YFM7FGPW - Modded Raptor

YFM7FGPW - Modded Raptor
YFM7FGPW
SERVICE MANUAL
LIT-11616-20-11
3B4-28197-10
EBS00001
YFM7FGPW
SERVICE MANUAL
©2006 by Yamaha Motor Corporation, U.S.A.
First Edition, May 2006
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
LIT-11616-20-11
EBS00002
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on
Yamaha vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle
repair. Repairs attempted by anyone without this knowledge are likely to render the vehicle unsafe
and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
vehicle will operate as designed. If there is any question about a service procedure, it is imperative
that you contact a Yamaha dealer for any service information changes that apply to this model. This
policy is intended to provide the customer with the most satisfaction from his vehicle and to conform
to federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
NOTE:
• This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
• Designs and specifications are subject to change without notice.
_
EBS00003
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death to
the vehicle operator, a bystander or a person checking or repairing the vehicle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the vehicle.
A NOTE provides key information to make procedures easier or clearer.
EBS00004
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “symbols”)
1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title 2: This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.
2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed
by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
6. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition
to the exploded diagram and the job instruction chart.
1
EBS00006
2
GEN
INFO
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1 to 0 indicate the subject of each
chapter.
SPEC
3
4
CHK
ADJ
1 General information
2 Specifications
3 Periodic checks and adjustments
4 Engine
5 Cooling system
6 Fuel injection system
7 Drive train
8 Chassis
9 Electrical
0 Troubleshooting
ENG
5
6
FI
COOL
7
8
CHAS
DRIV
9
0
–
ELEC
TRBL
SHTG
+
B
Symbols A to H indicate the following
C
D
A Can be serviced with engine mounted
B Filling fluid
C Lubricant
D Special tool
E Torque
F Wear limit, clearance
G Engine speed
H Electrical data (Ω, V, A)
E
F
A
T.
R.
G
H
I
J
Symbols I to N in the exploded diagrams
indicate the types of lubricants and lubrication
points.
K
G
E
L
M
M
B
N
M
LS
O
P
LT
New
I Apply engine oil
J Apply gear oil
K Apply molybdenum disulfide oil
L Apply wheel bearing grease
M Apply lithium-soap-based grease
N Apply molybdenum disulfide grease
Symbols O to P in the exploded diagrams
indicate where to apply a locking agent O and
when to install a new part P.
O Apply the locking agent (LOCTITE®)
P Replace
EBS00008
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
ENGINE
COOLING SYSTEM
FUEL INJECTION SYSTEM
DRIVE TRAIN
CHASSIS
GEN
INFO
1
SPEC
2
CHK
ADJ
3
ENG
4
COOL
5
FI
6
DRIV
7
CHAS
8
–
ELECTRICAL
TROUBLESHOOTING
+
ELEC
9
TRBL
SHTG
10
CONTENTS
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION............................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL.......................................................................................... 1-1
FEATURES...................................................................................................... 1-2
OUTLINE OF THE FI SYSTEM.................................................................1-2
FI SYSTEM................................................................................................1-3
OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM...... 1-4
EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM ..... 1-5
INSTRUMENT FUNCTIONS ..................................................................... 1-6
IMPORTANT INFORMATION ......................................................................... 1-9
PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-9
REPLACEMENT PARTS...........................................................................1-9
GASKETS, OIL SEALS AND O-RINGS .................................................... 1-9
LOCK WASHERS/PLATES AND COTTER PINS ................................... 1-10
BEARINGS AND OIL SEALS .................................................................. 1-10
CIRCLIPS ................................................................................................1-10
CHECKING THE CONNECTIONS.......................................................... 1-11
SPECIAL TOOLS .......................................................................................... 1-12
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................2-5
CHASSIS SPECIFICATIONS ........................................................................2-12
ELECTRICAL SPECIFICATIONS .................................................................2-14
TIGHTENING TORQUES .............................................................................. 2-16
ENGINE TIGHTENING TORQUES......................................................... 2-16
CHASSIS TIGHTENING TORQUES.......................................................2-19
HOW TO USE THE CONVERSION TABLE.................................................. 2-22
GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-22
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-23
ENGINE................................................................................................... 2-23
COOLANT FLOW DIAGRAMS ..................................................................... 2-25
OIL FLOW DIAGRAMS ................................................................................. 2-26
CABLE ROUTING ......................................................................................... 2-28
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION.............................................................................................. 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM ......................................................................................................... 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART............................ 3-2
ENGINE SKID PLATES, SEAT, CARRIERS AND FENDERS .......................3-4
ENGINE SKID PLATES.............................................................................3-4
SEAT AND SIDE PANELS ........................................................................ 3-5
FRONT CARRIER AND FRONT GUARD ................................................. 3-6
FRONT FENDERS AND FRONT GRILL................................................... 3-8
REAR CARRIER AND REAR FENDER .................................................... 3-9
ELECTRICAL COMPONENTS TRAY........................................................... 3-10
ELECTRICAL COMPONENTS TRAY 1/2 ............................................... 3-10
ELECTRICAL COMPONENTS TRAY 2/2 ............................................... 3-12
FOOTREST BOARDS ...................................................................................3-14
AIR FILTER CASE ........................................................................................ 3-15
ENGINE .........................................................................................................3-16
ADJUSTING THE VALVE CLEARANCE ................................................ 3-16
ADJUSTING THE ENGINE IDLING SPEED ...........................................3-19
ADJUSTING THE THROTTLE LEVER FREE PLAY ..............................3-20
ADJUSTING THE SPEED LIMITER........................................................ 3-22
CHECKING THE SPARK PLUG ............................................................. 3-23
CHECKING THE IGNITION TIMING.......................................................3-24
MEASURING THE COMPRESSION PRESSURE..................................3-25
CHECKING THE ENGINE OIL LEVEL....................................................3-28
CHANGING THE ENGINE OIL ...............................................................3-29
CLEANING THE AIR FILTER ELEMENT................................................ 3-31
CHECKING THE THROTTLE BODY JOINT...........................................3-33
CHECKING THE FUEL HOSE ................................................................3-34
CHECKING THE BREATHER HOSES ...................................................3-34
CHECKING THE COOLANT LEVEL.......................................................3-35
CHANGING THE COOLANT................................................................... 3-35
CHECKING THE COOLING SYSTEM ....................................................3-39
CHECKING THE COOLANT TEMPERATURE WARNING LIGHT.........3-40
CHECKING THE V-BELT........................................................................3-41
CHECKING THE EXHAUST SYSTEM....................................................3-42
CLEANING THE SPARK ARRESTER ....................................................3-43
CHASSIS ....................................................................................................... 3-44
ADJUSTING THE FRONT BRAKE ......................................................... 3-44
ADJUSTING THE REAR BRAKE............................................................ 3-44
CHECKING THE BRAKE FLUID LEVEL................................................. 3-46
CHECKING THE FRONT BRAKE PADS ................................................ 3-47
CHECKING THE REAR BRAKE PADS .................................................. 3-48
CHECKING THE REAR BRAKE HOSE PROTECTORS ........................ 3-48
CHECKING THE BRAKE HOSES........................................................... 3-49
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-49
ADJUSTING THE SELECT LEVER CONTROL CABLE AND
SHIFT ROD ............................................................................................ 3-51
CHECKING THE FINAL GEAR OIL LEVEL ............................................3-53
CHANGING THE FINAL GEAR OIL........................................................ 3-53
CHECKING THE DIFFERENTIAL GEAR OIL LEVEL............................. 3-55
CHANGING THE DIFFERENTIAL GEAR OIL ........................................ 3-55
CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS ..........3-56
CHECKING THE STEERING SYSTEM .................................................. 3-57
ADJUSTING THE TOE-IN....................................................................... 3-59
CHECKING THE FRONT AND REAR SHOCK ABSORBERS ............... 3-60
ADJUSTING THE FRONT SHOCK ABSORBERS .................................3-61
ADJUSTING THE REAR SHOCK ABSORBERS.................................... 3-62
CHECKING THE TIRES..........................................................................3-62
CHECKING THE WHEELS ..................................................................... 3-65
CHECKING AND LUBRICATING THE CABLES .................................... 3-65
LUBRICATING THE LEVERS AND PEDALS .........................................3-66
ELECTRICAL SYSTEM................................................................................. 3-67
CHECKING AND CHARGING THE BATTERY....................................... 3-67
CHECKING THE FUSES ........................................................................3-73
ADJUSTING THE HEADLIGHT BEAMS................................................. 3-76
REPLACING THE HEADLIGHT BULBS ................................................. 3-76
CHAPTER 4
ENGINE
ENGINE REMOVAL ........................................................................................4-1
AIR DUCTS, MUFFLER AND EXHAUST PIPE ........................................ 4-1
SELECT LEVER UNIT ..............................................................................4-3
LEADS, CABLES AND HOSES ................................................................4-4
ENGINE MOUNTING BOLTS ...................................................................4-6
INSTALLING THE ENGINE....................................................................... 4-8
INSTALLING THE SELECT LEVER UNIT ................................................ 4-9
CYLINDER HEAD.......................................................................................... 4-10
REMOVING THE CYLINDER HEAD.......................................................4-12
CHECKING THE CAMSHAFT SPROCKET............................................4-13
CHECKING THE TAPPET COVERS ......................................................4-13
CHECKING THE TIMING CHAIN TENSIONER...................................... 4-13
CHECKING THE CYLINDER HEAD .......................................................4-14
INSTALLING THE CYLINDER HEAD .....................................................4-15
ROCKER ARMS AND CAMSHAFT ..............................................................4-18
REMOVING THE ROCKER ARMS AND CAMSHAFT............................ 4-20
CHECKING THE CAMSHAFT.................................................................4-20
CHECKING THE DECOMPRESSION SYSTEM..................................... 4-21
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 4-21
INSTALLING THE CAMSHAFT AND ROCKER ARMS .......................... 4-22
VALVES AND VALVE SPRINGS.................................................................. 4-25
REMOVING THE VALVES AND VALVE SPRINGS ...............................4-26
CHECKING THE VALVES AND VALVE SPRINGS ................................4-27
INSTALLING THE VALVES AND VALVE SPRINGS ..............................4-31
CYLINDER AND PISTON.............................................................................. 4-34
REMOVING THE PISTON ...................................................................... 4-35
CHECKING THE CYLINDER AND PISTON ...........................................4-35
CHECKING THE PISTON RINGS........................................................... 4-37
CHECKING THE PISTON PIN ................................................................4-38
INSTALLING THE PISTON AND CYLINDER .........................................4-39
AC MAGNETO...............................................................................................4-42
REMOVING THE AC MAGNETO ROTOR.............................................. 4-45
CHECKING THE STATOR COIL AND CRANKSHAFT POSITION
SENSOR ................................................................................................4-46
CHECKING THE STARTER CLUTCH ....................................................4-46
CHECKING THE TORQUE LIMITER......................................................4-47
INSTALLING THE AC MAGNETO ROTOR ............................................4-47
BALANCER GEARS AND OIL PUMP GEARS ............................................4-49
REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP
DRIVEN GEAR ....................................................................................... 4-51
CHECKING THE OIL PUMP DRIVE .......................................................4-51
CHECKING THE BALANCER DRIVE .....................................................4-51
INSTALLING THE BALANCER DRIVE GEAR, BALANCER DRIVEN
GEAR, AND OIL PUMP DRIVEN GEAR ................................................ 4-52
PRIMARY AND SECONDARY SHEAVES....................................................4-53
PRIMARY SHEAVE................................................................................. 4-55
SECONDARY SHEAVE ..........................................................................4-56
REMOVING THE PRIMARY AND SECONDARY SHEAVES ................. 4-57
DISASSEMBLING THE SECONDARY SHEAVE.................................... 4-57
CHECKING THE PRIMARY SHEAVE ....................................................4-58
CHECKING THE SECONDARY SHEAVE .............................................. 4-58
ASSEMBLING THE PRIMARY SHEAVE ................................................ 4-59
ASSEMBLING THE SECONDARY SHEAVE..........................................4-60
INSTALLING THE PRIMARY AND SECONDARY SHEAVES................ 4-62
CLUTCH ........................................................................................................4-63
REMOVING THE CLUTCH ..................................................................... 4-65
CHECKING THE CLUTCH...................................................................... 4-66
INSTALLING THE CLUTCH.................................................................... 4-67
CRANKCASE ................................................................................................4-68
TIMING CHAIN AND OIL FILTER ........................................................... 4-68
CRANKCASE .......................................................................................... 4-70
CRANKCASE BEARINGS....................................................................... 4-71
SEPARATING THE CRANKCASE.......................................................... 4-72
CHECKING THE TIMING CHAIN AND GUIDE....................................... 4-72
CHECKING THE RELIEF VALVE ........................................................... 4-72
CHECKING THE BEARINGS.................................................................. 4-73
CHECKING THE CRANKCASE ..............................................................4-73
ASSEMBLING THE CRANKCASE.......................................................... 4-73
INSTALLING THE SHIFT LEVER ........................................................... 4-74
CRANKSHAFT AND OIL PUMP ................................................................... 4-75
OIL PUMP ...............................................................................................4-76
REMOVING THE CRANKSHAFT ........................................................... 4-77
CHECKING THE OIL PUMP ................................................................... 4-77
CHECKING THE OIL STRAINER ........................................................... 4-78
CHECKING THE CRANKSHAFT ............................................................ 4-78
ASSEMBLING THE OIL PUMP...............................................................4-79
INSTALLING THE CRANKSHAFT .......................................................... 4-79
TRANSMISSION............................................................................................ 4-81
DRIVE AXLE ........................................................................................... 4-83
REMOVING THE TRANSMISSION ........................................................ 4-85
CHECKING THE SHIFT FORKS............................................................. 4-85
CHECKING THE SHIFT DRUM ..............................................................4-86
CHECKING THE TRANSMISSION ......................................................... 4-86
CHECKING THE SECONDARY SHAFT................................................. 4-87
CHECKING THE STOPPER LEVER AND STOPPER WHEEL.............. 4-87
ASSEMBLING THE SHIFT FORK ASSEMBLY ...................................... 4-87
INSTALLING THE TRANSMISSION .......................................................4-88
MIDDLE GEAR ..............................................................................................4-89
MIDDLE DRIVE SHAFT ..........................................................................4-89
MIDDLE DRIVEN SHAFT........................................................................4-90
REMOVING THE MIDDLE DRIVE SHAFT ............................................. 4-92
REMOVING THE MIDDLE DRIVEN SHAFT...........................................4-93
CHECKING THE PINION GEARS .......................................................... 4-95
SELECTING MIDDLE DRIVE AND DRIVEN GEAR SHIMS................... 4-96
INSTALLING THE BEARING AND OIL SEALS ...................................... 4-99
INSTALLING THE MIDDLE DRIVEN SHAFT .......................................4-100
INSTALLING THE MIDDLE DRIVE SHAFT ..........................................4-102
MEASURING THE MIDDLE GEAR BACKLASH................................... 4-102
CHAPTER 5
COOLING SYSTEM
RADIATOR ...................................................................................................... 5-1
CHECKING THE RADIATOR.................................................................... 5-3
INSTALLING THE RADIATOR..................................................................5-4
THERMOSTAT ................................................................................................5-5
CHECKING THE THERMOSTAT.............................................................. 5-6
INSTALLING THE THERMOSTAT............................................................ 5-6
WATER PUMP.................................................................................................5-7
DISASSEMBLING THE WATER PUMP.................................................... 5-9
CHECKING THE WATER PUMP .............................................................. 5-9
ASSEMBLING THE WATER PUMP........................................................ 5-10
CHAPTER 6
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM............................................................................6-1
CIRCUIT DIAGRAM .................................................................................. 6-3
ECU SELF-DIAGNOSTIC FUNCTION......................................................6-5
SELF-DIAGNOSTIC FUNCTION TABLE .................................................. 6-6
TROUBLESHOOTING CHART .................................................................6-7
DIAGNOSTIC MODE ................................................................................ 6-8
TROUBLESHOOTING DETAILS ............................................................ 6-12
CHECKING THE INTAKE AIR PRESSURE SENSOR ........................... 6-26
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....................6-26
FUEL TANK................................................................................................... 6-28
REMOVING THE FUEL TANK ................................................................6-30
REMOVING THE FUEL PUMP ...............................................................6-30
CHECKING THE FUEL PUMP BODY.....................................................6-31
CHECKING THE ROLLOVER VALVE ....................................................6-31
INSTALLING THE FUEL PUMP..............................................................6-31
INSTALLING THE FUEL HOSE ..............................................................6-32
THROTTLE BODY......................................................................................... 6-33
REMOVING THE THROTTLE BODY ASSEMBLY .................................6-36
CHECKING THE FUEL INJECTOR ........................................................ 6-36
CHECKING THE THROTTLE BODY ......................................................6-36
INSTALLING THE THROTTLE BODY ASSEMBLY................................6-37
CHECKING THE FUEL PUMP AND PRESSURE REGULATOR
OPERATION .......................................................................................... 6-38
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR ................................................................................................6-39
CHAPTER 7
DRIVE TRAIN
TROUBLESHOOTING.....................................................................................7-1
CHECKING NOISES ................................................................................. 7-1
TROUBLESHOOTING CHART .................................................................7-3
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR........ 7-4
REMOVING THE DIFFERENTIAL GEAR ASSEMBLY........................... 7-10
CHECKING THE FRONT CONSTANT VELOCITY JOINTS................... 7-10
CHECKING THE DIFFERENTIAL GEARS ............................................. 7-11
CHECKING THE DIFFERENTIAL GEAR MOTOR .................................7-11
ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS .............. 7-12
ASSEMBLING THE DIFFERENTIAL GEARS.........................................7-13
MEASURING THE DIFFERENTIAL GEAR LASH ..................................7-14
ADJUSTING THE DIFFERENTIAL GEAR LASH.................................... 7-15
CHECKING THE DIFFERENTIAL GEAR OPERATION ......................... 7-16
REAR CONSTANT VELOCITY JOINTS AND FINAL DRIVE GEAR ...........7-17
ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS................. 7-24
DISASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY....... 7-25
POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR ... 7-25
ADJUSTING THE FINAL DRIVE PINION GEAR BACKLASH ................ 7-25
ADJUSTING THE FINAL DRIVEN PINION GEAR BACKLASH ............. 7-27
MEASURING THE FINAL DRIVEN PINION GEAR THRUST
WASHER CLEARANCE .........................................................................7-29
MEASURING THE WHEEL GEAR THRUST CLEARANCE ................... 7-30
CHECKING THE REAR DRIVE SHAFT.................................................. 7-31
CHECKING THE FINAL DRIVE ASSEMBLY..........................................7-31
MEASUREMENT THE FINAL GEAR LASH............................................7-32
ADJUSTING THE FINAL GEAR LASH ...................................................7-33
ASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY............. 7-34
ASSEMBLING THE FINAL GEAR CASE................................................ 7-35
CHAPTER 8
CHASSIS
FRONT AND REAR WHEELS ........................................................................ 8-1
FRONT WHEELS ......................................................................................8-1
REAR WHEELS ........................................................................................8-3
CHECKING THE WHEELS ....................................................................... 8-5
CHECKING THE WHEEL HUBS............................................................... 8-5
CHECKING THE BRAKE DISCS .............................................................. 8-6
INSTALLING THE BRAKE DISCS ............................................................ 8-6
INSTALLING THE WHEEL HUBS............................................................. 8-6
INSTALLING THE WHEELS ..................................................................... 8-7
FRONT AND REAR BRAKES......................................................................... 8-8
FRONT BRAKE PADS ..............................................................................8-8
REAR BRAKE PADS................................................................................. 8-9
REPLACING THE FRONT AND REAR BRAKE PADS........................... 8-10
FRONT BRAKE MASTER CYLINDER....................................................8-12
REAR BRAKE MASTER CYLINDER ......................................................8-15
CHECKING THE MASTER CYLINDERS................................................ 8-18
ASSEMBLING THE FRONT AND REAR BRAKE MASTER
CYLINDERS ........................................................................................... 8-18
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................8-19
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 8-21
FRONT BRAKE CALIPERS .................................................................... 8-23
REAR BRAKE CALIPERS....................................................................... 8-25
DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERS ..........8-27
CHECKING THE FRONT AND REAR BRAKE CALIPERS ....................8-27
ASSEMBLING THE FRONT AND REAR BRAKE CALIPERS ................ 8-28
INSTALLING THE FRONT AND REAR BRAKE CALIPERS .................. 8-29
STEERING SYSTEM .....................................................................................8-31
HANDLEBAR........................................................................................... 8-31
REMOVING THE HANDLEBAR GRIPS.................................................. 8-33
CHECKING THE HANDLEBAR ..............................................................8-33
INSTALLING THE HANDLEBAR ............................................................ 8-33
INSTALLING THE HANDLEBAR GRIPS ................................................ 8-34
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 8-34
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................8-35
INSTALLING THE THROTTLE LEVER ASSEMBLY ..............................8-35
STEERING STEM ...................................................................................8-36
CHECKING THE STEERING STEM .......................................................8-38
INSTALLING THE STEERING STEM .....................................................8-38
INSTALLING THE PITMAN ARM............................................................ 8-40
TIE-RODS AND STEERING KNUCKLES ............................................... 8-41
REMOVING THE STEERING KNUCKLES ............................................. 8-43
CHECKING THE TIE-RODS ................................................................... 8-43
CHECKING THE STEERING KNUCKLES.............................................. 8-43
INSTALLING THE TIE-RODS .................................................................8-46
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES ............. 8-47
REMOVING THE FRONT ARMS ............................................................ 8-49
CHECKING THE FRONT ARMS............................................................. 8-49
CHECKING THE FRONT SHOCK ABSORBERS................................... 8-51
INSTALLING THE FRONT ARMS AND FRONT SHOCK
ABSORBERS ......................................................................................... 8-51
REAR KNUCKLES AND STABILIZER ......................................................... 8-52
CHECKING THE REAR KNUCKLES ......................................................8-54
CHECKING THE STABILIZER................................................................8-54
REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES ................. 8-55
CHECKING THE REAR ARMS ...............................................................8-57
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................ 8-57
INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER
ASSEMBLIES ......................................................................................... 8-58
CHAPTER 9
ELECTRICAL
ELECTRICAL COMPONENTS........................................................................ 9-1
CHECKING SWITCH CONTINUITY................................................................9-4
CHECKING THE SWITCHES..........................................................................9-5
CHECKING THE BULBS AND BULB SOCKETS .......................................... 9-7
TYPES OF BULBS .................................................................................... 9-7
CHECKING THE CONDITION OF THE BULBS ....................................... 9-8
CHECKING THE CONDITION OF THE BULB SOCKETS .......................9-9
IGNITION SYSTEM ....................................................................................... 9-10
CIRCUIT DIAGRAM ................................................................................ 9-10
TROUBLESHOOTING ............................................................................9-11
ELECTRIC STARTING SYSTEM .................................................................. 9-16
CIRCUIT DIAGRAM ................................................................................ 9-16
STARTING CIRCUIT OPERATION......................................................... 9-17
TROUBLESHOOTING ............................................................................9-18
STARTER MOTOR........................................................................................ 9-22
CHECKING THE STARTER MOTOR .....................................................9-24
ASSEMBLING THE STARTER MOTOR................................................. 9-26
CHARGING SYSTEM....................................................................................9-27
CIRCUIT DIAGRAM ................................................................................ 9-27
TROUBLESHOOTING ............................................................................9-28
LIGHTING SYSTEM ......................................................................................9-30
CIRCUIT DIAGRAM ................................................................................ 9-30
TROUBLESHOOTING ............................................................................9-31
CHECKING THE LIGHTING SYSTEM....................................................9-32
SIGNALING SYSTEM ...................................................................................9-34
CIRCUIT DIAGRAM ................................................................................ 9-34
TROUBLESHOOTING ............................................................................9-36
CHECKING THE SIGNALING SYSTEM ................................................. 9-37
COOLING SYSTEM....................................................................................... 9-45
CIRCUIT DIAGRAM ................................................................................ 9-45
TROUBLESHOOTING ............................................................................9-46
FUEL PUMP SYSTEM...................................................................................9-50
CIRCUIT DIAGRAM ................................................................................ 9-50
TROUBLESHOOTING ............................................................................9-51
2WD/4WD SELECTING SYSTEM.................................................................9-53
CIRCUIT DIAGRAM ................................................................................ 9-53
TROUBLESHOOTING ............................................................................9-54
EPS (ELECTRIC POWER STEERING) SYSTEM.........................................9-58
CIRCUIT DIAGRAM ................................................................................ 9-58
EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION .....................9-59
EPS WARNING LIGHT DURING NORMAL OPERATION......................9-60
DIAGNOSTIC MODE .............................................................................. 9-61
SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)......................9-64
TROUBLESHOOTING DETAILS (EPS SYSTEM) ..................................9-65
CHECKING THE EPS MOTOR...............................................................9-69
CHECKING THE EPS TORQUE SENSOR............................................. 9-69
CHAPTER 10
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING .....................................................10-1
FUEL SYSTEM........................................................................................ 10-1
ELECTRICAL SYSTEM...........................................................................10-1
COMPRESSION SYSTEM...................................................................... 10-2
POOR IDLE SPEED PERFORMANCE ......................................................... 10-2
POOR IDLE SPEED PERFORMANCE...................................................10-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE................................10-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ......................... 10-2
FAULTY DRIVE TRAIN ................................................................................. 10-3
FAULTY GEAR SHIFTING............................................................................10-4
HARD SHIFTING.....................................................................................10-4
SHIFT LEVER DOES NOT MOVE .......................................................... 10-4
JUMPS OUT OF GEAR...........................................................................10-4
FAULTY CLUTCH PERFORMANCE ............................................................ 10-4
ENGINE OPERATES BUT VEHICLE WILL NOT MOVE ........................ 10-4
CLUTCH SLIPPING ................................................................................ 10-4
POOR STARTING PERFORMANCE......................................................10-4
POOR SPEED PERFORMANCE............................................................ 10-5
OVERHEATING............................................................................................. 10-5
OVERHEATING ......................................................................................10-5
OVERCOOLING ............................................................................................ 10-5
COOLING SYSTEM ................................................................................ 10-5
FAULTY BRAKE ........................................................................................... 10-5
POOR BRAKING EFFECT...................................................................... 10-5
SHOCK ABSORBER MALFUNCTION ......................................................... 10-6
MALFUNCTION....................................................................................... 10-6
UNSTABLE HANDLING................................................................................ 10-6
UNSTABLE HANDLING ..........................................................................10-6
LIGHTING SYSTEM ......................................................................................10-6
HEADLIGHT DOES NOT COME ON ......................................................10-6
BULB BURNT OUT ................................................................................. 10-6
VEHICLE IDENTIFICATION
GEN
INFO
EBS00009
GENERAL INFORMATION
VEHICLE IDENTIFICATION
EBS00010
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped into the front left side of the frame.
EBS00011
MODEL LABEL
The model label 1 is affixed at the location in
the illustration. This information will be needed
to order spare parts.
1-1
FEATURES
GEN
INFO
EAS20170
FEATURES
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the
combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet
used in the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies with the engine operating
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that
meter the fuel through the use of jets have been provided with various auxiliary devices, so that an
optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases
increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accommodate this need, this model has adopted an electronically controlled fuel injection
(FI) system, in place of the conventional carburetor system. This system can achieve an optimum
air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel
injection volume according to the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine
response, better fuel economy, and reduced exhaust emissions.
1 2 3 4
D
56 7
C
BA
1 ECU (engine control unit)
2 Lean angle sensor
3 Fuel injection system relay
4 Engine trouble warning light
5 Intake air pressure sensor
6 TPS (throttle position sensor)
7 Intake air temperature sensor
8 Fuel injector
8
9
0
9 Fuel pump
0 Speed sensor
A Crankshaft position sensor
B Coolant temperature sensor
C Spark plug
D Ignition coil
1-2
1
FEATURES
GEN
INFO
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains
the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm2, 46.1 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens,
causing the fuel to be injected into the intake manifold only during the time the passage remains
open. Therefore, the longer the length of time the fuel injector is energized (injection duration), the
greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector
is energized (injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from
the throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air temperature sensor, coolant temperature sensor, lean angle sensor and speed sensor enable the ECU
to determine the injection duration. The injection timing is determined through the signals from the
crankshaft position sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions.
Illustration is for reference only.
5
Ê
1
4
6
2
7
È
3
A
C
É
B
0
9
8
1 Fuel pump
2 Fuel injector
3 Ignition coil
4 ECU (engine control unit)
5 Speed sensor
6 Lean angle sensor
7 Coolant temperature sensor
8 Crankshaft position sensor
9 Intake air pressure sensor
0 Throttle body
A Throttle position sensor
B Intake air temperature sensor
C Air filter case
È Fuel system
É Air system
Ê Control system
1-3
FEATURES
GEN
INFO
OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM
Speed information from
speed sensor
Engine starting RPM
information from ECU
4. EPS control unit
calculates assist power
Battery
5. Electricity output
switched by EPS
control unit
1. Operates steering
3. Sends the torque
sensor signal
2. Twists torsion bar
6. Activates EPS motor
Steering stem
EPS control unit
Torque sensor
EPS motor
EPS unit
CAUTION:
To prevent accidental damage to the EPS unit, it must not be disassembled.
1-4
FEATURES
GEN
INFO
EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM
Meter assembly
Multifunction display
Odometer/Tripmeter A/Tripmeter B/Clock/Fuel
meter/Gear position
Indicator and warning lights
EPS UNIT
Torque sensor
EPS warning/Engine trouble warning/Coolant
temperature warning/Reverse indicator/Neutral
indicator/Park indicator/High-range indicator/
Low-range indicator/Differential lock
EPS motor
• FI and EPS self-diagnostic error codes
Coolant temperature sensor signal
Crankshaft position sensor signal
Speed sensor signal
EPS control unit
ECU
Fuel injector
Engine rpm signal
Fuel pump
Intake air temperature sensor signal
Battery
Throttle position sensor signal
Intake air pressure sensor signal
Lean angle sensor signal
1-5
Ignition coil
FEATURES
4
GEN
INFO
INSTRUMENT FUNCTIONS
5
EBU27291
Multifunction display
1 “CLOCK” button
2 “RESET” button
3 “SELECT” button
4 Speedometer
5 Fuel meter
6 Clock/Hour meter
7 Odometer/Tripmeter A/Tripmeter B
3
2
1
7
6
The multifunction display is equipped with the
following:
• a speedometer (which shows the riding
speed)
• an odometer (which shows the total distance traveled)
• two tripmeters (which show the distance
traveled since they were last set to zero)
• a clock
• an hour meter (which shows the total time
the key has been turned to “ON”)
• a fuel meter
• a self-diagnosis device
Odometer and tripmeter modes
Pushing the “SELECT” button switches the
display between the odometer mode “ODO”
and the tripmeter modes “A” and “B” in the following order:
ODO → TRIP A → TRIP B → ODO
To reset a tripmeter, select it by pushing the
“SELECT” button, and then push the “RESET”
button for at least three seconds. The tripmeters can be used to estimate the distance that
can be traveled with a full tank of fuel. This
information will enable you to plan future fuel
stops.
NOTE:
Holding in the “SELECT” button and then turning the key to “ON” switches the display
between “mph” and “km/h”.
1-6
FEATURES
GEN
INFO
Clock mode
Pushing the “CLOCK” button switches the display between the clock mode “CLOCK” and
the hour meter mode “HOUR” in the following
order:
CLOCK → HOUR → CLOCK
To set the clock
1. Set the display to the clock mode.
2. Push the “SELECT” button and “RESET”
button together for at least three seconds.
3. When the hour digits start flashing, push
the “RESET” button to set the hours.
4. Push the “SELECT” button, and the
minute digits will start flashing.
5. Push the “RESET” button to set the minutes.
6. Push the “SELECT” button and then
release it to start the clock.
Fuel meter
The fuel meter indicates the amount of fuel in
the fuel tank. The display segments of the fuel
meter disappear from “F” (full) towards “E”
(empty) as the fuel level decreases. When the
“E” segment disappears and the fuel level
warning indicator flashes, refuel as soon as
possible.
1
2
3
NOTE:
This fuel meter is equipped with a self-diagnosis system. If the electrical circuit is defective,
all the display segments and fuel level warning
indicator will start flashing. If this occurs, check
the electrical circuit.
Refer to “SIGNALING SYSTEM” in chapter 9.
1 Fuel level warning indicator
2 Fuel meter
3 “E” segment
1-7
FEATURES
GEN
INFO
Self-diagnosis device
This model is equipped with a self-diagnosis
device for various electrical circuits.
If any of those circuits are defective, the multifunction display will indicate a two-digit error
code. If the multifunction display indicates
such an error code, note the code number, and
check the vehicle.
1
ECB00810
CAUTION:
If the multifunction display indicates an error
code, the vehicle should be checked as soon
as possible in order to avoid engine damage.
1 Error code display
1-8
IMPORTANT INFORMATION
GEN
INFO
EBS00013
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to “SPECIAL TOOLS”.
3. When disassembling always keep mated
parts together. This includes gears, cylinders, pistons and other parts that have been
“mated” through normal wear. Mated parts
must always be reused or replaced as an
assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disassembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EBS00014
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all
replacements. Use oil and grease recommended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EBS00015
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be
cleaned.
2. During reassembly properly oil all mating
parts and bearings, and lubricate the oil
seal lips with grease.
1-9
IMPORTANT INFORMATION
GEN
INFO
EBS00016
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
1 and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.
EBS00017
BEARINGS AND OIL SEALS
Install bearings and oil seals 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 appropriate.
1 Oil seal
CAUTION:
_
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
1 Bearing
EBS00018
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip 1, make sure the
sharp-edged corner 2 is positioned opposite
the thrust 3 that the circlip receives.
4 Shaft
1 - 10
IMPORTANT INFORMATION
GEN
INFO
EBS00019
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• lead
• coupler
• connector
2. Check:
• lead
• coupler
• connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect several times.
3. Check:
• all connections
Loose connection → Connect properly.
NOTE:
If the pin 1 on the terminal is flattened, bend it
up.
_
4.
•
•
•
Connect:
lead
coupler
connector
NOTE:
Make sure all connections are tight.
_
5. Check:
• continuity (with the pocket tester)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NOTE:
• 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.
_
1 - 11
SPECIAL TOOLS
GEN
INFO
EBS00021
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools; this will help prevent damage caused by the use of inappropriate
tools or improvised techniques. Special tools may differ by shape and part number from country to
country. In such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.
For US and CDN
P/N. YM-, YU-, YS-, YK-, ACCExcept for US and CDN
P/N. 90890Tool No.
90890-01083
YU-01083-1
Tool name/How to use
Illustration
Slide hammer bolt
Slide hammer bolt 6 mm
This tool is used to remove the rocker
arm shaft.
Weight
90890-01084
YU-01083-3
YU-01083-3
This tool is used to remove the rocker
arm shaft.
Crankcase separating tool
Crankcase separator
90890-01135
YU-01135-B
This tool is used to separate the crankcase.
90890-01229
YM-01229
90890-01243
YM-01253-1
Coupling gear/middle shaft tool
Gear holder
This tool is needed when removing or
installing the coupling gear nut.
Valve spring compressor attachment
Valve spring compressor adapter
(26 mm)
This tool is needed to remove and install
the valve assemblies.
1 - 12
GEN
INFO
SPECIAL TOOLS
Tool No.
Tool name/How to use
Illustration
Crankshaft installer pot
Installing pot
Pot installer
90890-01274
YU-90058
YU-90059
YU-90058/YU-90059
This tool is used to install the crankshaft.
90890-01275
YU-90060
Crankshaft installer bolt
Bolt
This tool is used to install the crankshaft.
Piston pin puller set
Piston pin puller
90890-01304
YU-01304
YU-01304
This tool is used to remove the piston pin.
90890-01309
YU-90059
Spacer
Pot spacer
ø35
This tool is used to install the crankshaft.
Tappet adjusting tool
Valve adjuster 3 mm & 4 mm
90890-01311
YM-08035-A
This tool is necessary for adjusting the
valve clearance.
1 - 13
SPECIAL TOOLS
Tool No.
Tool name/How to use
Illustration
Radiator cap tester
Radiator pressure tester
90890-01325
YU-24460-01
YU-24460-01
This tool is used to check the cooling system.
Locknut wrench
90890-01348
YM-01348
This tool is needed when removing or
installing the secondary sheave spring.
Radiator cap tester adapter
Radiator pressure tester adapter
90890-01352
YU-33984
YU-33984
This tool is used to check the cooling system.
90890-01362
YU-33270-B
Flywheel puller
Heavy duty puller
This tool is used to remove the AC magneto rotor.
Oil filter wrench
90890-01426
YU-38411
This tool is needed to loosen or tighten
the oil filter cartridge.
Ring nut wrench
90890-01430
YM-38404
This tool is needed to removing and
installing the middle driven shaft bearing
retainer.
1 - 14
GEN
INFO
SPECIAL TOOLS
Tool No.
Tool name/How to use
Ball joint remover
90890-01474
YM-01474
90890-01475
YM-01475
90890-01480
YM-01480
These tools are used to removing or
installing the ball joints.
Gear lash measurement tool
Middle drive gear lash tool
This tool is used to measure the gear
lash.
Ball joint remover attachment set
Ball joint adapter set
These tools are used to removing or
installing the ball joints.
Final gear backlash band
90890-01511
This tool is needed when measuring the
final gear backlash.
Ball joint remover short shaft set
90890-01514
These tools are used to removing or
installing the ball joints.
90890-01701
YS-01880-A
90890-03079
YM-34483
90890-03081
YU-33223
90890-03112
YU-03112-C
Sheave holder
Primary clutch holder
This tool is needed to hold the primary
sheave when removing or installing the
sheave nuts.
Thickness gauge
Narrow gauge set
This tool is used to measure the valve
clearance.
Compression gauge
Engine compression tester
This tool is needed to measure engine
compression.
Pocket tester
Analog pocket tester
This instrument is needed for checking
the electrical systems.
1 - 15
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
90890-03141
YU-03141
Tool name/How to use
Timing light
Inductive clamp timing light
This tool is necessary for checking ignition timing.
Pressure gauge
90890-03153
YU-03153
90890-03170
YM-03170
90890-03174
YU-A1927
This tool is used to measure fuel pressure.
Belt tension gauge
Rear drive belt tension gauge
This tool is used to measure the steering
tension.
Digital circuit tester
Model 88 Multimeter with tachometer
This tool is used to check the electrical
systems.
Fuel pressure adapter
90890-03176
YM-03176
This tool is used to measure fuel pressure.
Valve spring compressor
90890-04019
YM-04019
90890-04058
YM-04058
90890-04064
YM-04064-A
90890-04065
YM-04065-A
This tool is used to remove or install the
valve assemblies.
Middle driven shaft bearing driver
Bearing driver 40 mm
This tool is used to install the water pump
seal.
Valve guide remover (ø6)
Valve guide remover (6.0 mm)
This tool is needed to remove and install
the valve guides.
Valve guide installer (ø6)
Valve guide installer (6.0 mm)
This tool is needed to install the valve
guides.
1 - 16
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
90890-04066
YM-04066
Tool name/How to use
Illustration
Valve guide reamer (ø6)
Valve guide reamer (6.0 mm)
This tool is needed to rebore the new
valve guides.
Spacer (crankshaft installer)
Pot spacer
90890-04081
YM-91044
YM-91044
This tool is used to install the crankshaft.
Extension
90890-04082
This tool is used to measure engine compression.
Universal clutch holder
90890-04086
YM-91042
This tool is needed to hold the clutch carrier when removing or installing the carrier nut.
90890-04128
YM-04128
90890-04130
YM-04059
Bearing retainer wrench
Middle gear bearing retainer
This tool is needed when removing or
installing the bearing retainers.
Adapter (M16)
Adapter #13
This tool is used to install the crankshaft.
90890-04132
YM-33221-A
Mechanical seal installer
Water pump seal installer
This tool is used to install the water pump
seal.
1 - 17
GEN
INFO
SPECIAL TOOLS
Tool No.
Tool name/How to use
Sheave spring compressor
90890-04134
YM-04134
This tool is needed when removing or
installing the secondary sheave spring.
Sheave fixed block
Sheave fixed bracket
90890-04135
YM-04135
This tool is needed when removing or
installing the secondary sheave spring.
90890-06754
YM-34487
Ignition checker
Opama pet-4000 spark checker
This instrument is necessary for checking
the ignition system components.
Digital tachometer
90890-06760
YU-39951-B
This tool is needed for checking engine
rpm.
Yamaha bond No. 1215
(Three bond No.1215®)
90890-85505
This bond is used on crankcase mating
surfaces, etc.
