1. DL manuals
  2. Yamaha
  3. Utility Vehicle
  4. Wolverine YX70EPNG
  5. Service Manual

Yamaha Wolverine YX70EPNG Service Manual

Other manuals for Wolverine YX70EPNG: Owner's Manual

Summary of Wolverine YX70EPNG

  • Page 1

    201 6-17 service manual yx70epng yxe70wpxg yxe70wphg yxe70wdxg yxe700e yxe700se 2mb- g 819 8 -e0

  • Page 2

    Ebs20002 yx70epng/yxe70wpxg/ yxe70wphg/yxe70wdxg/yxe700e / yxe700se service manual ©201 7 by yamaha motor co., ltd. 2nd edition, may 201 7 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited. Brought to you by for...

  • Page 3: Important

    Ebs20003 important this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on y...

  • Page 4: How to Use This Manual

    Ebs20004 how to use this manual this manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. • the manual is di...

  • Page 5: Symbols

    Ebs20005 symbols the following symbols are used in this manual for easier understanding. Tip the following symbols are not relevant to every vehicle. Symbol definition symbol definition serviceable with engine mounted gear oil filling fluid molybdenum disulfide oil lubricant brake fluid special tool...

  • Page 7: Table of Contents

    Ebs10003 table of contents general information 1 specifications 2 periodic checks and adjustments 3 chassis 4 engine 5 cooling system 6 fuel system 7 drive train 8 electrical system 9 troubleshooting 10

  • Page 9: General Information

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

  • Page 10: Identification

    Identification 1-1 ebs20009 identification ebs30003 vehicle identification number the vehicle identification number “1” is stamped into the frame. Ebs30004 model label the model label “1” is affixed to the frame under the driver seat. This information will be needed to order spare parts. 1 1.

  • Page 11: Identification

    Identification 1-2.

  • Page 12: Features

    Features 1-3 ebs20010 features ebs30007 outline of the eps (electric power steering) system (for eps model) 2 d 1 4 e c 3 5 6 7 f a b 5.

  • Page 13: Features

    Features 1-4 notice ecb01790 to prevent accidental damage to the eps unit, it must not be disassembled. 1. Speed information from speed sensor 2. Engine rpm information from ecu 3. Battery 4. Eps control unit 5. Eps unit 6. Eps motor 7. Torque sensor a. Operates steering b. Twists torsion bar c. Sen...

  • Page 14: Features

    Features 1-5 ebs30008 instrument functions multi-function meter unit the multi-function meter unit is equipped with the following: • a speedometer • an odometer • two tripmeters (which show the distance trav- eled since they were last set to zero) • a clock • an hour meter (which shows the total tim...

  • Page 15: Features

    Features 1-6 voltage display mode this display shows the battery voltage. “ ” appears for 1 second when the voltage display mode is first selected, and then “ ” ap- pears and the battery voltage is displayed. If the battery voltage is less than 10 volts, “lo” is displayed, and if the voltage is abov...

  • Page 16: Important Information

    Important information 1-7 ebs20011 important information ebs30009 preparation for removal and disassembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equip- ment. Refer to “special tools” on page 1-14. 3. When disassem...

  • Page 17: Important Information

    Important information 1-8 ebs30013 bearings and oil seals install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if ...

  • Page 18: Basic Service Information

    Basic service information 1-9 ebs20012 basic service information ebs30016 quick fasteners rivet type 1. Remove: • quick fastener tip to remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. 2. Install: • quick fastener tip to install the quick fastener, push its pin...

  • Page 19: Basic Service Information

    Basic service information 1-10 ebs30017 electrical system electrical parts handling notice ecb01460 never disconnect a battery lead while the en- gine is running; otherwise, the electrical components could be damaged. Notice ecb01510 when disconnecting the battery leads from the battery, be sure to ...

  • Page 20: Basic Service Information

    Basic service information 1-11 notice ecb01480 handle electrical components with special care, and do not subject them to strong shocks. Notice ecb01490 electrical components are very sensitive to and can be damaged by static electricity. Therefore, never touch the terminals and be sure to keep the ...

  • Page 21: Basic Service Information

    Basic service information 1-12 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector notice ecb01540 • when disconnecting a coupler, release the coupler lock, hold both sections of the cou- pler securely, and t...

  • Page 22: Basic Service Information

    Basic service information 1-13 4. Check: • continuity (with the pocket tester) tip • if there is no continuity, clean the terminals. • when checking the wire harness, perform steps (1) to (3). • as a quick remedy, use a contact revitalizer available at most part stores. 5. Check: • resistance tip th...

  • Page 23: Special Tools

    Special tools 1-14 ebs20013 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers o...

  • Page 24: Special Tools

    Special tools 1-15 pressure gauge 90890-03153 pressure gauge yu-03153 3-15, 7-4 oil pressure adapter h 90890-03139 3-15 ring nut wrench 90890-01268 spanner wrench yu-01268 3-27, 3-29 steering nut wrench 90890-01443 spanner wrench yu-33975 3-27, 3-30 boots band installation tool 90890-01526 boots ban...

  • Page 25: Special Tools

    Special tools 1-16 extension 90890-04136 5-1 compression gauge 90890-03081 engine compression tester yu-33223 5-1 piston pin puller set 90890-01304 piston pin puller yu-01304 5-20 valve spring compressor 90890-04019 valve spring compressor ym-04019 5-27, 5-32 valve spring compressor attachment 90890...

  • Page 26: Special Tools

    Special tools 1-17 valve guide remover & installer set (ø5.5) 90890-04016 valve guide installer (5.5 mm) ym-04015 5-29 valve guide remover & installer set (ø5.5) 90890-04016 valve guide reamer (5.5 mm) ym-01196 5-29 rotor holding tool 90890-04166 ym-04166 5-35, 5-35, 5-36, 5-37, 5-43, 5-44, 5-53, 5-...

  • Page 27: Special Tools

    Special tools 1-18 locknut wrench 90890-01348 locknut wrench ym-01348 5-53, 5-57 sheave spring compressor 90890-04134 sheave spring compressor ym-04134 5-53, 5-57 universal clutch holder 90890-04086 universal clutch holder ym-91042 5-62, 5-63 crankcase separating tool 90890-01135 crankcase separator...

  • Page 28: Special Tools

    Special tools 1-19 yamaha bond no. 1215 90890-85505 (three bond no.1215®) 5-69, 8-30 crankshaft installer pot 90890-01274 installing pot yu-90058 5-75, 8-28 crankshaft installer bolt 90890-01275 bolt yu-90060 5-75, 8-28 adapter (m16) 90890-04130 adapter #13 ym-04059 5-75 spacer (crankshaft installer...

  • Page 29: Special Tools

    Special tools 1-20 ring nut wrench 90890-01430 ring nut wrench ym-38404 5-88, 5-89 final gear backlash band 90890-01511 middle drive gear lash tool ym-01230 5-91 radiator cap tester 90890-01325 mityvac cooling system tester kit yu-24460-a 6-6 radiator cap tester adapter 90890-01352 pressure tester a...

  • Page 30: Special Tools

    Special tools 1-21 test harness– tps (3p) 90890-03204 test harness– tps (3p) yu-03204 7-13 universal joint holder 90890-04062 universal joint holder ym-04062 8-12, 8-15 ring gear fix bolt (m10) 90890-01527 ring gear fix bolt (m10) ym-01527 8-16 gear lash measurement tool 90890-01475 middle drive gea...

  • Page 31: Special Tools

    Special tools 1-22 ignition checker 90890-06754 oppama pet–4000 spark checker ym-34487 9-101 test harness– lean angle sensor (3p) 90890-03213 test harness– lean angle sensor (3p) yu-03213 9-102 test harness– speed sensor (3p) 90890-03208 test harness– speed sensor (3p) yu-03208 9-104 test harness s–...

  • Page 32: Special Tools

    Special tools 1-23.

  • Page 33: Specifications

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

  • Page 34: General Specifications

    General specifications 2-1 ebs20014 general specifications model model 2mb2 (yx70epng) (for cdn/eps models) 2mb6 (yx70epng) (for cdn/eps models) 2mb3 (yxe70wpxg) (for europe/eps models) 2mb7 (yxe70wphg) (for europe/eps models) b523 (yxe70wdxg) (for oceania) 2mb4 (yxe70wpxg) (for oceania/eps models) ...

  • Page 35: Engine Specifications

    Engine specifications 2-2 ebs20015 engine specifications engine engine type liquid cooled 4-stroke, dohc cylinder arrangement single cylinder displacement 708 cm³ bore × stroke 103.0 × 85.0 mm (4.06 × 3.35 in) compression ratio 10.1 : 1 standard compression pressure (at sea level) 650–1000 kpa (6.5–...

  • Page 36: Engine Specifications

    Engine specifications 2-3 cooling system coolant quantity radiator (including all routes) 2.85 l (3.01 us qt, 2.51 imp.Qt) coolant reservoir (up to the maximum level mark) 0.20 l (0.21 us qt, 0.18 imp.Qt) radiator core width 400.0 mm (15.75 in) height 253.4 mm (9.98 in) depth 28.0 mm (1.10 in) radia...

  • Page 37: Engine Specifications

    Engine specifications 2-4 valve-stem-to-valve-guide clearance (intake) limit 0.080 mm (0.0031 in) valve-stem-to-valve-guide clearance (exhaust) limit 0.100 mm (0.0039 in) valve stem runout 0.040 mm (0.0016 in) valve spring installed length (intake) 30.95 mm (1.22 in) installed length (exhaust) 32.20...

  • Page 38: Engine Specifications

    Engine specifications 2-5 clutch-stall revolution 3550–3650 r/min v-belt v-belt width limit 32.5 mm (1.28 in) transmission type v-belt automatic gear ratio 2.474–0.656 : 1 low range 31/16 (1.938) high range 30/22 (1.364) reverse gear 23/14 × 28/23 (2.000) drive axle runout limit 0.06 mm (0.0024 in) ...

  • Page 39: Chassis Specifications

    Chassis specifications 2-6 ebs20016 chassis specifications chassis frame type steel tube frame caster angle 3.7° camber angle 0.4° kingpin angle 12.7° kingpin offset 7.7 mm (0.30 in) trail 19.0 mm (0.75 in) toe-in (with tires touching the ground) 5.0–15.0 mm (0.20–0.59 in) tread rear (std) 1304.0 mm...

  • Page 40: Chassis Specifications

    Chassis specifications 2-7 disc outside diameter × thickness 207.0 × 4.0 mm (8.15 × 0.16 in) brake disc thickness limit 3.5 mm (0.14 in) brake disc deflection limit 0.10 mm (0.0039 in) brake pad lining thickness limit 1.0 mm (0.04 in) master cylinder inside diameter 17.46 mm (0.69 in) caliper cylind...

  • Page 41: Chassis Specifications

    Chassis specifications 2-8 installed length 378.0 mm (14.88 in) spring preload adjusting positions minimum 386.0 mm (15.20 in) standard 378.0 mm (14.88 in) maximum 372.0 mm (14.65 in) rebound damping adjusting positions minimum 30 click(s) out from the fully turned in position standard 14 click(s) o...

  • Page 42: Electrical Specifications

    Electrical specifications 2-9 ebs20017 electrical specifications voltage system voltage 12 v engine control unit model/manufacturer f8t85877/mitsubishi ignition system ignition system tci advancer type digital ignition timing (b.T.D.C.) 7.0°/1600 r/min pickup coil resistance 152.0–228.0 Ω ignition c...

  • Page 43: Electrical Specifications

    Electrical specifications 2-10 low-range indicator light led differential gear lock indicator light led helmet/seat belt indicator light 14 v, 0.85 w × 2 eps warning light led (for eps models) starter motor power output 0.80 kw armature coil resistance 0.025–0.035 Ω brush overall length limit 5.0 mm...

  • Page 44: Tightening Torques

    Tightening torques 2-11 ebs20018 tightening torques ebs30018 general tightening torque specifications this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapt...

  • Page 45: Tightening Torques

    Tightening torques 2-12 ebs30019 engine tightening torques item thread size q’ty tightening torque remarks exhaust pipe nut m8 2 20 nm (2.0 m·kgf, 14 ft·lbf) muffler bolt m8 1 23 nm (2.3 m·kgf, 17 ft·lbf) muffler mount shaft m8 1 17 nm (1.7 m·kgf, 12 ft·lbf) spark arrester bolt m6 4 10 nm (1.0 m·kgf...

  • Page 46: Tightening Torques

    Tightening torques 2-13 oil pipe bolt (ac magneto cover) m8 2 18 nm (1.8 m·kgf, 13 ft·lbf) oil pipe bolt m6 4 10 nm (1.0 m·kgf, 7.2 ft·lbf) oil pump drive sprocket nut m12 1 25 nm (2.5 m·kgf, 18 ft·lbf) oil pump driven sprocket nut m12 1 25 nm (2.5 m·kgf, 18 ft·lbf) oil pump bolt m6 3 see tip. Oil p...

  • Page 47: Tightening Torques

    Tightening torques 2-14 tip breather plate cover bolt tighten the breather plate cover bolts to 10 nm (1.0 m·kgf, 7.2 f·lbf) in the proper tightening sequence. Tip camshaft cap bolt tighten the camshaft cap bolts to 10 nm (1.0 m·kgf, 7.2 f·lbf) in the proper tightening sequence. Front drive shaft co...

  • Page 48: Tightening Torques

    Tightening torques 2-15 tip cylinder head bolt and cylinder bolt 1. Temporarily tighten the cylinder head bolts (m6) and cylinder bolts (m6). 2. Tighten the cylinder head bolts (m11) to 30 nm (3.0 m·kgf, 22 ft·lbf) in the proper tightening se- quence. 3. Tighten the cylinder head bolts (m11) to 70 n...

  • Page 49: Tightening Torques

    Tightening torques 2-16 tip oil pump bolt tighten the oil pump bolts to 10 nm (1.0 m·kgf, 7.2 ft·lbf) in the proper tightening sequence. 10 6 1 2 9 11 5 7 3 8 4 3 1 2.

  • Page 50: Tightening Torques

    Tightening torques 2-17 ebs30020 chassis tightening torques item thread size q’ty tightening torque remarks engine mounting bolt (front) (m6) m6 2 10 nm (1.0 m·kgf, 7.2 ft·lbf) engine mounting bolt (front) (m10) m10 2 42 nm (4.2 m·kgf, 30 ft·lbf) engine mounting bolt (rear) (m6) m6 2 10 nm (1.0 m·kg...

  • Page 51: Tightening Torques

    Tightening torques 2-18 seat back bolt m6 6 6 nm (0.6 m·kgf, 4.3 ft·lbf) driver seat frame bolt m8 4 23 nm (2.3 m·kgf, 17 ft·lbf) passenger seat frame bolt m8 4 23 nm (2.3 m·kgf, 17 ft·lbf) under-seat compartment panel bolt m6 1 4.0 nm (0.40 m·kgf, 2.9 ft·lbf) under-seat storage compartment bolt m6 ...

  • Page 52: Tightening Torques

    Tightening torques 2-19 instrument panel bolt m6 9 4.0 nm (0.40 m·kgf, 2.9 ft·lbf) glove compartment latch plate screw m4 2 1.3 nm (0.13 m·kgf, 0.94 ft·lbf) electrical components tray and frame bolt m6 4 4.0 nm (0.40 m·kgf, 2.9 ft·lbf) cargo bed bolt m6 9 9 nm (0.9 m·kgf, 6.5 ft·lbf) frame cross mem...

  • Page 53: Tightening Torques

    Tightening torques 2-20 steering wheel nut m12 1 35 nm (3.5 m·kgf, 25 ft·lbf) steering assembly bolt m10 4 see tip. Tie-rod m28 2 55 nm (5.5 m·kgf, 40 ft·lbf) steering joint bolt m8 2 33 nm (3.3 m·kgf, 24 ft·lbf) rack guide bolt — 1 3.9 nm (0.39 m·kgf, 2.8 ft·lbf) tie-rod end locknut m12 2 40 nm (4....

  • Page 54: Tightening Torques

    Tightening torques 2-21 parking brake cable adjusting lock- nut m6 1 16 nm (1.6 m·kgf, 12 ft·lbf) differential assembly nut m12 1 105 nm (10.5 m·kgf, 76 ft·lbf) differential assembly bolt m10 2 60 nm (6.0 m·kgf, 43 ft·lbf) differential assembly nut m10 1 60 nm (6.0 m·kgf, 43 ft·lbf) differential gea...

  • Page 55: Tightening Torques

    Tightening torques 2-22 tip enclosure bolt and nut tighten the enclosure bolts and nuts to specification in the proper tightening sequence. Enclosure tightening sequence: tip steering assembly bolt tighten the steering assembly bolts to 48 nm (4.8 m·kgf, 35 ft·lbf) in the proper tightening sequence....

  • Page 56: Tightening Torques

    Tightening torques 2-23 fuel pump tightening sequence: tip final drive assembly bolt and nut tighten the final drive assembly bolts and nuts to specification in the proper tightening sequence. Final drive assembly tightening sequence: 6 1 3 5 2 4 4 9 8 2 2 1 1 7 5 3 3 6 fwd.

  • Page 57: 2-24

    Lubrication and sealing points 2-24 ebs20019 lubrication and sealing points ebs30021 engine lubrication point lubricant/sealant oil seal lips bearings o-rings or cylinder head bolt threads and washers crankshaft seals piston pin cylinder inner surface, piston, piston rings and ring grooves valve ste...

  • Page 58: 2-25

    Lubrication system chart and diagrams 2-25 ebs20020 lubrication system chart and diagrams ebs30022 engine oil lubrication chart 13 12 11 10 9 1 8 5 4 7 2 3 6.

  • Page 59: 2-26

    Lubrication system chart and diagrams 2-26 1. Oil pan 2. Oil strainer 3. Oil pump 4. Relief valve 5. Oil cooler 6. Oil bypass valve 7. Oil filter cartridge 8. Drive axle 9. Reverse idle gear shaft 10. Oil pipe (crankcase) 11. Oil hose (crankcase to cylinder) 12. Crankshaft 13. Cylinder head.

  • Page 60: 2-27

    Lubrication system chart and diagrams 2-27 ebs30023 lubrication diagrams 6 1 2 3 4 5 7 8 9 3.

  • Page 61: 2-28

    Lubrication system chart and diagrams 2-28 1. Oil hose (crankcase to cylinder) 2. Oil pipe (crankcase) 3. Oil filter cartridge 4. Oil strainer 5. Oil pump 6. Oil pipe (ac magneto cover) 7. Reverse idle gear shaft 8. Drive axle 9. Relief valve.

