1. DL manuals
  2. Yamaha
  3. Offroad Vehicle
  4. Grizzly550
  5. User Manual

Yamaha Grizzly550 User Manual

Manual is about: ATV

Summary of Grizzly550

  • Page 2

    Information layout in the bookmarks to the left you will find the information divided into different color coded segments: primary information this is the core information for this vehicle. Use this segment as your major point of reference and information. Supplementary information (if available) th...

  • Page 3

    Eas20100 symbols the following symbols are used in this manual for easier understanding. Tip the following symbols are not relevant to every vehicle. G m e b ls m 9 10 11 12 13 14 15 16 17 18 lt new bf s t r . . 1 2 3 4 5 6 7 8 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Spec...

  • Page 5: Table of Contents

    Eas20110 table of contents general information 1 specifications 2 periodic checks and adjustments 3 chassis 4 engine 5 cooling system 6 fuel system 7 drive train 8 electrical system 9 troubleshooting 10 techsparkstudio.Com.

  • Page 7: General Information

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

  • Page 8: Identification

    Identification 1-1 eas20130 identification eas20140 vehicle identification number the vehicle identification number “1” is stamped into the front left side of the frame. Eas20150 model label the model label “1” is affixed to the location shown in the illustration. This information will be needed to ...

  • Page 9: Features

    Features 1-2 eas20170 features eas28p1031 outline of the fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor s...

  • Page 10: Features

    Features 1-3 eas28p1032 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 kgf/cm², 46.1 psi). Accordingly, when the energizing signal from the ecu energizes the...

  • Page 11: Features

    Features 1-4 techsparkstudio.Com.

  • Page 12: Features

    Features 1-5 eas28p1033 outline of the eps (electric power steering) system (yfm5fgp/yfm7fgp only) 1 2 3 d a e f 4 5 6 8 7 c b.

  • Page 13: Features

    Features 1-6 notice eca28p1027 to prevent accidental damage to the eps unit, it must not be disassembled. 1. Speed information from speed sensor 2. Engine starting rpm information from ecu 3. Battery 4. Steering stem 5. Eps control unit 6. Eps motor 7. Torque sensor 8. Eps unit a. Operates steering ...

  • Page 14: Features

    Features 1-7 eas28p1034 eps (electric power steering) system block diagram (yfm5fgp/yfm7fgp only) 1 2 4 5 18 7 8 9 12 11 6 13 14 17 16 15 10 3.

  • Page 15: Features

    Features 1-8 1. Eps unit 2. Torque sensor 3. Eps motor 4. Eps control unit 5. Battery 6. Engine rpm signal 7. Coolant temperature sensor signal 8. Crankshaft position sensor signal 9. Speed sensor signal 10. Ecu (engine control unit) 11. Intake air temperature sensor signal 12. Throttle position sen...

  • Page 16: Features

    Features 1-9 eas28p1035 instrument functions multifunction display the multifunction display is equipped with the following: • a speedometer (which shows the riding speed) • an odometer (which shows the total distance traveled) • two tripmeters (which show the distance trav- eled since they were las...

  • Page 17: Features

    Features 1-10 self-diagnosis device this model is equipped with a self-diagnosis de- vice for various electrical circuits. If any of those circuits are defective, the multi- function display will indicate a two-digit fault code. If the multifunction display indicates such a fault code, note the code...

  • Page 18: Important Information

    Important information 1-11 eas20180 important information eas20190 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 equip- ment. Refer to “special tools” on page 1-14. 3. When disasse...

  • Page 19: Important Information

    Important information 1-12 eas20230 bearings and oil seals install bearings “1” and oil seals “2” so that the manufacturer marks or numbers are visible. When installing oil seals “2”, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, ...

  • Page 20: Checking The Connections

    Checking the connections 1-13 eas20250 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 disconnect sev- e...

  • Page 21: Special Tools

    Special tools 1-14 eas20260 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers o...

  • Page 22: Special Tools

    Special tools 1-15 compression gauge 90890-03081 engine compression tester yu-33223 3-9 extension 90890-04082 3-9 oil filter wrench 90890-01426 yu-38411 3-11 belt tension gauge 90890-03170 rear drive belt tension gauge ym-03170 3-28 ring nut wrench 90890-01268 spanner wrench yu-01268 3-31, 3-32 ball...

  • Page 23: Special Tools

    Special tools 1-16 weight 90890-01084 yu-01083-3 5-18 valve spring compressor 90890-04019 ym-04019 5-22, 5-27 valve spring compressor attachment 90890-01243 valve spring compressor adapter (26 mm) ym-01253-1 5-22, 5-27 valve guide remover (ø6) 90890-04064 valve guide remover (6.0 mm) ym-04064-a 5-23...

  • Page 24: Special Tools

    Special tools 1-17 piston pin puller set 90890-01304 piston pin puller yu-01304 5-29 sheave holder 90890-01701 primary clutch holder ys-01880-a 5-36, 5-37, 5-38, 5-50, 5-54 flywheel puller 90890-01362 heavy duty puller yu-33270-b 5-36 yamaha bond no. 1215 90890-85505 (three bond no.1215®) 5-38, 5-66...

  • Page 25: Special Tools

    Special tools 1-18 locknut wrench 90890-01348 ym-01348 5-50, 5-53 sheave spring compressor 90890-04134 ym-04134 5-50, 5-53 universal clutch holder 90890-04086 ym-91042 5-58, 5-59 crankcase separating tool 90890-01135 crankcase separator yu-01135-b 5-70 tool name/tool no. Illustration reference pages...

  • Page 26: Special Tools

    Special tools 1-19 crankshaft installer pot 90890-01274 installing pot yu-90058 5-72 crankshaft installer bolt 90890-01275 bolt yu-90060 5-72 adapter (m16) 90890-04130 adapter #13 ym-04059 5-72 spacer (crankshaft installer) 90890-04081 pot spacer ym-91044 5-72 spacer 90890-01309 pot spacer yu-90059 ...

  • Page 27: Special Tools

    Special tools 1-20 bearing retainer wrench 90890-04128 middle gear bearing retainer ym-04128 5-83, 5-84 ring nut wrench 90890-01430 ym-38404 5-83, 5-84 final gear backlash band 90890-01511 middle drive gear lash tool ym-01230 5-86, 8-29 radiator cap tester 90890-01325 radiator pressure tester yu-244...

  • Page 28: Special Tools

    Special tools 1-21 middle driven shaft bearing driver 90890-04058 bearing driver 40 mm ym-04058 6-9 pressure gauge 90890-03153 yu-03153 7-7 fuel pressure adapter 90890-03176 ym-03176 7-7 boots band installation tool 90890-01526 ym-01526 8-9, 8-11, 8-22, 8-24 ring gear fix bolt (m10) 90890-01527 ym-0...

  • Page 29: Specifications

    2 specifications general specifications ........................................................................ 2-1 engine specifications ............................................................................ 2-2 chassis specifications ............................................................

  • Page 30: General Specifications

    General specifications 2-1 eas29110 general specifications model model 28p1, 28p5 (yfm5fgy) 34d1, 34d5, 34d8 (yfm5fgpy) 5c0a, 5c0c (yfm7fgy) 43p1, 43p5, 43p8, 43pa (yfm7fgpy) dimensions overall length 2065 mm (81.3 in) overall width 1180 mm (46.5 in) overall height 1240 mm (48.8 in) seat height 905 ...

  • Page 31: Engine Specifications

    Engine specifications 2-2 eas29120 engine specifications engine engine type liquid cooled 4-stroke, sohc displacement 558.0 cm³ (yfm5fgy/yfm5fgpy) 686.0 cm³ (yfm7fgy/yfm7fgpy) cylinder arrangement forward-inclined single cylinder bore × stroke 92.0 × 84.0 mm (3.62 × 3.31 in) (yfm5fgy/yfm5fgpy) 102.0...

  • Page 32: Engine Specifications

    Engine specifications 2-3 oil filter oil filter type cartridge (paper) oil pump oil pump type trochoid inner-rotor-to-outer-rotor-tip clearance less than 0.12 mm (0.0047 in) limit 0.20 mm (0.0079 in) outer-rotor-to-oil-pump-housing clearance 0.090–0.170 mm (0.0035–0.0067 in) limit 0.24 mm (0.0094 in...

  • Page 33: Engine Specifications

    Engine specifications 2-4 camshaft lobe dimensions intake a 43.488–43.588 mm (1.7121–1.7161 in) limit 43.388 mm (1.7082 in) intake b 36.959–37.059 mm (1.4551–1.4590 in) limit 36.859 mm (1.4511 in) exhaust a 43.129–43.229 mm (1.6980–1.7019 in) limit 43.029 mm (1.6941 in) exhaust b 37.007–37.107 mm (1...

  • Page 34: Engine Specifications

    Engine specifications 2-5 valve face width b (exhaust) 2.26 mm (0.0890 in) valve seat width c (intake) 1.00–1.20 mm (0.0394–0.0472 in) limit 1.60 mm (0.0630 in) valve seat width c (exhaust) 1.00–1.20 mm (0.0394–0.0472 in) limit 1.60 mm (0.0630 in) valve margin thickness d (intake) 0.80–1.20 mm (0.03...

  • Page 35: Engine Specifications

    Engine specifications 2-6 spring rate k1 (intake) 34.18 n/mm (3.49 kgf, 195.16 lbf) spring rate k2 (intake) 44.14 n/mm (4.50 kgf, 252.04 lbf) spring rate k1 (exhaust) 34.18 n/mm (3.49 kgf, 195.16 lbf) spring rate k2 (exhaust) 44.14 n/mm (4.50 kgf, 252.04 lbf) installed compression spring force (inta...

  • Page 36: Engine Specifications

    Engine specifications 2-7 limit 22.971 mm (0.9044 in) piston-pin-to-piston-pin-bore clearance 0.004–0.024 mm (0.0002–0.0009 in) limit 0.0740 mm (0.0029 in) piston ring top ring ring type barrel dimensions (b × t) 1.20 × 3.50 mm (0.05 × 0.14 in) (yfm5fgy/yfm5fgpy) 1.20 × 3.80 mm (0.05 × 0.15 in) (yfm...

  • Page 37: Engine Specifications

    Engine specifications 2-8 runout limit c 0.030 mm (0.0012 in) big end side clearance d 0.350–0.650 mm (0.0138–0.0256 in) balancer balancer drive method gear automatic centrifugal clutch clutch type wet, centrifugal automatic clutch shoe thickness 1.5 mm (0.06 in) limit 1.0 mm (0.04 in) clutch-in rev...

  • Page 38: Engine Specifications

    Engine specifications 2-9 fuel pump pump type electrical model/manufacturer 3b4/denso throttle body type/quantity 40eis/1 manufacturer mikuni id mark 28p1 00 (yfm5fgy/yfm5fgpy) 43p1 00 (yfm7fgy/yfm7fgpy) throttle valve size #50 fuel injector model/quantity 297510–1010/1 manufacturer denso idling con...

  • Page 39: Chassis Specifications

    Chassis specifications 2-10 eas29130 chassis specifications chassis frame type steel tube frame caster angle 5.0° camber angle 0.0° kingpin angle 11.0° kingpin offset 0.0 mm (0.00 in) trail 26.0 mm (1.02 in) tread rear (std) 915.0 mm (36.02 in) tread front (std) 940.0 mm (37.01 in) toe-in (with tire...

  • Page 40: Chassis Specifications

    Chassis specifications 2-11 front brake type dual disc brake operation right hand operation front brake lever free play (lever end) 0 mm (0 in) front disc brake disc outside diameter × thickness 220.0 × 3.5 mm (8.66 × 0.14 in) brake disc thickness limit 3.0 mm (0.12 in) brake disc deflection limit 0...

  • Page 41: Chassis Specifications

    Chassis specifications 2-12 spring preload adjusting positions minimum 1 standard 3 maximum 5 rear suspension type double wishbone spring/shock absorber type coil spring/oil damper wheel travel 230 mm (9.1 in) rear shock absorber assembly travel 109.2 mm (4.30 in) spring free length 318.1 mm (12.52 ...

  • Page 42: Electrical Specifications

    Electrical specifications 2-13 eas29140 electrical specifications voltage system voltage 12 v ignition system ignition system tci (digital) advancer type digital ignition timing (b.T.D.C.) 5.0°/1600 r/min engine control unit model/manufacturer f8t83872/mitsubishi (yfm5fgy/yfm5fgpy) f8t83874/mitsubis...

  • Page 43: Electrical Specifications

    Electrical specifications 2-14 headlight bulb type halogen bulb bulb voltage, wattage × quantity headlight 12 v, 35.0/35.0 w × 2 tail/brake light 12 v, 5.0/21.0 w × 1 meter lighting el indicator and warning lights neutral indicator light led reverse indicator light led coolant temperature warning li...

  • Page 44: Electrical Specifications

    Electrical specifications 2-15 headlight relay model/manufacturer g8hn-1c4t-dj/omron coil resistance 94.5–115.5 Ω four-wheel-drive motor relay 3 model/manufacturer acm33211/matsushita coil resistance 86.4–105.6 Ω four-wheel-drive motor relay 1, 2 model/manufacturer g8hn-1c4t-dj/omron coil resistance...

  • Page 45: Tightening Torques

    Tightening torques 2-16 eas20320 tightening torques eas20330 general tightening torque specifications this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapt...

  • Page 46: Tightening Torques

    Tightening torques 2-17 eas20340 engine tightening torques item thread size q’ty tightening torque remarks exhaust pipe nut m8 4 14 nm (1.4 m·kg, 10 ft·lb) muffler bolt m8 1 20 nm (2.0 m·kg, 14 ft·lb) muffler and muffler bracket bolt m8 2 20 nm (2.0 m·kg, 14 ft·lb) spark arrester bolt m6 3 10 nm (1....

  • Page 47: Tightening Torques

    Tightening torques 2-18 oil check bolt m8 1 10 nm (1.0 m·kg, 7.2 ft·lb) cylinder head air bleed bolt m6 1 10 nm (1.0 m·kg, 7.2 ft·lb) camshaft sprocket bolt m7 2 20 nm (2.0 m·kg, 14 ft·lb) decompression assembly bolt m7 2 20 nm (2.0 m·kg, 14 ft·lb) valve adjusting screw locknut m6 4 14 nm (1.4 m·kg,...

  • Page 48: Tightening Torques

    Tightening torques 2-19 tip 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). Cylinder head tightening sequence: middle drive pinion gear nut m22 1 190 nm (19.0 m·kg, 140 ft·lb) stake. Middle drive shaft bearing hous- ing bolt m...

  • Page 49: Tightening Torques

    Tightening torques 2-20 eas20350 chassis tightening torques item thread size q’ty tightening torque remarks engine mounting bolt (front lower side) m10 2 42 nm (4.2 m·kg, 30 ft·lb) engine mounting bolt (front upper side) m6 2 10 nm (1.0 m·kg, 7.2 ft·lb) engine mounting bolt (rear lower side) m10 2 4...

  • Page 50: Tightening Torques

    Tightening torques 2-21 front fender bolt m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) rear carrier bolt m8 4 34 nm (3.4 m·kg, 24 ft·lb) rear carrier bolt m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) rear carrier bracket bolt m10 4 53 nm (5.3 m·kg, 38 ft·lb) rear fender bolt m6 4 7 nm (0.7 m·kg, 5.1 ft·lb) front wheel nut m1...