1 - 18
GEN
INFO
Illustration
GENERAL SPECIFICATIONS
SPEC
EBS01001
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Standard
3B41
3B45
3B48
Model code
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Basic weight
With oil and fuel
Engine
Engine type
Cylinder arrangement
Displacement
Bore × stroke
Compression ratio
Standard compression pressure (at sea level)
Starting system
Lubrication system
Oil type or grade
Engine oil
0°
10°
30°
50°
70°
90°
110°
130°F
2,065 mm (81.3 in)
1,180 mm (46.5 in)
1,240 mm (48.8 in)
905 mm (35.6 in)
1,250 mm (49.2 in)
275 mm (10.8 in)
3,200 mm (126.0 in)
294.0 kg (648 lb)
Liquid-cooled 4-stroke, SOHC
Forward-inclined single cylinder
686.0 cm3 (41.86 cu. in)
102.0 × 84.0 mm (4.02 × 3.31 in)
9.20 : 1
450 kPa (4.50 kg/cm2, 64.0 psi)
Electric starter
Wet sump
API service SE, SF, SG type or higher
JASO standard MA
YAMALUBE4 (20W40) or SAE 20W40
YAMALUBE4 (10W30) or SAE 10W30
SAE 5W30
-20°
-10°
0°
10°
Final gear oil
Differential gear oil
20°
30°
40°
50°C
SAE 80 API GL-4 Hypoid gear oil
SAE 80 API GL-4 Hypoid gear oil
2-1
GENERAL SPECIFICATIONS
Item
Oil quantity
Engine oil
Periodic oil change
With oil filter replacement
Total amount
Final gear oil
Periodic oil change
Total amount
Differential gear case oil
Periodic oil change
Total amount
Radiator capacity (including all routes)
Air filter
Fuel
Type
Fuel tank capacity
Fuel reserve amount
Fuel injector
Type/quantity
Manufacturer
Spark plug
Type/manufacturer
Spark plug gap
Clutch type
Transmission
Primary reduction system
Secondary reduction system
Secondary reduction ratio
Transmission type
Operation
Single speed automatic
Sub transmission ratio
low
high
Reverse gear
Chassis
Frame type
Caster angle
Camber angle
Kingpin angle
Kingpin offset
Trail
Tread front (STD)
Tread rear (STD)
Toe-in (with tires touching the ground)
SPEC
Standard
2.00 L (1.76 Imp qt, 2.11 US qt)
2.10 L (1.85 Imp qt, 2.22 US qt)
2.40 L (2.11 Imp qt, 2.54 US qt)
0.20 L (0.18 Imp qt, 0.21 US qt)
0.25 L (0.22 Imp qt, 0.26 US qt)
0.215 L (0.19 Imp qt, 0.23 US qt)
0.23 L (0.20 Imp qt, 0.24 US qt)
1.99 L (1.75 Imp qt, 2.10 US qt)
Wet type element
Unleaded gasoline only
20.0 L (4.40 Imp gal, 5.28 US gal)
4.5 L (0.99 Imp gal, 1.19 US gal)
297500-1010/1
DENSO
CR8E/NGK
0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
Wet, centrifugal automatic
V-belt
Shaft drive
41/21 × 24/18 × 33/9 (9.544)
V-belt automatic
Left hand operation
2.380 ~ 0.700 : 1
31/16 (1.938)
29/25 (1.160)
23/14 × 28/23 (2.000)
Steel tube frame
5.0°
0°
11.0°
0 mm (0 in)
26.0 mm (1.02 in)
940.0 mm (37.01 in)
915.0 mm (37.01 in)
0 ~ 10.0 mm (0 ~ 0.39 in)
2-2
2
GENERAL SPECIFICATIONS
Item
Tire
Type
Size
Manufacturer/model
Tire pressure (cold tire)
Maximum load*
Off-road riding
SPEC
Standard
front
rear
front
rear
front
rear
Tubeless
Tubeless
AT25 × 8-12
AT25 × 10-12
DUNLOP/KT421
DUNLOP/KT425
front
rear
*Load is total weight of cargo, rider, accessories, and tongue
Brake
Front brake
type
operation
Rear brake
type
operation
Suspension
Front suspension
Rear suspension
Shock absorber
Front shock absorber
Rear shock absorber
Wheel travel
Front wheel travel
Rear wheel travel
Electrical system
Ignition system
Generator system
Battery type
Battery capacity
Bulb type
220.0 kg (485 lb)
32 ~ 38 kPa (0.32 ~ 0.38 kg/cm2, 4.6 ~ 5.5 psi)
27 ~ 33 kPa (0.27 ~ 0.33 kg/cm2, 3.9 ~ 4.8 psi)
Dual disc brake
Right hand operation
Dual disc brake
Left hand and right foot operation
Double wishbone
Double wishbone
Coil spring/oil damper
Coil spring/oil damper
180 mm (7.1 in)
230 mm (9.1 in)
Transistorized coil ignition (digital)
AC magneto
YTX20L-BS
12 V 18.0 Ah
Halogen bulb
2-3
GENERAL SPECIFICATIONS
Item
Bulb voltage/wattage × quantity
Headlight
Tail/brake light
Indicator light
Neutral indicator light
Reverse indicator light
Coolant temperature warning light
Engine trouble warning light
EPS warning light
Park indicator light
On-command four-wheel drive/differential
gear lock indicator
High-range indicator light
Low-range indicator light
Differential gear lock indicator light
SPEC
Standard
12 V 35.0 W/35.0 W × 2
12 V 21.0/5.0 W × 1
LED
LED
LED
LED
LED
LED
LCD
LED
LED
LED
2-4
ENGINE SPECIFICATIONS
SPEC
EBS01002
ENGINE SPECIFICATIONS
Item
Standard
Cylinder head
Maximum warpage
Cylinder
Bore
Measuring point
Limit
----
0.03 mm
(0.0012 in)
102.000 ~ 102.010 mm
(4.0157 ~ 4.0161 in)
50.0 mm (1.97 in)
102.080 mm
(4.0189 in)
----
Maximum taper
0.05 mm
(0.002 in)
0.05 mm
(0.002 in)
Out of round
Camshaft
Drive system
Camshaft lobe dimensions
Chain drive (left)
----
A
B
Intake measurement
“A”
“B”
Exhaust measurement
“A”
“B”
Maximum camshaft runout
43.488 ~ 43.588 mm (1.7121 ~ 1.7161 in) 43.388 mm
(1.7082 in)
36.959 ~ 37.059 mm (1.4551 ~ 1.4590 in) 36.859 mm
(1.4511 in)
43.129 ~ 43.229 mm (1.6980 ~ 1.7019 in) 43.029 mm
(1.6941 in)
37.007 ~ 37.107 mm (1.4570 ~ 1.4609 in) 36.907 mm
(1.4530 in)
---0.015 mm
(0.0006 in)
2-5
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Timing chain
Model/number of links
Tensioning system
Rocker arm/rocker arm shaft
Rocker arm inside diameter
Shaft outside diameter
Arm-to-shaft clearance
Rocker-arm-to-rocker-arm-shaft
clearance
Valve, valve seat, valve guide
Valve clearance–intake (cold)
Valve clearance–exhaust (cold)
Valve dimensions
Limit
98XRH2010/126
Automatic
-------
12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in)
11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in)
0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in)
0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in)
-------------
0.09 ~ 0.13 mm (0.0035 ~ 0.0051 in)
0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in)
-------
B
C
D
A
Head Diameter
Valve head diameter “A”
Intake
Exhaust
Valve face width “B”
Intake
Exhaust
Valve seat width “C”
Intake
Exhaust
Valve margin thickness “D”
Intake
Exhaust
Valve stem diameter
Intake
Exhaust
Valve guide inside diameter
Intake
Exhaust
Face Width
Seat Width
Margin Thickness
37.90 ~ 38.10 mm (1.4921 ~ 1.5000 in)
31.90 ~ 32.10 mm (1.2559 ~ 1.2638 in)
-------
2.26 mm (0.0890 in)
2.26 mm (0.0890 in)
-------
1.00 ~ 1.20 mm (0.0394 ~ 0.0472 in)
1.00 ~ 1.20 mm (0.0394 ~ 0.0472 in)
0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in)
0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in)
5.975 ~ 5.990 mm (0.2352 ~ 0.2358 in)
5.960 ~ 5.975 mm (0.2346 ~ 0.2352 in)
6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in)
6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in)
2-6
1.60 mm
(0.0630 in)
1.60 mm
(0.0630 in)
------5.945 mm
(0.2341 in)
5.930 mm
(0.2335 in)
6.050 mm
(0.2382 in)
6.050 mm
(0.2382 in)
ENGINE SPECIFICATIONS
Item
Valve-stem-to-valve-guide clearance
Intake
Exhaust
Standard
0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in)
0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in)
Valve stem runout
----
Valve seat width
Intake
1.00 ~ 1.20 mm (0.0394 ~ 0.0472 in)
Exhaust
Valve spring
Free length
Intake
Exhaust
Installed length (valve closed)
Intake
Exhaust
Compressed spring force (installed)
Intake
Exhaust
SPEC
1.00 ~ 1.20 mm (0.0394 ~ 0.0472 in)
38.79 mm (1.53 in)
38.79 mm (1.53 in)
Limit
0.080 mm
(0.0031 in)
0.100 mm
(0.0039 in)
0.040 mm
(0.0016 in)
1.60 mm
(0.0630 in)
1.60 mm
(0.0630 in)
36.85 mm
(1.45 in)
36.85 mm
(1.45 in)
35.00 mm (1.38 in)
35.00 mm (1.38 in)
-------
169 ~ 199 N
(17.23 ~ 20.29 kgf, 37.99 ~ 44.73 lb)
169 ~ 199 N
(17.23 ~ 20.29 kgf, 37.99 ~ 44.73 lb)
-------
Spring tilt
Intake
----
Exhaust
----
Winding direction (top view)
Intake
Exhaust
2.5°/1.70 mm
(2.5°/0.067 in)
2.5°/1.70 mm
(2.5°/0.067 in)
Clockwise
Clockwise
2-7
-------
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Piston
Piston-to-cylinder clearance
0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in)
Diameter “D”
101.955 ~ 101.970 mm
(4.0140 ~ 4.0146 in)
Limit
0.13 mm
(0.0051 in)
----
H
D
Height “H”
Offset
Offset direction
Piston pin bore inside diameter
Piston pin outside diameter
Piston-pin-to-piston-pin-bore clearance
Piston rings
Top ring
10.0 mm (0.39 in)
---0.50 mm (0.0197 in)
---Intake side
---23.004 ~ 23.015 mm (0.9057 ~ 0.9061 in) 23.045 mm
(0.9073 in)
22.991 ~ 23.000 mm (0.9052 ~ 0.9055 in) 22.971 mm
(0.9044 in)
0.004 ~ 0.024 mm (0.0002 ~ 0.0009 in)
0.074 mm
(0.0029 in)
B
T
Ring type
Dimensions (B × T)
End gap (installed)
Barrel
1.20 × 3.80 mm (0.05 × 0.15 in)
0.20 ~ 0.35 mm (0.008 ~ 0.014 in)
Ring side clearance
0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in)
------0.60 mm
(0.024 in)
0.12 mm
(0.0047 in)
2nd ring
B
T
Ring type
Dimensions (B × T)
End gap (installed)
Taper
1.20 × 4.00 mm (0.05 × 0.16 in)
0.75 ~ 0.90 mm (0.030 ~ 0.035 in)
Ring side clearance
0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in)
2-8
------1.25 mm
(0.049 in)
0.13 mm
(0.0051 in)
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Limit
Oil ring
B
T
Dimensions (B × T)
End gap (installed)
Ring side clearance
Crankshaft
2.50 × 2.80 mm (0.10 × 0.11 in)
0.20 ~ 0.70 mm (0.008 ~ 0.028 in)
0.060 ~ 0.150 mm (0.0024 ~ 0.0059 in)
----------
F
C
C
E
D
A
Crank width “A”
Maximum runout “C”
74.95 ~ 75.00 mm (2.951 ~ 2.953 in)
----
Big end side clearance “D”
0.350 ~ 0.650 mm (0.0138 ~ 0.0256 in)
Big end radial clearance “E”
Small end free play “F”
Balancer
Balancer drive method
Automatic centrifugal clutch
Clutch shoe thickness
0.010 ~ 0.025 mm (0.0004 ~ 0.0010 in)
0.16 ~ 0.40 mm (0.0063 ~ 0.0157 in)
Clutch-in revolution
Clutch-stall revolution
Transmission
Maximum main axle runout
Maximum drive axle runout
Shifting mechanism
Shift mechanism type
Decompression device
Device type
Air filter oil grade
Throttle body
Model/manufacturer × quantity
Engine idle speed
Intake vacuum
Gear
1.5 mm (0.06 in)
1,850 ~ 2,250 r/min
3,500 ~ 4,100 r/min
----
---0.030 mm
(0.0012 in)
1.0 mm
(0.04 in)
---------1.0 mm
(0.04 in)
------0.06 mm
(0.0024 in)
0.06 mm
(0.0024 in)
----
Shift drum and guide bar
----
Auto decomp
Foam air filter oil or equivalent oil
-------
44EIS/MIKUNI × 1
1,350 ~ 1,450 r/min
35.0 kPa (263 mmHg, 10.3 inHg)
----------
2-9
ENGINE SPECIFICATIONS
Item
Fuel pump
Pump type
Model/manufacturer
Oil filter type
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip clearance
Outer-rotor-to-oil-pump-housing
clearance
Oil-pump-housing-to-inner-andouter-rotor clearance
Oil pressure (hot)
Pressure check location
Cooling system
Radiator core
Width
Height
Depth
Radiator cap opening pressure
Coolant reservoir capacity
Up to the maximum level mark
From low to full level
Water pump
Water pump type
Reduction ratio
Shaft drive
Middle gear backlash
Final gear backlash
Differential gear backlash
SPEC
Standard
Electrical
3B4/DENSO
Cartridge (paper)
Trochoid
Less than 0.12 mm (0.0047 in)
0.090 ~ 0.170 mm (0.0035 ~ 0.0067 in)
0.03 ~ 0.10 mm (0.0012 ~ 0.0039 in)
50.0 kPa at 1,600 r/min (0.50 kg/cm2 at
1,600 r/min, 7.1 psi at 1,600 r/min)
Cylinder head
Limit
------------0.20 mm
(0.0079 in)
0.24 mm
(0.0094 in)
0.17 mm
(0.0067 in)
-------
340.0 mm (13.39 in)
248.2 mm (9.77 in)
22.0 mm (0.87 in)
93.3 ~ 122.7 kPa
(0.933 ~ 1.227 kg/cm2, 13.27 ~ 17.45 psi)
-------------
0.17 L (0.15 Imp qt, 0.18 US qt)
0.14 L (0.12 Imp qt, 0.15 US qt)
-------
Single-suction centrifugal pump
32/31 (1.032)
-------
0.10 ~ 0.30 mm (0.004 ~ 0.012 in)
0.10 ~ 0.20 mm (0.0039 ~ 0.0079 in)
0.05 ~ 0.25 mm (0.0020 ~ 0.0098 in)
----------
2 - 10
ENGINE SPECIFICATIONS
Cylinder head tightening sequence
5
7
8
2
3
1
4
6
2 - 11
SPEC
CHASSIS SPECIFICATIONS
SPEC
EBS01003
CHASSIS SPECIFICATIONS
Item
Steering system
Steering bearing type
Steering tension
Front suspension
Shock absorber travel
Spring free length
Installed length
Spring rate (K1)
Spring stroke (K1)
Optional spring available
Rear suspension
Shock absorber travel
Spring free length
Installed length
Spring rate (K1)
Spring rate (K2)
Spring stroke (K1)
Spring stroke (K2)
Optional spring available
Front wheel
Type
Rim size
Rim material
Maximum radial wheel runout
Maximum lateral wheel runout
Rear wheel
Type
Rim size
Rim material
Maximum radial wheel runout
Maximum lateral wheel runout
Standard
Limit
Ball and race bearing
50 N (5.0 kgf)
-------
90.7 mm (3.57 in)
292.0 mm (11.50 in)
237.0 mm (9.33 in)
23.00 N/mm (2.35 kg/mm, 131.33 lb/in)
0 ~ 90.7 mm (0 ~ 3.57 in)
No
-------------------
109.2 mm (4.30 in)
314.5 mm (12.38 in)
271.0 mm (10.67 in)
33.50 N/mm (3.42 kg/mm, 191.28 lb/in)
36.00 N/mm (3.67 kg/mm, 205.56 lb/in)
0 ~ 46.5 mm (0 ~ 1.83 in)
46.5 ~ 109.2 mm (1.83 ~ 4.30 in)
No
-------------------------
Panel wheel
12 × 6.0 AT
Aluminum
-------
Panel wheel
12 × 7.5 AT
Aluminum
-------
2 - 12
---------2.0 mm
(0.08 in)
2.0 mm
(0.08 in)
---------2.0 mm
(0.08 in)
2.0 mm
(0.08 in)
CHASSIS SPECIFICATIONS
Item
Front disc brake
Type
Disc outside diameter × thickness
Brake disc minimum thickness
Brake disc maximum deflection
Pad thickness inner
Pad thickness outer
Master cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type
Rear disc brake
Type
Disc outside diameter × thickness
Brake disc minimum thickness
Brake disc maximum deflection
Pad thickness inner
Pad thickness outer
Master cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type
Brake lever and brake pedal
Brake pedal position
Brake pedal free play
Throttle lever free play
Standard
Dual
220.0 × 3.5 mm (8.66 × 0.14 in)
3.0 mm (0.12 in)
0.1 mm (0.004 in)
4.4 mm (0.17 in)
4.4 mm (0.17 in)
12.70 mm (0.50 in)
33.96 mm (1.34 in)
DOT 4
Dual
205.0 × 3.5 mm (8.07 × 0.14 in)
3.0 mm (0.12 in)
0.1 mm (0.004 in)
5.8 mm (0.23 in)
5.8 mm (0.23 in)
12.70 mm (0.50 in)
33.96 mm (1.34 in)
DOT 4
56.7 mm (2.23 in)
0 ~ 5.0 mm (0 ~ 0.20 in)
3.0 ~ 5.0 mm (0.12 ~ 0.20 in)
2 - 13
SPEC
Limit
------------1.0 mm
(0.04 in)
1.0 mm
(0.04 in)
---------------------1.0 mm
(0.04 in)
1.0 mm
(0.04 in)
-------------------
ELECTRICAL SPECIFICATIONS
SPEC
EBS01004
ELECTRICAL SPECIFICATIONS
Item
Standard
System voltage
Ignition system
Ignition timing (B.T.D.C.)
Advancer type
Transistorized coil ignition
Crankshaft position sensor resistance/color
ECU
Model/manufacturer
Ignition coil
Model/manufacturer
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
Spark plug cap
Material
Resistance
AC magneto
Model/manufacturer
Standard output
Stator coil resistance/color
Rectifier/regulator
Type
Model/manufacturer
No load regulated voltage
Rectifier capacity
Withstand voltage
Electric starting system
Type
Starter motor
Model/manufacturer
Power output
Armature coil resistance
Brush overall length
Spring force
(DC)
Limit
12 V
----
12°/1,400 r/min
Digital
-------
459 ~ 561 Ω at 20 °C (68 °F)/
black-green/yellow
----
3B4/MITSUBISHI
----
JO226/DENSO
6.0 mm (0.24 in)
3.4 ~ 4.6 Ω at 20 °C (68 °F)
10.4 ~ 15.6 kΩ at 20 °C (68 °F)
-------------
Resin
10.0 kΩ
-------
F4T393/MITSUBISHI
14.0 V 35.0 A at 5,000 r/min
0.108 ~ 0.132 Ω at 20 °C (68 °F)/
white-white
----------
Semiconductor-short-circuit
FH012AA/SHINDENGEN
14.2 ~ 14.8 V
50.0 A
40.0 V
----------------
Constant mesh
----
SM-13/MITSUBA
0.80 kW
0.0250 ~ 0.0350 Ω at 20 °C (68 °F)
12.5 mm (0.49 in)
Commutator diameter
7.65 ~ 10.01 N
(780 ~ 1,021 gf, 27.54 ~ 36.03 oz)
28.0 mm (1.10 in)
Mica undercut
0.70 mm (0.03 in)
2 - 14
---------5.00 mm
(0.20 in)
---27.0 mm
(1.06 in)
----
ELECTRICAL SPECIFICATIONS
Item
Starter relay
Model/manufacturer
Amperage rating
Coil winding resistance
Fuel gauge
Sender unit resistance (full)
Sender unit resistance (empty)
Starting circuit cut-off relay
Model/manufacturer
Coil resistance
Radiator fan motor relay
Model/manufacturer
Coil resistance
Circuit breaker
Circuit breaker type
Fuses
Main fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Auxiliary DC jack fuse
Fuel injection system fuse
Four-wheel-drive motor fuse
EPS fuse
Radiator fan motor fuse
Spare fuse
Standard
SPEC
Limit
2768113-A/JIDECO
180.0 A
4.18 ~ 4.62 Ω at 20 °C (68 °F)
----------
19.00 ~ 21.00 Ω
139.00 ~ 141.00 Ω
-------
ACM33211/MATSUSHITA
96.0 Ω
-------
ACM33211/MATSUSHITA
96.0 Ω
-------
Fuse
----
40.0 A
15.0 A
5.0 A
10.0 A
15.0 A
15.0 A
10.0 A
40.0 A
15.0 A
40.0 A
15.0 A
10.0 A
5.0 A
----------------------------------------
2 - 15
TIGHTENING TORQUES
SPEC
EBS01005
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Item
Cylinder head (exhaust pipe)
Cylinder head
Cylinder head
Cylinder head
Spark plug
Oil gallery bolt
Part name
Thread
Q’ty
size
Tightening torque
Nm m · kg ft · lb
Stud bolt
Bolt
Bolt
Bolt
—
Union bolt
M8
M9
M9
M6
M10
M8
4
4
2
2
1
1
15
35
38
10
13
10
1.5
3.5
3.8
1.0
1.3
1.0
11
25
27
7.2
9.4
7.2
Cylinder
Bolt
M10
4
50
5.0
36
AC magneto rotor
Nut
M16
1
70
7.0
50
Balancer driven gear
Nut
M18
1
80
8.0
58
Bolt
Bolt
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
—
Union bolt
Union bolt
Union bolt
Bolt
M6
M6
M6
M7
M6
M16
M6
M6
M6
M6
M7
M8
M6
M6
M14
M20
M20
M14
M10
M6
2
1
4
2
2
1
2
2
2
8
2
2
4
8
1
1
1
2
1
3
10
10
14
20
10
20
10
10
10
10
20
26
10
10
30
17
68
35
20
10
1.0
1.0
1.4
2.0
1.0
2.0
1.0
1.0
1.0
1.0
2.0
2.6
1.0
1.0
3.0
1.7
6.8
3.5
2.0
1.0
7.2
7.2
10
14
7.2
14
7.2
7.2
7.2
7.2
14
19
7.2
7.2
22
12
49
25
14
7.2
Oil pump driven gear
Nut
M10
1
22
2.2
16
Bearing retainer (crankcase)
Exhaust pipe protector
Muffler and frame
Muffler and muffler bracket
Exhaust pipe
Water pump housing
Coolant drain bolt
Water pump air bleed bolt
Bolt
Bolt
Bolt
Bolt
Nut
Bolt
Bolt
Bolt
M6
M6
M8
M8
M8
M6
M6
M6
2
2
1
2
4
2
1
1
10
7
20
20
20
10
10
10
1.0
0.7
2.0
2.0
2.0
1.0
1.0
1.0
7.2
5.1
14
14
14
7.2
7.2
7.2
Thermostat cover
Cylinder head air bleed bolt
Valve adjusting screw
Decompression assembly
Timing chain guide (intake side)
Timing chain tensioner cap
Timing chain tensioner
Bearing retainer (camshaft)
Camshaft sprocket cover
Tappet cover
Camshaft sprocket
Crankcase
Engine oil drain bolt
Oil filter cartridge
Oil filter cartridge union bolt
Oil delivery pipe
Oil delivery pipe
Oil pump
2 - 16
Remarks
M
E
See NOTE.
E
Use a lock
washer.
LT
LT
E
Use a lock
washer.
LT
TIGHTENING TORQUES
Thread
Q’ty
size
SPEC
Tightening torque
Item
Part name
Water pump outlet pipe
Water jacket joint
Timing chain guide
Crankshaft end accessing screw
Timing mark accessing screw
Drive belt cover
Bearing housing (primary sheave
assembly)
AC magneto/crankshaft position sensor lead holder
Starter one-way clutch
Clutch housing assembly
Bolt
Bolt
Bolt
—
—
Bolt
M6
M6
M6
M36
M14
M6
1
2
2
1
1
12
10
10
10
10
6
10
1.0
1.0
1.0
1.0
0.6
1.0
7.2
7.2
7.2
7.2
4.3
7.2
Bolt
M6
4
10
1.0
7.2
Bolt
M5
2
7
0.7
5.1
Screw
Bolt
M8
M6
3
9
30
10
3.0
1.0
22
7.2
19.0
Left-hand
thread
140 Stake.
Clutch carrier assembly
Nut
M22
1
Nm m · kg ft · lb
190
Remarks
LT
LT
LT
M
Middle drive pinion gear nut
Middle driven shaft bearing housing
Middle drive shaft bearing retainer
Front drive shaft coupling gear nut
(middle gear side)
Nut
Bolt
Bolt
M22
M8
M6
1
4
4
180
32
29
18.0
3.2
2.9
130 Stake.
23
21
Nut
M16
1
115
11.5
85
Middle driven shaft bearing retainer
Nut
M55
1
80
8.0
58
Left-hand
thread
LT
Middle driven pinion gear bearing
retainer
Rear drive shaft coupling gear nut
(middle gear side)
Middle driven pinion gear bearing
housing
Primary sheave assembly
Secondary sheave spring retainer
Secondary sheave assembly
Shift lever 2 assembly
Shift drum stopper
Stopper lever stopper
Stator coil assembly
Crankshaft position sensor
Coolant temperature sensor
Gear position switch
Reverse switch
Speed sensor
Nut
M60
1
130
13.0
94
Left-hand
thread
LT
Nut
M16
1
150
15.0
110
Bolt
M8
4
25
2.5
18
Nut
Nut
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
—
Bolt
—
Bolt
M16
M36
M16
M6
M14
M14
M6
M5
M12
M6
M10
M6
1
1
1
1
1
1
3
2
1
2
1
1
140
90
100
14
18
18
7
7
18
7
17
10
14.0
9.0
10.0
1.4
1.8
1.8
0.7
0.7
1.8
0.7
1.7
1.0
100
65
72
10
13
13
5.1
5.1
13
5.1
12
7.2
2 - 17
LT
LT
LT
TIGHTENING TORQUES
SPEC
NOTE:
Temporarily tighten the cylinder bolts to 15 Nm (1.5 m · kg, 11 ft · lb) and then tighten them to 50 Nm
(5.0 m · kg, 36 ft · lb).
2 - 18
TIGHTENING TORQUES
SPEC
EBS01006
CHASSIS TIGHTENING TORQUES
Part to be tightened
Thread size
Tightening torque
Nm m · kg ft · lb
Engine and front rubber damper
Engine and front rubber damper
Engine and rear rubber damper
Engine and rear rubber damper
Rubber damper and frame
Differential gear case and frame
Differential gear case and frame
Final gear case and frame
Radiator and frame
Coolant reservoir and frame
Shift arm
Select lever shift rod locknut
Select lever unit and frame
Select lever guide and frame
Front grill and front grill bracket
Front grill bracket and frame
Front fender and frame
Rear fender and frame
Radiator bracket and frame
Rear upper arm and frame
Rear lower arm and frame
Rear shock absorber and frame
Rear shock absorber and rear lower arm
Rear knuckle and rear upper arm
Rear knuckle and rear lower arm
Rear brake hose guide and rear lower arm
Stabilizer joint and stabilizer
Stabilizer joint and rear lower arm
Stabilizer holder and frame
Rear arm protector and rear lower arm
Front upper arm and frame
Front lower arm and frame
Front shock absorber and frame
Front shock absorber and front lower arm
Front brake hose holder and front upper arm
M10
M6
M10
M6
M10
M10
M10
M10
M6
M6
M6
M8
M6
M6
M6
M6
M6
M6
M6
M10
M10
M10
M10
M10
M10
M6
M10
M10
M8
M6
M10
M10
M10
M10
M6
42
10
42
10
42
55
55
55
7
7
14
15
7
7
7
7
7
7
7
45
45
45
45
45
45
7
50
50
30
7
45
45
45
45
7
4.2
1.0
4.2
1.0
4.2
5.5
5.5
5.5
0.7
0.7
1.4
1.5
0.7
0.7
0.7
0.7
0.7
0.7
0.7
4.5
4.5
4.5
4.5
4.5
4.5
0.7
5.0
5.0
3.0
0.7
4.5
4.5
4.5
4.5
0.7
30
7.2
30
7.2
30
40
40
40
5.1
5.1
10
11
5.1
5.1
5.1
5.1
5.1
5.1
5.1
32
32
32
32
32
32
5.1
36
36
22
5.1
32
32
32
32
5.1
Select lever shift rod end
M10
15
1.5
11
Steering stem bushing and steering stem bracket
Steering stem joint bolt
EPS unit and frame
Steering stem bracket and frame
Steering stem bearing and frame
M8
M8
M8
M10
M10
23
30
30
50
50
2.3
3.0
3.0
5.0
5.0
17
22
22
36
36
2 - 19
Remarks
LT
LT
LT
LS
LS
LS
LS
Left-hand
thread
LT
LT
LT
LT
TIGHTENING TORQUES
Part to be tightened
Thread size
SPEC
Tightening torque
Nm m · kg ft · lb
Remarks
Pitman arm nut
EPS motor cover
Pitman arm and tie-rod
Steering knuckle and tie-rod
Steering knuckle and front lower arm
Front arm protector and front lower arm
Fuel tank and fuel pump
Fuel tank and frame
Fuel tank side cover and frame
Front wheel and front wheel hub
Front wheel axle nut
Front brake caliper and steering knuckle
Front brake caliper bleed screw
Front brake disc and front wheel hub
Rear brake disc and rear wheel hub
Rear wheel and rear wheel hub
Rear wheel axle nut
Rear brake caliper and rear knuckle
Rear brake caliper bleed screw
Brake pad holding bolt
Rear knuckle and brake disc guard
Steering knuckle and brake disc guard
Brake master cylinder and brake master cylinder
holder
M16
M6
M10
M10
M12
M6
M6
M6
M6
M10
M20
M8
M8
M8
M8
M10
M20
M8
M8
M6
M6
M6
210
7
25
25
30
7
7
7
7
55
260
30
5
30
30
55
260
30
5
17
7
7
21.0
0.7
2.5
2.5
3.0
0.7
0.7
0.7
0.7
5.5
26.0
3.0
0.5
3.0
3.0
5.5
26.0
3.0
0.5
1.7
0.7
0.7
150
5.1
18
18
22
5.1
5.1
5.1
5.1
40
190 Stake.
22
3.6
22
22
40
190 Stake.
22
3.6
12
5.1
5.1
M6
7
0.7
5.1
Brake lever pivot
M6
6
0.6
4.3
Handlebar holder and steering shaft
Brake hose joint and frame
Brake hose joint and brake hose
Brake hose union bolt
Rear knuckle and brake hose protector
Footrest bracket and frame
Footrest board and footrest bracket
Footrest and footrest board
Brake pedal adjusting nut
Shift control cable and shift lever cover
Front guard and frame
Front carrier and front guard
Front carrier and front carrier bracket
Front carrier bracket and frame
Front carrier and front fender
Rear carrier and rear carrier bracket
Rear carrier bracket and frame
M8
M6
M10
M10
M6
M10
M6
M6
M6
M14
M8
M8
M8
M8
M6
M8
M10
20
10
19
27
7
53
7
7
7
17
26
26
26
26
7
34
48
2.0
1.0
1.9
2.7
0.7
5.3
0.7
0.7
0.7
1.7
2.6
2.6
2.6
2.6
0.7
3.4
4.8
14
7.2
13
19
5.1
38
5.1
5.1
5.1
12
19
19
19
19
5.1
24
35
2 - 20
LT
LT
Silicone
grease
TIGHTENING TORQUES
Part to be tightened
Thread size
Rear carrier and rear fender
Engine skid plates
Trailer hitch and frame
Battery holding bracket
Battery bracket and fitting screw
Fitting screw and frame
Electrical components tray and frame
Differential gear case filler bolt
Differential gear case drain bolt
Differential gear case cover and differential gear
case
Differential gear motor and differential gear case
cover
Front drive shaft coupling gear and differential
drive pinion gear
Final gear case filler plug
Final gear case drain bolt
Final gear oil level check bolt
Final gear case and final gear case cover
Final drive pinion gear bearing housing and final
gear case
2 - 21
SPEC
Tightening torque
Nm m · kg ft · lb
M6
M6
M10
M6
M6
M6
M6
M14
M10
7
7
55
7
7
7
7
23
10
0.7
0.7
5.5
0.7
0.7
0.7
0.7
2.3
1.0
5.1
5.1
40
5.1
5.1
5.1
5.1
17
7.2
M8
24
2.4
17
M6
11
1.1
8.0
M14
62
6.2
45
M14
M14
M8
M8
23
23
10
23
2.3
2.3
1.0
2.3
17
17
7.2
17
M8
23
2.3
17
Remarks
LT
HOW TO USE THE CONVERSION TABLE/
GENERAL TIGHTENING TORQUE SPECIFICATIONS
SPEC
EBS00022
EBS00023
HOW TO USE THE CONVERSION
TABLE
GENERAL TIGHTENING TORQUE
SPECIFICATIONS
All specification data in this manual are listed
in SI and METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.
This chart specifies tightening torques for standard fasteners with a standard ISO thread
pitch. Tightening torque specifications for special components or assemblies are provided
for each chapter of this manual. To avoid
warpage, tighten multi-fastener assemblies in
a crisscross pattern and progressive stages
until the specified tightening torque is reached.
Unless otherwise specified, tightening torque
specifications require clean, dry threads. Components should be at room temperature.
A: Distance between flats
B: Outside thread diameter
Ex.
METRIC
MULTIPLIER
IMPERIAL
** mm
×
0.03937
=
** in
2 mm
×
0.03937
=
0.08 in
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit
Multiplier
Imperial unit
m · kg
m · kg
cm · kg
cm · kg
7.233
86.794
0.0723
0.8679
ft · lb
in · lb
ft · lb
in · lb
Weight
kg
g
2.205
0.03527
Speed
km/hr
A
(nut)
B
(bolt)
lb
oz
10 mm
0.6214
mph
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
Volume/
Capacity
cc (cm3)
cc (cm3)
lt (liter)
lt (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cu · in
qt (IMP liq.)
gal (IMP liq.)
Misc.
kg/mm
kg/cm2
Centigrade
(°C)
55.997
14.2234
9/5+32
lb/in
psi (lb/in2)
Fahrenheit
(°F)
Torque
2 - 22
General tightening
torques
Nm
m · kg
ft · lb
6 mm
6
0.6
4.3
12 mm
8 mm
15
1.5
11
14 mm
10 mm
30
3.0
22
17 mm
12 mm
55
5.5
40
19 mm
14 mm
85
8.5
61
22 mm
16 mm
130
13.0
94
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EBS00024
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point
Lubricant
Oil seal lips
LS
Bearings
E
O-ring
LS
Cylinder head bolts
M
Crankshaft pin
E
Connecting rod big end thrust surface
E
Crankshaft sprocket
M
Inner race (crankshaft)
E
Buffer boss (crankshaft)
E
Crankshaft seal
E
Piston pin
E
Piston and ring groove
E
Valve stems (intake and exhaust)
M
Valve stem ends (intake and exhaust)
M
Rocker arm shafts
E
Camshaft lobes
M
Decompressor lever pin
E
Decompressor lever spring
E
Rocker arms (intake and exhaust)
M
Oil pump shaft
E
O-ring (oil filter cartridge)
LS
Water pump impeller shaft
M
Dipstick mating surface
E
Starter idler gear inner surface
E
Starter idler gear shaft
E
Starter wheel gear
E
Torque limiter
E
Clutch housing shaft end
LS
Clutch carrier assembly
E
One-way clutch bearing
E
Clutch dog and middle drive gear
M
Reverse idle gear shaft
E
Middle driven shaft splines
M
Shift drum
E
Shift forks and shift fork guide bar
E
Ball (shift drum stopper)
E
Stopper lever and stopper lever shaft
E
2 - 23
LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point
SPEC
Lubricant
Shift lever 2 inner surface
LS
Shift lever 1
E
Shift lever 1 gear teeth and shift lever 2 gear teeth
E
Stopper lever stopper
E
Bearing (final drive pinion gear assembly)
G
Bearing (final gear)
G
AC magneto lead grommet
Yamaha bond No.1215
(Three bond No.1215®)
Crankcase mating surface
Yamaha bond No.1215
(Three bond No.1215®)
2 - 24
COOLANT FLOW DIAGRAMS
SPEC
EBS00025
COOLANT FLOW DIAGRAMS
1 Coolant reservoir hose
2 Radiator inlet hose
3 Fast idle plunger outlet hose
4 Coolant reservoir
5 Water pump
6 Water pump outlet pipe
7 Water pump outlet hose
8 Radiator outlet hose
9 Radiator
0 Fast idle plunger inlet hose
3
0
A
1
2
3
4
A
9
8
2 - 25
7
6
5
OIL FLOW DIAGRAMS
SPEC
EBS00026
OIL FLOW DIAGRAMS
1 Oil delivery pipe
2 Oil filter cartridge
3 Oil strainer
4 Drive axle
5 Relief valve assembly
6 Reverse idle gear shaft
1
B
2
B
4
3
2
6
B-B
2 - 26
5
OIL FLOW DIAGRAMS
SPEC
1 Camshaft
2 Crankshaft
3 Oil strainer
4 Oil pump rotor
5 Oil pump driven gear
1
2
5
3
4
2 - 27
SPEC
CABLE ROUTING
EBS00028
CABLE ROUTING
1 Front brake light switch lead
2 On-command four-wheel-drive motor switch and
differential gear lock switch lead
3 Front brake hose
4 Throttle cable
5 Rear brake cable
6 Shift control cable
7 Rear brake hose
8 Left handlebar switch lead
9 Rear brake light switch lead
0 Radiator fan motor breather hose
A Differential gear case breather hose
B EPS motor breather hose
C Radiator fan motor lead
D Meter assembly lead
E Final gear case breather hose
1234
6
5
È
7
8
9
É
Ê
Ï
Î
Í
Ì
Ë
2
2
1
8
9
1
Ù
A-A
A
A
B
Ù
EØ
B
Ð
Ð
0Ñ
AÒ
BÓ
Ú
8
9
B-B
0
×
Ú
D
A
C
D
C
C
Ô
D
C-C
0
Õ
Ö
D-D
2 - 28
SPEC
CABLE ROUTING
È Pass the front brake hose and throttle cable
through the guide on the handlebar cover.
É Pass the rear brake cable, shift control cable,
and rear brake hose through the guide on the
handlebar cover.
Ê Route the rear brake cable, shift control cable,
and rear brake hose in front of the left handlebar
switch lead and rear brake light switch lead.
Ë Pass the rear brake hose and throttle cable
through the guide, making sure to route the
cable behind the hose.
Ì Pass the rear brake cable and shift control cable
through the guide.
Í Pass the front brake hose through the guide.
Î Route the throttle cable behind the rear brake
cable and shift control cable.
1234
6
5
È
7
8
9
É
Ê
Ï
Î
Í
Ì
Ë
2
2
1
8
9
1
Ù
A-A
A
A
B
Ù
EØ
B
Ð
Ð
0Ñ
AÒ
BÓ
Ú
8
9
B-B
0
×
Ú
D
A
C
D
C
C
Ô
D
C-C
0
Õ
Ö
D-D
2 - 29
SPEC
CABLE ROUTING
Ï Route the front brake light switch lead, on-command four-wheel-drive motor switch and differential gear lock switch lead, left handlebar
switch lead, and rear brake light switch lead over
the throttle cable, rear brake cable, and shift
control cable, then to the front of where the
cables cross.
Ð Fasten the left handlebar switch lead and rear
brake light switch lead with the plastic bands at
the bends in the handlebar, making sure to route
the leads under the handlebar and to face the
ends of the bands forward.
Ñ Pass the radiator fan motor breather hose
through the guide on the meter bracket, making
sure to face the end of the hose downward.
Ò Pass the differential gear case breather hose
through the guide on the meter bracket, making
sure to face the end of the hose downward.
1234
6
5
È
7
8
9
É
Ê
Ï
Î
Í
Ì
Ë
2
2
1
8
9
1
Ù
A-A
A
A
B
Ù
EØ
B
Ð
Ð
0Ñ
AÒ
BÓ
Ú
8
9
B-B
0
×
Ú
D
A
C
D
C
C
Ô
D
C-C
0
Õ
Ö
D-D
2 - 30
SPEC
CABLE ROUTING
Ó Pass the EPS motor breather hose through the
guide on the meter bracket, making sure to face
the end of the hose downward.
Ô Route the radiator fan motor breather hose and
differential gear case breather hose in front of
the frame.
Õ Fasten the differential gear case breather hose
to the frame with the plastic band, making sure
to face the end of the band inward.
Ö Route the differential gear case breather hose to
the inside of the frame.
× Fasten the front brake light switch lead, on-command four-wheel-drive motor switch and differential gear lock switch lead, left handlebar
switch lead, and rear brake light switch lead with
a plastic locking tie. Be sure to fasten the plastic
locking tie above the couplers and fasten it
around the protective sleeves of the leads, not
the leads themselves.
Ø Pass the final gear case breather hose through
the guide on the meter bracket, making sure to
face the end of the hose downward.
1234
6
5
È
7
8
9
É
Ê
Ï
Î
Í
Ì
Ë
2
2
1
8
9
1
Ù
A-A
A
A
B
Ù
EØ
B
Ð
Ð
0Ñ
AÒ
BÓ
Ú
8
9
B-B
0
×
Ú
D
A
C
D
C
C
Ô
D
C-C
0
Õ
Ö
D-D
2 - 31
SPEC
CABLE ROUTING
Ù Fasten the front brake light switch lead and oncommand four-wheel-drive motor switch and differential gear lock switch lead with the plastic
bands at the bends in the handlebar, making
sure to route the leads under the handlebar and
to face the ends of the bands forward.
Ú 20 ~ 50 mm (0.79 ~ 1.97 in)
1234
6
5
È
7
8
9
É
Ê
Ï
Î
Í
Ì
Ë
2
2
1
8
9
1
Ù
A-A
A
A
B
Ù
EØ
B
Ð
Ð
0Ñ
AÒ
BÓ
Ú
8
9
B-B
0
×
Ú
D
A
C
D
C
C
Ô
D
C-C
0
Õ
Ö
D-D
2 - 32
CABLE ROUTING
1 Coolant reservoir hose
2 Radiator fan motor breather hose
3 Differential gear case breather hose
4 EPS motor breather hose
5 Ground lead
6 Coolant reservoir breather hose
7 Throttle cable
8 Fuel injector lead
9 Final gear case breather hose
0 Speed sensor lead
A Crankshaft position sensor lead
B Differential gear motor lead
C EPS torque sensor lead
D Fast idle plunger outlet hose
E Radiator outlet hose
F Gear position switch lead
G Reverse switch lead
H Shift control cable
I Starter motor lead
È Face the end of the coolant reservoir breather
hose downward.
Ê
2
1
SPEC
Ë
7
34 5 È 6 É
8Ì
A
Ó
B
D
C
A
B
Ò
D
C
9
Ñ
0
C
A
E
Ð
E
D
Ï B Î Í
5
Ô
E
A-A
1
1
4
4
F
Ö
C
×
0Ø
Õ
B-B
Õ
A
AØ
I
9Ù
G
D
5
E-E
HÚ
2 - 33
C-C
E
CABLE ROUTING
É Route the ground lead, radiator fan motor
breather hose, differential gear case breather
hose, and EPS motor breather hose to the inside
of the fast idle plunger outlet hose.
Ê Pass the radiator fan motor breather hose
through the larger diameter guide.
Ë Route the coolant reservoir breather hose to the
outside of the fast idle plunger outlet hose.
Ì Route the fuel injector lead under the fuel hose.
Í Fasten the radiator outlet hose to the frame with
the plastic band, making sure to face the end of
the band inward.
Î Route the EPS motor breather hose under the
coolant reservoir hose.
Ï Place the EPS torque sensor lead and differential gear motor lead in the holder, and then insert
the ends of the holder into the hole in the stay on
the frame.
Ð Route the differential gear case breather hose to
the inside of the frame.
