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Yamaha rhino 700 2008 Service Manual

Manual is about: Off-road motorcycle

Summary of rhino 700 2008

  • Page 1

    Service manual 2008 lit-11616-21-58 5b4-f8197-10 yxr70fx.

  • Page 2

    Ebs00001 yxr70fx service manual ©2007 by yamaha motor corporation, u.S.A. First edition, september 2007 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor corporation, u.S.A. Is expressly prohibited. Printed in u.S.A. Lit-11616-21-58.

  • Page 3: Important

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

  • Page 4: How to Use This Manual

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

  • Page 5: Gen

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

  • Page 7: Table of Contents

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

  • Page 8: Contents

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

  • Page 9: Chapter  3

    General tightening torque specifications............................... 2-24 lubrication points and lubricant types .................................... 2-25 engine................................................................................................... 2-25 coolant flow diagrams ............

  • Page 10: Chapter  4

    Chassis ....................................................................................................... 3-30 adjusting the brake pedal .......................................................... 3-30 adjusting the parking brake...................................................... 3-31 checki...

  • Page 11

    Cylinder head.......................................................................................... 4-11 removing the cylinder head....................................................... 4-14 checking the camshaft sprocket ............................................ 4-15 checking the tappet cov...

  • Page 12

    Primary and secondary sheaves.................................................... 4-55 primary sheave................................................................................. 4-57 secondary sheave .......................................................................... 4-58 removing the pr...

  • Page 13: Chapter  5

    Middle gear .............................................................................................. 4-91 middle drive shaft .......................................................................... 4-91 middle driven shaft.........................................................................

  • Page 14: Chapter  7

    Air filter case and air intake duct ............................................... 6-28 installing the air intake duct and air filter case............ 6-31 fuel pump and fuel tank .................................................................... 6-32 removing the fuel tank .........................

  • Page 15: Chapter  8

    Rear constant velocity joints, final drive gear and drive shaft .............................................................................................. 7-20 disassembling the rear constant velocity joints........... 7-28 assembling the rear constant velocity joints................. 7-29 disas...

  • Page 16

    Front and rear brakes....................................................................... 8-21 front brake pads ............................................................................ 8-21 rear brake pads............................................................................... 8-22 rep...

  • Page 17: Chapter  9

    Rear knuckle and stabilizer ........................................................... 8-67 checking the rear knuckles ...................................................... 8-68 checking the stabilizer................................................................ 8-68 rear arms and rear shock ab...

  • Page 18: Chapter  10

    Lighting system ...................................................................................... 9-27 circuit diagram ................................................................................ 9-27 troubleshooting .............................................................................

  • Page 19

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

  • Page 20: Gen

    1 - 1 gen info ebs00009 general information vehicle identification ebs00010 vehicle identification number the vehicle identification number 1 is stamped into the frame. Ebs00011 model label the model label 1 is affixed to the frame under the driver seat. Record the information on this label in the s...

  • Page 21: Gen

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

  • Page 22: Gen

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

  • Page 23: Gen

    1 - 4 gen info instrument functions 5b410004 multi-function meter unit 1 speedometer 2 fuel meter 3 “h” button 4 “m” button 5 clock/hour meter/voltage display 6 odometer/tripmeter a/tripmeter b 7 “trip/odo” button 8 clock/hour button “ / ” the multi-function meter unit is equipped with the following...

  • Page 24: Gen

    1 - 5 gen info features clock and voltage display modes 1 clock/hour button “ / ” 2 “h” button 3 “m” button 4 clock/hour meter/voltage display pushing the “ / ” button switches the dis- play between the clock mode “clock”, the hour meter mode “hour”, and the voltage dis- play mode “btry” in the foll...

  • Page 25: Gen

    1 - 6 gen info features fuel meter 1 fuel level warning indicator 2 fuel meter 3 “e” segment the fuel meter indicates the amount of fuel in the fuel tank. The display segments of the fuel meter disappear from “f” (full) towards “e” (empty) as the fuel level decreases. When the “e” segment disappears...

  • Page 26: Gen

    1 - 7 gen info important information ebs00013 important information preparation for removal and disassembly 1. Before removal and disassembly remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to “special tools”. 3. When disassembling always k...

  • Page 27: Gen

    1 - 8 gen info important information ebs00016 lock washers/plates and cotter pins after removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. Ebs00017 bearings and oil seals install b...

  • Page 28: Gen

    1 - 9 gen info important information ebs00019 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector moisture → dry with an air blower. Rust/stains → connect and disconnect...

  • Page 29: Gen

    1 - 10 gen info special tools ebs00021 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may di...

  • Page 30: Gen

    1 - 11 gen info special tools 90890-01268 yu-01268 ring nut wrench spanner wrench this tool is used to loosen or tighten the front and rear shock absorber locknuts. 90890-01274 yu-90058 crankshaft installer pot this tool is used to install the crankshaft. 90890-01275 yu-90060 crankshaft installer bo...

  • Page 31: Gen

    1 - 12 gen info special tools 90890-01325 yu-24460-01 radiator cap tester radiator pressure tester this tool is used to check the cooling sys- tem. 90890-01348 ym-01348 locknut wrench this tool is needed when removing or installing the secondary sheave spring. 90890-01352 yu-33984 radiator cap teste...

  • Page 32: Gen

    1 - 13 gen info special tools 90890-01467 ym-01467 gear lash measurement tool this tool is used to measure the gear lash. 90890-01474 ym-01474 ball joint remover these tools are used to remove or install the ball joints. 90890-01475 ym-01475 gear lash measurement tool middle drive gear lash tool thi...

  • Page 33: Gen

    1 - 14 gen info special tools 90890-03141 yu-03141 timing light inductive clamp timing light this tool is necessary for checking igni- tion timing. 90890-03153 yu-03153 pressure gauge this tool is used to measure fuel pres- sure. 90890-03174 yu-a1927 digital circuit tester model 88 multimeter with t...

  • Page 34: Gen

    1 - 15 gen info special tools 90890-04065 ym-04065-a valve guide installer (ø6) valve guide installer (6.0 mm) this tool is needed to install the valve guides. 90890-04066 ym-04066 valve guide reamer (ø6) valve guide reamer (6.0 mm) this tool is needed to rebore the new valve guides. 90890-04081 ym-...

  • Page 35: Gen

    1 - 16 gen info special tools 90890-04132 ym-33221-a mechanical seal installer water pump seal installer this tool is used to install the water pump seal. 90890-04134 ym-04134 sheave spring compressor this tool is needed when removing or installing the secondary sheave spring. 90890-04135 ym-04135 s...

  • Page 36: Spec

    2 - 1 spec ebs01001 specifications general specifications *1 for models equipped with panel wheels and oil damper shock absorbers *2 for models equipped with cast wheels and oil damper shock absorbers *3 for models equipped with cast wheels and gas-oil damper shock absorbers *4 for models equipped w...

  • Page 37: Spec

    2 - 2 spec general specifications oil quantity engine oil without oil filter cartridge replacement 2.00 l (1.76 imp qt, 2.11 us qt) with oil filter cartridge replacement 2.10 l (1.85 imp qt, 2.22 us qt) total amount 3.00 l (2.64 imp qt, 3.17 us qt) final gear oil periodic oil change 0.25 l (0.22 imp...

  • Page 38: Spec

    2 - 3 spec general specifications tire type front tubeless rear tubeless size front 25 × 8.00-12nhs rear 25 × 10.00-12nhs manufacturer/model front maxxis/m951y rear maxxis/m952y tire pressure (cold tire) maximum load* 367.0 kg (809 lb) *1, *2 359.0 kg (791 lb) *3, *4 off-road riding front 63 ~ 77 kp...

  • Page 39: Spec

    2 - 4 spec general specifications bulb voltage/wattage × quantity headlight 12 v 30.0 w/30.0 w × 2 tail/brake light 12 v 5.0/21.0 w × 2 indicator light neutral indicator light led reverse indicator light led coolant temperature warning light led engine trouble warning light led park indicator light ...

  • Page 40: Spec

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

  • Page 41: Spec

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

  • Page 42: Spec

    2 - 7 spec engine specifications valve-stem-to-valve-guide clearance intake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.080 mm (0.0031 in) exhaust 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) 0.100 mm (0.0039 in) valve stem runout ---- 0.040 mm (0.0016 in) valve spring free length intake 40.38 mm (1.59 in) 38....

  • Page 43: Spec

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

  • Page 44: Spec

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

  • Page 45: Spec

    2 - 10 spec engine specifications throttle body model/manufacturer × quantity 41ehs/mikuni × 1 ---- engine idle speed 1,550 ~ 1,650 r/min ---- intake vacuum 40.0 kpa (300 mmhg, 11.8 inhg) ---- water temperature 80 ~ 90 °c ---- oil temperature 60 ~ 70 °c ---- fuel pump pump type electrical ---- model...

  • Page 46: Spec

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

  • Page 47: Spec

    2 - 12 spec chassis specifications ebs01003 chassis specifications *1 for models equipped with panel wheels and oil damper shock absorbers *2 for models equipped with cast wheels and oil damper shock absorbers *3 for models equipped with cast wheels and gas-oil damper shock absorbers *4 for models e...

  • Page 48: Spec

    2 - 13 spec chassis specifications rear wheel wheel type panel wheel *1 ---- cast wheel *2, *3, *4 ---- rim size 12 × 7.5 at ---- rim material steel *1 ---- aluminum *2, *3, *4 ---- max. Radial wheel runout ---- 2.0 mm (0.08 in) max. Lateral wheel runout ---- 2.0 mm (0.08 in) front disc brake type d...

  • Page 49: Spec

    2 - 14 spec chassis specifications parking brake type disc ---- disc outside diameter × thickness 165.0 × 3.5 mm (6.50 × 0.14 in) ---- brake disc minimum thickness 3.0 mm (0.12 in) ---- brake disc maximum deflection 0.1 mm (0.004 in) ---- brake pad lining thickness-inner 3.2 mm (0.13 in) 1.0 mm (0.0...

  • Page 50: Spec

    2 - 15 spec electrical specifications ebs01004 electrical specifications item standard limit system voltage 12 v ---- ignition system ignition timing (b.T.D.C.) 12°/1,400 r/min ---- advancer type digital ---- transistorized coil ignition crankshaft position sensor resis- tance/color 459 ~ 561 Ω at 2...

  • Page 51: Spec

    2 - 16 spec electrical specifications starter relay model/manufacturer rc19-080a/mitsuba ---- amperage rating 180.0 a ---- coil winding resistance 4.18 ~ 4.62 Ω at 20 °c (68 °f) ---- fuel sender sender unit resistance (full) 19.00 ~ 21.00 Ω ---- sender unit resistance (empty) 137.00 ~ 143.00 Ω ---- ...

  • Page 52: Spec

    2 - 17 spec tightening torques ebs01005 tightening torques engine tightening torques item part name thread size q’ty tightening torque remarks nm m · kg ft · lb cylinder head (exhaust pipe) stud bolt m8 4 15 1.5 11 cylinder head bolt m9 4 35 3.5 25 m cylinder head bolt m9 2 38 3.8 27 e cylinder head...

  • Page 53: Spec

    2 - 18 spec tightening torques air intake duct bolt m6 2 7 0.7 5.1 muffler bolt m8 2 20 2.0 14 muffler bracket bolt m8 4 30 3.0 22 exhaust pipe nut m8 4 20 2.0 14 tailpipe bolt m6 3 10 1.0 7.2 radiator inlet pipe holder bolt m6 1 7 0.7 5.1 radiator outlet pipe holder bolt m6 1 7 0.7 5.1 oil cooler i...

  • Page 54: Spec

    2 - 19 spec tightening torques 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). Middle driven pinion gear bearing retainer nut m60 1 130 13.0 94 left-hand thread lt universal joint yoke nut (middle gear side) nut m...

  • Page 55: Spec

    2 - 20 spec tightening torques ebs01006 chassis tightening torques part to be tightened thread size tightening torque remarks nm m · kg ft · lb engine and front rubber damper m10 42 4.2 30 engine and front rubber damper m6 10 1.0 7.2 lt engine and rear rubber damper m10 42 4.2 30 engine and rear rub...

  • Page 56: Spec

    2 - 21 spec tightening torques top frame (enclosure) and side frame (enclosure) m10 65 6.5 47 headrest and upper support frame m6 7 0.7 5.1 seat belt and frame m10 59 5.9 43 seat belt and side frame (enclosure) m10 59 5.9 43 buckle and lower support frame m10 59 5.9 43 rectifier/regulator and frame ...

  • Page 57: Spec

    2 - 22 spec tightening torques stabilizer joint and stabilizer m10 60 6.0 43 stabilizer joint and rear lower arm m10 60 6.0 43 rear wheel and rear wheel hub m10 55 5.5 40 rear wheel hub and constant velocity joint m20 350 35.0 250 stake. Rear knuckle and brake disc guard m6 7 0.7 5.1 rear knuckle an...

  • Page 58: Spec

    2 - 23 spec tightening torques ring gear bearing housing and final gear case m10 40 4.0 29 m8 23 2.3 17 ring gear stopper nut m8 16 1.6 11 bearing retainer and final gear pinion gear bear- ing housing m65 170 17.0 125 left-hand thread. Lt drive shaft coupling gear and final drive pinion gear m12 80 ...

  • Page 59: Spec

    2 - 24 spec how to use the conversion table/ general tightening torque specifications ebs00022 how to use the conversion table all specification data in this manual are listed in si and metric units. Use this table to convert metric unit data to imperial unit data. Conversion table ebs00023 general ...

  • Page 60: Spec

    2 - 25 spec lubrication points and lubricant types ebs00024 lubrication points and lubricant types engine lubrication points lubricant oil seal lips ls bearings e o-ring ls cylinder head bolts m crankshaft pin e connecting rod big end thrust surface e crankshaft sprocket m inner race (crankshaft) e ...

  • Page 61: Spec

    2 - 26 spec lubrication points and lubricant types shift lever 1 e shift lever 1 gear teeth and shift lever 2 gear teeth e ac magneto lead grommet yamaha bond no.1215 (three bond no.1215 ® ) crankcase mating surface yamaha bond no.1215 (three bond no.1215 ® ) lubrication points lubricant.

  • Page 62: Spec

    2 - 27 spec coolant flow diagrams coolant flow diagrams 1 radiator outlet pipe 2 radiator inlet hose 3 radiator outlet hose 4 radiator cap 5 radiator 6 radiator inlet pipe 6 1 1 2 5 4 4 5 a a 3 3 2.

  • Page 63: Spec

    2 - 28 spec coolant flow diagrams 1 radiator inlet pipe 2 thermostat outlet hose 3 thermostat 4 radiator outlet pipe 5 water pump inlet hose 6 water pump 7 water pump outlet pipe 8 water pump outlet hose 1 2 2 1 3 4 5 6 7 8.

  • Page 64: Spec

    2 - 29 spec oil flow diagrams ebs00026 oil flow diagrams 1 oil delivery pipe 2 2 oil delivery pipe 3 3 oil delivery pipe 1 4 oil filter cartridge 5 oil strainer 6 reverse idle gear shaft 7 drive axle 8 relief valve assembly 6 7 8 4 2 1 4 3 4 5 1 2 b-b a a b b.

  • Page 65: Spec

    2 - 30 spec oil flow diagrams 1 camshaft 2 crankshaft 3 oil strainer 4 oil pump rotor 5 oil pump driven gear 1 2 4 5 3.

  • Page 66: Spec

    2 - 31 spec oil flow diagrams 1 oil delivery pipe 3 2 oil delivery pipe 2 3 oil outlet hose 4 oil inlet hose 5 oil cooler inlet pipe 2 6 oil cooler outlet pipe 2 7 oil cooler outlet hose 8 oil cooler outlet pipe 1 9 oil cooler inlet pipe 1 0 oil cooler a oil cooler inlet hose 5 6 1 2 a a a 9 0 8 7 6...

  • Page 67: Spec

    2 - 32 spec cable routing cable routing 1 left headlight lead 2 wire harness 3 throttle cable 4 light switch lead 5 brake light switch lead 6 thermostat outlet hose 7 radiator inlet pipe 8 brake pipe 9 radiator inlet hose 0 front brake hose a radiator fan motor breather hose b differential gear case...

  • Page 68: Spec

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

  • Page 69: Spec

    2 - 34 spec cable routing 1 throttle cable 2 wire harness 3 intake air temperature sensor lead 4 isc (idle speed control) unit lead 5 intake air pressure sensor lead 6 tail/brake light lead 7 parking brake cable 8 thermostat outlet hose 9 coolant temperature sensor lead 0 reverse switch lead a gear ...

  • Page 70: Spec

    2 - 35 spec cable routing Í fasten the wire harness with the plastic holder. Î push the excess tail/brake light lead into the rear fender so that there is no slack in the lead. Ï fasten the unused coupler to the wire harness with tape. Ð fasten the tail/brake light lead with the plastic holder. Ñ fa...

  • Page 71: Spec

    2 - 36 spec cable routing 1 light switch lead 2 main switch lead 3 meter assembly lead 4 auxiliary dc jack lead 5 on-command four-wheel-drive motor switch and differential gear lock switch lead 6 right headlight lead 7 radiator fan motor breather hose 8 differential gear case breather hose 9 front b...