  • Page 51: Tightening Torques

    Tightening torques 2-22 stabilizer holder bolt m8 4 30 nm (3.0 m·kg, 22 ft·lb) handlebar holder bolt m8 4 20 nm (2.0 m·kg, 14 ft·lb) front brake master cylinder hold- er bolt m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) rear brake master cylinder hold- er bolt m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) front brake lever pi...

  • Page 52: Tightening Torques

    Tightening torques 2-23 differential gear oil drain bolt m10 1 10 nm (1.0 m·kg, 7.2 ft·lb) differential case cover bolt m8 5 24 nm (2.4 m·kg, 17 ft·lb) differential motor bolt m6 3 11 nm (1.1 m·kg, 8.0 ft·lb) front drive shaft yoke nut (differ- ential case side) m14 1 62 nm (6.2 m·kg, 45 ft·lb) fina...

  • Page 53

    Lubrication points and lubricant types 2-24 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips bearings o-rings cylinder head bolts crankshaft pin connecting rod big end thrust surface crankshaft sprocket inner race (crankshaft) buffer boss (cra...

  • Page 54

    Lubrication points and lubricant types 2-25 shift drum shift forks and shift fork guide bar ball (shift drum stopper) stopper lever and stopper lever shaft shift lever 2 inner surface shift lever 1 shift lever 1 gear teeth and shift lever 2 gear teeth stopper lever stopper bearing (final drive pinio...

  • Page 55

    Lubrication points and lubricant types 2-26 techsparkstudio.Com.

  • Page 56

    Lubrication system chart and diagrams 2-27 eas20390 lubrication system chart and diagrams eas20410 lubrication diagrams a-a a 1 2 1 3 4 5 7 6 3 a.

  • Page 57

    Lubrication system chart and diagrams 2-28 1. Oil delivery pipe 1 2. Oil delivery pipe 2 3. Oil filter cartridge 4. Oil strainer 5. Drive axle 6. Relief valve assembly 7. Reverse idle gear shaft techsparkstudio.Com.

  • Page 58

    Lubrication system chart and diagrams 2-29 1 2 3 4 5.

  • Page 59

    Lubrication system chart and diagrams 2-30 1. Camshaft 2. Crankshaft 3. Oil strainer 4. Oil pump rotor 5. Oil pump driven gear techsparkstudio.Com.

  • Page 60: Cooling System Diagrams

    Cooling system diagrams 2-31 eas20420 cooling system diagrams 1 2 3 8 7 6 5 4.

  • Page 61: Cooling System Diagrams

    Cooling system diagrams 2-32 1. Coolant reservoir hose 2. Radiator inlet hose 3. Coolant reservoir 4. Water pump 5. Water pump outlet pipe 6. Water pump outlet hose 7. Radiator outlet hose 8. Radiator techsparkstudio.Com.

  • Page 62: Cable Routing

    Cable routing 2-33 eas20430 cable routing a-a b-b c-c d-d a a b b c c d d a b c d i e f g h j k l m n o p q r s t t u 1 2 1 2 1 2 3 4 8 9 8 9 5 6 7 8 9 10 10 11 11 11 12 13 14 15 16.

  • Page 63: Cable Routing

    Cable routing 2-34 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 light switch lead 10....

  • Page 64: Cable Routing

    Cable routing 2-35 a-a b-b b-b c-c c-c d d c c b b a a a b c d e f g h i j k k l m n n n o p q q r r 1 1 4 5 5 1 2 3 4 5 6 7 8 9 9 10 11 12 13 13 k k 1 1 4 13 13 11 12 10 13 14 15 15 16 17 18 19 ‚.

  • Page 65: Cable Routing

    Cable routing 2-36 1. Coolant reservoir hose 2. Radiator fan motor breather hose 3. Differential case breather hose 4. Eps motor breather hose (yfm5fgp/yfm7fgp only) 5. Ground lead 6. Coolant reservoir breather hose 7. Throttle cable 8. Fuel injector lead 9. Fuel tank drain hose 10. Final drive case...

  • Page 66: Cable Routing

    Cable routing 2-37 a-a b-b d-d e-e e-e f-f g-g c c b b g g a f f d d e e a a b c d e f g h i j k l m n o p q r s t u 1 1 4 4 5 5 6 6 9 1 2 3 4 5 6 7 8 8 9 10 12 13 r 13 13 14 17 18 19 20 20 11 12 13 14 15 16 17 18 19 20 24 25 26 27 21 22 23 24 25 27 8.

  • Page 67: Cable Routing

    Cable routing 2-38 1. Wire harness 2. Fuel hose 3. Intake air temperature sensor lead 4. Final drive case breather hose 5. Ground lead 6. Starter motor lead 7. Air filter case breather hose 8. Coolant temperature sensor lead 9. Throttle body breather hose 10. Main switch lead 11. Auxiliary dc jack l...

  • Page 68: Cable Routing

    Cable routing 2-39 a a b b c c a-a b-b c-c a c d e e f b 1 1 2 2 3 3 3 4 5 5 6 6 7 8.

  • Page 69: Cable Routing

    Cable routing 2-40 1. Tail/brake light lead 2. Rectifier/regulator lead 3. Ac magneto lead 4. Speed sensor lead 5. Final drive case breather hose 6. Fuel hose 7. Fuel pump lead 8. Wire harness a. To tail/brake light b. Fasten the tail/brake light lead to the frame with plastic locking ties, making s...

  • Page 70: Cable Routing

    Cable routing 2-41 a-a b-b a b b c d e g h i j 1 4 5 6 7 3 2 9 6 5 7 7 9 8 10 11 11 12 13 14 15 16 32 22 33 34 a a b b k l m n o p q r f 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 31 32 33.

  • Page 71: Cable Routing

    Cable routing 2-42 1. Left headlight lead 2. Four-wheel-drive motor relay 1 3. Four-wheel-drive motor relay 2 4. Headlight relay 5. Battery 6. Ecu (engine control unit) 7. Negative battery lead 8. Right headlight lead 9. Eps (electric power steering) control unit (yfm5fgp/yfm7fgp only) 10. Radiator ...

  • Page 72: Cable Routing

    Cable routing 2-43 a-a b-b c-c b c d e g f h h i j a l k 1 1 2 3 4 5 6 7 8 9 10 11 11 10 12 13 14 14 15 16 17 18 18 19 20 b a a c c b.

  • Page 73: Cable Routing

    Cable routing 2-44 1. Throttle cable 2. Rear brake hose 3. Rear brake cable 4. Front brake hose 5. Negative battery lead 6. Final drive case breather hose 7. Starter motor lead 8. Throttle body breather hose 9. Intake air pressure sensor lead 10. Tps lead 11. Intake air temperature sensor lead 12. F...

  • Page 74: Cable Routing

    Cable routing 2-45 a c d b b b b e e b-b e-e c d a 1 2 2 2 3 3 a b b c c d e e f 4 4 4.

  • Page 75: Cable Routing

    Cable routing 2-46 1. Front brake pipe 2. Rear brake pipe 3. Front brake hose 4. Rear brake hose a. Pass the front brake hose through the holder. B. Fasten the front brake hose with the holder. C. Pass the rear brake pipe through the holder. D. Fasten the rear brake pipe with the holder. E. Pass the...

  • Page 76: Cable Routing

    Cable routing 2-47.

  • Page 77

    3 periodic checks and adjustments periodic maintenance ............................................................................ 3-1 introduction ....................................................................................... 3-1 periodic maintenance chart for the emission control system ...

  • Page 78

    Chassis ....................................................................................................... 3-20 adjusting the front disc brake................................................ 3-20 adjusting the rear disc brake .................................................. 3-20 checking the ...

  • Page 79

    Techsparkstudio.Com.

  • Page 80: Periodic Maintenance

    Periodic maintenance 3-1 eas20450 periodic maintenance eas20460 introduction this chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a long- er service life and re...

  • Page 81: Periodic Maintenance

    Periodic maintenance 3-2 4 * brake hoses • check for cracks or other damage, and replace if necessary. √ √ √ √ • replace. Every 4 years 5 * rear brake hose pro- tectors • check for wear, cracks or other damage, and replace if necessary. √ √ √ √ √ 6 * wheels • check runout and for damage, and replace...

  • Page 82: Periodic Maintenance

    Periodic maintenance 3-3 ebu23070 tip • 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 components of the brake master cy...

  • Page 83: Engine

    Engine 3-4 eas20472 engine eas20520 adjusting the valve clearance the following procedure applies to all of the valves. Tip • valve clearance adjustment should be made on a cold engine, at room temperature. • when the valve clearance is to be measured or adjusted, the piston must be at top dead cent...

  • Page 84: Engine

    Engine 3-5 out of specification → adjust. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 7. Adjust: • valve clearance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen the locknut “1”. B. Insert a thickness gauge “2” between the end of the adjusting screw and the valve tip. C. Turn the ...

  • Page 85: Engine

    Engine 3-6 eas20660 adjusting the throttle lever free play 1. Check: • throttle lever free play “a” out of specification → adjust. 2. Remove: • left side panel refer to “general chassis” on page 4-1. 3. Adjust: • throttle lever free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ throttle bod...

  • Page 86: Engine

    Engine 3-7 2. Adjust: • speed limiter length “a” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen the locknut “1”. B. Turn the adjuster “2” in direction “b” or “c” until the specified speed limiter length is obtained. C. Tighten the locknut. Warning ewa14880 • particularly for a beginner ...

  • Page 87: Engine

    Engine 3-8 10.Install: • right side panel refer to “general chassis” on page 4-1. Eas20700 checking the ignition timing tip prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure all connections are tight and free of corrosion. 1. Remove: • left ...

  • Page 88: Engine

    Engine 3-9 notice eca28p1041 before removing the spark plug, use com- pressed air to blow away any dirt accumulat- ed in the spark plug well to prevent it from falling into the cylinder. 6. Attach: • extension “1” • compression gauge “2” 7. Measure: • compression pressure out of specification → refe...

  • Page 89: Engine

    Engine 3-10 notice eca28p1009 do not allow foreign materials to enter the crankcase. Tip to obtain an accurate oil level reading, the dip- stick must be inserted completely into the oil fil- ter hole. Notice eca28p1004 • engine oil also lubricates the clutch and the wrong oil types or additives coul...

  • Page 90: Engine

    Engine 3-11 6. Drain: • engine oil (completely from the crankcase) 7. If the oil filter cartridge is also to be replaced, perform the following procedure. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the oil filter cartridge “1” with an oil filter wrench “2”. B. Lubricate the o-ring “...

  • Page 91: Engine

    Engine 3-12 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas20951 cleaning the air filter element 1. Remove: • fuel tank cover • left side panel • right side panel refer to “general chassis” on page 4-1. Tip there are two check hoses “1” at the bottom of the air filter case. If dust and/or wate...

  • Page 92: Engine

    Engine 3-13 6. Apply the recommended oil to the entire sur- face of the air filter element and then carefully pat the air filter element on a clean cloth to re- move the excess oil. The air filter element should be wet but not dripping. 7. Install: • air filter element frame • air filter element • a...

  • Page 93: Engine

    Engine 3-14 c. Install the v-belt. Tip install the v-belt so that its arrow faces the direc- tion shown in the illustration. D. Remove the bolts. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas21020 checking the throttle body joint 1. Remove: • left side panel refer to “general chassis” on pag...

  • Page 94: Engine

    Engine 3-15 • left side panel refer to “general chassis” on page 4-1. Eas21080 checking the exhaust system 1. Check: • exhaust pipe “1” • muffler “2” • exhaust pipe protector “3” • muffler bracket “4” • springs “5” cracks/damage → replace. • gaskets “6” exhaust gas leaks → replace. 2. Check: • tight...

  • Page 95: Engine

    Engine 3-16 g. Start the engine and rev it up approximately twenty times while momentarily creating ex- haust system back pressure by blocking the end of the muffler with a shop towel. H. Stop the engine and allow the exhaust pipe to cool. I. Install the purging bolt and tighten it. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ...

  • Page 96: Engine

    Engine 3-17 3. Install: • left footrest board • front fenders refer to “general chassis” on page 4-1. Eas21130 changing the coolant 1. Remove: • right side panel • left side panel • front carrier • upper panel refer to “general chassis” on page 4-1. 2. Remove: • coolant reservoir cap “1” 3. Disconne...

  • Page 97: Engine

    Engine 3-18 8. Drain: • coolant (from the engine and radiator) 9. Check: • coolant drain bolt “1” damage → replace. 10.Install: • copper washer “2” • coolant drain bolt 11.Fill: • cooling system (with the specified amount of the recom- mended coolant) handling notes for coolant coolant is potentiall...

  • Page 98: Engine

    Engine 3-19 b. Loosen the water pump air bleed bolt “2”, without removing it, to allow all of the air to es- cape from the air bleed bolt hole. C. When coolant begins to flow out of the bolt hole, tighten the water pump air bleed bolt to specification. D. Loosen the cylinder head air bleed bolt “3”,...

  • Page 99: Chassis

    Chassis 3-20 eas29360 chassis eas21170 adjusting the front disc brake 1. Check: • front brake lever free play “a” out of specification → bleed the front brake system. Refer to “bleeding the hydraulic brake system” on page 3-23. Eas29180 adjusting the rear disc brake warning ewa14890 always adjust bo...

  • Page 100: Chassis

    Chassis 3-21 h. Adjust the drive select lever control cable. Refer to “adjusting the drive select lever control cable and shift rod” on page 3-24. Warning ewa14900 after this adjustment is performed, lift the front and rear wheels off the ground by plac- ing a block under the engine, and spin the re...

  • Page 101: Chassis

    Chassis 3-22 1. Remove: • front wheels refer to “front wheels” on page 4-14. 2. Operate the brake. 3. Check: • front brake pads a wear indicator groove “a” has almost disap- peared → replace the brake pads and brake pad spring as a set. Refer to “front brake” on page 4-21. 4. Install: • front wheels...

  • Page 102: Chassis

    Chassis 3-23 2. Check: • brake hose holders loose → tighten the clamp bolt. 3. Apply the brake several times. 4. Check: • brake hoses brake fluid leakage → replace any damaged hose. Refer to “rear brake” on page 4-32. Eas28p1007 checking the rear brake hose protectors the following procedure applies...

  • Page 103: Chassis

    Chassis 3-24 d. Place the other end of the hose into a con- tainer. E. Slowly apply the brake several times. F. Fully pull the brake lever or fully press down the brake pedal and hold it in position. G. Loosen the bleed screw. Tip loosening the bleed screw will release the pres- sure and cause the b...

  • Page 104: Chassis

    Chassis 3-25 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ drive select lever shift control cable: a. Make sure that the drive select lever is in “n” (neutral). B. Squeeze the brake lever 20 mm (0.79 in) “a”, loosen the locknut “1”, and then adjust the shift control cable “2” with the adjuster “...

  • Page 105: Chassis

    Chassis 3-26 4. Install: • final gear oil level check bolt eas21470 changing the final gear oil 1. Place the vehicle on a level surface. 2. Place a container under the final drive case. 3. Remove: • final gear oil filler bolt “1” 4. Remove: • final gear oil level check bolt • final gear oil drain bo...