  • Page 62: 2-29

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

  • Page 63: 2-30

    Lubrication system chart and diagrams 2-30 1. Camshaft 2. Crankshaft 3. Oil strainer 4. Oil pump 5. Oil pump driven sprocket.

  • Page 64: 2-31

    Lubrication system chart and diagrams 2-31 3 6 1 2 7 8 4 5.

  • Page 65: 2-32

    Lubrication system chart and diagrams 2-32 1. Oil cooler outlet hose 2. Oil cooler inlet hose 3. Oil cooler inlet pipe 4. Oil outlet hose 5. Oil inlet hose 6. Oil cooler outlet pipe 7. Oil outlet pipe 8. Oil inlet pipe.

  • Page 66: Cooling System Diagrams

    Cooling system diagrams 2-33 ebs20021 cooling system diagrams 6 1 2 2 6 1 3 4 4 5 5.

  • Page 67: Cooling System Diagrams

    Cooling system diagrams 2-34 1. Radiator 2. Radiator outlet hose 3. Radiator outlet pipe 4. Radiator inlet pipe 5. Radiator inlet hose 6. Radiator cap.

  • Page 68: Cooling System Diagrams

    Cooling system diagrams 2-35 4 3 3 4 1 2.

  • Page 69: Cooling System Diagrams

    Cooling system diagrams 2-36 1. Radiator outlet pipe 2. Water pump inlet hose 3. Thermostat outlet hose 4. Radiator inlet pipe.

  • Page 70: Cooling System Diagrams

    Cooling system diagrams 2-37 2 1 4 3 5 6.

  • Page 71: Cooling System Diagrams

    Cooling system diagrams 2-38 1. Thermostat outlet hose 2. Water pump inlet hose 3. Water pump 4. Water pump outlet pipe 5. Water pump outlet hose 6. Water jacket joint.

  • Page 72: Cable Routing

    Cable routing 2-39 ebs20022 cable routing frame front (left view) a b c d e f g h 2 f 3 4 7 9 10 1 6 4 8 3 4 11 3 5 3 5 1 2 9 12 13 1 5.

  • Page 73: Cable Routing

    Cable routing 2-40 1. Horn lead (except for cdn) 2. Headlight lead (left) 3. Throttle cable 4. Brake light switch lead 5. Radiator inlet hose 6. Wire harness 7. Eps torque sensor lead (for eps models) 8. Eps motor lead (for eps models) 9. Radiator fan motor breather hose 10. Radiator fan motor lead ...

  • Page 74: Cable Routing

    Cable routing 2-41 frame center (left view) a b 1 2 3 3 4 5 6 7 8 9 10

  • Page 75: Cable Routing

    Cable routing 2-42 1. Parking brake switch lead 2. Parking brake cable 3. Throttle cable 4. Seat belt switch lead 5. Thermostat outlet hose 6. Wire harness 7. Reverse switch lead 8. Gear position switch lead 9. Coolant temperature sensor lead 10. Spark plug lead a. Fasten the wire harness with the p...

  • Page 76: Cable Routing

    Cable routing 2-43 frame front (right view) 1 2 2 3 4 6 7 8 8 9 10 11 11 i a b c d e f g h j d 5 12 12 6 9.

  • Page 77: Cable Routing

    Cable routing 2-44 1. Radiator fan motor breather hose 2. Differential assembly breather hose 3. Coolant reservoir breather hose 4. Headlight lead (right) 5. Horn lead (except for cdn) 6. Radiator outlet hose 7. Differential motor lead 8. Coolant reservoir hose 9. Wire harness 10. Frame ground lead ...

  • Page 78: Cable Routing

    Cable routing 2-45 frame center (right view) 1 2 3 4 5 6 7 8 9 a b b c a d e.

  • Page 79: Cable Routing

    Cable routing 2-46 1. Wire harness 2. Seat belt switch lead 3. Parking brake switch lead 4. Ac magneto lead 5. Water pump inlet hose 6. Final drive assembly breather hose 7. Fuel injector lead 8. Tps (throttle position sensor) lead 9. Intake air pressure sensor lead a. Fasten the wire harness with t...

  • Page 80: Cable Routing

    Cable routing 2-47 electrical components tray (top view) 1 1 2 3 4 5 6 7 7 8 8 a b 9 9 10 11 12 13 13 14 14 15 15 16 17 18 19 20 21 22 23 24 1 17 17 23 c e d.

  • Page 81: Cable Routing

    Cable routing 2-48 1. Wire harness 2. Headlight lead (right) 3. Load control relay 4. Differential motor relay 2 5. Fuel injection system relay 6. Differential motor relay 1 7. Radiator fan motor relay 8. Headlight relay 9. Main fuse lead 10. Fuel injection system fuse 11. Battery 12. Eps control un...

  • Page 82: Cable Routing

    Cable routing 2-49 frame front (top view) a b b c d e f g 2 3 4 5 6 8 10 11 12 13 14 1 7 9 15 16.

  • Page 83: Cable Routing

    Cable routing 2-50 1. Horn lead (except for cdn) 2. Radiator outlet hose 3. Headlight lead (right) 4. Auxiliary dc jack lead 5. Meter assembly lead 6. Indicator light assembly lead 7. Parking brake switch lead 8. Throttle cable 9. Horn switch lead (except for cdn) 10. Main switch lead 11. On-command...

  • Page 84: Cable Routing

    Cable routing 2-51 frame center (top view) 1 fwd a b c 1 2 3 4 5 6 7 8 9 10 11.

  • Page 85: Cable Routing

    Cable routing 2-52 1. Fuel hose 2. Fuel injector lead 3. Wire harness 4. Coolant temperature sensor lead 5. Spark plug lead 6. Air induction system solenoid lead 7. Ignition coil lead 8. Seat belt switch lead 9. Thermostat outlet hose 10. Parking brake cable 11. Throttle cable a. Fasten the wire har...

  • Page 86: Cable Routing

    Cable routing 2-53 frame center (top view) 2 fwd 1 2 2 3 3 4 4 3 4 5 6 a b c d d d e f g 7.

  • Page 87: Cable Routing

    Cable routing 2-54 1. Parking brake switch lead 2. Wire harness 3. Ground lead 4. Starter motor lead 5. Fuel pump lead 6. Final drive assembly breather hose 7. Parking brake buzzer lead a. Fasten the parking brake switch lead with the plastic band. B. Fasten the parking brake switch lead with the ho...

  • Page 88: Cable Routing

    Cable routing 2-55 fuel tank (top view) fwd a a b c d d d 1 1 2 2 1 3 3 4 3 4.

  • Page 89: Cable Routing

    Cable routing 2-56 1. Fuel hose 2. Fuel pump lead 3. Fuel tank breather hose (fuel tank breather hose joint to atmosphere) 4. Fuel tank breather hose (fuel tank to fuel tank breather hose joint) a. Fasten the grommet on the fuel hose with the holder. B. Fasten the fuel pump lead with the holder. C. ...

  • Page 90: Cable Routing

    Cable routing 2-57 front brake caliper (left view) a 1 2 3 3 3 b b.

  • Page 91: Cable Routing

    Cable routing 2-58 1. Front brake pipe 2. Rear brake pipe 3. Front brake hose a. Fasten the grommet on the front brake hose with the holder. B. Fasten the front brake hose with the holder..

  • Page 92: Cable Routing

    Cable routing 2-59 rear brake caliper (left view) a b b c c c 1 2 a a c d 1 2 2 2.

  • Page 93: Cable Routing

    Cable routing 2-60 1. Rear brake pipe 2. Rear brake hose a. Fasten the rear brake hose with the holder. B. Fasten the grommet on the rear brake hose with the holder. C. Fasten the rear brake pipe with the holder. D. Face the paint mark forward..

  • Page 94: Cable Routing

    Cable routing 2-61 front brake caliper (top view) a b b c d 1 2 3 3.

  • Page 95: Cable Routing

    Cable routing 2-62 1. Front brake pipe 2. Rear brake pipe 3. Front brake hose a. Face the paint mark upward. B. Fasten the grommet on the front brake hose with the holder. C. Route the front brake hose under the front upper arm. D. Fasten the front brake hose with the holder..

  • Page 96: Cable Routing

    Cable routing 2-63 brake pipe (top and left view) fwd fwd a a a 1 1 1.

  • Page 97: Cable Routing

    Cable routing 2-64 1. Rear brake pipe a. Fasten the rear brake pipe with the holder..

  • Page 98: Cable Routing

    Cable routing 2-65 rear brake caliper (top view) a a b b b c c c 1 2 2.

  • Page 99: Cable Routing

    Cable routing 2-66 1. Rear brake pipe 2. Rear brake hose a. Fasten the rear brake pipe with the holder. B. Fasten the rear brake hose with the holder. C. Fasten the grommet on the rear brake hose with the holder..

  • Page 100: Cable Routing

    Cable routing 2-67 parking brake (left view) a b 1 1 1 1.

  • Page 101: Cable Routing

    Cable routing 2-68 1. Parking brake cable a. Fit the parking brake cable into the holder on the final drive case. B. Fit the parking brake cable into the slit in the parking brake lever..

  • Page 102: Cable Routing

    Cable routing 2-69 final drive assembly (left and right view) a a c c b b e e 1 1 1 1 2 2 4 4 4 3 3 d.

  • Page 103: Cable Routing

    Cable routing 2-70 1. Wire harness 2. Tail/brake light lead (left) 3. Final drive assembly breather hose 4. Tail/brake light lead (right) a. Fasten the wire harness with the holder. B. Place the slack in the tail/brake light lead in the area shown in the illustration. C. Fasten the tail/brake light ...

  • Page 104: Cable Routing

    Cable routing 2-71.

  • Page 105

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

  • Page 106: Periodic Maintenance

    Periodic maintenance 3-1 ebs20023 periodic maintenance ebs30024 introduction this chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon- ger service life and re...

  • Page 107: Periodic Maintenance

    Periodic maintenance 3-2 tip • some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full throttle. • hydraulic brake service • regularly check and, if necessary, correct the brake fluid level. • every two years replace the internal ...

  • Page 108: Periodic Maintenance

    Periodic maintenance 3-3 ebs30027 checking the fuel line 1. Remove: • rear panel (right) refer to “general chassis (1)” on page 4-1. • under-seat storage compartment refer to “general chassis (3)” on page 4-6. 2. Check: • fuel hose “1” cracks/damage → replace. Loose connection → connect properly. 3....

  • Page 109: Periodic Maintenance

    Periodic maintenance 3-4 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 6. Remove: • camshafts refer to “camshafts” on page 5-10. 7. Adjust: • valve clearance ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the valve lifter “1” and the valve pad “2” with a valve lapper “3”. Tip • cove...

  • Page 110: Periodic Maintenance

    Periodic maintenance 3-5 example: 1.775 mm (0.06988 in) + 0.07 mm (0.0028 in) = 1.845 mm (0.07264 in) the valve pad number is 185. D. Install a new valve pad “1” and the valve lifter “2”. Tip • lubricate the valve lifter with engine oil. • install the valve lifter and the valve pad in the correct pl...

  • Page 111: Periodic Maintenance

    Periodic maintenance 3-6 10.Connect: • spark plug cap refer to “throttle body” on page 7-8. • cylinder head breather hose refer to “throttle body” on page 7-8. 11.Install: • frame cross member refer to “general chassis (9)” on page 4-19. Ebs30029 checking the spark plug 1. Disconnect: • spark plug c...

  • Page 112: Periodic Maintenance

    Periodic maintenance 3-7 3. Install: • rear panel (right) refer to “general chassis (1)” on page 4-1. • center storage compartment refer to “general chassis (3)” on page 4-6. Ebs30031 checking the exhaust system 1. Check: • exhaust pipe “1” • muffler “2” • muffler mount “3” • springs “4” cracks/dama...

  • Page 113: Periodic Maintenance

    Periodic maintenance 3-8 d. Install a new gasket, and then insert the tail- pipe into the muffler and align the bolt holes. E. Install the bolts “1” and tighten them. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ebs30033 checking the air induction system refer to “checking the air induction sys...

  • Page 114: Periodic Maintenance

    Periodic maintenance 3-9 2. Check: • coolant level the coolant level should be between the maximum level mark “a” and minimum level mark “b”. Below the minimum level mark → add the recommended coolant to the proper level. Notice ecb01300 • adding water instead of coolant lowers the antifreeze conten...

  • Page 115: Periodic Maintenance

    Periodic maintenance 3-10 tip place a container under the engine, and then re- move the coolant drain bolt. 8. Drain: • coolant (from the engine and radiator) 9. Install: • coolant drain bolt (along with the copper washer ) 10.Fill: • cooling system (with the specified amount of the recom- mended co...

  • Page 116: Periodic Maintenance

    Periodic maintenance 3-11 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 begins to flow out of the bolt hole, tighten the thermostat cover air bleed bolt to specification. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...

  • Page 117: Periodic Maintenance

    Periodic maintenance 3-12 notice ecb01800 the engine should never be run without the air filter; excessive piston and/or cylinder wear may result. 6. Check: • air filter element • air filter element frame • air filter element holder damage → replace. 7. Clean: • air filter element ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼...

  • Page 118: Periodic Maintenance

    Periodic maintenance 3-13 8. Assemble: • air filter element frame • air filter element • air filter element holder 9. Install: • air filter element assembly 10.Install: • air filter case cover 11.Install: • center storage compartment refer to “general chassis (3)” on page 4-6. Ebs30038 checking the ...

  • Page 119: Periodic Maintenance

    Periodic maintenance 3-14 ebs30039 changing the engine oil 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Remove: • passenger seat cushion refer to “general chassis (2)” on page 4-3. • passenger seat belt buckle rubber cover refer to “general chassis (3)” on page 4-6...

  • Page 120: Periodic Maintenance

    Periodic maintenance 3-15 9. Install: • dipstick 10.Start the engine, warm it up for several min- utes, and then turn it off. 11.Check: • engine (for engine oil leaks) 12.Check: • engine oil level refer to “checking the engine oil level” on page 3-13. 13.Install: • passenger seat belt buckle rubber ...

  • Page 121: Periodic Maintenance

    Periodic maintenance 3-16 7. Install: • main gallery bolt • gasket 8. Install: • under-seat storage compartment • center cover refer to “general chassis (3)” on page 4-6. Ebs30040 checking the final gear oil level 1. Place the vehicle on a level surface. 2. Remove: • final gear oil filler bolt “1” (...

  • Page 122: Periodic Maintenance

    Periodic maintenance 3-17 ebs30042 checking the differential gear oil level 1. Place the vehicle on a level surface. 2. Remove: • differential gear oil filler bolt “1” (along with the gasket) 3. Check: • differential gear oil level the differential gear oil level should be up to the brim “2” of the ...

  • Page 123: Periodic Maintenance

    Periodic maintenance 3-18 ebs30044 checking the front brake pads the following procedure applies to all of the front brake pads. 1. Remove: • front wheels refer to “front and rear wheels” on page 4-23. 2. Operate the brake. 3. Check: • front brake pads wear indicator grooves “a” have almost dis- app...

  • Page 124: Periodic Maintenance

    Periodic maintenance 3-19 tip in order to ensure a correct reading of the brake fluid level, make sure the top of the brake master cylinder reservoir is horizontal. Ebs30046 bleeding the hydraulic brake system warning ewb02800 bleed the hydraulic brake system whenever: • the system is disassembled. ...

  • Page 125: Periodic Maintenance

    Periodic maintenance 3-20 3. Install: • rear wheels • front wheels refer to “front and rear wheels” on page 4-23. Ebs30047 checking the brake hoses and brake pipes 1. Remove: • rear panel (left) refer to “general chassis (1)” on page 4-1. • center storage compartment refer to “general chassis (3)” o...

  • Page 126: Periodic Maintenance

    Periodic maintenance 3-21 6. Check: • brake hose holders loose → tighten the holder bolts. Damage → replace. 7. Apply the brake several times. 8. Check: • brake hoses • brake pipe brake fluid leakage → replace any damaged hose and pipe. Refer to “front and rear brakes” on page 4-27. 9. Install: • ce...

  • Page 127: Periodic Maintenance

    Periodic maintenance 3-22 3. Remove: • center storage compartment refer to “general chassis (3)” on page 4-6. 4. Adjust: • parking brake lever free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Release the parking brake lever. B. Slide back the rubber cover “1”. C. Loosen the locknut “2”...

  • Page 128: Periodic Maintenance

    Periodic maintenance 3-23 tip if length “c” is 8.5 mm (0.33 in) or more, loosen locknut “5” and turn the adjusting nut “6” in direc- tion “d” or “e” until the specified accelerator ped- al free play is obtained. E. Tighten the locknuts to specification. F. Slide the rubber cover to its original posi...

  • Page 129: Periodic Maintenance

    Periodic maintenance 3-24 5. Install: • drive belt cover refer to “primary and secondary sheaves” on page 5-50. 6. Install: • v-belt cooling ducts refer to “general chassis (10)” on page 4-21. • frame cross member refer to “general chassis (9)” on page 4-19. Ebs30056 replacing the v-belt 1. Remove: ...

  • Page 130: Periodic Maintenance

    Periodic maintenance 3-25 2. Measure: • radial wheel runout • lateral wheel runout refer to “checking the wheels” on page 4-24. 3. Check: • wheel bearings refer to “checking the steering knuckles and front wheel bear- ings” on page 4-53 and “checking the rear knuckles and rear wheel bearings” on pag...

  • Page 131: Periodic Maintenance

    Periodic maintenance 3-26 1. Measure: • tire pressure out of specification → adjust. Warning ewb03000 uneven or improper tire pressure may ad- versely affect the handling of this vehicle and may cause loss of control. • maintain proper tire pressures. • set tire pressures when the tires are cold. • ...

  • Page 132: Periodic Maintenance

    Periodic maintenance 3-27 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Elevate the front wheels by placing a suitable stand under the frame. B. Loosen the locknut “1”. C. Turn the adjusting ring “2” in direction “a” or “b”. Notice ecb02470 never attempt to turn the adjusting ring be- yond th...

  • Page 133: Periodic Maintenance

    Periodic maintenance 3-28 notice ecb02480 do not force the adjuster past the minimum or maximum extent of adjustment. The ad- juster may be damaged. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Adjust: • compression damping force (fast compres- sion damping) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼...

  • Page 134: Periodic Maintenance

    Periodic maintenance 3-29 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ebs30060 checking the rear shock absorber assemblies the following procedure applies to both of the rear shock absorber assemblies. 1. Place the vehicle on a level place. 2. Check: • rear shock absorber assembly refer to “ch...