  • Page 72: Spec

    2 - 37 spec cable routing l throttle cable m radiator inlet pipe n oil cooler inlet pipe 2/oil cooler outlet pipe 2 o brake pipe p radiator outlet pipe q ac magneto/crankshaft position sensor lead r fuel pump/fuel sender lead È fasten the wire harness with the plastic band. É fasten the left headlig...

  • Page 73: Spec

    2 - 38 spec cable routing Ï 85 ~ 105 mm (3.35 ~ 4.13 in) Ð fasten the wire harness, starter motor lead, and ground lead with the plastic band. Ñ fasten the throttle cable with the plastic band. Ò fasten the radiator inlet pipe with the plastic band. Ó fasten the brake pipe with the plastic band. Ô f...

  • Page 74: Spec

    2 - 39 spec cable routing 1 final gear case breather hose 2 parking brake cable 3 intake air pressure sensor lead 4 throttle position sensor lead 5 throttle body breather hose 6 starter motor lead 7 ground lead 8 water pump inlet hose 9 oil delivery pipe 2 0 oil delivery pipe 3 a water pump outlet p...

  • Page 75: Spec

    2 - 40 spec cable routing È fasten the throttle position sensor lead with the holder. É fasten the final gear case breather hose and brake pipe with the plastic holder. Ê fasten the final gear case breather hose and parking brake cable with the plastic holder. Ë pass the wire harness through the gro...

  • Page 76: Spec

    2 - 41 spec cable routing Õ 20 ~ 40° Ö 1 mm (0.04 in) or less × fasten the brake pipe with the plastic holder. Ø fasten the fuel pump/fuel sender lead with the plastic holder. E f f g h h 8 9 0 a b c 2 c c c d 1 1 1 1 1 1 2 2 2 3 4 5 6 6 7 7 Ï Ê É Ê Ë Ì Í Î Ð Ñ Ò Õ Ô Ó Ö × È Ø f-f h-h i-i a-a b-b c-...

  • Page 77: Spec

    2 - 42 spec cable routing 1 throttle cable 2 radiator inlet pipe 3 oil cooler inlet pipe 2/oil cooler outlet pipe 2 4 brake pipe 5 radiator outlet pipe 6 wire harness 7 ground lead 8 starter motor lead 9 oil outlet hose 0 oil inlet hose a ac magneto/crankshaft position sensor lead b throttle body br...

  • Page 78: Spec

    2 - 43 spec cable routing m thermostat outlet hose n isc (idle speed control) unit lead o coolant temperature sensor lead p intake air temperature sensor lead q ignition coil lead È route the throttle cable through the cable guide. É fasten the starter motor lead, wire harness, and ground lead with ...

  • Page 79: Spec

    2 - 44 spec cable routing Ð fasten the parking brake cable with the metal holder. Ñ 20 ~ 40 mm (0.79 ~ 1.57 in) Ò fasten the ignition coil lead with the plastic band. Ó fasten the throttle cable at the white mark with the plastic band. Ô fasten the brake pipe with the plastic band. Õ fasten the wire...

  • Page 80: Spec

    2 - 45 spec cable routing 1 radiator fan motor relay 2 fuel injection system relay 3 headlight relay 4 four-wheel-drive motor relay 1 5 four-wheel-drive motor relay 2 6 negative battery lead 7 meter assembly lead 8 on-command four-wheel-drive motor switch and differential gear lock switch lead 9 mai...

  • Page 81: Spec

    2 - 46 spec cable routing l starter relay m positive battery lead n main fuse o load control relay p four-wheel-drive motor relay 3 q ecu lead r fuse box s ground lead È fasten the starter motor lead with the plastic holder. É fasten the differential gear case breather hose and coolant reservoir bre...

  • Page 82: Spec

    2 - 47 spec cable routing Í fasten the radiator fan motor breather hose, dif- ferential gear case breather hose, and coolant reservoir breather hose with the plastic band. Î route the radiator fan motor breather hose, dif- ferential gear case breather hose, throttle cable, brake light switch lead, a...

  • Page 83: Spec

    2 - 48 spec cable routing Ó fasten the right headlight lead, differential gear case breather hose, radiator fan motor lead, and coolant reservoir breather hose with the plastic band. Ô fasten the positive battery lead with the plastic holder. Õ 4 mm (0.16 in) of clearance or more is required around ...

  • Page 84: Spec

    2 - 49 spec cable routing 1 auxiliary dc jack lead 2 throttle cable 3 radiator fan motor breather hose 4 differential gear case breather hose 5 coolant reservoir breather hose 6 main switch lead 7 light switch lead 8 ground lead 9 rectifier/regulator lead 0 wire harness a radiator fan motor lead b b...

  • Page 85: Chk

    3 - 1 chk adj ebs00029 periodic checks and adjustments introduction this chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for...

  • Page 86: Chk

    3 - 2 chk adj general maintenance and lubrication chart general maintenance and lubrication chart recommended brake fluid: dot 4 brake fluid replacement: • replace the brake fluid when disassembling the master cylinder or caliper. • check the brake fluid level regularly and add fluid as required. • ...

  • Page 87: Chk

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

  • Page 88: Chk

    3 - 4 chk adj adjusting the valve clearance 5. Remove: • crankshaft end accessing screw 1 1 6. Measure: • valve clearance out of specification → adjust. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft counterclockwise. B. When the piston is at the top dead center (tdc) on th...

  • Page 89: Chk

    3 - 5 chk adj adjusting the valve clearance 7. Adjust: • valve clearance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen the locknut 1. B. Insert a thickness gauge 2 between the adjusting screw and the valve tip. C. Turn the adjusting screw 3 with the tappet adjusting tool 4 until the sp...

  • Page 90: Chk

    3 - 6 chk adj adjusting the valve clearance/ adjusting the throttle cable 11.Install: • o-ring • camshaft sprocket cover • o-ring 1 • intake tappet cover • o-ring • exhaust tappet cover 12.Install: • center protector refer to “panels and front con- sole” in chapter 8. • rear console • seats refer to...

  • Page 91: Chk

    3 - 7 chk adj adjusting the throttle cable/ checking the spark plug 4. Adjust: • throttle cable ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen the locknut 1. B. Turn the adjusting nut 2 in direction a or b until the correct free play is obtained. C. Tighten the locknut. Tip: _ after adj...

  • Page 92: Chk

    3 - 8 chk adj checking the spark plug 5. Check: • electrode 1 wear/damage → replace. • insulator 2 abnormal color → replace. Normal color is a medium-to-light tan color. 6. Clean: • spark plug (with a spark plug cleaner or wire brush) 7. Measure: • spark plug gap a use a wire gauge or thickness gaug...

  • Page 93: Chk

    3 - 9 chk adj checking the ignition timing ebs00058 checking the ignition timing tip: _ throttle cable free play should be adjusted properly before checking the ignition timing. 1. Remove: • seats • rear console refer to “seats, rear console and instrument panels” in chapter 8. • fuel tank refer to ...

  • Page 94: Chk

    3 - 10 chk adj checking the ignition timing/ measuring the compression pressure c. Visually check the stationary pointer a to verify it is within the required firing range b indicated on the ac magneto rotor. Incorrect firing range → check the ignition system. Tip: when checking the ignition timing,...

  • Page 95: Chk

    3 - 11 chk adj measuring the compression pressure 4. Disconnect: • spark plug cap 5. Remove: • spark plug notice _ before removing a spark plug, use com- pressed air to blow away any dirt accumu- lated in the spark plug well to prevent it from falling into the cylinder. 6. Attach: • extension 1 • co...

  • Page 96: Chk

    3 - 12 chk adj measuring the compression pressure b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. Warning _ to prevent sparking, ground the spark plug lead before cranking the engine. C. If the compression pressure is above the maximum specific...

  • Page 97: Chk

    3 - 13 chk adj checking the engine oil level ebs00064 checking the engine oil level 1. Place the vehicle on a level surface. 2. Check the engine oil level on a cold engine. Tip: _ if the engine was started before the oil level was checked, be sure to warm up the engine sufficiently, and then wait at...

  • Page 98: Chk

    3 - 14 chk adj checking the engine oil level/ changing the engine oil 5. Check the engine oil level again. Notice be sure the engine oil is at the correct level, otherwise engine damage may result. 6. Install: • rear console • seats refer to “seats, enclosure, hood and cargo bed” in chapter 8. Ebs00...

  • Page 99: Chk

    3 - 15 chk adj changing the engine oil 7. If the oil filter cartridge is also to be replaced, perform the following procedure. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Lift the cargo bed up. B. Remove the oil filter cartridge 1 with an oil filter wrench 2. C. Lubricate the o-ring 3 of th...

  • Page 100: Chk

    3 - 16 chk adj changing the engine oil/ cleaning the air filter element 13.Check: • engine (for engine oil leaks) 14.Check: • engine oil level refer to “checking the engine oil level”. 15.Check: • engine oil pressure ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Slightly loosen the oil check ...

  • Page 101: Chk

    3 - 17 chk adj cleaning the air filter element 2. Remove: • air intake duct shroud 1 1 3. Remove: • air filter case cover 1 1 4. Remove: • air filter element 1 • air filter element frame 2 notice _ the engine should never be run without the air filter; excessive piston and/or cylinder wear may resul...

  • Page 102: Chk

    3 - 18 chk adj cleaning the air filter element 6. Clean: • air filter element use compressed air to blow off dust from the inner surface of the element. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Wash the element gently, but thoroughly in solvent. Warning _ use a cleaning solvent which is ...

  • Page 103: Chk

    3 - 19 chk adj checking the throttle body joint/ checking the fuel hose/checking the breather hoses eas00094 checking the throttle body joint 1. Remove: • seats • rear console refer to “seats, rear console and instrument panels” in chapter 8. 2. Check: • throttle body joint 1 cracks/damage → replace...

  • Page 104: Chk

    3 - 20 chk adj checking the breather hoses/ checking the coolant level 2. Check: • cylinder head breather hose 1 • throttle body breather hose 2 cracks/damage → replace. Loose connection → connect properly. Notice make sure the breather hoses are routed correctly. 3. Install: • rear console • seats ...

  • Page 105: Chk

    3 - 21 chk adj changing the coolant ebs00075 changing the coolant 1. Remove: • seats • rear console refer to “seats, rear console and instrument panels” in chapter 8. • fuel tank refer to “fuel pump and fuel tank” in chapter 6. 2. Remove: • coolant reservoir cap 1 3. Disconnect: • coolant reservoir ...

  • Page 106: Chk

    3 - 22 chk adj changing the coolant 7. Remove: • coolant drain bolt 1 (along with the copper washer) • air bleeding bolt 2 8. Drain: • coolant (from the engine and radiator) 1 2 9. Check: • coolant drain bolt 1 damage → replace. 10.Install: • copper washer 2 • coolant drain bolt new t r . . 10 nm (1...

  • Page 107: Chk

    3 - 23 chk adj changing the coolant handling notes for coolant coolant is potentially harmful and should be handled with special care. Warning _ • if coolant splashes in your eyes, thor- oughly wash them with water and consult a doctor. • if coolant splashes on your clothes, quickly wash it away wit...

  • Page 108: Chk

    3 - 24 chk adj changing the coolant b. When coolant begins to flow out of the bolt hole, tighten the water pump air bleed bolt to specification. C. Loosen the thermostat cover air bleed bolt 2, without removing it, to allow all of the air to escape from the air bleed bolt hole. D. When coolant begin...

  • Page 109: Chk

    3 - 25 chk adj eas00104 checking the cooling system 1. Remove: • seats • rear console • side panels • front console refer to “seats, enclosure, hood and cargo bed” in chapter 8. • air intake duct refer to “air filter case and air intake duct” in chapter 6. 2. Check: • radiator 1 • coolant reservoir ...

  • Page 110: Chk

    3 - 26 chk adj 3. Install: • air intake duct refer to “air filter case and air intake duct” in chapter 6. • front console • side panels • rear console • seats refer to “seats, enclosure, hood and cargo bed” in chapter 8. Ebs00077 checking the coolant temperature warning light 1 coolant temperature w...

  • Page 111: Chk

    3 - 27 chk adj checking and replacing the v-belt ebs00078 checking and replacing the v-belt 1. Remove: • drive belt cover refer to “primary and secondary sheaves” in chapter 4. 2. Check: • v-belt 1 cracks/wear/scaling/chipping → replace. Oil/grease → check primary sheave and secondary sheave. 3. Mea...

  • Page 112: Chk

    3 - 28 chk adj checking and replacing the v-belt/ checking the exhaust system c. Install the new v-belt. Tip: _ install the v-belt so that its arrow faces the direction shown in the illustration. D. Remove the bolts. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas00099 checking the exhaust sys...

  • Page 113: Chk

    3 - 29 chk adj cleaning the spark arrester cleaning the spark arrester 1. Clean: • spark arrester ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ warning • select a well-ventilated area free of com- bustible materials. • always let the exhaust system cool before performing this operation. • do not...

  • Page 114: Chk

    3 - 30 chk adj adjusting the brake pedal chassis adjusting the brake pedal 1. Check: • brake pedal free play a out of specification → adjust. Tip: _ the end of the brake rod 1 should lightly con- tact the brake master cylinder 2. Brake pedal free play 0 mm (0.0 in) 2. Adjust: • brake pedal free play...

  • Page 115: Chk

    3 - 31 chk adj adjusting the parking brake adjusting the parking brake 1. Shift the drive select lever into low gear “l”. 2. Remove: • seats • rear console refer to “seats, enclosure, hood and cargo bed” in chapter 8. 3. Check: • parking brake lever free play a the maximum free play is equal to one ...

  • Page 116: Chk

    3 - 32 chk adj adjusting the parking brake/ checking the brake fluid level 5. Adjust: • parking brake cable free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Pull back the adjuster cover 1. B. Loosen the locknut 2. C. Turn the adjusting nut 3 in direction a or b until the correct free p...

  • Page 117: Chk

    3 - 33 chk adj checking the brake fluid level/ checking the front brake pads 3. Check: • brake fluid level fluid level is under “min” level line 1 → fill up. Notice brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately. Warning • use only the designed qua...

  • Page 118: Chk

    3 - 34 chk adj checking the rear brake pads/ checking the parking brake pads checking the rear brake pads 1. Remove: • rear wheels refer to “front and rear wheels” in chapter 8. 2. Check: • brake pads wear indicator grooves 1 almost disap- peared → replace the brake pads as a set. Refer to “front an...

  • Page 119: Chk

    3 - 35 chk adj checking the brake hoses and brake pipes checking the brake hoses and brake pipes 1. Remove: • seats • rear console refer to “seats, enclosure, hood and cargo bed” in chapter 8. 2. Lift the hood up. 3. Lift the cargo bed. 4. Check: • front brake hoses 1 • front brake pipe 2 • rear bra...

  • Page 120: Chk

    3 - 36 chk adj bleeding the hydraulic brake system bleeding the hydraulic brake system warning bleed the brake system if: • the system has been disassembled. • a brake hose or brake pipe have been loosened or removed. • the brake fluid has been very low. • the brake operation has been faulty. A loss...

  • Page 121: Chk

    3 - 37 chk adj bleeding the hydraulic brake system/ adjusting the select lever shift rod k. Add brake fluid to the proper level. Refer to “checking the brake fluid level”. Warning check the operation of the brake after bleeding the brake system. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ adju...

  • Page 122: Chk

    3 - 38 chk adj adjusting the brake light switch/ checking the final gear oil level adjusting the brake light switch tip: • the brake light switch is operated by move- ment of the brake pedal. • the brake light switch is properly adjusted when the brake light comes on just before the braking effect s...

  • Page 123: Chk

    3 - 39 chk adj checking the final gear oil level/ changing the final gear oil 4. Install: • oil filler plug t r . . 23 nm (2.3 m · kg, 17 ft · lb) changing the final gear oil 1. Place the vehicle on a level surface. 2. Remove: • rear skid plate 1 3. Place a container under the final gear case to col...

  • Page 124: Chk

    3 - 40 chk adj changing the final gear oil/ checking the differential gear oil 8. Fill: • final gear case notice take care not to allow foreign material to enter the final gear case. 9. Install: • oil filler plug 10.Install: • rear skid plate periodic oil change 0.25 l (0.22 imp qt, 0.26 us qt) tota...

  • Page 125: Chk

    3 - 41 chk adj checking the differential gear oil/ changing the differential gear oil 3. Check: • oil level oil level should be up to the brim of hole. Oil level low → add oil to proper level. Notice take care not allow foreign material to enter the differential gear case. 4. Install: • oil filler p...

  • Page 126: Chk

    3 - 42 chk adj changing the differential gear oil 5. Remove: • drain plug 1 6. Drain: • differential gear oil 7. Install: • drain plug tip: check the gasket (drain plug). If it is damaged, replace it with new one. 1 t r . . 10 nm (1.0 m · kg, 7.2 ft · lb) 8. Fill: • differential gear case notice tak...

  • Page 127: Chk

    3 - 43 chk adj checking the constant velocity joint dust boots/checking the steering system checking the constant velocity joint dust boots 1. Check: • dust boots 1 damage → replace. Refer to “front constant velocity joints, differential gear and drive shaft” in chapter 7. È front É rear È 1 1 É che...

