21 eng rocker arms and camshaft 3. Measure: • camshaft runout out of specification → replace. Camshaft runout limit 0.015 mm (0.0006 in) ebs00225 checking the decompression system 1. Check: • decompression system ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Check the decompression system...

  • Page 180: Eng

    4 - 22 eng rocker arms and camshaft 4. Measure: • rocker arm shaft outside diameter out of specification → replace. 5. Calculate: • rocker-arm-to-rocker-arm-shaft clearance note: _ calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Out o...

  • Page 181: Eng

    4 - 23 eng rocker arms and camshaft 2. Lubricate: • camshaft • decompressor lever pin • decompressor lever recommended lubricant engine oil 3. Install: • decompressor lever pin 1 • decompressor lever 2 note: _ install the decompressor lever pin 1 and decompressor lever 2 in the camshaft 3 as shown i...

  • Page 182: Eng

    4 - 24 eng rocker arms and camshaft 6. Install: • exhaust rocker arm 1 • exhaust rocker arm shaft 2 • intake rocker arm • intake rocker arm shaft note: _ • use a slide hammer bolt 3 to install the rocker arm shaft. • make sure the rocker arm shafts (intake and exhaust) are completely pushed into the...

  • Page 183: Eng

    4 - 25 eng valves and valve springs ebs00234 valves and valve springs m m m m m new new new new 7 6 5 5 4 4 3 2 1 6 7 7 6 3 2 3 2 1 2 3 6 7 8 8 order job/part q’ty remarks removing the valves and valve springs remove the parts in the order listed. Cylinder head refer to “cylinder head”. Rocker arms/...

  • Page 184: Eng

    4 - 26 eng valves and valve springs ebs00238 removing the valves and valve springs the following procedure applies to all of the valves and related components. Note: _ before removing the internal parts of the cylin- der head (e.G., valves, valve springs, valve seats), make sure the valves properly ...

  • Page 185: Eng

    4 - 27 eng valves and valve springs 3. Remove: • valve spring retainer 1 • valve spring 2 • valve 3 • valve stem seal 4 • valve spring seat 5 note: _ identify the position of each part very carefully so that it can be reinstalled in its original place. Ebs00240 checking the valves and valve springs ...

  • Page 186: Eng

    4 - 28 eng valves and valve springs 2. Replace: • valve guide note: _ to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °c (212 °f) in an oven. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the valve guide using a valve guide r...

  • Page 187: Eng

    4 - 29 eng valves and valve springs 4. Measure: • margin thickness a out of specification → replace. Margin thickness 0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in) 5. Measure: • valve stem runout out of specification → replace. Note: _ • when installing a new valve, always replace the valve guide. • if the va...

  • Page 188: Eng

    4 - 30 eng valves and valve springs e. If the valve seat is too wide, too narrow, or the seat is not centered, the valve seat must be refaced. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 9. Lap: • valve face • valve seat note: _ after refacing the valve seat or replacing the valve and valve gu...

  • Page 189: Eng

    4 - 31 eng valves and valve springs h. Press the valve through the valve guide and onto the valve seat to make a clear pattern. I. Measure the valve seat width again. If the valve seat width is out of specification, reface and relap the valve seat. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 1...

  • Page 190: Eng

    4 - 32 eng valves and valve springs 2. Lubricate: • valve stem 1 (with the recommended lubricant) recommended lubricant molybdenum disulfide oil 3. Install: • valve spring seats 1 • valve stem seals 2 • valves 3 • valve springs 4 • valve spring retainers 5 note: _ install the valve springs with the ...

  • Page 191: Eng

    4 - 33 eng 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood. Caution: _ hitting the valve tip with excessive force could damage the valve. Valves and valve springs.

  • Page 192: Eng

    4 - 34 eng cylinder and piston ebs00245 cylinder and piston t r . . 1st 15 nm (1.5 m • kg, 11 ft • lb) 2nd 50 nm (5.0m • kg, 36 ft • lb) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) e e e e e 1 2 7 3 4 4 5 6 5 10 9 8 new new new order job/part q’ty remarks removing the cylinder and piston remove the part...

  • Page 193: Eng

    4 - 35 eng cylinder and piston ebs00247 removing the piston 1. Remove: • piston pin clips 1 • piston pin 2 • piston 3 note: _ • before removing the piston pin clips, cover the crankcase opening with a clean rag to prevent the piston pin clips from falling into the crankcase. • before removing the pi...

  • Page 194: Eng

    4 - 36 eng cylinder and piston 2. Measure: • piston-to-cylinder clearance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure the cylinder bore “c” with a cylin- der bore gauge. Note: _ measure the cylinder bore “c” in parallel to and at right angles to the crankshaft. Then, find the averag...

  • Page 195: Eng

    4 - 37 eng cylinder and piston f. If out of specification, replace the cylinder, and the piston and piston rings as a set. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ebs00250 checking the piston rings 1. Measure: • piston ring side clearance out of specification → replace the piston and pisto...

  • Page 196: Eng

    4 - 38 eng cylinder and piston piston ring end gap top ring 0.20 ~ 0.35 mm (0.008 ~ 0.014 in) : 0.60 mm (0.024 in) 2nd ring 0.75 ~ 0.90 mm (0.030 ~ 0.035 in) : 1.25 mm (0.049 in) oil ring 0.20 ~ 0.70 mm (0.008 ~ 0.028 in) ebs00251 checking the piston pin 1. Check: • piston pin blue discoloration/gro...

  • Page 197: Eng

    4 - 39 eng cylinder and piston 4. Calculate: • piston-pin-to-piston-pin-bore clearance out of specification → replace the piston pin and piston as a set. Piston-pin-to-piston-pin-bore clearance = piston pin bore diameter b – piston pin outside diameter a piston-pin-to-piston clearance 0.004 ~ 0.024 ...

  • Page 198: Eng

    4 - 40 eng cylinder and piston 2. Install: • piston 1 • piston pin 2 • piston pin clips 3 note: _ • apply engine oil to the piston pin. • make sure the punch mark a on the piston points towards the exhaust side of the cylin- der. • before installing the piston pin clips, cover the crankcase opening ...

  • Page 199: Eng

    4 - 41 eng cylinder and piston 7. Install: • cylinder bolts note: lubricate the cylinder bolt 1 threads and mat- ing surface with engine oil. 8. Tighten: • cylinder bolts 1 (1st) • cylinder bolts 1 (2nd) • cylinder bolts (timing chain side) 2 1 1 2 2 e e t r . . 15 nm (1.5 m · kg, 11 ft · lb) t r . ...

  • Page 200: Eng

    4 - 42 eng ac magneto ebs00256 ac magneto lt lt lt 6 6 1 2 lt new 4 5 ls lt 16 12 11 14 13 17 e e e 10 15 e new 9 7 8 3 (10) t r . . 7 nm (0.7 m • kg, 5.1 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 . . 6 nm (0.6 m • kg, 4.3 ft • ib) t r . . 30 nm (3....

  • Page 201: Eng

    4 - 43 eng lt lt lt 6 6 1 2 lt new 4 5 ls lt 16 12 11 14 13 17 e e e 10 15 e new 9 7 8 3 (10) t r . . 7 nm (0.7 m • kg, 5.1 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 . . 6 nm (0.6 m • kg, 4.3 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) lt lt e t...

  • Page 202: Eng

    4 - 44 eng lt lt lt 6 6 1 2 lt new 4 5 ls lt 16 12 11 14 13 17 e e e 10 15 e new 9 7 8 3 (10) t r . . 7 nm (0.7 m • kg, 5.1 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 . . 6 nm (0.6 m • kg, 4.3 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) lt lt e t...

  • Page 203: Eng

    4 - 45 eng ac magneto ebs00259 removing the ac magneto rotor 1. Remove: • lead holder 1 • ac magneto cover note: _ loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 1 2. Remove: • ac magneto rotor nut 1 • washer n...

  • Page 204: Eng

    4 - 46 eng ac magneto flywheel puller 90890-01362 heavy duty puller yu-33270-b ebs00262 checking the stator coil and crankshaft position sensor 1. Check: • stator coil 1 • crankshaft position sensor 2 damage → replace the crankshaft position sensor/stator assembly. 2 1 ebs00263 checking the starter ...

  • Page 205: Eng

    4 - 47 eng ac magneto 2. Check: • starter idle gear teeth • starter wheel gear teeth burrs/clips/roughness/wear → replace. 3. Check: • starter wheel gear (contacting surface) damage/pitting/wear → replace. Checking the torque limiter • torque limiter damage/wear → replace. Note: do not disassemble t...

  • Page 206: Eng

    4 - 48 eng ac magneto 3. Install: • woodruff key • ac magneto rotor note: _ • before installing the rotor, clean the outside of the crankshaft and the inside of the rotor. • after installing the rotor, check that the rotor rotates smoothly. If not, reinstall the key and rotor. 4. Tighten: • ac magne...

  • Page 207: Eng

    4 - 49 eng 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 “ac magneto”. 1 lock washer 1 refer to “removing the balancer driven gear and oil pump driven gear” and “installin...

  • Page 208: Eng

    4 - 50 eng order job/part q’ty remarks 6 lock washer 1 refer to “removing the balancer driven gear and oil pump driven gear” and “installing the bal- ancer drive gear, balancer driven gear, and oil pump driven gear”. 7 oil pump driven gear 1 8 plate 1 9 spring 8 refer to “removing the balancer drive...

  • Page 209: Eng

    4 - 51 eng removing the balancer driven gear and oil pump driven gear 1. Straighten the lock washer tabs. 2. Loosen: • balancer driven gear nut 1 • oil pump driven gear nut 2 note: place an aluminum plate 3 between the teeth of the balancer drive gear 4 and balancer driven gear 5, then loosen the nu...

  • Page 210: Eng

    4 - 52 eng installing the balancer drive gear, balancer driven gear, and oil pump driven gear 1. Install: • pin • spring • balancer drive gear (onto the buffer boss) note: align the punch mark a on the balancer drive gear with the hole b to the buffer boss. 2. Install: • balancer drive gear 1 • bala...

  • Page 211: Eng

    4 - 53 eng primary and secondary sheaves ebs00269 primary and secondary sheaves 2 3 4 5 6 7 (8) 9 10 4 11 8 (11) new new new new e 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) 1 t r . . 100 nm (10.0 m • kg, 72 ft • lb) t r . ...

  • Page 212: Eng

    4 - 54 eng 2 3 4 5 6 7 (8) 9 10 4 11 8 (11) new new new new e 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) 1 t r . . 100 nm (10.0 m • kg, 72 ft • lb) t r . . 140 nm (14.0 m • kg, 100 ft • lb) ls t r . . 10 nm (1.0 m • kg, 7.2...

  • Page 213: Eng

    4 - 55 eng primary and secondary sheaves ebs00270 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 primary pulley cam 1 4 primary pulle...

  • Page 214: Eng

    4 - 56 eng primary and secondary sheaves ebs00271 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 ...