  • Page 135: Periodic Maintenance

    Periodic maintenance 3-30 tip • set the torque wrench at a right angle to the steering nut wrench. • always tighten the locknut against the adjust- ing ring, then torque it to specification. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Adjust: • rebound damping force ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ...

  • Page 136: Periodic Maintenance

    Periodic maintenance 3-31 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Adjust: • compression damping force (slow compres- sion damping) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. Notice ecb02480 do not force the adjuster past th...

  • Page 137: Periodic Maintenance

    Periodic maintenance 3-32 excessive free play → replace the front arms (upper and lower) and/or wheel bear- ings. Ebs30062 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 pressu...

  • Page 138: Periodic Maintenance

    Periodic maintenance 3-33 d. Tighten the tie-rod end locknuts to specifica- tion. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Check: • steering wheel tip after adjusting the toe-in, the steering wheel should be centered. Refer to “installing the steering wheel” on page 4-16. Ebs30064 checki...

  • Page 139: Periodic Maintenance

    Periodic maintenance 3-34 ty shaft assemblies, final drive assembly and rear drive shaft” on page 8-18. Ebs30069 checking the fastener 1. Check: • fasteners damage/pitting → replace. Refer to “general chassis (1)” on page 4-1, “general chassis (3)” on page 4-6, “general chassis (6)” on page 4-12, “g...

  • Page 140: Periodic Maintenance

    Periodic maintenance 3-35.

  • Page 141: Chassis

    4 chassis general chassis (1) ................................................................................. 4-1 installing the door.......................................................................... 4-2 general chassis (2) .....................................................................

  • Page 142

    Front and rear brakes....................................................................... 4-27 introduction ..................................................................................... 4-34 checking the brake discs ............................................................ 4-34 replaci...

  • Page 143

    Rear arms and rear shock absorber assemblies ................. 4-63 checking the rear arms ............................................................... 4-65 handling the rear shock absorber assemblies ................ 4-65 disposing of a rear shock absorber assembly ................. 4-65 checkin...

  • Page 144: General Chassis (1)

    General chassis (1) 4-1 ebs20024 general chassis (1) removing the doors and side panels order job/parts to remove q ’ ty remarks the following procedure applies to both of the doors. 1 door hinge 1 2 door 1 3 door handle latch 1 4 rubber damper 1 5 fuel tank cap 1 right side only. 6 side panel 1 7 r...

  • Page 145: General Chassis (1)

    General chassis (1) 4-2 ebs30419 installing the door the following procedure applies to both of the doors. 1. Install: • door hinge “1” 2. Install: • door “1” tip fit the tab “a” on the door hinge with the slot “b” in the frame. 3. Install: • door handle latch “1” tip adjust the position of the door...

  • Page 146: General Chassis (2)

    General chassis (2) 4-3 ebs20087 general chassis (2) removing the seats order job/parts to remove q ’ ty remarks 1 seat cushion 2 2 driver seat frame 1 3 passenger seat frame 1 4 seat back 2 5 shoulder holster 2 (3) (3) (4) (4) (3) 4 5 3 1 2 5 (3) 6 nm (0.6 m • kgf, 4.3 ft • ibf) t.R. 23 nm (2.3 m •...

  • Page 147: General Chassis (2)

    General chassis (2) 4-4 ebs30340 removing the seats the following procedure applies to both of the seats. 1. Remove: • seat cushion “1” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Lift the front of the seat cushion. B. Pull the cushion off. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ...

  • Page 148: General Chassis (2)

    General chassis (2) 4-5 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 1 b a a.

  • Page 149: General Chassis (3)

    General chassis (3) 4-6 ebs20088 general chassis (3) removing the center cover and floor boards order job/parts to remove q ’ ty remarks seat backs refer to “general chassis (2)” on page 4-3. 1 center storage compartment 1 2 driver seat belt buckle rubber cover 1 3 passenger seat belt buckle rubber ...

  • Page 150: General Chassis (4)

    General chassis (4) 4-7 ebs20089 general chassis (4) removing the seat belts order job/parts to remove q ’ ty remarks side panels/rear panels refer to “general chassis (1)” on page 4-1. Under-seat storage compartment refer to “general chassis (3)” on page 4-6. 1 driver seat belt 1 2 seat belt rubber...

  • Page 151: General Chassis (4)

    General chassis (4) 4-8 ebs30343 installing the seat belts 1. Install: • seat belt buckles tip • fit the passenger seat belt buckle “1” into the slot “a” in the frame. • fit the driver seat belt buckle “2” into the slot “b” in the seat belt buckle bracket. 2. Install: • seat belts tip • install the ...

  • Page 152: General Chassis (5)

    General chassis (5) 4-9 ebs20090 general chassis (5) removing the sun top order job/parts to remove q ’ ty remarks 1 sun top rear bracket 4 2 sun top front bracket 4 3 sun top 1 4 damper 4 5 damper 4 (8) (8) (4) (4) (4) (4) 2 1 4 3 5 new 3.0 nm (0.30 m • kgf, 2.2 ft • ibf) t.R ..

  • Page 153: General Chassis (5)

    General chassis (5) 4-10 removing the enclosure order job/parts to remove q ’ ty remarks seat backs refer to “general chassis (2)” on page 4-3. Seat belts refer to “general chassis (4)” on page 4-7. 1 rear lower frame rubber cover (right) 1 2 rear lower frame rubber cover (left) 1 3 front top frame ...

  • Page 154: General Chassis (5)

    General chassis (5) 4-11 ebs30344 installing the enclosure 1. Install: • rear lower frame “1” • side frame (left) “2” • side frame (right) “3” • rear upper frame “4” • rear top frame “5” • front top frame “6” tip do not fully tighten the bolts and nuts. 2. Tighten: • rear upper frame bolts • rear up...

  • Page 155: General Chassis (6)

    General chassis (6) 4-12 ebs20091 general chassis (6) removing the hood and battery order job/parts to remove q ’ ty remarks 1 skid plate 1 2 side guard 2 3 mudguard 2 4 hood 1 5 air intake duct cover 1 6 negative battery lead 1 disconnect. 7 positive battery lead 1 disconnect. 8 battery band 2 9 ba...

  • Page 156: General Chassis (7)

    General chassis (7) 4-13 ebs20092 general chassis (7) removing the front fender and instrument panel assembly order job/parts to remove q ’ ty remarks center cover/pedal assembly rubber cover refer to “general chassis (3)” on page 4-6. Side frames refer to “general chassis (5)” on page 4-9. Hood/sid...

  • Page 157: General Chassis (7)

    General chassis (7) 4-14 removing the front fender and instrument panel assembly order job/parts to remove q ’ ty remarks 10 main switch coupler 1 disconnect. 11 auxiliary dc jack coupler 1 disconnect. 12 horn switch lead 2 disconnect. Except for cdn 13 instrument panel assembly 1 3.0 nm (0.30 m • k...

  • Page 158: General Chassis (7)

    General chassis (7) 4-15 disassembling the instrument panel assembly order job/parts to remove q ’ ty remarks 1 meter assembly 1 2 indicator light assembly 1 3 on-command four-wheel-drive switch 1 4 light switch 1 5 main switch 1 6 auxiliary dc jack 1 7 horn switch 1 except for cdn 8 instrument pane...

  • Page 159: General Chassis (7)

    General chassis (7) 4-16 ebs30345 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” tip while pushing the ends of the projections “a” to- gether, remove the steering wheel cover from t...

  • Page 160: General Chassis (8)

    General chassis (8) 4-17 ebs20102 general chassis (8) removing the electrical components tray order job/parts to remove q ’ ty remarks instrument panel assembly refer to “general chassis (7)” on page 4-13. 1 headlight coupler 2 disconnect. 2 lean angle sensor 1 3 starter relay 1 4 main fuse 1 5 eps ...

  • Page 161: General Chassis (8)

    General chassis (8) 4-18 removing the electrical components tray order job/parts to remove q ’ ty remarks 10 differential motor relay 1 1 11 headlight relay 1 12 load control relay 1 13 fuel injection system relay 1 14 radiator fan motor relay 1 15 electrical components tray 1 2.5 nm (0.25 m • kgf, ...

  • Page 162: General Chassis (9)

    General chassis (9) 4-19 ebs20103 general chassis (9) removing the cargo bed order job/parts to remove q ’ ty remarks under-seat compartment panel refer to “general chassis (3)” on page 4-6. 1 tailgate 1 2 latch 2 3 tail/brake light connector 6 disconnect. 4 cargo bed 1 5 latch holder 4 6 tail/brake...

  • Page 163: General Chassis (9)

    General chassis (9) 4-20 ebs30420 installing the cargo bed 1. Install: • cargo bed “1” tip tighten the bolts “2” and “3” in the order listed, and then tighten the bolts “4”. T r . . Cargo bed bolt 9 nm (0.9 m·kgf, 6.5 ft·lbf) 4 4 2 3 1 fwd 4.

  • Page 164: General Chassis (10)

    General chassis (10) 4-21 ebs20104 general chassis (10) removing the v-belt cooling ducts order job/parts to remove q ’ ty remarks frame cross member refer to “general chassis (9)” on page 4-19. 1 v-belt cooling exhaust duct 1 2 v-belt cooling exhaust duct plate 1 3 v-belt cooling exhaust duct joint...

  • Page 165: General Chassis (10)

    General chassis (10) 4-22 ebs30348 installing the v-belt cooling ducts 1. Install: • v-belt cooling intake duct joint 2 “1” • v-belt cooling intake duct joint 1 “2” • v-belt cooling exhaust duct joint “3” tip • align the projection “a” on v-belt cooling intake duct joint 2 with the lib on the crankc...

  • Page 166: Front and Rear Wheels

    Front and rear wheels 4-23 ebs20025 front and rear wheels removing the wheels and brake discs order job/parts to remove q ’ ty remarks the following procedure applies to all of the wheels. 1 wheel 1 2 wheel cap 1 3 wheel axle nut 1 4 brake caliper 1 tip do not apply the brake pedal when the brake ca...

  • Page 167: Front and Rear Wheels

    Front and rear wheels 4-24 ebs30083 removing the wheels 1. Place the vehicle on a level surface. 2. Elevate: • wheels tip place the vehicle on a suitable stand so that the wheels are elevated. Ebs30084 removing the wheel hubs the following procedure applies to all of the wheel hubs. 1. Straighten th...

  • Page 168: Front and Rear Wheels

    Front and rear wheels 4-25 ebs30086 checking the wheel hubs the following procedure applies to all of the wheel hubs. 1. Check: • wheel hub “1” cracks/damage → replace. • splines (wheel hub) “2” wear/damage → replace the wheel hub. Ebs30087 installing the brake discs the following procedure applies ...

  • Page 169: Front and Rear Wheels

    Front and rear wheels 4-26 3. Check: • brake disc refer to “checking the brake discs” on page 4-34. Ebs30089 installing the wheels the following procedure applies to all of the wheels. 1. Tighten: • wheel nuts “1” warning ewb03130 tapered wheel nuts are used for both the front and rear wheels. Insta...

  • Page 170: Front and Rear Brakes

    Front and rear brakes 4-27 ebs20026 front and rear brakes removing the front brake pads order job/parts to remove q ’ ty remarks the following procedure applies to both of the front brake calipers. Front wheel refer to “front and rear wheels” on page 4-23. 1 brake caliper bolt 2 2 brake pad bolt 2 3...

  • Page 171: Front and Rear Brakes

    Front and rear brakes 4-28 removing the rear brake pads order job/parts to remove q ’ ty remarks the following procedure applies to both of the rear brake calipers. Rear wheel refer to “front and rear wheels” on page 4-23. 1 brake caliper bolt 2 2 brake pad bolt 2 3 brake pad 2 4 brake pad spring 1 ...

  • Page 172: Front and Rear Brakes

    Front and rear brakes 4-29 removing the front brake calipers order job/parts to remove q ’ ty remarks the following procedure applies to both of the front brake calipers. Front wheel refer to “front and rear wheels” on page 4-23. Brake fluid drain. Refer to “bleeding the hydraulic brake system” on p...

  • Page 173: Front and Rear Brakes

    Front and rear brakes 4-30 removing the rear brake calipers order job/parts to remove q ’ ty remarks the following procedure applies to both of the rear brake calipers. Rear wheel refer to “front and rear wheels” on page 4-23. Brake fluid drain. Refer to “bleeding the hydraulic brake system” on page...

  • Page 174: Front and Rear Brakes

    Front and rear brakes 4-31 disassembling the front brake calipers order job/parts to remove q ’ ty remarks the following procedure applies to both of the front brake calipers. 1 brake pad bolt 2 2 brake pad 2 3 brake pad spring 1 4 brake caliper bracket 1 5 brake caliper guide pin 1 6 brake caliper ...

  • Page 175: Front and Rear Brakes

    Front and rear brakes 4-32 disassembling the rear brake calipers order job/parts to remove q ’ ty remarks the following procedure applies to both of the rear brake calipers. 1 brake pad bolt 2 2 brake pad 2 3 brake pad spring 1 4 brake caliper bracket 1 5 brake caliper guide pin 1 6 brake caliper re...

  • Page 176: Front and Rear Brakes

    Front and rear brakes 4-33 removing the brake master cylinder order job/parts to remove q ’ ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-19. 1 brake master cylinder reservoir cap 1 2 brake master cylinder reservoir diaphragm 1 3 brake master cylinder reservo...

  • Page 177: Front and Rear Brakes

    Front and rear brakes 4-34 ebs30090 introduction warning ewb02930 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconn...

  • Page 178: Front and Rear Brakes

    Front and rear brakes 4-35 d. Measure the brake disc deflection. E. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. F. If the brake disc deflection cannot be brought within specification, replace the brake disc. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲...

  • Page 179: Front and Rear Brakes

    Front and rear brakes 4-36 ebs30093 disassembling the brake calipers the following procedure applies to all of the brake calipers. Tip before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • brake caliper pistons “1” • brake caliper piston dust seals ...

  • Page 180: Front and Rear Brakes

    Front and rear brakes 4-37 ebs30096 installing the brake calipers the following procedure applies to all of the brake calipers. 1. Install: • brake caliper “1” (temporarily) • copper washers • brake hose “2” • brake hose union bolt “3” warning ewb02870 proper brake hose routing is essential to in- s...

  • Page 181: Front and Rear Brakes

    Front and rear brakes 4-38 4. Fill: • brake master cylinder reservoir (with the specified amount of the specified brake fluid) warning ewb02880 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill wi...

  • Page 182: Front and Rear Brakes

    Front and rear brakes 4-39 warning ewb02880 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a h...

  • Page 183: Parking Brake

    Parking brake 4-40 ebs20027 parking brake disassembling the parking brake order job/parts to remove q ’ ty remarks final drive case cover assembly refer to “rear constant velocity shaft assemblies, final drive as- sembly and rear drive shaft” on page 8-18. 1 parking brake plate 5 2 parking brake spr...

  • Page 184: Parking Brake

    Parking brake 4-41 removing the parking brake lever order job/parts to remove q ’ ty remarks center cover refer to “general chassis (3)” on page 4-6. 1 parking brake switch 1 2 parking brake buzzer 1 3 parking brake lever 1 4 parking brake cable 1 disconnect. 7 nm (0.7 m • kgf, 5.1 ft • ibf) t.R . 1...

  • Page 185: Parking Brake

    Parking brake 4-42 ebs30421 checking the friction plates the following procedure applies to all of the fric- tion plates. 1. Check: • friction plate damage/wear → replace the friction plates as a set. 2. Measure: • friction plate thickness out of specification → replace the friction plates as a set....

  • Page 186: Parking Brake

    Parking brake 4-43 ebs30105 installing the parking brake lever 1. Install: • parking brake lever 2. Adjust: • parking brake lever free play refer to “adjusting the parking brake” on page 3-21. T r . . Parking brake lever bolt 13 nm (1.3 m·kgf, 9.4 ft·lbf).

  • Page 187: Pedal Assembly

    Pedal assembly 4-44 ebs20028 pedal assembly removing the pedal assembly order job/parts to remove q ’ ty remarks floor board (left) refer to “general chassis (3)” on page 4-6. Brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-19. Brake master cylinder refer to “front and re...

  • Page 188: Pedal Assembly

    Pedal assembly 4-45 disassembling the pedal assembly order job/parts to remove q ’ ty remarks 1 pin 1 2 brake pedal rod 1 3 spring 1 4 circlip 1 5 washer 2 6 brake pedal 1 7 spring 1 8 circlip 1 9 washer 2 10 accelerator pedal 1 11 pedal assembly bracket 1 1 6 5 5 4 11 9 9 10 8 3 2 7 new new new ls ...

  • Page 189: Pedal Assembly

    Pedal assembly 4-46 ebs30106 installing the pedal assembly 1. Install: • throttle cable ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the nut “1” until it stops, and then install the throttle cable to the plate. B. Tighten the locknut “2” to specification. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...

  • Page 190: Steering System

    Steering system 4-47 ebs20029 steering system removing the steering assembly * apply molykote ® em-30l grease order job/parts to remove q ’ ty remarks instrument panel assembly refer to “general chassis (7)” on page 4-13. 1 steering joint bolt 2 2 steering column 1 except for eps models 3 eps motor ...

  • Page 191: Steering System

    Steering system 4-48 removing the steering assembly * apply molykote ® em-30l grease order job/parts to remove q ’ ty remarks 7 tie-rod end locknut 2 8 steering assembly 1 9 tie-rod end 2 10 dust boot 2 11 tie-rod set 2 tip replace the tie-rod and lock washer as a set. New new new new new ls ls * * ...

  • Page 192: Steering System

    Steering system 4-49 ebs30488 removing the tie-rod 1. Straighten the lock washer “a”. 2. Loosen: • tie-rod “1” ebs30107 checking the steering joint 1. Check: • steering joint rough movement → replace. Ebs30108 checking the tie-rod ends the following procedure applies to both of the tie-rod ends. 1. ...

  • Page 193: Steering System

    Steering system 4-50 3. Bends the lock washer “a”. 4. Install: • dust boots ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Fit the tabs “a” into the holes “b” in the boot band “1”. B. Crimp the portion “c” of the boot band with the boots band installation tool “2”. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ...

  • Page 194: Steering System

    Steering system 4-51 7. Adjust: • toe-in refer to “adjusting the toe-in” on page 3-32. Ebs30426 lubricating the steering shaft lubricate the pivoting point and metal-to-metal moving parts of the shaft. Recommended lubricant lithium-soap-based grease 1 2 d e.