  • Page 128: Chk

    3 - 44 chk adj adjusting the toe-in adjusting the toe-in 1. Place the vehicle on a level surface. 2. Measure: • toe-in out of specification → adjust. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ tip: before measuring the toe-in, make sure that the tire pressure is correct. A. Mark both front ti...

  • Page 129: Chk

    3 - 45 chk adj adjusting the toe-in/adjusting the front shock absorbers ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Mark both tie-rods ends. This reference point will be needed during adjustment. B. Loosen the locknut (tie-rod end) 1 on each tie-rod. C. The same number of turns should be gi...

  • Page 130: Chk

    3 - 46 chk adj adjusting the front shock absorbers for models equipped with gas-oil damper shock absorbers warning _ always adjust the spring preload, rebound damping force and compression damping force of both front shock absorbers to the same setting. Uneven adjustment can result in poor handling ...

  • Page 131: Chk

    3 - 47 chk adj adjusting the front shock absorbers tip: _ always tighten the locknut against the adjust- ing ring, then torque it to specification. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Adjust: • rebound damping force ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjus...

  • Page 132: Chk

    3 - 48 chk adj adjusting the front shock absorbers/ adjusting the rear shock absorbers notice _ do not force the adjusting screw past the minimum or maximum extent of adjust- ment. The adjusting screw may be dam- aged. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ adjusting the rear shock absorb...

  • Page 133: Chk

    3 - 49 chk adj adjusting the rear shock absorbers for models equipped with gas-oil damper shock absorbers warning _ always adjust the spring preload, rebound damping force and compression damping force of both rear shock absorbers to the same setting. Uneven adjustment can result in poor handling an...

  • Page 134: Chk

    3 - 50 chk adj adjusting the rear shock absorbers tip: _ always tighten the locknut against the adjust- ing ring, then torque it to specification. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Adjust: • rebound damping force ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjust...

  • Page 135: Chk

    3 - 51 chk adj adjusting the rear shock absorbers/ checking the tires notice _ do not force the adjusting screw past the minimum or maximum extent of adjust- ment. The adjusting screw may be dam- aged. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ checking the tires warning • tire characteristic...

  • Page 136: Chk

    3 - 52 chk adj checking the tires • maximum loading limit 1) vehicle loading limit (total weight of cargo, operator, passenger and accesso- ries, and tongue weight): for models equipped with oil damper shock absorbers: 367 kg (809 lb) for models equipped with gas-oil damper shock absorbers: 359 kg (...

  • Page 137: Chk

    3 - 53 chk adj checking the tires/ checking the wheels warning uneven or improper tire pressure may adversely affect the handling of this vehicle and may cause loss of control. • maintain proper tire pressures. • set tire pressures when the tires are cold. • tire pressures must be equal in both fron...

  • Page 138: Chk

    3 - 54 chk adj checking and lubricating the cables/ lubricating the pedals, etc. Checking and lubricating the cables warning a damaged cable sheath may cause corro- sion and interfere with the cable move- ment. An unsafe condition may result so replace a damaged cable as soon as possi- ble. 1. Check...

  • Page 139: Chk

    3 - 55 chk adj checking and charging the battery ebs00120 electrical system checking and charging the battery warning _ batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: •...

  • Page 140: Chk

    3 - 56 chk adj checking and charging the battery tip: _ since mf batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery ...

  • Page 141: Chk

    3 - 57 chk adj checking and charging the battery b. Check the charge of the battery, as shown in the charts and the following example. Example c. Open-circuit voltage = 12.0 v d. Charging time = 6.5 hours e. Charge of the battery = 20 ~ 30% ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ op en-cir...

  • Page 142: Chk

    3 - 58 chk adj checking and charging the battery • if the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode! • as shown in the following illustration, the open-circuit vo...

  • Page 143: Chk

    3 - 59 chk adj checking and charging the battery charging method using a variable-current (voltage) charger measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the b...

  • Page 144: Chk

    3 - 60 chk adj checking and charging the battery charging method using a constant voltage charger measure the open-circuit voltage prior to charging. Tip: set the charging time to a maxi- mum of 20 hours. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than th...

  • Page 145: Chk

    3 - 61 chk adj checking and charging the battery/ checking the fuses 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) notice _ first, connect the positive battery lead 1, and then the negative battery lead 2. 8. Check: • battery terminals dirt → clean with a wire brush. L...

  • Page 146: Chk

    3 - 62 chk adj checking the fuses 2. Check: • fuse ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester to the fuse and check the continuity. Tip: _ set the pocket tester selector to “ Ω × 1”. B. If the pocket tester indicates “ ∞”, replace the fuse. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...

  • Page 147: Chk

    3 - 63 chk adj checking the fuses d. If the fuse immediately blows again, check the electrical circuit. Warning _ never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive damage to the electrical system, caus...

  • Page 148: Chk

    3 - 64 chk adj adjusting the headlight beams/ changing the headlight bulbs ebs00122 adjusting the headlight beams 1. Adjust: • headlight beam (vertically) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw 1 in direction a or b. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ...

  • Page 149: Chk

    3 - 65 chk adj changing the headlight bulbs/ changing the tail/brake light bulb 4. Remove: • headlight bulb holder 1 • bulb tip: remove the headlight bulb holder by pushing it in and turning it counterclockwise. Warning keep flammable products and your hands away from the bulb while it is on, since ...

  • Page 150: Chk

    3 - 66 chk adj changing the tail/brake light bulb 3. Remove: • tail/brake light bulb holder (with bulb) 1 • bulb tip: turn the bulb holder counterclockwise and remove the defective bulb. Warning keep flammable products and your hands away from the bulb while it is on, since it will be hot. Do not to...

  • Page 151: Eng

    4 - 1 eng engine engine removal v-belt cooling ducts, muffler and exhaust pipes (4) 1 10 6 5 5 3 2 4 2 2 9 9 7 8 new 4 new new ls t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 8 nm (0.8 m • kg, 5.8 ft • ib) order job/part...

  • Page 152: Eng

    4 - 2 eng engine removal (4) 1 10 6 5 5 3 2 4 2 2 9 9 7 8 new 4 new new ls t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 8 nm (0.8 m • kg, 5.8 ft • ib) order job/part q’ty remarks throttle body assembly refer to “throttle...

  • Page 153: Eng

    4 - 3 eng (4) 1 10 6 5 5 3 2 4 2 2 9 9 7 8 new 4 new new ls t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 8 nm (0.8 m • kg, 5.8 ft • ib) order job/part q’ty remarks 7 exhaust pipe 1 1 8 gasket 2 9 v-belt cooling duct 1 1 ...

  • Page 154: Eng

    4 - 4 eng installing the v-belt cooling ducts 1. Install: • v-belt cooling duct 2 1 tip: align the projection a on the section b of v- belt cooling duct 2 with the rib on the crank- case and fit the projection c on the section b between the projections on the section d of the duct. A b c b d 1 2. In...

  • Page 155: Eng

    4 - 5 eng engine removal shift arm 1 2 t r . . 15 nm (1.5 m • kg, 11 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) order job/part q’ty remarks removing the shift arm remove the parts in the order listed. 1 select lever shift rod 1 2 shift arm 1 for installation, reverse the removal pro- cedure..

  • Page 156: Eng

    4 - 6 eng engine removal hoses and leads t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) ls 1 8 5 11 6 7 9 10 2 4 3 13 15 14 12 order job/part q’ty remarks removing the hoses and leads remove the parts in the order listed. 1 cyli...

  • Page 157: Eng

    4 - 7 eng engine removal t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) ls 1 8 5 11 6 7 9 10 2 4 3 13 15 14 12 order job/part q’ty remarks 14 ac magneto coupler 2 disconnect. 15 crankshaft position sensor coupler 1 disconnect. F...

  • Page 158: Eng

    4 - 8 eng engine removal ebs00205 engine mounting bolts t r . . 42 nm (4.2 m • kg, 30 ft • ib) t r . . 42 nm (4.2 m • kg, 30 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) lt lt lt lt lt lt t r . . 10 nm (1.0 m • kg, 7...

  • Page 159: Eng

    4 - 9 eng t r . . 42 nm (4.2 m • kg, 30 ft • ib) t r . . 42 nm (4.2 m • kg, 30 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) lt lt lt lt lt lt t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 42 nm (4.2 m • kg, 30 ft •...

  • Page 160: Eng

    4 - 10 eng engine removal ebs00207 installing the engine 1. Install: • rubber dampers (rear side) 1 • engine mounting bolts (rear lower side) 2 • engine mounting bolts (rear upper side) 3 2. Tighten: • engine mounting bolts (rear lower side) 2 • engine mounting bolts (rear upper side) 3 3. Install: ...

  • Page 161: Eng

    4 - 11 eng cylinder head ebs00218 cylinder head 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 . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 f...

  • Page 162: Eng

    4 - 12 eng cylinder head 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 . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (...

  • Page 163: Eng

    4 - 13 eng 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 . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 20 nm (2.0 m • kg, 14 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7....

  • Page 164: Eng

    4 - 14 eng cylinder head ebs00220 removing the cylinder head 1. Align: • “i” mark on the ac magneto rotor (with the stationary pointer on the ac mag- neto cover) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft counterclockwise. B. When the piston is at the top dead center (t...

  • Page 165: Eng

    4 - 15 eng cylinder head 5. Remove: • cylinder head tip: _ • loosen the bolts in the proper sequence as shown. • loosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them. 6 8 5 7 2 1 4 3 ebs00224 checking the camshaft sprocket 1. Check: • camshaft sprocket wea...

  • Page 166: Eng

    4 - 16 eng cylinder head ebs00230 checking the cylinder head 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) tip: _ do not use a sharp instrument to avoid damag- ing or scratching: • spark plug bore threads • valve seats 2. Check: • cylinder head damage/scratches → replac...

  • Page 167: Eng

    4 - 17 eng cylinder head ebs00232 installing the cylinder head 1. Install: • dowel pins • cylinder head gasket 2. Install: • cylinder head • cylinder head bolts tip: _ • lubricate the threads of the cylinder head bolts 1 and 2 and mating surface with molybdenum disulfide grease. • lubricate the thre...

  • Page 168: Eng

    4 - 18 eng cylinder head tip: _ when installing the camshaft sprocket, keep the timing chain as tense as possible on the exhaust side. Notice _ do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. F. Remove the wire from the timing chain. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ...

  • Page 169: Eng

    4 - 19 eng cylinder head 7. Check: • “i” mark a tip: check that the “i” mark on the ac magneto rotor is aligned with the stationary pointer b on the ac magneto cover. • “i” mark c tip: check that the “i” mark on the camshaft sprocket is aligned with the stationary pointer d on the cylinder head. Out...

  • Page 170: Eng

    4 - 20 eng rocker arms and camshaft ebs00235 rocker arms and camshaft e e e lt 1 7 9 8 2 e 10 4 2 3 5 5 5 5 e 6 6 6 6 e t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) m order job/part q’ty remarks removing the rocker arms and cam...

  • Page 171: Eng

    4 - 21 eng rocker arms and camshaft e e e lt 1 7 9 8 2 e 10 4 2 3 5 5 5 5 e 6 6 6 6 e t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) m order job/part q’ty remarks 9 decompressor lever pin 1 refer to “removing the rocker arms and ...

  • Page 172: Eng

    4 - 22 eng rocker arms and camshaft ebs00237 removing the rocker arms and camshaft 1. Loosen: • locknuts • valve adjusting screws 2. Remove: • intake rocker arm shaft • exhaust rocker arm shaft • intake rocker arm • exhaust rocker arm tip: _ remove the rocker arm shafts with the slide hammer bolt 1 ...

  • Page 173: Eng

    4 - 23 eng rocker arms and camshaft 3. Measure: • camshaft runout out of specification → replace. Camshaft runout limit 0.015 mm (0.0006 in) ebs00225 checking the decompression system 1. Check: • decompression system ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Check the decompression system...

  • Page 174: Eng

    4 - 24 eng rocker arms and camshaft 4. Measure: • rocker arm shaft outside diameter out of specification → replace. 5. Calculate: • rocker-arm-to-rocker-arm-shaft clearance tip: _ calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Out of...

  • Page 175: Eng

    4 - 25 eng rocker arms and camshaft 2. Lubricate: • camshaft • decompressor lever pin • decompressor lever recommended lubricant molybdenum disulfide oil recommended lubricant engine oil 3. Install: • decompressor lever pin 1 • decompressor lever 2 tip: _ install the decompressor lever pin 1 and dec...

  • Page 176: Eng

    4 - 26 eng rocker arms and camshaft 6. Install: • exhaust rocker arm 1 • exhaust rocker arm shaft 2 • intake rocker arm • intake rocker arm shaft tip: _ • use a slide hammer bolt 3 to install the rocker arm shafts. • make sure the rocker arm shafts (intake and exhaust) are completely pushed into the...

  • Page 177: Eng

    4 - 27 eng valves and valve springs ebs00234 valves and valve springs m m m m m new new new new 7 6 5 5 4 4 3 2 1 6 7 7 6 3 2 3 2 1 2 3 6 7 8 8 order job/part q’ty remarks removing the valves and valve springs remove the parts in the order listed. Cylinder head refer to “cylinder head”. Rocker arms/...

  • Page 178: Eng

    4 - 28 eng valves and valve springs ebs00238 removing the valves and valve springs the following procedure applies to all of the valves and related components. Tip: _ before removing the internal parts of the cylin- der head (e.G., valves, valve springs, valve seats), make sure the valves properly s...

  • Page 179: Eng

    4 - 29 eng valves and valve springs 3. Remove: • valve spring retainer 1 • valve spring 2 • valve 3 • valve stem seal 4 • valve spring seat 5 tip: _ identify the position of each part very carefully so that it can be reinstalled in its original place. Ebs00240 checking the valves and valve springs t...

  • Page 180: Eng

    4 - 30 eng valves and valve springs 2. Replace: • valve guide tip: _ to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °c (212 °f) in an oven. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the valve guide using a valve guide re...

  • Page 181: Eng

    4 - 31 eng valves and valve springs 4. Measure: • margin thickness a out of specification → replace. Margin thickness 0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in) 5. Measure: • valve stem runout out of specification → replace. Tip: _ • when installing a new valve, always replace the valve guide. • if the val...

  • Page 182: Eng

    4 - 32 eng valves and valve springs e. If the valve seat is too wide, too narrow, or the seat is not centered, the valve seat must be refaced. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 9. Lap: • valve face • valve seat tip: _ after refacing the valve seat or replacing the valve and valve gui...

  • Page 183: Eng

    4 - 33 eng valves and valve springs h. Press the valve through the valve guide and onto the valve seat to make a clear pattern. I. Measure the valve seat width again. If the valve seat width is out of specification, reface and relap the valve seat. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 1...

  • Page 184: Eng

    4 - 34 eng valves and valve springs 2. Lubricate: • valve stem 1 (with the recommended lubricant) recommended lubricant molybdenum disulfide oil 3. Install: • valve spring seats 1 • valve stem seals 2 • valves 3 • valve springs 4 • valve spring retainers 5 tip: _ install the valve springs with the l...

  • Page 185: Eng

    4 - 35 eng valves and valve springs 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a mallet. Notice _ hitting the valve tip with excessive force could damage the valve..

  • Page 186: Eng

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

  • Page 187: Eng

    4 - 37 eng cylinder and piston ebs00247 removing the piston 1. Remove: • piston pin clips 1 • piston pin 2 • piston 3 tip: _ • before removing the piston pin clips, cover the crankcase opening with a clean rag to prevent the piston pin clips from falling into the crankcase. • before removing the pis...

  • Page 188: Eng

    4 - 38 eng cylinder and piston 2. Measure: • piston-to-cylinder clearance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure the cylinder bore “c” with a cylin- der bore gauge. Tip: _ measure the cylinder bore “c” in parallel to and at right angles to the crankshaft. Then, find the average...

  • Page 189: Eng

    4 - 39 eng cylinder and piston f. If out of specification, replace the cylinder, and the piston and piston rings as a set. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ebs00250 checking the piston rings 1. Measure: • piston ring side clearance out of specification → replace the piston and pisto...

  • Page 190: Eng

    4 - 40 eng cylinder and piston piston ring end gap top ring 0.20 ~ 0.35 mm (0.008 ~ 0.014 in) : 0.60 mm (0.024 in) 2nd ring 0.75 ~ 0.90 mm (0.030 ~ 0.035 in) : 1.25 mm (0.049 in) oil ring 0.20 ~ 0.70 mm (0.008 ~ 0.028 in) ebs00251 checking the piston pin 1. Check: • piston pin blue discoloration/gro...

  • Page 191: Eng

    4 - 41 eng cylinder and piston 4. Calculate: • piston-pin-to-piston-pin-bore clearance out of specification → replace the piston pin and piston as a set. Piston-pin-to-piston-pin-bore clearance = piston pin bore diameter b – piston pin outside diameter a piston-pin-to-piston clearance 0.004 ~ 0.024 ...

  • Page 192: Eng

    4 - 42 eng cylinder and piston 2. Install: • piston 1 • piston pin 2 • piston pin clips 3 tip: _ • apply engine oil to the piston pin. • make sure the punch mark a on the piston points towards the exhaust side of the cylin- der. • before installing the piston pin clips, cover the crankcase opening w...