  • Page 215: Eng

    4 - 57 eng primary and secondary sheaves ebs00272 removing the primary and secondary sheaves 1. Loosen: • secondary sheave nut 1 • primary sheave nut 2 note: _ • use the sheave holder 3 to hold the primary sheave. • first, loosen the secondary sheave nut 2, then loosen the primary sheave nut 1. Shea...

  • Page 216: Eng

    4 - 58 eng primary and secondary sheaves ebs00274 checking the primary sheave 1. Check: • weight outside diameter a out of specification → replace the weight. Weight outside diameter 30 mm (1.18 in) : 29.5 mm (1.16 in) 2. Check: • primary pulley slider • primary sliding sheave splines wear/cracks/da...

  • Page 217: Eng

    4 - 59 eng primary and secondary sheaves 5. Measure: • secondary sheave spring free length a out of specification → replace the second- ary sheave spring. Free length 130.6 mm (5.14 in) : 128.0 mm (5.04 in) ebs00276 assembling the primary sheave 1. Clean: • primary sliding sheave face 1 • primary fi...

  • Page 218: Eng

    4 - 60 eng primary and secondary sheaves 3. Install: • slider 1 • cam 2 • primary sliding sheave cap t r . . 3 nm (0.3 m · kg, 2.2 ft · lb) ebs00277 assembling the secondary sheave 1. Apply: • bel-ray assembly lube ® (to the secondary sliding sheave 1 inner surface and oil seals) • bel-ray assembly ...

  • Page 219: Eng

    4 - 61 eng primary and secondary sheaves 4. Install: • spring seat • compression spring • spring seat • nut ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Attach the sheave fixed block, locknut wrench and sheave spring compressor to the secondary sheave. B. Place the sheave fixed block in a vi...

  • Page 220: Eng

    4 - 62 eng primary and secondary sheaves ebs00279 installing the primary and secondary sheaves 1. Install: • secondary sheave • v-belt • primary sheave note: _ • tightening the bolts 1 will push the second- ary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to w...

  • Page 221: Eng

    4 - 63 eng clutch ebs00291 clutch order job/part q’ty remarks removing the clutch remove the parts in the order listed. Primary sheave/secondary sheave refer to “primary and secondary sheaves”. 1 clutch housing assembly 1 refer to “removing the clutch” and “installing the clutch”. 2 gasket 1 3 dowel...

  • Page 222: Eng

    4 - 64 eng clutch ebs00292 order job/part q’ty remarks disassembling the clutch housing assembly 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..

  • Page 223: Eng

    4 - 65 eng clutch ebs00296 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 caution: the c...

  • Page 224: Eng

    4 - 66 eng clutch ebs00299 checking the clutch 1. Check: • clutch housing heat damage/wear/damage → replace. • one-way clutch bearing chafing/wear/damage → replace. Note: _ • replace the one-way clutch assembly and clutch housing as a set. • the one-way clutch bearing must be installed with the flan...

  • Page 225: Eng

    4 - 67 eng clutch ebs00309 installing the clutch 1. Install: • clutch carrier assembly • nut 1 caution: the clutch carrier assembly nut has left- handed threads. To tighten the clutch car- rier assembly nut turn it counterclockwise. Note: use a clutch holding tool 2 to hold the clutch carrier assemb...

  • Page 226: Eng

    4 - 68 eng crankcase ebs00319 crankcase timing chain and oil filter lt t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 17 nm (1.7 m • kg, 12 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 . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 68 nm (6.8 m • kg, 49 f...

  • Page 227: Eng

    4 - 69 eng lt t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 17 nm (1.7 m • kg, 12 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 . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 68 nm (6.8 m • kg, 49 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 17...

  • Page 228: Eng

    4 - 70 eng crankcase ebs00320 crankcase 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 . . 26 nm (2.6 m • kg, 19 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) t r . . 18 nm (1.8 m • kg, 13 ft • ib) t r . . 18 nm (1.8 m • ...

  • Page 229: Eng

    4 - 71 eng crankcase ebs00321 crankcase bearings t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) . E e e e e e new new ls ls 7 7 7 7 7 7 7 e lt lt 4 7 3 2 1 5 6 lt order job/part q’ty remarks removing the crankcase bearings remove the parts in the order listed. Crankshaft/oil pump refer to “crankshaft and o...

  • Page 230: Eng

    4 - 72 eng crankcase ebs00332 separating the crankcase 1. Separate: • right crankcase • left crankcase ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the lead holders and crankcase bolts. Note: _ • loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove the...

  • Page 231: Eng

    4 - 73 eng crankcase ebs00339 checking the bearings 1. Check: • bearings clean and lubricate, then rotate the inner race with a finger. Roughness → replace. Ebs00338 checking the crankcase 1. Thoroughly wash the case halves in a mild solvent. 2. Clean all the gasket mating surfaces and crankcase mat...

  • Page 232: Eng

    4 - 74 eng crankcase 3. Fit the right crankcase onto the left crank- 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 bot...

  • Page 233: Eng

    4 - 75 eng crankshaft and oil pump ebs00326 crankshaft and oil pump 3 4 2 1 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) new order job/part q’ty remarks removing the crankshaft and oil pump remove the parts in the order listed. Crankcase separate. Refer to “crankca...

  • Page 234: Eng

    4 - 76 eng crankshaft and oil pump ebs00327 oil pump e 6 3 2 5 4 1 e t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) order job/part q’ty remarks disassembling the oil pump remove the parts in the order listed. 1 oil pump housing cover 1 2 pin 1 3 oil pump shaft 1 4 oil pump inner rotor 1 5 oil pump outer rot...

  • Page 235: Eng

    4 - 77 eng crankshaft and oil pump ebs00336 removing the crankshaft 1. Remove: • crankshaft 1 use a crankcase separating tool 2. Crankcase separating tool 90890-01135 crankcase separator yu-01135-b 2 1 ebs00331 checking the oil pump 1. Check: • oil pump housing • oil pump housing cover cracks/wear/d...

  • Page 236: Eng

    4 - 78 eng crankshaft and oil pump checking the oil strainer 1. Check: • oil strainer damage → replace. Contaminants → clean with engine oil. Ebs00360 checking the crankshaft 1. Measure: • crank width a out of specification → replace the crank- shaft. 2. Measure: • side clearance d out of specificat...

  • Page 237: Eng

    4 - 79 eng crankshaft and oil pump ebs00318 assembling the oil pump 1. Install: • oil pump housing 1 • oil pump outer rotor 2 • oil pump inner rotor 3 • oil pump shaft 4 • pin 5 note: _ when installing the oil pump shaft 4 align the pin 5 with the groove a in the inner rotor 3. 1 2 3 5 4 a a ebs0036...

  • Page 238: Eng

    4 - 80 eng crankshaft and oil pump 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 the bearing. Caution: _ apply engine oil to each bearing to pr...

  • Page 239: Eng

    4 - 81 eng transmission ebs00345 transmission m 1 7 6 8 5 10 12 11 9 4 3 2 new new new new new e e e e order job/part q’ty remarks removing the transmission remove the parts in the order listed. Crankcase separate. Refer to “crankcase”. Middle driven gear refer to “middle gear”. 1 shift drum 1 refer...

  • Page 240: Eng

    4 - 82 eng m 1 7 6 8 5 10 12 11 9 4 3 2 new new new new new e e e e order job/part q’ty remarks 11 stopper lever 1 refer to “removing the transmis- sion” and “installing the trans- mission”. 12 stopper lever shaft 1 for installation, reverse the removal pro- cedure. Transmission.

  • Page 241: Eng

    4 - 83 eng transmission ebs00348 drive axle 1 a c d e f h g b 0 2 3 4 5 6 7 8 9 m m m m m m m new new new order job/part q’ty remarks disassembling the drive axle assembly remove the parts in the order listed. 1 washer 1 2 collar 1 3 high wheel gear 1 4 washer 1 5 clutch dog 1 6 circlip 1 7 washer 1...

  • Page 242: Eng

    4 - 84 eng 1 a c d e f h g b 0 2 3 4 5 6 7 8 9 m m m m m m m new new new order job/part q’ty remarks d washer 1 e bearing 1 f reverse wheel gear 1 g stopper wheel 1 h drive axle 1 for assembly, reverse the disassembly procedure. Transmission.

  • Page 243: Eng

    4 - 85 eng removing the transmission 1. Remove: • shift drum 1 • shift fork assembly 2 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Pull out the guide bar from the left crank- case. B. Push down on the drive shaft, and then slide the shift fork assembly to remove the shift fork cam followers...

  • Page 244: Eng

    4 - 86 eng transmission ebs00351 checking the shift drum 1. Check: • shift drum grooves scratches/wear/damage → replace. Ebs00354 checking the transmission 1. Measure: • drive axle runout (with a centering device and dial gauge 1) out of specification → replace the drive axle. 2. Check: • transmissi...

  • Page 245: Eng

    4 - 87 eng checking the secondary shaft 1. Check: • gear teeth blue discoloration/pitting/wear → replace. Checking the stopper lever and stopper wheel 1. Check: • stopper lever pawl 1 bends/damage/wear → replace the stop- per lever and stopper wheel as a set. • stopper wheel 2 damage/wear → replace ...

  • Page 246: Eng

    4 - 88 eng transmission ebs00356 installing the transmission 1. Install: • stopper lever shaft • stopper lever • reverse idle gear 1 • drive axle assembly 2 • secondary shaft 3 • shift fork assembly 4 • shift drum 5 note: _ install the shift forks 6 with the “l” mark a and “r” mark b facing towards ...

  • Page 247: Eng

    4 - 89 eng middle gear ebs00363 middle gear middle drive shaft order job/part q’ty remarks removing the middle drive shaft remove the parts in the order listed. Crankcase separate. Refer to “crankcase”. 1 bearing housing 1 2 middle drive pinion gear nut 1 refer to “removing the middle drive shaft” a...

  • Page 248: Eng

    4 - 90 eng middle gear ebs00364 middle driven shaft order job/part q’ty remarks removing the middle driven shaft remove the parts in the order listed. Crankcase separate. Refer to “crankcase”. 1 front drive shaft coupling gear nut (middle gear side) 1 refer to “removing the middle driven shaft” and ...

  • Page 249: Eng

    4 - 91 eng order job/part q’ty remarks 10 bearing 1 refer to “removing the middle driven shaft” and “installing the middle driven shaft”. 11 middle driven pinion gear bearing retainer 1 12 bearing 1 13 middle driven shaft bearing retainer 1 14 bearing 1 15 middle driven shaft 1 for installation, rev...

  • Page 250: Eng

    4 - 92 eng middle gear ebs00365 removing the middle drive shaft 1. Straighten: • punched portion of the middle drive pinion gear nut 2. Loosen: • middle drive pinion gear nut 1 note: _ secure the middle drive shaft in the vise with a clean rag. 3. Remove: • middle drive pinion gear nut • middle driv...

  • Page 251: Eng

    4 - 93 eng middle gear ebs01020 removing the middle driven shaft 1. Remove: • front drive shaft coupling gear nut (middle gear side) 1 • washer • front drive shaft coupling gear (middle gear side) 2 note: _ use the coupling gear/middle shaft tool 3 to hold the coupling gear. Coupling gear/middle sha...