  • Page 195: Steering Knuckles

    Steering knuckles 4-52 ebs20030 steering knuckles removing the steering knuckles order job/parts to remove q ’ ty remarks the following procedure applies to both of the steering knuckles. Front wheel hub refer to “front and rear wheels” on page 4-23. 1 brake disc guard 1 2 tie-rod end 1 disconnect. ...

  • Page 196: Steering Knuckles

    Steering knuckles 4-53 ebs30110 removing the steering knuckles the following procedure applies to both of the steering knuckles. 1. Remove: • steering knuckle “1” tip use a general puller to separate the ball joints “2” from the steering knuckle “1” or the front low- er arm “3”. Ebs30111 checking th...

  • Page 197: Steering Knuckles

    Steering knuckles 4-54 d. Measure the ball joint bore inside diameter “a”. Out of specification → replace the steering knuckle. E. Attach the special tools and a new ball joint “5” to the steering knuckle “4”. Tip • always use a new ball joint. • do not tap or damage the top of the ball joint or rub...

  • Page 198: 4-55

    Front arms and front shock absorber assemblies 4-55 ebs20031 front arms and front shock absorber assemblies removing the front arms and front shock absorber assemblies order job/parts to remove q ’ ty remarks the following procedure applies to both of the front upper arms, front lower arms, and fron...

  • Page 199: 4-56

    Front arms and front shock absorber assemblies 4-56 removing the front arms and front shock absorber assemblies order job/parts to remove q ’ ty remarks 10 nut/bolt (front lower arm) 2/2 11 front lower arm 1 12 dust cover 2 13 circlip 1 14 ball joint 1 15 bushing 4 7 nm (0.7 m • kgf, 5.1 ft • ibf) t...

  • Page 200: 4-57

    Front arms and front shock absorber assemblies 4-57 ebs30113 checking the front arms the following procedure applies to both of the front upper arms and front lower arms. 1. Check: • front arm free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Check the front arm side play “a” by moving ...

  • Page 201: 4-58

    Front arms and front shock absorber assemblies 4-58 ebs30117 checking the front arm ball joints the following procedure applies to both of the front arm ball joints. 1. Check: • ball joint (front upper arm) damage/pitting → replace the ball joint. Rubber boot damage → replace the ball joint. Rough m...

  • Page 202: 4-59

    Front arms and front shock absorber assemblies 4-59 e. Hold the base plate “10” in place while turning in the long bolt “6” to install the new ball joint “5” into the front upper arm “4”. F. Remove the special tools. G. Install a new circlip. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ebs3011...

  • Page 203: Rear Knuckles and Stabilizer

    Rear knuckles and stabilizer 4-60 ebs20032 rear knuckles and stabilizer removing the rear knuckles and stabilizer order job/parts to remove q ’ ty remarks the following procedure applies to both of the rear knuckles. Rear wheel hub refer to “front and rear wheels” on page 4-23. 1 rear brake disc cle...

  • Page 204: Rear Knuckles and Stabilizer

    Rear knuckles and stabilizer 4-61 removing the rear knuckles and stabilizer order job/parts to remove q ’ ty remarks 10 stabilizer holder 2 11 bushing 2 12 stabilizer 1 10 12 11 10 11 ls ls new new new fwd fw d new 9 nm (0.9 m • kgf, 6.5 ft • ibf) t.R. 60 nm (6.0 m • kgf, 43 ft • ibf) t.R. 60 nm (6....

  • Page 205: Rear Knuckles and Stabilizer

    Rear knuckles and stabilizer 4-62 ebs30119 checking the rear knuckles and rear wheel bearings the following procedure applies to both of the rear knuckles and rear wheel bearings. 1. Check: • rear knuckle damage/pitting → replace. 2. Check: • rear wheel bearings “1” rough movement/excessive free pla...

  • Page 206: 4-63

    Rear arms and rear shock absorber assemblies 4-63 ebs20033 rear arms and rear shock absorber assemblies removing the rear arms and rear shock absorber assemblies order job/parts to remove q ’ ty remarks the following procedure applies to both of the rear upper arms, rear lower arms, and rear shock a...

  • Page 207: 4-64

    Rear arms and rear shock absorber assemblies 4-64 removing the rear arms and rear shock absorber assemblies order job/parts to remove q ’ ty remarks 9 nut/bolt (rear lower arm – rear knuckle) 1/1 10 nut/bolt (rear lower arm – frame) 2/2 11 rear lower arm 1 12 dust cover 2 13 bushing 4 12 13 12 13 9 ...

  • Page 208: 4-65

    Rear arms and rear shock absorber assemblies 4-65 ebs30122 checking the rear arms the following procedure applies to both of the rear upper arms and rear lower arms. 1. Check: • rear arm free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Check the rear arm side play “a” by moving it from...

  • Page 209: 4-66

    Rear arms and rear shock absorber assemblies 4-66 ebs30126 installing the rear arms and rear shock absorber assemblies the following procedure applies to both of the rear upper arms, rear lower arms, and rear shock absorber assemblies. 1. Install: • rear upper arm • rear lower arm • rear shock absor...

  • Page 210: 4-67

    Rear arms and rear shock absorber assemblies 4-67.

  • Page 211: Engine

    5 engine engine inspection .................................................................................... 5-1 measuring the compression pressure.................................... 5-1 engine removal (1) ................................................................................... 5-3 in...

  • Page 212

    Oil pump sprockets .............................................................................. 5-42 removing the oil pump drive sprocket and oil pump driven sprocket ........................................................... 5-43 checking the oil pump sprockets .....................................

  • Page 213

    Transmission............................................................................................ 5-76 removing the transmission ........................................................ 5-80 disassembling the drive axle..................................................... 5-80 checking the sh...

  • Page 214: Engine Inspection

    Engine inspection 5-1 ebs20105 engine inspection ebs30135 measuring the compression pressure tip insufficient compression pressure will result in a loss of performance. 1. Measure: • valve clearance out of specification → adjust. Refer to “adjusting the valve clear- ance” on page 3-3. 2. Start the e...

  • Page 215: Engine Inspection

    Engine inspection 5-2 10.Install: • frame cross member refer to “general chassis (9)” on page 4-19..

  • Page 216: Engine Removal (1)

    Engine removal (1) 5-3 ebs20034 engine removal (1) removing the muffler and exhaust pipe order job/parts to remove q ’ ty remarks 1 spring 2 2 muffler 1 3 muffler heat protector plate 1 4 gasket 1 5 muffler mount 1 6 exhaust pipe 1 7 gasket 1 17 nm (1.7 m • kgf, 12 ft • ibf) t.R . 20 nm (2.0 m • kgf...

  • Page 217: Engine Removal (1)

    Engine removal (1) 5-4 ebs30127 installing the exhaust pipe and muffler 1. Install: • gasket “1” (muffler side) notice ecb01640 be careful not to damage the muffler contact surface of the gasket. Tip install the gasket completely onto the exhaust pipe “2” by pushing the side “a” of the gasket. If th...

  • Page 218: Engine Removal (2)

    Engine removal (2) 5-5 ebs20093 engine removal (2) disconnecting the couplers and leads order job/parts to remove q ’ ty remarks frame cross member refer to “general chassis (9)” on page 4-19. V-belt cooling ducts refer to “general chassis (10)” on page 4-21. Drive select lever shift rod disconnect....

  • Page 219: Engine Removal (2)

    Engine removal (2) 5-6 disconnecting the couplers and leads order job/parts to remove q ’ ty remarks air cut-off valve refer to “air induction system” on page 7-14. Throttle body refer to “throttle body” on page 7-8. Front drive shaft (middle gear side) refer to “front constant velocity shaft assemb...

  • Page 220: Engine Removal (2)

    Engine removal (2) 5-7 disconnecting the couplers and leads order job/parts to remove q ’ ty remarks 6 engine ground lead 1 disconnect. 7 starter motor lead 1 disconnect. 8 speed sensor coupler 1 disconnect. 9 crankshaft position sensor coupler 1 disconnect. 10 ac magneto lead coupler 2 disconnect. ...

  • Page 221: Engine Removal (2)

    Engine removal (2) 5-8 removing the engine order job/parts to remove q ’ ty remarks 1 engine mounting bolt (front) 2 2 engine mounting bolt (front) 2 3 engine bracket nut (rear) 2 4 engine 1 tip remove the engine from the top of the vehi- cle. 5 engine bracket nut (front) 2 6 engine bracket (front) ...

  • Page 222: Engine Removal (2)

    Engine removal (2) 5-9 ebs30351 installing the engine 1. Install: • engine brackets (rear) “1” (onto the engine) • engine mounting bolts (rear) (m10) “2” • engine mounting bolts (rear) (m6) “3” tip before installing the engine, tighten the engine mounting bolts (rear) to specification. 2. Install: •...

  • Page 223: Camshafts

    Camshafts 5-10 ebs20106 camshafts removing the cylinder head cover * when installing a new spark plug, tighten the spark plug to 11 nm (1.1 m · kgf, 8.0 ft · lbf). * when reusing a spark plug, tighten the spark plug to 30 °– 45 ° . Order job/parts to remove q ’ ty remarks heat protector/frame cross ...

  • Page 224: Camshafts

    Camshafts 5-11 removing the camshafts order job/parts to remove q ’ ty remarks 1 crankshaft end accessing screw 1 2 timing mark accessing screw 1 3 timing chain tensioner 1 4 timing chain tensioner gasket 1 5 camshaft cap 1 6 bearing stopper 2 7 intake camshaft 1 8 exhaust camshaft 1 10 nm (1.0 m • ...

  • Page 225: Camshafts

    Camshafts 5-12 ebs30432 removing the camshafts 1. Remove: • crankshaft end accessing screw “1” • timing mark accessing screw “2” 2. Align: • mark “a” on the ac magneto rotor (with the mark “b” in the ac magneto cover) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft countercl...

  • Page 226: Camshafts

    Camshafts 5-13 ebs30433 checking the camshafts 1. Check: • camshaft lobes blue discoloration/pitting/scratches → re- place the camshaft. 2. Measure: • camshaft lobe dimensions “a” and “b” out of specification → replace the camshaft. 3. Measure: • camshaft-journal-to-camshaft-cap clearance out of spe...

  • Page 227: Camshafts

    Camshafts 5-14 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Measure: • camshaft journal diameter “a” out of specification → replace the camshaft. Within specification → replace the cylinder head and camshaft cap as a set. Ebs30434 checking the camshaft sprockets 1. Check: • camshaft sprocket...

  • Page 228: Camshafts

    Camshafts 5-15 b. Position the mark “a” on the ac magneto ro- tor with the mark “b” in the ac magneto cov- er. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Install: • timing chain “1” (onto the camshaft sprockets “2”) • exhaust camshaft • intake camshaft notice ecb02440 do not turn the crank...

  • Page 229: Camshafts

    Camshafts 5-16 c. Install a new gasket and the timing chain ten- sioner cap bolt. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Turn: • crankshaft (several turns counterclockwise) 6. Check: • mark “a” make sure the mark “a” on the ac magneto rotor is aligned with the mark “b” in the ac magnet...

  • Page 230: 5-17

    Cylinder head, cylinder, and piston 5-17 ebs20107 cylinder head, cylinder, and piston removing the cylinder head order job/parts to remove q ’ ty remarks coolant drain. Refer to “changing the coolant” on page 3-9. Engine oil drain. Refer to “changing the engine oil” on page 3-14. Exhaust pipe refer ...

  • Page 231: 5-18

    Cylinder head, cylinder, and piston 5-18 removing the cylinder head order job/parts to remove q ’ ty remarks 3 cylinder head bolt 2 m6 4 cylinder head bolt 4 m11 5 cylinder head 1 6 cylinder head gasket 1 7 dowel pin 2 1st 2nd 3rd 5th 6th t.R . Specified angle 85–90˚ specified angle 85–90˚ 30 nm (3....

  • Page 232: 5-19

    Cylinder head, cylinder, and piston 5-19 removing the cylinder and piston order job/parts to remove q ’ ty remarks 1 timing chain guide (exhaust side) 1 2 cylinder 1 3 cylinder gasket 1 4 dowel pin 2 5 piston pin clip 2 6 piston pin 1 7 piston 1 8 top ring 1 9 2nd ring 1 10 oil ring 1 new new e e e ...

  • Page 233: 5-20

    Cylinder head, cylinder, and piston 5-20 ebs30438 removing the cylinder head 1. Remove: • cylinder bolt (m6) ( × 2) • cylinder head bolt (m6) ( × 2) • cylinder head bolt (m11) ( × 4) • cylinder head tip • loosen the bolts in the proper sequence as shown. • loosen each bolt 1/2 of a turn at a time. A...

  • Page 234: 5-21

    Cylinder head, cylinder, and piston 5-21 ebs30439 checking the cylinder head 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) notice ecb01851 do not use a sharp instrument; otherwise, the following may be damaged or scratched: • spark plug bore threads • valve seats 2. Che...

  • Page 235: 5-22

    Cylinder head, cylinder, and piston 5-22 b. If out of specification, replace the cylinder, and replace the piston and piston rings as a set. C. Measure piston skirt diameter “p” with a mi- crometer. D. If out of specification, replace the piston and piston rings as a set. E. Calculate the piston-to-...

  • Page 236: 5-23

    Cylinder head, cylinder, and piston 5-23 ebs30149 checking the piston pin 1. Check: • piston pin blue discoloration/grooves → replace the piston pin, and then check the lubrication sys- tem. 2. Measure: • piston pin outside diameter “a” out of specification → replace the piston pin. 3. Measure: • pi...

  • Page 237: 5-24

    Cylinder head, cylinder, and piston 5-24 5. 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 cavity. Ebs...

  • Page 238: 5-25

    Cylinder head, cylinder, and piston 5-25 tip tighten the clamp screw of each clamp “2” until 6 slots are visible in the area “a” of the clamp as shown in the illustration. T r . . Oil hose bolt (crankcase to cylin- der) 18 nm (1.8 m·kgf, 13 ft·lbf) a 1 2 3 4.

  • Page 239: Valves and Valve Springs

    Valves and valve springs 5-26 ebs20037 valves and valve springs removing the valves and valve springs order job/parts to remove q ’ ty remarks cylinder head refer to “cylinder head, cylinder, and piston” on page 5-17. 1 valve lifter 4 2 valve pad 4 3 valve cotter 8 4 valve spring retainer 4 5 valve ...

  • Page 240: Valves and Valve Springs

    Valves and valve springs 5-27 ebs30141 removing the valves the following procedure applies to all of the valves and related components. Tip before removing the internal parts of the cylinder head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Remove: • valve lifte...

  • Page 241: Valves and Valve Springs

    Valves and valve springs 5-28 1. Measure: • valve-stem-to-valve-guide clearance out of specification → replace the valve guide. 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. ▼▼▼ ▼ ▼ ▼...

  • Page 242: Valves and Valve Springs

    Valves and valve springs 5-29 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Check: • valve face pitting/wear → grind the valve face. • valve stem end mushroom shape or diameter larger than the body of the valve stem → replac...

  • Page 243: Valves and Valve Springs

    Valves and valve springs 5-30 tip after replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply a coarse lapping compound “a” to the valve face. Notice ecb01360 do not let the lappi...

  • Page 244: Valves and Valve Springs

    Valves and valve springs 5-31 2. Measure: • valve spring tilt “a” out of specification → replace the valve spring. Ebs30441 checking the valve lifters the following procedure applies to all of the valve lifters. 1. Check: • valve lifter damage/scratches → replace the valve lift- ers and cylinder hea...

  • Page 245: Valves and Valve Springs

    Valves and valve springs 5-32 4. Install: • valve cotters tip install the valve cotters by compressing the valve spring with the valve spring compressor “1” and the valve spring compressor attachment “2”. 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face ...

  • Page 246: 5-33

    Ac magneto and starter clutch 5-33 ebs20039 ac magneto and starter clutch removing the ac magneto and starter clutch order job/parts to remove q ’ ty remarks engine refer to “engine removal (2)” on page 5-5. Water pump housing refer to “water pump” on page 6-11. 1 oil pipe (ac magneto cover) 1 2 oil...

  • Page 247: 5-34

    Ac magneto and starter clutch 5-34 removing the ac magneto and starter clutch order job/parts to remove q ’ ty remarks 8 starter idle gear 1 1 9 starter idle gear shaft 1 1 10 starter idle gear 2 1 11 starter idle gear shaft 2 1 12 ac magneto rotor 1 13 woodruff key 1 14 starter wheel gear 1 15 bush...

  • Page 248: 5-35

    Ac magneto and starter clutch 5-35 ebs30151 removing the ac magneto rotor 1. Remove: • ac magneto cover tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • ac magneto rotor nut “1” • washer tip ho...

  • Page 249: 5-36

    Ac magneto and starter clutch 5-36 3. Check: • starter clutch gear contact surfaces damage/pitting/wear → replace the defec- tive part(s). 4. Check: • starter clutch operation ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the starter clutch and stater wheel gear “1” onto the ac magnet...

  • Page 250: 5-37

    Ac magneto and starter clutch 5-37 2. Tighten: • ac magneto rotor nut “1” tip hold the ac magneto rotor “2” with the rotor holding tool “3” while tightening the ac magneto rotor nut. 3. Install: • ac magneto cover “1” tip • align the slot “a” in the impeller shaft “2” with the projection “b” on the ...

  • Page 251: Electric Starter

    Electric starter 5-38 ebs20040 electric starter removing the starter motor order job/parts to remove q ’ ty remarks center cover refer to “general chassis (3)” on page 4-6. Air intake silencer refer to “throttle body” on page 7-8. 1 engine ground lead 1 disconnect. 2 starter motor lead 1 disconnect....

  • Page 252: Electric Starter

    Electric starter 5-39 disassembling the starter motor order job/parts to remove q ’ ty remarks 1 starter motor front cover 1 2 starter motor rear cover 1 3 washer kit 1 4 armature assembly 1 5 brush set 1 6 starter motor yoke 1 2 6 3 5 3 4 1 new new new new new e 4.9 nm (0.49 m • kgf, 3.5 ft • ibf) ...

  • Page 253: Electric Starter

    Electric starter 5-40 ebs30157 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. 3. Measure: • mica undercut “a” out of specification → cut the mica to the proper measurement...

  • Page 254: Electric Starter

    Electric starter 5-41 8. Check: • bushing damage/wear → replace the starter motor rear cover. Ebs30158 assembling the starter motor 1. Install: • brush set “1” tip align the tab “a” on the brush set with the slot “b” in the starter motor yoke. 2. Install: • starter motor yoke “1” • starter motor fro...