Ê
2
1
SPEC
Ë
7
34 5 È 6 É
8Ì
A
Ó
B
D
C
A
B
Ò
D
C
9
Ñ
0
C
A
E
Ð
E
D
Ï B Î Í
5
Ô
E
A-A
1
1
4
4
F
Ö
C
×
0Ø
Õ
B-B
Õ
A
AØ
I
9Ù
G
D
5
E-E
HÚ
2 - 34
C-C
E
CABLE ROUTING
Ñ Fasten the differential gear case breather hose
to the frame with the plastic band, making sure
to face the end of the band inward.
Ò Attach the ground lead terminal to the frame
using the bolt.
Ó Route the radiator fan motor breather hose and
differential gear case breather hose to the inside
of the fast idle plunger outlet hose and radiator
outlet hose.
Ô Make sure that the catch of the holder is facing
outward.
Õ Face the end of the plastic band inward.
Ö Route the fuel tank drain hose and position the
end of the hose as shown in the illustration.
× Pass the speed sensor lead, AC magneto lead,
and final gear case breather hose through the
guide in the order listed.
Ø Route the speed sensor lead, AC magneto lead,
and final gear case breather hose to the right of
the reverse switch.
Ù Route the final gear case breather hose above
the reverse switch lead and ground leads.
Ê
2
1
SPEC
Ë
7
34 5 È 6 É
8Ì
A
Ó
B
D
C
A
B
Ò
D
C
9
Ñ
0
C
A
E
Ð
E
D
Ï B Î Í
5
Ô
E
A-A
1
1
4
4
F
Ö
C
×
0Ø
Õ
B-B
Õ
A
AØ
I
9Ù
G
D
5
E-E
HÚ
2 - 35
C-C
E
CABLE ROUTING
SPEC
Ú Route the shift control cable under the gear position switch lead, speed sensor lead, and crankshaft position sensor lead.
Ê
2
1
Ë
7
34 5 È 6 É
8Ì
A
Ó
B
D
C
A
B
Ò
D
C
9
Ñ
0
C
A
E
Ð
E
D
Ï B Î Í
5
Ô
E
A-A
1
1
4
4
F
Ö
C
×
0Ø
Õ
B-B
Õ
A
AØ
I
9Ù
G
D
5
E-E
HÚ
2 - 36
C-C
E
CABLE ROUTING
1 Wire harness
2 Fuel injector lead
3 Fuel hose
4 Intake air temperature sensor lead
5 Final gear case breather hose
6 Ground lead
7 Starter motor lead
8 Air filter case breather hose
9 Main switch lead
0 Auxiliary DC jack lead
A EPS motor lead
SPEC
B Differential gear motor lead
C EPS torque sensor lead
D Radiator fan motor lead
E Radiator inlet hose
F EPS motor breather hose
G Spark plug lead
H Rear brake cable
I Shift control cable
J Fuel tank drain hose
K Gear position switch lead
L AC magneto lead
567 8 É
Ê
4
90A B C
3È
2
1
DË
B
Ï
C
B
A
N
Î
E
A
D
F
M
L
K
E
C
E
Ì
D
F
JÍ
Ð
5
1
L
A-A
F
I
6
N
7
1
H G
5 6
7
1
P
Ñ
O
Ò
B-B
C-C
I
B
C
A
D-D
B
Ó
H
G
I
Ô
E-E
2 - 37
F-F
CABLE ROUTING
SPEC
Ë Route the radiator fan motor lead between the
electrical components tray and the radiator inlet
hose.
Ì Fasten the radiator fan motor lead to the frame
with the plastic band, making sure to face the
end of the band inward.
Í Route the fuel tank drain hose to the inside of
the leads and fuel hose, making sure to position
the end of the drain hose as shown in the illustration.
M Speed sensor lead
N Coolant temperature sensor lead
O EPS motor lead coupler
P EPS torque sensor lead coupler
È Route the fuel hose between the wire harness
and the fuel tank drain hose.
É Route the coolant temperature sensor lead
above the fast idle plunger inlet hose.
Ê Route the final gear case breather hose above
the V-belt cooling duct 1.
567 8 É
Ê
4
90A B C
3È
2
1
DË
B
Ï
C
B
A
N
Î
E
A
D
F
M
L
K
E
C
E
Ì
D
F
JÍ
Ð
5
1
L
A-A
F
I
6
N
7
1
H G
5 6
7
1
P
Ñ
O
Ò
B-B
C-C
I
B
C
A
D-D
B
Ó
H
G
I
Ô
E-E
2 - 38
F-F
CABLE ROUTING
Î Fasten the final gear case breather hose,
ground lead, starter motor lead, fuel injector
lead, coolant temperature sensor lead, AC magneto lead, and wire harness with the plastic
band, making sure to position the band near the
split in the wire harness.
Ï Route the fuel injector lead and coolant temperature sensor lead to the inside of the ground
lead, starter motor lead, final drive gear case
breather hose, and wire harness.
SPEC
Ð Face the end of the plastic band inward.
Ñ Pass the plastic band through the hole in the
plastic cover, and then fasten the leads and
hose with the band, making sure to face the end
of the band downward.
Ò Insert the projection on the coupler into the hole
in the frame from the inside of the frame.
Ó Face the end of the plastic band inward.
Ô Fasten the spark plug lead with the larger diameter section of each holder.
567 8 É
Ê
4
90A B C
3È
2
1
DË
B
Ï
C
B
A
N
Î
E
A
D
F
M
L
K
E
C
E
Ì
D
F
JÍ
Ð
5
1
L
A-A
F
I
6
N
7
1
H G
5 6
7
1
P
Ñ
O
Ò
B-B
C-C
I
B
C
A
D-D
B
Ó
H
G
I
Ô
E-E
2 - 39
F-F
CABLE ROUTING
SPEC
È To tail/brake light
É Fasten the tail/brake light lead to the frame with
a plastic locking tie, making sure to face the end
of the tie downward.
Ê Install the plastic band near the split in the wire
harness.
Ë Route the tail/brake light lead to the outside of
the frame.
Ì Face the end of the plastic band downward.
Í Pass the final gear case breather hose through
the guide.
1 Tail/brake light lead
2 Rectifier/regulator lead
3 AC magneto lead
4 Speed sensor lead
5 Final gear case breather hose
6 Fuel hose
7 Fuel pump lead
8 Wire harness
É
1
2
Ê
3
B
A
È
B
Ë
A
C
C
5
7
4
Ì
1
5
6
6
8
2
3
Ì
A-A
3
B-B
2 - 40
Í
C-C
SPEC
CABLE ROUTING
1 Left headlight lead
2 Negative battery lead
3 Right headlight lead
4 Radiator fan motor lead
5 EPS control unit lead
6 Auxiliary DC jack lead
7 Main switch lead
8 Final gear case breather hose
9 Starter motor lead
0 Differential gear motor lead
A Ignition coil lead
B Meter lead
C Lean angle sensor lead
D Coolant reservoir breather hose
E Positive battery lead
F Coolant reservoir hose
G EPS motor breather hose
H Differential gear case breather hose
I Radiator fan motor breather hose
J Ground lead
K Relay lead
L Wire harness
É
1
Ê
2
3
I
H
G
Ë
È
B
Ô
FÓ
Ò
É
C
4
C
A
A
5
Ì
E
6
E
Ñ
7
Í
Ð
D
E
ÏÎB 5
A D
C
09
B
IHG
D
C
8
DÕ
Ö
J G
2
G
L
34
2
K
A-A
B-B
1
L
K
C-C
3
4
L
G-G
D-D
F
F
K5
L
E-E
2 - 41
5
M
5
F-F
SPEC
CABLE ROUTING
Í To main switch and auxiliary DC jack
Î Fasten the left handlebar switch lead, on-command four-wheel-drive motor switch and differential gear lock switch lead, front brake light
switch lead, and rear brake light switch lead with
the clamp.
Ï Fasten the joint coupler lead with the clamp.
Ð Pass the coolant reservoir breather hose
through the guides on the plastic cover and electrical components tray and route it under the
positive battery lead and starter motor lead.
M Joint coupler lead
È To left headlight
É Connect the headlight lead coupler, and then
fasten the coupler with the holder on the electrical components tray.
Ê Route the negative battery lead along the guide
on the electrical components tray.
Ë To right headlight
Ì Place the couplers on the inside of the electrical
components tray.
É
1
Ê
2
3
I
H
G
Ë
È
B
Ô
FÓ
Ò
É
C
4
C
A
A
5
Ì
E
6
E
Ñ
7
Í
Ð
D
E
ÏÎB 5
A D
C
09
B
IHG
D
C
8
DÕ
Ö
J G
2
G
L
34
2
K
A-A
B-B
1
L
K
C-C
3
4
L
G-G
D-D
F
F
K5
L
E-E
2 - 42
5
M
5
F-F
SPEC
CABLE ROUTING
Ñ Route the hoses under the positive battery lead,
and then route them upward, to the inside of the
coolant reservoir breather hose.
Ò Fasten the coolant reservoir breather hose with
the holder on the electrical components tray.
Ó Fasten the coolant reservoir hose with the
holder on the electrical components tray.
Ô Pass the hoses and ground lead through the
opening in the electrical components tray.
Õ Route the coolant reservoir breather hose above
the other hoses.
É
1
Ö Route the hoses to the inside of the bolt.
Ê
2
3
I
H
G
Ë
È
B
Ô
FÓ
Ò
É
C
4
C
A
A
5
Ì
E
6
E
Ñ
7
Í
Ð
D
E
ÏÎB 5
A D
C
09
B
IHG
D
C
8
DÕ
Ö
J G
2
G
L
34
2
K
A-A
B-B
1
L
K
C-C
3
4
L
G-G
D-D
F
F
K5
L
E-E
2 - 43
5
M
5
F-F
CABLE ROUTING
1 Throttle cable
2 Rear brake hose
3 Rear brake cable
4 Front brake hose
5 Negative battery lead
6 Final gear case breather hose
7 Starter motor lead
8 Intake air pressure sensor lead
9 TPS lead
0 Intake air temperature sensor lead
A Fuel injector lead
SPEC
B Coolant temperature sensor lead
C Rectifier/regulator lead
D AC magneto lead
E Fuel hose
F Tail/brake light lead
G Fuel pump lead
H Fast idle plunger outlet hose
I Wire harness
È Route the final gear case breather hose on top
of the leads.
3
4
2
A
5
A
6È
1
7
8
HÏ
É
Ê
Î
B
B
9
0
AË
BË
C
D
G
E
Ì
1Ð
C
C
A-A
F
F
Ñ
I 0 9
Í
B-B
C-C
2 - 44
CABLE ROUTING
SPEC
Ï Route the fast idle plunger outlet hose above the
plastic cover.
Ð Pass the throttle cable through the guide on the
plastic cover.
Ñ Insert the projection on the wire harness holder
into the hole in the plastic cover.
É To engine
Ê To air filter case
Ë Route the fuel injector lead and coolant temperature sensor lead to the outside of the frame.
Ì Pass the tail/brake light lead through the hole in
the rear fender.
Í Fasten the tail/brake light lead with the holder,
making sure that the coupler is positioned to the
rear of the holder.
Î Route the throttle cable under the plastic cover.
3
4
2
A
5
A
6È
1
7
8
HÏ
É
Ê
Î
B
B
9
0
AË
BË
C
D
G
E
Ì
1Ð
C
C
A-A
F
F
Ñ
I 0 9
Í
B-B
C-C
2 - 45
INTRODUCTION/PERIODIC MAINTENANCE CHART
FOR THE EMISSION CONTROL SYSTEM
CHK
ADJ
EBS00029
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation
and a longer service life. The need for costly overhaul work will be greatly reduced. This information
applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All
service technicians should be familiar with this entire chapter.
EBU21742
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM
NOTE:
• For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
• For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance
intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month
maintenance intervals should be followed.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
INITIAL
NO.
ITEM
CHECK OR MAINTENANCE JOB
Whichever
comes first
EVERY
month
1
3
6
6
12
km
(mi)
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
hours
20
80
160
160
320
√
√
√
√
√
√
√
√
√
√
√
√
√
√
1 *
Fuel line
• Check fuel hoses for cracks or other damage, and
replace if necessary.
2
Spark plug
• Check condition and clean, regap, or replace if necessary.
√
3 *
Valves
• Check valve clearance and adjust if necessary.
√
4 *
Fuel injection
• Check and adjust engine idle speed.
√
5 *
Crankcase
breather system
• Check breather hose for cracks or other damage,
and replace if necessary.
√
√
√
6 *
Exhaust system
• Check for leakage and replace gasket(s) if necessary.
• Check for looseness and tighten all screw clamps
and joints if necessary.
√
√
√
7
Spark arrester
• Clean.
√
√
√
3-1
3
GENERAL MAINTENANCE AND LUBRICATION CHART
CHK
ADJ
EBU21863
GENERAL MAINTENANCE AND LUBRICATION CHART
INITIAL
NO.
1
2
*
ITEM
CHECK OR MAINTENANCE JOB
Whichever
comes first
1
3
6
6
12
km
(mi)
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
hours
20
80
160
160
320
Every 20–40 hours (more often in wet or dusty
areas)
Air filter element
• Clean and replace if necessary.
Front brake
• Check operation and correct if necessary.
• Check fluid level and ATV for fluid leakage, and
correct if necessary.
√
• Replace brake pads.
3
*
Rear brake
*
Brake hoses
√
√
√
√
Whenever worn to the limit
• Check operation and correct if necessary.
• Check brake pedal free play and adjust if necessary.
• Check fluid level and ATV for fluid leakage, and
correct if necessary.
√
• Replace brake pads.
4
EVERY
month
√
√
√
√
Whenever worn to the limit
• Check for cracks or other damage, and replace if
necessary.
√
• Replace.
√
√
√
√
√
√
Every 4 years
5
*
Rear brake hose
protectors
• Check for wear, cracks or other damage, and
replace if necessary.
√
6
*
Wheels
• Check runout and for damage, and replace if necessary.
√
√
√
√
7
*
Tires
• Check tread depth and for damage, and replace if
necessary.
• Check air pressure and balance, and correct if necessary.
√
√
√
√
8
*
Wheel bearings
• Check for looseness or damage, and replace if
necessary.
√
√
√
√
9
*
Upper and lower
arm pivots
• Lubricate with lithium-soap-based grease.
√
√
√
10 *
V-belt
• Check for wear, cracks or other damage, and
replace if necessary.
√
√
√
11 *
Drive shaft univer• Lubricate with lithium-soap-based grease.
sal joint
√
√
√
12 *
Chassis fasteners
• Make sure that all nuts, bolts, and screws are properly tightened.
√
√
√
13 *
Shock absorber
assemblies
• Check operation and correct if necessary.
• Check for oil leakage and replace if necessary.
√
√
√
14 *
Stabilizer bushes
• Check for cracks or other damage, and replace if
necessary.
√
√
√
√
√
√
√
15 *
Knuckle pivots
• Lubricate with lithium-soap-based grease.
√
√
√
16 *
Knuckle shafts
• Lubricate with lithium-soap-based grease.
√
√
√
17 *
Steering shaft
• Lubricate with lithium-soap-based grease.
√
√
√
18 *
Steering system
• Check operation and repair or replace if damaged.
• Check toe-in and adjust if necessary.
√
√
√
19 *
Engine mount
• Check for cracks or other damage, and replace if
necessary.
√
√
√
20 *
Axle boots
• Check for cracks or other damage, and replace if
necessary.
√
√
√
√
21
Engine oil
• Change.
• Check ATV for oil leakage, and correct if necessary.
√
√
√
√
3-2
√
√
√
GENERAL MAINTENANCE AND LUBRICATION CHART
CHK
ADJ
INITIAL
NO.
ITEM
CHECK OR MAINTENANCE JOB
Whichever
comes first
EVERY
month
1
3
6
6
12
km
(mi)
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
hours
20
80
160
160
320
22
Engine oil filter
cartridge
23
• Change.
Differential gear oil • Check ATV for oil leakage, and correct if necessary.
√
√
24
Final gear oil
• Change.
• Check ATV for oil leakage, and correct if necessary.
√
√
Cooling system
• Check coolant level and ATV for coolant leakage,
and correct if necessary.
√
25
26 *
Moving parts and
cables
• Lubricate.
27 *
Drive select lever
safety system
cable
• Check operation and adjust or replace if necessary.
28 *
• Check operation and correct if necessary.
• Check throttle cable free play and adjust if necesThrottle lever
sary.
housing and cable
• Lubricate throttle lever housing and cable.
√
29 *
Front and rear
brake switches
• Check operation and correct if necessary.
30 *
Lights and
switches
• Check operation and correct if necessary.
• Adjust headlight beams.
√
• Replace.
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
• Replace coolant.
√
√
Every 2 years
√
EBU23070
NOTE:
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-3
ENGINE SKID PLATES, SEAT, CARRIERS AND
FENDERS
CHK
ADJ
ENGINE SKID PLATES, SEAT, CARRIERS AND FENDERS
ENGINE SKID PLATES
3
2
1
T.
R.
Order
1
2
3
Job/Part
Removing the engine skid plates
Front engine skid plate
Center engine skid plate
Rear engine skid plate
Q’ty
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
Remove the parts in the order listed.
1
1
1
For installation, reverse the removal procedure.
3-4
ENGINE SKID PLATES, SEAT, CARRIERS AND
FENDERS
CHK
ADJ
SEAT AND SIDE PANELS
2
1
3
5
4
6
Order
1
Job/Part
Removing the seat and side panels
Seat
2
3
4
5
6
Battery cover
Fuel tank cover
Left side panel
Right side panel
Dipstick accessing panel
Q’ty
1
Remarks
Remove the parts in the order listed.
NOTE:
Pull up the seat lock lever, then pull up on
the rear of the seat.
1
1
1
1
1
For installation, reverse the removal procedure.
3-5
ENGINE SKID PLATES, SEAT, CARRIERS AND
FENDERS
CHK
ADJ
EBS00037
FRONT CARRIER AND FRONT GUARD
T.
R.
26 Nm (2.6 m • kg, 19 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
3
4
4
6
5
2
2
7
8
(4)
(4)
T.
R.
26 Nm (2.6 m • kg, 19 ft • Ib)
T.
R.
Order
1
2
3
4
Job/Part
Removing the front carrier and front
guard
Front engine skid plate
Seat/side panels
Front carrier
Front carrier bracket
Battery holding bracket
Battery lead
Q’ty
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “ENGINE SKID PLATES”.
Refer to “SEAT AND SIDE PANELS”.
1
2
1
2
Disconnect.
CAUTION:
First disconnect the negative battery
lead, then disconnect the positive
lead.
5
6
Battery
Upper panel
1
1
3-6
ENGINE SKID PLATES, SEAT, CARRIERS AND
FENDERS
CHK
ADJ
T.
R.
26 Nm (2.6 m • kg, 19 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
3
4
4
6
5
2
2
7
8
(4)
(4)
T.
R.
26 Nm (2.6 m • kg, 19 ft • Ib)
T.
R.
Order
7
8
Job/Part
Front guard
Front guard cover
Q’ty
1
2
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
For installation, reverse the removal procedure.
3-7
ENGINE SKID PLATES, SEAT, CARRIERS AND
FENDERS
CHK
ADJ
FRONT FENDERS AND FRONT GRILL
(3)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
4
2
3
(3)
4
5
5
6
1
T.
R.
T.
R.
Order
1
2
3
4
5
6
7 Nm (0.7 m • kg, 5.1 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Job/Part
Removing the front fenders and
front grill
Seat/side panels
Front carrier/front guard
Front fender inner panel
Auxiliary DC jack coupler
Main switch coupler
Front fender
Headlight coupler
Front grill
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “SEAT AND SIDE PANELS”.
Refer to “FRONT CARRIER AND FRONT
GUARD”.
2
1
1
2
2
1
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
3-8
ENGINE SKID PLATES, SEAT, CARRIERS AND
FENDERS
CHK
ADJ
EBS00040
REAR CARRIER AND REAR FENDER
T.
R.
34 Nm (3.4 m • kg, 24 ft • Ib)
T.
R.
48 Nm (4.8 m • kg, 35 ft • Ib)
1
4
2
T.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
R.
2
(4)
5
3
T
.
R.
(6)
T.
R.
6
48 Nm (4.8 m • kg, 35 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
(6)
Order
1
2
3
4
5
6
Job/Part
Removing the rear carrier and rear
fender
Seat/side panels
Rear carrier
Rear carrier bracket
Storage compartment
Tail/brake light cover
Tail/brake light connector
Rear fender
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “SEAT AND SIDE PANELS”.
1
2
1
1
3
1
Disconnect.
For installation, reverse the removal procedure.
3-9
ELECTRICAL COMPONENTS TRAY
CHK
ADJ
ELECTRICAL COMPONENTS TRAY
ELECTRICAL COMPONENTS TRAY 1/2
11 12
T.
R.
10
7 Nm (0.7 m • kg, 5.1 ft • Ib)
9
8
1
7
6
6
2
14
6
2
3
13
15
4
6
5
Order
1
2
Job/Part
Removing the electrical components tray
Front fender/front grill
Battery holding bracket
Battery lead
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “FRONT FENDERS AND
FRONT GRILL”.
1
2
Disconnect.
CAUTION:
First disconnect the negative battery
lead, then disconnect the positive
lead.
3
4
5
6
Battery
Lean angle sensor coupler
Lean angle sensor
EPS control unit coupler
1
1
1
5
3 - 10
Disconnect.
Disconnect.
ELECTRICAL COMPONENTS TRAY
11 12
T.
R.
10
CHK
ADJ
7 Nm (0.7 m • kg, 5.1 ft • Ib)
9
8
1
7
6
6
2
14
6
2
3
13
15
4
6
5
Order
7
8
9
10
11
12
13
14
15
Job/Part
EPS (electric power steering) control
unit
Four-wheel-drive motor relay 3
Rear brake relay
Four-wheel-drive motor relay 2
Four-wheel-drive motor relay 1
Headlight relay
Radiator fan motor coupler
ECU coupler
ECU (engine control unit)
Q’ty
1
1
1
1
1
1
1
1
1
Remarks
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
3 - 11
ELECTRICAL COMPONENTS TRAY
CHK
ADJ
ELECTRICAL COMPONENTS TRAY 2/2
15
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
11
14
19
(4)
10
3
7
8 9
6
5
4
1
12
13
20
2
17
16
T.
R.
Order
1
2
3
4
5
6
7
8
9
10
11
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Job/Part
Removing the electrical components tray
Starter relay coupler
Starter relay
Fuse box
EPS fuse
Main fuse
Spare fuse
Radiator fan motor relay
Fuel injection system relay
Starting circuit cut-off relay
Left handlebar switch coupler
On-command four-wheel-drive motor
switch and differential gear lock switch
coupler
Q’ty
1
1
1
1
1
1
1
1
1
2
2
3 - 12
18
Remarks
Remove the parts in the order listed.
Disconnect.
Disconnect.
Disconnect.
ELECTRICAL COMPONENTS TRAY
CHK
ADJ
15
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
11
14
19
(4)
10
3
7
8 9
6
5
4
1
12
13
20
2
17
16
T.
R.
Order
12
13
14
15
16
17
18
19
20
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Job/Part
Front brake light switch connector
Rear brake light switch connector
Meter assembly coupler
Meter assembly
Frame ground terminal
Ignition coil connector
Differential gear motor coupler
Wire harness
Electrical components tray
Q’ty
2
2
1
1
1
2
1
1
1
18
Remarks
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
3 - 13
FOOTREST BOARDS
CHK
ADJ
EBS00045
FOOTREST BOARDS
T.
R.
(5)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
1
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
(4)
1
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
2
3
2
(5)
(4)
(5)
(4)
(5)
3
T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)
(4)
T.
R.
Order
1
2
3
Job/Part
Removing the footrest boards
Seat/side panels
Footrest
Footrest board
Footrest bracket
Q’ty
53 Nm (5.3 m • kg, 38 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “SEAT AND SIDE PANELS”.
2
2
2
For installation, reverse the removal procedure.
3 - 14
AIR FILTER CASE
CHK
ADJ
AIR FILTER CASE
2
3
1
9
New
10
New
4
5
7
6
8
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the air filter case
Seat/side panels
Air filter case cover
Air filter element
Air filter element frame
Air filter case joint clamp screw
Intake air temperature sensor coupler
Breather hose (air filter case to throttle
body)
Breather hose (air filter case to fast idle
plunger unit)
Cylinder head breather hose
Intake air temperature sensor
Air filter case
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “SEAT AND SIDE PANELS”.
1
1
1
1
1
1
Loosen.
Disconnect.
Disconnect.
1
Disconnect.
1
1
1
Disconnect.
For installation, reverse the removal procedure.
3 - 15
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
EAS00049
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured
or adjusted, the piston must be at top dead
center (TDC) on the compression stroke.
1. Remove:
• left side panel
Refer to “SEAT AND SIDE PANELS”.
• front fender
Refer to “FRONT FENDERS AND FRONT
GRILL”.
• footrest board
Refer to “FOOTREST BOARDS”.
• air filter case
Refer to “AIR FILTER CASE”.
2. Remove:
• fast idle plunger unit 1
1
1
3.
•
•
•
2
3 - 16
Remove:
intake tappet cover 1
exhaust tappet cover
camshaft sprocket cover 2
ADJUSTING THE VALVE CLEARANCE
4.
•
5.
•
1
CHK
ADJ
Disconnect:
spark plug cap 1
Remove:
spark plug 2
2
6. Remove:
• timing mark accessing screw 1
• crankshaft end accessing screw 2
1
2
7. Measure:
• valve clearance
Out of specification → Adjust.
Valve clearance (cold)
Intake valve
0.09 ~ 0.13 mm
(0.0035 ~ 0.0051 in)
Exhaust valve
0.16 ~ 0.20 mm
(0.0063 ~ 0.0079 in)
a
b
d
c
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a. Turn the crankshaft counterclockwise.
b. When the piston is at the top dead center
(TDC) on the compression stroke, align the
“I” mark a on the AC magneto rotor with
the stationary pointer b on the AC magneto
cover.
NOTE:
To position the piston at top dead center (TDC)
on the compression stroke, align the “I” mark
c on the camshaft sprocket with the stationary
pointer d on the cylinder head, as shown in
the illustration.
3 - 17
ADJUSTING THE VALVE CLEARANCE
CHK
ADJ
c. Measure the valve clearance with a thickness gauge 1.
Thickness gauge
90890-03079
Narrow gauge set
YM-34483
1
Out of specification → Adjust.
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8. Adjust:
• valve clearance
4
3
1
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut 1.
b. Insert a thickness gauge 2 between the
end of the adjusting screw and the valve tip.
c. Turn the adjusting screw 3 with the tappet
adjusting tool 4 until the specified valve
clearance is obtained.
Tappet adjusting tool
90890-01311
Valve adjuster 3 mm & 4 mm
YM-08035-A
d. Hold the adjusting screw to prevent it from
moving and tighten the locknut to the specified torque.
T.
Locknut
14 Nm (1.4 m · kg, 10 ft · lb)
R.
e. Measure the valve clearance again.
f. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is
obtained.
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9. Install:
• timing mark accessing screw
T.
R.
6 Nm (0.6 m · kg, 4.3 ft · lb)
• crankshaft end accessing screw
T.
R.
R.
3 - 18
T.
10.Install:
• spark plug
11.Connect:
• spark plug cap
10 Nm (1.0 m · kg, 7.2 ft · lb)
13 Nm (1.3 m · kg, 9.4 ft · lb)
ADJUSTING THE VALVE CLEARANCE/
ADJUSTING THE ENGINE IDLING SPEED
12.Install:
• O-ring New
• camshaft sprocket cover
T.
R.
1
New
CHK
ADJ
10 Nm (1.0 m · kg, 7.2 ft · lb)
• O-ring 1 New
• intake tappet cover
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
• O-ring New
• exhaust tappet cover
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
13.Install:
• fast idle plunger unit
14.Install:
• air filter case
Refer to “AIR FILTER CASE”.
• footrest board
Refer to “FOOTREST BOARDS”.
• front fender
Refer to “FRONT FENDERS AND FRONT
GRILL”.
• left side panel
Refer to “SEAT AND SIDE PANELS”.
EBS00051
ADJUSTING THE ENGINE IDLING SPEED
1. Remove:
• fuel tank cover
Refer to “SEAT AND SIDE PANELS”.
2. Start the engine and let it warm up for several minutes.
3. Attach:
• tachometer
(to the spark plug lead)
Digital tachometer
90890-06760, YU-39951-B
4. Measure:
• engine idling speed
Out of specification → Adjust.
Engine idling speed
1,350 ~ 1,450 r/min
3 - 19
ADJUSTING THE ENGINE IDLING SPEED/
ADJUSTING THE THROTTLE LEVER FREE PLAY
5. Adjust:
• engine idling speed
1
a
CHK
ADJ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b
a. Turn the idle speed adjusting screw 1 in
direction a or b until the specified idling
speed is obtained.
Direction a
Idling speed becomes
higher.
Direction b
Idling speed becomes
lower.
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6.
•
7.
•
Detach:
tachometer
Adjust:
throttle lever free play
Refer to “ADJUSTING THE THROTTLE
LEVER FREE PLAY”.
Throttle lever free play
3.0 ~ 5.0 mm (0.12 ~ 0.20 in)
8. Install:
• fuel tank cover
Refer to “SEAT AND SIDE PANELS”.
EBS00052
ADJUSTING THE THROTTLE LEVER FREE
PLAY
NOTE:
Engine idling speed should be adjusted properly before adjusting the throttle lever free
play.
_
1. Measure:
• throttle lever free play a
Out of specification → Adjust.
Throttle lever free play
3.0 ~ 5.0 mm (0.12 ~ 0.20 in)
2. Remove:
• left side panel
Refer to “SEAT AND SIDE PANELS”.
3 - 20
ADJUSTING THE THROTTLE LEVER FREE PLAY
3. Adjust:
• throttle lever free play
b
2
1
3 a
CHK
ADJ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
First step:
a. Slide back the rubber cover 1.
b. Loosen the locknut 2 on the throttle body
side.
c. Turn the adjusting nut 3 in direction a or
b until the correct free play is obtained.
Direction a
Free play is increased.
Direction b
Free play is decreased.
d. Tighten the locknut.
e. Slide the rubber cover to its original position.
NOTE:
If the free play cannot be adjusted here, adjust
it at the throttle lever side of the cable.
_
Second step:
f. Slide back the rubber cover 4.
g. Loosen the locknut 5.
h. Turn the adjusting bolt 6 in direction c or
d until the correct free play is obtained.
Direction c
Free play is increased.
Direction d
Free play is decreased.
i. Tighten the locknut.
j. Slide the rubber cover to its original position.
WARNING
_
After adjusting the free play, turn the handlebar to the right and left to make sure
that the engine idling speed does not
increase.
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4. Install:
• left side panel
Refer to “SEAT AND SIDE PANELS”.
3 - 21
ADJUSTING THE SPEED LIMITER
CHK
ADJ
EBS00053
ADJUSTING THE SPEED LIMITER
The speed limiter keeps the throttle from
becoming fully-opened even when the throttle
lever is applied to the maximum position.
Screwing in the adjusting screw stops the
engine speed from increasing.
1. Measure:
• speed limiter length a
Out of specification → Adjust.
Speed limiter length
Less than 12 mm (0.47 in)
2. Adjust:
• speed limiter length
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a. Loosen the locknut 1.
b. Turn the adjuster 2 in direction b or c
until the specified speed limiter length is
obtained.
Direction b
Speed limiter length is
decreased.
Direction c
Speed limiter length is
increased.
c. Tighten the locknut.
WARNING
_
• Particularly for a beginner rider, the
speed limiter should be screwed in completely. Screw it out little by little as their
riding technique improves. Never remove
the speed limiter for a beginning rider.
• For proper throttle lever operation do not
turn out the adjuster more than 12 mm
(0.47 in). Also, always adjust the throttle
lever free play to 3.0 ~ 5.0 mm (0.12 ~
0.20 in).
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3 - 22
CHECKING THE SPARK PLUG
CHK
ADJ
EBS00057
CHECKING THE SPARK PLUG
1. Remove:
• right side panel
Refer to “SEAT AND SIDE PANELS”.
2. Disconnect:
• spark plug cap
3. Remove:
• spark plug
4. Check:
• spark plug type
Incorrect → Change.
Standard spark plug
CR8E/NGK
5. Check:
• electrode 1
Wear/damage → Replace.
• insulator 2
Abnormal color → Replace.
Normal color is a medium-to-light tan color.
6. Clean:
• spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
• spark plug gap a
Use a wire gauge or thickness gauge.
Out of specification → Regap.
Spark plug gap
0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
T.
R.
8. Tighten:
• spark plug
13 Nm (1.3 m · kg, 9.4 ft · lb)
NOTE:
Before installing a spark plug, clean the gasket
surface and plug surface.
_
9. Connect:
• spark plug cap
10.Install:
• right side panel
Refer to “SEAT AND SIDE PANELS”.
3 - 23
CHECKING THE IGNITION TIMING
CHK
ADJ
EBS00058
CHECKING THE IGNITION TIMING
NOTE:
Engine idling speed and throttle cable free play
should be adjusted properly before checking
the ignition timing.
_
1. Remove:
• left side panel
• right side panel
Refer to “SEAT AND SIDE PANELS”.
• footrest board
Refer to “FOOTREST BOARDS”.
2. Attach:
• tachometer
• timing light
(to spark plug lead)
Digital tachometer
90890-06760, YU-39951-B
Timing light
90890-03141
Inductive clamp timing light
YU-03141
3. Check:
• ignition timing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Warm up the engine and keep it at the
specified speed.
1
Engine speed
1,350 ~ 1,450 r/min
b. Remove the timing mark accessing screw
1.
3 - 24
CHECKING THE IGNITION TIMING/
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
c. Visually check the stationary pointer a to
verify it is within the required firing range b
indicated on the AC magneto rotor.
Incorrect firing range → Check the pulser
coil assembly.
b
a
NOTE:
When checking the ignition timing, make sure
that the timing light cord does not come in contact with the exhaust muffler.
d. Install the timing mark accessing screw.
T.
Timing mark accessing screw
6 Nm (0.6 m · kg, 4.3 ft · lb)
R.
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4.
•
•
5.
•
Detach:
timing light
tachometer
Install:
footrest board
Refer to “FOOTREST BOARDS”.
• right side panel
• left side panel
Refer to “SEAT AND SIDE PANELS”.
EBS00061
MEASURING THE COMPRESSION
PRESSURE
NOTE:
Insufficient compression pressure will result in
a loss of performance.
_
1. Measure:
• valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE
CLEARANCE”.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Remove:
• right side panel
Refer to “SEAT AND SIDE PANELS”.
• V-belt cooling duct 2
Refer to “ENGINE REMOVAL” in chapter 4.
3 - 25
MEASURING THE COMPRESSION PRESSURE
4.
•
5.
•
CHK
ADJ
Disconnect:
spark plug cap
Remove:
spark plug
CAUTION:
_
Before removing a spark plug, use compressed air to blow away any dirt accumulated in the spark plug well to prevent it
from falling into the cylinder.
2
1
6. Attach:
• extension 1
• compression gauge 2
Compression gauge
90890-03081
Engine compression tester
YU-33223
Extension
90890-04082
7. Measure:
• compression pressure
Out of specification → Refer to steps (c)
and (d).
Compression pressure (at sea
level)
Minimum
392 kPa (3.92 kg/cm2, 55.8 psi)
Standard
450 kPa (4.50 kg/cm2, 64.0 psi)
Maximum
504 kPa
(5.04 kg/cm2, 71.7 psi)
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a. Set the main switch to “ON”.
3 - 26
MEASURING THE COMPRESSION PRESSURE
CHK
ADJ
b. With the throttle wide open, crank the
engine until the reading on the compression
gauge stabilizes.
WARNING
_
To prevent sparking, ground the spark plug
lead before cranking the engine.
c. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces and piston crown for
carbon deposits.
Carbon deposits → Eliminate.
d. If the compression pressure is below the
minimum specification, squirt a few drops of
oil into the cylinder and measure again.
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading
Diagnosis
Higher than
without oil
Piston ring(s) wear
or damage →
Repair.
Same as without
oil
Piston, valves,
cylinder head
gasket or piston
rings possibly
defective → Repair.
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T.
8. Install:
• spark plug
13 Nm (1.3 m · kg, 9.4 ft · lb)
9. Connect:
• spark plug cap
10.Install:
• V-belt cooling duct 2
Refer to “ENGINE REMOVAL” in chapter 4.
• right side panel
Refer to “SEAT AND SIDE PANELS”.
R.
3 - 27
CHECKING THE ENGINE OIL LEVEL
CHK
ADJ
EBS00064
CHECKING THE ENGINE OIL LEVEL
1. Place the vehicle on a level surface.
2. Check the engine oil level on a cold engine.
NOTE:
If the engine was started before checking the
oil level, be sure to warm up the engine sufficiently, and then wait at least 10 minutes until
the oil settles for an accurate reading.
_
3. Remove:
• dipstick accessing panel
Refer to “SEAT AND SIDE PANELS”.
4. Check:
• engine oil level
Oil level should be between the minimum
level mark a and maximum level mark b.
Oil level low → Add oil to the proper level.
NOTE:
To obtain an accurate oil level reading, the dipstick must be inserted completely into the oil
filter hole.
b
a
0˚
10˚
30˚
50˚
70˚
90˚
110˚
Recommended engine oil type
YAMALUBE 4, SAE5W30,
SAE10W30 or SAE20W40
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
130˚F
YAMALUBE 4 (20W40) or SAE 20W40
YAMALUBE 4 (10W30) or SAE 10W30
SAE 5W30
-20˚
-10˚
0˚
10˚
20˚
30˚
40˚
CAUTION:
50˚C
Do not allow foreign material to enter the
crankcase.
5. Check the engine oil level again.
CAUTION:
Be sure the engine oil is at the correct
level, otherwise engine damage may result.
3 - 28
CHECKING THE ENGINE OIL LEVEL/
CHANGING THE ENGINE OIL
CHK
ADJ
6. Install:
• dipstick accessing panel
Refer to “SEAT AND SIDE PANELS”.
EBS00069
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several minutes, and then turn it off.
2. Place a container under the engine oil drain
bolt.
3. Remove:
• dipstick accessing panel
Refer to “SEAT AND SIDE PANELS”.
4. Remove:
• dipstick 1
1
1
5. Remove:
• engine oil drain bolt 1
(along with the gasket)
6. Drain:
• engine oil
(completely from the crankcase)
7. If the oil filter cartridge is also to be
replaced, perform the following procedure.
2
1
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a. Remove the oil filter cartridge 1 with an oil
filter wrench 2.
Oil filter wrench
90890-01426, YU-38411
3 - 29
CHANGING THE ENGINE OIL
CHK
ADJ
b. Lubricate the O-ring 3 of the new oil filter
cartridge with a thin coat of engine oil.
CAUTION:
_
Make sure the O-ring 3 is positioned correctly in the groove of the oil filter cartridge.
c. Tighten the new oil filter cartridge to specification with an oil filter wrench.
T.
Oil filter cartridge
17 Nm (1.7 m · kg, 12 ft · lb)
R.
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8. Check:
• engine oil drain bolt gasket
Damage → Replace.
9. Install:
• engine oil drain bolt
(along with the gasket)
T.
R.
30 Nm (3.0 m · kg, 22 ft · lb)
10.Fill:
• crankcase
(with the specified amount of the recommended engine oil)
Quantity
Total amount
2.40 L (2.11 Imp qt, 2.54 US qt)
Without oil filter cartridge
replacement
2.00 L (1.76 Imp qt, 2.11 US qt)
With oil filter cartridge replacement
2.10 L (1.85 Imp qt, 2.22 US qt)
11.Install:
• dipstick
12.Start the engine, warm it up for several minutes, and then turn it off.
13.Check:
• engine
(for engine oil leaks)
14.Check:
• engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
3 - 30
CHANGING THE ENGINE OIL/
CLEANING THE AIR FILTER ELEMENT
CHK
ADJ
15.Check:
• engine oil pressure
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slightly loosen the oil gallery bolt 1.
b. Start the engine and keep it idling until
engine oil starts to seep from the oil gallery
bolt. If no engine oil comes out after one
minute, turn the engine off so that it will not
seize.
c. Check the engine oil passages, the oil filter
cartridge and the oil pump for damage or
leakage. Refer to “CRANKSHAFT AND OIL
PUMP” in chapter 4.
d. Start the engine after solving the problem(s)
and check the engine oil pressure again.
e. Tighten the oil gallery bolt to specification.
T.
Oil gallery bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)
R.
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EBS00073
CLEANING THE AIR FILTER ELEMENT
1. Remove:
• fuel tank cover
• left side panel
• right side panel
Refer to “SEAT AND SIDE PANELS”.
1
NOTE:
There are two check hoses 1 at the bottom of
the air filter case. If dust and/or water collects
in them, clean the air filter element, air filter
mesh and air filter case.
_
1
3 - 31
CLEANING THE AIR FILTER ELEMENT
1
CHK
ADJ
2. Remove:
• air filter case cover 1
3. Remove:
• air filter element 1
• air filter element frame 2
CAUTION:
_
The engine should never be run without the
air filter; excessive piston and/or cylinder
wear may result.
4. Check:
• air filter element
• air filter element frame
Damage → Replace.
5. Clean:
• air filter element
Use compressed air to blow off dust from
the inner surface of the element.
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a. Wash the element gently, but thoroughly in
solvent.
WARNING
_
Use a cleaning solvent which is designed
to clean parts only. Never use gasoline or
low flash point solvents as they may cause
a fire or explosion.
b. Squeeze the excess solvent out of the element and let it dry.
CAUTION:
_
Do not twist or wring out the element. This
could damage the foam material.
c. Apply Yamaha foam air filter oil or other
quality foam air filter oil to the element.
3 - 32
CLEANING THE AIR FILTER ELEMENT/
CHECKING THE THROTTLE BODY JOINT
CHK
ADJ
d. Squeeze out the excess oil.
NOTE:
The element should be wet but not dripping.
_
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6. Install:
• air filter element frame
• air filter element
NOTE:
Make sure its sealing surface matches the
sealing surface of the case so there is no air
leak.
_
7.
•
8.
•
•
•
Install:
air filter case cover
Install:
right side panel
left side panel
fuel tank cover
Refer to “SEAT AND SIDE PANELS”.
EAS00094
1
CHECKING THE THROTTLE BODY JOINT
1. Remove:
• left side panel
Refer to “SEAT AND SIDE PANELS”.
2. Check:
• throttle body joint 1
Cracks/damage → Replace.
Refer to “THROTTLE BODY” in chapter 6.
3. Install:
• left side panel
Refer to “SEAT AND SIDE PANELS”.