  • Page 252: Eng

    4 - 94 eng middle gear caution: _ • never directly press the middle driven pinion gear end with a hydraulic press, this will result in damage to the middle driven pinion gear thread. • install a suitable socket 2 on the middle driven pinion gear end to protect the thread from damage. C. Press the mi...

  • Page 253: Eng

    4 - 95 eng middle gear 5. Remove: • oil seal 1 • middle driven shaft bearing retainer 2 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 90890-01430, ym-38404 2 1 3 6. Remove: ...

  • Page 254: Eng

    4 - 96 eng middle gear ebs00370 selecting 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 shim 1, 2. 1. Select: • middle drive gear shim 1 • middle driven gear shim 2 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼...

  • Page 255: Eng

    4 - 97 eng middle gear e = a numeral (usually a decimal number) on the left crankcase specifies a thickness of “9.0” example: 1) if the bearing housing is marked “–02”, ..... A is 0.58 2) b is 17.0 3) c is 55.0 4) if the right crankcase is marked “64.97”, ..... D is 64.97 5) if the left crankcase is...

  • Page 256: Eng

    4 - 98 eng middle gear c. To find shim thickness “b” use the following formula: where: f = a numeral (usually a decimal number) on the bearing housing is either added to or subtracted from “77.5” note: after replacing any part in the middle driven pinion gear assembly, the overall length of the asse...

  • Page 257: Eng

    4 - 99 eng middle gear 7) round off hundredth digit and select appro- priate shim(s). In the example above, the calculated shim thickness is 0.72 mm. The chart instructs you, however, to round off 2 to 0. Shims are supplied in the following thickness. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲...

  • Page 258: Eng

    4 - 100 eng middle gear ebs00373 installing the middle driven shaft 1. Install: • middle driven shaft 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. Ring nut wrenc...

  • Page 259: Eng

    4 - 101 eng middle gear 3. Install: • middle driven gear shim(s) 1 • bearing housing note: _ install the shim(s) so that the tabs are posi- tioned as shown in the illustration. 1 1 4. Install: • rear drive shaft coupling gear (middle gear side) 1 • washer • rear drive shaft coupling gear nut (middle...

  • Page 260: Eng

    4 - 102 eng middle gear installing the middle drive shaft 1. Install: • circlip • middle driven gear 1 (to the middle drive shaft 2) installed depth of middle driven gear a 24.7 ~ 24.9 mm (0.97 ~ 0.98 in) a 2 1 2. Tighten: • middle drive pinion gear nut 1 note: secure the middle drive shaft in the v...

  • Page 261: Eng

    4 - 103 eng middle gear e. If the gear lash is incorrect, adjust the gear lash by middle driven pinion gear shims and/or middle drive pinion gear shim(s). ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲.

  • Page 262: Cool

    5 - 1 cool ebs00125 cooling system radiator 12 (4) 11 10 8 7 6 5 4 9 1 2 3 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks removing the radiator remove the parts in the order listed. Front fenders refer to “front fenders and front grill” in c...

  • Page 263: Cool

    5 - 2 cool 12 (4) 11 10 8 7 6 5 4 9 1 2 3 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks 5 coolant reservoir cap 1 6 coolant reservoir 1 7 fast idle plunger outlet hose 1 8 radiator outlet hose 1 9 radiator inlet hose 1 10 radiator bracket 1...

  • Page 264: Cool

    5 - 3 cool radiator ebs00127 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/damage → repl...

  • Page 265: Cool

    5 - 4 cool radiator ebs00128 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. 3. Measure: • radiator cap opening pressure belo...

  • Page 266: Cool

    5 - 5 cool thermostat ebs00129 thermostat new new 2 3 ls 1 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 . . 18 nm (1.8 m • kg, 13 ft • ib) new 4 5 order job/part q’ty remarks removing the thermostat remove the parts in the order listed. Air filter case refer to...

  • Page 267: Cool

    5 - 6 cool thermostat ebs00132 checking the thermostat 1. Check: • thermostat 1 does not open at 50 ~ 54 °c (122 ~ 129.2 °f) → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Suspend the thermostat in a container filled with water. B. Slowly heat the water. C. Place a thermometer in th...

  • Page 268: Cool

    5 - 7 cool water pump ebs00134 water pump new new new new new e 2 3 4 ls new 6 7 m 9 10 ls 12 11 8 5 1 new 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) ls order job/part q’ty remarks removing the water pump remove the parts i...

  • Page 269: Cool

    5 - 8 cool new new new new new e 2 3 4 ls new 6 7 m 9 10 ls 12 11 8 5 1 new 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) ls order job/part q’ty remarks 7 gasket 1 8 circlip 1 9 impeller shaft 1 10 water pump seal 1 11 bearing...

  • Page 270: Cool

    5 - 9 cool water pump ebs00138 disassembling the water pump 1. Remove: • water pump seal 1 note: _ tap out the water pump seal from the inside of the ac magneto cover 2. 2 1 2. Remove: • bearing 1 • oil seal 2 note: _ tap out the bearing and oil seal from the out- side of the ac magneto cover 3. 1 2...

  • Page 271: Cool

    5 - 10 cool water pump ebs00140 assembling the water pump 1. Install: • oil seal 1 (into the ac magneto cover 2) note: _ • before installing the oil seal, apply tap water or coolant onto its out surface. • install the oil seal with a socket 3 that matches its outside diameter. Installed depth of oil...

  • Page 272: Cool

    5 - 11 cool water pump 3. Measure: • impeller shaft tilt out of specification → replace. Caution: _ make sure the rubber damper and rubber damper holder are flush with the impeller. 1 straightedge 2 impeller shaft impeller shaft tilt limit 0.15 mm (0.006 in).

  • Page 273: Fuel Injection System

    6 - 1 fi eas00894 fuel injection system fuel injection system 1 ecu (engine control unit) 2 lean angle sensor 3 fuel injection system relay 4 engine trouble warning light 5 intake air pressure sensor 6 tps (throttle position sensor) 7 intake air temperature sensor 8 fuel injector 9 fuel pump 0 speed...

  • Page 274

    6 - 2 fi fuel injection system 6.

  • Page 275

    6 - 3 fi fuel injection system eas27340 circuit diagram g /y b b /lg y bl lb br r /b (gray) r /br /w (gray) pb g w /b br l/ w g /y (green) b /l (gray) w l/ y b /l lw b /l g y b yg b g y b yg b b lg l/ b ly r /y l/ bl g b r /y yl g wg /r l/ b br o (black) g /r w (black) l o /w br l/ b ww w (gray) br ...

  • Page 276

    6 - 4 fi fuel injection system 1 crankshaft position sensor 4 main switch 6 main fuse 8 battery 9 fuel injection system fuse h fuel injection system relay k ecu (engine control unit) l ignition coil m spark plug n fuel injector o intake air temperature sensor p coolant temperature sensor q speed sen...

  • Page 277

    6 - 5 fi fuel injection system ecu self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute character...

  • Page 278

    6 - 6 fi fuel injection system eas27380 self-diagnostic function table if the ecu detects an abnormal signal from a sensor while the vehicle is being driven, the ecu illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate fo...

  • Page 279

    6 - 7 fi fuel injection system eas00904 troubleshooting chart engine operation is not normal or the engine trouble warning light is on. * engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light comes on. Check the fault code number di...

  • Page 280

    6 - 8 fi fuel injection system eas00905 diagnostic mode it is possible to monitor the sensor output data or check the activation of actuators without connecting the measurement equipment by simply switching the meter indication from the normal mode to the diagnostic monitoring mode. Setting the diag...

  • Page 281

    6 - 9 fi fuel injection system 6. Verify the operation of the sensor or actua- tor. • sensor operation the data representing the operating condi- tions of the sensor appears on the lcd meter. • actuator operation set the engine stop switch to “on” to oper- ate the actuator. * if the engine stop swit...

  • Page 282

    6 - 10 fi fuel injection system diagnostic code table fault code no. Symptom probable cause of malfunction diagnostic code no. 12 no normal signals are received from the crankshaft position sensor. • open or short circuit in wire harness. • defective crankshaft position sensor. • malfunction in pick...

  • Page 283

    6 - 11 fi fuel injection system sensor operation table diagnos- tic code no. Item meter display checking method d01 throttle angle • fully closed position 15 ~ 20 check with throttle fully closed. • fully opened position 95 ~ 100 check with throttle fully open. D03 pressure difference (atmospheric p...

  • Page 284

    6 - 12 fi fuel injection system actuator operation table • actuator operation set the engine stop switch to “off” and then to “run”. Eas00908 troubleshooting details this section describes the countermeasures per fault code number displayed on the meter. Check and service the items or components tha...

  • Page 285

    6 - 13 fi fuel injection system fault code no. 12 symptom no normal signals are received from the crankshaft posi- tion sensor. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of crankshaft position sensor. Check fo...

  • Page 286

    6 - 14 fi fuel injection system fault code no. 13 symptom intake air pressure sensor: open or short circuit detected. Diagnostic code no. D03 intake air pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • intake air pressure sensor c...

  • Page 287

    6 - 15 fi fuel injection system fault code no. 14 symptom intake air pressure sensor: hose system malfunction (clogged or detached hose). Diagnostic code no. D03 intake air pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 intake air pressure se...

  • Page 288

    6 - 16 fi fuel injection system fault code no. 15 symptom throttle position sensor: open or short circuit detected. Diagnostic code no. D01 throttle position sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of throttle posi- tion sen...

  • Page 289

    6 - 17 fi fuel injection system fault code no. 16 symptom stuck throttle position sensor detected. Diagnostic code no. D01 throttle position sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of throttle posi- tion sensor. • check the ...

  • Page 290

    6 - 18 fi fuel injection system fault code no. 22 symptom intake air temperature sensor: open or short circuit detected. Diagnostic code no. D05 intake air temperature sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of air tempera- ...

  • Page 291

    6 - 19 fi fuel injection system fault code no. 30 symptom the vehicle has overturned. Diagnostic code no. D08 lean angle sensor order item/components and probable cause check or maintenance job reinstatement method 1 the vehicle has overturned. Raise the vehicle upright. Turning the main switch to “...

  • Page 292

    6 - 20 fi fuel injection system fault code no. 33 symptom malfunction detected in the primary lead of the ignition coil. Diagnostic code no. D30 ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 connections • ignition coil connector (primary coil ...

  • Page 293

    6 - 21 fi fuel injection system fault code no. 39 symptom open circuit detected in a injector. Diagnostic code no. D36 injector order item/components and probable cause check or maintenance job reinstatement method 1 connections • injector coupler • main wire harness-ecu coupler • main wire harness ...

  • Page 294

    6 - 22 fi fuel injection system fault code no. 41 symptom lean angle sensor: open or short circuit detected. Diagnostic code no. D08 lean angle sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • lean angle sensor coupler • main wire harness-...

  • Page 295

    6 - 23 fi fuel injection system fault code no. 42 symptom no normal signals are received from the speed sensor. Diagnostic code no. D07 speed sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • speed sensor coupler • main wire harness-ecu cou...