  • Page 255: Oil Pump Sprockets

    Oil pump sprockets 5-42 ebs20114 oil pump sprockets removing the oil pump sprockets order job/parts to remove q ’ ty remarks ac magneto rotor refer to “ac magneto and starter clutch” on page 5-33. 1 timing chain stopper guide (lower) 1 2 oil pump driven sprocket 1 3 washer 1 4 oil pump drive sprocke...

  • Page 256: Oil Pump Sprockets

    Oil pump sprockets 5-43 ebs30524 removing the oil pump drive sprocket and oil pump driven sprocket 1. Loosen: • oil pump driven sprocket nut “1” • oil pump drive sprocket nut “2” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Temporarily install the ac magneto rotor. Refer to “ac magneto and s...

  • Page 257: Oil Pump Sprockets

    Oil pump sprockets 5-44 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Temporarily install the ac magneto rotor. Refer to “ac magneto and starter clutch” on page 5-33. B. Hold the ac magneto rotor “3” with the rotor holding tool “4” while tightening the oil pump drive sprocket nut and oil pump...

  • Page 258: Shift Lever

    Shift lever 5-45 ebs20042 shift lever removing the drive select lever shift rod and drive select lever order job/parts to remove q ’ ty remarks center cover/under-seat storage compartment refer to “general chassis (3)” on page 4-6. 1 drive select lever shift rod 1 2 drive select lever knob 1 3 drive...

  • Page 259: Shift Lever

    Shift lever 5-46 removing the shift levers and stopper lever order job/parts to remove q ’ ty remarks 1 shift arm 1 2 shift lever cover 1 3 shift lever cover gasket 1 4 dowel pin 1 5 oil seal 1 6 spacer 1 7 shift lever 1 1 8 stopper lever spring 1 9 shift lever 2 1 10 stopper lever 1 11 spacer 1 e e...

  • Page 260: Shift Lever

    Shift lever 5-47 ebs30163 checking the stopper lever 1. Check: • stopper lever damage/wear → replace. • stopper lever spring damage/wear → replace. Ebs30164 checking the shift levers 1. Check: • shift lever 1 • shift lever 2 damage/wear → replace. Ebs30165 installing the shift levers 1. Install: • s...

  • Page 261: Shift Lever

    Shift lever 5-48 tip press the spacer into the shift lever cover, mak- ing sure that the slit “a” in the spacer is facing up- ward as shown in the illustration. 6. Install: • oil seal “1” (into the shift lever cover “2”) 7. Install: • shift arm “1” tip align the slit “a” in the shift arm with the pr...

  • Page 262: Shift Lever

    Shift lever 5-49 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ t r . . Drive select lever shift rod lock- nut 15 nm (1.5 m·kgf, 11 ft·lbf).

  • Page 263: 5-50

    Primary and secondary sheaves 5-50 ebs20043 primary and secondary sheaves removing the primary and secondary sheaves * apply shell sunlight grease 3 ® . Order job/parts to remove q ’ ty remarks under-seat compartment panel refer to “general chassis (3)” on page 4-6. V-belt cooling ducts refer to “ge...

  • Page 264: 5-51

    Primary and secondary sheaves 5-51 disassembling the primary sheave * apply yamaha grizzly grease or yamaha grease f. Order job/parts to remove q ’ ty remarks 1 primary sheave cap 1 2 primary sheave slider 4 3 primary sheave cam 1 4 primary sheave weight 8 5 spacer 1 6 oil seal 2 7 primary sliding s...

  • Page 265: 5-52

    Primary and secondary sheaves 5-52 disassembling the secondary sheave * apply yamaha grease h or polyrex em ® order job/parts to remove q ’ ty remarks 1 secondary sheave spring retaining nut 1 2 upper spring seat 1 3 compression spring 1 4 lower spring seat 1 5 guide pin 4 6 secondary sliding sheave...

  • Page 266: 5-53

    Primary and secondary sheaves 5-53 ebs30167 removing the primary and secondary sheaves 1. Loosen: • primary sheave assembly nut “1” tip use the rotor holding tool “2” to hold the primary sheave. 2. Loosen: • secondary sheave assembly nut “1” tip shift the transmission into “r” (reverse), set the par...

  • Page 267: 5-54

    Primary and secondary sheaves 5-54 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ebs30169 checking the v-belt 1. Check: • v-belt “1” cracks/damage/wear → replace. Grease/oil → clean the primary and second- ary sheaves. 2. Measure: • v-belt width “a” out of specification → replace. Ebs30170 check...

  • Page 268: 5-55

    Primary and secondary sheaves 5-55 3. Check: • guide pins “2” damage/wear → replace the secondary fixed and sliding sheaves as a set. 4. Check: • secondary sheave spring damage → replace. 5. Measure: • secondary sheave spring free length “a” out of specification → replace the second- ary sheave spri...

  • Page 269: 5-56

    Primary and secondary sheaves 5-56 4. Install: • primary sheave weights “1” tip apply yamaha grizzly grease or yamaha grease f (90 g) to the whole outer surface of the weights and install. Ebs30175 assembling the secondary sheave 1. Install: • oil seals “1” (into the secondary sliding sheave “2”) 2....

  • Page 270: 5-57

    Primary and secondary sheaves 5-57 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Attach the sheave fixed block “5”, locknut wrench “6” and sheave spring compressor “7” to the secondary sheave. B. Place the sheave fixed block in a vise and se- cure it. C. Tighten the sheave spring compressor n...

  • Page 271: 5-58

    Primary and secondary sheaves 5-58 2. Check: • primary sheave weights position out of specification → repeat step (1). Tip to check that the primary sheave weights “1” are installed correctly, make sure that the sec- ondary sheave “2”, primary sheave “3”, and v- belt “4” are positioned as shown in t...

  • Page 272: 5-59

    Primary and secondary sheaves 5-59 tip shift the transmission into “l” (low) or “h” (high), set the parking brake, and then tighten the sec- ondary sheave assembly nut. 5. Lubricate: • bearing housing bearing inner surface and ball (with the recommended lubricant) tip apply 2.3 g or more of shell su...

  • Page 273: Clutch

    Clutch 5-60 ebs20044 clutch removing the clutch order job/parts to remove q ’ ty remarks drive belt case refer to “primary and secondary sheaves” on page 5-50. 1 clutch housing assembly 1 2 clutch housing assembly gasket 1 3 dowel pin 2 4 clutch carrier assembly nut 1 left-hand threads 5 clutch carr...

  • Page 274: Clutch

    Clutch 5-61 disassembling the clutch housing assembly order job/parts to remove q ’ ty remarks 1 oil seal 1 2 circlip 1 3 bearing housing 1 4 circlip 1 5 bearing 1 6 seal ring 1 7 one-way clutch bearing 1 8 bearing 1 9 clutch housing 1 6 7 8 9 e new.

  • Page 275: Clutch

    Clutch 5-62 ebs30177 removing the clutch 1. Remove: • clutch housing assembly tip working in crisscross pattern, loosen each bolt 1/4 of a turn. Remove them after all of them are loosened. 2. Straighten: • punched portion “a” of the clutch carrier as- sembly nut “1” 3. Remove: • clutch carrier assem...

  • Page 276: Clutch

    Clutch 5-63 ebs30180 assembling the clutch housing 1. Install: • bearing “1” (into the clutch housing “2”) 2. Install: • one-way clutch bearing tip the one-way clutch bearing should be installed in the clutch housing with the “out side” mark “a” facing the clutch housing. 3. Install: • oil seal “1” ...

  • Page 277: Clutch

    Clutch 5-64 tip • tighten the bolts in stages, using a crisscross pattern. • after tightening the bolts, check that the clutch housing assembly rotates smoothly. 1.

  • Page 278: Crankcase

    Crankcase 5-65 ebs20045 crankcase separating the crankcase order job/parts to remove q ’ ty remarks engine refer to “engine removal (2)” on page 5-5. Cylinder head/piston refer to “cylinder head, cylinder, and piston” on page 5-17. Ac magneto rotor refer to “ac magneto and starter clutch” on page 5-...

  • Page 279: Crankcase

    Crankcase 5-66 separating the crankcase order job/parts to remove q ’ ty remarks 4 oil bypass valve 1 5 oil pipe (crankcase) 1 6 timing chain guide (intake side) 1 7 timing chain 1 8 speed sensor 1 9 dipstick 1 10 reverse switch 1 11 gear position switch 1 12 main gallery bolt 1 13 thermostat outlet...

  • Page 280: Crankcase

    Crankcase 5-67 removing the crankcase bearings order job/parts to remove q ’ ty remarks crankshaft/oil pump refer to “crankshaft and oil pump” on page 5-71. Middle drive shaft/middle driven shaft refer to “middle gear” on page 5-83. Transmission refer to “transmission” on page 5-76. 1 collar 1 2 o-r...

  • Page 281: Crankcase

    Crankcase 5-68 ebs30182 separating the crankcase 1. Remove: • crankcase bolts tip loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • crankcase (left) “1” tip • remove the crankcase (left) with the cr...

  • Page 282: Crankcase

    Crankcase 5-69 ebs30186 checking the crankcase 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • crankcase cracks/damage → replace. • oil delivery passages obstruction → blow out with compressed air. Ebs3...

  • Page 283: Crankcase

    Crankcase 5-70 7. Apply: • 4-stroke engine oil (onto the crankshaft pin, bearings and oil de- livery hole) 8. Check: • crankshaft and transmission operation rough operation → repair. 9. Install: • o-ring “1” (onto the adapter) • adapter “2” • oil filter cartridge union bolt tip align the pin “a” in ...

  • Page 284: Crankshaft and Oil Pump

    Crankshaft and oil pump 5-71 ebs20046 crankshaft and oil pump removing the crankshaft and oil pump order job/parts to remove q ’ ty remarks crankcase separate. Refer to “crankcase” on page 5-65. 1 oil pump 1 2 crankshaft 1 3 balancer 1 4 bearing 1 5 plug 1 6 spring 1 7 steel ball 1 10 nm (1.0 m • kg...

  • Page 285: Crankshaft and Oil Pump

    Crankshaft and oil pump 5-72 disassembling the oil pump order job/parts to remove q ’ ty remarks 1 oil pump housing cover 1 2 pin 1 3 oil pump shaft 1 4 oil pump inner rotor 1 5 oil pump outer rotor 1 6 oil pump housing 1 e 6 3 2 5 4 1 e e 5 nm (0.5 m • kgf, 3.6 ft • ibf) t.R..

  • Page 286: Crankshaft and Oil Pump

    Crankshaft and oil pump 5-73 ebs30188 removing the crankshaft 1. Remove: • crankshaft “1” • balancer “2” tip • remove the crankshaft with the crankcase separating tool “3”. • make sure the crankcase separating tool is centered over the crankshaft. • remove the crankshaft “1” and balancer “2” at the ...

  • Page 287: Crankshaft and Oil Pump

    Crankshaft and oil pump 5-74 ebs30191 checking the crankshaft 1. Measure: • crankshaft width “a” out of specification → replace the crank- shaft. 2. Measure: • crankshaft runout “b” out of specification → replace the crank- shaft. 3. Measure: • big end side clearance “c” out of specification → repla...

  • Page 288: Crankshaft and Oil Pump

    Crankshaft and oil pump 5-75 ebs30445 installing the oil pump 1. Install: • oil pump tip tighten the bolts to specification in the proper tightening sequence as shown. Crankshaft installer pot 90890-01274 installing pot yu-90058 crankshaft installer bolt 90890-01275 bolt yu-90060 adapter (m16) 90890...

  • Page 289: Transmission

    Transmission 5-76 ebs20047 transmission removing the transmission, shift drum and shift forks order job/parts to remove q ’ ty remarks crankcase separate. Refer to “crankcase” on page 5-65. Middle driven gear refer to “middle gear” on page 5-83. 1 shift drum stopper bolt 1 2 spring 1 3 ball 1 4 shif...

  • Page 290: Transmission

    Transmission 5-77 removing the transmission, shift drum and shift forks order job/parts to remove q ’ ty remarks 11 drive axle assembly 1 12 collar 1 13 reverse idle gear 1 14 bearing 1 15 reverse idle gear shaft 1 e e e e e e new new m m e e e new 18 nm (1.8 m • kgf, 13 ft • ibf) t.R . 15 13 14 12 ...

  • Page 291: Transmission

    Transmission 5-78 disassembling the drive axle assembly order job/parts to remove q ’ ty remarks 1 washer 1 2 collar 1 3 high wheel gear 1 4 washer 1 5 clutch dog 1 6 circlip 1 7 washer 1 8 collar 1 9 low wheel gear 1 new ls new new ls m m 1 3 4 5 6 7 9 8 2.

  • Page 292: Transmission

    Transmission 5-79 disassembling the drive axle assembly order job/parts to remove q ’ ty remarks 10 washer 1 11 circlip 1 12 middle drive gear 1 13 circlip 1 14 washer 1 15 bearing 1 16 reverse wheel gear 1 17 collar 1 18 drive axle 1 new ls new new ls m m 17 18 16 10 11 12 13 14 15.

  • Page 293: Transmission

    Transmission 5-80 ebs30194 removing the transmission 1. Remove: • shift drum “1” • shift fork assembly “2” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Pull out the guide bar from the right crank- case, and then remove the shift fork cam fol- lowers. B. Remove the shift drum. C. Remove the s...

  • Page 294: Transmission

    Transmission 5-81 ebs30198 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: • transmission gears blue discoloration/pitting/wear → replace the defective gear(s). • transmission gear dogs cr...

  • Page 295: Transmission

    Transmission 5-82 ebs30202 installing the shift forks and shift drum 1. Install: • reverse idle gear “1” • drive axle assembly “2” • secondary shaft “3” • shift fork assembly “4” • shift drum “5” tip install the shift fork assembly “4” with the “l” mark “a” facing the right crankcase. 2. Check: • sh...

  • Page 296: Middle Gear

    Middle gear 5-83 ebs20048 middle gear removing the middle drive shaft order job/parts to remove q ’ ty remarks crankcase separate. Refer to “crankcase” on page 5-65. 1 middle drive shaft/bearing housing assembly 1 2 middle drive pinion gear nut 1 3 middle drive pinion gear 1 4 middle drive pinion ge...

  • Page 297: Middle Gear

    Middle gear 5-84 removing the middle drive shaft order job/parts to remove q ’ ty remarks 10 bearing retainer 2 11 bearing 1 12 washer 1 13 bearing housing 1 new lt lt lt lt lt lt lt new lt lt lt e e 190 nm (19 m • kgf, 137 ft • lbf) t.R. 38 nm (3.8 m • kgf, 27 ft • ibf) t.R . 12 13 11 10 10 29 nm (...

  • Page 298: Middle Gear

    Middle gear 5-85 removing the middle driven shaft order job/parts to remove q ’ ty remarks 1 rear drive shaft coupling gear nut (middle gear side) 1 2 rear drive shaft coupling gear (middle gear side) 1 3 front drive shaft coupling gear nut (middle gear side) 1 4 front drive shaft coupling gear (mid...

  • Page 299: Middle Gear

    Middle gear 5-86 removing the middle driven shaft order job/parts to remove q ’ ty remarks 10 middle driven pinion gear bearing retainer 1 left-hand threads 11 bearing 1 12 o-ring 1 13 bearing housing 1 14 oil seal 1 15 middle driven shaft bearing retainer 1 left-hand threads 16 bearing 1 17 middle ...

  • Page 300: Middle Gear

    Middle gear 5-87 ebs30203 removing the middle drive shaft 1. Straighten: • punched portion of the middle drive pinion gear nut 2. Loosen: • middle drive pinion gear nut “1” tip wrap the middle drive shaft in a folded rag, and then secure it in a vise. 3. Remove: • middle drive pinion gear nut • midd...

  • Page 301: Middle Gear

    Middle gear 5-88 • install a suitable socket “2” on the middle driven pinion gear end to protect the thread from damage. C. Press the middle driven pinion gear end and remove the bearing housing. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Remove: • middle driven pinion gear bearing retaine...

  • Page 302: Middle Gear

    Middle gear 5-89 ebs30206 installing the bearing and oil seals 1. Install: • bearing “1” • oil seal “2” (into the bearing housing “3”) 2. Install: • oil seal “1” (into the crankcase “2”) ebs30207 installing the middle driven shaft 1. Install: • middle driven shaft bearing retainer “1” tip attach the...

  • Page 303: Middle Gear

    Middle gear 5-90 notice ecb01770 the middle driven pinion gear bearing retain- er has left-hand threads. To tighten the re- tainer turn it counterclockwise. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • middle driven pinion gear shim(s) “1” • bearing housing “2” tip • install the s...

  • Page 304: Middle Gear

    Middle gear 5-91 2. Install: • washer “1” • bearing “2” • bearing retainers “3” • bearing retainer bolts “4” tip • install the washer “1” with its rounded side “a” facing away from the bearing. • stake the bearing retainer bolts at the cutouts “b” in the bearing retainers “3”. 3. Tighten: • middle d...

  • Page 305: Middle Gear

    Middle gear 5-92 d. Measure the gear lash while rotating the mid- dle driven shaft back and forth. Tip measure the gear lash at 4 positions. Rotate the middle driven gear 90° each time. E. If the gear lash is incorrect, adjust the gear lash by middle driven pinion gear shim(s). ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...

  • Page 306: Middle Gear

    Middle gear 5-93 “b” is 17.0 “c” is 55.0 if the crankcase (left) is marked “64.96”, “d” is 64.96 if the crankcase (right) is marked “9.01”, “e” is 9.01 therefore, “a” is 1.39. “a” = 9.01 + 64.96 - 17.0 - 55.0 - 0.58 = 1.39 round off hundredths digit and select appro- priate shim(s). In the above exa...

  • Page 307: Middle Gear

    Middle gear 5-94 if the driven pinion gear is marked “+02”, “g” is 61.02 if the driven pinion gear is marked “-10”, “h” is 80.40 if the right crankcase is marked “99.98”, “i” is 99.98 if the left crankcase is marked “8.12”, “j” is 8.12 therefore, “b” is 0.81. “b” = 89.53 - 61.02 + 80.40 - 99.98 - 8....

  • Page 308: Middle Gear

    Middle gear 5-95.

  • Page 309: Cooling System

    6 cooling system oil cooler................................................................................................... 6-1 checking the oil cooler ................................................................ 6-3 installing the horn (except for cdn) ..........................................

  • Page 310: Oil Cooler

    Oil cooler 6-1 ebs20050 oil cooler removing the oil cooler order job/parts to remove q ’ ty remarks floor boards refer to “general chassis (3)” on page 4-6. Front grill refer to “general chassis (6)” on page 4-12. Air filter case refer to “air filter case” on page 7-5. Engine oil drain. Refer to “ch...