3 - 33
CHECKING THE FUEL HOSE/
CHECKING THE BREATHER HOSES
CHK
ADJ
EAS00096
CHECKING THE FUEL HOSE
1. Remove:
• seat
• right side panel
Refer to “SEAT AND SIDE PANELS”.
• rear fender
Refer to “REAR CARRIER AND REAR
FENDER”.
• V-belt cooling duct 2
Refer to “ENGINE REMOVAL” in chapter 4.
2. Check:
• fuel hose 1
Cracks/damage → Replace.
Loose connection → Connect properly.
3. Install:
• V-belt cooling duct 2
Refer to “ENGINE REMOVAL” in chapter 4.
• rear fender
Refer to “REAR CARRIER AND REAR
FENDER”.
• right side panel
• seat
Refer to “SEAT AND SIDE PANELS”.
1
EAS00098
1
3
2
CHECKING THE BREATHER HOSES
1. Remove:
• left side panel
Refer to “SEAT AND SIDE PANELS”.
• air filter case
Refer to “AIR FILTER CASE”.
2. Check:
• cylinder head breather hose 1
• breather hose (air filter case to throttle
body) 2
• breather hose (air filter case to fast idle
plunger unit) 3
Cracks/damage → Replace.
Loose connection → Connect properly.
CAUTION:
Make sure the breather hoses are routed
correctly.
3 - 34
CHECKING THE COOLANT LEVEL/
CHANGING THE COOLANT
CHK
ADJ
EBS00076
CHECKING THE COOLANT LEVEL
1. Place the vehicle on a level surface.
NOTE:
The coolant level must be checked on a cold
engine since the level varies with engine temperature.
2. Check:
• coolant level
The coolant level should be between the
minimum level mark a and maximum level
mark b in the coolant reservoir.
CAUTION:
_
• Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant, check
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However, soft
water may be used if distilled water is not
available.
3. If the coolant is at or below the minimum
level mark, remove the left side panel.
Refer to “SEAT AND SIDE PANELS”.
1
FULL
4. Remove the reservoir cap 1, add coolant
or distilled water to the maximum level mark
a, install the reservoir cap, and then install
the panel.
a
Coolant reservoir capacity (up to
the maximum level mark):
0.17 L (0.15 Imp qt, 0.18 US qt)
LO W
EBS00075
CHANGING THE COOLANT
1. Remove:
• right side panel
• left side panel
Refer to “SEAT AND SIDE PANELS”.
• front carrier
• upper panel
Refer to “FRONT CARRIER AND FRONT
GUARD”.
3 - 35
CHANGING THE COOLANT
CHK
ADJ
2.
•
3.
•
4.
•
Remove:
coolant reservoir cap 1
Disconnect:
coolant reservoir hose 2
Drain:
coolant
(from the coolant reservoir)
5. Connect:
• coolant reservoir hose
1
2
6. Remove:
• radiator cap 1
1
WARNING
_
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the
engine is hot. Scalding hot fluid and steam
may be blown out, which could cause serious injury. When the engine has cooled,
open the radiator cap as follows:
Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap
counterclockwise toward the detent to
allow any residual pressure to escape.
When the hissing sound has stopped,
press down on the radiator cap and turn it
counterclockwise to remove.
1
7. Remove:
• coolant drain bolt 1
(along with the copper washer)
8. Drain:
• coolant
(from the engine and radiator)
9. Check:
• coolant drain bolt 1
Damage → Replace.
10.Install:
• copper washer 2 New
• coolant drain bolt
T.
R.
3 - 36
10 Nm (1.0 m · kg, 7.2 ft · lb)
CHANGING THE COOLANT
CHK
ADJ
11.Fill:
• cooling system
(with the specified amount of the recommended coolant)
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Quantity
Total amount
1.99 L
(1.75 Imp qt, 2.10 US qt)
Coolant reservoir capacity (up
to the maximum level mark)
0.17 L
(0.15 Imp qt, 0.18 US qt)
From minimum to maximum
level mark
0.14 L
(0.12 Imp qt, 0.15 US qt)
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
WARNING
_
• If coolant splashes in your eyes, thoroughly wash them with water and consult
a doctor.
• If coolant splashes on your clothes,
quickly wash it away with water and then
with soap and water.
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
CAUTION:
_
• Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant, check,
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However, if distilled water is not available, soft water
may be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with
water.
• Do not mix different types of antifreeze.
3 - 37
CHANGING THE COOLANT
12.Fill:
• coolant reservoir
(with the recommended coolant to the maximum level mark a)
13.Install:
• coolant reservoir cap 1
1
FULL
CHK
ADJ
a
LOW
1
14.Bleed:
• coolant system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the V-belt cooling duct 2 1.
b. Loosen the water pump air bleed bolt 2,
without removing it, to allow all of the air to
escape from the air bleed bolt hole.
c. When coolant begins to flow out of the bolt
hole, tighten the water pump air bleed bolt
to specification.
T.
2
Water pump air bleed bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)
R.
d. Loosen the cylinder head air bleed bolt 3,
without removing it, to allow all of the air to
escape from the air bleed bolt hole.
e. When coolant begins to flow out of the bolt
hole, tighten the cylinder head air bleed bolt
to specification.
T.
Cylinder head air bleed bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)
R.
3
f. Install the V-belt cooling duct 2.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
15.Start the engine, warm it up for ten minutes,
and then rev the engine five times.
16.Pour the recommended coolant into the
radiator until it is full.
17.Stop the engine and allow it to cool. If the
coolant level has dropped after the engine
has cooled, add sufficient coolant until it
reaches the top of the radiator, and then
install the radiator cap.
18.Start the engine, and then check for coolant
leakage.
3 - 38
CHANGING THE COOLANT/
CHECKING THE COOLING SYSTEM
CHK
ADJ
19.Install:
• upper panel
• front carrier
Refer to “FRONT CARRIER AND FRONT
GUARD”.
• left side panel
• right side panel
Refer to “SEAT AND SIDE PANELS”.
EAS00104
CHECKING THE COOLING SYSTEM
1. Remove:
• front fenders
Refer to “FRONT FENDERS AND FRONT
GRILL”.
• left footrest board
Refer to “FOOTREST BOARDS”.
2.
•
•
•
•
•
•
•
•
•
Check:
radiator 1
radiator inlet hose 2
coolant reservoir 3
coolant reservoir hose 4
radiator outlet hose 5
water jacket 6
water pump outlet hose 7
water pump outlet pipe 8
water pump housing 9
Cracks/damage → Replace.
Refer to “COOLING SYSTEM” in chapter 5.
3. Install:
• left footrest board
Refer to “FOOTREST BOARDS”.
• front fenders
Refer to “FRONT FENDERS AND FRONT
GRILL”.
2
3
4
1
5
7
6
9
8
3 - 39
CHECKING THE COOLANT TEMPERATURE WARNING
LIGHT
CHK
ADJ
EBS00077
1
CHECKING THE COOLANT TEMPERATURE
WARNING LIGHT
1 Coolant temperature warning light
Coolant temperature warning light checking method
Turn the main switch “ON” and the
engine stop switch to “RUN”.
Coolant temperature warning
light does not come on.
Coolant temperature warning
light comes on.
Push start switch with transmission
in “neutral”.
Coolant
temperature
warning light comes on
momentarily.
Coolant temperature and
electrical circuit are OK.
Go ahead with riding.
Coolant temperature warning
light does not come on.
Check the electrical circuit. Refer to
“SIGNALING SYSTEM” in chapter 9.
3 - 40
CHECKING THE V-BELT
CHK
ADJ
EBS00078
CHECKING THE V-BELT
1. Remove:
• drive belt cover
Refer to “PRIMARY AND SECONDARY
SHEAVES” in chapter 4.
2. Check:
• V-belt 1
Cracks/wear/scaling/chipping → Replace.
Oil/grease → Check primary sheave and
secondary sheave.
3. Measure:
• V-belt width 2
Out of specification → Replace.
V-belt width
31.7 mm (1.25 in)
<Limit>: 31.3 mm (1.23 in)
4. Replace:
• V-belt
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the bolts 1 (90101-06016) into the
secondary fixed sheave hold.
NOTE:
Tightening the bolts 1 will push the secondary
sliding sheave away, causing the gap between
the secondary fixed and sliding sheaves to
widen.
_
b. Remove the V-belt 1 from the primary
sheave and secondary sheave.
3 - 41
CHECKING THE V-BELT/
CHECKING THE EXHAUST SYSTEM
CHK
ADJ
c. Install the V-belt.
NOTE:
Install the V-belt so that its arrow faces the
direction shown in the illustration.
_
d. Remove the bolts.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00099
9
8
0
3
8
2 5
1
6
4
6
5
7
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the
exhaust pipe gaskets.
1. Check:
• exhaust pipe 1
• muffler 2
• exhaust pipe protector 3
• muffler bracket 4
• springs 5
Cracks/damage → Replace.
• gaskets 6
Exhaust gas leaks → Replace.
2. Check:
• tightening torques
T.
R.
3 - 42
Exhaust pipe nut 7
20 Nm (2.0 m · kg, 14 ft · lb)
Muffler and muffler bracket bolt 8
20 Nm (2.0 m · kg, 14 ft · lb)
Muffler bolt 9
20 Nm (2.0 m · kg, 14 ft · lb)
Exhaust pipe protector bolt 0
7 Nm (0.7 m · kg, 5.1 ft · lb)
CLEANING THE SPARK ARRESTER
CHK
ADJ
CLEANING THE SPARK ARRESTER
1. Clean:
• spark arrester
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
WARNING
• Select a well-ventilated area free of combustible materials.
• Always let the exhaust system cool
before performing this operation.
• Do not start the engine when removing
the tailpipe from the muffler.
• Make sure that the transmission is in neutral.
1
a. Remove the bolts 1.
b. Remove the tailpipe 2 by pulling it out of
the muffler and the gasket.
c. Tap the tailpipe lightly with a soft-face hammer or suitable tool, then use a wire brush
to remove any carbon deposits from the
spark arrester portion of the tailpipe and
inside of the tail pipe housing.
d. Install the gasket, and then insert the
tailpipe into the muffler and align the bolt
holes.
e. Insert the bolts 1 and tighten them.
2
2
T.
Bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)
R.
f. Remove the purging bolt 3.
g. Start the engine and rev it up approximately
twenty times while momentarily creating
exhaust system back pressure by blocking
the end of the muffler with a shop towel.
h. Stop the engine and allow the exhaust pipe
to cool.
i. Install the purging bolt 3 and tighten it.
3
T.
Purging bolt
27 Nm (2.7 m · kg, 19 ft · lb)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 43
ADJUSTING THE FRONT BRAKE/
ADJUSTING THE REAR BRAKE
CHK
ADJ
EBS00080
a
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Measure:
• front brake lever free play a
Out of specification → Bleed the front brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM”.
Front brake lever free play
(at the end of the brake lever)
0 mm (0 in)
EBS00085
ADJUSTING THE REAR BRAKE
a
WARNING
_
Always adjust both the brake pedal and the
rear brake lever whenever adjusting the
rear brake.
1. Measure:
• rear brake lever free play a
Out of specification → Bleed the rear brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM”.
Rear brake lever free play (at the
end of the brake lever)
0 mm (0 in)
2. Measure:
• brake pedal free play b
Out of specification → Adjust.
Brake pedal free play
0 ~ 5.0 mm (0 ~ 0.20 in)
b
3 - 44
ADJUSTING THE REAR BRAKE
CHK
ADJ
3. Measure:
• brake pedal height c
Out of specification → Adjust.
Brake pedal height
56.7 mm (2.23 in)
d Measuring points
4.
•
•
5.
•
Adjust:
brake pedal free play
brake pedal height
Remove:
front fender inner panel
Refer to “FRONT FENDERS AND FRONT
GRILL”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut 1.
b. Turn the adjusting bolt 2 until the brake
pedal height is within the specified limits.
Brake pedal height
56.7 mm (2.23 in)
2
c. Tighten the locknut 1.
3
4
a
R.
b
T.
1
Locknut
7 Nm (0.7 m · kg, 5.1 ft · lb)
d. Loosen the locknut 3.
e. Turn the adjusting nut 4 in direction a or
b until the specified brake pedal free play is
obtained.
Direction a
Brake pedal free play is
increased.
Direction b
Brake pedal free play is
decreased.
f. Tighten the locknut 3.
T.
R.
3 - 45
Locknut
7 Nm (0.7 m · kg, 5.1 ft · lb)
ADJUSTING THE REAR BRAKE/
CHECKING THE BRAKE FLUID LEVEL
CHK
ADJ
g. Adjust the shift control cable.
Refer to “ADJUSTING THE SELECT
LEVER CONTROL CABLE AND SHIFT
ROD”.
WARNING
_
After this adjustment is performed, lift the
front and rear wheels off the ground by
placing a block under the engine, and spin
the rear wheels to ensure there is no brake
drag. If any brake drag is noticed perform
the above steps again.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• front fender inner panel
Refer to “FRONT FENDERS AND FRONT
GRILL”.
EBS00087
CHECKING THE BRAKE FLUID LEVEL
1. Place the vehicle on a level surface.
NOTE:
When checking the brake fluid level, make
sure that the top of the brake fluid reservoir top
is horizontal.
_
È
a
2. Check:
• brake fluid level
Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Recommended brake fluid
DOT 4
È Front brake
É Rear brake
É
WARNING
_
a
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
3 - 46
CHECKING THE BRAKE FLUID LEVEL/
CHECKING THE FRONT BRAKE PADS
CHK
ADJ
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
CAUTION:
_
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the
brake fluid level, make sure that the top of the
brake master cylinder reservoir is horizontal.
_
EBS00088
a
CHECKING THE FRONT BRAKE PADS
1. Remove:
• front wheels
Refer to “FRONT AND REAR WHEELS” in
chapter 8.
2. Check:
• brake pads
Wear indicator groove a almost disappeared → Replace the brake pads as a set.
Refer to “FRONT AND REAR BRAKES” in
chapter 8.
Brake pad wear limit a
1.0 mm (0.04 in)
3. Operate the brake lever.
4. Install:
• front wheels
Refer to “FRONT AND REAR WHEELS” in
chapter 8.
3 - 47
CHECKING THE REAR BRAKE PADS/
CHECKING THE REAR BRAKE HOSE PROTECTORS
CHK
ADJ
EBS00089
a
CHECKING THE REAR BRAKE PADS
1. Remove:
• rear wheels
Refer to “FRONT AND REAR WHEELS” in
chapter 8.
2. Check:
• brake pads
Wear indicator groove a almost disappeared → Replace the brake pads as a set.
Refer to “FRONT AND REAR BRAKES” in
chapter 8.
Brake pad wear limit a
1.0 mm (0.04 in)
3. Operate the brake lever or brake pedal.
4. Install:
• rear wheels
Refer to “FRONT AND REAR WHEELS” in
chapter 8.
1
2
CHECKING THE REAR BRAKE HOSE
PROTECTORS
1. Remove:
• rear wheels
Refer to “FRONT AND REAR WHEELS” in
chapter 8.
2. Check:
• rear brake hose protectors 1
Wear indicator 2 becomes visible →
Replace the rear brake hose protector.
Refer to “REAR KNUCKLES AND STABILIZER” in chapter 8.
3. Install:
• rear wheels
Refer to “FRONT AND REAR WHEELS” in
chapter 8.
3 - 48
CHECKING THE BRAKE HOSES/
BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
EBS00092
CHECKING THE BRAKE HOSES
1. Check:
• front brake hoses 1
• rear brake hoses 2
Cracks/wear/damage → Replace.
2. Check:
• brake hose holders
Loosen → Tighten.
3. Hold the vehicle in an upright position and
apply the front or rear brake.
4. Check:
• brake hoses
Apply the brake lever several times.
Fluid leakage → Replace the hoses.
Refer to “FRONT AND REAR BRAKES” in
chapter 8.
1
2
1
2
1
2
EBS00094
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
_
Bleed the hydraulic brake system whenever:
• the system is disassembled,
• a brake hose is loosened, disconnected
or replaced,
• the brake fluid level is very low,
• brake operation is faulty.
NOTE:
• Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir to overflow.
_
3 - 49
BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
• When bleeding the hydraulic brake system,
make sure there is always enough brake
fluid before applying the brake. Ignoring this
precaution could allow air to enter the
hydraulic brake system, considerably lengthening the bleeding procedure.
• If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
1. Remove:
• rear wheel
Refer to “FRONT AND REAR WHEELS” in
chapter 8.
2. Bleed:
• hydraulic brake system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
È
2
1
a. Fill the brake master cylinder reservoir to
the proper level with the recommended
brake fluid.
b. Install the diaphragm (brake master cylinder
reservoir).
c. Connect a clear plastic hose 1 tightly to the
bleed screw 2.
È Front
É Rear
d. Place the other end of the hose into a container.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully
depress the brake pedal and hold it in position.
g. Loosen the bleed screw.
É
2
NOTE:
Loosening the bleed screw will release the
pressure and cause the brake lever to contact
the handlebar grip or the brake pedal to fully
extend.
_
1
h. Tighten the bleed screw and then release
the brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
T.
R.
3 - 50
Bleed screw
5 Nm (0.5 m · kg, 3.6 ft · lb)
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ADJUSTING THE
SELECT LEVER CONTROL CABLE AND SHIFT ROD
CHK
ADJ
k. Fill the brake master cylinder reservoir to
the proper level with the recommended
brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
WARNING
_
After bleeding the hydraulic brake system,
check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• rear wheel
Refer to “FRONT AND REAR WHEELS” in
chapter 8.
EBS00100
2
3
1
4
ADJUSTING THE SELECT LEVER
CONTROL CABLE AND SHIFT ROD
5
7
1 NEUTRAL
2 HIGH
3 LOW
4 REVERSE
5 PARK
6 Control cable
7 Select lever shift rod
WARNING
_
6
Before moving the select lever, bring the
vehicle to a complete stop and return the
throttle lever to its closed position. Otherwise the transmission may be damaged.
1. Adjust:
• brake pedal free play
Refer to “ADJUSTING THE REAR BRAKE”.
2. Remove:
• left side panel
Refer to “SEAT AND SIDE PANELS”.
3 - 51
ADJUSTING THE SELECT LEVER CONTROL CABLE
AND SHIFT ROD
CHK
ADJ
3. Adjust:
• shift control cable
• shift rod
a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
3
Shift control cable:
a. Make sure that the select lever is in NEUTRAL.
b. Squeeze the brake lever 30 mm (1.18 in) a,
loosen the locknut 1, and then adjust the
shift control cable 2 with the adjuster 3 so
that the select lever can be shifted to
REVERSE from NEUTRAL, and to PARK
from REVERSE.
c. Release the brake lever so that a is 0 mm
(0 in), and then verify that the select lever
cannot be shifted to REVERSE from NEUTRAL, or to PARK from REVERSE.
d. If the operation of the select lever is incorrect, repeat steps (a) to (c).
e. Tighten the locknut.
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a
1
Shift rod:
a. Make sure that the select lever and transmission are in HIGH.
b. Loosen both locknuts 1.
c. Adjust the length a of the shift rod to
413 mm (16.3 in).
d. Tighten the locknuts.
T.
Locknut
15 Nm (1.5 m · kg, 11 ft · lb)
R.
e. Start the engine, and then check that the
select lever can be shifted to each shift
position and that the appropriate indicator
light comes on when the lever is in each
position.
f. Adjust the shift control cable again.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 52
CHECKING THE FINAL GEAR OIL LEVEL/
CHANGING THE FINAL GEAR OIL
CHK
ADJ
EBS00101
1
2
CHECKING THE FINAL GEAR OIL LEVEL
1. Place the vehicle on a level place.
2. Remove:
• final gear oil level check bolt 1
3. Check:
• oil level
Oil level should be up to the bottom brim 2
of the hole.
Oil level low → Add oil to the proper level.
Recommended oil
SAE80 API GL-4 Hypoid gear oil
CAUTION:
_
Take care not allow foreign material to
enter the final gear case.
4. Install:
• final gear oil level check bolt
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
EBS00102
1
CHANGING THE FINAL GEAR OIL
1. Place the vehicle on a level surface.
2. Remove:
• final gear oil filler bolt 1
3. Place a receptacle under the final gear
case.
4.
•
•
5.
•
1
3 - 53
Remove:
final gear oil level check bolt
final gear oil drain bolt 1
Drain:
final gear oil
CHANGING THE FINAL GEAR OIL
CHK
ADJ
6. Install:
• final gear oil drain bolt
T.
R.
23 Nm (2.3 m · kg, 17 ft · lb)
NOTE:
Check the gasket (drain bolt). If it is damaged,
replace it with a new one.
_
7. Fill:
• final gear case
Periodic oil change
0.20 L (0.18 Imp qt, 0.21 US qt)
Total amount
0.25 L (0.22 Imp qt, 0.26 US qt)
Recommended oil
SAE80 API GL-4 Hypoid gear oil
CAUTION:
_
Take care not to allow foreign material to
enter the final gear case.
8. Check:
• oil level
Refer to “CHECKING THE FINAL GEAR
OIL LEVEL”.
9. Install:
• final gear oil level check bolt
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
• final gear oil filler bolt
T.
R.
3 - 54
23 Nm (2.3 m · kg, 17 ft · lb)
CHECKING THE DIFFERENTIAL GEAR OIL LEVEL/
CHANGING THE DIFFERENTIAL GEAR OIL
CHK
ADJ
EBS00103
1
2
CHECKING THE DIFFERENTIAL GEAR OIL
LEVEL
1. Place the vehicle on a level surface.
2. Remove:
• differential gear oil filler bolt 1
3. Check:
• oil level
Oil level should be up to the brim 2 of hole.
Oil level low → Add oil to proper level.
Recommended oil
SAE80 API GL-4 Hypoid gear oil
CAUTION:
_
Take care not allow foreign material to
enter the differential gear case.
4. Install:
• differential gear oil filler bolt
T.
R.
23 Nm (2.3 m · kg, 17 ft · lb)
EBS00104
CHANGING THE DIFFERENTIAL GEAR OIL
1. Place the vehicle on a level surface.
2. Place a receptacle under the differential
gear case.
1
3.
•
•
4.
•
5.
•
Remove:
differential gear oil filler bolt
differential gear oil drain bolt 1
Drain:
differential gear oil
Install:
differential gear oil drain bolt
T.
R.
3 - 55
10 Nm (1.0 m · kg, 7.2 ft · lb)
CHANGING THE DIFFERENTIAL GEAR OIL/CHECKING
THE CONSTANT VELOCITY JOINT DUST BOOTS
CHK
ADJ
6. Fill:
• differential gear case
Periodic oil change
0.215 L (0.19 Imp qt, 0.23 US qt)
Total amount
0.23 L (0.20 Imp qt, 0.24 US qt)
Recommended oil
SAE80 API GL-4 Hypoid gear oil
NOTE:
If gear oil is filled to the brim of the oil filler
hole, oil may start leaking from the differential
gear case breather hose. Therefore, check the
quantity of the oil, not its level.
_
CAUTION:
_
Take care not to allow foreign material to
enter the differential gear case.
7. Install:
• differential gear oil filler bolt
T.
R.
23 Nm (2.3 m · kg, 17 ft · lb)
EBS00105
È
1
1
CHECKING THE CONSTANT VELOCITY
JOINT DUST BOOTS
1. Check:
• dust boots 1
Damage → Replace.
Refer to “FRONT CONSTANT VELOCITY
JOINTS AND DIFFERENTIAL GEAR” and
“REAR CONSTANT VELOCITY JOINTS
AND FINAL DRIVE GEAR” in chapter 7.
È Front
É Rear
É
1
1
3 - 56
CHECKING THE STEERING SYSTEM
CHK
ADJ
EBS00106
CHECKING THE STEERING SYSTEM
1. Place the vehicle on a level surface.
2. Check:
• steering assembly bushings
Move the handlebar up and down, and/or
back and forth.
Excessive play → Replace the steering
stem bushings.
3. Check:
• tie-rod ends
Turn the handlebar to the left and/or right
until it stops completely, then move the handlebar from the left to the right slightly.
Tie-rod end has any vertical play →
Replace the tie-rod end(s).
4. Raise the front end of the vehicle so that
there is no weight on the front wheels.
5. Check:
• ball joints and/or wheel bearings
Move the wheels laterally back and forth.
Excessive free play → Replace the front
arms (upper and lower) and/or wheel bearings.
6. Measure:
• steering tension
Above specification → Adjust.
Steering tension
50 N (5.0 kgf)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
a. Turn the main switch to “OFF”.
b. Place the vehicle on a suitable stand so that
the front wheels are elevated.
c. Point the front wheels straight ahead.
d. Hold the belt tension gauge 1 at a 90°
angle to the handlebar, push the gauge
against the handlebar, and then record the
measurement when the handlebar starts to
turn.
3 - 57
CHECKING THE STEERING SYSTEM
CHK
ADJ
Belt tension gauge
90890-03170
Rear drive belt tension gauge
YM-03170
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Adjust:
• steering tension
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the electrical components tray.
Refer to “ELECTRICAL COMPONENTS
TRAY”.
b. Loosen the steering stem bracket bolts 1,
steering stem bearing bolts 2, and steering
stem joint bolts 3 completely.
1
2
3
NOTE:
After loosening the bolts, be sure to check that
the steering stem joint moves smoothly on the
serrations of the steering stem and shaft of the
EPS unit.
c. Tighten the steering stem bearing bolts to
specification.
T.
R.
Steering stem bearing bolt
50 Nm (5.0 m · kg, 36 ft · lb)
LOCTITE®
d. Tighten the steering stem bracket bolts to
specification.
T.
R.
Steering stem bracket bolt
50 Nm (5.0 m · kg, 36 ft · lb)
LOCTITE®
e. Tighten the steering stem joint bolts to
specification.
T.
R.
Steering stem joint bolt
30 Nm (3.0 m · kg, 22 ft · lb)
LOCTITE®
f. Measure the steering tension again.
g. Repeat the above procedure until the steering tension is below specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 58
ADJUSTING THE TOE-IN
CHK
ADJ
EBS00108
ADJUSTING THE TOE-IN
1. Place the vehicle on a level surface.
2. Measure:
• toe-in
Out of specification → Adjust.
Toe-in
0 ~ 10 mm (0 ~ 0.39 in)
(with tires touching the ground)
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NOTE:
Before measuring the toe-in, make sure that
the tire pressure is correct.
_
a.
b.
c.
d.
Mark both front tire tread centers.
Face the handlebar straight ahead.
Measure the width È between the marks.
Rotate the front tires 180° until the marks
are exactly opposite one another.
e. Measure the width É between the marks.
f. Calculate the toe-in using the formula given
below.
Toe-in = É – È
g. If the toe-in is incorrect, adjust it.
Ê Forward
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3. Adjust:
• toe-in
WARNING
_
• Be sure that both tie-rods are turned the
same amount. If not, the vehicle will drift
right or left even though the handlebar is
positioned straight. This may lead to mishandling and an accident.
• After setting the toe-in to specification,
run the vehicle slowly for some distance
with both hands lightly holding the handlebar and check that the handlebar
responds correctly. If not, turn either the
right or left tie-rod within the toe-in specification.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Mark both tie-rods ends.
This reference point will be needed during
adjustment.
3 - 59
ADJUSTING THE TOE-IN/CHECKING THE FRONT AND
REAR SHOCK ABSORBERS
1
1
2
2
CHK
ADJ
b. Loosen the locknuts (tie-rod end) 1 of both
tie-rods.
c. The same number of turns should be given
to both the right and left tie-rods 2 until the
specified toe-in is obtained. This is to keep
the length of the rods the same.
d. Tighten the rod end locknuts of both tie
rods.
T.
Locknut (rod end)
15 Nm (1.5 m · kg, 11 ft · lb)
R.
NOTE:
Adjust the rod ends so that A and B are equal.
_
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EBS00109
CHECKING THE FRONT AND REAR SHOCK
ABSORBERS
1. Place the vehicle on a level place.
2. Check:
• damper rod
Bends/damage → Replace the front/rear
shock absorber assembly.
Refer to “FRONT ARMS AND FRONT
SHOCK ABSORBER ASSEMBLIES” and
“REAR ARMS AND REAR SHOCK
ABSORBER ASSEMBLIES” in chapter 8.
• oil leakage
Excessive oil leakage → Replace the front/
rear shock absorber assembly.
Refer to “FRONT ARMS AND FRONT
SHOCK ABSORBER ASSEMBLIES” and
“REAR ARMS AND REAR SHOCK
ABSORBER ASSEMBLIES” in chapter 8.
• spring
Fatigue → Replace the front/rear shock
absorber assembly.
Refer to “FRONT ARMS AND FRONT
SHOCK ABSORBER ASSEMBLIES” and
“REAR ARMS AND REAR SHOCK
ABSORBER ASSEMBLIES” in chapter 8.
3 - 60
CHECKING THE FRONT AND REAR SHOCK ABSORBERS/
ADJUSTING THE FRONT SHOCK ABSORBERS
CHK
ADJ
È
3. Check:
• operation
Pump the shock absorbers up and down for
several times.
Unsmooth operation → Replace front/rear
shock absorber.
Refer to “FRONT ARMS AND FRONT
SHOCK ABSORBER ASSEMBLIES” and
“REAR ARMS AND REAR SHOCK
ABSORBER ASSEMBLIES” in chapter 8.
É
È Front shock absorber
É Rear shock absorber
EBS00110
ADJUSTING THE FRONT SHOCK
ABSORBERS
WARNING
_
Always adjust the spring preload for both
front shock absorber to the same setting.
Uneven adjustment can cause poor handling and loss of stability.
1 2
3
4
1. Adjust:
• spring preload
Turn the adjuster 1 in direction a or b.
5
Direction a
Spring preload is
increased (suspension
is harder).
Direction b
Spring preload is
decreased (suspension
is softer).
1
a
b
Standard position: 2
Minimum position: 1
Maximum position: 5
3 - 61
ADJUSTING THE REAR SHOCK ABSORBERS/
CHECKING THE TIRES
CHK
ADJ
EBS00112
ADJUSTING THE REAR SHOCK
ABSORBERS
WARNING
_
Always adjust the spring load for both rear
shock absorber spring preload to the same
setting. Uneven adjustment can cause poor
handling and loss of stability.
1 2
3
4
1
5
1. Adjust:
• spring preload
Turn the adjuster 1 in direction a or b.
b
Direction a
Spring preload is
increased (suspension
is harder).
Direction b
Spring preload is
decreased (suspension
is softer).
a
Standard position: 2
Minimum position: 1
Maximum position: 5
EBS00115
CHECKING THE TIRES
WARNING
_
This model is equipped with low pressure
tires. It is important that they be inflated
correctly and maintained at the proper
pressures.
• TIRE CHARACTERISTICS
1) Tire characteristics influence the handling of ATVs. The tires listed below
have been approved by Yamaha Motor
Co., Ltd. for this model. If other tire combinations are used, they can adversely
affect your vehicle’s handling characteristics and are therefore not recommended.
3 - 62
CHECKING THE TIRES
CHK
ADJ
Manufacturer
Size
Type
Front
DUNLOP
AT25 ×
8-12
KT421
Rear
DUNLOP
AT25 ×
10-12
KT425
• TIRE PRESSURE
1) Recommended tire pressure
Front 35 kPa (0.35 kg/cm2, 5.0 psi)
Rear 30 kPa (0.30 kg/cm2, 4.3 psi)
2) Tire pressure below the minimum specification could cause the tire to dislodge
from the rim under severe riding conditions.
The following are minimums:
Front 32 kPa (0.32 kg/cm2, 4.6 psi)
Rear 27 kPa (0.27 kg/cm2, 3.9 psi)
3) Use no more than
Front 250 kPa (2.5 kg/cm2, 36 psi)
Rear 250 kPa (2.5 kg/cm2, 36 psi)
when seating the tire beads. Higher
pressures may cause the tire to burst.
Inflate the tires slowly and carefully.
Fast inflation could cause the tire to
burst.
• MAXIMUM LOADING LIMIT
1) Vehicle load limits: 220 kg (485 lb)
*Total weight of the cargo, trailer hitch
vertical load, rider, and accessories.
2) Front carrier: 45.0 kg (99 lb)
3) Rear carrier: 85.0 kg (187 lb)
4) Front storage box: 0.5 kg (1 lb)
5) Rear storage box: 2.0 kg (4 lb)
6) Trailer hitch:
Pulling load (total weight of trailer and
cargo): 5,390 N (550 kg, 1,212 lb)
Tongue weight (vertical weight on trailer
hitch point): 147 N (15 kg, 33 lb)
Be extra careful of the vehicle balance and
stability when towing a trailer.
3 - 63
CHECKING THE TIRES
CHK
ADJ
1. Measure:
• tire pressure
Out of specification → Adjust.
NOTE:
• The low-pressure tire gauge 1 is included
as standard equipment.
• If dust or the like is stuck to this gauge, it will
not provide the correct readings. Therefore,
take two measurements of the tire’s pressure
and use the second reading.
_
Cold tire
pressure
Front
Rear
Standard
35 kPa
30 kPa
(0.35 kg/cm2, (0.30 kg/cm2,
5.0 psi)
4.3 psi)
Minimum
27 kPa
32 kPa
2
(0.32 kg/cm , (0.27 kg/cm2,
4.6 psi)
3.9 psi)
Maximum
33 kPa
38 kPa
2
(0.38 kg/cm , (0.33 kg/cm2,
5.5 psi)
4.8 psi)
WARNING
_
Uneven or improper tire pressure may
adversely affect the handling of this vehicle
and may cause loss of control.
• Maintain proper tire pressures.
• Set tire pressures when the tires are cold.
• Tire pressures must be equal in both front
tires and equal in both rear tires.
2. Check:
• tire surfaces
Wear/damage → Replace.
Tire wear limit a
Front and rear: 3 mm (0.12 in)
WARNING
_
It is dangerous to ride with a worn-out tire.
When tire wear is out of specification,
replace the tire immediately.
3 - 64
CHECKING THE WHEELS/
CHECKING AND LUBRICATING THE CABLES
CHK
ADJ
EBS00116
CHECKING THE WHEELS
1. Check:
• wheel 1
Damage/bends → Replace.
NOTE:
Always balance the wheel when a tire or wheel
has been changed or replaced.
_
WARNING
_
• Never attempt even small repairs to the
wheel.
• Ride conservatively after installing a tire
to allow it to seat itself properly on the
rim.
EBS00117
CHECKING AND LUBRICATING THE
CABLES
WARNING
_
A damaged cable sheath may cause corrosion and interfere with the cable movement. An unsafe condition may result, so
replace a damaged cable as soon as possible.
1. Check:
• cable sheath
Damage → Replace.
2. Check:
• cable operation
Unsmooth operation
replace.
→
Lubricate
or
Recommended lubricant
Yamaha chain and cable lube or
engine oil
NOTE:
Hold the cable end up and apply several drops
of lubricant to the cable.
_
3. Apply:
• lithium-soap-based grease
(onto end of the cable)
3 - 65
LUBRICATING THE LEVERS AND PEDALS
CHK
ADJ
EBS00118
LUBRICATING THE LEVERS AND PEDALS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers and pedals.
Recommended lubricant
Lithium-soap-based grease
3 - 66
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
EBS00120
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE
BATTERY
WARNING
_
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
• Wear protective eye gear when handling
or working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
• DO NOT SMOKE when charging or handling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk followed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
CAUTION:
_
• This is a sealed battery. Never remove the
sealing caps because the balance
between cells will not be maintained and
battery performance will deteriorate.
• Charging time, charging amperage and
charging voltage for an MF battery are different from those of conventional batteries. The MF battery should be charged as
explained in the charging method illustrations. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging the battery.
3 - 67
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
NOTE:
Since MF batteries are sealed, it is not possible to check the charge state of the battery by
measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to
be checked by measuring the voltage at the
battery terminals.
_
1. Remove:
• battery cover
Refer to “SEAT AND SIDE PANELS”.
• front carrier
• battery holding bracket
Refer to “FRONT CARRIER AND FRONT
GUARD”.
2. Disconnect:
• battery leads
(from the battery terminals)
1
CAUTION:
2
_
First, disconnect the negative battery lead
1, and then the positive battery lead 2.
3.
•
4.
•
Remove:
battery
Check:
battery charge
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a pocket tester to the battery terminals.
Positive tester probe →
positive battery terminal
Negative tester probe →
negative battery terminal
NOTE:
• The charge state of an MF battery can be
checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected).
• No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
_
3 - 68
CHECKING AND CHARGING THE BATTERY
Open-circuit voltage (V)
Relationship between the open-circuit voltage and the charging time at 20 °C (68 °F)
CHK
ADJ
b. Check the charge of the battery, as shown
in the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20 ~ 30%
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Charging time (hours)
These values vary with the temperature and the
condition of the battery plates.
Ambient temperature
20 °C (68 °F)
Open-circuit voltage (V)
Charging
5. Charge:
• battery
(refer to the appropriate charging method
illustration)
WARNING
_
Do not quick charge a battery.
Time (minutes)
Check the open-circuit
voltage.
CAUTION:
_
Open-circuit voltage (V)
Ambient
temperature
20 °C (68 °F)
Charging condition of the battery (%)
• Never remove the MF battery sealing
caps.
• Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause
battery overheating and battery plate
damage.
• If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
• When charging a battery, be sure to
remove it from the vehicle. (If charging
has to be done with the battery mounted
on the vehicle, disconnect the negative
battery lead from the battery terminal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the battery charger leads are connected to the
battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure
to turn off the battery charger.
• Make sure the battery charger lead clips
are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may
generate heat in the contact area and a
weak clip spring may cause sparks.
3 - 69
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
• If the battery becomes hot to the touch at
any time during the charging process,
disconnect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!
• As shown in the following illustration, the
open-circuit voltage of an MF battery stabilizes about 30 minutes after charging
has been completed. Therefore, wait 30
minutes after charging is completed
before measuring the open-circuit voltage.
3 - 70
CHK
ADJ
CHECKING AND CHARGING THE BATTERY
Charging method using a variable-current (voltage) charger
Measure the open-circuit
voltage prior to charging.
Charger
Ammeter
Connect a charger and
ammeter to the battery and
start charging.
YES
Is the amperage higher
than the standard charging
amperage written on the
battery?
NOTE:
Leave the battery unused for
more than 30 minutes before
measuring its open-circuit voltage.
NOTE:
Set the charging voltage to 16 ~
17 V. (If the charging voltage is
lower, charging will be insufficient,
if it is higher, the battery will be
over-charged.)
NO
Adjust the charging voltage to
20 ~ 25 V.
Adjust the voltage to obtain the
standard charging amperage.
YES
Monitor the amperage for
3 ~ 5 minutes. Is the standard
charging amperage exceeded?
NO
If the amperage does not
exceed the standard charging
amperage after 5 minutes,
replace the battery.
Set the timer to the charging
time determined by the opencircuit voltage.
Refer to “CHECKING AND
CHARGING THE BATTERY”.
If the required charging time exceeds 5 hours, it is advisable to check the
charging amperage after 5 hours. If there is any change in the amperage,
readjust the voltage to obtain the standard charging amperage.
Leave the battery unused for more than 30 minutes before measuring its
open-circuit voltage.
12.8 V → Charging is complete.
12.0 ~ 12.7 V → Recharging is required.
Under 12.0 V → Replace the battery.
3 - 71
CHK
ADJ
CHECKING AND CHARGING THE BATTERY
Charging method using a constant voltage charger
Measure the open-circuit
voltage prior to charging.
NOTE:
Leave the battery unused for
more than 30 minutes before
measuring its open-circuit voltage.
Connect a charger and
ammeter to the battery
and start charging.
YES
Is the amperage higher
than the standard charging amperage written on
the battery?
Charge the battery until the charging
voltage reaches 15 V.
NO
This type of battery charger cannot
charge an MF battery. A variablevoltage charger is recommended.
NOTE:
Set the charging time to a maximum of 20 hours.
Charger
Leave the battery unused for more than
30 minutes before measuring its open-circuit voltage.
12.8 V → Charging is complete.
12.0 ~ 12.7 V → Recharging is required.
Under 12.0 V → Replace the battery.
Ammeter
Voltmeter
CAUTION:
Constant amperage chargers are not
suitable for charging MF batteries.
3 - 72
CHECKING AND CHARGING THE BATTERY/
CHECKING THE FUSES
6.
•
7.
•
2
1
CHK
ADJ
Install:
battery
Connect:
battery leads
(to the battery terminals)
CAUTION:
_
First, connect the positive battery lead 1,
and then the negative battery lead 2.
8. Check:
• battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
9. Lubricate:
• battery terminals
Recommended lubricant
Dielectric grease
10.Install:
• battery holding bracket
• front carrier
Refer to “FRONT CARRIER AND FRONT
GUARD”.
• battery cover
Refer to “SEAT AND SIDE PANELS”.
EBS00121
CHECKING THE FUSES
The following procedure applies to all of the
fuses.
CAUTION:
_
To avoid a short circuit, always set the
main switch to “OFF” when checking or
replacing a fuse.
1. Remove:
• battery cover
Refer to “SEAT AND SIDE PANELS”.
3 - 73
CHECKING THE FUSES
CHK
ADJ
2. Check:
• fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and
check the continuity.
NOTE:
Set the pocket tester selector to “Ω × 1”.
_
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
b. If the pocket tester indicates “∞”, replace
the fuse.
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3. Replace:
• blown fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage.
c. Set on the switches to verify if the electrical
circuit is operational.
3 - 74
CHECKING THE FUSES
CHK
ADJ
d. If the fuse immediately blows again, check
the electrical circuit.
Items
Amperage
rating
Q’ty
Main fuse
40 A
1
EPS fuse
40 A
1
Fuel injection
system fuse
15 A
1
Ignition fuse
10 A
1
Headlight fuse
15 A
1
Four-wheeldrive motor fuse
10 A
1
Radiator fan
motor fuse
15 A
1
Signaling system fuse
5A
1
Auxiliary DC
jack fuse
15 A
1
Spare fuse
40 A
15 A
10 A
5A
1
2
1
1
WARNING
_
Never use a fuse with an amperage rating
other than that specified. Improvising or
using a fuse with the wrong amperage rating may cause extensive damage to the
electrical system, cause the lighting and
ignition systems to malfunction and could
possibly cause a fire.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• battery cover
Refer to “SEAT AND SIDE PANELS”.
3 - 75
ADJUSTING THE HEADLIGHT BEAMS/
REPLACING THE HEADLIGHT BULBS
CHK
ADJ
EBS00122
ADJUSTING THE HEADLIGHT BEAMS
1. Adjust:
• headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a
a. Turn the adjusting screw 1 in direction a
or b.
b
1
Direction a
Headlight beam is
raised.