  • Page 193: Eng

    4 - 43 eng cylinder and piston 6. Install: • cylinder 1 • timing chain guide (exhaust side) tip: _ • while compressing the piston rings with one hand, install the cylinder with the other hand. • pass the timing chain and timing chain guide (exhaust side) through the timing chain cav- ity. 1 7. Insta...

  • Page 194: Eng

    4 - 44 eng ac magneto ebs00256 ac magneto lt lt lt 6 6 1 2 lt new 4 5 ls lt 16 12 11 14 13 17 e e e 10 15 e new 9 7 8 3 (9) lt lt e lt lt t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) t r . ...

  • Page 195: Eng

    4 - 45 eng ac magneto lt lt lt 6 6 1 2 lt new 4 5 ls lt 16 12 11 14 13 17 e e e 10 15 e new 9 7 8 3 (9) lt lt e lt lt t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) t r . . 10 nm (1.0 m • kg,...

  • Page 196: Eng

    4 - 46 eng ac magneto lt lt lt 6 6 1 2 lt new 4 5 ls lt 16 12 11 14 13 17 e e e 10 15 e new 9 7 8 3 (9) lt lt e lt lt t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 6 nm (0.6 m • kg, 4.3 ft • ib) t r . . 10 nm (1.0 m • kg,...

  • Page 197: Eng

    4 - 47 eng ac magneto ebs00259 removing the ac magneto rotor 1. Remove: • pipe holder 1 • ac magneto cover tip: _ loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 1 2. Remove: • ac magneto rotor nut 1 • washer ti...

  • Page 198: Eng

    4 - 48 eng ac magneto flywheel puller 90890-01362 heavy duty puller yu-33270-b ebs00262 checking the stator coil and crankshaft position sensor 1. Check: • stator coil 1 • crankshaft position sensor 2 damage → replace the crankshaft position sensor/stator assembly. 2 1 ebs00263 checking the starter ...

  • Page 199: Eng

    4 - 49 eng ac magneto 2. Check: • starter idle gear teeth • starter wheel gear teeth burrs/clips/roughness/wear → replace. 3. Check: • starter wheel gear (contacting surface) damage/pitting/wear → replace. Checking the torque limiter 1. Check: • torque limiter damage/wear → replace. Tip: do not disa...

  • Page 200: Eng

    4 - 50 eng ac magneto 3. Install: • woodruff key • ac magneto rotor tip: _ • before installing the rotor, clean the outside of the crankshaft and the inside of the rotor. • after installing the rotor, check that the rotor rotates smoothly. If not, reinstall the key and rotor. 4. Tighten: • ac magnet...

  • Page 201: Eng

    4 - 51 eng balancer gears and oil pump gears balancer gears and oil pump gears order job/part q’ty remarks removing the balancer gears and oil pump gears remove the parts in the order listed. Starter wheel gear refer to “ac magneto”. 1 lock washer 1 refer to “removing the balancer driven gear and oi...

  • Page 202: Eng

    4 - 52 eng balancer gears and oil pump gears order job/part q’ty remarks 6 lock washer 1 refer to “removing the balancer driven gear and oil pump driven gear” and “installing the bal- ancer drive gear, balancer driven gear, and oil pump driven gear”. 7 oil pump driven gear 1 8 plate 1 9 spring 8 ref...

  • Page 203: Eng

    4 - 53 eng balancer gears and oil pump gears removing the balancer driven gear and oil pump driven gear 1. Straighten the lock washer tabs. 2. Loosen: • balancer driven gear nut 1 • oil pump driven gear nut 2 tip: place an aluminum plate 3 between the teeth of the balancer drive gear 4 and balancer ...

  • Page 204: Eng

    4 - 54 eng balancer gears and oil pump gears installing the balancer drive gear, balancer driven gear, and oil pump driven gear 1. Install: • pin • spring • balancer drive gear (onto the buffer boss) tip: align the punch mark a on the balancer drive gear with the hole b to the buffer boss. 2. Instal...

  • Page 205: Eng

    4 - 55 eng primary and secondary sheaves ebs00269 primary and secondary sheaves 5b4 new new new (11) (8) 1 10 8 5 9 11 13 12 2 6 7 4 4 3 t r . . 140 nm (14.0 m • kg, 100 ft • lb) new ls e t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 f...

  • Page 206: Eng

    4 - 56 eng primary and secondary sheaves 5b4 new new new (11) (8) 1 10 8 5 9 11 13 12 2 6 7 4 4 3 t r . . 140 nm (14.0 m • kg, 100 ft • lb) new ls e t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ...

  • Page 207: Eng

    4 - 57 eng primary and secondary sheaves ebs00270 primary sheave order job/part q’ty remarks disassembling the primary sheave remove the parts in the order listed. 1 primary pulley sheave cap 1 refer to “assembling the primary sheave”. 2 primary pulley slider 4 3 primary pulley cam 1 4 primary pulle...

  • Page 208: Eng

    4 - 58 eng primary and secondary sheaves ebs00271 secondary sheave order job/part q’ty remarks disassembling the secondary sheave remove the parts in the order listed. 1 nut 1 refer to “disassembling the sec- ondary sheave” and “assembling the secondary sheave”. 2 spring seat 1 3 compression spring ...

  • Page 209: Eng

    4 - 59 eng primary and secondary sheaves ebs00272 removing the primary and secondary sheaves 1. Loosen: • secondary sheave nut 1 • primary sheave nut 2 tip: _ • use the sheave holder 3 to hold the primary sheave. • first, loosen the secondary sheave nut 2, then loosen the primary sheave nut 1. Sheav...

  • Page 210: Eng

    4 - 60 eng primary and secondary sheaves ebs00274 checking the primary sheave 1. Check: • weight outside diameter a out of specification → replace the weight. Weight outside diameter 30 mm (1.18 in) : 29.5 mm (1.16 in) 2. Check: • primary pulley slider • primary sliding sheave splines wear/cracks/da...

  • Page 211: Eng

    4 - 61 eng primary and secondary sheaves 5. Measure: • secondary sheave spring free length a out of specification → replace the second- ary sheave spring. Free length 130.6 mm (5.14 in) : 128.0 mm (5.04 in) ebs00276 assembling the primary sheave 1. Clean: • primary sliding sheave face 1 • primary fi...

  • Page 212: Eng

    4 - 62 eng primary and secondary sheaves 3. Install: • slider 1 • cam 2 • primary sliding sheave cap t r . . 3 nm (0.3 m · kg, 2.2 ft · lb) ebs00277 assembling the secondary sheave 1. Apply: • bel-ray assembly lube ® (to the secondary sliding sheave 1 inner surface and oil seals) • bel-ray assembly ...

  • Page 213: Eng

    4 - 63 eng primary and secondary sheaves 4. Install: • spring seat • compression spring • spring seat • nut ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Attach the sheave fixed block, locknut wrench and sheave spring compressor to the secondary sheave. B. Place the sheave fixed block in a vi...

  • Page 214: Eng

    4 - 64 eng primary and secondary sheaves ebs00279 installing the primary and secondary sheaves 1. Install: • secondary sheave • v-belt fan • v-belt • primary sheave tip: _ • be sure to push in the primary pulley cam 1 when installing the primary sheave so that the primary pulley weights 2 will be pr...

  • Page 215: Eng

    4 - 65 eng clutch ebs00291 clutch order job/part q’ty remarks removing the clutch remove the parts in the order listed. Primary sheave/secondary sheave refer to “primary and secondary sheaves”. 1 clutch housing assembly 1 refer to “removing the clutch” and “installing the clutch”. 2 gasket 1 3 dowel...

  • Page 216: Eng

    4 - 66 eng clutch ebs00292 order job/part q’ty remarks disassembling the clutch housing assembly remove the parts in the order listed. 1 oil seal 1 2 circlip 1 3 bearing housing 1 4 circlip 1 5 bearing 1 6 circlip 1 7 bearing 1 8 clutch housing 1 for assembly, reverse the disassembly procedure..

  • Page 217: Eng

    4 - 67 eng clutch ebs00296 removing the clutch 1. Remove: • clutch housing assembly • gasket • dowel pins tip: _ working in crisscross pattern, loosen each bolt 1/4 of a turn. Remove them after all of them are loosened. 2. Straighten: • punched portion of the nut 1 3. Remove: • nut 1 notice the clut...

  • Page 218: Eng

    4 - 68 eng clutch ebs00299 checking the clutch 1. Check: • clutch housing heat damage/wear/damage → replace. • one-way clutch bearing chafing/wear/damage → replace. Tip: _ • replace the one-way clutch assembly and clutch housing as a set. • the one-way clutch bearing must be installed with the flang...

  • Page 219: Eng

    4 - 69 eng clutch ebs00309 installing the clutch 1. Install: • clutch carrier assembly • nut 1 notice the clutch carrier assembly nut has left- handed threads. To tighten the clutch car- rier assembly nut turn it counterclockwise. Tip: use a clutch holding tool 2 to hold the clutch carrier assembly....

  • Page 220: Eng

    4 - 70 eng crankcase ebs00319 crankcase timing chain and oil filter lt t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 17 nm (1.7 m • kg, 12 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 68 nm (6.8 m • kg, 49 f...

  • Page 221: Eng

    4 - 71 eng crankcase lt t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 17 nm (1.7 m • kg, 12 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 68 nm (6.8 m • kg, 49 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) ...

  • Page 222: Eng

    4 - 72 eng crankcase ebs00320 crankcase t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 26 nm (2.6 m • kg, 19 ft • ib) t r . . 14 nm (1.4 m • kg, 10 ft • ib) t r . . 18 nm (1.8 m • kg, 13 ft • ib) t r . . 18 nm (1.8 m • ...

  • Page 223: Eng

    4 - 73 eng crankcase ebs00321 crankcase bearings t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) . E e e e e e new new ls ls 7 7 7 7 7 7 7 e lt lt 4 7 3 2 1 5 6 lt order job/part q’ty remarks removing the crankcase bearings remove the parts in the order listed. Crankshaft/oil pump refer to “crankshaft and o...

  • Page 224: Eng

    4 - 74 eng crankcase ebs00332 separating the crankcase 1. Separate: • left crankcase • right crankcase ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the crankcase bolts. Tip: _ • loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. • loosen the bo...

  • Page 225: Eng

    4 - 75 eng crankcase ebs00339 checking the bearings 1. Check: • bearings clean and lubricate, then rotate the inner race with a finger. Roughness → replace. Ebs00338 checking the crankcase 1. Thoroughly wash the case halves in a mild solvent. 2. Clean all the gasket mating surfaces and crankcase mat...

  • Page 226: Eng

    4 - 76 eng crankcase 3. Fit the left crankcase onto the right crank- case. Tap lightly on the case with a soft hammer. Notice _ before installing and torquing the crank- case holding bolts, be sure to check whether the transmission is functioning properly by manually rotating the shift drum in both ...

  • Page 227: Eng

    4 - 77 eng crankshaft and oil pump ebs00326 crankshaft and oil pump 3 4 2 1 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) new order job/part q’ty remarks removing the crankshaft and oil pump remove the parts in the order listed. Crankcase separate. Refer to “crankca...

  • Page 228: Eng

    4 - 78 eng crankshaft and oil pump ebs00327 oil pump e 6 3 2 5 4 1 e t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) order job/part q’ty remarks disassembling the oil pump remove the parts in the order listed. 1 oil pump housing cover 1 2 pin 1 3 oil pump shaft 1 4 oil pump inner rotor 1 5 oil pump outer rot...

  • Page 229: Eng

    4 - 79 eng crankshaft and oil pump ebs00336 removing the crankshaft 1. Remove: • crankshaft 1 use a crankcase separating tool 2. Crankcase separating tool 90890-01135 crankcase separator yu-01135-b 2 1 ebs00331 checking the oil pump 1. Check: • oil pump housing • oil pump housing cover cracks/wear/d...

  • Page 230: Eng

    4 - 80 eng crankshaft and oil pump checking the oil strainer 1. Check: • oil strainer damage → replace. Contaminants → clean with engine oil. Ebs00360 checking the crankshaft 1. Measure: • crank width a out of specification → replace the crank- shaft. 2. Measure: • side clearance d out of specificat...

  • Page 231: Eng

    4 - 81 eng crankshaft and oil pump ebs00318 assembling the oil pump 1. Install: • oil pump housing 1 • oil pump outer rotor 2 • oil pump inner rotor 3 • oil pump shaft 4 • pin 5 tip: _ when installing the oil pump shaft 4 align the pin 5 with the groove a in the inner rotor 3. 1 2 3 5 4 a a ebs00362...

  • Page 232: Eng

    4 - 82 eng crankshaft and oil pump tip: _ hold the connecting rod at the top dead cen- ter (tdc) with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against the bearing. Notice _ apply engine oil to each bearing to prote...

  • Page 233: Eng

    4 - 83 eng transmission ebs00345 transmission m 1 7 6 8 5 10 9 4 3 2 new new new new e e e order job/part q’ty remarks removing the transmission remove the parts in the order listed. Crankcase separate. Refer to “crankcase”. Middle driven gear refer to “middle gear”. 1 shift drum 1 refer to “remov- ...

  • Page 234: Eng

    4 - 84 eng transmission m 1 7 6 8 5 10 9 4 3 2 new new new new e e e order job/part q’ty remarks 10 reverse idle gear shaft 1 refer to “removing the transmis- sion” and “installing the trans- mission”. For installation, reverse the removal pro- cedure..

  • Page 235: Eng

    4 - 85 eng transmission ebs00348 drive axle 1 a c d e f h g b 0 2 3 4 5 6 7 8 9 m m m m m m m new new new order job/part q’ty remarks disassembling the drive axle assembly remove the parts in the order listed. 1 washer 1 2 collar 1 3 high wheel gear 1 4 washer 1 5 clutch dog 1 6 circlip 1 7 washer 1...

  • Page 236: Eng

    4 - 86 eng transmission 1 a c d e f h g b 0 2 3 4 5 6 7 8 9 m m m m m m m new new new order job/part q’ty remarks d washer 1 e bearing 1 f reverse wheel gear 1 g stopper wheel 1 h drive axle 1 for assembly, reverse the disassembly procedure..

  • Page 237: Eng

    4 - 87 eng transmission removing the transmission 1. Remove: • shift drum 1 • shift fork assembly 2 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Pull out the guide bar from the left crank- case. B. Push down on the drive shaft, and then slide the shift fork assembly to remove the shift fork ...

  • Page 238: Eng

    4 - 88 eng transmission ebs00351 checking the shift drum 1. Check: • shift drum grooves scratches/wear/damage → replace. Ebs00354 checking the transmission 1. Measure: • drive axle runout (with a centering device and dial gauge 1) out of specification → replace the drive axle. 2. Check: • transmissi...

  • Page 239: Eng

    4 - 89 eng transmission checking the secondary shaft 1. Check: • gear teeth blue discoloration/pitting/wear → replace. Assembling the shift fork assembly 1. Install: • shift fork guide bar 1 • shift fork “l” 2 • spring 3 • shift fork “r” 4 • circlips 5 tip: install the shift forks with the “3b4” mar...

  • Page 240: Eng

    4 - 90 eng transmission 2. Check: • shift operation unsmooth operation → repair. Tip: _ • oil each gear and bearing thoroughly. • before assembling the crankcase, make sure that the transmission is in neutral and that the gears turn freely..

  • Page 241: Eng

    4 - 91 eng middle gear ebs00363 middle gear middle drive shaft order job/part q’ty remarks removing the middle drive shaft remove the parts in the order listed. Crankcase separate. Refer to “crankcase”. 1 bearing housing 1 2 middle drive pinion gear nut 1 refer to “removing the middle drive shaft” a...

  • Page 242: Eng

    4 - 92 eng middle gear ebs00364 middle driven shaft order job/part q’ty remarks removing the middle driven shaft remove the parts in the order listed. Crankcase separate. Refer to “crankcase”. 1 drive shaft coupling gear nut (middle gear side) 1 refer to “removing the middle driven shaft” and “insta...

  • Page 243: Eng

    4 - 93 eng middle gear order job/part q’ty remarks 10 o-ring 1 refer to “removing the middle driven shaft” and “installing the middle driven shaft”. 11 middle driven gear shim * 12 middle driven pinion gear 1 13 bearing 1 14 middle driven pinion gear bearing retainer 1 15 bearing 1 16 middle driven ...

  • Page 244: Eng

    4 - 94 eng middle gear ebs00365 removing the middle drive shaft 1. Straighten: • punched portion of the middle drive pinion gear nut 2. Loosen: • middle drive pinion gear nut 1 tip: _ secure the middle drive shaft in the vise with a clean rag. 3. Remove: • middle drive pinion gear nut • middle drive...

  • Page 245: Eng

    4 - 95 eng middle gear ebs01020 removing the middle driven shaft 1. Remove: • drive shaft coupling gear nut (middle gear side) 1 • washer • drive shaft coupling gear (middle gear side) 2 tip: _ use the coupling gear/middle shaft tool 3 to hold the coupling gear. Coupling gear/middle shaft tool 90890...