  • Page 296

    6 - 24 fi fuel injection system fault code no. 43 symptom power supply to the injector and fuel pump is not normal. Diagnostic code no. D09 fuel system voltage order item/components and probable cause check or maintenance job reinstatement method 1 connections • fuel injection system relay • main wi...

  • Page 297

    6 - 25 fi fuel injection system fault code no. 46 symptom power supply is not normal. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 connections • main wire harness-ecu coupler • check the coupler for any pins that may be pulled out. ...

  • Page 298

    6 - 26 fi fuel injection system eas28410 checking the intake air pressure sensor 1. Check: • intake air pressure sensor output voltage out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (dc 20 v) to the intake air pressure sensor coupler as...

  • Page 299

    6 - 27 fi fuel injection system ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 100) to the intake air temperature sensor terminal as shown. Pocket tester 90890-03112 analog pocket tester yu-03112-c positive tester probe → brown/white 1 negative tester probe → bl...

  • Page 300

    6 - 28 fi fuel tank fuel tank 2 1 11 8 (4) 12 9 (6) 5 7 10 3 4 5 6 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) new order job/part q’ty remarks removing the fuel tank remove the parts in the order listed. Rear fender refer to “engine skid plates, seat, carriers and f...

  • Page 301

    6 - 29 fi fuel tank 2 1 11 8 (4) 12 9 (6) 5 7 10 3 4 5 6 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) new order job/part q’ty remarks 11 fuel tank shield 1 12 damper 2 for installation, reverse the removal pro- cedure..

  • Page 302

    6 - 30 fi fuel tank removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel hose connector holder • fuel hose caution: • be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. • although the fuel has...

  • Page 303

    6 - 31 fi fuel tank caution: • do not drop the fuel pump or give it a strong shock. • do not touch the base section of the fuel sender. Checking the fuel pump body 1. Check: • fuel pump body obstruction → clean. Cracks/damage → replace the fuel pump assembly. Checking the rollover valve 1. Check: • ...

  • Page 304

    6 - 32 fi fuel tank installing the fuel hose 1. Install: • fuel hose • fuel hose connector holder 1 • fuel pump coupler caution: when installing the fuel hose, make sure that it is securely connected, and that the fuel hose holder is in the correct position, otherwise the fuel hose will not be prope...

  • Page 305

    6 - 33 fi throttle body eas00909 throttle body 5 6 9 9 13 new ls t r . . 3 nm (0.3 m • kg, 2.2 ft • ib) 4 7 3 2 1 11 12 10 8 order job/part q’ty remarks removing the throttle body remove the parts in the order listed. Air filter case refer to “air filter case” in chapter 3. Coolant drain. Refer to “...

  • Page 306

    6 - 34 fi throttle body 5 6 9 9 13 new ls t r . . 3 nm (0.3 m • kg, 2.2 ft • ib) 4 7 3 2 1 11 12 10 8 order job/part q’ty remarks 9 throttle body joint clamp screw 2 loosen. Refer to “installing the throttle body assem- bly”. 10 throttle body assembly 1 11 fuel hose 1 disconnect. Refer to “removing ...

  • Page 307

    6 - 35 fi throttle body new new 1 2 3 4 5 6 7 order job/part q’ty remarks disassembling the throttle body assembly remove the parts in the order listed. 1 intake air pressure sensor 1 2 intake air pressure sensor hose 1 3 throttle position sensor 1 4 injector fuel rail 1 5 fuel injector 1 6 fast idl...

  • Page 308

    6 - 36 fi throttle body removing the throttle body assembly 1. Disconnect: • fuel hose caution: • be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. • although the fuel has been removed from the fuel tank be careful when disconnect- ing the fuel hose, sinc...

  • Page 309

    6 - 37 fi throttle body ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Wash the throttle body in a petroleum- based solvent. Do not use any caustic carburetor cleaning solution. B. Blow out all of the passages with com- pressed air. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ installing ...

  • Page 310

    6 - 38 fi throttle body 4. Install: • throttle cable 5. Check: • throttle position sensor refer to “checking and adjusting the throttle position sensor”. 6. Adjust: • throttle lever free play refer to “adjusting the throttle lever free play” in chapter 3. 7. Adjust: • engine idling speed refer to “a...

  • Page 311

    6 - 39 fi throttle body e. Start the engine. F. Measure the fuel pressure. Out of specification → replace the fuel pump. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ fuel pressure 324 kpa (3.24 kg/cm 2 , 46.1 psi) eas00916 checking and adjusting the throttle position sensor 1. Check: • throttle...

  • Page 312

    6 - 40 fi b. Connect the digital circuit tester to the throt- tle position sensor coupler. C. Measure the throttle position sensor volt- age. D. Adjust the throttle position sensor angle so that the voltage is within the specified range. E. After adjusting the throttle position sensor angle, tighten...

  • Page 313: Driv

    7 - 1 driv ebs00155 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 re...

  • Page 314: Driv

    7 - 2 driv troubleshooting c. A slight “thunk” evident at low speed opera- tion. This noise must be distinguished from normal vehicle operation. Diagnosis: possible broken gear teeth. Warning _ stop riding immediately if broken gear teeth are suspected. This condition could result in the shaft drive...

  • Page 315: Driv

    7 - 3 driv troubleshooting ebs00157 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 knuckles and stabilizer” in chapter 8.) no c...

  • Page 316: Driv

    7 - 4 driv front constant velocity joints and differential gear ebs00158 front constant velocity joints and differential gear 1 1 3 9 10 2 8 7 6 5 4 new new ls ls ls ls ls lt lt t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 55 nm (5.5 m • kg, 40 ft • ib) lt order job/part q’ty remarks removing the ...

  • Page 317: Driv

    7 - 5 driv 1 1 3 9 10 2 8 7 6 5 4 new new ls ls ls ls ls lt lt t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 55 nm (5.5 m • kg, 40 ft • ib) lt order job/part q’ty remarks 4 differential gear case assembly 1 5 front drive shaft 1 6 spring 1 7 damper 1 8 coupling gear 1 9 dust seal 1 10 dust seal 1 f...

  • Page 318: Driv

    7 - 6 driv front constant velocity joints and differential gear ebs00159 order job/part q’ty remarks disassembling the front constant velocity joints remove the parts in the order listed. The following procedure applies to both of the front constant velocity joints. 1 clip 1 2 boot band 2 refer to “...

  • Page 319: Driv

    7 - 7 driv order job/part q’ty remarks a clip 1 refer to “assembling the front constant velocity joints”. B joint shaft 1 for assembly, reverse the disassembly procedure. Front constant velocity joints and differential gear.

  • Page 320: Driv

    7 - 8 driv front constant velocity joints and differential gear ebs00160 t r . . 62 nm (6.2 m • kg, 45 ft • ib) t r . . 24 nm (2.4 m • kg, 17 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 11 nm (1.1 m • kg, 8.0 ft • ib) lt ls ls new new new new new n...

  • Page 321: Driv

    7 - 9 driv t r . . 62 nm (6.2 m • kg, 45 ft • ib) t r . . 24 nm (2.4 m • kg, 17 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 11 nm (1.1 m • kg, 8.0 ft • ib) lt ls ls new new new new new new ls ls g f 4 3 a b d c e 1 2 5 6 9 8 7 0 f (5) order job/par...

  • Page 322: Driv

    7 - 10 driv front constant velocity joints and differential gear ebs00163 removing the differential gear assembly 1. Remove: • differential gear assembly 1 note: _ the ring gear and the differential gear should be fastened together. Do not disassemble the differential gear. Caution: _ the differenti...

  • Page 323: Driv

    7 - 11 driv front constant velocity joints and differential gear ebs00166 checking the differential gears 1. Check: • gear teeth pitting/galling/wear → replace. • bearing pitting/damage → replace. • oil seal • o-ring damage → replace. 2. Check: • front drive shaft splines • differential drive pinion...

  • Page 324: Driv

    7 - 12 driv front constant velocity joints and differential gear É check that the pinion gear 2 turns clockwise. Note: be sure not to disassemble the gear motor and remove the pinion gear. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3v 2 1 É ebs00167 assembling the front constant velocity join...

  • Page 325: Driv

    7 - 13 driv front constant velocity joints and differential gear ebs01009 assembling the differential gears 1. Measure: • gear lash refer to “measuring the differen- tial gear lash”. 2. Install: • differential gear motor ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Slide the shift fork slidi...

  • Page 326: Driv

    7 - 14 driv front constant velocity joints and differential gear 3. 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. Ebs00174 measuring the differential ...

  • Page 327: Driv

    7 - 15 driv front constant velocity joints and differential gear 5. Measure: • gear lash gently rotate the coupling gear from engagement to engagement. Note: _ measure the gear lash at four positions. Rotate the shaft 90° each time. Differential gear lash 0.05 ~ 0.25 mm (0.0020 ~ 0.0098 in) ebs00176...

  • Page 328: Driv

    7 - 16 driv front constant velocity joints and differential gear ebs00177 checking the differential gear operation 1. Block the rear wheels, and elevate the front wheels by placing a suitable stand under the frame. 2. Remove the wheel cap from the axle nut (right or left). 3. Measure the starting to...

  • Page 329: Driv

    7 - 17 driv rear constant velocity joints and final drive gear ebs00178 rear constant velocity joints and final drive gear 1 3 10 8 9 7 6 2 5 1 4 t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 55 nm (5.5 m • kg, 40 ft • ib) ls ls ls ls new new order job/part q’ty remarks removing the rear constant v...

  • Page 330: Driv

    7 - 18 driv 1 3 10 8 9 7 6 2 5 1 4 t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 55 nm (5.5 m • kg, 40 ft • ib) ls ls ls ls new new order job/part q’ty remarks 6 spring 1 7 damper 1 8 coupling gear 1 9 dust seal 1 10 dust seal 1 for installation, reverse the removal pro- cedure. Rear constant veloc...

  • Page 331: Driv

    7 - 19 driv rear constant velocity joints and final drive gear ebs01011 order job/part q’ty remarks disassembling the rear constant velocity joints remove the parts in the order listed. The following procedure applies to both of the rear constant velocity joints. 1 clip 1 2 boot band 2 refer to “ass...

  • Page 332: Driv

    7 - 20 driv order job/part q’ty remarks a clip 1 refer to “assembling the rear constant velocity joints”. B joint shaft 1 for assembly, reverse the disassembly procedure. Rear constant velocity joints and final drive gear.

  • Page 333: Driv

    7 - 21 driv rear constant velocity joints and final drive gear ebs00179 i j k e h 4 g 1 m n (4) (11) o p r q l 2 d c b a 8 5 7 9 0 f 4 3 6 new new new new new new new new t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 23 n...

  • Page 334: Driv

    7 - 22 driv i j k e h 4 g 1 m n (4) (11) o p r q l 2 d c b a 8 5 7 9 0 f 4 3 6 new new new new new new new new t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft...

  • Page 335: Driv

    7 - 23 driv i j k e h 4 g 1 m n (4) (11) o p r q l 2 d c b a 8 5 7 9 0 f 4 3 6 new new new new new new new new t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft...