Direction b
Headlight beam is
lowered.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS00124
REPLACING THE HEADLIGHT BULBS
1. Remove:
• cover at the rear of the headlight 1
1
2. Remove:
• headlight bulb cover 1
1
3. Disconnect:
• headlight coupler 1
1
3 - 76
REPLACING THE HEADLIGHT BULBS
CHK
ADJ
4. Remove:
• headlight bulb holder 1
• headlight bulb 2
1
NOTE:
Unhook the headlight bulb holder, and then
remove the defective bulb.
_
2
WARNING
_
Keep flammable products and your hands
away from the bulb while it is on, as it will
be hot. Do not touch the bulb until it cools
down.
5. Install:
• bulb New
Secure the new bulb with the headlight unit.
CAUTION:
_
Avoid touching the glass part of the bulb.
Keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and
luminous flux will be adversely affected. If
oil gets on the bulb, thoroughly clean it
with a cloth moistened with alcohol or lacquer thinner.
6.
•
7.
•
8.
•
•
3 - 77
Install:
headlight bulb holder
Connect:
headlight coupler
Install:
headlight bulb cover
cover at the rear of the headlight
ENGINE REMOVAL
ENG
EBS00200
ENGINE
ENGINE REMOVAL
AIR DUCTS, MUFFLER AND EXHAUST PIPE
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
3
5
4
8
7
9
4
New 6
New
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
2
1
Order
Job/Part
Removing the air ducts, muffler and
exhaust pipe
Front fender/rear fender
Q’ty
Refer to “ENGINE SKID PLATES, SEAT,
CARRIERS AND FENDERS” in chapter
3.
Refer to “FOOTREST BOARDS” in chapter 3.
Refer to “AIR FILTER CASE” in chapter
3.
Refer to “ELECTRICAL COMPONENTS
TRAY” in chapter 3.
Left footrest board
Air filter case
Meter assembly
1
2
3
4
5
V-belt cooling duct 2
V-belt cooling duct 1
Exhaust pipe protector
Spring
Muffler
Remarks
Remove the parts in the order listed.
1
1
1
2
1
4-1
ENGINE REMOVAL
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
ENG
3
5
4
8
7
9
New 6
4
New
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
2
1
Order
6
7
8
9
Job/Part
Gasket
Muffler bracket
Exhaust pipe
Gasket
Q’ty
1
1
1
2
Remarks
For installation, reverse the removal procedure.
4-2
4
ENGINE REMOVAL
ENG
EBS00202
SELECT LEVER UNIT
T.
T.
R.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
15 Nm (1.5 m • kg, 11 ft • Ib)
T.
R.
15 Nm (1.5 m • kg, 11 ft • Ib)
1
LS
3
2
T.
R.
Order
1
2
3
Job/Part
Removing the select lever unit
Select lever shift rod
Select lever unit
Shift arm
Q’ty
1
1
1
14 Nm (1.4 m • kg, 10 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “INSTALLING THE SELECT
LEVER UNIT”.
For installation, reverse the removal procedure.
4-3
ENGINE REMOVAL
ENG
EBS00204
LEADS, CABLES AND HOSES
9
5
2
8
7
6
1
10
4
3
Order
Job/Part
Removing the leads, cables and
hoses
Footrest board
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “FOOTREST BOARDS” in chapter 3.
Refer to “AIR FILTER CASE” in chapter
3.
Refer to “THROTTLE BODY” in chapter
6.
Refer to “FUEL TANK” in chapter 6.
Refer to “RADIATOR” in chapter 5.
Refer to “THERMOSTAT” in chapter 5.
Refer to “WATER PUMP” in chapter 5.
Refer to “CYLINDER HEAD”.
Refer to “REAR CONSTANT VELOCITY
JOINTS AND FINAL DRIVE GEAR” in
chapter 7.
Air filter case
Throttle body assembly
Fuel tank/fuel tank shield
Coolant reservoir
Thermostat
Water pump assembly
Oil delivery pipe
Final gear case assembly
4-4
ENGINE REMOVAL
ENG
9
5
2
8
7
6
1
10
4
3
Order
Job/Part
Q’ty
Starter motor
Drive belt case
1
2
3
4
5
6
7
8
9
10
Cylinder head breather hose
Fast idle plunger inlet hose
Coolant temperature sensor coupler
Spark plug cap
Shift control cable
Reverse switch lead
Speed sensor coupler
Crankshaft position sensor coupler
AC magneto coupler
Gear position switch coupler
1
1
1
1
1
1
1
1
1
1
4-5
Remarks
Refer to “STARTER MOTOR” in chapter
9.
Refer to “PRIMARY AND SECONDARY
SHEAVES”.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
ENG
ENGINE REMOVAL
EBS00205
ENGINE MOUNTING BOLTS
T.
R.
.
T
R.
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
T.
R.
3
42 Nm (4.2 m • kg, 30 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
6
8
5
7
1
LT
LT
9
6
.
T
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
42 Nm (4.2 m • kg, 30 ft • Ib)
4
2
8
9
LT
T.
R.
7
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
Order
1
2
3
4
3
Job/Part
Removing the engine mounting
bolts
Rubber damper nut (front side)
Engine mounting bolt (rear upper side)
Engine mounting bolt (rear lower side)
Engine
Q’ty
2
2
2
1
42 Nm (4.2 m • kg, 30 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “INSTALLING THE ENGINE”.
CAUTION:
Make sure that the engine does not
strike the brake pipe when removing
it.
NOTE:
Remove the engine from the left side
of the vehicle.
_
5
Rubber damper nut (rear side)
2
4-6
ENG
ENGINE REMOVAL
T.
R.
.
T
R.
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
T.
R.
3
42 Nm (4.2 m • kg, 30 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
6
8
5
7
1
LT
LT
9
6
.
T
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
42 Nm (4.2 m • kg, 30 ft • Ib)
4
2
8
9
LT
T.
R.
7
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
Order
6
7
8
9
3
Job/Part
Q’ty
Rubber damper (rear side)
2
Engine mounting bolt (front upper side)
2
Engine mounting bolt (front lower side)
2
Rubber damper (front side)
2
42 Nm (4.2 m • kg, 30 ft • Ib)
Remarks
Refer to “INSTALLING THE ENGINE”.
For installation, reverse the removal procedure.
4-7
ENGINE REMOVAL
ENG
EBS00207
INSTALLING THE ENGINE
1. Install:
• rubber dampers (front side) 1
• engine mounting bolts (front lower side) 2
• engine mounting bolts (front upper side) 3
• rubber dampers (rear side) 4
• rubber damper nuts (rear side) 5
• engine 6
• engine mounting bolts (rear lower side) 7
• engine mounting bolts (rear upper side) 8
• rubber damper nuts (front side) 9
7 8
4
9
5 3
2
1
6
CAUTION:
4
1
8
Make sure that the engine does not strike
the brake pipe when installing it.
7
NOTE:
Do not fully tighten the bolts and nuts.
_
3
2
2. Tighten:
• engine mounting bolts (front lower side) 2
T.
R.
42 Nm (4.2 m · kg, 30 ft · lb)
• engine mounting bolts (front upper side) 3
LT
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
• engine mounting bolts (rear lower side) 7
T.
R.
42 Nm (4.2 m · kg, 30 ft · lb)
• engine mounting bolts (rear upper side) 8
LT
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
• rubber damper nuts (front side) 9
T.
R.
42 Nm (4.2 m · kg, 30 ft · lb)
• rubber damper nuts (rear side) 5
T.
R.
4-8
42 Nm (4.2 m · kg, 30 ft · lb)
ENGINE REMOVAL
ENG
INSTALLING THE SELECT LEVER UNIT
1. Install:
14 Nm (1.4 m · kg, 10 ft · lb)
• shift arm 1
• select lever unit 2
N
2
T.
R.
a
T.
R.
7 Nm (0.7 m · kg, 5.1 ft · lb)
• select lever shift rod 3
3
T.
R.
N
15 Nm (1.5 m · kg, 11 ft · lb)
NOTE:
• Make sure that the select lever and transmission are in NEUTRAL.
• The installed length a of the shift rod is
413 mm (16.3 in).
1
4-9
ENG
CYLINDER HEAD
EBS00218
CYLINDER HEAD
R.
R.
T.
R.
R.
T.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
1
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
T.
20 Nm (2.0 m • kg, 14 ft • Ib)
6
13 Nm (1.3 m • kg, 9.4 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
New
R.
35 Nm (3.5 m • kg, 25 ft • Ib)
2
9
M
(4)
8
New
5
16
E
10
11
New
LS
New
New
LS
LS
15
7
(4)
13
5
14
12
New
LS
3
New
T.
R.
4
T.
R.
35 Nm (3.5 m • kg, 25 ft • Ib)
R.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
T.
New
T.
R.
R.
T.
Q’ty
Thermostat/coolant temperature sensor
Air ducts/exhaust pipe
Spark plug cap
Spark plug
Cylinder head breather hose
Camshaft sprocket cover
Tappet cover
Fast idle plunger inlet hose
Oil delivery pipe
Oil gallery bolt
1
1
1
1
2
1
1
1
4 - 10
R.
R.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Job/Part
Removing the cylinder head
Throttle body assembly
LS
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
T.
T.
Order
E
38 Nm (3.8 m • kg, 27 ft • Ib)
35 Nm (3.5 m • kg, 25 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
1
2
3
4
5
6
7
8
New
10 Nm (1.0 m • kg, 7.2 ft • Ib)
6 Nm (0.6 m • kg, 4.3 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “THROTTLE BODY” in chapter
6.
Refer to “THERMOSTAT” in chapter 5.
Refer to “ENGINE REMOVAL”.
Disconnect.
ENG
CYLINDER HEAD
R.
R.
T.
R.
R.
T.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
1
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
T.
20 Nm (2.0 m • kg, 14 ft • Ib)
6
13 Nm (1.3 m • kg, 9.4 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
New
R.
35 Nm (3.5 m • kg, 25 ft • Ib)
2
9
M
(4)
8
New
5
16
E
10
11
New
LS
New
New
LS
LS
15
7
(4)
13
5
14
12
New
LS
3
New
New
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
4
T.
R.
35 Nm (3.5 m • kg, 25 ft • Ib)
R.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
T.
New
R.
R.
Q’ty
1
1
1
1
1
1
1
2
R.
R.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
T.
T.
Job/Part
Timing chain tensioner cap bolt
Timing chain tensioner
Gasket
Camshaft sprocket
Decompressor assembly
Cylinder head
Cylinder head gasket
Dowel pin
T.
T.
Order
9
10
11
12
13
14
15
16
LS
38 Nm (3.8 m • kg, 27 ft • Ib)
35 Nm (3.5 m • kg, 25 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
E
6 Nm (0.6 m • kg, 4.3 ft • Ib)
Remarks
Refer to “REMOVING THE CYLINDER
HEAD” and “INSTALLING THE CYLINDER HEAD”.
For installation, reverse the removal procedure.
4 - 11
CYLINDER HEAD
ENG
EBS00220
a
b
REMOVING THE CYLINDER HEAD
1. Align:
• “I” mark on the AC magneto rotor
(with the stationary pointer on the AC magneto cover)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
b. When the piston is at the top dead center
(TDC) on the compression stroke, align the
“I” mark a on the AC magneto rotor with
the stationary pointer b on the AC magneto
cover.
d
c
NOTE:
To position the piston at top dead center (TDC)
on the compression stroke, align the “I” mark
c on the camshaft sprocket with the stationary
pointer d on the cylinder head, as shown in
the illustration.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Loosen:
• camshaft sprocket bolts 1
• decompressor assembly bolts 2
1
NOTE:
While holding the AC magneto rotor nut with a
wrench, loosen the camshaft sprocket bolts
and decompressor assembly bolts.
2
3.
•
4.
•
Loosen:
timing chain tensioner cap bolt
Remove:
timing chain tensioner
(along with the gasket)
• camshaft sprocket
• timing chain
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire.
_
4 - 12
CYLINDER HEAD
5. Remove:
• cylinder head
4
2
7
1
5
6
8
3
ENG
NOTE:
• Loosen the bolts in the proper sequence as
shown.
• Loosen each bolt 1/2 of a turn at a time. After
all of the bolts are fully loosened, remove
them.
_
EBS00224
CHECKING THE CAMSHAFT SPROCKET
1. Check:
• camshaft sprocket
Wear/damage → Replace the camshaft
sprocket and timing chain as a set.
a 1/4 of a tooth
b Correct
1 Roller
2 Sprocket
EBS00227
CHECKING THE TAPPET COVERS
1. Check:
• tappet covers
• camshaft sprocket cover
Cracks/damage → Replace.
EBS00229
CHECKING THE TIMING CHAIN
TENSIONER
1. Check:
• timing chain tensioner
Cracks/damage → Replace.
2. Check:
• one-way cam operation
Rough movement → Replace the timing
chain tensioner.
3. Check:
• timing chain tensioner cap bolt
• spring
• one-way cam
• timing chain tensioner rod
Damage/wear → Replace the defective
part(s).
4 - 13
CYLINDER HEAD
ENG
EBS00230
CHECKING THE CYLINDER HEAD
1. Eliminate:
• combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damaging or scratching:
• spark plug bore threads
• valve seats
_
2. Check:
• cylinder head
Damage/scratches → Replace.
• cylinder head water jacket
Mineral deposits/rust → Eliminate.
3. Measure:
• cylinder head warpage
Out of specification → Resurface the cylinder head.
Maximum cylinder head warpage
0.03 mm (0.0012 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
2
a. Place a straightedge 1 and a thickness
gauge 2 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder head as follows.
d. Place a 400 ~ 600 grit wet sandpaper on
the surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder
head several times.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 14
CYLINDER HEAD
ENG
EBS00232
INSTALLING THE CYLINDER HEAD
1. Install:
• dowel pins
• cylinder head gasket New
2. Install:
• cylinder head
• cylinder head bolts
NOTE:
• Lubricate the cylinder head bolt 1 and 2
threads and mating surface with molybdenum disulfide grease.
• Lubricate the cylinder head bolts 3 threads
and mating surface with engine oil.
_
3
4
5
7
2
3
1
2
8
4
6
T.
R.
4
3. Tighten:
• cylinder head bolts 1:
1
• cylinder head bolts 2:
3
= 135 mm (5.31 in)
35 Nm (3.5 m · kg, 25 ft · lb)
= 145 mm (5.71 in)
T.
R.
35 Nm (3.5 m · kg, 25 ft · lb)
• cylinder head bolts 3
T.
R.
38 Nm (3.8 m · kg, 27 ft · lb)
• cylinder head bolts 4
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
NOTE:
Tighten the cylinder head bolts in the proper
tightening sequence as shown and torque
them in two stages.
_
a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b
4
d
c
2
4
3
1
4. Install:
• decompressor assembly
• camshaft sprocket
(onto the camshaft)
a. Install the decompressor assembly onto the
camshaft, and then finger tighten the
decompressor assembly bolts 1.
b. Turn the crankshaft counterclockwise.
c. Align the “I” mark a on the AC magneto
rotor with the stationary pointer b on the
AC magneto cover.
d. Install the timing chain 2 onto the camshaft
sprocket 3, then the camshaft sprocket
onto the camshaft, and then finger tighten
the camshaft sprocket bolts 4.
e. Make sure the “I” mark c on the camshaft
sprocket with the stationary pointer d on
the cylinder head.
4 - 15
CYLINDER HEAD
ENG
NOTE:
When installing the camshaft sprocket, keep
the timing chain as tense as possible on the
exhaust side.
_
CAUTION:
_
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
f. Remove the wire from the timing chain.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• timing chain tensioner
6 New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3
2 New
1
a. Remove the timing chain tensioner cap bolt
1, copper washer 2 and spring 3.
b. Release the timing chain tensioner one-way
cam 4 and push the timing chain tensioner
rod 5 all the way into the timing chain tensioner housing.
c. Install the timing chain tensioner and gasket
6 onto the cylinder.
T.
4
Timing chain tensioner bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)
R.
NOTE:
Install the gasket with its beaded side facing
the timing chain tensioner end.
5
d. Install the spring and timing chain tensioner
cap bolt.
T.
Timing chain tensioner cap bolt
20 Nm (2.0 m · kg, 14 ft · lb)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Turn:
• crankshaft
(several turns counterclockwise)
4 - 16
CYLINDER HEAD
a
ENG
7. Check:
• “I” mark a
NOTE:
Check that the “I” mark on the AC magneto
rotor is aligned with the stationary pointer b
on the AC magneto cover.
b
• “I” mark c
NOTE:
Check that the “I” mark on the camshaft
sprocket is aligned with the stationary pointer
d on the cylinder head.
d
c
Out of alignment → Correct.
Repeat steps (4) to (7), if necessary.
8. Tighten:
• camshaft sprocket bolts 1
1
T.
R.
20 Nm (2.0 m · kg, 14 ft · lb)
• decompressor assembly bolts 2
T.
R.
2
20 Nm (2.0 m · kg, 14 ft · lb)
NOTE:
• While holding the AC magneto rotor nut with
a wrench, tighten the camshaft sprocket
bolts and decompressor assembly bolts.
• After tightening the decompressor assembly
bolts, check that decompressor assembly
moves smoothly.
CAUTION:
_
Be sure to tighten the camshaft sprocket
bolts to the specified torque to avoid the
possibility of the bolts coming loose and
damaging the engine.
9. Measure:
• valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE
CLEARANCE” in chapter 3.
4 - 17
VALVE
ENG
ROCKER ARMS AND CAMSHAFT
EBS00235
ROCKER ARMS AND CAMSHAFT
14 Nm (1.4 m • kg, 10 ft • Ib)
T.
5
6
R.
T.
R.
14 Nm (1.4 m • kg, 10 ft • Ib)
5
3
6
5
5
6
E
2
6
4
E
E
10
T.
9
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
7
1
E
E
2
8
E
E
Order
1
2
3
4
5
6
7
LT
Job/Part
Q’ty
Remarks
Removing the rocker arms and camRemove the parts in the order listed.
shaft
Cylinder head
Refer to “CYLINDER HEAD”.
Bearing retainer
1
Rocker arm shaft
2
Refer to “REMOVING THE ROCKER
Intake rocker arm
1
ARMS AND CAMSHAFT” and
“INSTALLING THE CAMSHAFT AND
Exhaust rocker arm
1
ROCKER ARMS”.
Locknut
4
Valve adjusting screw
4
Camshaft
1
CAUTION:
Do not disassemble the camshaft
assembly.
8
Decompressor lever
1
4 - 18
ENG
ROCKER ARMS AND CAMSHAFT
14 Nm (1.4 m • kg, 10 ft • Ib)
T.
5
6
R.
T.
R.
14 Nm (1.4 m • kg, 10 ft • Ib)
5
3
6
5
5
6
E
2
6
4
E
E
10
T.
9
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
7
1
E
E
2
8
E
E
Order
9
10
Job/Part
Decompressor lever pin
Bearing
Q’ty
1
1
4 - 19
LT
Remarks
Refer to “REMOVING THE ROCKER
ARMS AND CAMSHAFT” and
“INSTALLING THE CAMSHAFT AND
ROCKER ARMS”.
For installation, reverse the removal procedure.
ROCKER ARMS AND CAMSHAFT
ENG
EBS00237
REMOVING THE ROCKER ARMS AND
CAMSHAFT
1. Loosen:
• locknuts
• valve adjusting screws
2. Remove:
• intake rocker arm shaft
• exhaust rocker arm shaft
• intake rocker arm
• exhaust rocker arm
NOTE:
Remove the rocker arm shafts with the slide
hammer bolt 1 and weight 2.
_
2 1
Slide hammer bolt
90890-01083
Slide hammer bolt 6 mm
YU-01083-1
Weight
90890-01084, YU-01083-3
EBS00223
CHECKING THE CAMSHAFT
1. Check:
• cam lobes
Pitting/scratches/blue discoloration →
Replace.
2. Measure:
• cam lobe dimensions a and b
Out of specification → Replace.
Camshaft lobe dimensions
Intake
a 43.488 ~ 43.588 mm
(1.7121 ~ 1.7161 in)
<Limit>:
43.388 mm (1.7082 in)
b 36.959 ~ 37.059 mm
(1.4551 ~ 1.4590 in)
<Limit>:
36.859 mm (1.4511 in)
Exhaust
a 43.129 ~ 43.229 mm
(1.6980 ~ 1.7019 in)
<Limit>:
43.029 mm (1.6941 in)
b 37.007 ~ 37.107 mm
(1.4570 ~ 1.4609 in)
<Limit>:
36.907 mm (1.4530 in)
4 - 20
ROCKER ARMS AND CAMSHAFT
ENG
3. Measure:
• camshaft runout
Out of specification → Replace.
Camshaft runout limit
0.015 mm (0.0006 in)
EBS00225
CHECKING THE DECOMPRESSION
SYSTEM
1. Check:
• decompression system
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2
a. Check the decompression system with the
camshaft sprocket installed on the decompressor lever and pin installed in the camshaft.
b. Check that the decompressor lever pin 1
projects from the camshaft.
c. Check that the decompressor cam 2
moves smoothly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS00239
CHECKING THE ROCKER ARMS AND
ROCKER ARM SHAFTS
The following procedure applies to both of the
rocker arms and rocker arm shafts.
1. Check:
• rocker arm
Damage/wear → Replace.
2. Check:
• rocker arm shaft
Blue discoloration/excessive wear/pitting/
scratches → Replace or check the lubrication system.
3. Measure:
• rocker arm inside diameter
Out of specification → Replace.
Rocker arm inside diameter
12.000 ~ 12.018 mm
(0.4724 ~ 0.4731 in)
4 - 21
ROCKER ARMS AND CAMSHAFT
ENG
4. Measure:
• rocker arm shaft outside diameter
Out of specification → Replace.
Rocker arm shaft outside diameter
11.981 ~ 11.991 mm
(0.4717 ~ 0.4721 in)
5. Calculate:
• rocker-arm-to-rocker-arm-shaft clearance
NOTE:
Calculate the clearance by subtracting the
rocker arm shaft outside diameter from the
rocker arm inside diameter.
_
Out of specification → Replace the defective
part(s).
Rocker-arm-to-rocker-arm-shaft
clearance
0.009 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
EAS00243
1
a
b
INSTALLING THE CAMSHAFT AND
ROCKER ARMS
1. Install:
• bearing 1
(onto the cylinder head)
NOTE:
• Apply engine oil to the bearing.
• Install the bearing so that the seal is facing
a the camshaft.
Installed depth b
0 mm (0 in)
4 - 22
ROCKER ARMS AND CAMSHAFT
2.
•
•
•
ENG
Lubricate:
camshaft
decompressor lever pin
decompressor lever
Recommended lubricant
Engine oil
3
3. Install:
• decompressor lever pin 1
• decompressor lever 2
NOTE:
Install the decompressor lever pin 1 and
decompressor lever 2 in the camshaft 3 as
shown in the illustration.
_
2
1
1
4. Install:
• camshaft 1
NOTE:
Install the camshaft so that its projection a
becomes horizontal.
5. Lubricate:
• rocker arm shafts
a
Recommended lubricant
Engine oil
4 - 23
ROCKER ARMS AND CAMSHAFT
6.
•
•
•
•
1
2
3
ENG
Install:
exhaust rocker arm 1
exhaust rocker arm shaft 2
intake rocker arm
intake rocker arm shaft
NOTE:
• Use a slide hammer bolt 3 to install the
rocker arm shaft.
• Make sure the rocker arm shafts (intake and
exhaust) are completely pushed into the cylinder head.
_
Slide hammer bolt
90890-01083
Slide hammer bolt 6 mm
YU-01083-1
4 - 24
ENG
VALVES AND VALVE SPRINGS
EBS00234
VALVES AND VALVE SPRINGS
1
3
3
2
3
M
6
M
M
New
7
6
New
1
2
2
2
6
3
New
7
6
New
M
7
7
8
8
5
4
4
5
M
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the valves and valve
springs
Cylinder head
Rocker arms/rocker arm shafts/camshaft
Valve cotter
Valve spring retainer
Valve spring
Exhaust valve
Intake valve
Valve stem seal
Valve spring seat
Valve guide
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
Refer to “ROCKER ARMS AND CAMSHAFT”.
8
4
4
2
2
4
4
4
4 - 25
Refer to “REMOVING THE VALVES
AND VALVE SPRINGS” and “INSTALLING THE VALVES AND VALVE
SPRINGS”.
Refer to “CHECKING THE VALVES AND
VALVE SPRINGS”.
For installation, reverse the removal procedure.
VALVES AND VALVE SPRINGS
ENG
EBS00238
REMOVING THE VALVES AND VALVE
SPRINGS
The following procedure applies to all of the
valves and related components.
NOTE:
Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal.
_
1. Check:
• valve sealing
Leakage at the valve seat → Check the
valve face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVES AND
VALVE SPRINGS”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pour a clean solvent a into the intake and
exhaust ports.
b. Check that the valve seals properly.
There should be no leakage at the valve
seat 1.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Remove:
• valve cotters
NOTE:
Attach a valve spring compressor 1 and
attachment 2 between the valve spring
retainer and the cylinder head to remove the
valve cotters.
_
Valve spring compressor
90890-04019, YM-04019
Valve spring compressor attachment
90890-01243
Valve spring compressor adapter
(26 mm)
YM-01253-1
4 - 26
VALVES AND VALVE SPRINGS
3.
•
•
•
•
•
ENG
Remove:
valve spring retainer 1
valve spring 2
valve 3
valve stem seal 4
valve spring seat 5
NOTE:
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
_
EBS00240
CHECKING THE VALVES AND VALVE
SPRINGS
The following procedure applies to all of the
valves and valve guides.
1. Measure:
• valve-stem-to-valve-guide clearance
Stem-to-guide clearance =
valve guide inside diameter a valve stem diameter b
Out of specification → Replace the valve
guide.
Stem-to-guide clearance
Intake
0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
<Limit>: 0.08 mm (0.0031 in)
Exhaust
0.025 ~ 0.052 mm
(0.0010 ~ 0.0020 in)
<Limit>: 0.10 mm (0.0039 in)
4 - 27
VALVES AND VALVE SPRINGS
ENG
2. Replace:
• valve guide
NOTE:
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100 °C (212 °F) in an oven.
_
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide using a valve guide
remover 1.
b. Install the new valve guide using a valve
guide remover 1 and valve guide installer
2.
Valve guide position a
12.7 ~ 13.1 mm (0.50 ~ 0.52 in)
c. After installing the valve guide, bore the
valve guide using a valve guide reamer 3
to obtain proper stem-to-guide clearance.
Valve guide remover (ø6)
90890-04064
Valve guide remover (6.0 mm)
YM-04064-A
Valve guide installer (ø6)
90890-04065
Valve guide installer (6.0 mm)
YM-04065-A
Valve guide reamer (ø6)
90890-04066
Valve guide reamer (6.0 mm)
YM-04066
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
NOTE:
After replacing the valve guide, reface the
valve seat.
_
3. Check:
• valve face
Pitting/wear → Grind the face.
• valve stem end
Mushroom shape or diameter larger than
the body of the valve stem → Replace.
4 - 28
VALVES AND VALVE SPRINGS
ENG
4. Measure:
• margin thickness a
Out of specification → Replace.
Margin thickness
0.80 ~ 1.20 mm
(0.0315 ~ 0.0472 in)
5. Measure:
• valve stem runout
Out of specification → Replace.
Runout limit
0.040 mm (0.0016 in)
NOTE:
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always
replace the valve stem seal.
_
6. Eliminate:
• carbon deposits
(from the valve face and valve seat)
7. Check:
• valve seats
Pitting/wear → Reface the valve seat.
8. Measure:
• valve seat width a
Out of specification → Reface the valve
seat.
Valve seat width
1.00 ~ 1.20 mm
(0.0394 ~ 0.0472 in)
<Limit>: 1.60 mm (0.0630 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply Mechanic’s blueing dye (Dykem) b to
the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
d. Measure the valve seat width. Where the
valve seat and valve face made contact,
blueing will have been removed.
4 - 29
VALVES AND VALVE SPRINGS
ENG
e. If the valve seat is too wide, too narrow, or
the seat is not centered, the valve seat must
be refaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9. Lap:
• valve face
• valve seat
NOTE:
After refacing the valve seat or replacing the
valve and valve guide, the valve seat and
valve face should be lapped.
_
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound to the
valve face.
CAUTION:
_
Do not let the compound enter the gap
between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil to the valve
stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all
of the compound.
NOTE:
For best lapping results, lightly tap the valve
seat while rotating the valve back and forth
between your hands.
_
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
NOTE:
After every lapping operation be sure to clean
off all of the compound from the valve face and
valve seat.
_
f. Apply Mechanic’s blueing dye (Dykem) to
the valve face.
g. Install the valve into the cylinder head.
4 - 30
VALVES AND VALVE SPRINGS
ENG
h. Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
i. Measure the valve seat width again. If the
valve seat width is out of specification,
reface and relap the valve seat.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
10.Measure:
• valve spring free length a
Out of specification → Replace.
Valve spring free length
38.79 mm (1.53 in)
<Limit>: 36.85 mm (1.45 in)
11.Measure:
• compressed spring force a
Out of specification → Replace.
b Installed length
Compressed spring force
169.0 ~ 199.0 N at 35.00 mm
(17.23 ~ 20.29 kg at 35.00 mm,
37.99 ~ 44.73 lb at 1.38 in)
12.Measure:
• spring tilt a
Out of specification → Replace.
Spring tilt limit
2.5°/1.70 mm (0.067 in)
EBS00241
INSTALLING THE VALVES AND VALVE
SPRINGS
The following procedure applies to all of the
valves and related components.
1. Deburr:
• valve stem end
(with an oil stone)
4 - 31
VALVES AND VALVE SPRINGS
ENG
2. Lubricate:
• valve stem 1
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
3.
•
•
•
•
•
Install:
valve spring seats 1
valve stem seals 2
valves 3
valve springs 4
valve spring retainers 5
NOTE:
Install the valve springs with the larger pitch a
facing upwards.
_
b Smaller pitch
4. Install:
• valve cotters
NOTE:
Install the valve cotters while compressing the
valve spring with the valve spring compressor
1 and attachment 2.
_
Valve spring compressor
90890-04019, YM-04019
Valve spring compressor attachment
90890-01243
Valve spring compressor adapter
(26 mm)
YM-01253-1
4 - 32
VALVES AND VALVE SPRINGS
ENG
5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a piece of
wood.
CAUTION:
_
Hitting the valve tip with excessive force
could damage the valve.
4 - 33
CYLINDER AND PISTON
ENG
EBS00245
CYLINDER AND PISTON
T.
E
R.
1st 15 Nm (1.5 m • kg, 11 ft • lb)
2nd 50 Nm (5.0m • kg, 36 ft • lb)
E
1
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
2
E
E
8
7
9
10
3 New
4
New 5
4
6
E
Order
1
2
3
4
5
6
7
8
9
10
New 5
Job/Part
Removing the cylinder and piston
Cylinder head
Water jacket joint
Timing chain guide (exhaust side)
Cylinder
Cylinder gasket
Dowel pin
Piston pin clip
Piston pin
Piston
Top ring
2nd ring
Oil ring
Q’ty
1
1
1
2
2
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
Refer to “WATER PUMP” in chapter 5.
Refer to “INSTALLING THE PISTON
AND CYLINDER”.
Refer to “REMOVING THE PISTON”
and “INSTALLING THE PISTON AND
CYLINDER”.
For installation, reverse the removal procedure.
4 - 34
CYLINDER AND PISTON
ENG
EBS00247
2
1
REMOVING THE PISTON
1. Remove:
• piston pin clips 1
• piston pin 2
• piston 3
NOTE:
• Before removing the piston pin clips, cover
the crankcase opening with a clean rag to
prevent the piston pin clips from falling into
the crankcase.
• Before removing the piston pin, deburr the
piston pin clip grooves and the piston pin
bore area. If both areas are deburred and the
piston pin is still difficult to remove, remove it
with the piston pin puller set 4.
_
3
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
CAUTION:
_
Do not use a hammer to drive the piston
pin out.
2. Remove:
• piston rings
NOTE:
Spread the end gaps apart while at the same
time lifting the piston ring over the top of the
piston crown, as shown in the illustration.
_
EBS00249
CHECKING THE CYLINDER AND PISTON
1. Check:
• piston wall
• cylinder wall
Vertical scratches → Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
4 - 35
CYLINDER AND PISTON
ENG
2. Measure:
• piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the cylinder bore “C” with a cylinder bore gauge.
NOTE:
Measure the cylinder bore “C” in parallel to and
at right angles to the crankshaft. Then, find the
average of the measurements.
_
Cylinder bore
“C”
102.000 ~ 102.010 mm
(4.0157 ~ 4.0161 in)
Taper limit “T”
0.05 mm (0.002 in)
Out of round
“R”
0.05 mm (0.002 in)
“C” = Maximum D
“T” = (Maximum D1 or D2)
– (Maximum D5 or D6)
“R” = (Maximum D1, D3 or D5)
– (Minimum D2, D4 or D6)
b. If out of specification, replace the cylinder,
and the piston and piston rings as a set.
c. Measure piston skirt diameter “P” with the
micrometer.
a 10 mm (0.39 in) from the bottom edge of the piston
Piston size “P”
Standard
101.955 ~ 101.970 mm
(4.0140 ~ 4.0146 in)
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.030 ~ 0.055 mm
(0.0012 ~ 0.0022 in)
<Limit>: 0.13 mm (0.051 in)
4 - 36
CYLINDER AND PISTON
ENG
f. If out of specification, replace the cylinder,
and the piston and piston rings as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS00250
CHECKING THE PISTON RINGS
1. Measure:
• piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
NOTE:
Before measuring the piston ring side clearance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
_
Piston ring side clearance
Top ring
0.030 ~ 0.070 mm
(0.0012 ~ 0.0028 in)
<Limit>: 0.12 mm (0.0047 in)
2nd ring
0.030 ~ 0.070 mm
(0.0012 ~ 0.0028 in)
<Limit>: 0.13 mm (0.0051 in)
2. Install:
• piston ring
(into the cylinder)
NOTE:
Level the piston ring into the cylinder with the
piston crown.
_
a 50 mm (1.97 in)
3. Measure:
• piston ring end gap
Out of specification → Replace the piston
ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is excessive, replace all three piston rings.
_
4 - 37
CYLINDER AND PISTON
ENG
Piston ring end gap
Top ring
0.20 ~ 0.35 mm
(0.008 ~ 0.014 in)
<Limit>: 0.60 mm (0.024 in)
2nd ring
0.75 ~ 0.90 mm
(0.030 ~ 0.035 in)
<Limit>: 1.25 mm (0.049 in)
Oil ring
0.20 ~ 0.70 mm
(0.008 ~ 0.028 in)
EBS00251
CHECKING THE PISTON PIN
1. Check:
• piston pin
Blue discoloration/grooves → Replace the
piston pin and then check the lubrication
system.
2. Measure:
• piston pin outside diameter a
Out of specification → Replace the piston
pin.
Piston pin outside diameter
22.991 ~ 23.000 mm
(0.9052 ~ 0.9055 in)
<Limit>: 22.971 mm (0.9044 in)
3. Measure:
• piston pin bore inside diameter b
Out of specification → Replace the piston.
Piston pin bore inside diameter
23.004 ~ 23.015 mm
(0.9057 ~ 0.9061 in)
<Limit>: 23.045 mm (0.9073 in)
4 - 38
CYLINDER AND PISTON
ENG
4. Calculate:
• piston-pin-to-piston-pin-bore clearance
Out of specification → Replace the piston
pin and piston as a set.
Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter b –
Piston pin outside diameter a
Piston-pin-to-piston clearance
0.004 ~ 0.024 mm
(0.0002 ~ 0.0009 in)
<Limit>: 0.074 mm (0.0029 in)
EBS00252
INSTALLING THE PISTON AND CYLINDER
1. Install:
• top ring 1
• 2nd ring 2
• oil ring expander 3
• lower oil ring rail 4
• upper oil ring rail 5
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.
_
4 - 39
CYLINDER AND PISTON
2.
•
•
•
1
a
ENG
Install:
piston 1
piston pin 2
piston pin clips 3 New
NOTE:
• Apply engine oil to the piston pin.
• Make sure the punch mark a on the piston
points towards the exhaust side of the cylinder.
• Before installing the piston pin clips, cover
the crankcase opening with a clean rag to
prevent the clips from falling into the crankcase.
_
2
3 New
3.
•
•
4.
•
•
•
Install:
cylinder gasket New
dowel pins
Lubricate:
piston
piston rings
cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
e
a
120˚
b
120˚
120˚
90˚
a Top ring
b Oil ring expander
c Upper oil ring rail
d Lower oil ring rail
e 2nd ring
È Exhaust side
c
d
45˚
1
5. Offset:
• piston ring end gaps
È
45˚
6. Install:
• cylinder 1
• timing chain guide (exhaust side)
NOTE:
• 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.
_
4 - 40
CYLINDER AND PISTON
7. Install:
• cylinder bolts
2
E
1
1
2
ENG
E
NOTE:
Lubricate the cylinder bolt 1 threads and mating surface with engine oil.
8. Tighten:
• cylinder bolts 1 (1st)
T.
R.
15 Nm (1.5 m · kg, 11 ft · lb)
• cylinder bolts 1 (2nd)
T.
R.
50 Nm (5.0 m · kg, 36 ft · lb)
• cylinder bolts (timing chain side) 2
T.
R.
4 - 41
10 Nm (1.0 m · kg, 7.2 ft · lb)
AC MAGNETO
ENG
EBS00256
AC MAGNETO
E
10
T.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
R.
6
15
E
12
11
17
E
14
1
LT
2
E
9
6
LT
16
LT
E
New
8
7
13
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
3
LT
LT
LS
LT
R.
R.
T.
R.
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
(10)
T.
R.
New 5
4
T.
R.
Job/Part
Removing the AC magneto
Engine oil
Q’ty
Coolant
Left footrest board
1
2
3
4
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
T.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Order
LT
Select lever unit
Water pump
AC magneto coupler
Crankshaft position sensor coupler
Lead holder
AC magneto cover
1
1
1
1
4 - 42
70 Nm (7.0 m • kg, 50 ft • lb)
6 Nm (0.6 m • kg, 4.3 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Refer to “FOOTREST BOARDS” in chapter 3.
Refer to “SELECT LEVER UNIT”.
Refer to “WATER PUMP” in chapter 5.
Disconnect.
Disconnect.
Refer to “REMOVING THE AC MAGNETO ROTOR” and “INSTALLING THE
AC MAGNETO ROTOR”.
AC MAGNETO
E
ENG
10
T.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
R.
6
15
E
12
11
17
E
14
1
LT
2
E
9
6
LT
16
LT
E
New
8
7
13
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
3
LT
LT
LS
LT
R.
R.
T.
R.
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
(10)
T.
R.
New 5
4
T.
R.
14
15
16
Job/Part
AC magneto cover gasket
Dowel pin
Lead holder
Crankshaft position sensor
Stator coil
Torque limiter
Starter idle gear
Starter idle gear shaft
AC magneto rotor
Starter clutch
Woodruff key
Starter wheel gear
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
T.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Order
5
6
7
8
9
10
11
12
13
LT
70 Nm (7.0 m • kg, 50 ft • lb)
6 Nm (0.6 m • kg, 4.3 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Q’ty
Remarks
1
2
1
1
1
1
1
1
1
Refer to “REMOVING THE AC MAGNETO ROTOR” and “INSTALLING THE
AC MAGNETO ROTOR”.
1
1
1
4 - 43
AC MAGNETO
E
ENG
10
T.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
R.
6
15
E
12
11
17
E
14
1
LT
2
E
9
6
LT
16
LT
E
New
8
7
13
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
3
LT
LT
LS
LT
R.
R.
T.
R.
(10)
T.
R.
New 5
R.
T.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
4
T.
R.
Job/Part
Washer
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
T.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Order
17
LT
Q’ty
1
70 Nm (7.0 m • kg, 50 ft • lb)
6 Nm (0.6 m • kg, 4.3 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
For installation, reverse the removal procedure.
4 - 44
AC MAGNETO
ENG
EBS00259
REMOVING THE AC MAGNETO ROTOR
1. Remove:
• lead holder 1
• AC magneto cover
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
_
1
3
2
2. Remove:
• AC magneto rotor nut 1
• washer
NOTE:
• While holding the AC magneto rotor 2 with
the sheave holder 3, loosen the AC magneto rotor nut.
• Do not allow the sheave holder to touch the
projection on the rotor.
_
1
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
1
2
3. Remove:
• AC magneto rotor 1
(with the starter clutch)
• woodruff key
CAUTION:
To protect the end of the crankshaft, place
an appropriate sized socket between the
flywheel puller set center bolt and the
crankshaft.
NOTE:
• Use the flywheel puller 2.
• Install the flywheel puller bolts to the
threaded holes of the starter clutch.
• Make sure the flywheel puller is centered
over the AC magneto rotor.
4 - 45
AC MAGNETO
ENG
Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B
EBS00262
CHECKING THE STATOR COIL AND
CRANKSHAFT POSITION SENSOR
1. Check:
• stator coil 1
• crankshaft position sensor 2
Damage → Replace the crankshaft position
sensor/stator assembly.
2
1
EBS00263
1
LT
2
CHECKING THE STARTER CLUTCH
1. Check:
• starter one-way clutch 1
Cracks/damage → Replace.
• bolts 2
Loose → Replace with a new one, and
clinch the end of the bolt.
NOTE:
The arrow mark on the starter clutch must face
inward, away from the AC magneto rotor.
_
É
T.
R.
Starter clutch bolt
30 Nm (3.0 m · kg, 22 ft · lb)
LOCTITE®
È
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter wheel gear to the starter
clutch, and hold the starter clutch.
b. When turning the starter wheel gear
counter clockwise È, the starter clutch and
the wheel gear should be engaged.
If not, the starter clutch is faulty. Replace it.
c. When turning the starter wheel gear clockwise É, the starter wheel gear should turn
freely.
If not, the starter clutch is faulty. Replace it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 46
AC MAGNETO
ENG
2. Check:
• starter idle gear teeth
• starter wheel gear teeth
Burrs/clips/roughness/wear → Replace.
3. Check:
• starter wheel gear
(contacting surface)
Damage/pitting/wear → Replace.
CHECKING THE TORQUE LIMITER
• torque limiter
Damage/wear → Replace.
NOTE:
Do not disassemble the torque limiter.
EBS00268
1
INSTALLING THE AC MAGNETO ROTOR
1. Install:
• stator coil 1
LT
T.
R.
7 Nm (0.7 m · kg, 5.1 ft · lb)
a
T.
Stator coil bolt
7 Nm (0.7 m · kg, 5.1 ft · lb)
R.
b
NOTE:
Align the projection a on the stator coil with
the slot b in the AC magneto cover.
2. Apply:
• Sealant 1
(into the slit)
1
Yamaha bond No. 1215
90890-85505
(Three bond No.1215®)
4 - 47
AC MAGNETO
ENG
3. Install:
• woodruff key
• AC magneto rotor
NOTE:
• Before installing the rotor, clean the outside
of the crankshaft and the inside of the rotor.