  • Page 311: Oil Cooler

    Oil cooler 6-2 removing the oil cooler order job/parts to remove q ’ ty remarks 7 oil inlet hose 1 8 oil outlet hose 1 9 oil inlet pipe 1 10 oil outlet pipe 1 11 oil cooler outlet pipe 1 12 oil cooler inlet pipe 1 new 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R . 7 nm (0.7 m • kgf, 5.1 ft • ibf) t.R . 7 n...

  • Page 312: Oil Cooler

    Oil cooler 6-3 ebs30211 checking the oil cooler 1. Check: • oil cooler fins obstruction → clean. Apply compressed air to the rear of the oil cooler. Damage → repair or replace. Tip straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: • oil cooler hoses • oil cooler pipes • oil...

  • Page 313: Radiator

    Radiator 6-4 ebs20051 radiator removing the radiator order job/parts to remove q ’ ty remarks oil cooler refer to “oil cooler” on page 6-1. Coolant drain. Refer to “changing the coolant” on page 3-9. 1 radiator cap 1 2 coolant reservoir hose 1 3 coolant reservoir breather hose 1 4 coolant reservoir ...

  • Page 314: Radiator

    Radiator 6-5 removing the radiator order job/parts to remove q ’ ty remarks 10 radiator inlet pipe 1 11 radiator outlet pipe 1 12 radiator fan motor coupler 1 disconnect. 13 radiator bracket 1 14 radiator 1 15 radiator fan motor breather hose 1 16 radiator fan 1 10 16 12 14 13 15 (4) 11 7 nm (0.7 m ...

  • Page 315: Radiator

    Radiator 6-6 ebs30213 checking the radiator 1. Check: • radiator fins obstruction → clean. Apply compressed air to the rear of the radia- tor. Damage → repair or replace. Tip straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: • radiator hoses • radiator pipes cracks/damage/w...

  • Page 316: Radiator

    Radiator 6-7 refer to “changing the coolant” on page 3-9. 3. Check: • cooling system leaks → repair or replace any faulty part. 4. Measure: • radiator cap opening pressure below the specified pressure → replace the radiator cap. Refer to “checking the radiator” on page 6-6..

  • Page 317: Thermostat

    Thermostat 6-8 ebs20052 thermostat removing the thermostat order job/parts to remove q ’ ty remarks coolant drain. Refer to “changing the coolant” on page 3-9. 1 coolant temperature sensor coupler 1 disconnect. 2 coolant temperature sensor 1 3 thermostat outlet hose 1 disconnect. 4 thermostat cover ...

  • Page 318: Thermostat

    Thermostat 6-9 ebs30215 checking the thermostat 1. Check: • thermostat does not open at 69–73 °c (156–163°f) → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Suspend the thermostat “1” in a container “2” filled with water. B. Slowly heat the water “3”. C. Place a thermometer “4” in th...

  • Page 319: Thermostat

    Thermostat 6-10 refer to “checking the radiator” on page 6-6..

  • Page 320: Water Pump

    Water pump 6-11 ebs20053 water pump removing the water pump order job/parts to remove q ’ ty remarks engine refer to “engine removal (2)” on page 5-5. 1 water jacket joint 1 2 water pump outlet hose 1 3 water pump outlet pipe 1 4 water pump breather hose 1 5 water pump housing 1 6 gasket 1 7 ac magn...

  • Page 321: Water Pump

    Water pump 6-12 ebs30217 disassembling the water pump 1. Remove: • mechanical seal “1” tip remove the mechanical seal from the inside of the ac magneto cover. 2. Remove: • bearing “1” • oil seal “2” tip remove the bearing and oil seal from the inside of the ac magneto cover. Ebs30218 checking the wa...

  • Page 322: Water Pump

    Water pump 6-13 3. Install: • impeller “1” tip after installation, check that the impeller shaft ro- tates smoothly. 4. Install: • ac magneto cover refer to “ac magneto and starter clutch” on page 5-33. Ebs30471 installing the water jacket joint 1. Install: • clamps “1” (onto the water pump outlet h...

  • Page 323: Fuel System

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

  • Page 324: Fuel Tank

    Fuel tank 7-1 ebs20054 fuel tank removing the fuel tank order job/parts to remove q ’ ty remarks rear panel (right) refer to “general chassis (1)” on page 4-1. Under-seat storage compartment refer to “general chassis (3)” on page 4-6. 1 fuel tank breather hose 2 2 fuel tank breather hose joint 1 3 f...

  • Page 325: Fuel Tank

    Fuel tank 7-2 ebs30221 removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel hose connector holder • fuel hose warning ewb03050 cover fuel hose connections with a cloth when disconnecting them. Residual pres- sure in the fuel lines could...

  • Page 326: Fuel Tank

    Fuel tank 7-3 ebs30225 installing the fuel pump 1. Install: • fuel pump gasket “1” tip • always use a new fuel pump gasket. • install the fuel pump gasket with the lip side “a” facing upward. 2. Install: • fuel pump • fuel pump bracket tip • do not damage the installation surfaces of the fuel tank w...

  • Page 327: Fuel Tank

    Fuel tank 7-4 4. Install: • fuel hose • fuel hose connector holder “1” • fuel pump coupler notice ecb02010 when installing the fuel hose, make sure that it is securely connected, and that the fuel hose holder is in the correct position, other- wise the fuel hose will not be properly in- stalled. Tip...

  • Page 328: Air Filter Case

    Air filter case 7-5 ebs20055 air filter case removing the air filter case and air intake duct order job/parts to remove q ’ ty remarks floor boards refer to “general chassis (3)” on page 4-6. Instrument panel assembly refer to “general chassis (7)” on page 4-13. 1 air filter case cover 1 2 air filte...

  • Page 329: Air Filter Case

    Air filter case 7-6 removing the air filter case and air intake duct order job/parts to remove q ’ ty remarks 10 air filter case 1 11 intake air temperature sensor 1 12 air intake duct 1 11 10 new new 12 2.0 nm (0.20 m • kgf, 1.4 ft • ibf) t.R . 2.0 nm (0.20 m • kgf, 1.4 ft • ibf) t.R . 7 nm (0.7 m ...

  • Page 330: Air Filter Case

    Air filter case 7-7 ebs30228 installing the air filter case 1. Install: • air intake duct joint “1” (to the air filter case “2”) tip align the projection “a” on the air intake duct joint between the projections “b” on the air filter case. 2. Install: • air filter case joint “1” (to the air filter ca...

  • Page 331: Throttle Body

    Throttle body 7-8 ebs20056 throttle body removing the throttle body assembly order job/parts to remove q ’ ty remarks cargo bed refer to “general chassis (9)” on page 4-19. 1 intake air pressure sensor coupler 1 disconnect. 2 throttle position sensor coupler 1 disconnect. 3 throttle body breather ho...

  • Page 332: Throttle Body

    Throttle body 7-9 removing the throttle body order job/parts to remove q ’ ty remarks 10 air intake silencer joint clamp screw 2 loosen. 11 air intake silencer joint 1 12 throttle body joint clamp screw 2 loosen. 13 throttle body assembly 1 14 throttle body joint 1 15 air induction system solenoid h...

  • Page 333: Throttle Body

    Throttle body 7-10 disassembling the throttle body assembly order job/parts to remove q ’ ty remarks 1 intake air pressure sensor 1 2 intake air pressure sensor hose 1 3 throttle position sensor 1 4 fuel rail 1 5 fuel injector 1 6 throttle body 1 new new new 1 2 3 4 5 6 3.5 nm (0.35 m • kgf, 2.5 ft ...

  • Page 334: Throttle Body

    Throttle body 7-11 ebs30229 removing the throttle body 1. Disconnect: • fuel hose warning ewb03050 cover fuel hose connections with a cloth when disconnecting them. Residual pres- sure in the fuel lines could cause fuel to spurt out when removing the hose. Notice ecb01700 • be sure to disconnect the...

  • Page 335: Throttle Body

    Throttle body 7-12 3. Install: • throttle body joint clamp “1” tip align the projection on the throttle body joint with the gap in throttle body joint clamp. 4. Install: • throttle body assembly “1” tip align the projection “a” on the throttle body as- sembly between the tabs “b” on the throttle bod...

  • Page 336: Throttle Body

    Throttle body 7-13 ebs30234 adjusting the throttle position sensor warning ewb03070 • handle the throttle position sensor with special care. • never subject the throttle position sensor to strong shocks. If the throttle position sensor is dropped, replace it. 1. Check: • throttle position sensor ref...

  • Page 337: Air Induction System

    Air induction system 7-14 ebs20057 air induction system 1 2 3 5 4 1. Air intake silencer 2. Air induction system hose (air intake silencer to air cut-off valve) 3. Air cut-off valve 4. Air induction system hose (air cut-off valve to reed valve cover) 5. Reed valve.

  • Page 338: Air Induction System

    Air induction system 7-15 removing the air cut-off valve order job/parts to remove q ’ ty remarks cargo bed refer to “general chassis (9)” on page 4-19. 1 air induction system solenoid coupler 1 disconnect. 2 air induction system hose (air cut-off valve to reed valve cover) 1 3 air induction system ...

  • Page 339: Air Induction System

    Air induction system 7-16 removing the reed valve order job/parts to remove q ’ ty remarks 1 reed valve cover 1 2 reed valve assembly 1 3 reed valve plate 1 lt lt 3 2 1 10 nm (1.0 m • kgf, 7.2 ft • ibf) t.R ..

  • Page 340: Air Induction System

    Air induction system 7-17 ebs30235 checking the air induction system air injection the air induction system burns unburned ex- haust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the ree...

  • Page 341: Drive Train

    8 drive train troubleshooting..................................................................................... 8-1 checking noises ................................................................................. 8-2 troubleshooting chart ............................................................

  • Page 342: Troubleshooting

    Troubleshooting 8-1 ebs20058 troubleshooting the following conditions may indicate damaged shaft drive components: tip areas a, b, and c above may be extremely difficult to diagnose. The symptoms are quite subtle and difficult to distinguish from normal vehicle operating noise. If there is reason to...

  • Page 343: Troubleshooting

    Troubleshooting 8-2 ebs30237 checking noises 1. Investigate any unusual noises. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ the following “noises” may indicate a me- chanical defect: a. A “rolling rumble” noise during coasting, ac- celeration, or deceleration. The noise in- creases with front ...

  • Page 344: Troubleshooting

    Troubleshooting 8-3 ebs30238 troubleshooting chart when basic conditions (a) and (b) described in “checking noises” exist, check the following points: yes → no ↓ no → yes ↓ no → yes ↓ no → yes ↓ no → yes ↓ 1. Elevate and spin both wheels. Feel for wheel bearing damage. Replace the wheel bearing. (re...

  • Page 345: 8-4

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shafts 8-4 ebs20059 front constant velocity shaft assemblies, differential assembly and front drive shafts removing the front constant velocity shaft assemblies, differential assembly, and front drive shafts order job/...

  • Page 346: 8-5

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shafts 8-5 removing the front constant velocity shaft assemblies, differential assembly, and front drive shafts order job/parts to remove q ’ ty remarks 4 differential assembly 1 5 support bearing bracket 1 6 front dri...

  • Page 347: 8-6

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shafts 8-6 disassembling the front constant velocity shaft assemblies a: wheel side b: differential side order job/parts to remove q ’ ty remarks the following procedure applies to both of the front constant velocity s...

  • Page 348: 8-7

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shafts 8-7 disassembling the front constant velocity shaft assemblies a: wheel side b: differential side order job/parts to remove q ’ ty remarks 10 dust boot 1 11 constant velocity joint 1 12 clip 1 13 constant veloci...

  • Page 349: 8-8

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shafts 8-8 disassembling the differential assembly * sae 80 api gl-4 hypoid gear oil order job/parts to remove q ’ ty remarks 1 differential motor 1 2 front drive shaft yoke nut (differential case side) 1 3 front drive...

  • Page 350: 8-9

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shafts 8-9 disassembling the differential assembly * sae 80 api gl-4 hypoid gear oil order job/parts to remove q ’ ty remarks 11 clip 1 12 differential pinion gear 1 13 bearing 1 14 bearing 1 15 oil seal 2 16 different...

  • Page 351: 8-10

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shafts 8-10 ebs30239 disassembling the universal joints 1. Remove: • universal joint ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the circlips “1” b. Place the universal joint in a press. C. With a suita...

  • Page 352: 8-11

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shafts 8-11 ebs30241 checking the front constant velocity shaft assemblies the following procedure applies to both of the front constant velocity shaft assemblies. 1. Check: • double offset joint splines • constant vel...

  • Page 353: 8-12

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shafts 8-12 3. Apply: • molybdenum disulfide grease (into the double offset joint, constant velocity joint, and dust boots) tip molybdenum disulfide grease is included in the repair kit. 4. Install: • dust boots “1” • ...

  • Page 354: 8-13

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shafts 8-13 ebs30244 removing the differential gear assembly 1. Remove: • differential gear assembly “1” notice ecb01570 the ring gear and differential gear are as- sembled into a proper unit at the factory by means of...

  • Page 355: 8-14

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shafts 8-14 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ebs30248 assembling the front drive shaft 1. Install: • oil seal “1” • oil seal “2” ebs30249 assembling the differential assembly 1. Install: • oil seals “1...

  • Page 356: 8-15

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shafts 8-15 “a” on the differential motor pinion gear is aligned with the mark “b” on the differential motor case. Notice ecb01650 do not use a 12 v battery to operate the dif- ferential motor pinion gear. C. Insert 6 ...

  • Page 357: 8-16

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shafts 8-16 b. Apply lithium-soap-based grease to the bear- ings. C. Install the bearing “1” onto the front drive shaft yoke. Notice ecb01670 the needles can easily fall out of their races, so check each bearing carefu...

  • Page 358: 8-17

    Front constant velocity shaft assemblies, differen- tial assembly and front drive shafts 8-17 ebs30252 adjusting the differential gear backlash 1. Remove: • differential gear assembly shim(s) “1” • differential gear assembly “2” 2. Adjust: • gear backlash ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ...

  • Page 359: 8-18

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-18 ebs20060 rear constant velocity shaft assemblies, final drive assembly and rear drive shaft removing the rear constant velocity shaft assemblies, final drive assembly, and rear drive shaft order job/parts to remo...

  • Page 360: 8-19

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-19 removing the rear constant velocity shaft assemblies, final drive assembly, and rear drive shaft order job/parts to remove q ’ ty remarks 8 damper 1 9 rear drive shaft coupling sleeve 1 10 dust seal 1 11 dust sea...

  • Page 361: 8-20

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-20 disassembling the rear constant velocity shaft assemblies a: wheel side b: final drive side order job/parts to remove q ’ ty remarks the following procedure applies to both of the rear constant velocity shaft ass...

  • Page 362: 8-21

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-21 disassembling the rear constant velocity shaft assemblies a: wheel side b: final drive side order job/parts to remove q ’ ty remarks 10 dust boot 1 11 constant velocity joint 1 12 clip 1 13 constant velocity shaf...

  • Page 363: 8-22

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-22 disassembling the final drive assembly * apply yamaha bond no. 1215 (90890-85505). Order job/parts to remove q ’ ty remarks 1 ring gear stopper 1 2 ring gear bearing housing 1 3 ring gear bearing housing gasket 1...

  • Page 364: 8-23

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-23 disassembling the final drive assembly * apply yamaha bond no. 1215 (90890-85505). Order job/parts to remove q ’ ty remarks 10 oil seal 2 11 rear drive shaft coupling gear nut (final drive assembly side) 1 12 rea...

  • Page 365: 8-24

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-24 disassembling the final drive assembly * apply yamaha bond no. 1215 (90890-85505). Order job/parts to remove q ’ ty remarks 20 circlip 1 21 final drive pinion gear bearing housing 1 22 final drive pinion gear 1 2...

  • Page 366: 8-25

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-25 ebs30253 disassembling the rear constant velocity shaft assemblies the following procedure applies to both of the rear constant velocity shaft assemblies. 1. Remove: • boot bands “1” use the boot band installatio...

  • Page 367: 8-26

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-26 b. Install the constant velocity joint. Tip • install the clip into the groove in the constant velocity shaft as shown. • secure the constant velocity joint in a vise, and then fit the constant velocity shaft int...

  • Page 368: 8-27

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-27 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the dust boots. B. Install the boot bands “2” and “3”. Use the boot band installation tool “4”. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5. Ch...

  • Page 369: 8-28

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-28 4. Remove: • final drive pinion gear “1” ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Clean the outside surface of the final drive pinion gear. B. Place the final drive gear in a hydraulic press. Notice e...

  • Page 370: 8-29

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-29 b. Turn the ring gear stopper 120° counterclock- wise. C. Tighten the ring gear stopper nut “3”. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ebs30260 measuring the final gear backlash 1. Remove: • final dri...

  • Page 371: 8-30

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-30 • final drive ring gear shim (ring gear bearing housing side) “3” • final drive ring gear shim (final drive case side) “4” 2. Adjust: • gear backlash ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Select a ...

  • Page 372: 8-31

    Rear constant velocity shaft assemblies, final drive assembly and rear drive shaft 8-31 3. Install: • rear drive shaft coupling gear (final drive as- sembly side) “1” tip • secure the final drive assembly in a vise. • use the coupling gear holding tool (35) “2” to hold the rear drive shaft coupling ...

  • Page 373: Electrical System

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

  • Page 374

    Eps (electric power steering) system (for eps models)........... 9-73 circuit diagram ................................................................................ 9-73 eps control unit’s self-diagnostic function ..................... 9-75 eps warning light during normal operation...................

  • Page 376: Ignition System

    Ignition system 9-1 ebs20074 ignition system ebs30264 circuit diagram gy b gy b /l w (gy) (gy) w r br /l br /r b (b) r b (gy) w ww br /r br /r (b) l /y r /b r r br /b r /yl /y (b) br /yr /w (b) b /y (b) br /r b br /r y /b b /y w /b b /r b br /b o /l p /w b /g (gy) (b) w /r sb gy /g lw gy (b) (w) l/ ...

  • Page 377: Ignition System

    Ignition system 9-2 1. Crankshaft position sensor 5. Frame ground 6. Main switch 7. Engine ground 8. Battery 9. Main fuse 21.Ecu (engine control unit) 22.Ignition coil 23.Spark plug 30.Lean angle sensor 34.Joint coupler 60.Ignition fuse b. Wire harness c. Negative battery sub-wire harness.