  • Page 336: Driv

    7 - 24 driv rear constant velocity joints and final drive gear ebs00167 assembling the rear constant velocity joints 1. Apply: • molybdenum disulfide grease (into the ball joint assembly) note: _ molybdenum disulfide grease is included in the repair kit. 2. Install: • dust boots 1 • boot bands 2, 3 ...

  • Page 337: Driv

    7 - 25 driv rear constant velocity joints and final drive gear disassembling the final drive pinion gear assembly 1. Loosen: • rear drive shaft coupling gear (final gear side) nut 1 note: secure the final drive pinion gear teeth in the vise with a clean rag. 1 ebs00184 positioning the final drive pi...

  • Page 338: Driv

    7 - 26 driv rear constant velocity joints and final drive gear 3) if “–05” is stamped on the final drive pinion gear bearing housing, c = 67.8 – 0.05 = 67.75 note: after replacing any part in the final drive pinion gear assembly, the overall length of the assembly will change. Therefore, be sure to ...

  • Page 339: Driv

    7 - 27 driv rear constant velocity joints and final drive gear ebs00186 adjusting the final driven pinion gear backlash 1. Select: • final driven pinion gear shim(s) 1, 2 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. To find the final driven pinion gear shim thickness “b”, use the following f...

  • Page 340: Driv

    7 - 28 driv rear constant velocity joints and final drive gear 6) round off the hundredth digit and select the appropriate shim(s). In the example above, the calculated number is 5.16. The chart instructs you to round off 6 to 5 at the hun- dredth place. Thus, the shim thickness is 5.15 mm. Shims ar...

  • Page 341: Driv

    7 - 29 driv rear constant velocity joints and final drive gear ebs00187 measuring the final driven pinion gear thrust washer clearance 1. Measure: • final driven pinion gear thrust washer clear- ance “c” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Place four pieces of plastigauge ® between ...

  • Page 342: Driv

    7 - 30 driv rear constant velocity joints and final drive gear ebs00187 measuring the wheel gear thrust clearance 1. Measure: • wheel gear thrust clearance “d” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Place four pieces of plastigauge ® between the originally fitted wheel gear shim(s) and...

  • Page 343: Driv

    7 - 31 driv rear constant velocity joints and final drive gear ebs00191 checking the rear drive shaft 1. Check: • rear drive shaft splines • coupling gear splines wear/damage → replace. Ebs00192 checking the final drive assembly 1. Check: • final gear case • final gear case cover cracks/damage → rep...

  • Page 344: Driv

    7 - 32 driv rear constant velocity joints and final drive gear ebs00193 measurement 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 the drain plug hole) caution: _ finger tighten t...

  • Page 345: Driv

    7 - 33 driv rear constant velocity joints and final drive gear ebs00194 adjusting the final gear lash 1. Remove: • final driven pinion gear assembly 1 • final driven pinion gear shim 2 • final driven pinion gear shim 3 • thrust washer 4 2. Adjust: • gear lash ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ...

  • Page 346: Driv

    7 - 34 driv rear constant velocity joints and final drive gear ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ thrust washer thickness (mm) 0.25 0.30 0.35 0.40 0.45 0.50 assembling the final drive pinion gear assembly 1. Tighten: • rear drive shaft coupling gear nut (final gear side) 1 note: secur...

  • Page 347: Driv

    7 - 35 driv rear constant velocity joints and final drive gear assembling the final gear case 1. Install: • oil seals 1 installed depth of oil seal a 5.5 mm (0.22 in) a a 1 1.

  • Page 348: Chas

    8 - 1 chas ebs00378 chassis front and rear wheels front wheels lt lt 3 2 5 6 4 1 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) t r . . 30 nm (3.0 m • kg, 22 ft • ib) new order job/part q’ty remarks removing the front wheels re...

  • Page 349: Chas

    8 - 2 chas lt lt 3 2 5 6 4 1 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) t r . . 30 nm (3.0 m • kg, 22 ft • ib) new order job/part q’ty remarks 4 front brake caliper assembly 1 note: _ do not squeeze the front brake lever wh...

  • Page 350: Chas

    8 - 3 chas front and rear wheels ebs00379 rear wheels lt lt 3 2 5 6 4 1 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) t r . . 30 nm (3.0 m • kg, 22 ft • ib) new order job/part q’ty remarks removing the rear wheels remove the p...

  • Page 351: Chas

    8 - 4 chas lt lt 3 2 5 6 4 1 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) t r . . 30 nm (3.0 m • kg, 22 ft • ib) new order job/part q’ty remarks 4 rear brake caliper assembly 1 note: do not squeeze the rear brake lever and br...

  • Page 352: Chas

    8 - 5 chas front and rear wheels ebs00383 checking the wheels 1. Check: • wheels 2. Measure: • wheel runout over the specified limit → replace the wheel or check the wheel bearing play 1. Wheel runout limit front radial 2: 2.0 mm (0.08 in) lateral 3: 2.0 mm (0.08 in) rear radial 2: 2.0 mm (0.08 in) ...

  • Page 353: Chas

    8 - 6 chas front and rear wheels ebs00389 checking the brake discs 1. Check: • brake discs galling/damage → replace. 2. Measure: • brake disc deflection out of specification → check the wheel runout. • brake disc thickness a out of specification → replace. Brake disc maximum deflection front: 0.1 mm...

  • Page 354: Chas

    8 - 7 chas front and rear wheels ebs00392 installing the wheels 1. Install: • wheels note: _ the arrow mark 1 on the tire must point in the direction of rotation È of the wheel. 2. Tighten: • wheel nuts 1 warning tapered wheel nuts 1 are used for both the front and rear wheels. Install each nut with...

  • Page 355: Chas

    8 - 8 chas front and rear brakes ebs00400 front and rear brakes front brake pads 1 2 3 4 5 t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 17 nm (1.7 m • kg, 12 ft • ib) t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) order job/part q’ty remarks removing the front brake pads remove the parts in the order list...

  • Page 356: Chas

    8 - 9 chas front and rear brakes ebs00401 rear brake pads 2 3 1 4 5 t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 17 nm (1.7 m • kg, 12 ft • ib) t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) order job/part q’ty remarks removing the rear brake pads remove the parts in the order listed. The following proced...

  • Page 357: Chas

    8 - 10 chas front and rear brakes ebs00402 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 fl...

  • Page 358: Chas

    8 - 11 chas front and rear brakes 2. Install: • brake pad spring • brake pads 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...

  • Page 359: Chas

    8 - 12 chas front and rear brakes ebs00407 front brake master cylinder 11 10 9 1 2 3 12 8 7 6 5 4 t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) ∗ new t r . . 27 nm (2.7 m • kg, 19 ft • ib) t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) * apply silicone grease. Order job/part ...

  • Page 360: Chas

    8 - 13 chas 11 10 9 1 2 3 12 8 7 6 5 4 t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) ∗ new t r . . 27 nm (2.7 m • kg, 19 ft • ib) t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) * apply silicone grease. Order job/part q’ty remarks 6 union bolt 1 refer to “installing the front ...

  • Page 361: Chas

    8 - 14 chas front and rear brakes ebs00409 3 2 1 new new order job/part q’ty remarks disassembling the front brake mas- ter cylinder remove the parts in the order listed. 1 dust boot 1 refer to “assembling the front and rear brake master cylin- ders”. 2 circlip 1 3 brake master cylinder kit 1 for as...

  • Page 362: Chas

    8 - 15 chas front and rear brakes ebs00410 rear brake master cylinder 14 13 12 1 2 3 15 11 10 9 7 8 6 5 4 new new ∗ t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) r . . 6 nm (0.6 m • kg, 4.3 ft • ib) ∗ ls ls t t r . . 27 nm (2.7 m • kg, 19 ft • ib) * apply silicone gre...

  • Page 363: Chas

    8 - 16 chas 14 13 12 1 2 3 15 11 10 9 7 8 6 5 4 new new ∗ t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) r . . 6 nm (0.6 m • kg, 4.3 ft • ib) ∗ ls ls t t r . . 27 nm (2.7 m • kg, 19 ft • ib) * apply silicone grease. Order job/part q’ty remarks 9 union bolt 1 refer to “...

  • Page 364: Chas

    8 - 17 chas front and rear brakes ebs00411 3 2 1 new new order job/part q’ty remarks disassembling the rear brake mas- ter cylinder remove the parts in the order listed. 1 dust boot 1 refer to “assembling the front and rear brake master cylin- ders”. 2 circlip 1 3 brake master cylinder kit 1 for ass...

  • Page 365: Chas

    8 - 18 chas front and rear brakes ebs00413 checking the master cylinders 1. Check: • brake master cylinder 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 ...

  • Page 366: Chas

    8 - 19 chas front and rear brakes ebs00418 installing the front brake master cylinder 1. Install: • brake master cylinder 1 • brake master cylinder holder 2 note: _ • align the end of the brake master cylinder holder with the punch mark a on the handle- bar. • the “up” mark b on the brake master cyl...

  • Page 367: Chas

    8 - 20 chas front and rear brakes 3. Fill: • brake fluid 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, causi...

  • Page 368: Chas

    8 - 21 chas front and rear brakes ebs00418 installing the rear brake master cylinder 1. Install: • brake master cylinder 1 • brake master cylinder holder 2 note: _ • align the end of the brake master cylinder holder with the punch mark a on the handle- bar. • the “up” mark b on the brake master cyli...

  • Page 369: Chas

    8 - 22 chas front and rear brakes 3. Fill: • brake fluid 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, causi...

  • Page 370: Chas

    8 - 23 chas front and rear brakes ebs00421 front brake calipers 6 1 3 2 7 4 5 t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 27 nm (2.7 m • kg, 19 ft • ib) t r . . 17 nm (1.7 m • kg, 12 ft • ib) new order job/part q’ty remarks removing the front brake calipers remove the parts in the order listed. T...

  • Page 371: Chas

    8 - 24 chas front and rear brakes ebs00423 2 8 1 3 4 5 6 7 t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) t r . . 17 nm (1.7 m • kg, 12 ft • ib) ∗ ∗ new new * apply silicone grease. Order job/part q’ty remarks disassembling the front brake cali- pers remove the parts in the order listed. The following proce...

  • Page 372: Chas

    8 - 25 chas front and rear brakes ebs00424 rear brake calipers 3 1 2 4 5 7 6 t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 27 nm (2.7 m • kg, 19 ft • ib) t r . . 17 nm (1.7 m • kg, 12 ft • ib) new order job/part q’ty remarks removing the rear brake calipers remove the parts in the order listed. The...

  • Page 373: Chas

    8 - 26 chas front and rear brakes ebs00425 1 2 3 4 5 7 6 8 t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) t r . . 17 nm (1.7 m • kg, 12 ft • ib) ∗ ∗ new new * apply silicone grease. Order job/part q’ty remarks disassembling the rear brake cali- pers remove the parts in the order listed. The following proced...