  • Page 246: Eng

    4 - 96 eng middle gear 3. Remove: • universal joint yoke nut (middle gear side) 1 • washer • universal joint yoke (middle gear side) tip: use the universal joint holder 2 to hold the universal joint yoke. Universal joint holder 90890-04062, ym-04062 4. Remove: • bearing housing assembly 1 ▼▼▼ ▼ ▼ ▼▼...

  • Page 247: Eng

    4 - 97 eng middle gear 5. Remove: • middle driven pinion gear bearing retainer • bearing ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Fold a rag around the bearing housing 1. B. Secure the bearing housing edge in the vise. C. Attach the bearing retainer wrench 2. Notice _ the middle driven p...

  • Page 248: Eng

    4 - 98 eng middle gear 7. Remove: • middle driven shaft 1 (with bearing) 1 ebs01021 checking the pinion gears 1. Check: • drive pinion gear teeth • driven pinion gear teeth pitting/galling/wear → replace. 2. Check: • o-ring damage → replace. • bearings pitting/damage → replace. Ebs00370 selecting mi...

  • Page 249: Eng

    4 - 99 eng middle gear ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Position middle drive and driven gear by using shims 1 and 2 with their respective thickness calculated from information marked on crankcase, bearing housing and drive gear end. 1 shim thickness “a” 2 shim thickness “b” b. T...

  • Page 250: Eng

    4 - 100 eng middle gear 8) round off the hundredth digit and select the appropriate shim(s). In the example above, the calculated num- ber is 1.38. The chart instructs you to round off 8 to 10 at the hundredth place. Thus, the shim thickness is 1.40 mm (0.055 in). Shims are supplied in the following...

  • Page 251: Eng

    4 - 101 eng middle gear g = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or subtracted from “49.0” h = a numeral (usually a decimal number) on the middle driven pinion gear is either added to or subtracted from “80.5” i = a numeral (usually a decimal numbe...

  • Page 252: Eng

    4 - 102 eng middle gear shims are supplied in the following thickness. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ middle drive pinion gear shim thickness (mm) 0.10 0.40 0.15 0.50 0.20 0.60 0.30 installing the bearing and oil seals 1. Install: • bearing 1 • oil seal 2 • oil seal 3 4 middle dri...

  • Page 253: Eng

    4 - 103 eng middle gear ebs00373 installing the middle driven shaft 1. Install: • middle driven shaft bearing retainer 1 tip: _ attach the ring nut wrench 2. Notice _ the middle driven shaft bearing retainer has left-handed threads. To tighten the retainer turn it counterclockwise. Ring nut wrench 9...

  • Page 254: Eng

    4 - 104 eng middle gear 3. Install: • middle driven gear shim(s) 1 • bearing housing tip: _ install the shim(s) so that the tabs are posi- tioned as shown in the illustration. 1 1 4. Install: • universal joint yoke (middle gear side) • washer • universal joint yoke nut (middle gear side) 1 tip: use ...

  • Page 255: Eng

    4 - 105 eng middle gear d. Press each bearing into the universal joint using a suitable socket. Tip: the bearing must be inserted far enough into the universal joint so that the circlip can be installed. E. Install the circlips 2 into the groove of each bearing. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 256: Eng

    4 - 106 eng middle gear 2. Tighten: • middle drive pinion gear nut 1 tip: secure the middle drive shaft in the vise with a clean rag. 3. Lock the threads with a drift punch. New t r . . 190 nm (19.0 m · kg, 140 ft · lb) ebs01022 measuring the middle gear backlash 1. Measure: • gear lash ▼▼▼ ▼ ▼ ▼▼▼ ...

  • Page 257: Cool

    5 - 1 cool cooling system radiator and coolant reservoir 13 14 10 12 9 11 r t. . 7 nm (0.7 m • kg, 5.1 ft • ib) r t. . 7 nm (0.7 m • kg, 5.1 ft • ib) 3 5 4 6 15 (4) (4) 1 8 2 7 order job/part q’ty remarks removing the radiator and coolant reservoir remove the parts in the order listed. Oil cooler re...

  • Page 258: Cool

    5 - 2 cool radiator and coolant reservoir 13 14 10 12 9 11 r t. . 7 nm (0.7 m • kg, 5.1 ft • ib) r t. . 7 nm (0.7 m • kg, 5.1 ft • ib) 3 5 4 6 15 (4) (4) 1 8 2 7 order job/part q’ty remarks 10 radiator outlet pipe 1 11 thermostat outlet hose 1 12 water pump inlet hose 1 13 oil cooler bracket 2 14 ra...

  • Page 259: Cool

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

  • Page 260: Cool

    5 - 4 cool radiator and coolant reservoir installing the radiator 1. Fill: • cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” in chapter 3. 2. Check: • cooling system leaks → repair or replace any faulty part..

  • Page 261: Cool

    5 - 5 cool thermostat ebs00129 thermostat new new 2 3 ls 1 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 18 nm (1.8 m • kg, 13 ft • ib) new 5 4 order job/part q’ty remarks removing the thermostat remove the parts in the order listed. Seats/rear console refer...

  • Page 262: Cool

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

  • Page 263: Cool

    5 - 7 cool water pump ebs00134 water pump new new new new new 2 3 4 ls new new 6 7 1 m 9 10 ls 12 e 11 8 5 new r t. . 10 nm (1.0 m • kg, 7.2 ft • ib) r t. . 10 nm (1.0 m • kg, 7.2 ft • ib) r t. . 10 nm (1.0 m • kg, 7.2 ft • ib) ls order job/part q’ty remarks removing the water pump remove the parts ...

  • Page 264: Cool

    5 - 8 cool water pump new new new new new 2 3 4 ls new new 6 7 1 m 9 10 ls 12 e 11 8 5 new r t. . 10 nm (1.0 m • kg, 7.2 ft • ib) r t. . 10 nm (1.0 m • kg, 7.2 ft • ib) r t. . 10 nm (1.0 m • kg, 7.2 ft • ib) ls order job/part q’ty remarks 7 gasket 1 8 circlip 1 9 impeller shaft 1 10 water pump seal ...

  • Page 265: Cool

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

  • Page 266: Cool

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

  • Page 267: Cool

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

  • Page 268: Cool

    5 - 12 cool oil cooler oil cooler 1 5 7 ls 6 8 9 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 21 nm (2.1 m • kg, 15 ft • ib) new new new 4 2 3 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • i...

  • Page 269: Cool

    5 - 13 cool oil cooler 1 5 7 ls 6 8 9 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 21 nm (2.1 m • kg, 15 ft • ib) new new new 4 2 3 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) (4) (4) ...

  • Page 270: Cool

    5 - 14 cool oil cooler checking the oil cooler 1. Check: • oil cooler obstruction → clean. Apply compressed air to the rear of the oil cooler. Damage → repair or replace the oil cooler. Tip: straighten any flattened fins with a thin, flat- head screwdriver. 2. Check: • oil hoses cracks/damage → repl...

  • Page 271: Fuel Injection System

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

  • Page 272

    6 - 2 fi fuel injection system eas27340 circuit diagram gy b b /l gy b r /w lb br (black) y y (black) br /y l /rb bl /b r /lb o /bb /w (black) l /y r /y g /y (green) b /l w l/ y b /l lw b /l g y b yg b g y b yg b ww w (gray) br (black) w (gray) w (gray) w ww (gray) w (gray) b b r r r r /l br /r y /r...

  • Page 273

    6 - 3 fi fuel injection system 1 crankshaft position sensor 4 main fuse 5 frame ground 6 ignition fuse 7 main switch 8 battery 9 fuel injection system fuse b backup fuse d fuel injection system relay f isc (idle speed control) unit g ecu (engine control unit) h ignition coil i spark plug j fuel inje...

  • Page 274

    6 - 4 fi fuel injection system ecu self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute character...

  • Page 275

    6 - 5 fi fuel injection system eas27380 self-diagnostic function table if the ecu detects an abnormal signal from a sensor while the vehicle is being driven, the ecu illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate fo...

  • Page 276

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

  • Page 277

    6 - 7 fi fuel injection system eas00905 diagnostic mode it is possible to monitor the sensor output data or check the activation of actuators without connecting the measurement equipment by simply switching the meter indication from the normal mode to the diagnostic monitoring mode. Setting the diag...

  • Page 278

    6 - 8 fi fuel injection system 6. Verify the operation of the sensor or actua- tor. • sensor operation the data representing the operating condi- tions of the sensor appears on the lcd meter. • actuator operation set the differential gear lock switch to “lock” to operate the actuator. * if the diffe...

  • Page 279

    6 - 9 fi fuel injection system diagnostic code table fault code no. Symptom probable cause of malfunction diagnostic code no. 12 no normal signals are received from the crankshaft position sensor. • open or short circuit in wire harness. • defective crankshaft position sensor. • malfunction in picku...

  • Page 280

    6 - 10 fi fuel injection system sensor operation table 50 faulty ecu memory. (when this mal- function is detected in the ecu, the fault code number might not appear on the lcd of the meter.) • malfunction in ecu. (the program and data are not properly written on or read from the internal memory.) — ...

  • Page 281

    6 - 11 fi fuel injection system actuator operation table • actuator operation set the differential gear lock switch to “4wd” and then to “lock”. Eas00908 troubleshooting details this section describes the countermeasures per fault code number displayed on the meter. Check and service the items or co...

  • Page 282

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

  • Page 283

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

  • Page 284

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

  • Page 285

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

  • Page 286

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

  • Page 287

    6 - 17 fi fuel injection system fault code no. 22 symptom intake air temperature sensor: open or short circuit detected. Diagnostic code no. D05 intake air temperature sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of air tempera- ...

  • Page 288

    6 - 18 fi fuel injection system fault code no. 30 symptom the vehicle has overturned. Diagnostic code no. D08 lean angle sensor order item/components and probable cause check or maintenance job reinstatement method 1 the vehicle has overturned. Raise the vehicle upright. Turning the main switch to “...

  • Page 289

    6 - 19 fi fuel injection system fault code no. 33 symptom malfunction detected in the primary lead of the ignition coil. Diagnostic code no. D30 ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 connections • ignition coil connector (primary coil ...

  • Page 290

    6 - 20 fi fuel injection system fault code no. 37 symptom engine speed is high when the engine is idling. Diagnostic code no. D54 isc valve order item/components and probable cause check or maintenance job reinstatement method 1 backup fuse is blown. • check the backup fuse. Refer to “checking the f...

  • Page 291

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

  • Page 292

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

  • Page 293

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

  • Page 294

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

  • Page 295

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

  • Page 296

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

  • Page 297

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

  • Page 298

    6 - 28 fi air filter case and air intake duct air filter case and air intake duct 5 5 7 6 (4) 3 4 2 1 16 21 17 15 22 18 20 20 23 12 14 11 10 13 19 9 8 new t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 15 nm (1.5 m • kg, 11 ft • ib) t r . . 13 nm (1.3 m • kg, 9.4 ft • ib) t r . . 7 nm (0.7 m • kg, 5...

  • Page 299

    6 - 29 fi air filter case and air intake duct 5 5 7 6 (4) 3 4 2 1 16 21 17 15 22 18 20 20 23 12 14 11 10 13 19 9 8 new t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 15 nm (1.5 m • kg, 11 ft • ib) t r . . 13 nm (1.3 m • kg, 9.4 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 32 nm (3.2 m • k...

  • Page 300

    6 - 30 fi 5 5 7 6 (4) 3 4 2 1 16 21 17 15 22 18 20 20 23 12 14 11 10 13 19 9 8 new t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 15 nm (1.5 m • kg, 11 ft • ib) t r . . 13 nm (1.3 m • kg, 9.4 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 32 nm (3.2 m • kg, 23 ft • ib) order job/part q’ty r...

  • Page 301

    6 - 31 fi installing the air intake duct and air filter case 1. Install: • air intake duct joint 1 tip: fit the projection a on the air intake duct joint between the projections on the air intake duct. 1 a 2. Install: • air intake duct joint clamp 1 (throttle body side) tip: align the projection a o...

  • Page 302

    6 - 32 fi fuel pump and fuel tank fuel pump and fuel tank fwd (9) 2 7 3 9 10 6 5 1 8 8 4 5 new t r . . 16 nm (1.6 m • kg, 11 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 8 nm (0.8 m • kg, 5.8 ft • ib) order job/part q’ty remarks removing the fuel pump and fuel tank remove the parts in the...

  • Page 303

    6 - 33 fi fuel pump and fuel tank fwd (9) 2 7 3 9 10 6 5 1 8 8 4 5 new t r . . 16 nm (1.6 m • kg, 11 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 8 nm (0.8 m • kg, 5.8 ft • ib) order job/part q’ty remarks 8 fuel tank holder 2 9 fuel tank cap 1 10 fuel tank 1 for installation, reverse the ...

  • Page 304

    6 - 34 fi fuel pump and fuel tank removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel hose notice • be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. • although the fuel has been removed fro...

  • Page 305

    6 - 35 fi fuel pump and fuel tank checking the fuel pump body 1. Check: • fuel pump body obstruction → clean. Cracks/damage → replace the fuel pump assembly. Checking the rollover valve 1. Check: • rollover valve damage/faulty → replace. Installing the fuel pump 1. Install: • fuel pump gasket • fuel...

  • Page 306

    6 - 36 fi fuel pump and fuel tank installing the fuel hose 1. Install: • fuel hose • fuel pump coupler tip: to install the fuel hose onto the throttle body and the fuel tank, slide the fuel hose connector cover 1 on the end of the hose in direction of the arrow shown..

  • Page 307

    6 - 37 fi throttle body eas00909 throttle body 10 9 9 7 3 11 13 11 12 4 8 1 2 6 5 new ls order job/part q’ty remarks removing the throttle body remove the parts in the order listed. Seats/rear console refer to “seats, rear console and instrument panels” in chapter 8. 1 intake air pressure sensor cou...

  • Page 308

    6 - 38 fi throttle body 10 9 9 7 3 11 13 11 12 4 8 1 2 6 5 new ls order job/part q’ty remarks 8 fuel hose 1 disconnect. Refer to “removing the throttle body assembly” and “installing the throttle body assembly”. 9 air intake duct joint clamp 2 10 air intake duct joint 1 11 throttle body joint clamp ...

  • Page 309

    6 - 39 fi throttle body 1 2 4 5 3 6 new new order job/part q’ty remarks disassembling the throttle body assembly remove the parts in the order listed. 1 intake air pressure sensor 1 2 intake air pressure sensor hose 1 3 throttle position sensor 1 4 injector fuel rail 1 5 fuel injector 1 6 throttle b...

  • Page 310

    6 - 40 fi throttle body removing the throttle body assembly 1. Disconnect: • fuel hose notice • be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. • although the fuel has been removed from the fuel tank be careful when disconnect- ing the fuel hose, since ...

  • Page 311

    6 - 41 fi ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Wash the throttle body in a petroleum- based solvent. Do not use any caustic carburetor cleaning solution. B. Blow out all of the passages with com- pressed air. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ installing the throttle b...

  • Page 312

    6 - 42 fi 5. Connect: • fuel hose notice when connecting the fuel hose, make sure that it is securely connected, and that the fuel hose connector cover is in the correct position, otherwise the fuel hose will not be properly connected. Tip: to connect the fuel hose onto the throttle body, slide the ...

  • Page 313

    6 - 43 fi eas00915 checking the fuel pump and pressure regulator operation 1. Check: • pressure regulator operation ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the seat. Refer to “seats, rear console and instrument panels” in chapter 8. B. Disconnect the fuel hose 1 from the fuel pum...

  • Page 314

    6 - 44 fi eas00916 checking and adjusting the throttle position sensor 1. Check: • throttle position sensor ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the throttle position sensor cou- pler from the throttle position sensor. B. Remove the throttle position sensor from the thrott...

  • Page 315

    6 - 45 fi c. Measure the throttle position sensor volt- age. D. Adjust the throttle position sensor angle so that the voltage is within the specified range. E. After adjusting the throttle position sensor angle, tighten the throttle position sensor screws 3. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲...

  • Page 316: Driv

    7 - 1 driv ebs00155 drive train 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 rea...

  • Page 317: Driv

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

  • Page 318: Driv

    7 - 3 driv troubleshooting ebs00157 troubleshooting chart when basic conditions “(a)” and “(b)” exist, check the following points: elevate and spin both wheels. Feel for wheel bearing damage. Yes replace the wheel bearing. (refer to “steering system” and “rear knuckle and stabilizer” in chapter 8.) ...

  • Page 319: Driv

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

  • Page 320: Driv

    7 - 5 driv front constant velocity joints, differential gear and drive shaft ls 5 6 7 9 8 3 2 4 t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 55 nm (5.5 m • kg, 40 ft • ib) 1 1 ls ls ls new new new order job/part q’ty remarks 4 differential gear case assembly 1 5 compression spring 1 6 washer 1 7 d...

  • Page 321: Driv

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

  • Page 322: Driv

    7 - 7 driv front constant velocity joints, differential gear and drive shaft È wheel side É gear case side order job/part q’ty remarks c clip 1 refer to “disassembling the front constant velocity joints” and “assembling the front constant velocity joints”. D joint shaft 1 for assembly, reverse the d...