• After installing the rotor, check that the rotor
rotates smoothly. If not, reinstall the key and
rotor.
_
4. Tighten:
• AC magneto rotor nut 1
3
T.
2
R.
70 Nm (7.0 m · kg, 50 ft · lb)
NOTE:
While holding the AC magneto rotor 2 with the
sheave holder 3, tighten the AC magneto
rotor nut.
_
1
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
5.
•
•
•
Install:
AC magneto cover
lead holder 1
AC magneto cover bolts
T.
R.
1
10 Nm (1.0 m · kg, 7.2 ft · lb)
NOTE:
Tighten the AC magneto cover bolts in stages,
using a crisscross pattern.
_
4 - 48
BALANCER GEARS AND OIL PUMP GEARS
ENG
BALANCER GEARS AND OIL PUMP GEARS
Order
1
2
Job/Part
Removing the balancer gears and oil
pump gears
Starter wheel gear
Lock washer
Balancer driven gear
3
4
5
Oil pump drive gear
Chain
Straight key
Q’ty
1
1
1
1
1
4 - 49
Remarks
Remove the parts in the order listed.
Refer to “AC MAGNETO”.
Refer to “REMOVING THE BALANCER
DRIVEN GEAR AND OIL PUMP
DRIVEN GEAR” and “INSTALLING THE
BALANCER DRIVE GEAR, BALANCER
DRIVEN GEAR, AND OIL PUMP
DRIVEN GEAR”.
BALANCER GEARS AND OIL PUMP GEARS
Order
6
7
8
9
10
11
Job/Part
Lock washer
Oil pump driven gear
Plate
Spring
Pin
Balancer drive gear
ENG
Q’ty
Remarks
1
Refer to “REMOVING THE BALANCER
DRIVEN GEAR AND OIL PUMP DRIVEN
GEAR” and “INSTALLING THE BALANCER DRIVE GEAR, BALANCER
DRIVEN GEAR, AND OIL PUMP
DRIVEN GEAR”.
1
1
8
Refer to “REMOVING THE BALANCER
DRIVEN GEAR AND OIL PUMP
4
DRIVEN GEAR” and “INSTALLING THE
1
BALANCER DRIVE GEAR, BALANCER
DRIVEN GEAR, AND OIL PUMP
DRIVEN GEAR”.
For installation, reverse the removal procedure.
4 - 50
BALANCER GEARS AND OIL PUMP GEARS
3
4
ENG
1
REMOVING THE BALANCER DRIVEN
GEAR AND OIL PUMP DRIVEN GEAR
1. Straighten the lock washer tabs.
2. Loosen:
• balancer driven gear nut 1
• oil pump driven gear nut 2
2
NOTE:
Place an aluminum plate 3 between the teeth
of the balancer drive gear 4 and balancer
driven gear 5, then loosen the nuts.
5
CHECKING THE OIL PUMP DRIVE
1. Check:
• oil pump drive gear
• oil pump driven gear
Cracks/wear/damage → Replace.
CHECKING THE BALANCER DRIVE
1. Check:
• balancer drive gear
• balancer driven gear
Damage/wear → Replace the balancer
drive gear and balancer driven gear as a
set.
Excessive noise during operation →
Replace the balancer drive gear and balancer driven gear as a set.
4 - 51
BALANCER GEARS AND OIL PUMP GEARS
ENG
INSTALLING THE BALANCER DRIVE
GEAR, BALANCER DRIVEN GEAR, AND
OIL PUMP DRIVEN GEAR
1. Install:
• pin
• spring
• balancer drive gear
(onto the buffer boss)
NOTE:
Align the punch mark a on the balancer drive
gear with the hole b to the buffer boss.
a
b
2.
•
•
•
2
1
c
3
NOTE:
• Align the punch mark a on the balancer
drive gear with the punch mark b on the balancer driven gear.
• Install the oil pump driven gear with the “3B4”
mark c facing out.
3. Install:
• lock washers New
• oil pump driven gear nut 1
5
4
Install:
balancer drive gear 1
balancer driven gear 2
oil pump driven gear 3
2
T.
R.
22 Nm (2.2 m · kg, 16 ft · lb)
• balancer driven gear nut 2
T.
R.
3
1
80 Nm (8.0 m · kg, 58 ft · lb)
NOTE:
• Place an aluminum plate 3 between the
teeth of the balancer drive gear 4 and balancer driven gear 5, then tighten the nuts.
• Apply the engine oil to the thread of axles
and nuts.
4. Bend the lock washer tabs along the balancer driven gear nut and oil pump driven
gear nut.
4 - 52
ENG
PRIMARY AND SECONDARY SHEAVES
EBS00269
PRIMARY AND SECONDARY SHEAVES
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
11 New
2 New
1
(11)
10 New
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
(8)
9
7
8
LS
6
4
5
4
New
E
T.
R.
140 Nm (14.0 m • kg, 100 ft • lb)
3
T.
R.
100 Nm (10.0 m • kg, 72 ft • lb)
Q’ty
Air ducts
Drive belt cover
Rubber gasket
Bearing housing
Dowel pin
Primary sheave assembly
V-belt
Primary fixed sheave
Secondary sheave assembly
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “ENGINE SKID PLATES, SEAT,
CARRIERS AND FENDERS” in chapter
3.
Refer to “FOOTREST BOARDS” in chapter 3.
Refer to “ENGINE REMOVAL”.
Right footrest board
1
2
3
4
5
6
7
8
R.
R.
Job/Part
Removing the primary and secondary sheaves
Front fender/rear fender
T.
T.
Order
10 Nm (1.0 m • kg, 7.2 ft • Ib)
1
1
1
2
1
1
1
1
4 - 53
Refer to “REMOVING THE PRIMARY
AND SECONDARY SHEAVES” and
“INSTALLING THE PRIMARY AND
SECONDARY SHEAVES”.
ENG
PRIMARY AND SECONDARY SHEAVES
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
11 New
2 New
1
(11)
10 New
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
(8)
9
7
8
LS
6
4
5
4
New
E
T.
R.
140 Nm (14.0 m • kg, 100 ft • lb)
3
T.
R.
100 Nm (10.0 m • kg, 72 ft • lb)
Q’ty
1
1
1
R.
R.
Job/Part
Drive belt case
Rubber gasket
Rubber gasket
T.
T.
Order
9
10
11
10 Nm (1.0 m • kg, 7.2 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
For installation, reverse the removal procedure.
4 - 54
PRIMARY AND SECONDARY SHEAVES
ENG
EBS00270
PRIMARY SHEAVE
Order
1
2
3
4
5
6
7
8
Job/Part
Disassembling the primary sheave
Primary pulley sheave cap
Primary pulley slider
Primary pulley cam
Primary pulley weight
Collar
Oil seal
Primary sliding sheave
O-ring
Q’ty
1
4
1
8
1
2
1
1
Remarks
Remove the parts in the order listed.
Refer to “ASSEMBLING THE PRIMARY
SHEAVE”.
For assembly, reverse the disassembly
procedure.
4 - 55
PRIMARY AND SECONDARY SHEAVES
ENG
EBS00271
SECONDARY SHEAVE
Order
1
2
3
4
5
6
7
8
9
Job/Part
Disassembling the secondary
sheave
Nut
Spring seat
Compression spring
Spring seat
Guide pin
Secondary sliding sheave
O-ring
Secondary fixed sheave
Oil seal
Q’ty
1
1
1
1
4
1
2
1
2
Remarks
Remove the parts in the order listed.
Refer to “DISASSEMBLING THE SECONDARY SHEAVE” and “ASSEMBLING
THE SECONDARY SHEAVE”.
For assembly, reverse the disassembly
procedure.
4 - 56
PRIMARY AND SECONDARY SHEAVES
ENG
EBS00272
REMOVING THE PRIMARY AND
SECONDARY SHEAVES
1. Loosen:
• secondary sheave nut 1
• primary sheave nut 2
NOTE:
• Use the sheave holder 3 to hold the primary
sheave.
• First, loosen the secondary sheave nut 2,
then loosen the primary sheave nut 1.
_
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
EBS00273
DISASSEMBLING THE SECONDARY
SHEAVE
1. Remove:
• nut 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Attach the sheave fixed block 2, locknut
wrench 3 and sheave spring compressor
4 to the secondary sheave assembly.
Sheave fixed block
90890-04135
Sheave fixed bracket
YM-04135
Locknut wrench
90890-01348, YM-01348
Sheave spring compressor
90890-04134, YM-04134
b. Place the sheave fixed block in a vise and
secure it.
c. Tighten the sheave spring compressor nut
5 and compress the spring.
d. Loosen the nut 1 with the locknut wrench
3.
e. Remove the nut 1.
f. Remove the sheave spring compressor and
locknut wrench.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 57
PRIMARY AND SECONDARY SHEAVES
ENG
EBS00274
CHECKING THE PRIMARY SHEAVE
1. Check:
• weight outside diameter a
Out of specification → Replace the weight.
Weight outside diameter
30 mm (1.18 in)
<Limit>: 29.5 mm (1.16 in)
2. Check:
• primary pulley slider
• primary sliding sheave splines
Wear/cracks/damage → Replace.
• primary pulley cam
Cracks/damage → Replace.
3. Check:
• primary sliding sheave
• primary fixed sheave
Cracks/damage → Replace.
EBS00275
CHECKING THE SECONDARY SHEAVE
1. Check:
• secondary fixed sheave smooth operation
• secondary sliding sheave smooth operation
Scratches/damage → Replace as a set.
2. Check:
• torque cam grooves 1
Wear/damage → Replace.
3. Check:
• guide pins 2
Wear/damage → Replace.
4. Check:
• secondary sheave spring
Damage → Replace.
4 - 58
PRIMARY AND SECONDARY SHEAVES
ENG
5. Measure:
• secondary sheave spring free length a
Out of specification → Replace the secondary sheave spring.
Free length
130.6 mm (5.14 in)
<Limit>: 128.0 mm (5.04 in)
EBS00276
ASSEMBLING THE PRIMARY SHEAVE
1. Clean:
• primary sliding sheave face 1
• primary fixed sheave face 2
• collar 3
• weights 4
• primary sliding sheave cam face
NOTE:
Remove any excess grease.
_
2. Install:
• weights 1
NOTE:
• Apply Yamaha Grizzly grease (90 g) to the
whole outer surface of the weights and
install.
• Apply Yamaha Grizzly grease (2.5 g) to the
inner surface of the collar.
• Apply Yamaha Grizzly grease (2.5 g) to the
inner surface of the primary sliding sheave.
_
4 - 59
PRIMARY AND SECONDARY SHEAVES
3.
•
•
•
ENG
Install:
slider 1
cam 2
primary sliding sheave cap
T.
R.
3 Nm (0.3 m · kg, 2.2 ft · lb)
EBS00277
ASSEMBLING THE SECONDARY SHEAVE
1. Apply:
• BEL-RAY assembly lube®
(to the secondary sliding sheave 1 inner
surface and oil seals)
• BEL-RAY assembly lube®
(to the bearings, oil seals and inner surface
of the secondary fixed sheave 2)
2. Install:
• guide pins 1
3. Apply:
• BEL-RAY assembly lube®
(to the guide pin sliding grooves 1, and oil
seals 2 New )
4 - 60
PRIMARY AND SECONDARY SHEAVES
4.
•
•
•
•
ENG
Install:
spring seat
compression spring
spring seat
nut
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Attach the sheave fixed block, locknut
wrench and sheave spring compressor to
the secondary sheave.
Sheave fixed block
90890-04135
Sheave fixed bracket
YM-04135
Locknut wrench
90890-01348, YM-01348
Sheave spring compressor
90890-04134, YM-04134
b. Place the sheave fixed block in a vise and
secure it.
c. Tighten the sheave spring compressor nut
1 and compress the spring.
d. Install the nut 2 and tighten it to the specified torque using the locknut wrench.
T.
Nut
90 Nm (9.0 m · kg, 65 ft · lb)
R.
e. Remove the sheave spring compressor,
locknut wrench, and sheave fixed block.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 61
PRIMARY AND SECONDARY SHEAVES
ENG
EBS00279
INSTALLING THE PRIMARY AND
SECONDARY SHEAVES
1. Install:
• secondary sheave
• V-belt
• primary sheave
NOTE:
• Tightening the bolts 1 will push the secondary sliding sheave away, causing the gap
between the secondary fixed and sliding
sheaves to widen.
• Install the V-belt so that its arrow faces the
direction shown in the illustration.
_
2. Tighten:
• primary sheave nut 1
T.
R.
140 Nm (14.0 m · kg, 100 ft · lb)
• secondary sheave nut 2
T.
R.
100 Nm (10.0 m · kg, 72 ft · lb)
NOTE:
• Use the sheave holder 3 to hold the primary
sheave.
• First, tighten the primary sheave nut 1, then
tighten the secondary sheave nut 2.
_
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
4 - 62
CLUTCH
ENG
EBS00291
CLUTCH
Order
1
2
3
4
5
6
Job/Part
Removing the clutch
Primary sheave/secondary sheave
Clutch housing assembly
Gasket
Dowel pin
One-way clutch bearing
Nut
Clutch carrier assembly
Q’ty
1
1
2
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “PRIMARY AND SECONDARY
SHEAVES”.
Refer to “REMOVING THE CLUTCH”
and “INSTALLING THE CLUTCH”.
For installation, reverse the removal procedure.
4 - 63
CLUTCH
ENG
EBS00292
Order
1
2
3
4
5
6
7
8
Job/Part
Disassembling the clutch housing
assembly
Oil seal
Circlip
Bearing housing
Circlip
Bearing
Circlip
Bearing
Clutch housing
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
4 - 64
CLUTCH
ENG
EBS00296
REMOVING THE CLUTCH
1. Remove:
• clutch housing assembly
• gasket
• dowel pins
NOTE:
Working in crisscross pattern, loosen each bolt
1/4 of a turn. Remove them after all of them
are loosened.
_
2.
•
3.
•
Straighten:
punched portion of the nut 1
Remove:
nut 1
CAUTION:
The clutch carrier assembly nut has lefthanded threads. To loosen the clutch carrier assembly nut turn it clockwise.
NOTE:
Use a clutch holding tool 2 to hold the clutch
carrier assembly.
_
Universal clutch holder
90890-04086, YM-91042
4 - 65
CLUTCH
ENG
EBS00299
CHECKING THE CLUTCH
1. Check:
• clutch housing
Heat damage/wear/damage → Replace.
• one-way clutch bearing
Chafing/wear/damage → Replace.
NOTE:
• Replace the one-way clutch assembly and
clutch housing as a set.
• The one-way clutch bearing must be
installed with the flange side facing in.
_
2. Check:
• one-way clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the one-way clutch bearing and
clutch carrier assembly to the clutch housing and hold the clutch carrier assembly.
b. When turning the clutch housing clockwise
È, the clutch housing should turn freely.
If not, the one-way clutch assembly is
faulty.
Replace it.
c. When turning the clutch housing counterclockwise É, the clutch housing and crankshaft should be engaged.
If not, the one-way clutch assembly is
faulty.
Replace it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• clutch shoe
Heat damage → Replace.
4. Measure:
• clutch shoe thickness
Out of specification → Replace.
Clutch shoe thickness
1.5 mm (0.06 in)
Clutch shoe wear limit a
1.0 mm (0.04 in)
4 - 66
CLUTCH
ENG
EBS00309
INSTALLING THE CLUTCH
1. Install:
• clutch carrier assembly
• nut 1 New
T.
190 Nm (19.0 m · kg, 140 ft · lb)
R.
CAUTION:
The clutch carrier assembly nut has lefthanded threads. To tighten the clutch carrier assembly nut turn it counterclockwise.
NOTE:
Use a clutch holding tool 2 to hold the clutch
carrier assembly.
Universal clutch holder
90890-04086, YM-91042
2. Lock the threads with a drift punch.
3. Install:
• one-way clutch bearing
NOTE:
The one-way clutch bearing should be
installed in the clutch carrier assembly with the
“OUT SIDE” mark a facing toward the clutch
housing.
_
4.
•
•
•
Install:
dowel pins
gasket New
clutch housing assembly
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
NOTE:
• Tighten the bolts in stages, using a crisscross pattern.
• After tightening the bolts, check that the
clutch housing assembly rotates smoothly.
_
4 - 67
CRANKCASE
ENG
EBS00319
CRANKCASE
TIMING CHAIN AND OIL FILTER
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
17 Nm (1.7 m • kg, 12 ft • Ib)
6
9
E
8 New
LS
T.
New
R.
T.
R.
68 Nm (6.8 m • kg, 49 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LS
New
LS
5
T.
R.
New
10 Nm (1.0 m • kg, 7.2 ft • Ib)
E
1
LS
LT
New
4
LS
LT
3
New
New
2
7
LT
T.
R.
New
30 Nm (3.0 m • kg, 22 ft • Ib)
LT
T.
R.
17 Nm (1.7 m • kg, 12 ft • Ib)
T.
R.
Order
1
2
3
4
Job/Part
Removing the timing chain and oil
filter
Engine
Cylinder head
Cylinder/piston
AC magneto rotor/starter wheel gear
Balancer driven gear/oil pump driven
gear
Primary sheave assembly/secondary
sheave assembly
Clutch carrier assembly
Timing chain guide (intake side)
Timing chain guide
Timing chain
Oil filter cartridge
Q’ty
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “ENGINE REMOVAL”.
Refer to “CYLINDER HEAD”.
Refer to “CYLINDER AND PISTON”.
Refer to “AC MAGNETO”.
Refer to “BALANCER GEARS AND OIL
PUMP GEARS”.
Refer to “PRIMARY AND SECONDARY
SHEAVES”.
Refer to “CLUTCH”.
1
1
1
1
4 - 68
CRANKCASE
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
ENG
T.
R.
17 Nm (1.7 m • kg, 12 ft • Ib)
6
9
E
8 New
LS
T.
New
R.
T.
R.
68 Nm (6.8 m • kg, 49 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LS
New
LS
5
T.
R.
New
10 Nm (1.0 m • kg, 7.2 ft • Ib)
E
1
LS
LT
New
4
LS
LT
3
New
New
2
7
LT
T.
R.
New
30 Nm (3.0 m • kg, 22 ft • Ib)
LT
T.
R.
17 Nm (1.7 m • kg, 12 ft • Ib)
T.
R.
Order
5
6
7
8
9
Job/Part
Speed sensor
Dipstick
Relief valve assembly
Reverse switch
Gear position switch
Q’ty
1
1
1
1
1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
For installation, reverse the removal procedure.
4 - 69
CRANKCASE
ENG
EBS00320
CRANKCASE
T.
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R.
18 Nm (1.8 m • kg, 13 ft • Ib)
T.
R.
7
18 Nm (1.8 m • kg, 13 ft • Ib)
New
E
9
T.
6
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
2
New
New
(4)
8
E
1
4
9
New
LS
E
3
10
LS
5
T.
R.
Q’ty
1
1
1
1
1
1
1
1
2
1
4 - 70
R.
R.
1
2
3
4
5
6
7
8
9
10
Job/Part
Separating the crankcase
Shift lever cover
Gasket
Dowel pin
Shift lever 1
Shift lever 2 assembly
Shift drum stopper
Stopper lever stopper
Right crankcase
Dowel pin
Left crankcase
26 Nm (2.6 m • kg, 19 ft • Ib)
T.
T.
Order
E
10 Nm (1.0 m • kg, 7.2 ft • Ib)
14 Nm (1.4 m • kg, 10 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “INSTALLING THE SHIFT
LEVER”.
Spring identification color: red
Spring identification color: yellow
Refer to “SEPARATING THE CRANKCASE” and “ASSEMBLING THE
CRANKCASE”.
For installation, reverse the removal procedure.
ENG
CRANKCASE
EBS00321
CRANKCASE BEARINGS
New
LS
LS
1
E
2
4
LT
New 3
T.
R.
7
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
.
7
E
7
7
6
5
7
E
E
7
7
E
7
E
Order
1
2
3
4
5
6
7
Job/Part
Removing the crankcase bearings
Crankshaft/oil pump
Transmission
Middle drive shaft/middle driven shaft
Collar
O-ring
Oil seal
Bearing retainer
Spacer
Crank seal
Bearing
Q’ty
E
Remarks
Remove the parts in the order listed.
Refer to “CRANKSHAFT AND OIL
PUMP”.
Refer to “TRANSMISSION”.
Refer to “MIDDLE GEAR”.
1
1
1
1
1
2
9
For installation, reverse the removal procedure.
4 - 71
CRANKCASE
ENG
EBS00332
SEPARATING THE CRANKCASE
1. Separate:
• right crankcase
• left crankcase
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the lead holders and crankcase
bolts.
NOTE:
• Loosen each bolt 1/4 of a turn at a time and
after all the bolts are loosened, remove
them.
• Loosen the bolts in numerical order (see
numbers on the illustration).
_
È
È Left crankcase
É Right crankcase
b. Remove the right crankcase.
CAUTION:
_
Use a soft hammer to tap on one side of the
crankcase. Tap only on reinforced portions
of the crankcase. Do not tap on the crankcase mating surfaces. Work slowly and
carefully. Make sure that the crankcase
halves separate evenly.
É
c. Remove the dowel pins.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS00335
CHECKING THE TIMING CHAIN AND GUIDE
1. Check:
• timing chain
Cracks/stiff → Replace the timing chain and
camshaft sprocket as a set.
2. Check:
• intake side timing chain guide
Wear/damage → Replace.
4
3
2
1
CHECKING THE RELIEF VALVE
1. Check:
• spring seat 1
• spring 2
• relief valve body 3
• relief valve 4
Damage/wear → Replace the defective
part(s).
4 - 72
CRANKCASE
ENG
EBS00339
CHECKING THE BEARINGS
1. Check:
• bearings
Clean and lubricate, then rotate the inner
race with a finger.
Roughness → Replace.
EBS00338
CHECKING THE CRANKCASE
1. Thoroughly wash the case halves in a mild
solvent.
2. Clean all the gasket mating surfaces and
crankcase mating surfaces thoroughly.
3. Check:
• crankcase
Cracks/damage → Replace.
• oil delivery passages
Clogged → Blow out with compressed air.
a
EBS00342
1
2
2
ASSEMBLING THE CRANKCASE
1. Apply:
• sealant 1
(to the mating surfaces of both case halves)
Yamaha bond No. 1215
90890-85505
(Three bond No.1215®)
NOTE:
Apply two coats of sealant to the area a
shown in the illustration.
2. Install:
• dowel pins 2
4 - 73
CRANKCASE
ENG
3. Fit the right crankcase onto the left crankcase. Tap lightly on the case with a soft
hammer.
CAUTION:
_
Before installing and torquing the crankcase holding bolts, be sure to check
whether the transmission is functioning
properly by manually rotating the shift
drum in both directions.
È
4.
•
•
5.
•
Install:
lead holder
crankcase bolts
Tighten:
crankcase bolts
(follow the proper tightening sequence)
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
È Right crankcase
É Left crankcase
É
NOTE:
Tighten the bolts in stages, using a crisscross
pattern.
_
6. Apply:
• 4-stroke engine oil
(to the crankshaft pin, bearing and oil delivery hole)
7. Check:
• crankshaft and transmission operation
Unsmooth operation → Repair.
INSTALLING THE SHIFT LEVER
1. Install:
• shift lever 2 assembly 1
T.
R.
14 Nm (1.4 m · kg, 10 ft · lb)
• shift lever 1 2
NOTE:
When installing the shift lever 1, align the
punch mark a on the shift lever 1 with the
punch marks b on the shift lever 2.
4 - 74
CRANKSHAFT AND OIL PUMP
ENG
EBS00326
CRANKSHAFT AND OIL PUMP
3
4
2 New
1
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
Order
1
2
3
4
Job/Part
Removing the crankshaft and oil
pump
Crankcase
Oil pump
Gasket
Balancer
Crankshaft
Q’ty
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
1
1
1
1
4 - 75
Refer to “REMOVING THE CRANKSHAFT” and “INSTALLING THE CRANKSHAFT”.
For installation, reverse the removal procedure.
CRANKSHAFT AND OIL PUMP
ENG
EBS00327
OIL PUMP
6
3
2
5
4
1
E
E
T.
R.
Order
1
2
3
4
5
6
5 Nm (0.5 m • kg, 3.6 ft • Ib)
Job/Part
Disassembling the oil pump
Oil pump housing cover
Pin
Oil pump shaft
Oil pump inner rotor
Oil pump outer rotor
Oil pump housing
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
4 - 76
CRANKSHAFT AND OIL PUMP
ENG
EBS00336
REMOVING THE CRANKSHAFT
1. Remove:
• crankshaft 1
Use a crankcase separating tool 2.
2
Crankcase separating tool
90890-01135
Crankcase separator
YU-01135-B
1
EBS00331
CHECKING THE OIL PUMP
1. Check:
• oil pump housing
• oil pump housing cover
Cracks/wear/damage → Replace.
2. Measure:
• inner-rotor-to-outer-rotor-tip clearance a
• outer-rotor-to-oil-pump-housing clearance
b
• oil-pump-housing-to-inner-rotor-and-outerrotor clearance c
Out of specification → Replace the oil
pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing
Inner-rotor-to-outer-rotor-tip
clearance
Less than 0.12 mm (0.0047 in)
<Limit>: 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing
clearance
0.090 ~ 0.170 mm
(0.0035 ~ 0.0067 in)
<Limit>: 0.24 mm (0.0094 in)
Oil-pump-housing-to-inner-rotorand-outer-rotor clearance
0.030 ~ 0.100 mm
(0.0012 ~ 0.0039 in)
<Limit>: 0.17 mm (0.0067 in)
3. Check:
• oil pump operation
Rough movement → Repeat steps (1) and
(2) or replace the defective part(s).
4 - 77
CRANKSHAFT AND OIL PUMP
ENG
CHECKING THE OIL STRAINER
1. Check:
• oil strainer
Damage → Replace.
Contaminants → Clean with engine oil.
EBS00360
CHECKING THE CRANKSHAFT
1. Measure:
• crank width a
Out of specification → Replace the crankshaft.
d
c
Crank width
74.95 ~ 75.00 mm
(2.951 ~ 2.953 in)
c
2. Measure:
• side clearance d
Out of specification → Replace the crankshaft.
Big end side clearance
0.350 ~ 0.650 mm
(0.0138 ~ 0.0256 in)
<Limit>: 1.0 mm (0.04 in)
a
3. Measure:
• runout c
Out of specification → Replace the crankshaft.
Runout limit
0.030 mm (0.0012 in)
4 - 78
CRANKSHAFT AND OIL PUMP
ENG
EBS00318
2
1
3
a
a
4
ASSEMBLING THE OIL PUMP
1. Install:
• oil pump housing 1
• oil pump outer rotor 2
• oil pump inner rotor 3
• oil pump shaft 4
• pin 5
NOTE:
When installing the oil pump shaft 4 align the
pin 5 with the groove a in the inner rotor 3.
5
_
EBS00362
INSTALLING THE CRANKSHAFT
1. Install:
• crankshaft 1
5
1
6
Crankshaft installer pot 2
90890-01274
Installing pot
YU-90058
Pot installer
YU-90059
Crankshaft installer bolt 3
90890-01275
Bolt
YU-90060
Adapter (M16) 4
90890-04130
Adapter #13
YM-04059
Spacer (crankshaft installer) 5
90890-04081
Pot spacer
YM-91044
Spacer 6
90890-01309
Pot spacer
YU-90059
4
2
3
4 - 79
CRANKSHAFT AND OIL PUMP
ENG
NOTE:
Hold the connecting rod at the Top Dead Center (TDC) with one hand while turning the nut
of the installing tool with the other. Operate the
installing tool until the crankshaft bottoms
against the bearing.
_
CAUTION:
_
Apply engine oil to each bearing to protect
the crankshaft against scratches and to
make installation easier.
4 - 80
TRANSMISSION
ENG
EBS00345
TRANSMISSION
E
1
11
12
E
New
7
New
M
10
New
6
9
New
5
E
4
8
3
New
E
2
Order
Job/Part
Removing the transmission
Crankcase
Q’ty
1
2
3
4
5
6
Middle driven gear
Shift drum
Shift fork assembly
Shift fork “R”
Spring
Shift fork “L”
Shift fork guide bar
1
1
1
1
1
1
7
8
9
10
Secondary shaft
Drive axle assembly
Reverse idle gear
Reverse idle gear shaft
1
1
1
1
4 - 81
Remarks
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
Refer to “MIDDLE GEAR”.
Refer to “ASSEMBLING THE
SHIFT FORK
ASSEMBLY”.
Refer to “REMOVING THE TRANSMISSION” and
“INSTALLING THE
TRANSMISSION”.
TRANSMISSION
ENG
E
1
11
12
E
New
7
New
M
10
New
6
9
New
5
E
4
8
3
New
E
2
Order
11
12
Job/Part
Stopper lever
Stopper lever shaft
Q’ty
1
1
4 - 82
Remarks
Refer to “REMOVING THE TRANSMISSION” and “INSTALLING THE TRANSMISSION”.
For installation, reverse the removal procedure.
ENG
TRANSMISSION
EBS00348
DRIVE AXLE
9
8
7
New 6
5
4
3
M
2
M
1
G
M
H
M
F
M
M
E
M
D
B
0
Order
1
2
3
4
5
6
7
8
9
0
A
B
C
C New
A New
Job/Part
Disassembling the drive axle
assembly
Washer
Collar
High wheel gear
Washer
Clutch dog
Circlip
Washer
Collar
Low wheel gear
Washer
Circlip
Middle drive gear
Circlip
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
1
4 - 83
Remarks
Remove the parts in the order listed.
ENG
TRANSMISSION
9
8
7
New 6
5
4
3
M
2
M
1
G
M
H
M
F
M
M
E
M
D
B
0
Order
D
E
F
G
H
C New
A New
Job/Part
Washer
Bearing
Reverse wheel gear
Stopper wheel
Drive axle
Q’ty
1
1
1
1
1
Remarks
For assembly, reverse the disassembly
procedure.
4 - 84
TRANSMISSION
ENG
REMOVING THE TRANSMISSION
1. Remove:
• shift drum 1
• shift fork assembly 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pull out the guide bar from the left crankcase.
b. Push down on the drive shaft, and then
slide the shift fork assembly to remove the
shift fork cam followers.
c. Remove the shift drum.
d. Remove the shift fork assembly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS00349
CHECKING THE SHIFT FORKS
1. Check:
• shift fork cam follower 1
• shift fork pawl 2
Scoring/bends/wear/damage → Replace.
2. Check:
• guide bar
Roll the guide bar on a flat surface.
Bends → Replace.
WARNING
_
Do not attempt to straighten a bent guide
bar.
3. Check:
• shift fork movement
(on the guide bar)
Unsmooth operation → Replace the shift
fork and the guide bar.
4. Check:
• spring
Cracks/damage → Replace.
4 - 85
TRANSMISSION
ENG
EBS00351
CHECKING THE SHIFT DRUM
1. Check:
• shift drum grooves
Scratches/wear/damage → Replace.
EBS00354
CHECKING THE TRANSMISSION
1. Measure:
• drive axle runout
(with a centering device and dial gauge 1)
Out of specification → Replace the drive
axle.
Drive axle runout limit
0.06 mm (0.0024 in)
2. Check:
• transmission gears
Blue discoloration/pitting/wear → Replace
the defective gear(s).
• transmission gear dogs
Cracks/damage/rounded edges → Replace
the defective gear(s).
3. Check:
• transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission
axle assemblies.
4. Check:
• transmission gear movement
Rough movement → Replace the defective
part(s).
5. Check:
• circlips
Bends/damage/looseness → Replace.
4 - 86
TRANSMISSION
ENG
CHECKING THE SECONDARY SHAFT
1. Check:
• gear teeth
Blue discoloration/pitting/wear → Replace.
CHECKING THE STOPPER LEVER AND
STOPPER WHEEL
1. Check:
• stopper lever pawl 1
Bends/damage/wear → Replace the stopper lever and stopper wheel as a set.
• stopper wheel 2
Damage/wear → Replace the stopper
wheel and stopper lever as a set.
• stopper lever shaft 3
Bends/damage/wear → Replace.
New 5
1
2
3
3B4
New 5
a
4
ASSEMBLING THE SHIFT FORK
ASSEMBLY
1. Install:
• shift fork guide bar 1
• shift fork “L” 2
• spring 3
• shift fork “R” 4
• circlips 5 New
NOTE:
Install the shift forks with their “3B4” marks a
facing each other.
4 - 87
TRANSMISSION
ENG
EBS00356
INSTALLING THE TRANSMISSION
1. Install:
• stopper lever shaft
• stopper lever
• reverse idle gear 1
• drive axle assembly 2
• secondary shaft 3
• shift fork assembly 4
• shift drum 5
3
2
4
5
1
NOTE:
Install the shift forks 6 with the “L” mark a
and “R” mark b facing towards the left and
right sides of the crankcase respectively.
_
a
b
6
2. Check:
• shift operation
Unsmooth operation → Repair.
NOTE:
• Oil each gear and bearing thoroughly.
• Before assembling the crankcase, make
sure that the transmission is in neutral and
that the gears turn freely.
_
4 - 88
MIDDLE GEAR
ENG
EBS00363
MIDDLE GEAR
MIDDLE DRIVE SHAFT
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the middle drive shaft
Crankcase
Bearing housing
Middle drive pinion gear nut
Middle drive pinion gear
Middle drive gear shim
Middle drive shaft
Bearing retainer
Bearing
Circlip
Middle driven gear
Q’ty
1
1
1
*
1
2
1
1
1
Remarks
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
Refer to “REMOVING THE MIDDLE
DRIVE SHAFT” and “INSTALLING THE
MIDDLE DRIVE SHAFT”.
For installation, reverse the removal procedure.
4 - 89
MIDDLE GEAR
ENG
EBS00364
MIDDLE DRIVEN SHAFT
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the middle driven shaft
Crankcase
Q’ty
Front drive shaft coupling gear nut
(middle gear side)
Front drive shaft coupling gear (middle
gear side)
Middle driven pinion gear assembly
Rear drive shaft coupling gear nut
(middle gear side)
Rear drive shaft coupling gear (middle
gear side)
Bearing housing
O-ring
Middle driven gear shim
Middle driven pinion gear
Remarks
Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
1
1
1
1
1
1
1
*
1
4 - 90
Refer to “REMOVING THE MIDDLE
DRIVEN SHAFT” and “INSTALLING
THE MIDDLE DRIVEN SHAFT”.
MIDDLE GEAR
Order
10
11
12
13
14
15
Job/Part
Bearing
Middle driven pinion gear bearing
retainer
Bearing
Middle driven shaft bearing retainer
Bearing
Middle driven shaft
Q’ty
1
1
1
1
1
1
ENG
Remarks
Refer to “REMOVING THE MIDDLE
DRIVEN SHAFT” and “INSTALLING
THE MIDDLE DRIVEN SHAFT”.
For installation, reverse the removal procedure.
4 - 91
MIDDLE GEAR
ENG
EBS00365
REMOVING THE MIDDLE DRIVE SHAFT
1. Straighten:
• punched portion of the middle drive pinion
gear nut
2. Loosen:
• middle drive pinion gear nut 1
NOTE:
Secure the middle drive shaft in the vise with a
clean rag.
_
1
2
3.
•
•
•
Remove:
middle drive pinion gear nut
middle drive pinion gear
shim(s)
4.
•
•
•
Remove:
middle driven gear 1
circlip
middle drive shaft 2
NOTE:
Press the middle drive shaft end and remove
the middle driven gear.
4 - 92
MIDDLE GEAR
ENG
EBS01020
2
1
REMOVING THE MIDDLE DRIVEN SHAFT
1. Remove:
• front drive shaft coupling gear nut (middle
gear side) 1
• washer
• front drive shaft coupling gear (middle gear
side) 2
NOTE:
Use the coupling gear/middle shaft tool 3 to
hold the coupling gear.
3
_
Coupling gear/middle shaft tool
90890-01229
Gear holder
YM-01229
2
1
3
2. Remove:
• rear drive shaft coupling gear nut (middle
gear side) 1
• washer
• rear drive shaft coupling gear (middle gear
side) 2
NOTE:
Use the coupling gear/middle shaft tool 3 to
hold the coupling gear.
Coupling gear/middle shaft tool
90890-01229
Gear holder
YM-01229
3. Remove:
• bearing housing assembly 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the bearing housing
assembly.
b. Place the bearing housing assembly onto a
hydraulic press.
4 - 93
MIDDLE GEAR
ENG
CAUTION:
_
• Never directly press the middle driven
pinion gear end with a hydraulic press,
this will result in damage to the middle
driven pinion gear thread.
• Install a suitable socket 2 on the middle
driven pinion gear end to protect the
thread from damage.
c. Press the middle driven pinion gear end
and remove the bearing housing.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
2
4. Remove:
• middle driven pinion gear bearing retainer
• bearing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Attach the folded rag 1.
b. Secure the bearing housing edge in the
vise.
c. Attach the bearing retainer wrench 2.
Bearing retainer wrench
90890-04128
Middle gear bearing retainer
YM-04128
CAUTION:
_
The middle driven pinion gear bearing
retainer has left-handed threads. To loosen
the retainer, turn it clockwise.
d. Remove the bearing retainer and bearing.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 94
MIDDLE GEAR
ENG
5. Remove:
• oil seal 1
• middle driven shaft bearing retainer 2
NOTE:
Attach the ring nut wrench 3.
_
2
Ring nut wrench
90890-01430, YM-38404
1
CAUTION:
_
The middle driven shaft bearing retainer
has left-handed threads. To loosen the
retainer turn it clockwise.
3
6. Remove:
• middle driven shaft 1
(with bearing)
1
EBS01021
CHECKING THE PINION GEARS
1. Check:
• drive pinion gear teeth
• driven pinion gear teeth
Pitting/galling/wear → Replace.
2. Check:
• O-ring
Damage → Replace.
• bearings
Pitting/damage → Replace.
4 - 95
MIDDLE GEAR
ENG
EBS00370
SELECTING MIDDLE DRIVE AND DRIVEN
GEAR SHIMS
When the drive and driven gear, bearing housing assembly and/or crankcase replaced, be
sure to adjust the gear shim 1, 2.
1. Select:
• middle drive gear shim 1
• middle driven gear shim 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Position middle drive and driven gear by
using shims 1 and 2 with their respective
thickness calculated from information
marked on crankcase, bearing housing and
drive gear end.
“A”
1 Shim thickness “A”
2 Shim thickness “B”
b. To find shim thickness “A” use following formula:
1
Middle drive pinion gear shim thickness
“A” = e + d – b – c – a
2
“B”
Where:
a = a numeral (usually a decimal number) on
the bearing housing is either added to or
subtracted from “0.6”
b = 17.0
c = 55.0
d = a numeral (usually a decimal number) on
the right crankcase specifies a thickness
of “65.0”
a
d
4 - 96
MIDDLE GEAR
e
ENG
e = a numeral (usually a decimal number) on
the left crankcase specifies a thickness of
“9.0”
Example:
1) If the bearing housing is marked “–02”,
..... a is 0.58
2) b is 17.0
3) c is 55.0
4) If the right crankcase is marked “64.97”,
..... d is 64.97
5) If the left crankcase is marked “9.01”,
..... e is 9.01
6) Therefore, the shim thickness is 1.40 mm.
“A” = 9.01 + 64.97 – 17.0 – 55.0 – 0.58
= 1.40
7) Round off hundredths digit and select
appropriate shim(s). In the example above,
the calculated shim thickness is 1.40 mm.
The chart instructs you, however, to round
off 0 to 0.
Hundredths
Round value
0, 1, 2
0
3, 4, 5, 6, 7
5
8, 9
10
Shims are supplied in the following thickness.
Middle drive pinion gear shim
Thickness (mm)
4 - 97
0.50 0.70 1.00
0.55 0.80
0.60 0.90
MIDDLE GEAR
f
ENG
c. To find shim thickness “B” use the following
formula:
Middle driven pinion gear shim thickness
“B” = f – g + h – i – j – 0.05
Where:
f = a numeral (usually a decimal number) on
the bearing housing is either added to or
subtracted from “77.5”
NOTE:
After replacing any part in the middle driven
pinion gear assembly, the overall length of the
assembly will change. Therefore, be sure to
measure distance f to select the correct middle driven pinion gear shim thickness.
f
g
h
g = a numeral (usually a decimal number) on
the middle driven pinion gear is either
added to or subtracted from “49.0”
h = a numeral (usually a decimal number) on
the middle driven pinion gear is either
added to or subtracted from “80.5”
i = a numeral (usually a decimal number) on
the left crankcase specifies a thickness of
“99.98”
j = a numeral (usually a decimal number) on
the right crankcase specifies a thickness
of “8.12”
Example:
1) If the bearing housing is marked “+03”,
..... f is 77.53
2) If the driven pinion gear is marked “+0”,
..... g is 49.0
3) If the driven pinion gear is marked “–10”,
..... h is 80.40
4) If the left crankcase is marked “99.99”,
..... i is 99.99
5) If the right crankcase is marked “8.17”,
..... j is 8.17
6) Therefore, the shim thickness is 0.72 mm.
“B” = 77.53 – 49.0 + 80.40 – 99.99 – 8.17 –
0.05
= 0.72
i
4 - 98
MIDDLE GEAR
ENG
7) Round off hundredth digit and select appropriate shim(s). In the example above, the
calculated shim thickness is 0.72 mm. The
chart instructs you, however, to round off 2
to 0.
j
Hundredths
Round value
0, 1, 2
0
3, 4, 5, 6, 7
5
8, 9
10
Shims are supplied in the following thickness.
Middle drive pinion gear shim
Thickness (mm)
0.10 0.40
0.15 0.50
0.20 0.60
0.30
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a
1
5
4
INSTALLING THE BEARING AND OIL
SEALS
1. Install:
• bearing 1
• oil seal 2
• oil seal 3
2
Installed depth of bearing a
0.9 ~ 1.4 mm (0.035 ~ 0.055 in)
Installed depth of oil seal b
1.0 ~ 1.5 mm (0.039 ~ 0.059 in)
Installed depth of oil seal c
1.0 ~ 1.5 mm (0.039 ~ 0.059 in)
b
c
6
7
3
4 Middle drive pinion gear bearing retainer
5 Bearing housing
6 Middle driven shaft bearing retainer
7 Crankcase
4 - 99
MIDDLE GEAR
ENG
EBS00373
INSTALLING THE MIDDLE DRIVEN SHAFT
1. Install:
• middle driven shaft bearing retainer 1
LT
T.
R.
80 Nm (8.0 m · kg, 58 ft · lb)
NOTE:
Attach the ring nut wrench 2.