  • Page 106: Chassis

    Chassis 3-27 4. Install: • differential gear oil filler bolt eas29260 changing the differential gear oil 1. Place the vehicle on a level surface. 2. Place a receptacle under the differential case. 3. Remove: • differential gear oil filler bolt • differential gear oil drain bolt “1” completely drain ...

  • Page 107: Chassis

    Chassis 3-28 eas29280 checking the steering system 1. Place the vehicle on a level surface. 2. Check: • steering assembly bushings move the handlebar up and down, and back and forth. Excessive play → replace the steering stem bushings. 3. Check: • tie-rod ends free play → replace the tie-rod end. ▼▼...

  • Page 108: Chassis

    Chassis 3-29 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 7. Adjust: (yfm5fgp/yfm7fgp only) • steering tension ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the electrical components tray. Refer to “general chassis” on page 4-1. B. Loosen the steering stem bracket bolts “1”, steer...

  • Page 109: Chassis

    Chassis 3-30 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Adjust: • toe-in warning ewa14910 • be sure that both tie-rods are turned the same amount. If not, the vehicle will drift right or left even though the handlebar is positioned straight. This may lead to mis- handling and an accident. ...

  • Page 110: Chassis

    Chassis 3-31 refer to “front arms and front shock absorber assemblies” on page 4-59. 3. Check: • operation pump the front shock absorber assembly up and down several times. Rough operation → replace front shock ab- sorber assembly. Refer to “front arms and front shock absorber assemblies” on page 4-...

  • Page 111: Chassis

    Chassis 3-32 eas29330 adjusting the rear shock absorber assemblies the following procedure applies to both of the rear shock absorber assemblies. Warning ewa14930 always adjust the spring preload for both rear shock absorber assemblies to the same setting. Uneven adjustment can cause poor handling a...

  • Page 112: Chassis

    Chassis 3-33 • use no more than the following pressures when seating the tire beads. Front 250 kpa (2.5 kgf/cm², 36 psi) rear 250 kpa (2.5 kgf/cm², 36 psi) higher pressures and fast inflation may cause a tire to burst. Inflate the tires very slowly and carefully. Maximum loading limit warning ewa149...

  • Page 113: Chassis

    Chassis 3-34 tip the arrow mark “1” on the tire must point in the direction of wheel rotation. Eas29350 checking the wheels the following procedure applies to all of the wheels. 1. Check: • wheel “1” damage/bends → replace. Warning ewa14990 • never attempt even small repairs to the wheel. • ride con...

  • Page 114: Electrical System

    Electrical system 3-35 eas21750 electrical system eas21760 checking and charging the battery refer to “electrical components” on page 9-75. Eas21770 checking the fuses refer to “electrical components” on page 9-75. Eas21790 replacing the headlight bulbs the following procedure applies to both of the...

  • Page 115: Electrical System

    Electrical system 3-36 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ direction “a” headlight beam is raised. Direction “b” headlight beam is lowered. A b 1 techsparkstudio.Com.

  • Page 116: Electrical System

    Electrical system 3-37.

  • Page 117: Chassis

    4 chassis general chassis....................................................................................... 4-1 installing the rear fender........................................................... 4-6 installing the footrest boards............................................... 4-12 front whee...

  • Page 118

    Handlebar ................................................................................................ 4-44 removing the handlebar.............................................................. 4-46 checking the handlebar .............................................................. 4-46 install...

  • Page 119

    Techsparkstudio.Com.

  • Page 120: General Chassis

    General chassis 4-1 eas21830 general chassis removing the engine skid plates order job/parts to remove q’ty remarks 1 front engine skid plate 1 2 center engine skid plate 1 3 rear engine skid plate 1 for installation, reverse the removal proce- dure. 1 2 3 7 nm (0.7 m • kg, 5.1 ft • ib) t.R. T r . ....

  • Page 121: General Chassis

    General chassis 4-2 removing the seat and side panels order job/parts to remove q’ty remarks 1 seat 1 tip 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 panel 1 6 dipstick accessing panel 1 for installation, r...

  • Page 122: General Chassis

    General chassis 4-3 removing the front carrier and front guard order job/parts to remove q’ty remarks front engine skid plate refer to “removing the engine skid plates”. 1 front carrier 1 2 front carrier bracket 2 3 battery holding bracket 1 4 battery lead 2 disconnect. Notice eca28p1013 first disco...

  • Page 123: General Chassis

    General chassis 4-4 removing the front fenders and front grill order job/parts to remove q’ty remarks seat/side panels refer to “removing the seat and side pan- els”. Front carrier/front guard refer to “removing the front carrier and front guard”. 1 front fender inner panel 2 2 auxiliary dc jack cou...

  • Page 124: General Chassis

    General chassis 4-5 removing the rear carrier and rear fender order job/parts to remove q’ty remarks seat/side panels refer to “removing the seat and side pan- els”. 1 rear carrier 1 2 rear carrier bracket 2 3 storage compartment 1 4 tail/brake light cover 1 5 tail/brake light connector 3 disconnect...

  • Page 125: General Chassis

    General chassis 4-6 eas28p1002 installing the rear fender 1. Install: • rear fender tip the bolts may be tightened to the specified torque in any tightening sequence. However, in- stall the front bolts “1” and tighten them tempo- rarily before installing the rear bolts “2”. T r . . Rear fender bolt ...

  • Page 126: General Chassis

    General chassis 4-7 removing the electrical components tray 1/2 order job/parts to remove q’ty remarks front fender/front grill refer to “removing the front fenders and front grill”. 1 battery holding bracket 1 2 battery lead 2 disconnect. Notice eca28p1013 first disconnect the negative battery lead...

  • Page 127: General Chassis

    General chassis 4-8 13 ecu bracket 1 14 radiator fan motor coupler 1 disconnect. For installation, reverse the removal proce- dure. Removing the electrical components tray 1/2 order job/parts to remove q’ty remarks 7 nm (0.7 m • kg, 5.1 ft • ib) t.R. 7 nm (0.7 m • kg, 5.1 ft • ib) t.R. 6 7 8 3 11 12...

  • Page 128: General Chassis

    General chassis 4-9 removing the electrical components tray 2/2 order job/parts to remove q’ty remarks 1 starter relay coupler 1 disconnect. 2 starter relay 1 3 fuse box 1 4 eps fuse 1 yfm5fgp/yfm7fgp only 5 main fuse 1 6 spare fuse 1 7 radiator fan motor relay 1 8 fuel injection system relay 1 9 fo...

  • Page 129: General Chassis

    General chassis 4-10 18 differential motor coupler 1 disconnect. 19 wire harness 1 20 electrical components tray 1 for installation, reverse the removal proce- dure. Removing the electrical components tray 2/2 order job/parts to remove q’ty remarks 4 3 2 18 1 5 6 12 17 13 20 16 15 (4) 19 14 7 8 9 10...

  • Page 130: General Chassis

    General chassis 4-11 removing the footrest boards order job/parts to remove q’ty remarks seat/side panels refer to “removing the seat and side pan- els”. 1 footrest 2 2 footrest board 2 3 footrest bracket 2 for installation, reverse the removal proce- dure. (4) (5) 1 (4) 1 2 3 2 3 (4) (4) (5) (5) (5...

  • Page 131: General Chassis

    General chassis 4-12 eas28p1003 installing the footrest boards the following procedure applies to both of the footrest boards. 1. Install: • footrest board tip tighten the footrest board bolts to the specified torque in the proper tightening sequence as shown. 2. Install: • footrest tip install the ...

  • Page 132: General Chassis

    General chassis 4-13 removing the air filter case order job/parts to remove q’ty remarks seat/side panels refer to “removing the seat and side pan- els”. 1 air filter case cover 1 2 air filter element 1 3 air filter element frame 1 4 intake air temperature sensor coupler 1 disconnect. 5 air filter c...

  • Page 133: Front Wheels

    Front wheels 4-14 eas21870 front wheels removing the front wheels and brake discs order job/parts to remove q’ty remarks the following procedure applies to both of the front wheels. Place the vehicle on a level surface. 1 front wheel 1 2 wheel cap 1 3 front wheel axle nut 1 4 front brake caliper ass...

  • Page 134: Front Wheels

    Front wheels 4-15 eas21890 removing the front wheels 1. Place the vehicle on a level surface. 2. Elevate: • front wheels tip place the vehicle on a suitable stand so that the front wheels are elevated. 3. Remove: • front brake calipers tip do not apply the brake lever when removing the brake caliper...

  • Page 135: Front Wheels

    Front wheels 4-16 eas28p1009 installing the front brake discs the following procedure applies to both of the front brake discs. 1. Install: • brake disc tip install the brake disc so that the recessed por- tion of the bolt hole faces away from the hub. Eas28p1010 installing the front wheel hubs the ...

  • Page 136: Front Wheels

    Front wheels 4-17.

  • Page 137: Rear Wheels

    Rear wheels 4-18 eas22020 rear wheels removing the rear wheels and brake discs order job/parts to remove q’ty remarks the following procedure applies to both of the rear wheels. Place the vehicle on a level surface. 1 rear wheel 1 2 wheel cap 1 3 rear wheel axle nut 1 4 rear brake caliper assembly 1...

  • Page 138: Rear Wheels

    Rear wheels 4-19 eas22040 removing the rear wheels 1. Place the vehicle on a level surface. 2. Elevate: • rear wheels tip place the vehicle on a suitable stand so that the rear wheels are elevated. 3. Remove: • rear brake calipers tip do not apply the brake lever and depress the brake pedal when rem...

  • Page 139: Rear Wheels

    Rear wheels 4-20 2. Check: • brake disc refer to “checking the rear brake discs” on page 4-38. Eas28p1014 installing the rear wheels the following procedure applies to both of the rear wheels. 1. Install: • wheel tip the arrow mark “1” on the tire must point in the direction of wheel rotation. 2. Ti...

  • Page 140: Front Brake

    Front brake 4-21 eas22210 front brake removing the front brake pads order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. Front wheel refer to “front wheels” on page 4-14. 1 front brake caliper bolt 2 2 brake pad holding bolt plug 1 3 brake pad h...

  • Page 141: Front Brake

    Front brake 4-22 removing the front brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-23. On-command four-wheel-drive motor switch and differential gear lock switch refer to “handlebar” on page 4-44. 1 brake fluid...

  • Page 142: Front Brake

    Front brake 4-23 disassembling the front brake master cylinder order job/parts to remove q’ty remarks 1 dust boot 1 2 circlip 1 3 brake master cylinder kit 1 4 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure. 3 2 1 4 new new s fwd.

  • Page 143: Front Brake

    Front brake 4-24 removing the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. Brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-23. Front wheel refer to “front wheels” on page 4-14. 1 union bol...

  • Page 144: Front Brake

    Front brake 4-25 disassembling the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. 1 brake pad holding bolt 1 2 brake pad 2 3 brake pad spring 1 4 brake caliper bracket 1 5 brake caliper piston 1 6 brake caliper dust se...

  • Page 145: Front Brake

    Front brake 4-26 eas22220 introduction warning ewa14100 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the...

  • Page 146: Front Brake

    Front brake 4-27 d. Measure the brake disc deflection. E. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. F. If the brake disc deflection cannot be brought within specification, replace the brake disc. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ...

  • Page 147: Front Brake

    Front brake 4-28 tip before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • brake caliper piston “1” • brake caliper dust seal “2” • brake caliper piston seal “3” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Blow compressed air into the brake...

  • Page 148: Front Brake

    Front brake 4-29 • whenever a brake caliper is disassembled, replace the brake caliper piston seal and dust seal. Eas22440 installing the front brake calipers the following procedure applies to both of the brake calipers. 1. Install: • brake caliper assembly • brake caliper bolts “1” • brake hose “2...

  • Page 149: Front Brake

    Front brake 4-30 4. Check: • brake hoses cracks/damage/wear → replace. Eas22520 assembling the front brake master cylinder warning ewa28p1008 • before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • never use solvents on internal brake ...

  • Page 150: Front Brake

    Front brake 4-31 c. Fit the hole “b” in the front brake lever cover over the nut. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) warning ewa13540 • use only the designated brake fluid. Other br...

  • Page 151: Rear Brake

    Rear brake 4-32 eas22550 rear brake removing the rear brake pads order job/parts to remove q’ty remarks the following procedure applies to both of the rear brake calipers. Rear wheel refer to “rear wheels” on page 4-18. 1 rear brake caliper bolt 2 2 brake pad holding bolt plug 1 3 brake pad holding ...

  • Page 152: Rear Brake

    Rear brake 4-33 removing the rear brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-23. 1 brake fluid reservoir cap 1 2 brake fluid reservoir diaphragm holder 1 3 brake fluid reservoir diaphragm 1 4 rear brake lev...

  • Page 153: Rear Brake

    Rear brake 4-34 15 rear brake master cylinder 1 for installation, reverse the removal proce- dure. Removing the rear brake master cylinder order job/parts to remove q’ty remarks s s 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 • ...

  • Page 154: Rear Brake

    Rear brake 4-35 disassembling the rear brake master cylinder order job/parts to remove q’ty remarks 1 dust boot 1 2 circlip 1 3 brake master cylinder kit 1 4 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure. 3 2 1 4 new new s.

  • Page 155: Rear Brake

    Rear brake 4-36 removing the rear brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the rear brake calipers. Brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-23. Rear wheel refer to “rear wheels” on page 4-18. 1 union bolt 1 2...

  • Page 156: Rear Brake

    Rear brake 4-37 disassembling the rear brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the rear brake calipers. 1 brake pad holding bolt 1 2 brake pad 2 3 brake pad spring 1 4 brake caliper bracket 1 5 brake caliper piston 1 6 brake caliper dust seal ...

  • Page 157: Rear Brake

    Rear brake 4-38 eas22560 introduction warning ewa14100 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the ...

  • Page 158: Rear Brake

    Rear brake 4-39 tip always install new brake pads and a brake pad spring as a set. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. B. Loosen the bleed screw and push the brake ...

  • Page 159: Rear Brake

    Rear brake 4-40 b. Remove the brake caliper dust seal and brake caliper piston seal. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas22640 checking the rear brake calipers the following procedure applies to both of the brake calipers. 1. Check: • brake caliper piston “1” rust/scratches/wear → r...

  • Page 160: Rear Brake

    Rear brake 4-41 notice eca28p1014 when installing the brake hose onto the brake caliper, make sure the brake pipe touches the projection “a” on the brake cali- per. 2. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) warning ewa13090 • use only the...

  • Page 161: Rear Brake

    Rear brake 4-42 tip • align the end of the brake master cylinder hold- er with the punch mark “a” on the handlebar. • install the brake master cylinder holder with the “up” mark “b” facing up. • install the brake master cylinder holder so that the gaps between the brake master cylinder and the brake...

  • Page 162: Rear Brake

    Rear brake 4-43 notice eca13540 brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 6. Bleed: • brake system refer to “bleeding the hydraulic brake system” on page 3-23. 7. Check: • brake fluid level below the minimum level mark → ...