  • Page 378: Ignition System

    Ignition system 9-3 ebs30265 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Tip • before troubleshooting, remove the following part(s): 1. Hood 2. Cargo bed 3. Passenger seat frame 4. Passenger seat belt buckle rubber cover ng → ok ↓ ng → ok ↓ ng → ok ↓ ok → n...

  • Page 379: Ignition System

    Ignition system 9-4 ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the main switch. Refer to “checking the switches” on page 9-89. Replace the main switch. 9. Check the lean angle sensor. Refer to “checking the lean angle sensor” on page 9-102. Replace the lean angle sensor. 10.Check the entire ignition sys...

  • Page 380: Electric Starting System

    Electric starting system 9-5 ebs20075 electric starting system ebs30266 circuit diagram gy b gy b /l w (gy) (gy) w r br /l br /r b (b) r b (gy) w ww br /r br /r (b) l /y r /b r r br /b r /yl /y (b) br /yr /w (b) b /y (b) br /r b br /r y /b b /y w /b b /r b br /b o /l p /w b /g (gy) (b) w /r sb gy /g...

  • Page 381: Electric Starting System

    Electric starting system 9-6 4. Load control relay 5. Frame ground 6. Main switch 7. Engine ground 8. Battery 9. Main fuse 11.Starter relay 12.Starter motor 17.Gear position switch 21.Ecu (engine control unit) 34.Joint coupler 56.Brake light switch 60.Ignition fuse 62.Signaling system fuse b. Wire h...

  • Page 382: Electric Starting System

    Electric starting system 9-7 ebs30267 starting circuit cut-off system operation if the main switch is set to “ ” (start), the starter motor can only operate if at least one of the following conditions is met: • the transmission is in neutral (the neutral circuit of the gear position switch is closed...

  • Page 383: Electric Starting System

    Electric starting system 9-8 ebs30268 troubleshooting the starter motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Hood 2. Cargo bed ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ignition, and signaling s...

  • Page 384: Electric Starting System

    Electric starting system 9-9 ng → ok ↓ ng → ok ↓ 9. Check the gear position switch. Refer to “checking the switches” on page 9-89. Replace the gear position switch. 10.Check the entire starting system wiring. Refer to “circuit diagram” on page 9-5. Properly connect or replace the wire har- ness. Rep...

  • Page 385: Electric Starting System

    Electric starting system 9-10

  • Page 386: Charging System

    Charging system 9-11 ebs20076 charging system ebs30269 circuit diagram gy b gy b /l w (gy) (gy) w r br /l br /r b (b) r b (gy) w ww br /r br /r (b) l /y r /b r r br /b r /yl /y (b) br /yr /w (b) b /y (b) br /r b br /r y /b b /y w /b b /r b br /b o /l p /w b /g (gy) (b) w /r sb gy /g lw gy (b) (w) l/...

  • Page 387: Charging System

    Charging system 9-12 2. Ac magneto 3. Rectifier/regulator 5. Frame ground 8. Battery 9. Main fuse b. Wire harness c. Negative battery sub-wire harness.

  • Page 388: Charging System

    Charging system 9-13 ebs30270 troubleshooting the battery is not being charged. Tip • before troubleshooting, remove the following part(s): 1. Hood 2. Passenger seat frame 3. Passenger seat belt buckle rubber cover ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. (main) refer to ...

  • Page 389: Charging System

    Charging system 9-14.

  • Page 390: Lighting System

    Lighting system 9-15 ebs20077 lighting system ebs30271 circuit diagram gy b gy b /l w (gy) (gy) w r br /l br /r b (b) r b (gy) w ww br /r br /r (b) l /y r /b r r br /b r /yl /y (b) br /yr /w (b) b /y (b) br /r b br /r y /b b /y w /b b /r b br /b o /l p /w b /g (gy) (b) w /r sb gy /g lw gy (b) (w) l/...

  • Page 391: Lighting System

    Lighting system 9-16 4. Load control relay 5. Frame ground 6. Main switch 8. Battery 9. Main fuse 52.Light switch 53.Headlight relay 54.Headlight 57.Tail/brake light 60.Ignition fuse 63.Headlight fuse b. Wire harness c. Negative battery sub-wire harness.

  • Page 392: Lighting System

    Lighting system 9-17 ebs30272 troubleshooting any of the following fail to light: headlight or taillight. Tip • before troubleshooting, remove the following part(s): 1. Hood ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the condition of each bulb and bulb socket. Ref...

  • Page 393: Lighting System

    Lighting system 9-18 ng → ok ↓ 8. Check the entire lighting system wiring. Refer to “circuit diagram” on page 9-15. Properly connect or replace the wire har- ness. The lighting system circuit is ok..

  • Page 394: Signaling System

    Signaling system 9-19 ebs20078 signaling system ebs30273 circuit diagram (except for eps models) gy b gy b /l w (gy) (gy) w r br /l br /r b (b) r b (gy) w ww br /r br /r (b) l /y r /b r r br /b r /yl /y (b) br /yr /w (b) b /y (b) br /r b br /r y /b b /y w /b b /r b br /b o /l p /w b /g (gy) (b) w /r...

  • Page 395: Signaling System

    Signaling system 9-20 4. Load control relay 5. Frame ground 6. Main switch 7. Engine ground 8. Battery 9. Main fuse 17.Gear position switch 21.Ecu (engine control unit) 26.Coolant temperature sensor 27.Speed sensor 31.Parking brake switch 32.Parking brake buzzer 33.Reverse switch 34.Joint coupler 35...

  • Page 396: Signaling System

    Signaling system 9-21 ebs30352 circuit diagram (for eps models) gy b gy b /l w (gy) (gy) w r br /l br /r b (b) r b (gy) w ww br /r br /r (b) l /y r /b r r r r /b br /b r /yl /y (b) br /yr /w (b) b /y (b) br /r b br /r y /b b /y w /b b /r b br /b o /l p /w b /g (gy) (b) w /r sb gy /g lw gy (b) (w) l/...

  • Page 397: Signaling System

    Signaling system 9-22 4. Load control relay 5. Frame ground 6. Main switch 7. Engine ground 8. Battery 9. Main fuse 18.Gear position switch 22.Ecu (engine control unit) 27.Coolant temperature sensor 28.Speed sensor 32.Parking brake switch 33.Parking brake buzzer 34.Reverse switch 35.Joint coupler 41...

  • Page 398: Signaling System

    Signaling system 9-23 ebs30274 troubleshooting • any of the following fail to light: warning light, brake light or an indicator light. • the fuel meter fails to come on. • the speedometer fails to operate. • the parking brake buzzer fails to sound. • the horn fails to sound. (except for cdn) tip • b...

  • Page 399: Signaling System

    Signaling system 9-24 checking the signaling system the tail/brake lights fail to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ the neutral, high-range, and/or low-range indicator light fails to come on. Ng → ok ↓ ng → ok ↓ the reverse indicator light fails to come on. Ng → ok ↓ 1. Check the tail/brake lig...

  • Page 400: Signaling System

    Signaling system 9-25 ng → ok ↓ the parking brake indicator light fails to come on. Ng → ok ↓ ng → ok ↓ the coolant temperature warning light fails to come on. Ng → ok ↓ ng → ok ↓ the fuel meter fails to come on. Ng → ok ↓ 2. Check the entire signaling system wiring. Refer to “circuit diagram (ex- c...

  • Page 401: Signaling System

    Signaling system 9-26 ng → ok ↓ the speedometer fails to come on. Ng → ok ↓ ng → ok ↓ the helmet/seat belt indicator light fails to come on. Ng → ok ↓ ng → ok ↓ the parking brake buzzer fails to sound. Ng → ok ↓ 2. Check the entire signaling system wiring. Refer to “circuit diagram (ex- cept for eps...

  • Page 402: Signaling System

    Signaling system 9-27 ng → ok ↓ the horn fails to sound. (except for cdn) . Ng → ok ↓ . Ng → ok ↓ 2. Check the entire signaling system wiring. Refer to “circuit diagram (ex- cept for eps models)” on page 9-19 and “circuit diagram (for eps models)” on page 9-21. Properly connect or replace the wire h...

  • Page 403: Signaling System

    Signaling system 9-28.

  • Page 404: Cooling System

    Cooling system 9-29 ebs20079 cooling system ebs30275 circuit diagram gy b gy b /l w (gy) (gy) w r br /l br /r b (b) r b (gy) w ww br /r br /r (b) l /y r /b r r br /b r /yl /y (b) br /yr /w (b) b /y (b) br /r b br /r y /b b /y w /b b /r b br /b o /l p /w b /g (gy) (b) w /r sb gy /g lw gy (b) (w) l/ w...

  • Page 405: Cooling System

    Cooling system 9-30 5. Frame ground 6. Main switch 8. Battery 9. Main fuse 21.Ecu (engine control unit) 26.Coolant temperature sensor 34.Joint coupler 58.Radiator fan motor fuse 60.Ignition fuse 65.Radiator fan motor 66.Radiator fan motor circuit breaker 67.Radiator fan motor relay b. Wire harness c...

  • Page 406: Cooling System

    Cooling system 9-31 ebs30276 troubleshooting the radiator fan motor fails to turn. Tip • before troubleshooting, remove the following part(s): 1. Hood 2. Heat protector ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, radiator fan motor, and igni- tion...

  • Page 407: Cooling System

    Cooling system 9-32 ng → ok ↓ 8. Check the entire cooling system wiring. Refer to “circuit diagram” on page 9-29. Properly connect or replace the wire har- ness. Replace the ecu..

  • Page 408: Fuel Injection System

    Fuel injection system 9-33 ebs20080 fuel injection system ebs30277 circuit diagram (except for eps models) gy b gy b /l w (gy) (gy) w r br /l br /r b (b) r b (gy) w ww br /r br /r (b) l /y r /b r r br /b r /yl /y (b) br /yr /w (b) b /y (b) br /r b br /r y /b b /y w /b b /r b br /b o /l p /w b /g (gy...

  • Page 409: Fuel Injection System

    Fuel injection system 9-34 1. Crankshaft position sensor 4. Load control relay 5. Frame ground 6. Main switch 7. Engine ground 8. Battery 9. Main fuse 10.Fuel injection system fuse 13.Fuel injection system relay 14.Air induction system solenoid 17.Gear position switch 19.Yamaha diagnostic tool coupl...

  • Page 410: Fuel Injection System

    Fuel injection system 9-35 ebs30353 circuit diagram (for eps models) gy b gy b /l w (gy) (gy) w r br /l br /r b (b) r b (gy) w ww br /r br /r (b) l /y r /b r r r r /b br /b r /yl /y (b) br /yr /w (b) b /y (b) br /r b br /r y /b b /y w /b b /r b br /b o /l p /w b /g (gy) (b) w /r sb gy /g lw gy (b) (...

  • Page 411: Fuel Injection System

    Fuel injection system 9-36 1. Crankshaft position sensor 4. Load control relay 5. Frame ground 6. Main switch 7. Engine ground 8. Battery 9. Main fuse 11.Fuel injection system fuse 14.Fuel injection system relay 15.Air induction system solenoid 18.Gear position switch 20.Yamaha diagnostic tool coupl...

  • Page 412: Fuel Injection System

    Fuel injection system 9-37 ebs30278 ecu self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute ch...

  • Page 413: Fuel Injection System

    Fuel injection system 9-38 ebs30279 troubleshooting method the engine operation is not normal and the engine trouble warning light comes on. 1. Check: • fault code number ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Check the fault code number displayed on the multi-function meter. B. Identi...

  • Page 414: Fuel Injection System

    Fuel injection system 9-39 ebs30280 yamaha diagnostic tool this model uses the yamaha diagnostic tool to identify malfunctions. For information about using the yamaha diagnostic tool, refer to the operation manual that is included with the tool. Features of the yamaha diagnostic tool you can use the...

  • Page 415: Fuel Injection System

    Fuel injection system 9-40 operation of the yamaha diagnostic tool (malfunction mode) malfunction results are displayed in the top part of the window area. 1. Recovered the item list of the malfunction detected in the past (already recovered) are displayed. 2. Detected the item list of the malfuncti...

  • Page 416: Fuel Injection System

    Fuel injection system 9-41 5. Item the item names of the detected malfunction are displayed. 6. Condition the current conditions are displayed. (detected/recovered) 7. Symptom the symptoms of the detected malfunction are displayed. 8. Diagnosis code the diagnosis codes related to the detected malfun...

  • Page 417: Fuel Injection System

    Fuel injection system 9-42 fault code no. 13 tip if fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number “13” first. 2 connection of ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken ter...

  • Page 418: Fuel Injection System

    Fuel injection system 9-43 1 connection of intake air pres- sure sensor coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Improperly connected → con- nect the coupler securely or re- place the ...

  • Page 419: Fuel Injection System

    Fuel injection system 9-44 fault code no. 14 tip if fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number “13” first. 5 defective intake air pressure sensor. Execute the diagnostic mode. (code no. 03) when engine is stopped: atmospheric pressure at the...

  • Page 420: Fuel Injection System

    Fuel injection system 9-45 fault code no. 15 tip if fault code numbers “15” and “16” are both indicated, take the actions specified for fault code number “15” first. 2 defective intake air pressure sensor. Execute the diagnostic mode. (code no. 03) when engine is stopped: atmospheric pressure at the...

  • Page 421: Fuel Injection System

    Fuel injection system 9-46 fault code no. 16 tip • if fault code numbers “15” and “16” are both indicated, take the actions specified for fault code number “15” first. • if fault code numbers “16” and “37” are both indicated, take the actions specified for fault code number “16” first. 2 connection ...

  • Page 422: Fuel Injection System

    Fuel injection system 9-47 fault code no. 21 tip if fault code numbers “21” and “37” are both indicated, take the actions specified for fault code number “21” first. Fault code no. 16 item throttle position sensor: stuck throttle position sensor is detected. Fail-safe system able to start engine abl...

  • Page 423: Fuel Injection System

    Fuel injection system 9-48 fault code no. 22 tip if fault code numbers “22” and “37” are both indicated, take the actions specified for fault code number “22” first. 1 connection of coolant tempera- ture sensor coupler. Check the locking condition of the coupler. Disconnect the coupler and check the...

  • Page 424: Fuel Injection System

    Fuel injection system 9-49 fault code no. 22 item intake air temperature sensor: open or short circuit detected. Fail-safe system able to start engine able to drive vehicle diagnostic code no. 05 indicated displays the intake air temperature. Procedure compare the actually measured intake air temper...

  • Page 425: Fuel Injection System

    Fuel injection system 9-50 fault code no. 30 5 defective intake air temperature sensor. Execute the diagnostic mode. (code no. 05) when engine is cold: displayed temperature is close to the ambient temperature. The displayed temperature is not close to the ambient tem- perature. → check the intake a...

  • Page 426: Fuel Injection System

    Fuel injection system 9-51 fault code no. 33 fault code no. 33 item ignition coil: open or short circuit detected in the primary lead of the ignition coil. Fail-safe system unable to start engine unable to drive vehicle diagnostic code no. 30 actuation actuates the ignition coil five times at one-se...

  • Page 427: Fuel Injection System

    Fuel injection system 9-52 fault code no. 37 tip • if fault code numbers “21” and “37” are both indicated, take the actions specified for fault code number “21” first. • if fault code numbers “22” and “37” are both indicated, take the actions specified for fault code number “22” first. • if fault co...

  • Page 428: Fuel Injection System

    Fuel injection system 9-53 a-5 malfunction in ecu. Replace the ecu. Fault code no. 37 item a component other than isc (idle speed control) unit is defective (isc operating sound is heard). B defective isc (idle speed control) unit (isc operating sound is not heard). Fail-safe system able to start en...

  • Page 429: Fuel Injection System

    Fuel injection system 9-54 fault code no. 39 b-4 wire harness continuity. Open or short circuit → replace the wire harness. Between isc (idle speed con- trol) unit coupler and ecu cou- pler. Red/green–red/green pink/blue–pink/blue white/green–white/green brown/blue–brown/blue between isc (idle speed...

  • Page 430: Fuel Injection System

    Fuel injection system 9-55 fault code no. 41 1 connection of fuel injector cou- pler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Improperly connected → con- nect the coupler securely or re- place...

  • Page 431: Fuel Injection System

    Fuel injection system 9-56 fault code no. 42 tip if fault code numbers “37” and “42” are both indicated, take the actions specified for fault code number “42” first. 1 connection of lean angle sen- sor coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (be...

  • Page 432: Fuel Injection System

    Fuel injection system 9-57 procedure check that the number increases when the rear wheels are rotated. The number is cumulative and does not reset each time the wheel is stopped. Item probable cause of malfunc- tion and check maintenance job confirmation of service com- pletion 1 connection of speed...

  • Page 433: Fuel Injection System

    Fuel injection system 9-58 fault code no. 43 6 delete the fault code. Start the engine, and input the vehicle speed signals by operat- ing the vehicle at 20 to 30 km/h (12 to 19 mph). Check that the fault code num- ber is not displayed. Fault code no. 42 item speed sensor: no normal signals are rece...

  • Page 434: Fuel Injection System

    Fuel injection system 9-59 fault code no. 44 3 wire harness continuity. Open or short circuit → replace the wire harness. Between fuel injection system relay coupler and ecu coupler. Blue/red–blue/red between fuel injection system relay coupler and joint coupler. Red/blue–red/blue between joint coup...

  • Page 435: Fuel Injection System

    Fuel injection system 9-60 fault code no. 46 tip if fault code numbers “37” and “46” are both indicated, take the actions specified for fault code number “46” first. Fault code no. 50 2 “01” is indicated in diagnostic mode (code no. 60). Eeprom data error for adjustment of co concentration. Change t...

  • Page 436: Fuel Injection System

    Fuel injection system 9-61 fault code no. Er-1 1 malfunction in ecu. Replace the ecu. Turn the main switch to “ ” (on). Check that the fault code num- ber is not displayed. Fault code no. 50 item faulty ecu (engine control unit) memory. (when this malfunction is detected in the ecu, the fault code n...

  • Page 437: Fuel Injection System

    Fuel injection system 9-62 fault code no. Er-2 fault code no. Er-3 fault code no. Er-2 item ecu (engine control unit) internal malfunction (output signal error): no signals are received from the ecu within the specified duration. Fail-safe system able to start engine able to drive vehicle diagnostic...

  • Page 438: Fuel Injection System

    Fuel injection system 9-63 fault code no. Er-4 1 connection of meter assembly coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Improperly connected → con- nect the coupler securely or re- plac...

  • Page 439: Fuel Injection System

    Fuel injection system 9-64 2 connection of ecu coupler. Check the locking condition of the coupler. Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Improperly connected → con- nect the coupler securely or re- place the wire harness. Turn the ma...