  • Page 374: Chas

    8 - 27 chas front and rear brakes ebs00427 disassembling the front and rear brake calipers 1. Remove: • brake caliper piston 1 • dust seal 2 • caliper piston seal 3 È front É rear ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Blow compressed air into the hose joint opening a to force out the ...

  • Page 375: Chas

    8 - 28 chas front and rear brakes 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 piston 1 scratches/rust/wear → replace the brake caliper assembly. • brake caliper cylinde...

  • Page 376: Chas

    8 - 29 chas front and rear brakes 2. Install: • brake caliper piston 1 1 ebs00434 installing the front and rear brake calipers 1. Install: • brake caliper assembly • brake caliper bolts 1 • brake hose 2 • copper washers 3 • union bolt 4 caution: _ when installing the brake hose on the brake caliper,...

  • Page 377: Chas

    8 - 30 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 378: Chas

    8 - 31 chas steering system ebs00444 steering system handlebar 1 11 9 6 15 15 12 13 14 5 8 3 4 7 10 2 2 16 14 t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks removing the handlebar remove the parts in the order listed. 1 handlebar cover 1 2 p...

  • Page 379: Chas

    8 - 32 chas 1 11 9 6 15 15 12 13 14 5 8 3 4 7 10 2 2 16 14 t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks 10 rear brake master cylinder holder 1 refer to “installing the rear brake master cylinder”. 11 rear brake master cylinder 1 12 spacer ...

  • Page 380: Chas

    8 - 33 chas steering system ebs00447 removing the handlebar grips 1. Remove: • handlebar grips 1 note: _ blow compressed air between the handlebar and handlebar grip, and gradually push the grip off the handlebar. Ebs00448 checking the handlebar 1. Check: • handlebar bends/cracks/damage → replace. W...

  • Page 381: Chas

    8 - 34 chas steering system ebs00450 installing the handlebar grips 1. Install: • handlebar grip 1 note: _ • before applying adhesive, wipe off grease or oil on the handlebar surface a with a lacquer thinner. • install the handlebar grips to the handlebar so that arrow mark l faces up on the left ha...

  • Page 382: Chas

    8 - 35 chas steering system ebs00453 installing the front brake master cylinder 1. Install: • front brake master cylinder 1 • front brake master cylinder holder 2 note: _ • align the end of the brake master cylinder holder with the punch mark a on the handle- bar. • the “up” mark b on the brake mast...

  • Page 383: Chas

    8 - 36 chas steering system ebs00454 steering stem 13 12 11 8 9 6 7 16 4 3 3 10 20 5 5 2 1 14 15 19 18 17 new new new new t r . . 50 nm (5.0 m • kg, 36 ft • ib) t r . . 50 nm (5.0 m • kg, 36 ft • ib) lt lt lt lt ls 15 (4) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) ...

  • Page 384: Chas

    8 - 37 chas 13 12 11 8 9 6 7 16 4 3 3 10 20 5 5 2 1 14 15 19 18 17 new new new new t r . . 50 nm (5.0 m • kg, 36 ft • ib) t r . . 50 nm (5.0 m • kg, 36 ft • ib) lt lt lt lt ls 15 (4) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) ...

  • Page 385: Chas

    8 - 38 chas steering system ebs00456 checking the steering stem 1. Check: • steering stem bends → replace. Warning _ do not attempt to straighten a bent stem; this may dangerously weaken the stem. 2. Check: • oil seals • steering stem bushings wear/damage → replace. 3. Check: • steering stem joint c...

  • Page 386: Chas

    8 - 39 chas steering system 4. Install: • collar d • steering stem joint e • steering stem joint bolts f (temporarily tighten) note: • apply loctite ® to the steering stem joint bolts. • align the spline a on the steering stem with the groove b in the steering stem joint. • align the punch mark c on...

  • Page 387: Chas

    8 - 40 chas steering system installing the pitman arm 1. Install: • pitman arm 1 • washer • pitman arm nut • clip note: align the punch mark b on the eps unit with the groove a in the pitman arm. 1 a b t r . . 210 nm (21.0 m · kg, 150 ft · lb).

  • Page 388: Chas

    8 - 41 chas steering system ebs00460 tie-rods and steering knuckles t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 25 nm (2.5 m • kg, 18 ft • ib) t r . . 25 nm (2.5 m • kg, 18 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 25 nm (2.5 m • kg, 18 ft • ib...

  • Page 389: Chas

    8 - 42 chas t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 25 nm (2.5 m • kg, 18 ft • ib) t r . . 25 nm (2.5 m • kg, 18 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 25 nm (2.5 m • kg, 18 ft • ib) new new new ls new ls new new new 3 1 8 6 7 9 2 5 4 10...

  • Page 390: Chas

    8 - 43 chas steering system ebs00461 removing the steering knuckles 1. Remove: • steering knuckle 1 note: _ use a general puller to separate the ball joint 2 from the steering knuckle 1 or the front lower arm 3. Ebs00462 checking the tie-rods 1. Check: • tie-rod free play and movement free play → re...

  • Page 391: Chas

    8 - 44 chas steering system c. Remove the ball joint. Note: use a remover attachment 3 to separate the ball joint 1 from the steering knuckle 2. 2 1 3 d. Measure the ball joint bore inside diameter a. Out of specification → replace the steering knuckle. E. Install the new ball joint. Use the ball jo...

  • Page 392: Chas

    8 - 45 chas steering system f. Attach the ball joint remover/installer, new ball joint (with rubber boot and retaining ring) 1, installer spacer 6 and installer washer 2 to the steering knuckle 3. Note: do not tap or damage the top of the ball joint. G. Hold the body 4 in place while turning in the ...

  • Page 393: Chas

    8 - 46 chas ebs00465 installing the tie-rods 1. Install: • tie-rods (left and right) note: _ the tie-rod side which must be installed on the out side has grooves 1. 2. Adjust: • toe-in refer to “adjusting the toe-in” in chapter 3. T r . . 25 nm (2.5 m · kg, 18 ft · lb) steering system.

  • Page 394: Chas

    8 - 47 chas front arms and front shock absorber assemblies ebs00468 front arms and front shock absorber assemblies 9 11 1 17 17 10 10 8 8 8 8 10 10 6 6 6 6 3 3 14 13 13 15 7 12 12 16 4 5 2 t r . . 25 nm (2.5 m • kg, 18 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 ...

  • Page 395: Chas

    8 - 48 chas 9 11 1 17 17 10 10 8 8 8 8 10 10 6 6 6 6 3 3 14 13 13 15 7 12 12 16 4 5 2 t r . . 25 nm (2.5 m • kg, 18 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 . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 45 nm (4.5 ...

  • Page 396: Chas

    8 - 49 chas front arms and front shock absorber assemblies ebs00469 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 ...

  • Page 397: Chas

    8 - 50 chas front arms and front shock absorber assemblies c. Install the body 4, long bolt 5, base 6 and attachment 7 onto ball joint. D. Hold the body 4 in place while turning in the long bolt 5 to remove the ball joint 0 from the front upper arm a. E. Remove the ball joint remover. F. Attach the ...

  • Page 398: Chas

    8 - 51 chas front arms and front shock absorber assemblies ebs00471 checking the front shock absorbers 1. Check: • shock absorber assembly oil leaks → replace the shock absorber assembly. • spring fatigue → replace the shock absorber assembly. Move the spring up and down. Ebs00475 installing the fro...

  • Page 399: Chas

    8 - 52 chas rear knuckles and stabilizer ebs01023 rear knuckles and stabilizer 12 12 13 13 14 4 5 11 1 7 10 9 2 8 7 7 8 7 6 11 3 ls ls ls 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 . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . ...

  • Page 400: Chas

    8 - 53 chas 12 12 13 13 14 4 5 11 1 7 10 9 2 8 7 7 8 7 6 11 3 ls ls ls 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 . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 50 nm (5.0 m • kg, 36 ft • ib) t r . . 50 nm (5.0 m • kg, 36 ft •...

  • Page 401: Chas

    8 - 54 chas rear knuckles and stabilizer ebs01024 checking the rear knuckles 1. Check: • rear knuckle damage/pitting → replace. 2. Check: • rear wheel bearing 1 bearing allow play in the wheel hub or the wheel turns roughly → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Clean the ou...

  • Page 402: Chas

    8 - 55 chas rear arms and rear shock absorber assemblies ebs00476 rear arms and rear shock absorber assemblies ls 4 7 6 10 10 1 4 7 7 7 9 10 2 8 5 2 10 9 3 ls 2 4 2 t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 45 nm (4.5...

  • Page 403: Chas

    8 - 56 chas ls 4 7 6 10 10 1 4 7 7 7 9 10 2 8 5 2 10 9 3 ls 2 4 2 t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks 10 bushing ...

  • Page 404: Chas

    8 - 57 chas rear arms and rear shock absorber assemblies checking the rear arms 1. Check: • rear arms bends/damage → replace. 2. Check: • bushings wear/damage → replace. Ebs00478 checking the rear shock absorber assemblies 1. Check: • shock absorber assemblies oil leaks → replace the shock absorber ...

  • Page 405: Chas

    8 - 58 chas rear arms and rear shock absorber assemblies ebs01027 installing the rear arms and rear shock absorber assemblies 1. Install: • rear arms • rear shock absorber assemblies ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the rear upper arm 1 and rear lower arm 2. Note: _ • lub...

  • Page 406: Elec

    9 - 1 – + elec ebs00500 electrical electrical components 1 four-wheel-drive motor relay 3 2 rear brake relay 3 four-wheel-drive motor relay 2 4 four-wheel-drive motor relay 1 5 headlight relay 6 fuel injection system fuse 7 starter relay 8 eps fuse 9 main fuse 0 fuse box (ignition, headlights, four-...

  • Page 407: Elec

    9 - 2 – + elec electrical components c reverse switch d gear position switch e auxiliary dc jack f main switch g differential gear motor h eps motor i eps torque sensor j radiator fan motor 1 2 3 4 5 9 8 0 b a c d e f g h j i 6 7.

  • Page 408: Elec

    9 - 3 – + elec electrical components 1 lean angle sensor 2 radiator fan motor relay 3 fuel injection system relay 4 starting circuit cut-off relay 5 front brake light switch 6 rear brake light switch 7 intake air temperature sensor 8 intake air pressure sensor 9 tps (throttle position sensor) 0 fuel...

  • Page 409: Elec

    9 - 4 – + elec checking switch continuity ebs01028 checking switch continuity check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. Caution: _ never insert the tester probes into the cou...

  • Page 410: Elec

    9 - 5 – + elec checking the switches ebs01029 checking the switches check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “checking switch continuity”. Damage/wear → repair or replace. Improperly connected → properly connect. Incorrect co...

  • Page 411: Elec

    9 - 6 – + elec checking the switches 1 main switch 2 light switch 3 engine stop switch 4 start switch 5 override switch 6 on-command four-wheel-drive motor switch and differential gear lock switch 7 four-wheel-drive motor switch 8 gear position switch 9 reverse switch 0 rear brake light switch a fro...

  • Page 412: Elec

    9 - 7 – + elec checking the bulbs and bulb sockets ebs01030 checking the bulbs and bulb sockets check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or both. Improperly connected...