  • Page 163: Handlebar

    Handlebar 4-44 eas22840 handlebar removing the handlebar order job/parts to remove q’ty remarks 1 handlebar cover 1 2 plastic band 4 3 on-command four-wheel-drive motor switch and differential gear lock switch 1 4 throttle lever assembly holder 1 5 throttle lever assembly 1 6 front brake light switc...

  • Page 164: Handlebar

    Handlebar 4-45 15 handlebar 1 for installation, reverse the removal proce- dure. Removing the handlebar order job/parts to remove q’ty remarks 1 11 9 6 14 14 12 13 5 8 3 4 7 10 2 2 15 13 t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib).

  • Page 165: Handlebar

    Handlebar 4-46 eas22860 removing the handlebar 1. Place the vehicle on a level surface. 2. Remove: • handlebar grip “1” tip blow compressed air between the left handlebar end and the handlebar grip, and gradually push the grip off the handlebar. Eas22880 checking the handlebar 1. Check: • handlebar ...

  • Page 166: Handlebar

    Handlebar 4-47 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Install: • left handlebar switch • rear brake master cylinder “1” • rear brake master cylinder holder “2” tip • align the end of the brake master cylinder hold- er with the punch mark “a” on the handlebar. • the “up” mark “b” on the...

  • Page 167: Steering Stem

    Steering stem 4-48 eas29540 steering stem removing the steering stem (for yfm5fg/yfm7fg) order job/parts to remove q’ty remarks front fender/air filter case/electrical compo- nents tray refer to “general chassis” on page 4-1 handlebar refer to “handlebar” on page 4-44 1 lock washer 1 2 cable guide 1...

  • Page 168: Steering Stem

    Steering stem 4-49 14 circlip 1 15 bearing 1 16 steering stem bracket 1 for installation, reverse the removal proce- dure. Removing the steering stem (for yfm5fg/yfm7fg) order job/parts to remove q’ty remarks 8 13 9 6 7 4 3 3 10 16 5 5 2 1 new new new new new new new lt lt ls (4) t r . . 23 nm (2.3 ...

  • Page 169: Steering Stem

    Steering stem 4-50 removing the steering stem (for yfm5fgp/yfm7fgp) order job/parts to remove q’ty remarks front fender/air filter case/electrical compo- nents tray refer to “general chassis” on page 4-1 handlebar refer to “handlebar” on page 4-44 1 lock washer 1 2 cable guide 1 3 steering stem bush...

  • Page 170: Steering Stem

    Steering stem 4-51 16 steering stem joint 1 17 eps motor breather hose 1 18 eps motor cover 1 19 eps unit 1 notice eca28p1008 the eps unit should not be disassem- bled. 20 steering stem bracket 1 for installation, reverse the removal proce- dure. Removing the steering stem (for yfm5fgp/yfm7fgp) orde...

  • Page 171: Steering Stem

    Steering stem 4-52 eas29560 checking the steering stem 1. Check: • steering stem bends → replace. Warning ewa15030 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: (yfm5fgp/yfm7fgp only) • ...

  • Page 172: Steering Stem

    Steering stem 4-53 • steering stem bolts “13” (temporarily tighten) tip apply lithium-soap-based grease to the oil seals and steering stem bushings. 4. Install: • collar “14” • steering stem joint “15” • steering stem joint bolts “16” (temporarily tighten) tip • apply loctite® to the steering stem j...

  • Page 173: Steering Stem

    Steering stem 4-54 tip align the punch mark “a” on the eps unit with the groove “b” in the pitman arm. 1 b a techsparkstudio.Com.

  • Page 174

    Tie-rods and steering knuckles 4-55 eas29660 tie-rods and steering knuckles removing the tie-rods and steering knuckles order job/parts to remove q’ty remarks the following procedure applies to both of the tie-rods and steering knuckles. Front wheel hub refer to “front wheels” on page 4-14 1 brake d...

  • Page 175

    Tie-rods and steering knuckles 4-56 eas29670 removing the steering knuckles the following procedure applies to both of the steering knuckles. 1. Remove: • steering knuckle “1” tip use a general puller to separate the ball joints “2” from the steering knuckle “1” or the front low- er arm “3”. Eas2968...

  • Page 176

    Tie-rods and steering knuckles 4-57 c. Remove the ball joint “4”. Tip use a ball joint remover “5” to separate the ball joint “4” from the steering knuckle “6”. D. Measure the ball joint bore inside diameter “a”. Out of specification → replace the steering knuckle. E. Attach the ball joint remover/a...

  • Page 177

    Tie-rods and steering knuckles 4-58 i. Install a new circlip. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas29700 installing the tie-rods the following procedure applies to both of the tie-rods. 1. Install: • tie-rod tip install the tie-rod so that the groove “1” is on the wheel side. 2. Adju...

  • Page 178

    Front arms and front shock absorber assemblies 4-59 eas29710 front arms and front shock absorber assemblies removing the front arms and front shock absorber assemblies order job/parts to remove q’ty remarks the following procedure applies to both of the front upper arms, front lower arms, and front ...

  • Page 179

    Front arms and front shock absorber assemblies 4-60 13 bushing 2 14 circlip 1 15 clip 1 16 rubber boot 1 17 ball joint 1 18 bushing 2 for installation, reverse the removal proce- dure. Removing the front arms and front shock absorber assemblies order job/parts to remove q’ty remarks 9 11 18 18 10 10...

  • Page 180

    Front arms and front shock absorber assemblies 4-61 eas29730 checking the front arms the following procedure applies to both of the front upper arms and front lower arms. 1. Check: • front arm free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Check the front arm side play “a” by moving ...

  • Page 181

    Front arms and front shock absorber assemblies 4-62 d. Hold the base “11” in place while turning in the long bolt “5” to remove the ball joint “4” from the front upper arm “12”. E. Remove the ball joint remover/attachment set. F. Attach the ball joint remover/attachment set and new ball joint (with ...

  • Page 182

    Front arms and front shock absorber assemblies 4-63 d. Install the new cotter pins. E. Tighten the front upper and lower arm nuts “4” to specification. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28p1071 installing the front arm protectors the following procedure applies to both of the fron...

  • Page 183: Rear Knuckles and Stabilizer

    Rear knuckles and stabilizer 4-64 eas29800 rear knuckles and stabilizer removing the rear knuckles and stabilizer order job/parts to remove q’ty remarks the following procedure applies to both of the rear knuckles. Rear wheel hub refer to “rear wheels” on page 4-18 1 brake disc guard 1 2 plate 1 3 r...

  • Page 184: Rear Knuckles and Stabilizer

    Rear knuckles and stabilizer 4-65 14 bushing 2 15 stabilizer 1 for installation, reverse the removal proce- dure. Removing the rear knuckles and stabilizer order job/parts to remove q’ty remarks 13 13 14 14 15 5 6 12 1 8 11 10 2 9 8 8 9 8 7 12 3 4 ls ls ls t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r ...

  • Page 185: Rear Knuckles and Stabilizer

    Rear knuckles and stabilizer 4-66 eas29810 checking the rear knuckles and rear wheel bearings the following procedure applies to both of the rear knuckles and rear wheel bearings. 1. Check: • rear knuckle damage/pitting → replace. 2. Check: • rear wheel bearing “1” rough movement/excessive free play...

  • Page 186

    Rear arms and rear shock absorber assemblies 4-67 eas29840 rear arms and rear shock absorber assemblies removing the rear arms and rear shock absorber assemblies order job/parts to remove q’ty remarks the following procedure applies to both of the rear upper arms, rear lower arms, and rear shock abs...

  • Page 187

    Rear arms and rear shock absorber assemblies 4-68 eas29850 checking the rear arms the following procedure applies to both of the rear upper arms and rear lower arms. 1. Check: • rear arm free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Check the rear arm side play “a” by moving it from...

  • Page 188

    Rear arms and rear shock absorber assemblies 4-69 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 7 6, 7 6, 4 3, 5 2 8 8 1.

  • Page 189: Engine

    5 engine engine removal ........................................................................................ 5-1 installing the muffler ................................................................... 5-2 installing the v-belt cooling ducts......................................... 5-2 install...

  • Page 190

    Electric starter ................................................................................... 5-40 checking the starter motor ..................................................... 5-42 assembling the starter motor................................................. 5-43 balancer gears and oil pu...

  • Page 191

    Transmission............................................................................................ 5-73 removing the transmission ........................................................ 5-76 checking the shift forks............................................................. 5-76 checking th...

  • Page 192: Engine Removal

    Engine removal 5-1 eas23710 engine removal removing the v-belt cooling ducts, muffler and exhaust pipe order job/parts to remove q’ty remarks front fender/rear fender/left footrest board/air filter case/meter assembly refer to “general chassis” on page 4-1. 1 v-belt cooling exhaust duct 1 2 v-belt c...

  • Page 193: Engine Removal

    Engine removal 5-2 eas28p1023 installing the muffler 1. Install: • gaskets “1” • exhaust pipe “2” • exhaust pipe nuts “3” 2. Install: • muffler bracket “4” • muffler bracket bolts “5” 3. Install: • gasket “6” • muffler “7” • washer “8” • muffler bolt “9” tip do not fully tighten the muffler bolt. 4....

  • Page 194: Engine Removal

    Engine removal 5-3 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Install: • v-belt cooling exhaust duct joint “1” • v-belt cooling exhaust duct “2” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Position the v-belt cooling exhaust duct joint with its arrow mark “a” pointing toward the e...

  • Page 195: Engine Removal

    Engine removal 5-4 removing the drive select lever unit order job/parts to remove q’ty remarks 1 drive select lever shift rod 1 2 drive select lever unit 1 3 shift arm 1 for installation, reverse the removal proce- dure. 3 2 1 2 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft...

  • Page 196: Engine Removal

    Engine removal 5-5 eas28p1025 installing the drive select lever unit 1. Install: • shift arm “1” • drive select lever unit “2” • drive select lever shift rod “3” tip • make sure that the drive select lever and trans- mission are in “n” (neutral). • the installed length “a” of the shift rod is 413 mm...

  • Page 197: Engine Removal

    Engine removal 5-6 disconnecting the leads, cables and hoses order job/parts to remove q’ty remarks footrest board/air filter case refer to “general chassis” on page 4-1. Throttle body assembly refer to “throttle body” on page 7-4. Fuel tank/fuel tank shield refer to “fuel tank” on page 7-1. Coolant...

  • Page 198: Engine Removal

    Engine removal 5-7 drive belt case refer to “primary and secondary sheaves” on page 5-47. 1 cylinder head breather hose 1 2 coolant temperature sensor coupler 1 disconnect. 3 spark plug cap 1 4 shift control cable 1 disconnect. 5 reverse switch lead 1 disconnect. 6 speed sensor coupler 1 disconnect....

  • Page 199: Engine Removal

    Engine removal 5-8 removing the engine order job/parts to remove q’ty remarks 1 rubber damper nut (front side) 2 2 engine mounting bolt (rear upper side) 2 3 engine mounting bolt (rear lower side) 2 4 engine 1 notice eca28p1024 make sure that the engine does not strike the brake pipe when removing i...

  • Page 200: Engine Removal

    Engine removal 5-9 eas23720 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 (re...

  • Page 201: Cylinder Head

    Cylinder head 5-10 eas24100 cylinder head removing the cylinder head order job/parts to remove q’ty remarks throttle body assembly refer to “throttle body” on page 7-4. Thermostat/coolant temperature sensor refer to “thermostat” on page 6-4. V-belt cooling ducts/exhaust pipe refer to “engine removal...

  • Page 202: Cylinder Head

    Cylinder head 5-11 14 cylinder head gasket 1 15 dowel pin 2 for installation, reverse the removal proce- dure. Removing the cylinder head order job/parts to remove q’ty remarks new new new ls ls e ls new 12 11 ls 4 3 new ls new new m (4) 5 1 2 new 15 14 10 9 8 5 (4) 6 13 7 new e t r . . 10 nm (1.0 m...

  • Page 203: Cylinder Head

    Cylinder head 5-12 eas24130 removing the cylinder head 1. Align: • “i” mark “a” on the ac magneto rotor (with the stationary pointer “b” on the ac magneto cover) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft counterclockwise. B. When the piston is at tdc on the compres- si...

  • Page 204: Cylinder Head

    Cylinder head 5-13 3. Measure: • cylinder head warpage out of specification → resurface the cylinder head. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Place a straightedge “1” and a thickness gauge “2” across the cylinder head. B. Measure the warpage. C. If the limit is exceeded, resurface ...

  • Page 205: Cylinder Head

    Cylinder head 5-14 eas24230 installing the cylinder head 1. Install: • cylinder head gasket • dowel pins 2. Install: • cylinder head • cylinder head bolts cylinder head bolts “1” length: 135 mm (5.31 in) cylinder head bolts “2” length: 145 mm (5.71 in) tip • lubricate the cylinder head bolt “1” and ...

  • Page 206: Cylinder Head

    Cylinder head 5-15 tip install the gasket with its beaded side facing the timing chain tensioner end. D. Install the spring, copper washer and timing chain tensioner cap bolt. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Turn: • crankshaft (several turns counterclockwise) 6. Check: • “i” mar...

  • Page 207: Cylinder Head

    Cylinder head 5-16 8. Measure: • valve clearance out of specification → adjust. Refer to “adjusting the valve clear- ance” on page 3-4. Techsparkstudio.Com.

  • Page 208: Rocker Arms and Camshaft

    Rocker arms and camshaft 5-17 eas28p1027 rocker arms and camshaft removing the rocker arms and camshaft order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-10. 1 bearing retainer 1 2 rocker arm shaft 2 3 intake rocker arm 1 4 exhaust rocker arm 1 5 locknut 4 6 val...

  • Page 209: Rocker Arms and Camshaft

    Rocker arms and camshaft 5-18 eas23770 removing the rocker arms and camshaft 1. Loosen: • locknuts • valve clearance adjusting screws 2. Remove: • intake rocker arm shaft • exhaust rocker arm shaft • intake rocker arm • exhaust rocker arm tip remove the rocker arm shafts with the slide hammer bolt “...

  • Page 210: Rocker Arms and Camshaft

    Rocker arms and camshaft 5-19 eas28p1028 checking the decompression system 1. Check: • decompression system ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Check the decompression system with the camshaft sprocket installed on the decom- pressor lever and pin installed in the cam- shaft. B. Che...

  • Page 211: Rocker Arms and Camshaft

    Rocker arms and camshaft 5-20 tip • apply engine oil to the bearing. • install the bearing so that the seal is facing “a” the camshaft. 2. Lubricate: • camshaft • decompressor lever pin • decompressor lever 3. Install: • decompressor lever pin “1” • decompressor lever “2” tip install the decompresso...

  • Page 212: Valves and Valve Springs

    Valves and valve springs 5-21 eas24270 valves and valve springs removing the valves and valve springs order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-10. Rocker arms/rocker arm shafts/camshaft refer to “rocker arms and cam- shaft” on page 5-17. 1 valve cotter ...

  • Page 213: Valves and Valve Springs

    Valves and valve springs 5-22 eas24280 removing the valves the following procedure applies to all of the valves and related components. Tip before removing the internal parts of the cylinder head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Check: • valve sealin...