1
_
Ring nut wrench
90890-01430, YM-38404
CAUTION:
_
The middle driven shaft bearing retainer
has left-handed threads. To tighten the
retainer turn it counterclockwise.
2
2. Install:
• middle driven pinion gear bearing retainer
1
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Secure the bearing housing edge in the vise
with a clean rag.
b. Attach the bearing retainer wrench 2.
2
Bearing retainer wrench
90890-04128
Middle gear bearing retainer
YM-04128
c. Tighten the bearing retainer.
CAUTION:
_
The middle driven pinion gear bearing
retainer has left-handed threads. To tighten
the retainer turn it counterclockwise.
T.
R.
Bearing retainer
130 Nm (13.0 m · kg, 94 ft · lb)
LOCTITE®
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 100
MIDDLE GEAR
1
ENG
3. Install:
• middle driven gear shim(s) 1
• bearing housing
NOTE:
Install the shim(s) so that the tabs are positioned as shown in the illustration.
_
1
1
4. Install:
• rear drive shaft coupling gear (middle gear
side) 1
• washer
• rear drive shaft coupling gear nut (middle
gear side) 2
2
LT
T.
R.
150 Nm (15.0 m · kg, 110 ft · lb)
NOTE:
Use the coupling gear/middle shaft tool 3 to
hold the coupling gear.
3
Coupling gear/middle shaft tool
90890-01229
Gear holder
YM-01229
1
5. Install:
• front drive shaft coupling gear (middle gear
side) 1
• washer
• front drive shaft coupling gear nut (middle
gear side) 2
R.
3
T.
2
115 Nm (11.5 m · kg, 85 ft · lb)
NOTE:
Use the coupling gear/middle shaft tool 3 to
hold the coupling gear.
Coupling gear/middle shaft tool
90890-01229
Gear holder
YM-01229
4 - 101
MIDDLE GEAR
ENG
INSTALLING THE MIDDLE DRIVE SHAFT
1. Install:
• circlip
• middle driven gear 1
(to the middle drive shaft 2)
a
Installed depth of middle driven
gear a
24.7 ~ 24.9 mm (0.97 ~ 0.98 in)
2
1
2. Tighten:
• middle drive pinion gear nut 1 New
T.
R.
180 Nm (18.0 m · kg, 130 ft · lb)
NOTE:
Secure the middle drive shaft in the vise with a
clean rag.
3. Lock the threads with a drift punch.
EBS01022
MEASURING THE MIDDLE GEAR
BACKLASH
1. Measure:
• gear lash
Middle gear lash
0.10 ~ 0.30 mm
(0.004 ~ 0.012 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
4
3
a. Temporarily install the left crankcase.
b. Wrap a rag 1 around a screwdriver 2, and
then insert it into the installation hole a of
the left crankcase speed sensor to hold the
middle driven gear.
c. Attach the final gear backlash band 3 and
dial gauge 4.
Final gear backlash band
90890-01511
b
b 45 mm (1.8 in)
d. Measure the gear lash while rotating the
middle driven shaft back and forth.
NOTE:
Measure the gear lash at 4 positions. Rotate
the middle driven gear 90° each time.
_
4 - 102
MIDDLE GEAR
ENG
e. If the gear lash is incorrect, adjust the gear
lash by middle driven pinion gear shims
and/or middle drive pinion gear shim(s).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 103
RADIATOR
COOL
EBS00125
COOLING SYSTEM
RADIATOR
(4)
1
9
12
2
4
11
5
6
3
5
10
Job/Part
Removing the radiator
Front fenders
R.
R.
Order
7
T.
T.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
8
Q’ty
Front guard
Left footrest board
Air filter case
Coolant
1
2
3
4
Radiator fan motor coupler
Radiator fan breather hose
Coolant reservoir hose
Coolant reservoir breather hose
1
1
1
1
5-1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “FRONT FENDERS AND
FRONT GRILL” in chapter 3.
Refer to “FRONT CARRIER AND FRONT
GUARD” in chapter 3.
Refer to “FOOTREST BOARDS” in chapter 3.
Refer to “AIR FILTER CASE” in chapter
3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Disconnect.
RADIATOR
(4)
COOL
1
9
12
2
4
11
5
6
3
10
Job/Part
Coolant reservoir cap
Coolant reservoir
Fast idle plunger outlet hose
Radiator outlet hose
Radiator inlet hose
Radiator bracket
Radiator
Radiator fan
R.
R.
Order
5
6
7
8
9
10
11
12
7
T.
T.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
8
Q’ty
1
1
1
1
1
1
1
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
For installation, reverse the removal procedure.
5-2
RADIATOR
COOL
EBS00127
CHECKING THE RADIATOR
1. Check:
• radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the radiator.
Damage → Repair or replace.
NOTE:
Straighten any flattened fins with a thin, flathead screwdriver.
_
2. Check:
• radiator hoses
Cracks/damage → Replace.
3. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Radiator cap opening pressure
93.3 ~ 122.7 kPa
(0.933 ~ 1.227 kg/cm2,
13.27 ~ 17.45 psi)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the radiator cap tester 1 and radiator
cap tester adapter 2 to the radiator cap 3.
Radiator cap tester
90890-01325
Radiator pressure tester
YU-24460-01
Radiator cap tester adapter
90890-01352
Radiator pressure tester adapter
YU-33984
b. Apply the specified pressure for ten seconds and make sure there is no drop in
pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” in chapter 9.
5-3
RADIATOR
COOL
EBS00128
INSTALLING THE RADIATOR
1. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
2. Check:
• cooling system
Leaks → Repair or replace any faulty part.
3. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Refer to “CHECKING THE RADIATOR”.
5-4
THERMOSTAT
COOL
EBS00129
THERMOSTAT
4
1
5 New
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
2
New
LS
New
3
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Order
Job/Part
Removing the thermostat
Air filter case
Q’ty
Coolant
1
2
3
4
5
Radiator inlet hose
Thermostat cover
Thermostat
Coolant temperature sensor
Copper washer
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “AIR FILTER CASE” in chapter
3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Disconnect.
For installation, reverse the removal procedure.
5-5
THERMOSTAT
COOL
EBS00132
CHECKING THE THERMOSTAT
1. Check:
• thermostat 1
Does not open at 50 ~ 54 °C (122 ~
129.2 °F) → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suspend the thermostat in a container filled
with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the thermostat and thermometer’s indicated temperature.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1 Thermometer
2 Water
3 Thermostat
4 Container
È Fully closed
É Fully open
NOTE:
If the accuracy of the thermostat is in doubt,
replace it. A faulty thermostat could cause serious overheating or overcooling.
_
2. Check:
• thermostat housing cover
• thermostat housing (cylinder head)
Cracks/damage → Replace.
EBS00133
INSTALLING THE THERMOSTAT
1. Install:
• thermostat 1
• O-ring 2 New
• thermostat cover 3
3
2
New
a
1
NOTE:
Install the thermostat with its breather hole a
facing up.
_
LS
2. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
3. Check:
• cooling system
Leak → Repair or replace any faulty part.
5-6
WATER PUMP
COOL
EBS00134
WATER PUMP
E
LS
12 New
11
5
10 New
8 New
9
New
1
M
7 New
New
3
LS
2
6
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
4
New
Q’ty
Left front fender
AC magneto cover
Coolant
1
2
3
4
5
6
Radiator outlet hose
Water jacket joint
Water pump outlet hose
Water pump outlet pipe
Water pump breather hose
Water pump housing
1
1
1
1
1
1
5-7
R.
R.
Job/Part
Removing the water pump
Left footrest board
T.
T.
Order
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LS
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “FOOTREST BOARDS” in chapter 3.
Refer to “FRONT FENDERS AND
FRONT GRILL” in chapter 3.
Refer to “AC MAGNETO” in chapter 4.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Disconnect.
WATER PUMP
COOL
E
LS
12 New
11
5
10 New
8 New
9
M
New
1
7 New
New
3
LS
2
6
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
4
New
Q’ty
1
1
1
1
1
1
R.
R.
Job/Part
Gasket
Circlip
Impeller shaft
Water pump seal
Bearing
Oil seal
T.
T.
Order
7
8
9
10
11
12
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LS
10 Nm (1.0 m • kg, 7.2 ft • Ib)
Remarks
For installation, reverse the removal procedure.
5-8
WATER PUMP
COOL
EBS00138
DISASSEMBLING THE WATER PUMP
1. Remove:
• water pump seal 1
NOTE:
Tap out the water pump seal from the inside of
the AC magneto cover 2.
_
2
1
2. Remove:
• bearing 1
• oil seal 2
1
2
3
NOTE:
Tap out the bearing and oil seal from the outside of the AC magneto cover 3.
_
EBS00139
CHECKING THE WATER PUMP
1. Check:
• water pump housing
• impeller shaft
Cracks/damage/wear → Replace.
2. Check:
• water jacket
• water jacket outlet hose
• water jacket outlet pipe
Cracks/damage/wear → Replace.
• bearing
Rough movement → Replace.
5-9
WATER PUMP
COOL
EBS00140
2
3
ASSEMBLING THE WATER PUMP
1. Install:
• oil seal 1 New
(into the AC magneto cover 2)
NOTE:
• Before installing the oil seal, apply tap water
or coolant onto its out surface.
• Install the oil seal with a socket 3 that
matches its outside diameter.
_
a
1 New
Installed depth of oil seal a
8.1 ~ 8.7 mm (0.32 ~ 0.34 in)
È
4
3
1 New
2
2. Install:
• water pump seal 1 New
(into the AC magneto cover 2)
CAUTION:
_
Never lubricate the water pump seal surface with oil or grease.
NOTE:
Install the water pump seal with the special
tools.
_
Mechanical seal installer 3
90890-04132
Water pump seal installer
YM-33221-A
Middle driven shaft bearing driver
4
90890-04058
Bearing driver 40 mm
YM-04058
È Push down.
5 - 10
WATER PUMP
COOL
3. Measure:
• impeller shaft tilt
Out of specification → Replace.
CAUTION:
_
Make sure the rubber damper and rubber
damper holder are flush with the impeller.
Impeller shaft tilt limit
0.15 mm (0.006 in)
1 Straightedge
2 Impeller shaft
5 - 11
FUEL INJECTION SYSTEM
EAS00894
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
1 ECU (engine control unit)
2 Lean angle sensor
3 Fuel injection system relay
4 Engine trouble warning light
5 Intake air pressure sensor
6 TPS (throttle position sensor)
7 Intake air temperature sensor
8 Fuel injector
9 Fuel pump
0 Speed sensor
A Crankshaft position sensor
B Coolant temperature sensor
C Spark plug
D Ignition coil
1 2 3 4
D
56 7
C
B
6-1
A
8
0
9
FI
FUEL INJECTION SYSTEM
FI
6
6-2
B/L Gy
5
B/L
Gy
R
G
W
B
B
2
B
W R G B R
B
B
R
R
B
Y
W Sb Gy Br Y/B Y/L Y/W B/L R/B O
R/B
Gy
O/W
G/W
B
B
W
G/R
O/W
L/B
L
(BLACK)
3
P Y/G G/Y Br/W L
L/W W/B B/R Gy/G W/R G/W Lg G/R R/L L/R Y/R O/W Y/W B/W L/B B
R
(BLACK)
W
W
W
W
W
W
W R G B R
G
R/B
1
G/Y B
W
R
R
R/B
B
Br
R/B
D
W W W
R
(GRAY)
R
6
7
O/W Br L/B
R
G W G/R
G/R W
R/B
(BLACK)
R
R
R
J
(BLACK)
R
Br
L/W
Br/B
R
L/W
Br/B
4
ON
}
(BLACK)
R/B
Br
L/B
Br/W
O
B/L
Br/W
Sb L/B
L/R
B/Y
G/Y B/L
B/Y
Y/W
Y/W
I
H
R/L
(GREEN)
G/Y
Sb B/Y
L/R
K
P
L/B
B
B/L
Y
L
Y
Lg
Y/R
Y/B
G/R
W/B
B/R
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4WD
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FUEL INJECTION SYSTEM
A
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Br/L R
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EAS27340
B
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CIRCUIT DIAGRAM
C
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FUEL INJECTION SYSTEM
1 Crankshaft position sensor
4 Main switch
6 Main fuse
8 Battery
9 Fuel injection system fuse
H Fuel injection system relay
K ECU (engine control unit)
L Ignition coil
M Spark plug
N Fuel injector
O Intake air temperature sensor
P Coolant temperature sensor
Q Speed sensor
R TPS (throttle position sensor)
S Intake air pressure sensor
T Lean angle sensor
W Multifunction meter
X Engine trouble warning light
c Fuel pump
n Engine stop switch
s Ignition fuse
6-4
FI
FI
FUEL INJECTION SYSTEM
ECU SELF-DIAGNOSTIC FUNCTION
The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system
is operating normally. If this function detects a malfunction in the system, it immediately operates
the engine under substitute characteristics and illuminates the engine trouble warning light to alert
the rider that a malfunction has occurred in the system. Once a malfunction has been detected, a
fault code is stored in the memory of the ECU.
• To inform the rider that the fuel injection system is not functioning, the engine trouble
1
warning light flashes when the start switch is
being pushed to start the engine.
• If a malfunction is detected in the system by
the self-diagnostic function, the ECU provides an appropriate substitute characteristic
operation, and alerts the rider of the detected
malfunction by illuminating the engine trouble warning light.
1 Engine trouble warning light
• After the engine has been stopped, the lowest fault code number appears on the odometer/tripmeter LCD. Once a fault code has
been displayed, it remains stored in the
memory of the ECU until it is deleted.
Engine trouble warning light indication and fuel injection system operation
Warning light indication
Flashing*
Remains on
ECU operation
Fuel injection operation
Vehicle operation
Warning provided
when unable to start
engine
Operation stopped
Cannot be operated
Malfunction detected
Operated with substitute characteristics in
accordance with the
description of the malfunction
Can or cannot be
operated depending
on the fault code
*The warning light flashes when any one of the conditions listed below is present and the start
switch is pushed:
12:
Crankshaft position sensor
41:
Lean angle sensor
(open or short-circuit)
30:
Lean angle sensor
(latch up detected)
50:
ECU internal malfunction
(memory check error)
6-5
FUEL INJECTION SYSTEM
FI
EAS27380
SELF-DIAGNOSTIC FUNCTION TABLE
If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illuminates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that
are programmed for each sensor in order to provide the engine with alternate operating instructions
that enable the engine to continue to operate or stop operating, depending on the conditions.
Self-diagnostic function table
Fault
code No.
Item
Symptom
Able / unable
to start
Able / unable
to drive
12
Crankshaft position sensor
No normal signals are received from the crankshaft
position sensor.
Unable
Unable
13
Intake air pressure sensor
(open or short circuit)
Intake air pressure sensor: open or short circuit
detected.
Able
Able
14
Intake air pressure sensor
(hose line)
Intake air pressure sensor: hose system malfunction
(clogged or detached hose).
Able
Able
15
Throttle position sensor (open
or short circuit)
Throttle position sensor: open or short circuit
detected.
Able
Able
16
Throttle position sensor
Stuck throttle position sensor detected.
Able
Able
21
Coolant temperature sensor
Coolant temperature sensor: open or short circuit
detected.
Able
Able
22
Intake air temperature sensor (open or short circuit)
Intake air temperature sensor: open or short circuit
detected.
Able
Able
30
Lean angle sensor (latch up
detected)
The vehicle has overturned.
Unable
Unable
33
Ignition coil (faulty ignition)
Malfunction detected in the primary wire of ignition
coil.
Unable
Unable
39
Injector (open circuit)
Injector: open circuit detected.
Unable
Unable
41
Lean angle sensor (open or
short circuit)
Lean angle sensor: open or short circuit detected.
Unable
Unable
42
Speed sensor
No normal signals are received from the speed sensor.
Able
Able
43
Fuel system voltage (monitoring voltage)
The ECU is unable to monitor the battery voltage (an
open or short circuit in the line to the ECU).
Able
Able
44
Error in writing the amount of
CO adjustment on EEPROM
Error is detected while reading or writing on EEPROM
(CO adjustment value).
Able
Able
46
Vehicle system power supply
(Monitoring voltage)
Power supply is not normal.
Able
Able
50
ECU internal malfunction
(memory check error)
Faulty ECU memory. (When this malfunction is
detected in the ECU, the fault code number might not
appear on the meter).
Unable
Unable
Communication error with the meter
Fault
code No.
Item
Symptom
Able / unable
to start
Able / unable
to drive
Er-1
ECU internal malfunction
(output signal error)
No signals are received from the ECU.
Unable
Unable
Er-2
ECU internal malfunction
(output signal error)
No signals are received from the ECU within the specified duration.
Unable
Unable
Er-3
ECU internal malfunction
(output signal error)
Data from the ECU cannot be received correctly.
Unable
Unable
Er-4
ECU internal malfunction
(input signal error)
Non-registered data has been received from the
meter.
Unable
Unable
6-6
FI
FUEL INJECTION SYSTEM
EAS00904
TROUBLESHOOTING CHART
Engine operation is not normal or the engine trouble warning light is on.
* Engine trouble warning light may not come on even if the engine operation is not normal.
The engine trouble warning light comes on.
The engine trouble warning light does not come on.
Check the fault code number displayed on the meter.
Check the operation of following sensors and actuators in the diagnostic mode. Refer to “Sensor operation table” and “Actuator operation table”.
D01: Throttle position sensor (throttle angle)
D30: Ignition coil
D36: Fuel injector
Identify the system with the malfunction. Refer to
“Self-diagnostic function table”.
Identify the probable cause of the malfunction. Refer
to “Diagnostic code table”.
OK
Check and repair the probable cause of malfunction.
Fault code No. YES
Fault code No. NO
Check and repair.
Refer to “TROUBLESHOOTING DETAILS”.
Monitor the operation of
the sensors and actuators in the diagnostic
mode. Refer to “Sensor operation table” and
“Actuator operation
table”.
Check and repair.
Refer to “Self-diagnostic function table”.
NG
Engine malfunction
Defective sensor or
actuator
Check and repair the
inner parts of engine.
Refer to Chapter 4.
Check and repair the
corresponding sensor or actuator.
OK
NG
OK
Check the engine condition.
Perform ECU reinstatement action. Refer to “Reinstatement method” in “TROUBLESHOOTING
DETAILS”.
Fault code number
displayed
Turn the main switch to “OFF”, turn the main switch
back to “ON”, and then check if the fault code number
is still displayed.
OK
No fault code number displayed
Repairs completed
Erasing the malfunction history:*
The malfunction history is stored even if the main switch is turned OFF.
The malfunction history must be erased in the diagnostic mode. Refer to “Sensor operation table” and “Actuator operation table” (Diagnostic code No.D62).
* Operated when the engine trouble warning light is on.
6-7
FUEL INJECTION SYSTEM
FI
EAS00905
DIAGNOSTIC MODE
It is possible to monitor the sensor output data
or check the activation of actuators without
connecting the measurement equipment by
simply switching the meter indication from the
normal mode to the diagnostic monitoring
mode.
Setting the diagnostic mode
1. Turn the main switch to “OFF” and set the
engine stop switch to “OFF”.
2. Disconnect the wire harness coupler from
the fuel pump.
3. Simultaneously press and hold the
“SELECT” and “RESET” buttons, turn the
main switch to “ON”, and continue to press
the buttons for 8 seconds or more.
“SELECT”
“RESET”
NOTE:
• All displays on the meter disappear.
• “dIAG” appears on the LCD meter.
4. Simultaneously press the “SELECT” and
“RESET” buttons for 2 seconds or more to
execute the selection.
5. Select the diagnostic code number that
applies to the item that was verified with the
fault code number by pressing the
“SELECT” and “RESET” buttons.
NOTE:
• The diagnostic code number appears on the
LCD meter (01-70).
• To decrease the selected diagnostic code
number, press the “RESET” button. Press
the “RESET” button for 1 second or longer to
automatically decrease the diagnostic code
numbers.
• To increase the selected diagnostic code
number, press the “SELECT” button. Press
the “SELECT” button for 1 second or longer
to automatically increase the diagnostic code
numbers.
“d01 d70”
“d70 d01”
6-8
FUEL INJECTION SYSTEM
FI
6. Verify the operation of the sensor or actuator.
• Sensor operation
The data representing the operating conditions of the sensor appears on the LCD
meter.
• Actuator operation
Set the engine stop switch to “ON” to operate the actuator.
* If the engine stop switch is set to “ON”, set it
to “OFF”, and then set it to “ON” again.
7. Turn the main switch to “OFF” to cancel the
diagnostic mode.
NOTE:
To perform a reliable diagnosis, make sure to
turn off the power supply before every check
and then start right from the beginning.
6-9
FUEL INJECTION SYSTEM
FI
Diagnostic code table
Fault
code No.
Symptom
Probable cause of malfunction
12
No normal signals are received from
the crankshaft position sensor.
•
•
•
•
•
13
Intake air pressure sensor: open or
short circuit detected.
• Open or short circuit in wire harness.
• Defective intake air pressure sensor.
• Malfunction in ECU.
D03
14
Intake air pressure sensor: hose system malfunction (clogged or detached
hose).
• Intake air pressure sensor hose is detached, clogged,
kinked, or pinched.
• Malfunction in ECU.
D03
15
Throttle position sensor: open or short
circuit detected.
•
•
•
•
•
D01
16
Stuck throttle position sensor
detected.
• Stuck throttle position sensor.
• Malfunction in ECU.
D01
21
Coolant temperature sensor: open or
short circuit detected.
•
•
•
•
Open or short circuit in wire harness.
Defective coolant temperature sensor.
Malfunction in ECU.
Improperly installed coolant temperature sensor.
D06
22
Intake air temperature sensor: open
or short circuit detected.
•
•
•
•
Open or short circuit in wire harness.
Defective intake air temperature sensor.
Malfunction in ECU.
Improperly installed intake air temperature sensor.
D05
30
The vehicle has overturned.
• Overturned.
• Malfunction in ECU.
•
•
•
•
Open or short circuit in wire harness.
Defective crankshaft position sensor.
Malfunction in pickup rotor.
Malfunction in ECU.
Improperly installed sensor.
Diagnostic code No.
Open or short circuit in wire sub lead.
Open or short circuit in wire harness.
Defective throttle position sensor.
Malfunction in ECU.
Improperly installed throttle position sensor.
Open or short circuit in wire harness.
Malfunction in ignition coil.
Malfunction in ECU.
Malfunction in a component of ignition cut-off circuit system.
—
D08
D30
D32
33
Malfunction detected in the primary
lead of the ignition coil.
39
Open circuit detected in a injector.
• Open or short circuit in wire harness.
• Improperly installed injector.
• Defective injector.
D36
41
Lean angle sensor: open or short circuit detected.
• Open or short circuit in wire harness.
• Defective lean angle sensor.
• Malfunction in ECU.
D08
42
No normal signals are received from
the speed sensor.
•
•
•
•
•
D07
43
Power supply to the injector and fuel
pump is not normal.
• Open or short circuit in wire harness.
• Malfunction in ECU.
D09
44
Error is detected while reading or writing on EEPROM (CO adjustment
value).
• Malfunction in ECU. (The CO adjustment value is not
properly written on or read from the internal memory).
D60
46
Power supply to the fuel injection system is not normal.
• Malfunction in the charging system. Refer to “CHARGING SYSTEM” in chapter 9.
—
50
Faulty ECU memory. (When this malfunction is detected in the ECU, the
fault code number might not appear
on the LCD of the meter.)
• Malfunction in ECU. (The program and data are not
properly written on or read from the internal memory.)
—
Open circuit in wire harness.
Defective speed sensor.
Malfunction in vehicle speed sensor detected.
Malfunction in the engine side of the neutral switch.
Malfunction in ECU.
6 - 10
FUEL INJECTION SYSTEM
FI
Sensor operation table
Diagnostic code
No.
Item
Meter display
Checking method
Throttle angle
D01
D03
D05
D06
• Fully closed position
15 ~ 20
• Fully opened position
95 ~ 100
Check with throttle fully closed.
Check with throttle fully open.
Pressure difference
(atmospheric pressure
and intake air pressure)
Displays the intake air pressure.
Set the engine stop switch to “RUN”,
then operate the throttle while pushing the start switch. (If the display
value changes, the performance is
OK.)
Intake air temperature
Displays the intake air temperature.
Compare the actually measured
intake air temperature with the meter.
Coolant temperature
Displays the coolant temperature.
Compare the actually measured coolant temperature with the meter.
Vehicle speed pulse
0 ~ 999
Check that the number increases
when the rear wheel is rotated. The
number is cumulative and does not
reset each time the wheel is stopped.
D07
Lean angle sensor
D08
• Upright
0.4 ~ 1.4
• Overturned
3.7 ~ 4.4
Fuel system voltage
(battery voltage)
Approximately 12.0
Remove the lean angle sensor and
incline it more than 65 degrees.
Set the engine stop switch to “RUN”,
and then compare with the actually
measured battery voltage. (If the battery voltage is lower, perform recharging.)
D09
Neutral switch
D21
D60
Shift the transmission.
• Neutral
ON
• In gear
OFF
EEPROM fault code display
—
• No history
00
• History exists
01
Malfunction history code
display
—
• 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 detected code numbers. When all code numbers are shown, the display repeats the same process.)
D61
Malfunction history code
erasure
D62
D70
• No history
0
—
• History exists
Up to 16 fault codes
To erase the history, set the engine
stop switch to “OFF” and then to
“RUN”.
Control number
00 ~ 255
—
6 - 11
FUEL INJECTION SYSTEM
FI
Actuator operation table
• Actuator operation
Set the engine stop switch to “OFF” and then to “RUN”.
Diagnostic code
No.
Item
Actuation
Checking method
D30
Ignition coil
Actuates the ignition coil five times in one-second
intervals.
The engine trouble warning light also flashes five
times.
D36
Injector
Actuates the injector five times in one-second intervals.
Check the operating sound of the
injector five times.
D50
Fuel pump relay
Actuates the fuel pump relay five times in one-second intervals.
The engine trouble warning light also flashes five
times.
(The engine trouble warning light is OFF when the
relay is ON, and the engine trouble warning light is
ON when the relay is OFF).
Check the operating sound of the fuel
pump relay five times.
D51
Radiator fan motor relay
Actuates the radiator fan motor relay and illuminates
the engine trouble warning light five cycles (5 seconds per cycle–2 seconds ON, 3 seconds OFF).
(ON 2 seconds, OFF 3 seconds)
Check the operating sound of the
radiator fan motor relay five times.
Check the spark five times.
• Connect an ignition checker.
EAS00908
TROUBLESHOOTING DETAILS
This section describes the countermeasures per fault code number displayed on the meter. Check
and service the items or components that are the probable cause of the malfunction following the
order given.
After the check and service of the malfunctioning part has been completed, reset the meter display
according to the “Reinstatement method”.
Fault code No.:
Fault code number displayed on the meter when the engine failed to work normally.
Refer to “Diagnostic code table”.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC MODE”.
6 - 12
FUEL INJECTION SYSTEM
Fault code No.
12
FI
Symptom No normal signals are received from the crankshaft position sensor.
Diagnostic code No. —
—
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Installed condition of crankshaft
position sensor.
Check for looseness or pinching.
Cranking the
engine.
2
Connections
• Crankshaft position sensor coupler
• Main wire harness-ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
3
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between the crankshaft position
sensor coupler and ECU coupler.
(gray–gray)
(black/blue–black/blue)
4
Defective crankshaft position sensor.
• Replace if defective.
Refer to “IGNITION SYSTEM” in
chapter 9.
6 - 13
FUEL INJECTION SYSTEM
Fault code No.
13
FI
Symptom Intake air pressure sensor: open or short circuit detected.
Diagnostic code No. D03
Intake air pressure sensor
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Connections
• Intake air pressure sensor coupler
• Main wire harness-ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
Turning the
main switch to
“ON”.
2
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between intake air pressure sensor coupler and ECU coupler
(black/blue–black/blue)
(pink–pink)
(blue–blue)
3
Defective intake air pressure sensor.
• Execute the diagnostic mode.
(Code No.D03)
• Replace if defective.
Refer to “CHECKING THE
INTAKE AIR PRESSURE SENSOR”.
6 - 14
FUEL INJECTION SYSTEM
Fault code No.
14
FI
Symptom Intake air pressure sensor: hose system malfunction
(clogged or detached hose).
Diagnostic code No. D03
Intake air pressure sensor
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Intake air pressure sensor hose
• Check the intake air pressure
sensor hose condition.
• Repair or replace the sensor
hose.
Starting the
engine and
operating it at
idle.
2
Intake air pressure sensor malfunction at intermediate electrical
potential.
• Check and repair the connection.
• Replace it if there is a malfunction.
3
Connections
• Intake air pressure sensor coupler
• Main wire harness-ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
4
Defective intake air pressure sensor.
• Execute the diagnostic mode.
(Code No.D03)
• Replace if defective.
Refer to “CHECKING THE
INTAKE AIR PRESSURE SENSOR”.
6 - 15
FUEL INJECTION SYSTEM
Fault code No.
15
FI
Symptom Throttle position sensor: open or short circuit detected.
Diagnostic code No. D01
Throttle position sensor
Order Item/components and probable
cause
Check or maintenance job
1
Installed condition of throttle position sensor.
• Check for looseness or pinching. Turning the
• Check that the sensor is installed main switch to
in the specified position.
“ON”.
2
Connections
• Throttle position sensor coupler
• Main wire harness-ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
3
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between throttle position sensor
coupler and ECU coupler
(blue–blue)
(yellow–yellow)
(black/blue–black/blue)
4
Throttle position sensor lead wire
open circuit output voltage check.
• Check for open circuit and
replace the throttle position sensor.
(yellow–black/blue)
5
Defective throttle position sensor.
• Execute the diagnostic mode.
(Code No.D01)
• Replace if defective.
Refer to “CHECKING AND
ADJUSTING THE THROTTLE
POSITION SENSOR”.
6 - 16
Reinstatement
method
FUEL INJECTION SYSTEM
Fault code No.
16
FI
Symptom Stuck throttle position sensor detected.
Diagnostic code No. D01
Throttle position sensor
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Installed condition of throttle position sensor.
• Check the installed area for
looseness or pinching.
• Check that the throttle position
sensor is installed in the specified position.
Refer to “CHECKING AND
ADJUSTING THE THROTTLE
POSITION SENSOR”.
Reinstated by
starting the
engine, operating it at idle, and
then racing it.
2
Defective throttle position sensor.
• Execute the diagnostic monitoring mode.
(Code No.D01)
• Replace if defective.
Refer to “CHECKING AND
ADJUSTING THE THROTTLE
POSITION SENSOR”.
Fault code No.
21
Symptom Coolant temperature sensor: open or short circuit
detected.
Diagnostic code No. D06
Coolant temperature sensor
Order Item/components and probable
cause
Check or maintenance job
1
Installed condition of coolant temperature sensor.
2
Check the installed area for loose- Turning the
ness or pinching.
main switch to
“ON”.
• Check the coupler for any pins
Connections
• Coolant temperature sensor couthat may have pulled out.
pler
• Check the locking condition of
• Main wire harness-ECU coupler
the coupler.
If there is a malfunction, repair it
and connect the coupler securely.
3
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between coolant temperature
sensor coupler and ECU coupler.
(black/blue–black/blue)
(green/yellow–green/yellow)
4
Defective coolant temperature
sensor.
• Execute the diagnostic mode.
(Code No.D06)
• Replace if defective.
Refer to “SIGNALING SYSTEM”
in chapter 9.
6 - 17
Reinstatement
method
FUEL INJECTION SYSTEM
Fault code No.
22
FI
Symptom Intake air temperature sensor: open or short circuit
detected.
Diagnostic code No. D05
Intake air temperature sensor
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Installed condition of air temperature sensor.
Check for looseness or pinching.
2
Connections
• Intake air temperature sensor
coupler
• Main wire harness-ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
Turning the
main switch to
“ON”.
3
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between intake air temperature
sensor coupler and ECU coupler
(brown/white–brown/white)
(black/blue–black/blue)
4
Defective air temperature sensor.
• Execute the diagnostic mode.
(Code No.D05)
• Replace if defective.
Refer to “CHECKING THE
INTAKE AIR TEMPERATURE
SENSOR”.
6 - 18
FUEL INJECTION SYSTEM
Fault code No.
30
FI
Symptom The vehicle has overturned.
Diagnostic code No. D08
Lean angle sensor
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
The vehicle has overturned.
Raise the vehicle upright.
2
Installed condition of the lean
angle sensor.
Check for looseness or pinching.
3
Connections
• Lean angle sensor coupler
• Main wire harness-ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
Turning the
main switch to
“ON” (however,
the engine cannot be restarted
unless the main
switch is first
turned “OFF”).
4
Defective lean angle sensor.
• Execute the diagnostic mode.
(Code No.D08)
• Replace if defective.
Refer to “IGNITION SYSTEM” in
chapter 9.
6 - 19
FUEL INJECTION SYSTEM
Fault code No.
33
FI
Symptom Malfunction detected in the primary lead of the ignition
coil.
Diagnostic code No. D30
Ignition coil
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Connections
• Ignition coil connector (primary
coil side)
• Main wire harness-ECU coupler
• Check the connector and coupler for any pins that may be
pulled out.
• Check the locking condition of
the connector and coupler.
• If there is a malfunction, repair it
and connect the coupler or connector securely.
Starting the
engine and
operating it at
idle.
2
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between ignition coil connector
and ECU coupler.
(orange–orange)
• Between ignition coil connector
and left handlebar switch coupler.
(red/black–red/black)
3
Defective ignition coil.
• Execute the diagnostic mode.
(Code No.D30)
• Test the primary and secondary
coils for continuity.
• Replace if defective.
Refer to “IGNITION SYSTEM” in
chapter 9.
6 - 20
FUEL INJECTION SYSTEM
Fault code No.
39
FI
Symptom Open circuit detected in a injector.
Diagnostic code No. D36
Injector
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Connections
• Injector coupler
• Main wire harness-ECU coupler
• Main wire harness fuel pump
coupler
• Check the couplers for any pins
that may be pulled out.
• Check the locking condition of
the couplers.
• If there is a malfunction, repair it
and connect the coupler
securely.
Cranking the
engine. (Connect the fuel
injector coupler.)
2
Open or short circuit in wire harness and/or sub-wire harness 2.
• Repair or replace if there is an
open or short circuit.
• Between injector coupler and
ECU coupler.
(red/blue–red/blue)
(red/black–red/black)
3
Defective injector.
• Execute the diagnostic mode.
(Code No.D36)
• Replace if defective.
Refer to “CHECKING THE FUEL
INJECTOR”.
6 - 21
FUEL INJECTION SYSTEM
Fault code No.
41
FI
Symptom Lean angle sensor: open or short circuit detected.
Diagnostic code No. D08
Lean angle sensor
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Connections
• Lean angle sensor coupler
• Main wire harness-ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
Turning the
main switch to
“ON”.
2
Open or short circuit in lead wire.
• Repair or replace if there is an
open or short circuit.
• Between lean angle sensor coupler and ECU coupler.
(blue–blue)
(yellow/green–yellow/green)
(black/blue–black/blue)
3
Defective lean angle switch.
• Execute the diagnostic mode.
(Code No.D08)
• Replace if defective.
Refer to “IGNITION SYSTEM” in
chapter 9.
6 - 22
FUEL INJECTION SYSTEM
Fault code No.
42
FI
Symptom No normal signals are received from the speed sensor.
Diagnostic code No. D07
Speed sensor
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Connections
• Speed sensor coupler
• Main wire harness-ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
2
Open or short circuit in speed sen- • Repair or replace if there is an
sor lead.
open or short circuit.
• Between speed sensor coupler
and ECU coupler.
(blue–blue)
(white–white)
(black/blue–black/blue)
Starting the
engine, and
activating the
vehicle speed
sensor by operating the vehicle at 20 to 30
km/h.
3
Gear for detecting vehicle speed
has broken.
• Replace if defective.
Refer to “TRANSMISSION” in
chapter 4.
4
Defective speed sensor.
• Execute the diagnostic mode.
(Code No.D07)
• Replace if defective.
Refer to “SIGNALING SYSTEM”
in chapter 9.
6 - 23
FUEL INJECTION SYSTEM
Fault code No.
43
FI
Symptom Power supply to the injector and fuel pump is not normal.
Diagnostic code No. D09
Fuel system voltage
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Connections
• Fuel injection system relay
• Main wire harness-ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
Starting the
engine and
operating it at
idle.
2
Open or short circuit in the wire
harness.
• Repair or replace if there is an
open or short circuit.
• Between fuel injection system
relay coupler and ECU coupler.
(blue/red–blue/red)
(red/blue–red/blue)
• Between fuel injection system
relay coupler and starter relay
coupler.
(brown/black–brown/black)
• Between fuel injection system
relay coupler and left handlebar
switch coupler.
(red/black–red/black)
3
Malfunction or open circuit in fuel
pump relay.
• Execute the diagnostic mode.
(Code No.D09)
• Replace if defective.
• If there is no malfunction with the
relay unit, replace the ECU.
Fault code No.
44
Symptom Error is detected while reading or writing on EEPROM
(CO adjustment value).
Diagnostic code No. D60
EEPROM improper cylinder indication
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
• Execute the diagnostic mode.
(Code No.D60)
1. Check the faulty cylinder.
• Replace ECU if defective.
Turning the
main switch to
“ON”.
Malfunction in ECU.
6 - 24
FUEL INJECTION SYSTEM
Fault code No.
46
FI
Symptom Power supply is not normal.
Diagnostic code No. —
—
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Connections
• Main wire harness-ECU coupler
• Check the coupler for any pins
that may be pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
Starting the
engine and
operating it at
idle.
2
Faulty battery.
• Replace or charge the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” in
chapter 3.
3
Malfunction in rectifier/regulator
• Replace if defective.
Refer to “CHARGING SYSTEM”
in chapter 9.
4
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between battery lead and main
switch coupler
(red–red)
• Between main switch coupler
and ignition fuse
(brown/blue–brown/blue)
• Between ignition fuse and ECU
coupler
(brown–brown)
Fault code No.
50
Symptom Faulty ECU memory. (When this malfunction is detected
in the ECU, the fault code number might not appear on
the meter.)
Diagnostic code No. —
—
Order Item/components and probable
cause
Check or maintenance job
1
Replace the ECU.
Malfunction in ECU.
Reinstatement
method
Turning the
main switch to
NOTE:
Do not perform this procedure with “ON”.
the main switch turned to “ON”.
6 - 25
FUEL INJECTION SYSTEM
FI
EAS28410
CHECKING THE INTAKE AIR PRESSURE
SENSOR
1. Check:
• intake air pressure sensor output voltage
Out of specification → Replace.
Intake air pressure sensor output
voltage
3.00 ~ 4.00 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
intake air pressure sensor coupler as
shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe → pink terminal 1
Negative tester probe →
black/blue terminal 2
b. Turn the main switch to “ON”.
c. Measure the intake air pressure sensor output voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE INTAKE AIR
TEMPERATURE SENSOR
1. Remove:
• intake air temperature sensor
WARNING
_
• Handle the intake air temperature sensor
with special care.
• Never subject the intake air temperature
sensor to strong shocks. If the intake air
temperature sensor is dropped, replace it.
2. Check:
• intake air temperature sensor resistance
Out of specification → Replace.
Intake air temperature sensor
resistance
290 ~ 390 Ω at 80 °C (176 °F)
6 - 26
FUEL INJECTION SYSTEM
FI
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 100) to the
intake air temperature sensor terminal as
shown.
Br/W B/L
2
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
1
Positive tester probe → brown/white 1
Negative tester probe → black/blue 2
b. Immerse the air temperature sensor 1 in a
container filled with water 2.
3
NOTE:
Make sure that the air temperature sensor terminals do not get wet.
1
2
c. Place a thermometer 3 in the water.
d. Slowly heat the water, then let it cool down
to the specified temperature.
e. Measure the air temperature sensor resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 27
FI
FUEL TANK
FUEL TANK
3
T.
(6)
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
2
4
5
9
(4)
6
New
8
5
11
7
12
1
10
T.
R.
Order
Job/Part
Removing the fuel tank
Rear fender
Q’ty
1
2
3
4
5
6
7
8
9
Fuel tank side cover
Fuel pump coupler
Fuel hose connector holder
Fuel hose
Fuel tank breather hose
Rollover valve
Fuel tank overflow hose
Fuel tank
Fuel pump assembly
1
1
1
1
2
1
1
1
1
10
Final drive case breather hose
1
6 - 28
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “ENGINE SKID PLATES, SEAT,
CARRIERS AND FENDERS” in chapter
3.
Disconnect.
Refer to “REMOVING THE FUEL TANK”
and “INSTALLING THE FUEL HOSE”.
Refer to “REMOVING THE FUEL PUMP”
and “INSTALLING THE FUEL PUMP”.
Disconnect.
FI
FUEL TANK
3
T.
(6)
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
2
4
5
9
(4)
6
New
8
5
11
7
12
1
10
T.
R.
Order
11
12
Job/Part
Fuel tank shield
Damper
Q’ty
1
2
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
For installation, reverse the removal procedure.
6 - 29
FUEL TANK
FI
REMOVING THE FUEL TANK
1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Remove:
• fuel hose connector holder
• fuel hose
CAUTION:
• Be sure to disconnect the fuel hose by
hand. Do not forcefully disconnect the
hose with tools.
• Although the fuel has been removed from
the fuel tank be careful when removing
the fuel hose, since there may be fuel
remaining in it.
NOTE:
• When removing the fuel hose from the fuel
pump, remove the fuel hose connector
holder first, and next, insert a slotted head
screwdriver etc. in the slot part a of the fuel
hose connector cover 1, then slide it in the
direction of the arrow, and remove the fuel
hose.
• To remove the fuel hose from the throttle
body, slide the fuel hose connector cover 2
on the end of the hose in direction of the
arrow shown, press the two buttons 3 on the
sides of the connector, and then remove the
hose.
• Before removing the hose, place a few rags
in the area under where it will be removed.
3. Remove:
• fuel tank
NOTE:
Do not set the fuel tank down on the installation surface of the fuel pump. Be sure to lean
the fuel tank against a wall or like.
REMOVING THE FUEL PUMP
1. Remove:
• fuel pump bracket
• fuel pump
• fuel pump gasket
6 - 30
FUEL TANK
FI
CAUTION:
• Do not drop the fuel pump or give it a
strong shock.
• Do not touch the base section of the fuel
sender.
CHECKING THE FUEL PUMP BODY
1. Check:
• fuel pump body
Obstruction → Clean.
Cracks/damage → Replace the fuel pump
assembly.
CHECKING THE ROLLOVER VALVE
1. Check:
• rollover valve
Damage/faulty → Replace.
INSTALLING THE FUEL PUMP
1. Install:
• fuel pump gasket New
• fuel pump
• fuel pump bracket
T.