  • Page 413: Elec

    9 - 8 – + elec checking the bulbs and bulb sockets checking the condition of the bulbs the following procedure applies to all of the bulbs. 1. Remove: • bulb warning _ since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. Cau...

  • Page 414: Elec

    9 - 9 – + elec checking the bulbs and bulb sockets ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the positive tester probe to termi- nal 1 and the negative tester probe to ter- minal 2, and check the continuity. B. Connect the positive tester probe to termi- nal 1 and the negative tes...

  • Page 415: Elec

    9 - 10 – + elec ignition system ebs00503 ignition system circuit diagram g /y b b /lg y bl lb br r /b (gray) r /br /w (gray) pb g w /b br l/ w g /y (green) b /l (gray) w l/ y b /l lw b /l g y b yg b g y b yg b b lg l/ b ly r /y l/ bl g b r /y yl g wg /r l/ b br o (black) g /r w (black) l o /w br l/ ...

  • Page 416: Elec

    9 - 11 – + elec ignition system ebs01045 troubleshooting check: 1. Main and ignition fuses 2. Battery 3. Spark plug 4. Ignition spark gap 5. Spark plug cap resistance 6. Ignition coil resistance 7. Main switch 8. Engine stop switch 9. Crankshaft position sensor resistance 10.Lean angle sensor 11.Wir...

  • Page 417: Elec

    9 - 12 – + elec ignition system ebs01032 yes no ebs01034 no yes 3. Spark plug • check the condition of the spark plug. • check the spark plug type. • measure the spark plug gap. Refer to “checking the spark plug” in chapter 3. Standard spark plug cr8e (ngk) spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031...

  • Page 418: Elec

    9 - 13 – + elec ignition system ebs01036 yes no ebs01038 yes no 5. Spark plug cap resistance • remove the spark plug cap from the spark plug lead. • connect the pocket tester ( Ω × 1k) to the spark plug cap as shown. • measure the spark plug cap resistance. Spark plug cap resistance 10.0 k Ω at 20 °...

  • Page 419: Elec

    9 - 14 – + elec ignition system ebs01041 yes no ebs01042 yes no ebs01040 yes no 7. Main switch • check the main switch for continuity. Refer to “checking the switches”. • is the main switch ok? Replace the main switch. 8. Engine stop switch • check the engine stop switch for continu- ity. Refer to “...

  • Page 420: Elec

    9 - 15 – + elec ignition system yes no ebs01047 yes no 10.Lean angle sensor • remove the lean angle sensor. • connect the pocket tester (dc 20 v) to the lean angle sensor coupler as shown. Positive tester probe → yellow/green 1 negative tester probe → black/blue 2 • set the main switch to “on”. • tu...

  • Page 421: Elec

    9 - 16 – + elec electric starting system ebs00506 electric starting system circuit diagram g /y b b /lg y bl lb br r /b (gray) r /br /w (gray) pb g w /b br l/ w g /y (green) b /l (gray) w l/ y b /l lw b /l g y b yg b g y b yg b b lg l/ b ly r /y l/ bl g b r /y yl g wg /r l/ b br o (black) g /r w (bl...

  • Page 422: Elec

    9 - 17 – + elec electric starting system ebs00507 starting circuit operation the starting circuit on this model consists of the starter motor, starter relay, starting circuit cut-off relay, rear brake light switch, rear brake relay and gear position switch. If the main switch is on and the engine st...

  • Page 423: Elec

    9 - 18 – + elec electric starting system ebs01048 troubleshooting check: 1. Main, ignition and signaling system fuses 2. Battery 3. Starter motor 4. Starting circuit cut-off relay 5. Starter relay 6. Rear brake relay 7. Diode 2 8. Main switch 9. Engine stop switch 10.Start switch 11.Rear brake light...

  • Page 424: Elec

    9 - 19 – + elec electric starting system ebs01052 yes no ebs01054 yes no 4. Starting circuit cut-off relay • remove the starting circuit cut-off relay from the wire harness. • connect the pocket tester ( Ω × 1) and bat- tery (12 v) to the starting circuit cut-off relay as shown. Positive battery ter...

  • Page 425: Elec

    9 - 20 – + elec electric starting system ebs01054 yes no ebs01053 yes no 6. Rear brake relay • remove the rear brake relay from the wire harness. • connect the pocket tester ( Ω × 1) and bat- tery (12 v) to the rear brake relay as shown. Positive battery terminal → yellow/white 1 negative battery te...

  • Page 426: Elec

    9 - 21 – + elec ebs01041 yes no ebs01042 yes no ebs01057 yes no yes no ebs01058 yes no ebs01059 yes no 8. Main switch • check the main switch for continuity. Refer to “checking the switches”. • is the main switch ok? Replace the main switch. 9. Engine stop switch • check the engine stop switch for c...

  • Page 427: Elec

    9 - 22 – + elec starter motor ebs01061 starter motor order job/part q’ty remarks removing the starter motor remove the parts in the order listed. Muffler refer to “engine removal” in chapter 4. 1 starter motor lead 1 disconnect. 2 ground lead 1 disconnect. 3 starter motor 1 for installation, reverse...

  • Page 428: Elec

    9 - 23 – + elec starter motor order job/part q’ty remarks 7 bushing 1 refer to “assembling the starter motor”. 8 shim * 9 brush holder set 1 0 armature assembly 1 a starter motor yoke 1 for assembly, reverse the disassembly procedure..

  • Page 429: Elec

    9 - 24 – + elec starter motor ebs01064 checking the starter motor 1. Check: • commutator dirt → clean with 600-grit sandpaper. 2. Measure: • commutator diameter a out of specification → replace the starter motor. Commutator wear limit 27 mm (1.06 in) a 3. Measure: • mica undercut a out of specificat...

  • Page 430: Elec

    9 - 25 – + elec starter motor ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure the armature assembly resis- tances with the pocket tester. B. If any resistance is out of specification, replace the starter motor. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ pocket tester 90890-03112 ...

  • Page 431: Elec

    9 - 26 – + elec starter motor ebs00515 assembling the starter motor 1. Install: • brush holder set 1 note: _ align the projection a on the brush holder set with the slot b in the starter motor yoke. 2. Install: • starter motor yoke 1 • starter motor front cover 2 • starter motor rear cover 3 note: _...

  • Page 432: Elec

    9 - 27 – + elec charging system ebs00516 charging system circuit diagram g/y b b/l gy b l l b w w w (gray) b r (black) r (gray) br/l b (black) br/l r b b r r/b r r r/b l br y/r br/b l/w (black) br on off br/b r/b r r r r/w r br/l br br/l br/y br/l r/y r r b b b b b b b b b w w w w r w w br l/w b r b...

  • Page 433: Elec

    9 - 28 – + elec charging system ebs01065 troubleshooting check: 1. Main fuse 2. Battery 3. Charging voltage 4. Stator coil resistance 5. Wiring connections (of the entire charging system) note: _ • before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Right side cover 4. ...

  • Page 434: Elec

    9 - 29 – + elec charging system ebs01066 no yes ebs01100 yes no yes no 3. Charging voltage • connect the engine tachometer to the spark plug lead. • connect the pocket tester (dc 20 v) to the battery as shown. Positive tester probe → positive battery terminal 1 negative tester probe → negative batte...

  • Page 435: Elec

    9 - 30 – + elec lighting system ebs00518 lighting system circuit diagram g/y b b/l gy b l l b br r/b (gray) r/b r/w (gray) p b g w/b br l/w g y b y g b g y b y g b b lg l/b l y r/y l/b lg b r/y y l w w w (gray) b r (black) r (gray) br/l b (black) br/l r g r b w r g w b b b r r/b r r r/b l br y/r l/w...

  • Page 436: Elec

    9 - 31 – + elec lighting system ebs01067 troubleshooting check: 1. Main and headlight fuses 2. Battery 3. Main switch 4. Light switch 5. Wiring connections (of the entire lighting system) note: _ • before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Tail/brake light cov...

  • Page 437: Elec

    9 - 32 – + elec lighting system ebs01069 yes no ebs01070 checking the lighting system 1. The headlights fail to come on. Yes no yes no 5. Wiring • check the entire lighting system’s wiring. Refer to “circuit diagram”. • is the lighting system wiring properly con- nected and without defects? Check th...

  • Page 438: Elec

    9 - 33 – + elec lighting system yes no 2. The taillight fails to come on. Yes no yes no 3. Voltage • connect the pocket tester (dc 20 v) to the headlight couplers as shown. È when the light switch is set to “lo” É when the light switch is set to “hi” headlight coupler (wire harness side) headlight p...

  • Page 439: Elec

    9 - 34 – + elec signaling system ebs00521 signaling system circuit diagram g /y b b /lg y bl lb br r /b (gray) r /br /w (gray) pb g w /b br l/ w g /y (green) b /l (gray) w l/ y b /l lw b /l g y b yg b g y b yg b b lg l/ b ly r /y l/ bl g b r /y yl g wg /r l/ b br o (black) g /r w (black) l o /w br l...

  • Page 440: Elec

    9 - 35 – + elec signaling system 4 main switch 6 main fuse 8 battery j reverse switch k ecu (engine control unit) p coolant temperature sensor q speed sensor u gear position switch w multifunction meter y coolant temperature warning light z park indicator light [ reverse indicator light \ neutral in...

  • Page 441: Elec

    9 - 36 – + elec signaling system ebs01073 troubleshooting check: 1. Main, signaling system and ignition fuses 2. Battery 3. Main switch 4. Wiring connections (of the entire signaling system) note: _ • before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Side panels 4. V-...

  • Page 442: Elec

    9 - 37 – + elec signaling system ebs01075 checking the signaling system ebs01076 1. The brake light fails to come on. Yes no yes no ebs01053 yes no 1. Brake light bulb and bulb socket • check the brake light bulb and bulb socket for continuity. Refer to “checking the bulbs and bulb sockets”. • are t...

  • Page 443: Elec

    9 - 38 – + elec signaling system yes no ebs01078 2. The neutral, park, high-range, and/or low- range indicator light fails to come on. Yes no yes no 4. Voltage • connect the pocket tester (dc 20 v) to the tail/brake light connectors (wire harness side) as shown. Positive tester probe → yellow 1 nega...

  • Page 444: Elec

    9 - 39 – + elec signaling system ebs01079 3. The reverse indicator light fails to come on. Yes no yes no ebs01081 4. The differential gear lock indicator light and/ or four-wheel-drive motor indicator light fails to come on. Yes no yes no 1. Reverse switch • check the reverse switch for continuity. ...

  • Page 445: Elec

    9 - 40 – + elec signaling system 5. While the override switch is pushed, the segments of the speedometer digits will not appear as shown in the illustration. Yes no yes no 1. Override switch • check the override switch for continuity. Refer to “checking the switches”. • is the override switch ok? Re...

  • Page 446: Elec

    9 - 41 – + elec signaling system ebs01083 6. The coolant temperature warning light does not come on when the main switch is set to “on”, or if the coolant temperature warning light does not come on when the tempera- ture is high (more than 112 °c (233.6 °f)). Ebs00812 yes no 1. Coolant temperature s...