  • Page 323: Driv

    7 - 8 driv front constant velocity joints, differential gear and drive shaft ebs00160 5 3 3 4 4 6 g e f d c 9 b i h (5) 0 a h 7 2 1 8 new ls t r . . 11 nm (1.1 m • kg, 8.0 ft • ib) t r . . 24 nm (2.4 m • kg, 17 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 62 nm (6.2 m • kg, 45 ft • ib) ne...

  • Page 324: Driv

    7 - 9 driv front constant velocity joints, differential gear and drive shaft 5 3 3 4 4 6 g e f d c 9 b i h (5) 0 a h 7 2 1 8 new ls t r . . 11 nm (1.1 m • kg, 8.0 ft • ib) t r . . 24 nm (2.4 m • kg, 17 ft • ib) t r . . 23 nm (2.3 m • kg, 17 ft • ib) t r . . 62 nm (6.2 m • kg, 45 ft • ib) new new new...

  • Page 325: Driv

    7 - 10 driv front constant velocity joints, differential gear and drive shaft disassembling the front constant velocity joints È gear case side É wheel side 1. Remove: • clip 1 • double off-set joint 2 • circlip 3 • ball bearing 4 • dust boot 5 tip: before removing the clip 1, slide the dust boot aw...

  • Page 326: Driv

    7 - 11 driv front constant velocity joints, differential gear and drive shaft disassembling the universal joint 1. Remove: • universal joint ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the circlips 1. B. Place the universal joint in a press. C. With a suitable diameter pipe 2 beneath...

  • Page 327: Driv

    7 - 12 driv front constant velocity joints, differential gear and drive shaft ebs00165 checking the front constant velocity joints 1. Check: • double off-set joint spline • ball joint spline • shaft spline wear/damage → replace. 2. Check: • dust boots cracks/damage → replace. Notice _ always use a n...

  • Page 328: Driv

    7 - 13 driv front constant velocity joints, differential gear and drive shaft checking the differential gear motor 1. Check: • differential gear motor ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect two c size batteries to the gear motor terminals 1 (as shown in illustration). Notice • ...

  • Page 329: Driv

    7 - 14 driv front constant velocity joints, differential gear and drive shaft tip: • install the clip 1 into the groove in the joint shaft as shown. • secure the off-set joint in a vise, and then fit the joint shaft into the off-set joint using a hammer. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 330: Driv

    7 - 15 driv front constant velocity joints, differential gear and drive shaft b. Install the dust boots 1. C. Install the dust boot bands 4, 5. Use a boot band installing tool 6. Tip: _ • the new boot bands may differ from the orig- inal ones. • the dust boots should be fastened with the boot bands ...

  • Page 331: Driv

    7 - 16 driv front constant velocity joints, differential gear and drive shaft b. Connect two c-size batteries to the gear motor terminal 2 to operate the pinion gear 3, and operate it until the mark 4 on the gear is aligned with the mark 5 on the gear motor case. Notice _ do not use a 12 v battery t...

  • Page 332: Driv

    7 - 17 driv front constant velocity joints, differential gear and drive shaft 4. Check: • differential gear operation unsmooth operation → replace the differ- ential gear assembly. Insert the double off-set joint into the differ- ential gear, and turn the gear back and forth. Assembling the universa...

  • Page 333: Driv

    7 - 18 driv front constant velocity joints, differential gear and drive shaft 3. Install: • ring gear fix bolt (m10) 1 (into the drain plug hole) notice _ finger tighten the bolt until it holds the ring gear. Otherwise, the ring gear will be dam- aged. 4. Attach: • gear lash measurement tool 2 • dia...

  • Page 334: Driv

    7 - 19 driv front constant velocity joints, differential gear and drive shaft 2. Adjust: • gear lash ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Select the suitable shims using the following chart. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ too little gear lash reduce shim thickness....

  • Page 335: Driv

    7 - 20 driv rear constant velocity joints, final drive gear and drive shaft 3 1 4 9 8 7 6 5 1 2 t r . . 70 nm (7.0 m • kg, 51 ft • ib) ls ls ls new new order job/part q’ty remarks removing the rear constant velocity joints, final drive gear and drive shaft remove the parts in the order listed. Rear ...

  • Page 336: Driv

    7 - 21 driv rear constant velocity joints, final drive gear and drive shaft 3 1 4 9 8 7 6 5 1 2 t r . . 70 nm (7.0 m • kg, 51 ft • ib) ls ls ls new new order job/part q’ty remarks 1 rear constant velocity joint 2 tip: remove the constant velocity joint on the right side of the vehicle, rotate the fi...

  • Page 337: Driv

    7 - 22 driv rear constant velocity joints, final drive gear and drive shaft 3 1 4 9 8 7 6 5 1 2 t r . . 70 nm (7.0 m • kg, 51 ft • ib) ls ls ls new new order job/part q’ty remarks 9 drive shaft 1 for installation, reverse the removal pro- cedure..

  • Page 338: Driv

    7 - 23 driv rear constant velocity joints, final drive gear and drive shaft order job/part q’ty remarks disassembling the rear constant velocity joints remove the parts in the order listed. The following procedure applies to both of the rear constant velocity joints. 1 dust cover 1 2 clip 1 3 boot b...

  • Page 339: Driv

    7 - 24 driv rear constant velocity joints, final drive gear and drive shaft È wheel side É gear case side order job/part q’ty remarks c off-set joint 1 refer to “disassembling the rear constant velocity joints” and “assembling the rear constant velocity joints”. D clip 1 e joint shaft 1 for assembly...

  • Page 340: Driv

    7 - 25 driv rear constant velocity joints, final drive gear and drive shaft order job/part q’ty remarks disassembling the final gear case remove the parts in the order listed. 1 final drive pinion gear assembly 1 2 final drive pinion gear shim * 3 drive shaft coupling gear 1 refer to “disassembling ...

  • Page 341: Driv

    7 - 26 driv rear constant velocity joints, final drive gear and drive shaft order job/part q’ty remarks a ring gear bearing housing 1 tip: working in a crisscross pattern, loosen each bolt 1/4 of a turn. After all the bolts are loosened, remove them. B oil seal 1 c bearing 1 d ring gear shim * e rin...

  • Page 342: Driv

    7 - 27 driv rear constant velocity joints, final drive gear and drive shaft * apply yamaha bond no.1215 90890-85505 (three bond no.1215 ® ) order job/part q’ty remarks h bearing 1 refer to “removing the final drive roller bearings” and “installing the final drive roller bearings”. I bearing 1 j fina...

  • Page 343: Driv

    7 - 28 driv rear constant velocity joints, final drive gear and drive shaft disassembling the rear constant velocity joints È gear case side É wheel side 1. Remove: • clip 1 • double off-set joint 2 • circlip 3 • ball bearing 4 • dust boot 5 tip: before removing the clip 1, slide the dust boot away ...

  • Page 344: Driv

    7 - 29 driv rear constant velocity joints, final drive gear and drive shaft assembling the rear constant velocity joints È wheel side É gear case side 1. Install: • dust boot • clip 1 • off-set joint 2 • joint shaft 3 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the clip 1. B. Instal...

  • Page 345: Driv

    7 - 30 driv rear constant velocity joints, final drive gear and drive shaft 3. Apply: • molybdenum disulfide grease (into the ball joint assembly) tip: _ molybdenum disulfide grease is included in the repair kit. 4. Install: • dust boots 1 • boot bands 2, 3, 4, 5 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ...

  • Page 346: Driv

    7 - 31 driv rear constant velocity joints, final drive gear and drive shaft disassembling the final gear case 1. Remove: • drive shaft coupling gear nut ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Place a folded rag 1. B. Secure the drive shaft coupling gear edge in the vise. C. Remove the ...

  • Page 347: Driv

    7 - 32 driv rear constant velocity joints, final drive gear and drive shaft removing the final drive roller bearings 1. Remove: • roller bearing (ring gear) 1 use a suitable press tool 2 and an appro- priate support for the main housing. 2. Remove: • roller bearing (final drive pinion gear) 1 ▼▼▼ ▼ ...

  • Page 348: Driv

    7 - 33 driv rear constant velocity joints, final drive gear and drive shaft positioning the final drive pinion gear and ring gear when the final drive pinion gear, ring gear, final gear case and/or ring gear bearing hous- ing are replaced, be sure to adjust the posi- tions of the final drive pinion ...

  • Page 349: Driv

    7 - 34 driv rear constant velocity joints, final drive gear and drive shaft 6) round off the hundredth digit and select the appropriate shim(s). In the example above, the calculated num- ber is 0.97. The chart instructs you to round off 7 to 5 at the hundredth place. Thus, the shim thickness is 0.95...

  • Page 350: Driv

    7 - 35 driv rear constant velocity joints, final drive gear and drive shaft h = bearing thickness (considered constant) example: 1) if “98” is stamped on the final gear case, e = 50 + 0.98 = 50.98 2) if “55” is stamped on the ring gear bearing housing, f = 1 + 0.55 = 1.55 3) if “–05” is stamped on t...

  • Page 351: Driv

    7 - 36 driv rear constant velocity joints, final drive gear and drive shaft selecting thrust washer 1. Measure: • ring gear thrust clearance “c” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Place four pieces of plastigauge ® between the originally fitted thrust washer and the ring gear. B. I...

  • Page 352: Driv

    7 - 37 driv rear constant velocity joints, final drive gear and drive shaft 2. Select: • ring gear thrust clearance “c” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Select a suitable thrust washer using the following chart. B. Repeat the measurement steps until the ring gear thrust clearance...

  • Page 353: Driv

    7 - 38 driv rear constant velocity joints, final drive gear and drive shaft checking the drive shaft 1. Check: • drive shaft (splines) • coupling gear (splines) wear/damage → replace. Checking the final gear case 1. Check: • final gear case • ring gear bearing housing cracks/damage → replace. Tip: w...

  • Page 354: Driv

    7 - 39 driv rear constant velocity joints, final drive gear and drive shaft 3. Install: • ring gear fix bolt (m10) 1 (into the drain plug hole) notice finger tighten the bolt until it holds the ring gear. Otherwise, the ring gear will be dam- aged. Ring gear fix bolt (m10) 90890-01527, ym-01527 4. A...

  • Page 355: Driv

    7 - 40 driv rear constant velocity joints, final drive gear and drive shaft adjusting the final gear lash 1. Remove: • ring gear bearing housing 1 • ring gear shim(s) 2 • ring gear 3 • thrust washer 4 2. Adjust: • gear lash ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Select a suitable shim(...

  • Page 356: Driv

    7 - 41 driv rear constant velocity joints, final drive gear and drive shaft 2. Install: • ring gear bearing housing • m8 bolts (ring gear bearing housing) 1 • m10 bolts (ring gear bearing housing) 2 tip: apply sealant to the bolts 1 and 2 threads. T r . . 23 nm (2.3 m · kg, 17 ft · lb) t r . . 40 nm...

  • Page 357: Driv

    7 - 42 driv rear constant velocity joints, final drive gear and drive shaft 4. Install: • drive shaft coupling gear nut ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Place a folded rag 1. B. Secure the drive shaft coupling gear edge in the vise. C. Tighten the drive shaft coupling gear nut. ▲...

  • Page 358: Chas

    8 - 1 chas chassis seats, enclosure, hood and cargo bed front guard and hood 4 3 1 2 (4) t r . . 32 nm (3.2 m • kg, 23 ft • ib) t r . . 59 nm (5.9 m • kg, 43 ft • ib) order job/part q’ty remarks removing the front guard and hood remove the parts in the order listed. 1 front guard 1 2 radiator mesh 1...

  • Page 359: Chas

    8 - 2 chas seats, enclosure, hood and cargo bed seats, rear console and instrument panels 1 2 6 7 8 9 18 15 12 13 11 10 14 (8) (8) (16) (5) (4) 16 16 17 (4) lt lt 3 4 5 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 35 nm (3.5 m • kg, 25 ft • ib) t r . . 8 nm (...

  • Page 360: Chas

    8 - 3 chas seats, enclosure, hood and cargo bed 1 2 6 7 8 9 18 15 12 13 11 10 14 (8) (8) (16) (5) (4) 16 16 17 (4) lt lt 3 4 5 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 35 nm (3.5 m • kg, 25 ft • ib) t r . . 8 nm (0.8 m • kg, 5.8 ft • ib) order job/part q’...

  • Page 361: Chas

    8 - 4 chas removing the steering wheel 1. Turn the steering wheel so that it is straight and the front wheels are pointing straight ahead. 2. Remove: • steering wheel cover 1 • steering wheel tip: while pushing the ends of the projections a together, remove the steering wheel cover from the steering...

  • Page 362: Chas

    8 - 5 chas side doors 2 3 (4) (4) 5 1 6 t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) new 1 4 new 4 1 t r . . 8 nm (0.8 m • kg, 5.8 ft • ib) lt lt t r . . 23 nm (2.3 m • kg, 17 ft • ib) order job/part q’ty remarks removing the side doors remove the parts in the order ...

  • Page 363: Chas

    8 - 6 chas seats, enclosure, hood and cargo bed panels and front console 1 (4) 5 7 2 3 4 10 8 9 (8) (4) (4) (6) (4) (4) (4) 6 12 11 (8) t r . . 16 nm (1.6 m • kg, 11 ft • ib) t r . . 32 nm (3.2 m • kg, 23 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 16 nm (1.6 m • kg, 11 ft • ib) order jo...

  • Page 364: Chas

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

  • Page 365: Chas

    8 - 8 chas removing the side panels the following procedure applies to both of the side panels. 1. Remove: • quick fastener 1 tip: to remove the quick fastener, push its center with a screwdriver 2, then pull the fastener out. 1 2 2. Remove: • side panel 1 • corner panel 2 tip: • remove the side pan...

  • Page 366: Chas

    8 - 9 chas seats, enclosure, hood and cargo bed cargo bed 4 2 3 new new 1 2 3 1 16 nm (1.6 m • kg, 11 ft • ib) 16 nm (1.6 m • kg, 11 ft • ib) t r . . T r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . Order job/part q’ty remarks removing the cargo bed remove the parts in the order listed. 1 tail/brake l...

  • Page 367: Chas

    8 - 10 chas seats, enclosure, hood and cargo bed 6 8 8 8 8 4 1 2 2 3 6 5 7 9 5 (8) (8) 7 nm (0.7 m • kg, 5.1 ft • ib) 7 nm (0.7 m • kg, 5.1 ft • ib) 7 nm (0.7 m • kg, 5.1 ft • ib) 7 nm (0.7 m • kg, 5.1 ft • ib) 7 nm (0.7 m • kg, 5.1 ft • ib) 16 nm (1.6 m • kg, 11 ft • ib) t r . . T r . . T r . . T r...

  • Page 368: Chas

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

  • Page 369: Chas

    8 - 12 chas seats, enclosure, hood and cargo bed installing the rear skid plate 1. Install: • rear skid plate 1 tip: make sure that the hole a in the rear skid plate 1 is towards the left side of the vehicle. È forward É left side Ê right side È É Ê 1 a.

  • Page 370: Chas

    8 - 13 chas seats, enclosure, hood and cargo bed enclosure and seat belts 59 nm (5.9 m • kg, 43 ft • ib) 8 2 1 3 9 7 9 6 (4) (4) (4) (3) (3) (8) (14) 4 4 5 10 64 nm (6.4 m • kg, 46 ft • ib) 59 nm (5.9 m • kg, 43 ft • ib) 7 nm (0.7 m • kg, 5.1 ft • ib) 59 nm (5.9 m • kg, 43 ft • ib) t r . . 65 nm (6....

  • Page 371: Chas

    8 - 14 chas seats, enclosure, hood and cargo bed installing the enclosure 1. Install: • lower support frame 1 2. Install: • left side frame 2 • right side frame 3 • upper support frame 4 • rear top frame 5 • front top frame 6 tip: do not fully tighten the bolts and nuts. 3. Tighten: • upper support ...

  • Page 372: Chas

    8 - 15 chas front and rear wheels ebs00378 front and rear wheels front wheels 4 6 5 3 new lt lt 2 1 t r . . 48 nm (4.8 m • kg, 35 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 350 nm (35.0 m • kg, 255 ft • lb) order job/part q’ty remarks removing the ...

  • Page 373: Chas

    8 - 16 chas front and rear wheels 4 6 5 3 new lt lt 2 1 t r . . 48 nm (4.8 m • kg, 35 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 350 nm (35.0 m • kg, 255 ft • lb) order job/part q’ty remarks 4 front brake caliper assembly 1 tip: _ do not depress th...

  • Page 374: Chas

    8 - 17 chas front and rear wheels ebs00379 rear wheels lt new 1 3 5 6 4 2 t r . . 350 nm (35.0 m • kg, 255 ft • lb) t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 48 nm (4.8 m • kg, 35 ft • ib) (4) order job/part q’ty remarks removing the rear wheels remove the...

  • Page 375: Chas

    8 - 18 chas front and rear wheels lt new 1 3 5 6 4 2 t r . . 350 nm (35.0 m • kg, 255 ft • lb) t r . . 55 nm (5.5 m • kg, 40 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 48 nm (4.8 m • kg, 35 ft • ib) (4) order job/part q’ty remarks 4 rear brake caliper assembly 1 tip: do not depress the ...