  • Page 440: Fuel Pump System

    Fuel pump system 9-65 ebs20081 fuel pump system ebs30282 circuit diagram gy b gy b /l w (gy) (gy) w r br /l br /r b (b) r b (gy) w ww br /r br /r (b) l /y r /b r r br /b r /yl /y (b) br /yr /w (b) b /y (b) br /r b br /r y /b b /y w /b b /r b br /b o /l p /w b /g (gy) (b) w /r sb gy /g lw gy (b) (w) ...

  • Page 441: Fuel Pump System

    Fuel pump system 9-66 5. Frame ground 6. Main switch 8. Battery 9. Main fuse 10.Fuel injection system fuse 13.Fuel injection system relay 21.Ecu (engine control unit) 34.Joint coupler 50.Fuel pump 60.Ignition fuse b. Wire harness c. Negative battery sub-wire harness.

  • Page 442: Fuel Pump System

    Fuel pump system 9-67 ebs30283 troubleshooting if the fuel pump fails to operate. Tip • before troubleshooting, remove the following part(s): 1. Hood 2. Rear panel (right) 3. Under-seat storage compartment ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, fuel in...

  • Page 443: Fuel Pump System

    Fuel pump system 9-68.

  • Page 444: 2Wd/4Wd Selecting System

    2wd/4wd selecting system 9-69 ebs20082 2wd/4wd selecting system ebs30284 circuit diagram gy b gy b /l w (gy) (gy) w r br /l br /r b (b) r b (gy) w ww br /r br /r (b) l /y r /b r r br /b r /yl /y (b) br /yr /w (b) b /y (b) br /r b br /r y /b b /y w /b b /r b br /b o /l p /w b /g (gy) (b) w /r sb gy /...

  • Page 445: 2Wd/4Wd Selecting System

    2wd/4wd selecting system 9-70 4. Load control relay 5. Frame ground 6. Main switch 8. Battery 9. Main fuse 15.Differential motor relay 1 16.Differential motor 18.On-command four-wheel-drive switch 21.Ecu (engine control unit) 34.Joint coupler 39.Meter assembly 40.Multi-function meter 48.On-command d...

  • Page 446: 2Wd/4Wd Selecting System

    2wd/4wd selecting system 9-71 ebs30285 troubleshooting • the on-command differential gear lock indicator light/on-command four-wheel-drive/differential gear lock indicator fails to come on. • the on-command differential gear lock indicator light/on-command four-wheel-drive/differential gear lock ind...

  • Page 447: 2Wd/4Wd Selecting System

    2wd/4wd selecting system 9-72 ng → ok ↓ ng → ok ↓ the on-command differential gear lock indicator light/on-command four-wheel-drive/differential gear lock indicator flashes. Ng → ok ↓ ng → ok ↓ 8. Check the differential motor opera- tion. Refer to “checking the dif- ferential motor operation” on pag...

  • Page 448: 9-73

    Eps (electric power steering) system (for eps models) 9-73 ebs20083 eps (electric power steering) system (for eps models) ebs30286 circuit diagram gy b gy b /l w (gy) (gy) w r br /l br /r b (b) r b (gy) w ww br /r br /r (b) l /y r /b r r r r /b br /b r /yl /y (b) br /yr /w (b) b /y (b) br /r b br /r...

  • Page 449: 9-74

    Eps (electric power steering) system (for eps models) 9-74 4. Load control relay 5. Frame ground 6. Main switch 8. Battery 9. Main fuse 10.Eps fuse 22.Ecu (engine control unit) 28.Speed sensor 35.Joint coupler 36.Eps unit 37.Eps motor 38.Eps torque sensor 39.Eps self-diagnosis signal connector 40.Ep...

  • Page 450: 9-75

    Eps (electric power steering) system (for eps models) 9-75 ebs30287 eps control unit’s self-diagnostic function the eps control unit is equipped with a self-diagnostic function. If this function detects a malfunction in the eps system, it lights the eps warning light to alert the rider that a malfun...

  • Page 451: 9-76

    Eps (electric power steering) system (for eps models) 9-76 ebs30289 diagnostic mode setting the diagnostic mode (present and past malfunctions) 1. Disconnect the eps self-diagnosis signal connector “1”. 2. Turn the main switch to “ ” (on). 3. Select the signaling mode by grounding the eps self-diagn...

  • Page 452: 9-77

    Eps (electric power steering) system (for eps models) 9-77 signaling method example 1: fault code no. 23 after the mode selection judgment is completed (present or past malfunction mode), the current fault code signaling stops immediately, and then the first code of the mode is signaled 2 seconds la...

  • Page 453: 9-78

    Eps (electric power steering) system (for eps models) 9-78 after the mode selection judgment is completed (present display or past malfunction mode), the current fault code signaling stops immediately, and then the eps warning light starts flashing at 1.5-second in- tervals. Deleting fault codes to ...

  • Page 454: 9-79

    Eps (electric power steering) system (for eps models) 9-79 ebs30291 troubleshooting details (eps system) tip the malfunction history is stored even if the main switch is turned to “ ” (off), therefore, be sure to erase the history (present and past malfunction signaling modes) after repairing the ca...

  • Page 455: 9-80

    Eps (electric power steering) system (for eps models) 9-80 fault code no. 21 fault code no. 22 fault code no. 21 symptom speed sensor: no normal signals are received from the speed sensor. Order item/components and probable cause check or maintenance job reinstatement method 1 connections • speed se...

  • Page 456: 9-81

    Eps (electric power steering) system (for eps models) 9-81 fault code no. 41, 42, 43, 45 fault code no. 52 fault code no. 53 fault code no. 41, 42, 43, 45 symptom eps motor: no normal signals are received from the eps motor. Order item/components and probable cause check or maintenance job reinstate...

  • Page 457: 9-82

    Eps (electric power steering) system (for eps models) 9-82 fault code no. 54 fault code no. 55 fault code no. 54 symptom relay contacts in the eps control unit are welded together. Order item/components and probable cause check or maintenance job reinstatement method 1 malfunction in eps control uni...

  • Page 458: Electrical Components

    Electrical components 9-83 ebs20084 electrical components 5 6 7 11 13 14 15 21 1 2 19 18 17 16 20 10 9 8 3 4 12.

  • Page 459: Electrical Components

    Electrical components 9-84 1. Radiator fan motor 2. Lean angle sensor 3. Brake light switch 4. Parking brake buzzer 5. Parking brake switch 6. Seat belt switch 7. Gear position switch 8. Reverse switch 9. Intake air pressure sensor 10. Tps (throttle position sensor) 11. Fuel injector 12. Isc (idle s...

  • Page 460: Electrical Components

    Electrical components 9-85 3 4 10 12 2 1 9 8 7 5 6 13 14 11.

  • Page 461: Electrical Components

    Electrical components 9-86 1. Auxiliary dc jack 2. Meter assembly 3. Indicator light assembly 4. Main switch 5. On-command four-wheel-drive switch 6. Light switch 7. Eps torque sensor (for eps models) 8. Eps motor (for eps models) 9. Eps control unit (for eps models) 10. Radiator fan motor circuit b...

  • Page 462: Electrical Components

    Electrical components 9-87 6 1 4 5 3 2 11 8 19 18 17 16 15 14 10 9 7 8 13 12 12.

  • Page 463: Electrical Components

    Electrical components 9-88 1. Load control relay 2. Fuel injection system relay 3. Radiator fan motor relay 4. Headlight relay 5. Differential motor relay 1 6. Differential motor relay 2 7. Fuel injection system fuse 8. Spare fuse 9. Starter relay 10. Eps fuse (for eps models) 11. Main fuse 12. Fuse...

  • Page 464: Electrical Components

    Electrical components 9-89 ebs30292 checking the switches 2 4 5 3 9 4wd 2wd diff lock l/w b g/r l/w g/r b (w) l w gy 7 br y g/w 6 8 b l/r (b) r/b br/r br/r l/y (off) (on) (start) (b) (off) br y l b l 1 off on br p.

  • Page 465: Electrical Components

    Electrical components 9-90 1. Horn switch (except for cdn) 2. Main switch 3. On-command four-wheel-drive switch 4. Gear position switch 5. Reverse switch 6. Seat belt switch 7. Light switch 8. Parking brake switch 9. Brake light switch.

  • Page 466: Electrical Components

    Electrical components 9-91 check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Notice ecb01430 never insert the tester probes into the coupler terminal slots “a”. Always insert the probes ...

  • Page 467: Electrical Components

    Electrical components 9-92 ebs30293 checking the bulbs and bulb sockets tip do not check any of the lights that use leds. Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or bo...

  • Page 468: Electrical Components

    Electrical components 9-93 tip check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install a good bulb into the bulb socket. B. Connect the pocket tester probes to the re- spectiv...

  • Page 469: Electrical Components

    Electrical components 9-94 9. Install: • headlight rear cover ebs30295 adjusting the headlight beams the following procedure applies to both of the headlights. 1. Adjust: • headlight beam (vertically) ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw “1” in direction “a” ...

  • Page 470: Electrical Components

    Electrical components 9-95 d. If the fuse immediately blows again, check the electrical circuit. Warning ewb02850 never use a fuse with an amperage rating other than that specified. Improvising or us- ing a fuse with the wrong amperage rating may cause extensive damage to the electri- cal system, ca...

  • Page 471: Electrical Components

    Electrical components 9-96 tip • the charge state of a vrla (valve regulated lead acid) battery can be checked by measur- ing its open-circuit voltage (i.E., the voltage when the positive battery terminal is discon- nected). • no charging is necessary when the open-cir- cuit voltage equals or exceed...

  • Page 472: Electrical Components

    Electrical components 9-97 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ charging method using a constant volt- age charger a. Measure the open-circuit voltage prior to charging. Tip voltage should be measured 30 minutes after the engine is stopped. B. Connect a charger and ammeter to the bat- t...

  • Page 473: Electrical Components

    Electrical components 9-98 starter relay load control relay headlight relay first step: second step: 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe result continuity (between “3” and “4”) 1. Positive battery terminal 2. Negative battery te...

  • Page 474: Electrical Components

    Electrical components 9-99 radiator fan motor relay fuel injection system relay differential motor relay 1 first step: second step: 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe result continuity (between “3” and “4”) 1. Positive battery ...

  • Page 475: Electrical Components

    Electrical components 9-100 differential motor relay 2 first step: second step: ebs30299 checking the spark plug cap 1. Check: • spark plug cap resistance out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the spark plug cap from the spark plug lead. B. Conne...

  • Page 476: Electrical Components

    Electrical components 9-101 c. Measure the primary coil resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Check: • secondary coil resistance out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the spark plug cap from the igni- tion coil. B. ...

  • Page 477: Electrical Components

    Electrical components 9-102 b. Measure the crankshaft position sensor re- sistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ebs30303 checking the lean angle sensor 1. Remove: • lean angle sensor 2. Check: • lean angle sensor output voltage out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼...

  • Page 478: Electrical Components

    Electrical components 9-103 ebs30305 checking the stator coil 1. Disconnect: • stator coil couplers (from the wire harness) 2. Check: • stator coil resistance out of specification → replace the crank- shaft position sensor/stator assembly. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect...

  • Page 479: Electrical Components

    Electrical components 9-104 b. Move the fuel sender float to minimum “3” and maximum “4” level positions. C. Measure the fuel sender resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ebs30308 checking the fuel meter/fuel level warning light this model is equipped with a self-diagnosis de...

  • Page 480: Electrical Components

    Electrical components 9-105 c. Turn the main switch to “ ” (on). D. Elevate the rear wheels and slowly rotate them. E. Measure the voltage (dc 20 v) of white and black/blue. With each full rotation of the rear wheels, the voltage reading should cycle from 0.6 v to 4.8 v to 0.6 v to 4.8 v. ▲▲▲ ▲ ▲ ▲▲...

  • Page 481: Electrical Components

    Electrical components 9-106 b. Measure the radiator fan motor circuit break- er resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ebs30312 checking the coolant temperature sensor 1. Remove: • coolant temperature sensor warning ewb02950 • handle the coolant temperature sensor with special...

  • Page 482: Electrical Components

    Electrical components 9-107 b. Measure the throttle position sensor maxi- mum resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • throttle position sensor tip when installing the throttle position sensor, ad- just its angle properly. Refer to “adjusting the throttle position ...

  • Page 483: Electrical Components

    Electrical components 9-108 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 1k or Ω × 100) to the intake air temperature sensor terminals as shown. B. Immerse the intake air temperature sensor “1” in a container filled with water “2”. Tip make sure that the intak...

  • Page 484: Electrical Components

    Electrical components 9-109 ebs30318 checking the differential motor position switch 1. Check: • differential motor position switch out of specification → replace. Tip check the differential motor position switch for continuity between the terminals “1” and “3” and between the terminals “2” and “3” ...

  • Page 485: Electrical Components

    Electrical components 9-110 ebs30320 checking the eps torque sensor (for eps models) 1. Remove: • eps unit notice ecb01660 make sure do not remove the torque sensor and its protector from the eps unit. 2. Check: • eps torque sensor resistance out of specification → replace the steering column. ▼▼▼ ▼...

  • Page 486: Electrical Components

    Electrical components 9-111.

  • Page 487: Troubleshooting

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

  • Page 488: Troubleshooting

    Troubleshooting 10-1 ebs20085 troubleshooting ebs30321 general information tip the following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic trouble- shooting. Refer to the relative procedure in this manual for checks, a...

  • Page 489: Troubleshooting

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

  • Page 490: Troubleshooting

    Troubleshooting 10-3 ebs30325 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. If there is reaso...

  • Page 491: Troubleshooting

    Troubleshooting 10-4 ebs30326 faulty gear shifting shifting is difficult refer to “faulty clutch performance” on page 10-4. Ebs30327 shift lever does not move shift drum and shift forks • foreign object in a shift drum groove • seized shift fork • bent shift fork guide bar transmission • seized tran...

  • Page 492: Troubleshooting

    Troubleshooting 10-5 • damaged pipe • improperly connected pipe fuel system 1. Throttle body • faulty throttle body • damaged or loose throttle body joint 2. Air filter • clogged air filter element chassis 1. Brake(s) • dragging brake electrical system 1. Spark plug • incorrect spark plug gap • inco...

  • Page 493: Troubleshooting

    Troubleshooting 10-6 tail/brake light bulb burnt out • wrong tail/brake light bulb • faulty battery • faulty brake light switch • tail/brake light bulb life expired • faulty rectifier/regulator • improperly grounded circuit.

  • Page 494: 10-7

    Self-diagnostic function and diagnostic code table 10-7 ebs20086 self-diagnostic function and diagnostic code table ebs30336 self-diagnostic function table tip for details of the fault code, refer to “troubleshooting method” on page 9-38. Ebs30337 communication error with the meter tip for details o...

  • Page 495: 10-8

    Self-diagnostic function and diagnostic code table 10-8 ebs30338 diagnostic code: sensor operation table tip the diagnostic code numbers cannot be displayed on the multi-function meter. To display the diagnos- tic code numbers, use the yamaha diagnostic tool. Diagnostic code no. Item display procedu...

  • Page 496: 10-9

    Self-diagnostic function and diagnostic code table 10-9 ebs30339 diagnostic code: actuator operation table 61 malfunction history code dis- play • no history 00 — • history exists fault codes 12–50 • (if more than one code number is detected, the display alternates every two seconds to show all the ...

  • Page 497: 10-10

    Self-diagnostic function and diagnostic code table 10-10 50 fuel injection system relay actuates the fuel injection system relay five times at one-second intervals. The “check” indicator and “ ” on the yamaha diag- nostic tool screen come on each time the relay is actuat- ed. (when the relay is on, ...

  • Page 498: Wiring Diagram

    Ebs20008 wiring diagram yxe70wdxg 2016 1. Crankshaft position sensor 2. Ac magneto 3. Rectifier/regulator 4. Load control relay 5. Frame ground 6. Main switch 7. Engine ground 8. Battery 9. Main fuse 10. Fuel injection system fuse 11. Starter relay 12. Starter motor 13. Fuel injection system relay 1...

  • Page 499

    55. Eps warning light 56. Fuel sender 57. Fuel pump 58. Differential motor relay 2 59. Light switch 60. Headlight relay 61. Headlight 62. Auxiliary dc jack 63. Brake light switch 64. Tail/brake light 65. Radiator fan motor fuse 66. Four-wheel-drive motor fuse 67. Ignition fuse 68. Backup fuse 69. Si...

  • Page 500

    Yxe70wdxg 2016 wiring diagram yxe70wdxg 2016 schÉma de cblage gy b gy b/l w (gy) (gy) w r br/l br/r b (b) r b (gy) w w w br/r br/r (b) l/y r/b r r br/b r/y l/y (b) br/y r/w (b) b/y (b) br/r b br/r y/b b/y w/b b/r b br/b o/l p/w b/g (gy) (b) w/r sb gy/g l w gy (b) (w) l/w g/r b g/r l/w b/w b/w r/w y/...

  • Page 501

    Yxe70wdxg 2016 wiring diagram yxe70wdxg 2016 schÉma de cblage (gy) (gy) (b) (gy) (b) (b) (b) (b) (gy) (b) (b) (w) (b) (b) (b) (gy) (b) (b) (b) (b) (b) (gy) (b) (b) (b) (b) (b) (b) (gy) (gy) (w) (b) (b) (b) (gy) (gy) (gy) diff lock 4wd 2wd (off) (off) (on) (start) a b c a off on 1 2 3 4 5 6 71 70 67 ...

  • Page 502

    Yx70epng/yxe70wpxg/yxe70wphg/yxe700e 2016 wiring diagram yx70epng/yxe70wpxg/yxe70wphg/yxe700e 2016 schÉma de cblage 75 76 gy b gy b/l w (gy) (gy) w r br/l br/r b (b) r b (gy) w w w br/r br/r (b) l/y r/b r r r r/b br/b r/y l/y (b) br/y r/w (b) b/y (b) br/r b br/r y/b b/y w/b b/r b br/b o/l p/w b/g (g...

  • Page 503

    Yx70epng/yxe70wpxg/yxe70wphg/yxe700e 2016 wiring diagram yx70epng/yxe70wpxg/yxe70wphg/yxe700e 2016 schÉma de cblage (gy) (gy) (b) (gy) (b) (b) (b) (b) (gy) (b) (b) (w) (b) (b) (b) (gy) (gy) (b) (b) (b) (gy) (b) (b) (b) (gy) (b) (b) (b) (b) (b) (b) (b) (b) (gy) (gy) (gy) (w) (gy) (gy) (b) (b) (b) (gy...