  • Page 447: Elec

    9 - 42 – + elec signaling system yes no 7. The fuel level indicator light fails to come on. Yes no 2. Voltage • connect the pocket tester (dc 20 v) to the meter assembly coupler as shown. Positive tester probe → brown 1 negative tester probe → black/white 2 • set the main switch to “on”. • measure t...

  • Page 448: Elec

    9 - 43 – + elec yes no 8. The speedometer fails to come on. Yes no 2. Voltage • connect the pocket tester (dc 20 v) to the meter assembly coupler as shown. Positive tester probe → brown 1 negative tester probe → black/white 2 • set the main switch to “on”. • measure the voltage (12 v) of brown 1 and...

  • Page 449: Elec

    9 - 44 – + elec yes no 2. Voltage • connect the pocket tester (dc 20 v) to the meter assembly coupler as shown. Positive tester probe → brown 1 negative tester probe → black/white 2 • set the main switch to “on”. • measure the voltage (12 v) of brown 1 and black/white 2 at the meter assembly coupler...

  • Page 450: Elec

    9 - 45 – + elec cooling system ebs00532 cooling system circuit diagram g /y b b /lg y bl lb br r /b (gray) r /br /w (gray) pb g w /b br l/ w g /y (green) b /l (gray) w l/ y b /l lw b /l g y b yg b g y b yg b b lg l/ b ly r /y l/ bl g b r /y yl g wg /r l/ b br o (black) g /r w (black) l o /w br l/ b ...

  • Page 451: Elec

    9 - 46 – + elec cooling system ebs01085 troubleshooting check: 1. Main, ignition, and radiator fan motor fuses 2. Battery 3. Main switch 4. Radiator fan motor 5. Radiator fan motor relay 6. Radiator fan motor circuit breaker 7. Coolant temperature sensor 8. Wiring connections (the entire cooling sys...

  • Page 452: Elec

    9 - 47 – + elec cooling system ebs01086 yes no yes no 4. Radiator fan motor • disconnect the radiator fan motor coupler from the wire harness. • connect the battery (12 v) as shown. Positive battery lead → blue 1 negative battery lead → black 2 • does the radiator fan motor turn? The radiator fan mo...

  • Page 453: Elec

    9 - 48 – + elec cooling system yes no 6. Radiator fan motor circuit breaker • remove the radiator fan motor circuit breaker from the wire harness. Note: the radiator fan motor circuit breaker 1 is attached to the wire harness with black tape near the tail/brake light connectors 2. • connect the pock...

  • Page 454: Elec

    9 - 49 – + elec cooling system ebs00812 yes no ebs01090 yes no 7. Coolant temperature sensor • remove the coolant temperature sensor from the cylinder head. • connect the pocket tester ( Ω × 100) to the coolant temperature sensor 1 as shown. • immerse the coolant temperature sensor in a container fi...

  • Page 455: Elec

    9 - 50 – + elec fuel pump system fuel pump system circuit diagram g /y g /y y /w g /y b b /lg y bl lb br r /b (gray) r /br /w (gray) pb g w /b br l/ w g /y (green) b /l (gray) w l/ y b /l lw b /l g y b yg b g y b yg b b lg l/ b ly r /y l/ bl g b r /y yl g wg /r l/ b br o (black) g /r w (black) l o /...

  • Page 456: Elec

    9 - 51 – + elec troubleshooting check: 1. Main, ignition, and fuel injection system fuses 2. Battery 3. Main switch 4. Engine stop switch 5. Fuel injection system relay 6. Fuel pump 7. Wiring connections (the entire fuel pump system) note: _ • before troubleshooting, remove the following part(s): 1....

  • Page 457: Elec

    9 - 52 – + elec fuel pump system yes no yes no yes no 5. Fuel injection system relay • remove the fuel injection system relay from the wire harness. • connect the pocket tester ( Ω × 1) and bat- tery (12 v) to the fuel injection system relay terminal as shown. • check the fuel injection system relay...

  • Page 458: Elec

    9 - 53 – + elec 2wd/4wd selecting system ebs00535 2wd/4wd selecting system circuit diagram g /y g /y y /w g /y b b /lg y bl lb br r /b (gray) r /br /w (gray) pb g w /b br l/ w g /y (green) b /l (gray) w l/ y b /l lw b /l g y b yg b g y b yg b b lg l/ b ly r /y l/ bl g b r /y yl g wg /r l/ b br o (bl...

  • Page 459: Elec

    9 - 54 – + elec 2wd/4wd selecting system ebs01095 troubleshooting check: 1. Main and four-wheel-drive motor fuses 2. Battery 3. Main switch 4. Four-wheel-drive motor relay 1 5. Four-wheel-drive motor relay 2 6. Four-wheel-drive motor relay 3 7. On-command four-wheel-drive motor switch and differenti...

  • Page 460: Elec

    9 - 55 – + elec 2wd/4wd selecting system ebs01096 yes no ebs01097 yes no 4. Four-wheel-drive motor relay 1 • remove the four-wheel-drive motor relay 1 from the wire harness. • connect the pocket tester ( Ω × 1) and the battery (12 v) to the four-wheel-drive motor relay 1 terminals. Positive tester p...

  • Page 461: Elec

    9 - 56 – + elec 2wd/4wd selecting system ebs01098 yes no ebs01092 yes no 6. Four-wheel-drive motor relay 3 • remove the four-wheel-drive motor relay 3 from the wire harness. • connect the pocket tester ( Ω × 1) and the battery (12 v) to the four-wheel-drive motor relay 3 terminals. Positive battery ...

  • Page 462: Elec

    9 - 57 – + elec 2wd/4wd selecting system yes no ebs01094 yes no 8. Differential gear motor • disconnect the differential gear motor cou- pler. • remove the differential gear motor from the differential gear case. Refer to “front constant velocity joints and differential gear” in chapter 7. • connect...

  • Page 463: Elec

    9 - 58 – + elec eps (electric power steering) system ebs00532 eps (electric power steering) system circuit diagram g /y g /y y /w g /y b b /lg y bl lb br r /b (gray) r /br /w (gray) pb g w /b br l/ w g /y (green) b /l (gray) w l/ y b /l lw b /l g y b yg b g y b yg b b lg l/ b ly r /y l/ bl g b r /y ...

  • Page 464: Elec

    9 - 59 – + elec eps (electric power steering) system eps control unit’s self-diagnostic function the eps control unit is equipped with a self-diagnostic function. If this function detects a malfunc- tion in the eps system, it lights the eps warning light to alert the rider that a malfunction has occ...

  • Page 465: Elec

    9 - 60 – + elec eps (electric power steering) system eps warning light during normal operation the eps warning light comes on initially for 2 seconds after the main switch is turned to “on”. How- ever, the warning light remains on until the engine is started. In addition, if a malfunction is detecte...

  • Page 466: Elec

    9 - 61 – + elec diagnostic mode setting the diagnostic mode (present and past malfunctions) 1. Turn the main switch to “on”. 2. Disconnect the eps self-diagnosis signal connector 1. Note: do not disconnect the eps self-diagnosis sig- nal connector before turning the main switch to “on”. 3. Select th...

  • Page 467: Elec

    9 - 62 – + elec eps (electric power steering) system identifying fault codes when the diagnostic mode is activated, the fault codes determined by the fail-safe specifications are signaled by the eps warning light as follows. • present malfunction signaling mode: currently detected fault codes are si...

  • Page 468: Elec

    9 - 63 – + elec eps (electric power steering) system deleting fault codes to delete fault codes, ground the eps self-diagnosis signal connector 3 or more times within 5 sec- onds while the present or past malfunction mode is activated. The currently selected mode remains active after the fault codes...

  • Page 469: Elec

    9 - 64 – + elec eps (electric power steering) system self-diagnostic function table (eps system) fault code no. Item symptom probable cause of malfunction 11 13 15 16 eps torque sensor no normal signals are received from the torque sensor. • open or short circuit in wire harness. • malfunction in to...

  • Page 470: Elec

    9 - 65 – + elec eps (electric power steering) system troubleshooting details (eps system) note: the malfunction history is stored even if the main switch is turned to “off”, therefore, be sure to erase the history (present and past malfunction signaling modes) after repairing the cause of the eps sy...

  • Page 471: Elec

    9 - 66 – + elec eps (electric power steering) system fault code no. 21 symptom speed sensor: open or short circuit detected. Order item/components and probable cause check or maintenance job reinstatement method 1 connections • speed sensor coupler • eps control unit coupler at the wire harness • ch...

  • Page 472: Elec

    9 - 67 – + elec eps (electric power steering) system fault code no. 41, 42, 43, 45 symptom eps motor: open or short circuit detected. Order item/components and probable cause check or maintenance job reinstatement method 1 connections • eps motor coupler • check the coupler for any pins that may hav...

  • Page 473: Elec

    9 - 68 – + elec eps (electric power steering) system fault code no. 54 symptom relay contacts in the eps control unit are welded together. Order item/components and probable cause check or maintenance job reinstatement method 1 malfunction in eps control unit. Replace the eps control unit. Turning t...

  • Page 474: Elec

    9 - 69 – + elec eps (electric power steering) system checking the eps motor 1. Remove: • eps unit 2. Check: • eps motor out of specification → replace. Note: the pocket tester and the analog pocket tester readings are shown in the following table. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a....

  • Page 475: Elec

    9 - 70 – + elec eps (electric power steering) system ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 1k) to the eps torque sensor coupler terminal as shown. B. Measure the eps torque sensor resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ pocket test...

  • Page 476: 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 477: 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 478: 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 479: Trbl

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

  • Page 480: Trbl

    10 - 5 trbl shtg faulty clutch performance/ overheating/overcooling/faulty brake 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 • worn primary sl...

  • Page 481: Trbl

    10 - 6 trbl shtg shock absorber malfunction/ unstable handling/lighting system ebs00551 shock absorber malfunction malfunction • bent or damaged damper rod • damaged oil seal lip • fatigued shock absorber spring ebs00552 unstable handling unstable handling handlebar • improperly installed or bent st...

  • Page 482: Trbl

    10 - 7 trbl shtg.

  • Page 483

    Yfm7fgpw 2007 wiring diagram 1 crankshaft position sensor 2 ac magneto 3 rectifier/regulator 4 main switch 5 frame ground 6 main fuse 7 eps fuse 8 battery 9 fuel injection system fuse 0 starter relay a starter motor b eps torque sensor c eps motor d eps (electric power steering) control unit e eps s...

  • Page 484

    Yamaha motor co., ltd. 2500 shingai iwata shizuoka japan printed in u.S.A..

  • Page 485

    Yfm7fgpw 2007 wiring diagram g/y b b/l gy b l l b br r/b (gray) r/b r/w (gray) p b g w/b br l/w g/y (green) b/l (gray) w l/y b/l l w b/l g y b y g b g y b y g b b lg l/b l y r/y l/b lg b r/y y l g w g/r l/b br o (black) g/r w (black) l o/w br l/b w w w (gray) b r (black) r (gray) br/l b (black) br/l...