  • Page 376: Chas

    8 - 19 chas front and rear wheels ebs00383 checking the wheels 1. Check: • wheels 2. Measure: • wheel runout over the specified limit → replace the wheel or check the wheel bearing play 1. Wheel runout limit front radial 2: 2.0 mm (0.08 in) lateral 3: 2.0 mm (0.08 in) rear radial 2: 2.0 mm (0.08 in)...

  • Page 377: Chas

    8 - 20 chas front and rear wheels ebs00389 checking the brake discs 1. Check: • brake discs galling/damage → replace. 2. Measure: • brake disc deflection out of specification → check the wheel runout. • brake disc thickness a out of specification → replace. Brake disc maximum deflection front: 0.1 m...

  • Page 378: Chas

    8 - 21 chas front and rear brakes front and rear brakes front brake pads 4 3 t r . . 17 nm (1.7 m • kg, 12 ft • ib) 2 1 t r . . 48 nm (4.8 m • kg, 35 ft • ib) order job/part q’ty remarks removing the front brake pads remove the parts in the order listed. The following procedure applies to both of th...

  • Page 379: Chas

    8 - 22 chas front and rear brakes ebs00401 rear brake pads 4 2 3 1 1 t r . . 17 nm (1.7 m • kg, 12 ft • ib) t r . . 48 nm (4.8 m • kg, 35 ft • ib) order job/part q’ty remarks removing the rear brake pads remove the parts in the order listed. The following procedure applies to both of the rear brake ...

  • Page 380: Chas

    8 - 23 chas front and rear brakes notice disc brake components rarely require dis- assembly. Do not: • disassemble components unless abso- lutely necessary; • use solvents on internal brake compo- nents; • use spent brake fluid for cleaning; (use only clean brake fluid) • allow brake fluid to come i...

  • Page 381: Chas

    8 - 24 chas front and rear brakes 2. Install: • brake pads • brake pad spring tip: always install new brake pads and brake pad spring as a set. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a suitable hose 1 tightly to the brake caliper bleed screw 2. Put the other end of this hose in...

  • Page 382: Chas

    8 - 25 chas front and rear brakes brake master cylinder 5 4 t r . . 19 nm (1.9 m • kg, 13 ft • ib) t r . . 19 nm (1.9 m • kg, 13 ft • ib) t r . . 16 nm (1.6 m • kg, 11 ft • ib) 6 1 2 3 order job/part q’ty remarks removing the brake master cylinder remove the parts in the order listed. Brake fluid dr...

  • Page 383: Chas

    8 - 26 chas front and rear brakes 3 6 2 1 4 t r . . 9 nm (0.9 m • kg, 6.5 ft • ib) new new new 5 new s order job/part q’ty remarks disassembling the brake master cyl- inder remove the parts in the order listed. 1 dust boot 1 2 circlip 1 3 primary brake master cylinder kit 1 4 secondary brake master ...

  • Page 384: Chas

    8 - 27 chas front and rear brakes checking the master cylinder 1. Check: • brake master cylinder 1 wear/scratches → replace the brake mas- ter cylinder assembly. • brake master cylinder body cracks/damage → replace. • brake fluid delivery passage (brake master cylinder body) blockage → blow out with...

  • Page 385: Chas

    8 - 28 chas front and rear brakes installing the brake master cylinder 1. Install: • brake master cylinder 2. Install: • brake pipes warning proper brake pipe routing is essential to insure safe vehicle operation. Refer to “cable routing” in chapter 2. 3. Fill: • brake master cylinder reservoir noti...

  • Page 386: Chas

    8 - 29 chas front and rear brakes 5. Check: • brake fluid level brake fluid level is under the “min” level line → fill up. Refer to “checking the brake fluid level” in chapter 3. 6. Adjust: • brake pedal free play refer to “adjusting the brake pedal” in chapter 3..

  • Page 387: Chas

    8 - 30 chas front and rear brakes front brake caliper order job/part q’ty remarks removing the front brake caliper remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Brake fluid drain. Front wheel refer to “front and rear wheels”. 1 union bolt ...

  • Page 388: Chas

    8 - 31 chas front and rear brakes new new 5 6 6 7 7 4 1 3 8 2 t r . . 17 nm (1.7 m • kg, 12 ft • ib) t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) s s bf bf order job/part q’ty remarks disassembling the front brake cali- per remove the parts in the order listed. The following procedure applies to both of t...

  • Page 389: Chas

    8 - 32 chas front and rear brakes ebs00424 rear brake calipers 3 1 2 6 5 5 4 t r . . 27 nm (2.7 m • kg, 19 ft • ib) t r . . 17 nm (1.7 m • kg, 12 ft • ib) t r . . 48 nm (4.8 m • kg, 35 ft • ib) new order job/part q’ty remarks removing the rear brake calipers remove the parts in the order listed. The...

  • Page 390: Chas

    8 - 33 chas front and rear brakes ebs00425 new s t r . . 5 nm (0.5 m • kg, 3.6 ft • ib) t r . . 17 nm (1.7 m • kg, 12 ft • ib) 2 3 8 1 4 5 6 7 7 6 new s s s bf bf order job/part q’ty remarks disassembling the rear brake cali- pers remove the parts in the order listed. The following procedure applies...

  • Page 391: Chas

    8 - 34 chas front and rear brakes ebs00427 disassembling the front and rear brake calipers 1. Remove: • brake caliper pistons • brake caliper dust seals 1 • brake caliper piston seals 2 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Blow compressed air into the hose joint opening to force out ...

  • Page 392: Chas

    8 - 35 chas front and rear brakes 1. Check: • brake caliper pistons 1 scratches/rust/wear → replace the brake caliper assembly. • brake caliper cylinders 2 wear/scratches → replace the brake cali- per assembly. • brake caliper body 3 cracks/damage → replace. • brake fluid delivery passage (brake cal...

  • Page 393: Chas

    8 - 36 chas front and rear brakes ebs00434 installing the front and rear brake calipers 1. Install: • brake caliper assembly • brake caliper bolts • brake hose 1 • copper washers 2 • union bolt 3 notice _ when installing the brake hose on the brake caliper, make sure that the brake pipe touches the ...

  • Page 394: Chas

    8 - 37 chas front and rear brakes warning _ • use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. • refill with the same type of brake fluid: mixing brake fluids may result in a harm- ful chemical reaction and ...

  • Page 395: Chas

    8 - 38 chas parking brake parking brake parking brake pads lt lt t r . . 17 nm (1.7 m • kg, 12 ft • ib) 5 6 6 7 1 4 2 3 t r . . 40 nm (4.0 m • kg, 29 ft • ib) order job/part q’ty remarks removing the parking brake pads remove the parts in the order listed. Rear skid plate refer to “seats, enclosure,...

  • Page 396: Chas

    8 - 39 chas parking brake replacing the parking brake pads 1. Measure: • brake pad wear limit a out of specification → replace the brake pads as a set. Brake pad wear limit 1.0 mm (0.04 in) 2. Install: • brake pad spring • parking brake pads • parking brake pad holding bolts tip: always install new ...

  • Page 397: Chas

    8 - 40 chas parking brake parking brake t r . . 40 nm (4.0m • kg, 29 ft • ib) 4 7 5 6 1 2 t r . . 13 nm (1.3 m • kg, 9.4 ft • ib) 3 order job/part q’ty remarks removing the parking brake remove the parts in the order listed. Seats/rear console refer to “seats, rear console and instrument panels”. Re...

  • Page 398: Chas

    8 - 41 chas t r . . 40 nm (4.0m • kg, 29 ft • ib) 4 7 5 6 1 2 t r . . 13 nm (1.3 m • kg, 9.4 ft • ib) 3 order job/part q’ty remarks 7 parking brake cable (parking brake side) 1 disconnect. Refer to “assembling the parking brake”. For installation, reverse the removal pro- cedure. Parking brake.

  • Page 399: Chas

    8 - 42 chas parking brake new new s s s t r . . 17 nm (1.7 m • kg, 12 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) 2 3 7 a 6 1 9 8 5 4 0 new t r . . 17 nm (1.7 m • kg, 12 ft • ib) lt lt lt order job/part q’ty remarks disassembling the parking brake remove the parts in the order listed. 1 parking...

  • Page 400: Chas

    8 - 43 chas parking brake parking brake disc (6) 1 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) order job/part q’ty remarks removing the parking brake disc remove the parts in the order listed. Parking brake assembly refer to “front and rear brakes”. Final drive gear assembly refer to “rear constant velo...

  • Page 401: Chas

    8 - 44 chas parking brake eb702040 checking the parking brake 1. Check: • parking brake piston scratches/rust/wear → replace the parking brake assembly. • parking brake body cracks/damage → replace. Checking the parking brake disc 1. Check: • brake disc galling/damage → replace. 2. Measure: • brake ...

  • Page 402: Chas

    8 - 45 chas parking brake 2. Install: • push rod 1 • wave washers • retainer • o-ring • parking brake piston 2 • circlip tip: turn in the push rod until it protrudes a from the end of the parking brake arm shaft 3. A 5 ~ 6 mm (0.20 ~ 0.24 in) a 1 2 3 new new 3. Install: • parking brake arm 1 tip: in...

  • Page 403: Chas

    8 - 46 chas parking brake 7. Install: • parking brake cable 1 • parking brake assembly 2 • parking brake bolts tip: turn the parking brake lever 3 to the position shown in the illustration so that there is enough space between the parking brake pads, and then install the parking brake assembly. 8. A...

  • Page 404: Chas

    8 - 47 chas pedal assembly pedal assembly 5 6 new t r . . 16 nm (1.6 m • kg, 11 ft • ib) 2 3 7 4 1 ls order job/part q’ty remarks removing the pedal assembly remove the parts in the order listed. Steering wheel cover/steering wheel/ pedal cover/upper instrument panel/ lower instrument panel refer to...

  • Page 405: Chas

    8 - 48 chas pedal assembly 2 3 4 3 9 5 1 7 7 6 8 ls new new order job/part q’ty remarks disassembling the pedal assembly remove the parts in the order listed. 1 spring 1 2 circlip 1 3 washer 2 4 brake pedal 1 5 spring 1 6 circlip 1 7 washer 2 8 accelerator pedal 1 9 pedal assembly bracket 1 for asse...

  • Page 406: Chas

    8 - 49 chas steering system steering system steering shaft and steering assembly 1 2 3 t r . . 48 nm (4.8 m • kg, 35 ft • ib) t r . . 21 nm (2.1 m • kg, 15 ft • ib) t r . . 22 nm (2.2 m • kg, 16 ft • ib) t r . . 39 nm (3.9 m • kg, 28 ft • ib) new new order job/part q’ty remarks removing the steering...

  • Page 407: Chas

    8 - 50 chas steering system 2 4 3 1 8 9 a b 7 6 5 c 2 4 1 3 new new new t r . . 40 nm (4.0 m • kg, 29 ft • ib) 0 new new lt ls ls ls ls ls ls m m t r . . 4 nm (0.4 m • kg, 2.9 ft • ib) t r . . 40 nm (4.0 m • kg, 29 ft • ib) m order job/part q’ty remarks disassembling the steering assem- bly remove t...

  • Page 408: Chas

    8 - 51 chas steering system 2 4 3 1 8 9 a b 7 6 5 c 2 4 1 3 new new new t r . . 40 nm (4.0 m • kg, 29 ft • ib) 0 new new lt ls ls ls ls ls ls m m t r . . 4 nm (0.4 m • kg, 2.9 ft • ib) t r . . 40 nm (4.0 m • kg, 29 ft • ib) m order job/part q’ty remarks c steering rack assembly 1 refer to “assemblin...

  • Page 409: Chas

    8 - 52 chas steering system disassembling the steering assembly 1. Remove: • oil seal • circlip • pinion gear with bearing 1 tip: lightly tap on the steering housing with a soft hammer to remove the pinion gear easily. Checking the steering joint 1. Check: • steering joint rough movement → replace. ...

  • Page 410: Chas

    8 - 53 chas steering system 3. Check: • rack gear teeth 1 • pinion gear teeth 2 wear/damage → replace the steering rack assembly. Tip: the wear pattern on the rack and pinion gear teeth should be uniform. An uneven wear pat- tern may indicate improper adjustment or lack of lubrication. 1 2 4. Check:...

  • Page 411: Chas

    8 - 54 chas steering system 2. Install: • bearing • circlips • pinion gear • oil seal tip: after centering the rack gear, make two align- ment marks a on the pinion gear and the steering rack assembly to mark the position of the pinion gear. This is necessary to install the steering joint to the pin...

  • Page 412: Chas

    8 - 55 chas steering system tie-rod and steering knuckle 3 6 8 9 7 4 2 5 new 3 new new new new new new ls ls 1 t r . . 30 nm (3.0 m • kg, 22 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 39 nm (3.9 m • kg, 28 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) order job/part q’ty remarks remov...

  • Page 413: Chas

    8 - 56 chas steering system removing the steering knuckles 1. Remove: • steering knuckle 1 tip: use a general puller to separate the ball joints 2 from the steering knuckle 1 or the front lower arm 3. Checking the tie-rods 1. Check: • tie-rod free play and movement free play → replace the tie-rod en...

  • Page 414: Chas

    8 - 57 chas steering system d. Install the body 3, short bolt 5, remover washer 6 and remover spacer 7 onto the ball joint. Tip: • remover washer 6 must be aligned with the projection on the head of the ball joint. • surface a of the remover spacer 7 must be aligned with the surface b of the steerin...

  • Page 415: Chas

    8 - 58 chas steering system h. Attach the assembled ball joint remover, new ball joint b and installer attachment 8 to the steering knuckle c. Tip: do not tap or damage the top of the ball joint. I. Hold the body 3 in place while turning in the long bolt 4 to install the new ball joint b into the st...

  • Page 416: Chas

    8 - 59 chas steering system h. Install the new oil seals. Tip: when installing the oil seals, the “seal side” of the oil seal faces out. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲.

  • Page 417: Chas

    8 - 60 chas front arms and front shock absorbers front arms and front shock absorbers 6 9 9 4 3 4 4 5 5 1 6 10 6 11 12 10 7 6 new ls new 4 ls 9 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) ...

  • Page 418: Chas

    8 - 61 chas front arms and front shock absorbers 6 9 9 4 3 4 4 5 5 1 6 10 6 11 12 10 7 6 new ls new 4 ls 9 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 30 nm (3.0 m • kg, 22 ft • ib) 3 2 ls ls 9 10 8 t r . . 45 nm (4.5 m...

  • Page 419: Chas

    8 - 62 chas front arms and front shock absorbers removing the front arms 1. Check: • front arm free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Check the front arm side play È by moving it from side to side. If side play is noticeable, check the bush- ings. B. Check the front arm verti...

  • Page 420: Chas

    8 - 63 chas front arms and front shock absorbers c. Install the body 3, long bolt 4, remover washer 5 and remover spacer 6 onto ball joint. Tip: remover washer 5 must be aligned with the projection on the head of the ball joint. D. Hold the body 3 in place while turning in the long bolt 4 to remove ...

  • Page 421: Chas

    8 - 64 chas front arms and front shock absorbers j. Apply lithium-soap base grease to the new ball joint a. K. Install a new rubber boot and new circlip. Tip: always use a new ball joint set. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ handling the front shock absorbers and gas cylinders (for ...

  • Page 422: Chas

    8 - 65 chas front arms and front shock absorbers ebs00486 disposing of a front shock absorber and gas cylinder (for models equipped with gas-oil damper shock absorbers) gas pressure must be released before dispos- ing of a front shock absorber and gas cylinder. To release the gas pressure, press on ...

  • Page 423: Chas

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

  • Page 424: Chas

    8 - 67 chas rear knuckle and stabilizer rear knuckle and stabilizer 8 9 7 8 9 10 7 5 2 5 3 4 6 5 5 6 t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 60 nm (6.0 m • kg, 43 ft • ib) t r . . 60 nm (6.0 m • kg, 43 ft • ib) 1 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) ne...

  • Page 425: Chas

    8 - 68 chas rear knuckle and stabilizer checking the rear knuckles 1. Check: • rear knuckle damage/pitting → replace. 2. Check: • rear wheel bearings bearings allow play in the wheel hubs or the wheel turns roughly → replace. • oil seals damage → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ...

  • Page 426: Chas

    8 - 69 chas rear arms and rear shock absorber rear arms and rear shock absorber 4 7 7 3 5 4 8 4 7 t r . . 45 nm (4.5 m • kg, 32 ft • ib) 2 2 2 t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) 2 ls ls ls 6 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) 1 order job/part q’ty remar...

  • Page 427: Chas

    8 - 70 chas rear arms and rear shock absorber 4 7 7 3 5 4 8 4 7 t r . . 45 nm (4.5 m • kg, 32 ft • ib) 2 2 2 t r . . 45 nm (4.5 m • kg, 32 ft • ib) t r . . 45 nm (4.5 m • kg, 32 ft • ib) 2 ls ls ls 6 t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) 1 order job/part q’ty remarks 6 rear shock absorber 1 for mod...

  • Page 428: Chas

    8 - 71 chas rear arms and rear shock absorber checking the rear arms 1. Check: • rear arms bends/damage → replace. 2. Check: • bushings wear/damage → replace. Ebs00485 handling the rear shock absorbers and gas cylinders (for models equipped with gas-oil damper shock absorbers) warning _ this rear sh...