  • Page 214: Valves and Valve Springs

    Valves and valve springs 5-23 2. Replace: • valve guide tip to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °c (212 °f) in an oven. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the valve guide with the valve guide remover “1...

  • Page 215: Valves and Valve Springs

    Valves and valve springs 5-24 4. Check: • valve face pitting/wear → grind the valve face. • valve stem end mushroom shape or diameter larger than the body of the valve stem → replace the valve. 5. Measure: • valve margin thickness “a” out of specification → replace the valve. 6. Measure: • valve ste...

  • Page 216: Valves and Valve Springs

    Valves and valve springs 5-25 tip where the valve seat and valve face contacted one another, the blueing will have been re- moved. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Lap: • valve face • valve seat tip after replacing the cylinder head or replacing the valve and valve guide, the val...

  • Page 217: Valves and Valve Springs

    Valves and valve springs 5-26 2. Measure: • compressed valve spring force “a” out of specification → replace the valve spring. 3. Measure: • valve spring tilt “a” out of specification → replace the valve spring. Eas24340 installing the valves the following procedure applies to all of the valves and ...

  • Page 218: Valves and Valve Springs

    Valves and valve springs 5-27 • valve “3” • valve spring “4” • valve spring retainer “5” (into the cylinder head) tip • make sure each valve is installed in its original place. • install the valve springs with the larger pitch “a” facing up. 4. Install: • valve cotters tip install the valve cotters ...

  • Page 219: Cylinder and Piston

    Cylinder and piston 5-28 eas24350 cylinder and piston removing the cylinder and piston order job/parts to remove q’ty remarks cylinder head refer to “cylinder head” on page 5-10. Water jacket joint refer to “water pump” on page 6-7. 1 timing chain guide (exhaust side) 1 2 cylinder 1 3 cylinder gaske...

  • Page 220: Cylinder and Piston

    Cylinder and piston 5-29 eas24380 removing the piston 1. Remove: • piston pin clips “1” • piston pin “2” • piston “3” notice eca13810 do not use a hammer to drive the piston pin out. Tip • before removing the piston pin clips, cover the crankcase opening with a clean rag to prevent the piston pin cl...

  • Page 221: Cylinder and Piston

    Cylinder and piston 5-30 b. If out of specification, replace the cylinder, and replace the piston and piston rings as a set. C. Measure piston skirt diameter d “a” with the micrometer. D. If out of specification, replace the piston and piston rings as a set. E. Calculate the piston-to-cylinder clear...

  • Page 222: Cylinder and Piston

    Cylinder and piston 5-31 2. Install: • piston ring (into the cylinder) tip level the piston ring into the cylinder with the piston crown. 3. Measure: • piston ring end gap out of specification → replace the piston ring. Tip the oil ring expander spacer end gap cannot be measured. If the oil ring rai...

  • Page 223: Cylinder and Piston

    Cylinder and piston 5-32 eas24450 installing the piston and cylinder 1. Install: • lower oil ring rail “1” • oil ring expander “2” • upper oil ring rail “3” • 2nd ring “4” • top ring “5” tip be sure to install the piston rings so that the manufacturer’s marks or numbers face up. 2. Install: • piston...

  • Page 224: Cylinder and Piston

    Cylinder and piston 5-33 8. Tighten: • cylinder bolts “1” • cylinder bolts (timing chain side) “2” t r . . Cylinder bolt 1st 15 nm (1.5 m·kg, 11 ft·lb) 2nd 50 nm (5.0 m·kg, 36 ft·lb) cylinder bolt (timing chain side) 10 nm (1.0 m·kg, 7.2 ft·lb) e e 2 1 1 2.

  • Page 225

    Ac magneto and starter clutch 5-34 eas28p1029 ac magneto and starter clutch removing the ac magneto and starter clutch order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-10. Coolant drain. Refer to “changing the coolant” on page 3-17. Left footrest ...

  • Page 226

    Ac magneto and starter clutch 5-35 9 crankshaft position sensor 1 10 stator coil 1 11 torque limiter 1 12 starter idle gear 1 13 starter idle gear shaft 1 14 ac magneto rotor 1 15 starter clutch 1 16 woodruff key 1 17 starter wheel gear 1 18 washer 1 for installation, reverse the removal proce- dure...

  • Page 227

    Ac magneto and starter clutch 5-36 eas24490 removing the ac magneto rotor 1. Remove: • lead holder “1” • ac magneto cover tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • ac magneto rotor nut “...

  • Page 228

    Ac magneto and starter clutch 5-37 eas28p1038 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. Eas24570 checking the starter clutch 1. Check: • starter clutch rollers ...

  • Page 229

    Ac magneto and starter clutch 5-38 eas28p1068 installing the ac magneto 1. Install: • stator coil “1” tip align the projection “a” on the stator coil with the slot “b” in the ac magneto cover. 2. Apply: • sealant “1” (onto the crankshaft position sensor/stator assembly lead grommet) 3. Install: • wo...

  • Page 230

    Ac magneto and starter clutch 5-39 1.

  • Page 231: Electric Starter

    Electric starter 5-40 eas24780 electric starter removing the starter motor order job/parts to remove q’ty remarks muffler refer to “engine removal” on page 5-1. 1 starter motor lead 1 disconnect. 2 ground lead 1 disconnect. 3 starter motor 1 for installation, reverse the removal proce- dure. 2 3 1 t...

  • Page 232: Electric Starter

    Electric starter 5-41 disassembling the starter motor order job/parts to remove q’ty remarks 1 starter motor front cover 1 2 starter motor rear cover 1 3 brush holder set 1 4 armature assembly 1 5 starter motor yoke 1 for assembly, reverse the disassembly pro- cedure. 1 3 5 4 (4) 2 ls new new new ne...

  • Page 233: Electric Starter

    Electric starter 5-42 eas24790 checking the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpaper. 2. Measure: • mica undercut “a” out of specification → cut the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Tip the mica of the ...

  • Page 234: Electric Starter

    Electric starter 5-43 7. Check: • bearing • oil seal damage/wear → replace the defective part(s). Eas24800 assembling the starter motor 1. Install: • starter motor yoke “1” • starter motor front cover “2” • starter motor rear cover “3” tip align the alignment marks “a” on the starter mo- tor yoke wi...

  • Page 235

    Balancer gears and oil pump gears 5-44 eas28p1040 balancer gears and oil pump gears removing the balancer gears and oil pump gears order job/parts to remove q’ty remarks starter wheel gear refer to “ac magneto and starter clutch” on page 5-34. 1 lock washer 1 2 balancer driven gear 1 3 oil pump driv...

  • Page 236

    Balancer gears and oil pump gears 5-45 eas28p1041 removing the balancer driven gear and oil pump driven gear 1. Straighten the lock washer tabs. 2. Loosen: • balancer driven gear nut “1” • oil pump driven gear nut “2” tip place an aluminum plate “3” between the teeth of the balancer drive gear “4” a...

  • Page 237

    Balancer gears and oil pump gears 5-46 4. Bend the lock washer tabs along the balancer driven gear nut and oil pump driven gear nut. 5 2 3 4 1 techsparkstudio.Com.

  • Page 238

    Primary and secondary sheaves 5-47 eas28p1045 primary and secondary sheaves removing the primary and secondary sheaves order job/parts to remove q’ty remarks front fender/rear fender/right footrest board refer to “general chassis” on page 4-1. V-belt cooling ducts refer to “engine removal” on page 5...

  • Page 239

    Primary and secondary sheaves 5-48 * apply yamaha grizzly grease. Disassembling the primary sheave order job/parts to remove q’ty remarks 1 primary sheave cap 1 2 primary sheave slider 4 3 primary sheave cam 1 4 primary sheave weight 8 5 collar 1 6 oil seal 2 7 primary sliding sheave 1 8 o-ring 1 fo...

  • Page 240

    Primary and secondary sheaves 5-49 * apply bel-ray assembly lube®. Disassembling the secondary sheave order job/parts to remove q’ty remarks 1 nut 1 2 spring seat 1 3 compression spring 1 4 spring seat 1 5 guide pin 4 6 secondary sliding sheave 1 7 o-ring 2 8 secondary fixed sheave 1 9 oil seal 2 fo...

  • Page 241

    Primary and secondary sheaves 5-50 eas28p1046 removing the primary and secondary sheaves 1. Loosen: • secondary sheave nut “1” • primary sheave nut “2” tip • use the sheave holder “3” to hold the primary sheave. • first, loosen the secondary sheave nut “2”, then loosen the primary sheave nut “1”. Ea...

  • Page 242

    Primary and secondary sheaves 5-51 eas24680 checking the primary sheave 1. Check: • primary sliding sheave splines wear/cracks/damage → replace. • primary sheave cam cracks/damage → replace. 2. Check: • primary sliding sheave • primary fixed sheave cracks/damage → replace. Eas24690 checking the prim...

  • Page 243

    Primary and secondary sheaves 5-52 eas24720 assembling the primary sheave 1. Clean: • primary sliding sheave “1” • primary fixed sheave “2” • collar “3” • primary sheave weights “4” • primary sliding sheave cam face tip remove any excess grease. 2. Install: • oil seals “1” 3. Install: • primary shea...

  • Page 244

    Primary and secondary sheaves 5-53 • secondary fixed sheave “2” (with the recommended lubricant) tip apply bel-ray assembly lube® (15 g) to the in- ner surface of the secondary fixed sheave. 3. Install: • secondary sliding sheave 4. Install: • guide pins “1” 5. Lubricate: • guide pin grooves “1” (wi...

  • Page 245

    Primary and secondary sheaves 5-54 eas28p1047 installing the primary and secondary sheaves 1. Install: • secondary sheave • v-belt • primary sheave tip • be sure to push in the primary sheave cam “1” when installing the primary sheave so that the primary sheave weights “2” will be properly po- sitio...

  • Page 246

    Primary and secondary sheaves 5-55.

  • Page 247: Clutch

    Clutch 5-56 eas25061 clutch removing the clutch order job/parts to remove q’ty remarks primary sheave/secondary sheave refer to “primary and secondary sheaves” on page 5-47. 1 clutch housing assembly 1 2 gasket 1 3 dowel pin 2 4 one-way clutch bearing 1 5 nut 1 6 clutch carrier assembly 1 for instal...

  • Page 248: Clutch

    Clutch 5-57 disassembling the clutch housing assembly order job/parts to remove q’ty remarks 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 pro- cedure..

  • Page 249: Clutch

    Clutch 5-58 eas25070 removing the clutch 1. Remove: • clutch housing assembly • gasket • dowel pins tip working in crisscross pattern, loosen each bolt 1/4 of a turn. Remove them after all of them are loosened. 2. Straighten: • punched portion “a” of the nut “1” 3. Remove: • nut “1” notice eca28p103...

  • Page 250: Clutch

    Clutch 5-59 eas28p1037 assembling the clutch housing 1. Install: • bearing “1” 2. Install: • oil seal “1” eas28p1049 installing the clutch 1. Install: • clutch carrier assembly • nut “1” notice eca28p1033 the clutch carrier assembly nut has left- handed threads. To tighten the clutch carrier assembl...

  • Page 251: Clutch

    Clutch 5-60 tip • tighten the bolts in stages, using a crisscross pattern. • after tightening the bolts, check that the clutch housing assembly rotates smoothly. Techsparkstudio.Com.

  • Page 252: Crankcase

    Crankcase 5-61 eas25540 crankcase removing the timing chain and oil filter cartridge order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-1. Cylinder head refer to “cylinder head” on page 5-10. Cylinder/piston refer to “cylinder and piston” on page 5-28. Ac magneto rotor...

  • Page 253: Crankcase

    Crankcase 5-62 7 relief valve assembly 1 8 reverse switch 1 9 gear position switch 1 for installation, reverse the removal proce- dure. Removing the timing chain and oil filter cartridge order job/parts to remove q’ty remarks lt t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 17 nm (1.7 m • kg, 12 ft...

  • Page 254: Crankcase

    Crankcase 5-63 separating the crankcase order job/parts to remove q’ty remarks 1 shift lever cover 1 2 gasket 1 3 dowel pin 1 4 shift lever 1 1 5 shift lever 2 assembly 1 6 shift drum stopper 1 spring identification color: white 7 stopper lever stopper 1 spring identification color: red 8 right cran...

  • Page 255: Crankcase

    Crankcase 5-64 removing the crankcase bearings order job/parts to remove q’ty remarks crankshaft/oil pump refer to “crankshaft and oil pump” on page 5-68. Transmission refer to “transmission” on page 5-73 middle drive shaft/middle driven shaft refer to “middle gear” on page 5-79 1 collar 1 2 o-ring ...

  • Page 256: Crankcase

    Crankcase 5-65 eas25560 separating the crankcase 1. Remove: • crankcase bolts • lead holders tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • right crankcase • dowel pins notice eca13900 tap on...

  • Page 257: Crankcase

    Crankcase 5-66 eas25580 checking the crankcase 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • crankcase cracks/damage → replace. • oil delivery passages obstruction → blow out with compressed air. Eas2...

  • Page 258: Crankcase

    Crankcase 5-67 8. Apply: • 4-stroke engine oil (to the crankshaft pin, bearings and oil deliv- ery hole) 9. Check: • crankshaft and transmission operation rough operation → repair. Eas28p1052 installing the shift lever 1. Install: • shift lever 2 assembly “1” • shift lever 1 “2” tip when installing ...

  • Page 259: Crankshaft and Oil Pump

    Crankshaft and oil pump 5-68 eas28p1053 crankshaft and oil pump removing the crankshaft and oil pump order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-61. 1 oil pump 1 2 gasket 1 3 balancer 1 4 crankshaft 1 for installation, reverse the removal proce- dure. 3 ...

  • Page 260: Crankshaft and Oil Pump

    Crankshaft and oil pump 5-69 disassembling the oil pump order job/parts to remove q’ty remarks 1 oil pump housing cover 1 2 pin 1 3 oil pump shaft 1 4 inner rotor 1 5 outer rotor 1 6 oil pump housing 1 for assembly, reverse the disassembly pro- cedure. E 6 3 2 5 4 1 e t r . . 5 nm (0.5 m • kg, 3.6 f...

  • Page 261: Crankshaft and Oil Pump

    Crankshaft and oil pump 5-70 eas28p1054 removing the crankshaft 1. Remove: • crankshaft “1” tip • remove the crankshaft with the crankcase separating tool “2”. • make sure the crankcase separating tool is centered over the crankshaft. Notice eca28p1029 • to protect the end of the crankshaft, place a...

  • Page 262: Crankshaft and Oil Pump

    Crankshaft and oil pump 5-71 eas24990 checking the oil strainer 1. Check: • oil strainer damage → replace. Contaminants → clean with solvent. Eas28p1055 checking the crankshaft 1. Measure: • crankshaft width a “a” out of specification → replace the crank- shaft. 2. Measure: • crankshaft runout c “b”...

  • Page 263: Crankshaft and Oil Pump

    Crankshaft and oil pump 5-72 3. Check: • oil pump operation refer to “checking the oil pump” on page 5-70. Eas28p1056 installing the crankshaft 1. Install: • crankshaft “1” tip install the crankshaft assembly with the crank- shaft installer pot “2”, crankshaft installer bolt “3”, adapter (m16) “4”, ...