  • Page 429: Chas

    8 - 72 chas rear arms and rear shock absorber ebs00486 disposing of a rear shock absorber and gas cylinder (for models equipped with gas-oil damper shock absorbers) gas pressure must be released before dispos- ing of a rear shock absorber and gas cylinder. To release the gas pressure, press on the g...

  • Page 430: Chas

    8 - 73 chas rear arms and rear shock absorber installing the rear arms and rear shock absorber 1. Install: • rear arms • rear shock absorber ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the rear upper arm 1 and rear lower arm 2. Tip: • lubricate the bolts 3 with lithium-soap- based g...

  • Page 431: Elec

    9 - 1 – + elec eb800000 electrical electrical components 1 diode 2 lean angle sensor 3 gear position switch 4 reverse switch 5 parking brake switch 6 intake air temperature sensor 7 intake air pressure sensor 8 tps (throttle position sensor) 9 isc (idle speed control) unit 0 coolant temperature sens...

  • Page 432: Elec

    9 - 2 – + elec electrical components 1 auxiliary dc jack 2 on-command four-wheel-drive motor switch and differential gear lock switch 3 main switch 4 light switch 5 rectifier/regulator 6 four-wheel-drive motor relay 2 7 four-wheel-drive motor relay 1 8 starter relay 9 fuel injection system fuse 0 he...

  • Page 433: Elec

    9 - 3 – + elec checking switch continuity ebs01028 checking switch continuity check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. Notice _ never insert the tester probes into the cou- ...

  • Page 434: Elec

    9 - 4 – + elec checking the switches ebs01029 checking the switches check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “checking switch continuity”. Damage/wear → repair or replace. Improperly connected → properly connect. Incorrect co...

  • Page 435: Elec

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

  • Page 436: Elec

    9 - 6 – + elec checking the bulbs and bulb sockets ebs01030 checking the bulbs and bulb sockets check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or both. Improperly connected...

  • Page 437: Elec

    9 - 7 – + elec checking the bulbs and bulb sockets checking the condition of the bulbs the following procedure applies to all of the bulbs. 1. Remove: • bulb warning _ since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. Not...

  • Page 438: Elec

    9 - 8 – + elec checking the bulbs and bulb sockets ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the positive tester probe to termi- nal 1 and the negative tester probe to ter- minal 2, and check the continuity. B. Connect the positive tester probe to termi- nal 1 and the negative tes...

  • Page 439: Elec

    9 - 9 – + elec ignition system ebs00503 ignition system circuit diagram gy b b /l gy b r /w lb br (black) y y (black) br /y l /rb bl /b r /lb o /bb /w (black) l /y r /y g /y (green) b /l w l/ y b /l lw b /l g y b yg b g y b yg b ww w (gray) br (black) w (gray) w (gray) w ww (gray) w (gray) b b r r r...

  • Page 440: Elec

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

  • Page 441: Elec

    9 - 11 – + elec ignition system ebs01032 yes no ebs01034 no yes 3. Spark plug • check the condition of the spark plug. • check the spark plug type. • measure the spark plug gap. Refer to “checking the spark plug” in chapter 3. Standard spark plug cpr7ea-9 (ngk) spark plug gap 0.8 ~ 0.9 mm (0.031 ~ 0...

  • Page 442: Elec

    9 - 12 – + elec ignition system ebs01036 yes no ebs01038 yes no 5. Spark plug cap resistance • remove the spark plug cap from the spark plug lead. • connect the pocket tester ( Ω × 1k) to the spark plug cap as shown. • measure the spark plug cap resistance. Spark plug cap resistance 10.0 k Ω at 20 °...

  • Page 443: Elec

    9 - 13 – + elec ignition system ebs01041 yes no ebs01040 yes no yes no ebs01047 yes no 7. Main switch • check the main switch for continuity. Refer to “checking the switches”. • is the main switch ok? Replace the main switch. 8. Crankshaft position sensor resistance • disconnect the crankshaft posit...

  • Page 444: Elec

    9 - 14 – + elec electric starting system ebs00506 electric starting system circuit diagram gy b b /l gy b r /w lb br (black) y y (black) br /y l /rb bl /b r /lb o /bb /w (black) l /y r /y g /y (green) b /l w l/ y b /l lw b /l g y b yg b g y b yg b ww w (gray) br (black) w (gray) w (gray) w ww (gray)...

  • Page 445: Elec

    9 - 15 – + elec electric starting system ebs00507 starting circuit operation the starting circuit on this model consists of the starter motor, starter relay, load control relay, brake light switch, ecu (engine control unit) and gear position switch. If the main switch is “start” position, the starte...

  • Page 446: Elec

    9 - 16 – + elec electric starting system ebs01048 troubleshooting check: 1. Main, ignition, backup and signaling system fuses 2. Battery 3. Starter motor 4. Starter relay 5. Load control relay 6. Main switch 7. Brake light switch 8. Gear position switch 9. Wiring connections (of the entire starting ...

  • Page 447: Elec

    9 - 17 – + elec electric starting system ebs01054 yes no ebs01054 yes no 4. Starter relay • remove the starter relay from the wire harness. • connect the pocket tester ( Ω × 1) and bat- tery (12 v) to the starter relay as shown. Positive battery terminal → blue/yellow 1 negative battery terminal → r...

  • Page 448: Elec

    9 - 18 – + elec electric starting system ebs01041 yes no yes no ebs01058 yes no ebs01059 yes no 6. Main switch • check the main switch for continuity. Refer to “checking the switches”. • is the main switch ok? Replace the main switch. 7. Brake light switch • check the brake light switch for continui...

  • Page 449: Elec

    9 - 19 – + elec ebs01061 starter motor order job/part q’ty remarks removing the starter motor remove the parts in the order listed. Air intake duct refer to “air filter case and air intake duct” in chapter 6. 1 starter motor lead 1 disconnect. 2 starter motor 1 for installation, reverse the removal ...

  • Page 450: Elec

    9 - 20 – + elec starter motor order job/part q’ty remarks 7 bushing 1 refer to “assembling the starter motor”. 8 shim * 9 brush holder set 1 0 armature assembly 1 a starter motor yoke 1 for assembly, reverse the disassembly procedure..

  • Page 451: Elec

    9 - 21 – + elec starter motor ebs01064 checking the starter motor 1. Check: • commutator dirt → clean with 600-grit sandpaper. 2. Measure: • commutator diameter a out of specification → replace the starter motor. Commutator wear limit 27 mm (1.06 in) a 3. Measure: • mica undercut a out of specificat...

  • Page 452: Elec

    9 - 22 – + elec starter motor ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure the armature assembly resis- tances with the pocket tester. B. If any resistance is out of specification, replace the starter motor. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ pocket tester 90890-03112 ...

  • Page 453: Elec

    9 - 23 – + elec starter motor ebs00515 assembling the starter motor 1. Install: • brush holder set 1 tip: _ align the projection a on the brush holder set with the slot b in the starter motor yoke. 2. Install: • starter motor yoke 1 • starter motor front cover 2 • starter motor rear cover 3 tip: _ a...

  • Page 454: Elec

    9 - 24 – + elec charging system ebs00516 charging system circuit diagram gy b b/l gy w w w (gray) b r (black) w (gray) w (gray) w w w (gray) w (gray) b b r r r r/l br/r y/r r br/l br/r b l/y (black) br/r br/r r/b br/b r/y (black) l/y off on start br/b r r br/l p r r/w br/l br/y r r r r b b b b b b b...

  • Page 455: Elec

    9 - 25 – + elec charging system ebs01065 troubleshooting check: 1. Main fuse 2. Battery 3. Charging voltage 4. Stator coil resistance 5. Wiring connections (of the entire charging system) tip: _ • before troubleshooting, remove the following part(s): 1. Rear console 2. Front console • troubleshoot w...

  • Page 456: Elec

    9 - 26 – + elec charging system ebs01066 no yes ebs01100 yes no yes no 3. Charging voltage • connect the engine tachometer to the spark plug lead. • connect the pocket tester (dc 20 v) to the battery as shown. Positive tester probe → positive battery terminal 1 negative tester probe → negative batte...

  • Page 457: Elec

    9 - 27 – + elec lighting system ebs00518 lighting system circuit diagram gy b b/l gy b r/w l b br (black) y y (black) br/y l/y r/y g y b y g b g y b y g b w w w (gray) b r (black) w (gray) w (gray) w w w (gray) w (gray) b b r r r r/l br/r y/r r br/l br/r b br gy br/r y/b br/b r/l br/r l/r l (black) ...

  • Page 458: Elec

    9 - 28 – + elec lighting system ebs01067 troubleshooting check: 1. Main, ignition and headlight fuses 2. Battery 3. Main switch 4. Light switch 5. Load control relay 6. Wiring connections (of the entire lighting system) tip: _ • before troubleshooting, remove the following part(s): 1. Rear console •...

  • Page 459: Elec

    9 - 29 – + elec lighting system ebs01054 yes no ebs01069 yes no 5. Load control relay • remove the load control relay from the wire harness. • connect the pocket tester ( Ω × 1) and bat- tery (12 v) to the load control relay as shown. Positive battery terminal → brown/red 1 negative battery terminal...

  • Page 460: Elec

    9 - 30 – + elec lighting system ebs01070 checking the lighting system 1. The headlights fail to come on. Yes no yes no 1. Headlight bulb and socket • check the headlight bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets”. • are the headlight bulb and socket ok? Replace th...

  • Page 461: Elec

    9 - 31 – + elec lighting system yes no 2. The taillight fails to come on. Yes no yes no 3. Voltage • connect the pocket tester (dc 20 v) to the headlight couplers as shown. È when the light switch is set to “hi”. É when the light switch is set to “lo”. Headlight coupler (wire harness side) headlight...

  • Page 462: Elec

    9 - 32 – + elec signaling system ebs00521 signaling system circuit diagram gy b b /l gy b r /w lb br (black) y y (black) br /y l /rb bl /b r /lb o /bb /w (black) l /y r /y g /y (green) b /l w l/ y b /l lw b /l g y b yg b g y b yg b ww w (gray) br (black) w (gray) w (gray) w ww (gray) w (gray) b b r ...

  • Page 463: Elec

    9 - 33 – + elec signaling system 4 main fuse 5 frame ground 6 ignition fuse 7 main switch 8 battery b backup fuse e reverse switch g ecu (engine control unit) l coolant temperature sensor m speed sensor q gear position switch r parking brake switch t multifunction meter v coolant temperature warning...

  • Page 464: Elec

    9 - 34 – + elec signaling system ebs01073 troubleshooting check: 1. Main, backup, signaling system and ignition fuses 2. Battery 3. Main switch 4. Load control relay 5. Wiring connections (of the entire signaling system) tip: _ • before troubleshooting, remove the following part(s): 1. Rear console ...

  • Page 465: Elec

    9 - 35 – + elec signaling system ebs01054 yes no ebs01074 yes no 4. Load control relay • remove the load control relay from the wire harness. • connect the pocket tester ( Ω × 1) and bat- tery (12 v) to the load control relay as shown. Positive battery terminal → brown/red 1 negative battery termina...

  • Page 466: Elec

    9 - 36 – + elec signaling system ebs01075 checking the signaling system ebs01076 1. The brake light fails to come on. Yes no yes no yes no 1. Brake light bulb and bulb socket • check the brake light bulb and bulb socket for continuity. Refer to “checking the bulbs and bulb sockets”. • are the brake ...

  • Page 467: Elec

    9 - 37 – + elec signaling system ebs01078 2. The neutral, high-range, and/or low-range indicator light fails to come on. Yes no yes no yes no 1. Gear position switch • check the gear position switch for continu- ity. Refer to “checking the switches”. • is the gear position switch ok? Replace the gea...

  • Page 468: Elec

    9 - 38 – + elec signaling system ebs01079 3. The reverse indicator light fails to come on. Yes no yes no yes no 1. Reverse switch • check the reverse switch for continuity. Refer to “checking the switches”. • is the reverse switch ok? Replace the reverse switch. 2. Wiring • check the wiring circuit ...

  • Page 469: Elec

    9 - 39 – + elec signaling system ebs01081 4. The park indicator light fails to come on. Yes no yes no yes no 1. Parking brake switch • check the parking brake switch for conti- nuity. Refer to “checking the switches”. • is the parking brake switch ok? Replace the parking brake switch. 2. Wiring • ch...

  • Page 470: Elec

    9 - 40 – + elec signaling system ebs01081 5. The differential gear lock indicator light and/ or four-wheel-drive motor indicator light fails to come on. Yes no yes no yes no 1. Four-wheel-drive motor switch (differential gear motor) • check the four-wheel-drive motor switch for continuity. Refer to ...

  • Page 471: Elec

    9 - 41 – + elec ebs01083 6. The coolant temperature warning light does not come on when the main switch is set to “on”, or if the coolant temperature warning light does not come on when the tempera- ture is high (more than 122 °c (251.6 °f)). Ebs00812 yes no yes no 1. Coolant temperature sensor • re...

  • Page 472: Elec

    9 - 42 – + elec yes no 7. The fuel meter fails to come on. Yes no 3. Voltage • connect the pocket tester (dc 20 v) to the meter assembly coupler as shown. Positive tester probe → brown/yellow 1 negative tester probe → black/white 2 • set the main switch to “on”. • measure the voltage (12 v) of brown...

  • Page 473: Elec

    9 - 43 – + elec signaling system yes no yes no 8. The speedometer fails to come on. Yes no yes no 2. Wiring • check the wiring circuit from the fuel pump to ecu (brown/white) and fuel pump to meter assembly (orange/black). • is the wiring circuit properly connect and without defects? Properly connec...

  • Page 474: Elec

    9 - 44 – + elec signaling system yes no 3. Voltage • connect the pocket tester (dc 20 v) to the meter assembly coupler as shown. Positive tester probe → brown/yellow 1 negative tester probe → black/white 2 • set the main switch to “on”. • measure the voltage (12 v) of brown/yel- low 1 and black/whit...

  • Page 475: Elec

    9 - 45 – + elec cooling system ebs00532 cooling system circuit diagram gy b b /l gy b r /w lb br (black) y y (black) br /y l /rb bl /b r /lb o /bb /w (black) l /y r /y g /y (green) b /l w l/ y b /l lw b /l g y b yg b g y b yg b ww w (gray) br (black) w (gray) w (gray) w ww (gray) w (gray) b b r r r ...

  • Page 476: Elec

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

  • Page 477: Elec

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

  • Page 478: Elec

    9 - 48 – + elec yes no 6. Radiator fan motor circuit breaker • remove the radiator fan motor circuit breaker from the wire harness. • connect the pocket tester ( Ω × 1) to the radiator fan motor circuit breaker. Radiator fan motor circuit breaker resistance 0 ~ 0.05 Ω at 25 °c (77 °f) replace the ra...

  • Page 479: Elec

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

  • Page 480: Elec

    9 - 50 – + elec fuel pump system fuel pump system circuit diagram gy b b /l gy b r /w lb br (black) y y (black) br /y l /rb bl /b r /lb o /bb /w (black) l /y r /y g /y (green) b /l w l/ y b /l lw b /l g y b yg b g y b yg b ww w (gray) br (black) w (gray) w (gray) w ww (gray) w (gray) b b r r r r /l ...

  • Page 481: Elec

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

  • Page 482: Elec

    9 - 52 – + elec fuel pump system yes no yes no yes no 4. Fuel injection system relay • remove the fuel injection system relay from the wire harness. • connect the pocket tester ( Ω × 1) and bat- tery (12 v) to the fuel injection system relay terminal as shown. • check the fuel injection system relay...

  • Page 483: Elec

    9 - 53 – + elec 2wd/4wd selecting system ebs00535 2wd/4wd selecting system circuit diagram gy b b /l gy b r /w lb br (black) y y (black) br /y l /rb bl /b r /lb o /bb /w (black) l /y r /y g /y (green) b /l w l/ y b /l lw b /l g y b yg b g y b yg b ww w (gray) br (black) w (gray) w (gray) w ww (gray)...

  • Page 484: Elec

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

  • Page 485: Elec

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

  • Page 486: Elec

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

  • Page 487: Elec

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

  • Page 488: Trbl

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

  • Page 489: Trbl

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

  • Page 490: Trbl

    10 - 3 trbl shtg faulty drive train ebs00540 faulty drive train 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....

  • Page 491: Trbl

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

  • Page 492: Trbl

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

  • Page 493: Trbl

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

  • Page 494

    Yxr70fx 2008 wiring diagram 1 crankshaft position sensor 2 ac magneto 3 rectifier/regulator 4 main fuse 5 frame ground 6 ignition fuse 7 main switch 8 battery 9 fuel injection system fuse 0 starter relay a starter motor b backup fuse c diode d fuel injection system relay e reverse switch f isc (idle...

  • Page 496

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

  • Page 497

    Yxr70fx 2008 wiring diagram gy b b/l gy br b b r/w l b br (black) y y (black) br/y l/r b b l/b r/l b o/b b/w (black) l/y r/y g/y (green) b/l w l/y b/l l w b/l g y b y g b g y b y g b w w w (gray) b r (black) w (gray) w (gray) w w w (gray) w (gray) b b r r r r/l br/r y/r r br/l br/r b br/b (black) br...