  • Page 264: Transmission

    Transmission 5-73 eas26241 transmission removing the transmission, shift drum and shift forks order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-61 middle driven gear refer to “middle gear” on page 5-79 1 shift drum 1 2 shift fork assembly 1 3 shift fork “r” 1 ...

  • Page 265: Transmission

    Transmission 5-74 disassembling the drive axle assembly order job/parts to remove q’ty remarks 1 washer 1 2 collar 1 3 high wheel gear 1 4 washer 1 5 clutch dog 1 6 circlip 1 7 washer 1 8 collar 1 9 low wheel gear 1 10 washer 1 11 circlip 1 12 middle drive gear 1 13 circlip 1 14 washer 1 15 bearing ...

  • Page 266: Transmission

    Transmission 5-75 18 drive axle 1 for assembly, reverse the disassembly pro- cedure. Disassembling the drive axle assembly order job/parts to remove q’ty remarks m m m m m m m new new new 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 17.

  • Page 267: Transmission

    Transmission 5-76 eas26250 removing the transmission 1. Remove: • shift drum “1” • shift fork assembly “2” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Pull out the guide bar from the left crankcase. B. Push down on the drive shaft, and then slide the shift fork assembly to remove the shift ...

  • Page 268: Transmission

    Transmission 5-77 2. Check: • transmission gears blue discoloration/pitting/wear → replace the defective gear(s). • transmission gear dogs cracks/damage/rounded edges → replace the defective gear(s). 3. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) incorrect →...

  • Page 269: Transmission

    Transmission 5-78 tip install the shift forks “6” with the “l” mark “a” and “r” mark “b” facing towards the left and right sides of the crankcase respectively. 2. Check: • shift operation rough operation → repair. Tip • oil each gear and bearing thoroughly. • before assembling the crankcase, make su...

  • Page 270: Middle Gear

    Middle gear 5-79 eas25710 middle gear removing the middle drive shaft order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-61. 1 bearing housing 1 2 middle drive pinion gear nut 1 3 middle drive pinion gear 1 4 middle drive pinion gear shim refer to “aligning the...

  • Page 271: Middle Gear

    Middle gear 5-80 removing the middle driven shaft order job/parts to remove q’ty remarks crankcase separate. Refer to “crankcase” on page 5-61. 1 front drive shaft yoke nut (middle gear side) 1 2 front drive shaft yoke (middle gear side) 1 3 middle driven pinion gear assembly 1 4 rear drive shaft yo...

  • Page 272: Middle Gear

    Middle gear 5-81 15 middle driven shaft 1 for installation, reverse the removal proce- dure. Removing the middle driven shaft order job/parts to remove q’ty remarks.

  • Page 273: Middle Gear

    Middle gear 5-82 eas28p1062 removing the middle drive shaft 1. Straighten: • punched portion of the middle drive pinion gear nut 2. Loosen: • middle drive pinion gear nut “1” tip wrap the middle drive shaft in a folded rag, and then secure it in a vise. 3. Remove: • middle drive pinion gear nut • mi...

  • Page 274: Middle Gear

    Middle gear 5-83 • install a suitable socket “2” on the middle driven pinion gear end to protect the thread from damage. C. Press the middle driven pinion gear end and remove the bearing housing. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Remove: • middle driven pinion gear bearing retaine...

  • Page 275: Middle Gear

    Middle gear 5-84 • bearings pitting/damage → replace. Eas28p1065 installing the bearing and oil seals 1. Install: • bearing “1” • oil seal “2” • oil seal “3” eas28p1066 installing the middle driven shaft 1. Install: • middle driven shaft bearing retainer “1” tip attach the ring nut wrench “2”. Notic...

  • Page 276: Middle Gear

    Middle gear 5-85 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • middle driven pinion gear shim(s) “1” • bearing housing tip install the shim(s) so that the tabs are positioned as shown in the illustration. 4. Install: • rear drive shaft yoke (middle gear side) “1” • washer • rear dr...

  • Page 277: Middle Gear

    Middle gear 5-86 2. Tighten: • bearing retainer bolts “1” • middle drive pinion gear nut “2” tip wrap the middle drive shaft in a folded rag, and then secure it in a vise. 3. Lock the threads with a drift punch. Tip stake the bearing retainer bolts at the cutouts “a” in the bearing retainers “3”. Ea...

  • Page 278: Middle Gear

    Middle gear 5-87 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). ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas25930 aligning the middle gear tip aligning the middle gear is necessary when any of the following ...

  • Page 279: Middle Gear

    Middle gear 5-88 therefore, “a” is 1.40. “a” = 9.01 + 64.97 - 17.0 - 55.0 - 0.58 = 1.40 round off hundredths digit and select appro- priate shim(s). In the above example, the calculated shim thickness is 1.40 mm. The following chart in- structs you, however, to round off 0 to 0. Shims are supplied i...

  • Page 280: Middle Gear

    Middle gear 5-89 if the left crankcase is marked “99.99”, “i” is 99.99 if the right crankcase is marked “8.17”, “j” is 8.17 therefore, “b” is 0.72. “b” = 77.53 - 49.0 + 80.40 - 99.99 - 8.17 - 0.05 = 0.72 round off hundredth digit and select appro- priate shim(s). In the example above, the calculated...

  • Page 281: Cooling System

    6 cooling system radiator ...................................................................................................... 6-1 checking the radiator.................................................................... 6-3 installing the radiator.....................................................

  • Page 282: Radiator

    Radiator 6-1 eas26380 radiator removing the radiator order job/parts to remove q’ty remarks front fenders/front guard/left footrest board/air filter case refer to “general chassis” on page 4-1. Coolant drain. Refer to “changing the coolant” on page 3-17. 1 radiator fan motor coupler 1 disconnect. 2 ...

  • Page 283: Radiator

    Radiator 6-2 11 radiator fan 1 for installation, reverse the removal proce- dure. Removing the radiator order job/parts to remove q’ty remarks 11 (4) 10 9 7 6 5 4 8 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) techsparkstudio.Com.

  • Page 284: Radiator

    Radiator 6-3 eas26390 checking the radiator 1. Check: • radiator fins obstruction → clean. Apply compressed air to the rear of the radia- tor. Damage → repair or replace. Tip straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: • radiator hoses cracks/damage → replace. 3. Meas...

  • Page 285: Thermostat

    Thermostat 6-4 eas26440 thermostat removing the thermostat order job/parts to remove q’ty remarks air filter case refer to “general chassis” on page 4-1. V-belt cooling exhaust duct/v-belt cooling intake duct refer to “engine removal” on page 5-1. Coolant drain. Refer to “changing the coolant” on pa...

  • Page 286: Thermostat

    Thermostat 6-5 eas26450 checking the thermostat 1. Check: • thermostat does not open at 50–54 °c (122–129.2 °f) → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Suspend the thermostat “1” in a container “2” filled with water. B. Slowly heat the water “3”. C. Place a thermometer “4” in...

  • Page 287: Thermostat

    Thermostat 6-6 5. Measure: • radiator cap opening pressure below the specified pressure → replace the radiator cap. Refer to “checking the radiator” on page 6-3. Techsparkstudio.Com.

  • Page 288: Water Pump

    Water pump 6-7 eas26500 water pump removing the water pump order job/parts to remove q’ty remarks left footrest board/left front fender refer to “general chassis” on page 4-1. Ac magneto cover refer to “ac magneto and starter clutch” on page 5-34. Coolant drain. Refer to “changing the coolant” on pa...

  • Page 289: Water Pump

    Water pump 6-8 11 bearing 1 12 oil seal 1 for installation, reverse the removal proce- dure. Removing the water pump order job/parts to remove q’ty remarks 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)...

  • Page 290: Water Pump

    Water pump 6-9 eas26510 disassembling the water pump 1. Remove: • water pump seal “1” tip remove the water pump seal from the inside of the ac magneto cover “2”. 2. Remove: • bearing “1” • oil seal “2” tip remove the bearing and oil seal from the out- side of the ac magneto cover “3”. Eas26540 check...

  • Page 291: Water Pump

    Water pump 6-10 3. Measure: • impeller shaft tilt out of specification → replace. 4. Install: • impeller shaft “1” • circlip tip after installation, check that the impeller shaft ro- tates smoothly. 3. Mechanical seal installer 4. Middle driven shaft bearing driver a. Push down. Impeller shaft tilt ...

  • Page 292: Water Pump

    Water pump 6-11.

  • Page 293: Fuel System

    7 fuel system fuel tank..................................................................................................... 7-1 removing the fuel tank .................................................................. 7-2 removing the fuel pump .........................................................

  • Page 294: Fuel Tank

    Fuel tank 7-1 eas26620 fuel tank removing the fuel tank order job/parts to remove q’ty remarks rear fender refer to “general chassis” on page 4-1. 1 fuel tank side cover 1 2 fuel pump coupler 1 disconnect. 3 fuel hose connector holder 1 4 fuel hose 1 5 fuel tank breather hose 2 6 fuel tank breather ...

  • Page 295: Fuel Tank

    Fuel tank 7-2 eas26630 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 notice eca28p1019 • be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. • although ...

  • Page 296: Fuel Tank

    Fuel tank 7-3 eas28p1021 installing the fuel tank 1. Install: • dampers “1” tip fit the projections on each damper into the 3rd and 4th holes in the frame. Determine the 3rd and 4th holes by counting outward from the cen- ter hole in the frame. 2. Install: • fuel hose • fuel hose connector holder “1...

  • Page 297: Throttle Body

    Throttle body 7-4 eas26970 throttle body removing the throttle body order job/parts to remove q’ty remarks air filter case refer to “general chassis” on page 4-1. 1 intake air pressure sensor coupler 1 disconnect. 2 throttle position sensor coupler 1 disconnect. 3 throttle body breather hose 1 4 isc...

  • Page 298: Throttle Body

    Throttle body 7-5 disassembling the throttle body assembly order job/parts to remove q’ty remarks 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 throttle body 1 notice eca28p1021 the throttle body should not ...

  • Page 299: Throttle Body

    Throttle body 7-6 eas28p1036 removing the throttle body assembly 1. Disconnect: • fuel hose notice eca28p1022 • 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 ...

  • Page 300: Throttle Body

    Throttle body 7-7 eas27010 checking the fuel pressure 1. Check: • fuel pressure ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the rear fender. Refer to “general chassis” on page 4-1. B. Remove the fuel hose connector holder. C. Disconnect the fuel hose “1” from the fuel pump. Tip • whe...

  • Page 301: Throttle Body

    Throttle body 7-8 c. Turn the main switch to “on”. D. Measure the throttle position sensor voltage. E. Adjust the throttle position sensor angle so that the voltage is within the specified range. F. After adjusting the throttle position sensor an- gle, tighten the throttle position sensor screws “3”...

  • Page 302: Throttle Body

    Throttle body 7-9.

  • Page 303: Drive Train

    8 drive train troubleshooting..................................................................................... 8-1 checking noises ................................................................................. 8-1 troubleshooting chart ............................................................

  • Page 304: Troubleshooting

    Troubleshooting 8-1 eas29890 troubleshooting the following conditions may indicate damaged shaft drive components: tip areas a, b, and c above may be extremely difficult to diagnose. The symptoms are quite subtle and difficult to distinguish from normal vehicle operating noise. If there is reason to...

  • Page 305: Troubleshooting

    Troubleshooting 8-2 • always clean the vehicle and recheck the sus- pected location of an apparent leakage. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas29910 troubleshooting chart when basic conditions (a) and (b) exist, check the following points: yes → no ↓ no → yes ↓ no → yes ↓ no → yes ...

  • Page 306

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shaft 8-3 eas29920 front constant velocity shaft assemblies, differential assembly and front drive shaft removing the front constant velocity shaft assemblies, differential assembly and front drive shaft order job/part...

  • Page 307

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shaft 8-4 8 front drive shaft coupling sleeve 1 9 dust seal 1 10 dust seal 1 for installation, reverse the removal proce- dure. Removing the front constant velocity shaft assemblies, differential assembly and front dri...

  • Page 308

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shaft 8-5 disassembling the front constant velocity shaft assemblies order job/parts to remove q’ty remarks the following procedure applies to both of the front constant velocity shaft assemblies. 1 clip 1 2 boot band ...

  • Page 309

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shaft 8-6 a: wheel side b: differential side 14 constant velocity shaft 1 for assembly, reverse the disassembly pro- cedure. Disassembling the front constant velocity shaft assemblies order job/parts to remove q’ty rem...

  • Page 310

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shaft 8-7 disassembling the differential assembly order job/parts to remove q’ty remarks tip do not disassemble the differential motor or remove the differential motor pinion gear. 1 differential motor 1 2 o-ring 1 3 f...

  • Page 311

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shaft 8-8 15 bearing 1 16 oil seal 2 17 differential case 1 for assembly, reverse the disassembly pro- cedure. Disassembling the differential assembly order job/parts to remove q’ty remarks t r . . 62 nm (6.2 m • kg, 4...

  • Page 312

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shaft 8-9 eas29930 disassembling the front constant velocity shaft assemblies the following procedure applies to both of the front constant velocity shaft assemblies. 1. Remove: • boot bands • clip “1” • double offset ...

  • Page 313

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shaft 8-10 eas29990 assembling the front constant velocity shaft assemblies the following procedure applies to both of the front constant velocity shaft assemblies. 1. Install: • clip “1” • constant velocity joint “2” ...

  • Page 314

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shaft 8-11 • the dust boots should be fastened with the boot bands “3” and “5” at the grooves in the constant velocity shaft. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the dust boots. B. Install the ...

  • Page 315

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shaft 8-12 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect two c-size batteries to the differen- tial motor terminals “1” (as shown in the illus- trations). Notice eca28p1018 • do not use a 12 v battery to...

  • Page 316

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shaft 8-13 d. Remove the 6 mm bolts, and then install the motor with the differential motor bolts. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Check: • differential assembly operation unsmooth operation → repl...

  • Page 317

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shaft 8-14 b. Measure the differential gear backlash again. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ techsparkstudio.Com.

  • Page 318

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-15 eas30050 rear constant velocity shaft assemblies, final drive assembly and rear drive shaft removing the rear constant velocity shaft assemblies, final drive assembly and rear drive shaft order job/parts to remov...

  • Page 319

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-16 10 dust seal 1 for installation, reverse the removal proce- dure. Removing the rear constant velocity shaft assemblies, final drive assembly and rear drive shaft order job/parts to remove q’ty remarks 1 3 10 8 9 ...

  • Page 320

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-17 disassembling the rear constant velocity shaft assemblies order job/parts to remove q’ty remarks the following procedure applies to both of the rear constant velocity shaft assemblies. 1 clip 1 2 boot band 1 3 bo...

  • Page 321

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-18 a: wheel side b: final drive side 14 constant velocity shaft 1 for assembly, reverse the disassembly pro- cedure. Disassembling the rear constant velocity shaft assemblies order job/parts to remove q’ty remarks t...

  • Page 322

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-19 disassembling the final drive assembly order job/parts to remove q’ty remarks 1 final drive pinion gear assembly 1 2 final drive pinion gear shim refer to “selecting the final drive pinion gear shim(s)” on page 8...

  • Page 323

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-20 13 final driven pinion gear 1 14 thrust washer refer to “selecting the final driven pinion gear shim (final drive case side) and thrust washer” on page 8-26. 15 final driven pinion gear shim (final drive case sid...

  • Page 324

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-21 26 expander 1 27 washer 1 28 bearing 1 29 final drive pinion gear bearing housing 1 for assembly, reverse the disassembly pro- cedure. Disassembling the final drive assembly order job/parts to remove q’ty remarks...

  • Page 325

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-22 eas30060 disassembling the rear constant velocity shaft assemblies the following procedure applies to both of the rear constant velocity shaft assemblies. 1. Remove: • boot bands • clip “1” • double offset joint ...

  • Page 326

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-23 eas30070 assembling the rear constant velocity shaft assemblies the following procedure applies to both of the rear constant velocity shaft assemblies. 1. Install: • clip “1” • constant velocity joint “2” • const...

  • Page 327

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-24 • the dust boots should be fastened with the boot bands “3” and “5” at the grooves in the constant velocity shaft. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the dust boots. B. Install the dust ...

  • Page 328

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-25 eas28p1019 assembling the final drive case 1. Install: • oil seals “1” eas28p1020 assembling the final drive pinion gear assembly 1. Install: • rear drive shaft yoke nut “1” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ...

  • Page 329

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-26 example: “a” = 55 if “-02” is stamped on the final drive pinion gear, “b” = 22.2 - 0.02 = 22.18 if “-05” is stamped on the final drive pinion gear bearing housing, “c” = 67.8 - 0.05 = 67.75 if “-01” is stamped on...

  • Page 330

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-27 “f” = a numeral (usually a decimal number) on the final driven pinion gear either added to or subtracted from “51.0” “g” = a numeral (usually a decimal number) on the final driven pinion gear either added to or s...

  • Page 331

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-28 tip be sure to use one of each of the final driven pin- ion gear shim (final drive case side) “1” and thrust washer “2” to obtain the shim and thrust washer thickness. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ...

  • Page 332

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-29 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Place four pieces of plastigauge® between the originally fitted wheel gear shim(s) and the wheel gear. B. Install the wheel gear and tighten the bolts to speci...

  • Page 333

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-30 5. Measure: • gear backlash gently rotate the final drive pinion gear from engagement to engagement. Tip • when measuring the gear backlash, be sure the right side (gear oil level check bolt side) of the final dr...

  • Page 334

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-31.

  • Page 335: Electrical System

    9 electrical system ignition system ......................................................................................... 9-1 circuit diagram .................................................................................. 9-1 troubleshooting ......................................................

  • Page 336

    Eps (electric power steering) system (for yfm5fgp/yfm7fgp) ........................................................................... 9-63 circuit diagram ................................................................................ 9-63 eps control unit’s self-diagnostic function .................

  • Page 337

    Techsparkstudio.Com.

  • Page 338: Ignition System

    Ignition system 9-1 eas27090 ignition system eas27100 circuit diagram on off off push 2wd 4wd lock b g (black) y l y rb br gr bw rg wb g (gray) b (black) (gray) r /b (black) b l/ b l w g /r o /w br ( black ) r /g p /l r /w br /l w /gr /w o g /r w g l/ b br ( black ) l b lg l/ y r /y y r /y l/ y lg b...

  • Page 339: Ignition System

    Ignition system 9-2 1. Crankshaft position sensor 4. Main switch 5. Frame ground 6. Main fuse 8. Battery 20.Ecu (engine control unit) 21.Ignition coil 22.Spark plug 29.Lean angle sensor 54.Engine stop switch 59.Ignition fuse techsparkstudio.Com.

  • Page 340: Ignition System

    Ignition system 9-3 eas27130 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Right side panel 4. V-belt cooling exhaust duct ng → ok ↓ ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ...

  • Page 341: Ignition System

    Ignition system 9-4 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the main switch. Refer to “checking the switches” on page 9-79. Replace the main switch. 9. Check the engine stop switch. Refer to “checking the switches” on page 9-79. The engine stop switch is faulty. Replace the left handlebar s...

  • Page 342: Electric Starting System

    Electric starting system 9-5 eas27160 electric starting system eas27170 circuit diagram on off off push 2wd 4wd lock b g (black) y l y rb br gr bw rg wb g (gray) b (black) (gray) r /b (black) b l/ b l w g /r o /w br ( black ) r /g p /l r /w br /l w /gr /w o g /r w g l/ b br ( black ) l b lg l/ y r /...

  • Page 343: Electric Starting System

    Electric starting system 9-6 4. Main switch 5. Frame ground 6. Main fuse 8. Battery 10.Starter relay 11.Starter motor 16.Diode 1 20.Ecu (engine control unit) 30.Gear position switch 54.Engine stop switch 55.Start switch 59.Ignition fuse 60.Signaling system fuse 62.Rear brake light switch techsparkst...

  • Page 344: Electric Starting System

    Electric starting system 9-7 eas27180 starting circuit cut-off system operation if the engine stop switch is set to “ ” and the main switch is set to “on” (both switch circuits are closed), the starter motor can only operate if at least one of the following conditions is met: • the transmission is i...

  • Page 345: Electric Starting System

    Electric starting system 9-8 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Start switch 7. Signaling system fuse 8. Rear brake light switch 9. Ecu (engine control unit) 10. Park switch (gear position switch) 11. Neutral switch (gear position switch) 12. Diode 1 13....

  • Page 346: Electric Starting System

    Electric starting system 9-9 eas27190 troubleshooting the starter motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Side covers ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, igniti...

  • Page 347: Electric Starting System

    Electric starting system 9-10 ng → ok ↓ ng → ok ↓ ng → ok ↓ 9. Check the rear brake light switch. Refer to “checking the switches” on page 9-79. Replace the rear brake light switch. 10.Check the gear position switch. Refer to “checking the switches” on page 9-79. Replace the gear position switch. 11...

  • Page 348: Charging System

    Charging system 9-11 eas27200 charging system eas27210 circuit diagram on off b (black) gy b gy b/l b b r br/l br br br/l r w (gray) w w r (black) b br/b r/w l/y r/y (black) r r r r/b w r r/w r br/l br/l br/l br/y r/y r/y l/y br w w b r br/l br/b r/w br r/b y/r r/w r/b l br b b/l gy r r/b r r r b b ...

  • Page 349: Charging System

    Charging system 9-12 2. Ac magneto 3. Rectifier/regulator 5. Frame ground 6. Main fuse 8. Battery techsparkstudio.Com.

  • Page 350: Charging System

    Charging system 9-13 eas27230 troubleshooting the battery is not being charged. Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Right side cover 4. V-belt cooling exhaust duct ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. (main) refer to...

  • Page 351: Charging System

    Charging system 9-14 techsparkstudio.Com.

  • Page 352: Lighting System

    Lighting system 9-15 eas27240 lighting system eas27250 circuit diagram on off off push b g (black) y l y r b g r b w r g w b g (gray) b (black) (gray) r/b (black) b g l/b (bl l b lg l/y r/y y r/y l/y lg b l y g y b g y b y g b y g b b l b l br r/b (gray) br (gray) r/b p b w/b g gy b gy b/l b b r br/...

  • Page 353: Lighting System

    Lighting system 9-16 4. Main switch 5. Frame ground 6. Main fuse 8. Battery 53.Light switch 57.Headlight 58.Headlight relay 61.Headlight fuse 65.Tail/brake light techsparkstudio.Com.

  • Page 354: Lighting System

    Lighting system 9-17 eas27260 troubleshooting any of the following fail to light: headlight or taillight. Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Tail/brake light cover ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the ...

  • Page 355: Lighting System

    Lighting system 9-18 techsparkstudio.Com.

  • Page 356: Signaling System

    Signaling system 9-19 eas27270 signaling system eas27280 circuit diagram on off off push 2wd 4wd lock b g (black) y l y rb br gr bw rg wb g (gray) b (black) (gray) r /b (black) b l/ b l w g /r o /w br ( black ) r /g p /l r /w br /l w /gr /w o g /r w g l/ b br ( black ) l b lg l/ y r /y y r /y l/ y l...

  • Page 357: Signaling System

    Signaling system 9-20 4. Main switch 5. Frame ground 6. Main fuse 8. Battery 18.Reverse switch 20.Ecu (engine control unit) 25.Coolant temperature sensor 26.Speed sensor 30.Gear position switch 32.Multifunction meter 34.Coolant temperature warning light 35.Park indicator light 36.Reverse indicator l...

  • Page 358: Signaling System

    Signaling system 9-21 eas27290 troubleshooting • any of the following fail to light: warning light, brake light or an indicator light. Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Side panels 4. V-belt cooling exhaust duct 5. Rear fender ng → ok ↓ ng → ok ↓...

  • Page 359: Signaling System

    Signaling system 9-22 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ the neutral, park, high-range, and/or low-range indicator light fails to come on. Ng → ok ↓ ng → ok ↓ the reverse indicator light fails to come on. Ng → ok ↓ 2. Check the front brake light switch. Refer to “checking the switches” on page ...

  • Page 360: Signaling System

    Signaling system 9-23 ng → ok ↓ the differential gear lock indicator light and /or four-wheel-drive motor indicator light fails to come on. Ng → ok ↓ ng → ok ↓ while the override switch is pushed, the segments of the speedometer digits will not appear as shown in the illustration. Ng → ok ↓ 2. Check...

  • Page 361: Signaling System

    Signaling system 9-24 ng → ok ↓ the coolant temperature warning light fails to come on. Ng → ok ↓ ng → ok ↓ the fuel level indicator fails to come on. Ng → ok ↓ ng → ok ↓ the speedometer fails to operate. Ng → ok ↓ 2. Check the entire signaling system wiring. Refer to “circuit diagram” on page 9-19....

  • Page 362: Signaling System

    Signaling system 9-25 ng → ok ↓ 2. Check the entire signaling system wiring. Refer to “circuit diagram” on page 9-19. Properly connect or repair the signaling system wiring. Replace the meter assembly or ecu..

  • Page 363: Signaling System

    Signaling system 9-26 techsparkstudio.Com.

  • Page 364: Cooling System

    Cooling system 9-27 eas27300 cooling system eas27310 circuit diagram on off off push 2wd 4wd lock b g (black) y l y rb br gr bw rg wb g (gray) b (black) (gray) r /b (black) b l/ b l w g /r o /w br ( black ) r /g p /l r /w br /l w /gr /w o g /r w g l/ b br ( black ) l b lg l/ y r /y y r /y l/ y lg b ...

  • Page 365: Cooling System

    Cooling system 9-28 4. Main switch 5. Frame ground 6. Main fuse 8. Battery 20.Ecu (engine control unit) 25.Coolant temperature sensor 59.Ignition fuse 66.Radiator fan motor 67.Radiator fan motor circuit breaker 68.Radiator fan motor relay 69.Radiator fan motor fuse techsparkstudio.Com.

  • Page 366: Cooling System

    Cooling system 9-29 eas27320 troubleshooting the radiator fan motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Side panels 4. Front fenders ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ign...

  • Page 367: Cooling System

    Cooling system 9-30 ng → ok ↓ 8. Check the entire cooling system wiring. Refer to “circuit diagram” on page 9-27. Properly connect or repair the cooling sys- tem wiring. Replace the ecu. Techsparkstudio.Com.

  • Page 368: Fuel Injection System

    Fuel injection system 9-31 eas27330 fuel injection system eas27340 circuit diagram on off off push 2wd 4wd lock b g (black) y l y rb br gr bw rg wb g (gray) b (black) (gray) r /b (black) b l/ b l w g /r o /w br ( black ) r /g p /l r /w br /l w /gr /w o g /r w g l/ b br ( black ) l b lg l/ y r /y y r...

  • Page 369: Fuel Injection System

    Fuel injection system 9-32 1. Crankshaft position sensor 4. Main switch 5. Frame ground 6. Main fuse 8. Battery 9. Fuel injection system fuse 17.Fuel injection system relay 19.Isc (idle speed control) unit 20.Ecu (engine control unit) 21.Ignition coil 22.Spark plug 23.Fuel injector 24.Intake air tem...

  • Page 370: Fuel Injection System

    Fuel injection system 9-33 eas27350 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 en- gine under substitute ch...

  • Page 371: Fuel Injection System

    Fuel injection system 9-34 self-diagnostic function table fault code no. Item symptom able / un- able to start able / un- able to drive 12 crankshaft position sensor no normal signals are received from the crankshaft position sen- sor. Unable unable 13 intake air pressure sensor (open or short circu...

  • Page 372: Fuel Injection System

    Fuel injection system 9-35 communication error with the meter eas27400 troubleshooting method the engine operation is not normal and the engine trouble warning light comes on. 1. Check: • fault code number ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Check the fault code number displayed on ...

  • Page 373: Fuel Injection System

    Fuel injection system 9-36 5. Erase the malfunction history in the diagnos- tic mode. Refer to “sensor operation table (di- agnostic code no.D62)”. The engine operation is not normal but the engine trouble warning light does not come on. 1. Check the operation of following sensors and actuators in t...

  • Page 374: Fuel Injection System

    Fuel injection system 9-37 6. Verify the operation of the sensor or actuator. • sensor operation the data representing the operating conditions of the sensor appears on the multifunction meter. • actuator operation set the engine stop switch to “on” to operate the actuator. Tip if the engine stop sw...

  • Page 375: Fuel Injection System

    Fuel injection system 9-38 22 intake air temperature sen- sor: open or short circuit detected. • open or short circuit in wire harness. • defective intake temperature sensor. • malfunction in ecu. • improperly installed intake air temperature sensor. D05 30 the vehicle has over- turned. • the vehicl...

  • Page 376: Fuel Injection System

    Fuel injection system 9-39 sensor operation table 50 faulty ecu memory. (when this malfunction is detected in the ecu, the fault code number might not appear on the multi- function meter.) • malfunction in ecu. (the program and data are not properly written on or read from the internal memory.) — fa...

  • Page 377: Fuel Injection System

    Fuel injection system 9-40 actuator operation table • actuator operation set the engine stop switch to “off” and then to “run”. D21 neutral switch shift the transmission. • neutral on • in gear off d60 eeprom fault code dis- play — • no history 00 • history exists 01 d61 malfunction history code dis...

  • Page 378: Fuel Injection System

    Fuel injection system 9-41 eas27481 troubleshooting details this section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunc...

  • Page 379: Fuel Injection System

    Fuel injection system 9-42 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 posi- tion sensor check for lo...

  • Page 380: Fuel Injection System

    Fuel injection system 9-43 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 couple...

  • Page 381: Fuel Injection System

    Fuel injection system 9-44 fault code no. 14 symptom intake air pressure sensor: hose line 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 sensor ho...

  • Page 382: Fuel Injection System

    Fuel injection system 9-45 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 position sensor. • ...

  • Page 383: Fuel Injection System

    Fuel injection system 9-46 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 position sensor. • check the install...

  • Page 384: Fuel Injection System

    Fuel injection system 9-47 fault code no. 22 symptom intake air temperature sensor: open or short circuit de- tected. Diagnostic code no. D05 intake air temperature sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of intake air tem- ...

  • Page 385: Fuel Injection System

    Fuel injection system 9-48 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 side)...

  • Page 386: Fuel Injection System

    Fuel injection system 9-49 fault code no. 37 symptom engine speed is high when the engine is idling. Diagnostic code no. D54 isc valve order item/components and probable cause check or maintenance job reinstatement method 1 fuel injection system fuse is blown. • check the fuel injection system fuse....

  • Page 387: Fuel Injection System

    Fuel injection system 9-50 fault code no. 39 symptom fuel injector: open or short circuit detected. Diagnostic code no. D36 fuel injector order item/components and probable cause check or maintenance job reinstatement method 1 connections • fuel injector coupler • main wire harness-ecu coupler • mai...

  • Page 388: Fuel Injection System

    Fuel injection system 9-51 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 coupler ...

  • Page 389: Fuel Injection System

    Fuel injection system 9-52 fault code no. 43 symptom power supply to the fuel injector and fuel pump is not nor- mal. 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 ...

  • Page 390: Fuel Injection System

    Fuel injection system 9-53 fault code no. 46 symptom power supply to the fuel injection system 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 ...

  • Page 391: Fuel Injection System

    Fuel injection system 9-54 techsparkstudio.Com.

  • Page 392: Fuel Pump System

    Fuel pump system 9-55 eas27550 fuel pump system eas27560 circuit diagram on off off push 2wd 4wd lock b g (black) y l y rb br gr bw rg wb g (gray) b (black) (gray) r /b (black) b l/ b l w g /r o /w br ( black ) r /g p /l r /w br /l w /gr /w o g /r w g l/ b br ( black ) l b lg l/ y r /y y r /y l/ y l...

  • Page 393: Fuel Pump System

    Fuel pump system 9-56 4. Main switch 5. Frame ground 6. Main fuse 8. Battery 9. Fuel injection system fuse 17.Fuel injection system relay 20.Ecu (engine control unit) 42.Fuel pump 43.Diode 2 54.Engine stop switch 59.Ignition fuse techsparkstudio.Com.

  • Page 394: Fuel Pump System

    Fuel pump system 9-57 eas27570 troubleshooting if the fuel pump fails to operate. Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover 3. Rear fender ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition and fuel inj...

  • Page 395: Fuel Pump System

    Fuel pump system 9-58 techsparkstudio.Com.

  • Page 396: 2Wd/4Wd Selecting System

    2wd/4wd selecting system 9-59 eas30200 2wd/4wd selecting system eas30210 circuit diagram on off off push 2wd 4wd lock b g (black) y l y rb br gr bw rg wb g (gray) b (black) (gray) r /b (black) b l/ b l w g /r o /w br ( black ) r /g p /l r /w br /l w /gr /w o g /r w g l/ b br ( black ) l b lg l/ y r ...

  • Page 397: 2Wd/4Wd Selecting System

    2wd/4wd selecting system 9-60 4. Main switch 5. Frame ground 6. Main fuse 8. Battery 20.Ecu (engine control unit) 44.Four-wheel-drive motor relay 1 45.Four-wheel-drive motor relay 2 46.Four-wheel-drive motor relay 3 47.On-command four-wheel-drive motor switch and differential lock switch 48.Differen...

  • Page 398: 2Wd/4Wd Selecting System

    2wd/4wd selecting system 9-61 eas30220 troubleshooting the four-wheel-drive motor indicator light fails to come on. Tip • before troubleshooting, remove the following part(s): 1. Seat 2. Battery cover ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main and...

  • Page 399: 2Wd/4Wd Selecting System

    2wd/4wd selecting system 9-62 ng → ok ↓ ng → ok ↓ 8. Check the differential motor. Refer to “checking the dif- ferential motor” on page 8-11. Replace the differential motor. 9. Check the entire 2wd/4wd select- ing system wiring. Refer to “circuit diagram” on page 9-59. Properly connect or repair the...

  • Page 400: Yfm5Fgp/yfm7Fgp)

    Eps (electric power steering) system (for yfm5fgp/yfm7fgp) 9-63 eas30230 eps (electric power steering) system (for yfm5fgp/yfm7fgp) eas30240 circuit diagram on off off push 2wd 4wd lock b g (black) y l y rb br gr bw rg wb g (gray) b (black) (gray) r /b (black) b l/ b l w g /r o /w br ( black ) r /g ...

  • Page 401: Yfm5Fgp/yfm7Fgp)

    Eps (electric power steering) system (for yfm5fgp/yfm7fgp) 9-64 4. Main switch 5. Frame ground 6. Main fuse 7. Eps fuse 8. Battery 12.Eps torque sensor 13.Eps motor 14.Eps (electric power steering) control unit 15.Eps self-diagnosis signal connectors 20.Ecu (engine control unit) 26.Speed sensor 40.E...

  • Page 402: Yfm5Fgp/yfm7Fgp)

    Eps (electric power steering) system (for yfm5fgp/yfm7fgp) 9-65 eas30250 eps control unit’s self-diagnostic function the eps control unit is equipped with a self-diagnostic function. If this function detects a malfunction in the eps system, it lights the eps warning light to alert the rider that a m...

  • Page 403: Yfm5Fgp/yfm7Fgp)

    Eps (electric power steering) system (for yfm5fgp/yfm7fgp) 9-66 eas30270 diagnostic mode setting the diagnostic mode (present and past malfunctions) 1. Set the main switch to “on”. 2. Disconnect the eps self-diagnosis signal connector “1”. 3. Select the signaling mode by grounding the eps self-diagn...

  • Page 404: Yfm5Fgp/yfm7Fgp)

    Eps (electric power steering) system (for yfm5fgp/yfm7fgp) 9-67 • present malfunction signaling mode: currently detected fault codes are signaled. • past malfunction signaling mode: both previously detected fault codes and currently detected fault codes are signaled. Signaling method example 1: faul...

  • Page 405: Yfm5Fgp/yfm7Fgp)

    Eps (electric power steering) system (for yfm5fgp/yfm7fgp) 9-68 example 2: no malfunctions are detected after the mode selection judgment is completed (present display or past malfunction mode), the current fault code signaling stops immediately, and then the eps warning light starts flashing at 1.5...

  • Page 406: Yfm5Fgp/yfm7Fgp)

    Eps (electric power steering) system (for yfm5fgp/yfm7fgp) 9-69 eas30280 self-diagnostic function table (eps system) fault code no. Item symptom probable cause of mal- function 11 13 15 16 eps torque sensor no normal signals are received from the torque sensor. • open or short circuit in wire harnes...

  • Page 407: Yfm5Fgp/yfm7Fgp)

    Eps (electric power steering) system (for yfm5fgp/yfm7fgp) 9-70 eas30290 troubleshooting details (eps system) tip 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 c...

  • Page 408: Yfm5Fgp/yfm7Fgp)

    Eps (electric power steering) system (for yfm5fgp/yfm7fgp) 9-71 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 h...

  • Page 409: Yfm5Fgp/yfm7Fgp)

    Eps (electric power steering) system (for yfm5fgp/yfm7fgp) 9-72 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 tha...

  • Page 410: Yfm5Fgp/yfm7Fgp)

    Eps (electric power steering) system (for yfm5fgp/yfm7fgp) 9-73 fault code no. 54 symptom relay contacts in the eps control unit are welded togeth- er. Order item/components and probable cause check or maintenance job reinstatement method 1 malfunction in eps control unit. Replace the eps control un...

  • Page 411: Yfm5Fgp/yfm7Fgp)

    Eps (electric power steering) system (for yfm5fgp/yfm7fgp) 9-74 techsparkstudio.Com.

  • Page 412: Electrical Components

    Electrical components 9-75 eas27972 electrical components 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3.

  • Page 413: Electrical Components

    Electrical components 9-76 1. Four-wheel-drive motor relay 1 2. Four-wheel-drive motor relay 2 3. Headlight relay 4. Fuel injection system fuse 5. Starter relay 6. Eps fuse (yfm5fgp/yfm7fgp only) 7. Main fuse 8. Fuse box (ignition, headlights, four-wheel- drive motor, radiator fan motor, signaling s...

  • Page 414: Electrical Components

    Electrical components 9-77 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18.

  • Page 415: Electrical Components

    Electrical components 9-78 1. Lean angle sensor 2. Radiator fan motor relay 3. Fuel injection system relay 4. Four-wheel drive motor relay 3 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) 10. Isc...

  • Page 416: Electrical Components

    Electrical components 9-79 eas27980 checking the switches r br/l br r/b r/b br br (gray) l/y r/b lg lg b b l/y r/y y l push off r/y l y b b br br g/r g/r gy gy (gray) sb sb l/b l/b l/r l/r l/g l/g (black) 4wd 2wd lock gy w l p br/y y br/y y/w g/w 1 2 3 4 5 6 7 8 9 10 11 on off r br/l br.

  • Page 417: Electrical Components

    Electrical components 9-80 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 (differential motor) 8. Gear position switch 9. Reverse switch 10. Rear br...

  • Page 418: Electrical Components

    Electrical components 9-81 check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Notice eca14370 never insert the tester probes into the coupler terminal slots “a”. Always insert the probes ...

  • Page 419: Electrical Components

    Electrical components 9-82 eas27990 checking the bulbs and bulb sockets tip do not check any of the lights that use leds. Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or bo...

  • Page 420: Electrical Components

    Electrical components 9-83 checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) no continuity → replace. Tip check each bulb socket for continuity in the same manner as described in th...

  • Page 421: Electrical Components

    Electrical components 9-84 warning ewa13310 never use a fuse with an amperage rating other than that specified. Improvising or us- ing a fuse with the wrong amperage rating may cause extensive damage to the electri- cal system, cause the lighting and ignition systems to malfunction and could possibl...

  • Page 422: Electrical Components

    Electrical components 9-85 tip • the charge state of a vrla (valve regulated lead acid) battery can be checked by measur- ing its open-circuit voltage (i.E., the voltage when the positive battery terminal is discon- nected). • no charging is necessary when the open-cir- cuit voltage equals or exceed...

  • Page 423: Electrical Components

    Electrical components 9-86 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ charging method using a variable-current (voltage) charger a. Measure the open-circuit voltage prior to charging. Tip voltage should be measured 30 minutes after the engine is stopped. B. Connect a charger and ammeter to th...

  • Page 424: Electrical Components

    Electrical components 9-87 notice eca13630 first, connect the positive battery lead “1”, and then the negative battery lead “2”. 8. Check: • battery terminals dirt → clean with a wire brush. Loose connection → connect properly. 9. Lubricate: • battery terminals 10.Install: • battery holding bracket ...

  • Page 425: Electrical Components

    Electrical components 9-88 second step: radiator fan motor relay fuel injection system relay four-wheel-drive motor relay 1 first step: 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe 5. Negative tester probe result no continuity (between “...

  • Page 426: Electrical Components

    Electrical components 9-89 second step: four-wheel-drive motor relay 2 first step: second step: four-wheel-drive motor relay 3 eas28050 checking the diode 1. Check: • diode 3 out of specification → replace. 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negativ...

  • Page 427: Electrical Components

    Electrical components 9-90 tip the pocket tester or the analog pocket tester readings are shown in the following table. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the diode 3 from the wire har- ness. B. Connect the pocket tester ( Ω × 1) to the diode 3 coupler as shown. C. Check...

  • Page 428: Electrical Components

    Electrical components 9-91 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the spark plug cap from the igni- tion coil. B. Connect the pocket tester ( Ω × 1k) to the ig- nition coil as shown. C. Measure the secondary coil resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ...

  • Page 429: Electrical Components

    Electrical components 9-92 b. Measure the crankshaft position sensor re- sistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28130 checking the lean angle sensor 1. Remove: • lean angle sensor 2. Check: • lean angle sensor output voltage out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼...

  • Page 430: Electrical Components

    Electrical components 9-93 b. Measure the stator coil resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28170 checking the rectifier/regulator 1. Check: • charging voltage out of specification → replace the rectifi- er/regulator. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Co...

  • Page 431: Electrical Components

    Electrical components 9-94 b. Move the fuel sender float to the minimum “3” and maximum “4” level positions. C. Measure the fuel sender resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28240 checking the speed sensor 1. Check: • speed sensor output voltage out of specification → repl...

  • Page 432: Electrical Components

    Electrical components 9-95 eas28p1001 checking the radiator fan motor circuit breaker 1. Remove: • radiator fan motor circuit breaker (from the wire harness) tip the radiator fan motor circuit breaker “1” is at- tached to the wire harness with black tape near the tail/brake light connectors “2”. 2. ...

  • Page 433: Electrical Components

    Electrical components 9-96 eas28300 checking the throttle position sensor 1. Remove: • throttle position sensor (from the throttle body) 2. Check: • throttle position sensor maximum resistance out of specification → replace the throttle position sensor. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ...

  • Page 434: Electrical Components

    Electrical components 9-97 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 100) to the in- take air temperature sensor terminal as shown. B. Immerse the intake air temperature sensor “1” in a container filled with water “2”. Tip make sure that the air temperature...

  • Page 435: Electrical Components

    Electrical components 9-98 b. Measure the eps torque sensor resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ pocket tester 90890-03112 analog pocket tester yu-03112-c • positive tester probe → red “1” • negative tester probe → black “2” g r b w 1 2 techsparkstudio.Com.

  • Page 436: Electrical Components

    Electrical components 9-99.

  • Page 437: Troubleshooting

    10 troubleshooting troubleshooting................................................................................... 10-1 general information ..................................................................... 10-1 starting failures....................................................................

  • Page 438: Troubleshooting

    Troubleshooting 10-1 eas28451 troubleshooting eas28460 general information tip the following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic trouble- shooting. Refer to the relative procedure in this manual for checks, a...

  • Page 439: Troubleshooting

    Troubleshooting 10-2 electrical system 1. Battery • discharged battery • faulty battery 2. Spark plug • incorrect spark plug gap • incorrect spark plug heat range • fouled spark plug • worn or damaged electrode • worn or damaged insulator • faulty spark plug cap 3. Ignition coil • broken or shorted ...

  • Page 440: Troubleshooting

    Troubleshooting 10-3 transmission • worn gear dog eas28580 faulty clutch engine operates but vehicle will not move 1. V-belt • damaged or worn v-belt • slipping v-belt 2. Primary pulley cam and primary pulley slider • damaged or worn primary pulley cam • damaged or worn primary pulley slider 3. Clut...

  • Page 441: Troubleshooting

    Troubleshooting 10-4 eas28620 poor braking performance • worn brake pad • worn brake disc • air in hydraulic brake system • leaking brake fluid • faulty brake caliper kit • faulty brake caliper piston seal • loose union bolt • damaged brake hose • oil or grease on the brake disc • oil or grease on t...

  • Page 442

    Eas28740 wiring diagram yfm5fgy/yfm5fgpy/ yfm7fgy/yfm7fgpy 2009 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 10. Starter relay 11. Starter motor 12. Eps torque sensor 13. Eps motor ...

  • Page 443

    Yfm5fgy/yfm5fgpy/yfm7fgy/yfm7fgpy 2009 wiring diagram on off off push 2wd 4wd lock (black) (gray) (black) (gray) (black) (black) (black) (black) (black) (gray) (black) (green) (black) (black) (gray) (gray) (gray) (gray) (black) (black) (black) (gray) (gray) (black) (gray) (gray) (black) (black) (bla...