R.
7 Nm (0.7 m · kg, 5.1 ft · lb)
NOTE:
• Do not damage the installation surface of the
fuel tank when installing the fuel pump.
• Always use a new fuel pump gasket.
• Install the fuel pump in the direction shown in
the illustration.
• Install the fuel pump bracket by aligning the
projection a on the fuel pump with the projection on the fuel tank.
• Tighten the nuts to the specified torque in the
proper tightening sequence as shown.
6 - 31
FUEL TANK
FI
INSTALLING THE FUEL HOSE
1. Install:
• fuel hose
• fuel hose connector holder 1
• fuel pump coupler
CAUTION:
When installing the fuel hose, make sure
that it is securely connected, and that the
fuel hose holder is in the correct position,
otherwise the fuel hose will not be properly
installed.
NOTE:
• Install the fuel hose connector holder 1
securely onto the fuel pump until a distinct
“click” is heard, and then make sure that it
does not come loose.
• To install the fuel hose onto the throttle body,
slide the fuel hose connector cover 2 on the
end of the hose in direction of the arrow
shown.
6 - 32
FI
THROTTLE BODY
EAS00909
THROTTLE BODY
LS
4
8
New
10
7
1
2
12
11
13
5
3
6
9
T.
R.
Order
9
3 Nm (0.3 m • kg, 2.2 ft • Ib)
Job/Part
Removing the throttle body
Air filter case
Q’ty
Coolant
1
2
3
4
5
6
7
8
Intake air pressure sensor coupler
Throttle position sensor coupler
Breather hose (air filter case to throttle
body)
Breather hose (air filter case to fast idle
plunger unit)
Fast idle plunger outlet hose
Fast idle plunger inlet hose
Throttle cable housing cover
Throttle cable
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “AIR FILTER CASE” in chapter
3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Disconnect.
Disconnect.
1
1
1
1
1
6 - 33
Disconnect.
Disconnect.
Disconnect.
FI
THROTTLE BODY
LS
4
8
New
10
7
1
2
12
11
13
5
3
9
T.
R.
Order
9
10
Job/Part
Throttle body joint clamp screw
Throttle body assembly
6
9
3 Nm (0.3 m • kg, 2.2 ft • Ib)
Q’ty
2
Loosen.
1
11
Fuel hose
1
12
13
Fuel injector coupler
Throttle body joint
1
1
6 - 34
Remarks
Refer to “INSTALLING THE
THROTTLE BODY ASSEMBLY”.
Disconnect.
Refer to “REMOVING THE THROTTLE
BODY ASSEMBLY” and “INSTALLING
THE THROTTLE BODY ASSEMBLY”.
Disconnect.
Refer to “INSTALLING THE THROTTLE
BODY ASSEMBLY”.
For installation, reverse the removal procedure.
FI
THROTTLE BODY
6
4
New
3
5
New
7
1
2
Order
1
2
3
4
5
6
7
Job/Part
Disassembling the throttle body
assembly
Intake air pressure sensor
Intake air pressure sensor hose
Throttle position sensor
Injector fuel rail
Fuel injector
Fast idle plunger unit
Throttle body
Q’ty
1
1
1
1
1
1
1
Remarks
Remove the parts in the order listed.
CAUTION:
The throttle body should not be disassembled.
For assembly, reverse the disassembly
procedure.
6 - 35
THROTTLE BODY
FI
REMOVING THE THROTTLE BODY
ASSEMBLY
1. Disconnect:
• fuel hose
CAUTION:
• Be sure to disconnect the fuel hose by
hand. Do not forcefully disconnect the
hose with tools.
• Although the fuel has been removed from
the fuel tank be careful when disconnecting the fuel hose, since there may be fuel
remaining in it.
NOTE:
• To disconnect the fuel hose from the throttle
body, slide the fuel hose connector cover 1
on the end of the hose in direction of the
arrow shown, press the two buttons 2 on the
sides of the connector, and then disconnect
the hose.
• Before disconnecting the hose, place a few
rags in the area under where it will be disconnected.
EAS00912
CHECKING THE FUEL INJECTOR
1. Check:
• fuel injector
Damage → Replace.
EAS00913
CHECKING THE THROTTLE BODY
1. Check:
• throttle body
Cracks/damage → Replace the throttle
body.
2. Check:
• fuel passages
Obstructions → Clean.
6 - 36
THROTTLE BODY
FI
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the throttle body in a petroleumbased solvent.
Do not use any caustic carburetor cleaning
solution.
b. Blow out all of the passages with compressed air.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
b
a
INSTALLING THE THROTTLE BODY
ASSEMBLY
1. Install:
• throttle body joint 1
NOTE:
Align the projection a on the cylinder head
with the slot b in the throttle body joint.
2. Install:
• throttle body assembly 1
1
a
NOTE:
Align the projection a on the throttle body
assembly with the slot b in the throttle body
joint.
b
3. Connect:
• fuel hose
CAUTION:
When connecting the fuel hose, make sure
that it is securely connected, and that the
fuel hose connector cover is in the correct
position, otherwise the fuel hose will not be
properly connected.
NOTE:
To connect the fuel hose onto the throttle
body, slide the fuel hose connector cover 1 on
the end of the hose in direction of the arrow
shown.
6 - 37
THROTTLE BODY
4.
•
5.
•
6.
•
7.
•
FI
Install:
throttle cable
Check:
throttle position sensor
Refer to “CHECKING AND ADJUSTING
THE THROTTLE POSITION SENSOR”.
Adjust:
throttle lever free play
Refer to “ADJUSTING THE THROTTLE
LEVER FREE PLAY” in chapter 3.
Adjust:
engine idling speed
Refer to “ADJUSTING THE ENGINE
IDLING SPEED” in chapter 3.
EAS00915
CHECKING THE FUEL PUMP AND
PRESSURE REGULATOR OPERATION
1. Check:
• pressure regulator operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2
a. Remove the rear fender.
Refer to “REAR CARRIER AND REAR
FENDER” in chapter 3.
b. Remove the fuel hose connector holder.
c. Disconnect the fuel hose 1 from the fuel
pump.
2
a
1
1
3
1
4
NOTE:
• When removing the fuel hose from the fuel
pump, remove the fuel hose connector
holder first, and next, insert a slotted head
screw driver etc. in the slot part a of the fuel
hose connector cover 2, then slide it in the
direction of the arrow, and remove the fuel
hose.
• Before removing the hose, place a few rags
in the area under where it will be removed.
d. Connect the pressure gauge 3 and adapter
4 to the fuel pump and fuel hose.
Pressure gauge
90890-03153, YU-03153
Fuel pressure adapter
90890-03176, YM-03176
6 - 38
THROTTLE BODY
FI
e. Start the engine.
f. Measure the fuel pressure.
Fuel pressure
324 kPa (3.24 kg/cm2, 46.1 psi)
Out of specification → Replace the fuel
pump.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00916
CHECKING AND ADJUSTING THE
THROTTLE POSITION SENSOR
1. Check:
• throttle position sensor
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the throttle position sensor coupler from the throttle position sensor.
b. Remove the throttle position sensor from
the throttle body.
c. Connect the pocket tester (Ω × 1k) to the
terminals of the throttle position sensor.
Positive tester probe → blue 1
Negative tester probe → black/blue 2
d. Measure the maximum throttle position sensor resistance.
Out of specification → Replace the throttle
position sensor.
Maximum throttle position sensor
resistance
4.0 ~ 6.0 kΩ at 20 °C (68 °F)
(blue-black/blue)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• throttle position sensor angle
NOTE:
Before adjusting the throttle position sensor,
the engine idling speed should be properly
adjusted.
_
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the throttle position sensor coupler
to the throttle position sensor.
6 - 39
THROTTLE BODY
FI
b. Connect the digital circuit tester to the throttle position sensor coupler.
Positive digital circuit tester probe →
yellow 1
Negative digital circuit tester probe →
black/blue 2
L Y B/L
1 2
3
Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927
3
c. Measure the throttle position sensor voltage.
d. Adjust the throttle position sensor angle so
that the voltage is within the specified
range.
Throttle position sensor voltage
0.63 ~ 0.73 V (yellow-black/blue)
e. After adjusting the throttle position sensor
angle, tighten the throttle position sensor
screws 3.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 40
TROUBLESHOOTING
DRIV
EBS00155
DRIVE TRAIN
TROUBLESHOOTING
The following conditions may indicate damaged shaft drive components:
Symptoms
Possible Causes
1. A pronounced hesitation or “jerky” movement during acceleration, deceleration or
sustained speed. (This must not be confused with engine surging or transmission
characteristics.)
2. A “rolling rumble” noticeable at low speed; a
high-pitched whine; a “clunk” from a shaft
drive component or area.
3. A locked-up condition of the shaft drive train
mechanism, no power transmitted from the
engine to the front and/or rear wheel.
A. Bearing damage.
B. Improper gear lash.
C. Gear tooth damage.
D. Broken drive shaft.
E. Broken gear teeth.
F. Seizure due to lack of lubrication.
G. Small foreign objects lodged between the
moving parts.
NOTE:
Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite subtle and
difficult to distinguish from normal vehicle operating noise. If there is reason to believe these components are damaged, remove the components and check them.
_
EBS00156
CHECKING NOISES
1. Investigate any unusual noises.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. A “rolling rumble” noise during coasting,
acceleration, or deceleration. The noise
increases with front and/or rear wheel
speed, but it does not increase with higher
engine or transmission speeds.
Diagnosis: Possible wheel bearing damage.
b. A “whining” noise that varies with acceleration and deceleration.
Diagnosis: Possible incorrect reassembly,
too-little gear lash.
CAUTION:
_
Too little gear lash is extremely destructive
to the gear teeth. If a test ride following
reassembly indicates this condition, stop
riding immediately to minimize gear damage.
7-1
TROUBLESHOOTING
DRIV
c. A slight “thunk” evident at low speed operation. This noise must be distinguished from
normal vehicle operation.
Diagnosis: Possible broken gear teeth.
WARNING
_
Stop riding immediately if broken gear
teeth are suspected. This condition could
result in the shaft drive assembly locking
up, causing loss of control of the vehicle
and possible injury to the rider.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• drained oil
Drained oil shows large amounts of metal
particles → Check the bearing for seizure.
NOTE:
A small amount of metal particles in the oil is
normal.
_
3. Check:
• oil leakage
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the entire vehicle thoroughly, then dry
it.
b. Apply a leak-localizing compound or dry
powder spray to the shaft drive.
c. Road test the vehicle for the distance necessary to locate the leak.
Leakage → Check the component housing,
gasket, and/or seal for damage.
Damage → Replace the component.
NOTE:
• An apparent oil leak on a new or nearly new
vehicle may be the result of a rust preventative coating or excessive seal lubrication.
• Always clean the vehicle and recheck the
suspected location of an apparent leakage.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-2
7
TROUBLESHOOTING
DRIV
EBS00157
TROUBLESHOOTING CHART
When basic condition “a” and “b” exist, check the following points:
Elevate and spin both wheels. Feel for YES Replace the wheel bearing.
(Refer to “STEERING SYSTEM” and “REAR
wheel bearing damage.
KNUCKLES AND STABILIZER” in chapter
8.)
NO
Check the wheel nuts and hub nuts for tightness.
NO
Torque to specification.
(Refer to “FRONT AND REAR WHEELS” in
chapter 8.)
NO
Constant velocity joint bearings and differential gear bearings are probably not damaged. Repeat the test or remove the
individual components.
NO
Adjust per instructions.
(Refer to “ADJUSTING THE REAR BRAKE”
in chapter 3.)
NO
Constant velocity joint bearings and final
drive gear bearings are probably not damaged. Repeat the test or remove the individual components.
YES
Check the front constant velocity joints. Feel
for bearing damage.
YES
Check the rear brake adjustment.
YES
Check the rear constant velocity joints. Feel
for bearing damage.
YES
Remove the drive shaft components.
7-3
FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
EBS00158
FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR
T.
55 Nm (5.5 m • kg, 40 ft • Ib)
R.
LT
1
LS
New
9
6
5
New
2
10
LT
8
LS
7
LS
LS
T.
R.
LS
4
Order
1
3
Job/Part
Removing the front constant velocity joints and differential gear
Front engine skid plate/front fender
Q’ty
Front arms
Differential gear oil
Front constant velocity joint
Differential gear motor coupler
Differential gear case breather hose
Remarks
Remove the parts in the order listed.
Refer to “ENGINE SKID PLATES, SEAT,
CARRIERS AND FENDERS” in chapter
3.
Refer to “STEERING SYSTEM” in chapter 8.
Refer to “FRONT ARMS AND FRONT
SHOCK ABSORBER ASSEMBLIES” in
chapter 8.
Drain.
Refer to “CHANGING THE DIFFERENTIAL GEAR OIL” in chapter 3.
Steering knuckles
1
2
3
55 Nm (5.5 m • kg, 40 ft • Ib)
2
1
1
7-4
Disconnect.
Disconnect.
FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
T.
R.
55 Nm (5.5 m • kg, 40 ft • Ib)
DRIV
LT
1
LS
New
9
6
5
New
2
10
LT
8
LS
7
LS
LS
T.
R.
LS
4
Order
4
5
6
7
8
9
10
55 Nm (5.5 m • kg, 40 ft • Ib)
1
3
Job/Part
Differential gear case assembly
Front drive shaft
Spring
Damper
Coupling gear
Dust seal
Dust seal
Q’ty
1
1
1
1
1
1
1
Remarks
For installation, reverse the removal procedure.
7-5
FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
EBS00159
Order
1
2
3
4
5
6
7
8
9
0
Job/Part
Disassembling the front constant
velocity joints
Clip
Boot band
Boot band
Dust boot
Clip
Double off-set joint
Circlip
Boot band
Dust boot
Off-set joint
Q’ty
1
2
1
1
1
1
1
1
1
1
7-6
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front constant velocity joints.
Refer to “ASSEMBLING THE FRONT
CONSTANT VELOCITY JOINTS”.
FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
Order
A
B
Job/Part
Clip
Joint shaft
Q’ty
1
1
7-7
DRIV
Remarks
Refer to “ASSEMBLING THE FRONT
CONSTANT VELOCITY JOINTS”.
For assembly, reverse the disassembly
procedure.
FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
EBS00160
3
T.
R.
4
24 Nm (2.4 m kg, 17 ft Ib)
•
•
A
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
B
D
C
E
New
LS
T.
(5)
R.
F
G
LS
62 Nm (6.2 m • kg, 45 ft • Ib)
New
0
7
T.
R.
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
11 Nm (1.1 m • kg, 8.0 ft • Ib)
New
1
5
2
9
LS
New
8
6
LS
New
Order
1
2
3
4
5
6
7
8
9
0
A
F
Job/Part
Disassembling the differential gear
case assembly
Differential gear motor
Q’ty
O-ring
Front drive shaft coupling gear nut
Front drive shaft coupling gear (differential gear case side)
Differential gear case cover
O-ring
Differential gear assembly
Differential drive pinion gear shim
Bearing
Bearing
Oil seal
1
1
1
1
1
1
1
*
1
1
1
7-8
New
Remarks
Remove the parts in the order listed.
Refer to “ASSEMBLING THE DIFFERENTIAL GEARS”.
FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
3
T.
R.
4
24 Nm (2.4 m kg, 17 ft Ib)
•
•
A
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
B
D
C
E
New
LS
T.
(5)
R.
F
G
LS
62 Nm (6.2 m • kg, 45 ft • Ib)
New
0
7
T.
R.
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
11 Nm (1.1 m • kg, 8.0 ft • Ib)
New
1
5
2
9
LS
New
8
6
LS
New
Order
B
C
D
E
F
G
Job/Part
Clip
Differential drive pinion gear
Bearing
Bearing
Oil seal
Differential gear case
F
Q’ty
1
1
1
1
2
1
New
Remarks
For assembly, reverse the disassembly
procedure.
7-9
FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
EBS00163
REMOVING THE DIFFERENTIAL GEAR
ASSEMBLY
1. Remove:
• differential gear assembly 1
NOTE:
The ring gear and the differential gear should
be fastened together. Do not disassemble the
differential gear.
_
CAUTION:
_
The differential gear are assembled into a
proper unit at the factory by means of specialized equipment. Do not attempt to disassemble this unit. Disassembly will result
in the malfunction of the unit.
EBS00165
CHECKING THE FRONT CONSTANT
VELOCITY JOINTS
1. Check:
• double off-set joint spline
• ball joint spline
• shaft spline
Wear/damage → Replace.
2. Check:
• dust boots
Cracks/damage → Replace.
CAUTION:
_
Always use a new boot band.
3. Check:
• balls and ball races
• inner surface of double off-set joint
Pitting/wear/damage → Replace.
7 - 10
FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
EBS00166
CHECKING THE DIFFERENTIAL GEARS
1. Check:
• gear teeth
Pitting/galling/wear → Replace.
• bearing
Pitting/damage → Replace.
• oil seal
• O-ring
Damage → Replace.
2. Check:
• front drive shaft splines
• differential drive pinion gear splines
Wear/damage → Replace.
• spring
Fatigue → Replace.
Move the spring up and down.
3. Check:
• front drive shaft
Bends → Replace.
WARNING
_
Do not attempt to straighten a bent shaft;
this may dangerously weaken the shaft.
È
3V
1
2
CHECKING THE DIFFERENTIAL GEAR
MOTOR
1. Check:
• differential gear motor
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect two C size batteries to the gear
motor terminals 1 (as shown in illustration).
CAUTION:
• Be sure to check the motor operation
after removing it from the differential gear
case assembly.
• Do not use a 12 V battery to operate the
pinion gear.
È Check that the pinion gear 2 turns counterclockwise.
7 - 11
FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
É Check that the pinion gear 2 turns clockwise.
É
3V
NOTE:
Be sure not to disassemble the gear motor and
remove the pinion gear.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2
1
EBS00167
ASSEMBLING THE FRONT CONSTANT
VELOCITY JOINTS
1. Apply:
• molybdenum disulfide grease
(into the ball joint assembly)
NOTE:
Molybdenum disulfide grease is included in the
repair kit.
_
2. Install:
• dust boots 1
• boot bands 2, 3 New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply molybdenum disulfide grease into the
dust boots.
Molybdenum disulfide grease
40 g (1.4 oz) per dust boot (front
wheel side)
55 g (1.9 oz) per dust boot (differential gear case side)
b. Install the dust boots 1.
c. Install the dust boot bands.
NOTE:
• The new boot bands may differ from the original ones.
• The dust boots should be fastened with the
boot bands 3 at the grooves in the joint
shaft.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• thrust movement free play
Excessive play → Replace the joint assembly.
7 - 12
FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
EBS01009
ASSEMBLING THE DIFFERENTIAL GEARS
1. Measure:
• gear lash
Refer to “MEASURING THE DIFFERENTIAL GEAR LASH”.
2. Install:
• differential gear motor
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slide the shift fork sliding gear 1, which is
installed to the differential gear, to the left to
put it into the 2WD mode.
3V
3
4
b. Connect two C size batteries to the gear
motor terminal 2 to operate the pinion gear
3, and operate it until the mark 4 on the
gear is aligned with the mark 5 on the gear
motor case.
5
CAUTION:
_
Do not use a 12 V battery to operate the
pinion gear.
2
6
6
7
9
6
c. Insert 6 mm bolts 6 into the gear motor 7
and use them as a guide to set the motor on
the differential gear assembly 8 so that the
shift fork sliding gear 9 does not move.
CAUTION:
_
8
If the position of the shift fork sliding gear
is moved, the position of the differential
gear and the indicator light display may differ, and the 2WD or differential lock mode
may not be activated.
d. Remove the 6 mm bolts, and then install the
motor with the gear motor bolts.
T.
Differential gear motor bolt
11 Nm (1.1 m · kg, 8.0 ft · lb)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 13
FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
3. Check:
• differential gear operation
Unsmooth operation → Replace the differential gear assembly.
Insert the double off-set joint into the differential gear, and turn the gear back and
forth.
EBS00174
MEASURING THE DIFFERENTIAL GEAR
LASH
1. Secure the gear case in a vise or another
supporting device.
2. Remove:
• drain plug
• gasket
3. Install:
• a bolt of the specified size 1
(into the drain plug hole)
CAUTION:
_
Finger tighten the bolt until it holds the ring
gear. Otherwise, the ring gear will be damaged.
4. Attach:
• gear lash measurement tool 2
• dial gauge 3
Gear lash measurement tool
90890-01475
Middle drive gear lash tool
YM-01475
a Measuring point is 22.5 mm (0.86 in)
7 - 14
FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
5. Measure:
• gear lash
Gently rotate the coupling gear from
engagement to engagement.
Differential gear lash
0.05 ~ 0.25 mm
(0.0020 ~ 0.0098 in)
NOTE:
Measure the gear lash at four positions. Rotate
the shaft 90° each time.
_
EBS00176
2
1
ADJUSTING THE DIFFERENTIAL GEAR
LASH
1. Remove:
• differential drive pinion gear shim(s) 1
• differential gear assembly 2
2. Adjust:
• gear lash
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Select the suitable shims using the following
chart.
Too little gear
lash
Reduce shim thickness.
Too large
gear lash
Increase shim thickness.
Ring gear shim
Thickness (mm)
0.1
0.2
0.3
0.4
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 15
FRONT CONSTANT VELOCITY JOINTS AND
DIFFERENTIAL GEAR
DRIV
EBS00177
CHECKING THE DIFFERENTIAL GEAR
OPERATION
1. Block the rear wheels, and elevate the front
wheels by placing a suitable stand under
the frame.
2. Remove the wheel cap from the axle nut
(right or left).
3. Measure the starting torque of the front
wheel (i.e., differential gear preload) with
the torque wrench.
NOTE:
• Repeat this step several times to obtain an
average figure.
• During this test, the other front wheel will turn
in the opposite direction.
_
T.
R.
Front wheel starting torque
(differential gear preload)
New unit
17 ~ 25 Nm
(1.7 ~ 2.5 m · kg, 12 ~ 18 ft · lb)
Minimum
10 Nm (1.0 m · kg, 7.2 ft · lb)
4. Out of specification → Replace the differential gear assembly.
5. Within specification → Install the new cotter
pin and wheel cap.
7 - 16
REAR CONSTANT VELOCITY JOINTS AND FINAL
DRIVE GEAR
DRIV
EBS00178
REAR CONSTANT VELOCITY JOINTS AND FINAL DRIVE GEAR
T.
R.
55 Nm (5.5 m • kg, 40 ft • Ib)
2
1
3
LS
LS
6
5
10 9
New
8
7
New
T.
R.
55 Nm (5.5 m • kg, 40 ft • Ib)
LS
LS
4
1
Order
Job/Part
Removing the rear constant velocity
joints and final drive gear
Rear engine skid plate/rear fender
Q’ty
Refer to “ENGINE SKID PLATES, SEAT,
CARRIERS AND FENDERS” in chapter
3.
Refer to “REAR ARMS AND REAR
SHOCK ABSORBER ASSEMBLIES” in
chapter 8.
Drain.
Refer to “CHANGING THE FINAL GEAR
OIL” in chapter 3.
Rear arms
Final gear oil
1
2
3
4
5
Rear constant velocity joint
Final gear case breather hose
Trailer hitch
Final gear case assembly
Rear drive shaft
Remarks
Remove the parts in the order listed.
2
1
1
1
1
7 - 17
Disconnect.
REAR CONSTANT VELOCITY JOINTS AND FINAL
DRIVE GEAR
DRIV
T.
R.
55 Nm (5.5 m • kg, 40 ft • Ib)
2
1
3
LS
LS
6
5
10 9
New
8
7
New
T.
R.
55 Nm (5.5 m • kg, 40 ft • Ib)
LS
LS
4
1
Order
6
7
8
9
10
Job/Part
Spring
Damper
Coupling gear
Dust seal
Dust seal
Q’ty
1
1
1
1
1
Remarks
For installation, reverse the removal procedure.
7 - 18
REAR CONSTANT VELOCITY JOINTS AND FINAL
DRIVE GEAR
DRIV
EBS01011
Order
1
2
3
4
5
6
7
8
9
0
Job/Part
Disassembling the rear constant
velocity joints
Clip
Boot band
Boot band
Dust boot
Clip
Double off-set joint
Circlip
Boot band
Dust boot
Off-set joint
Q’ty
1
2
1
1
1
1
1
1
1
1
7 - 19
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the rear constant velocity joints.
Refer to “ASSEMBLING THE REAR
CONSTANT VELOCITY JOINTS”.
REAR CONSTANT VELOCITY JOINTS AND FINAL
DRIVE GEAR
Order
A
B
Job/Part
Clip
Joint shaft
Q’ty
1
1
7 - 20
DRIV
Remarks
Refer to “ASSEMBLING THE REAR
CONSTANT VELOCITY JOINTS”.
For assembly, reverse the disassembly
procedure.
REAR CONSTANT VELOCITY JOINTS AND FINAL
DRIVE GEAR
DRIV
EBS00179
L
G
1
Q
New
R
G
R.
T.
R.
(4)
J
23 Nm (2.3 m • kg, 17 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LS
T.
R.
I
N
P
T.
New M
K
O
23 Nm (2.3 m • kg, 17 ft • Ib)
E New
LT
LS
New
4
F
New
H
G
0
LS
LS
2
G
9 7
4
3
G
6 New
D
New
C
B
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
A
G
T.
R.
Order
1
2
3
Job/Part
Disassembling the final gear case
assembly
Final drive pinion gear assembly
Final drive pinion gear shim
Final gear case cover
Q’ty
1
*
1
Dowel pin
Gasket
Oil seal
Bearing
Bearing
Wheel gear shim
Wheel gear
2
1
1
1
1
*
1
7 - 21
8
New 5
23 Nm (2.3 m • kg, 17 ft • Ib)
(11)
LS
Remarks
Remove the parts in the order listed.
NOTE:
Working in a crisscross pattern, loosen
each bolt 1/4 of a turn. After all the bolts
are loosened, remove them.
_
4
5
6
7
8
9
0
G
REAR CONSTANT VELOCITY JOINTS AND FINAL
DRIVE GEAR
L
G
1
Q
New
R
G
P
R.
N
O
T.
T.
R.
New M
K
(4)
J
23 Nm (2.3 m • kg, 17 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LS
T.
R.
I
DRIV
23 Nm (2.3 m • kg, 17 ft • Ib)
E New
LT
LS
New
4
F
New
H
G
0
LS
LS
2
G
9 7
4
3
G
6 New
D
New
C
B
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
A
G
T.
R.
Order
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Job/Part
Thrust washer
Pinion gear
Final driven pinion gear
Final driven pinion gear shim
Oil seal
Bearing
Bearing
Final gear case
Rear drive shaft coupling gear nut
Washer
Rear drive shaft coupling gear (final
gear case side)
Final drive pinion gear
Oil seal
Bearing
G
Q’ty
*
1
1
*
1
1
1
1
1
1
1
1
1
1
7 - 22
8
New 5
23 Nm (2.3 m • kg, 17 ft • Ib)
(11)
LS
Remarks
Refer to “DISASSEMBLING THE FINAL
DRIVE PINION GEAR ASSEMBLY” and
“ASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY”.
REAR CONSTANT VELOCITY JOINTS AND FINAL
DRIVE GEAR
L
G
1
Q
New
R
G
P
R.
N
O
T.
T.
R.
New M
K
(4)
J
23 Nm (2.3 m • kg, 17 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LS
T.
R.
I
DRIV
23 Nm (2.3 m • kg, 17 ft • Ib)
E New
LT
LS
New
4
F
New
H
G
0
LS
LS
2
G
9 7
4
3
G
6 New
D
New
C
B
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
A
G
T.
R.
Order
O
P
Q
R
G
Job/Part
Q’ty
Expander
1
Washer
1
Bearing
1
Final drive pinion gear bearing housing
1
8
New 5
23 Nm (2.3 m • kg, 17 ft • Ib)
(11)
LS
Remarks
Refer to “DISASSEMBLING THE FINAL
DRIVE PINION GEAR ASSEMBLY” and
“ASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY”.
For assembly, reverse the disassembly
procedure.
7 - 23
REAR CONSTANT VELOCITY JOINTS AND FINAL
DRIVE GEAR
DRIV
EBS00167
ASSEMBLING THE REAR CONSTANT
VELOCITY JOINTS
1. Apply:
• molybdenum disulfide grease
(into the ball joint assembly)
NOTE:
Molybdenum disulfide grease is included in the
repair kit.
_
2. Install:
• dust boots 1
• boot bands 2, 3 New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply molybdenum disulfide grease into the
dust boots.
Molybdenum disulfide grease
40 g (1.4 oz) per dust boot (rear
wheel side)
60 g (2.1 oz) per dust boot (final
gear case side)
b. Install the dust boots 1.
c. Install the dust boot bands.
NOTE:
• The new boot bands may differ from the original ones.
• The dust boots should be fastened with the
boot bands 3 at the grooves in the joint
shaft.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• thrust movement free play
Excessive play → Replace the joint assembly.
7 - 24
REAR CONSTANT VELOCITY JOINTS AND FINAL
DRIVE GEAR
DRIV
DISASSEMBLING THE FINAL DRIVE
PINION GEAR ASSEMBLY
1. Loosen:
• rear drive shaft coupling gear (final gear
side) nut 1
1
NOTE:
Secure the final drive pinion gear teeth in the
vise with a clean rag.
EBS00184
POSITIONING THE FINAL DRIVE PINION
GEAR AND RING GEAR
When the final drive pinion gear, wheel gear,
final gear case and/or final driven pinion gear
are replaced, be sure to adjust the positions of
the final drive pinion gear, wheel gear and final
driven pinion gear using the shim(s).
EBS00185
ADJUSTING THE FINAL DRIVE PINION
GEAR BACKLASH
1. Select:
• final drive pinion gear shim(s) 1
1
“A”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. To find the final drive pinion gear shim thickness “A”, use the following formula.
c
b
a
b
Final drive pinion gear shim thickness
“A” = a + (c – b) – d
d
a = 55 mm (2.2 in).
b = a numeral (usually a decimal number) on
the final drive pinion gear either added to
or subtracted from “22.2”.
c = a numeral (usually a decimal number) on
the final drive pinion gear bearing housing
either added to or subtracted from “67.8”.
d = a numeral (usually a decimal number) on
the final gear case either added to or subtracted from “100”.
Example:
1) a = 55
2) If “–02” is stamped on the final drive pinion
gear,
b = 22.2 – 0.02
= 22.18
7 - 25
REAR CONSTANT VELOCITY JOINTS AND FINAL
DRIVE GEAR
DRIV
3) If “–05” is stamped on the final drive pinion
gear bearing housing,
c = 67.8 – 0.05
= 67.75
c
NOTE:
After replacing any part in the final drive pinion
gear assembly, the overall length of the
assembly will change. Therefore, be sure to
measure distance c to select the correct final
drive pinion gear shim thickness.
c
4) If “–01” is stamped on the final gear case,
d = 100 – 0.01
= 99.99
5) Therefore, “A” is 0.58
“A” = 55 + (67.75 – 22.18) – 99.99
= 0.58
6) Round off the hundredth digit and select the
appropriate shim(s).
In the example above, the calculated number is 0.58. The chart instructs you to round
off 8 to 10 at the hundredth place. Thus, the
shim thickness is 0.60 mm (0.024 in).
d
Hundredths
Rounded value
0, 1, 2
0
3, 4, 5, 6, 7
5
8, 9
10
Shims are supplied in the following thicknesses.
Final drive pinion gear shim
Thickness (mm)
0.25 0.30 0.35
0.40 0.45 0.50
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 26
REAR CONSTANT VELOCITY JOINTS AND FINAL
DRIVE GEAR
DRIV
EBS00186
e
ADJUSTING THE FINAL DRIVEN PINION
GEAR BACKLASH
1. Select:
• final driven pinion gear shim(s) 1, 2
f
g
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. To find the final driven pinion gear shim
thickness “B”, use the following formula.
Final driven pinion gear shim thickness
“B” = h – (e – f + g)
1
2
h
e
“B”
e = a numeral (usually a decimal number) on
the final gear case either added to or subtracted from “71.6”.
f = a numeral (usually a decimal number) on
the outside of the final driven pinion gear
either added to or subtracted from “51.0”.
g = a numeral (usually a decimal number) on
the outside of the final driven pinion gear
either added to or subtracted from “24.0”.
h = 49.8
Example:
1) If “–03” is stamped on the final gear case,
e = 71.6 – 0.03
= 71.57
2) If “–12” is stamped on the outside of the
final driven pinion gear,
f = 51.0 – 0.12
= 50.88
3) If “–05” is stamped on the outside of the
final driven pinion gear,
g = 24.0 – 0.05
= 23.95
4) h = 49.8
5) Therefore, shim thickness “B” is 5.16
“B” = 49.8 – (71.57 – 50.88 + 23.95)
= 5.16
f
7 - 27
REAR CONSTANT VELOCITY JOINTS AND FINAL
DRIVE GEAR
g
DRIV
6) Round off the hundredth digit and select the
appropriate shim(s). In the example above,
the calculated number is 5.16. The chart
instructs you to round off 6 to 5 at the hundredth place.
Thus, the shim thickness is 5.15 mm.
Hundredths
Rounded value
0, 1, 2
0
3, 4, 5, 6, 7
5
8, 9
10
Shims are supplied in the following thicknesses.
Final driven pinion gear shim 1
Thickness (mm)
0.25 0.30 0.35
0.40 0.45 0.50
Final driven pinion gear shim 2
Thickness (mm)
4.5 4.8
5.1 5.4
NOTE:
Be sure to use one of each of the final driven
pinion gear shims 1 and 2 to obtain the shim
thickness.
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7 - 28
REAR CONSTANT VELOCITY JOINTS AND FINAL
DRIVE GEAR
DRIV
EBS00187
MEASURING THE FINAL DRIVEN PINION
GEAR THRUST WASHER CLEARANCE
1. Measure:
• final driven pinion gear thrust washer clearance “C”
“C”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place four pieces of Plastigauge® between
the originally fitted thrust washer and the
final driven pinion gear assembly.
b. Install the final driven pinion gear assembly
and final driven pinion gear shim(s), and
then tighten the bolts to specification.
T.
Final gear case cover bolt
23 Nm (2.3 m · kg, 17 ft · lb)
R.
NOTE:
Do not turn the drive pinion gear, wheel gear,
and driven pinion gear when measuring the
clearance with Plastigauge®.
_
c. Remove the final driven pinion gear assembly.
d. Measure the thrust clearance. Calculate the
width of the flattened Plastigauge® 1.
Final driven pinion gear thrust
clearance
0.08 ~ 0.12 mm
(0.0031 ~ 0.0047 in)
1
e. If out of specification, select the correct
washer.
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2. Select:
• final driven pinion gear thrust washer
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Select a suitable thrust washer using the
following chart.
Thrust washer
Thickness (mm)
0.25 0.30 0.35
0.40 0.45 0.50
b. Repeat the measurement steps until the
final driven pinion gear thrust clearance is
within the specified limits.
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7 - 29
REAR CONSTANT VELOCITY JOINTS AND FINAL
DRIVE GEAR
DRIV
EBS00187
MEASURING THE WHEEL GEAR THRUST
CLEARANCE
1. Measure:
• wheel gear thrust clearance “D”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place four pieces of Plastigauge® between
the originally fitted wheel gear shim(s) and
the wheel gear.
b. Install the wheel gear and tighten the bolts
to specification.
T.
Final gear case cover bolt
23 Nm (2.3 m · kg, 17 ft · lb)
R.
NOTE:
Do not turn the drive pinion gear, wheel gear,
and driven pinion gear when measuring the
clearance with Plastigauge®.
_
“D”
1
c. Remove the wheel gear.
d. Measure the thrust clearance. Calculate the
width of the flattened Plastigauge® 1.
Wheel gear thrust clearance
0.03 ~ 0.07 mm
(0.0012 ~ 0.0028 in)
e. If out of specification, select the correct
shim(s).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Select:
• wheel gear thrust clearance “D”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Select a suitable wheel gear shim(s) using
the following chart.
Wheel gear shim
Thickness (mm)
0.25 0.30 0.35
0.40 0.45 0.50
b. Repeat the measurement steps until the
wheel gear thrust clearance is within the
specified limits.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 30
REAR CONSTANT VELOCITY JOINTS AND FINAL
DRIVE GEAR
DRIV
EBS00191
CHECKING THE REAR DRIVE SHAFT
1. Check:
• rear drive shaft splines
• coupling gear splines
Wear/damage → Replace.
EBS00192
CHECKING THE FINAL DRIVE ASSEMBLY
1. Check:
• final gear case
• final gear case cover
Cracks/damage → Replace.
NOTE:
When the final gear case and/or the final gear
case cover are replaced, be sure to adjust the
shim thickness of the final drive pinion gear,
final driven pinion gear and/or wheel gear.
_
2. Check:
• gear teeth
Pitting/galling/wear → Replace the drive
pinion gear and ring gear as a set.
• oil seals
• O-rings
Damage → Replace.
3. Check:
• bearings
Damage → Replace.
NOTE:
• Reusing roller bearings is acceptable, but
Yamaha recommends installing new ones.
Do not reuse the oil seal.
• When the final drive pinion gear, final driven
pinion gear and/or wheel gear are replaced,
be sure to adjust the shim thickness of the
final drive pinion gear, final driven pinion
gear and/or wheel gear.
_
7 - 31
REAR CONSTANT VELOCITY JOINTS AND FINAL
DRIVE GEAR
DRIV
EBS00193
MEASUREMENT THE FINAL GEAR LASH
1. Secure the gear case in a vise or another
supporting device.
2. Remove:
• drain plug
• gasket
3. Install:
• a bolt of the specified size 1
(into the drain plug hole)
CAUTION:
_
Finger tighten the bolt until it holds the ring
gear. Otherwise, the ring gear will be damaged.
1
3
4. Attach:
• final gear backlash band 2
• dial gauge 3
Final gear backlash band
90890-01511
2
a Measuring point is 31.5 mm (1.24 in)
a
5. Measure:
• gear lash
Gently rotate the coupling gear from
engagement to engagement.
Final gear lash
0.10 ~ 0.20 mm
(0.0039 ~ 0.0079 in)
NOTE:
• When measuring the gear lash, be sure the
right side (gear oil level check bolt side) of
the final gear case assembly is facing downward.
• Measure the gear lash at four positions.
Rotate the shaft 90° each time.
_
7 - 32
REAR CONSTANT VELOCITY JOINTS AND FINAL
DRIVE GEAR
DRIV
EBS00194
1
2
4
3
ADJUSTING THE FINAL GEAR LASH
1. Remove:
• final driven pinion gear assembly 1
• final driven pinion gear shim 2
• final driven pinion gear shim 3
• thrust washer 4
2. Adjust:
• gear lash
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Select a suitable shim(s) and thrust washer
using the following chart.
Too little gear
lash
Increase shim thickness.
Too large
gear lash
Reduce shim thickness.
b. If increased by more than 0.2 mm (0.008
in):
Reduce the thrust washer thickness by 0.2
mm (0.008 in) for every 0.2 mm (0.008 in) of
final driven pinion gear shim increase.
c. If reduced by more than 0.2 mm (0.008 in):
Increase the thrust washer thickness by 0.2
mm (0.008 in) for every 0.2 mm (0.008 in)
that the final driven pinion gear shim is
decreased.
Final driven pinion gear shim 2
Thickness (mm)
0.25 0.30 0.35
0.40 0.45 0.50
Final driven pinion gear shim 3
Thickness (mm)
4.5 4.8
5.1 5.4
NOTE:
Be sure to use one of each of the final driven
pinion gear shims 2 and 3 to obtain the shim
thickness.
7 - 33
REAR CONSTANT VELOCITY JOINTS AND FINAL
DRIVE GEAR
DRIV
Thrust washer
Thickness (mm)
0.25 0.30 0.35
0.40 0.45 0.50
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1
ASSEMBLING THE FINAL DRIVE PINION
GEAR ASSEMBLY
1. Tighten:
• rear drive shaft coupling gear nut (final gear
side) 1
LT
NOTE:
Secure the final drive pinion gear teeth in the
vise with a clean rag.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Tighten the nut to 80 Nm (8.0 m · kg, 58 ft · lb).
b. Secure the final drive pinion gear bearing
housing in a vice, and then turn the nut with
a torque wrench to check the starting
torque.
T.
R.
Final drive pinion gear starting
torque (final drive pinion gear
preload)
0.8 ~ 1.3 Nm (0.08 ~ 0.13 m · kg)
c. Out of specification → Tighten the nut further.
d. Repeat step (b).
e. Repeat steps (c) and (d) until the starting
torque is within specification.
a
NOTE:
• Be careful not to exceed the specified starting torque.
• If the specified starting torque is exceeded,
replace the expander with a new one and
reassemble the final drive pinion gear
assembly.
• Make sure that the distance a is 67.5 ~
68.1 mm (2.66 ~ 2.68 in) as shown.
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7 - 34
REAR CONSTANT VELOCITY JOINTS AND FINAL
DRIVE GEAR
DRIV
ASSEMBLING THE FINAL GEAR CASE
1. Install:
• oil seals 1
1
1
a
Installed depth of oil seal a
5.5 mm (0.22 in)
a
7 - 35
FRONT AND REAR WHEELS
CHAS
EBS00378
CHASSIS
FRONT AND REAR WHEELS
FRONT WHEELS
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
LT
R.
260 Nm (26.0 m • kg, 190 ft • lb)
1
2
6
5
3 New
4
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
R.
Order
Job/Part
Removing the front wheels
Q’ty
55 Nm (5.5 m • kg, 40 ft • Ib)
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front wheels.
Place the vehicle on a level surface.
WARNING
_
Securely support the vehicle so there
is no danger of it falling over.
1
2
3
Front wheel
Wheel cap
Front wheel axle nut
1
1
1
8-1
Refer to “INSTALLING THE WHEELS”.
Refer to “INSTALLING THE WHEEL
HUBS”.
8
FRONT AND REAR WHEELS
CHAS
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
LT
R.
260 Nm (26.0 m • kg, 190 ft • lb)
1
2
6
5
3 New
4
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
R.
Order
4
Job/Part
Front brake caliper assembly
55 Nm (5.5 m • kg, 40 ft • Ib)
Q’ty
Remarks
1
NOTE:
Do not squeeze the front brake lever
when the brake caliper is off of the brake
disc as the brake pads will be forced shut.
_
5
6
Front wheel hub
Front brake disc
1
1
8-2
Refer to “INSTALLING THE BRAKE
DISCS”.
For installation, reverse the removal procedure.
FRONT AND REAR WHEELS
CHAS
EBS00379
REAR WHEELS
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
R.
LT
260 Nm (26.0 m • kg, 190 ft • lb)
1
2
6
5
4
3 New
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
R.
Order
Job/Part
Removing the rear wheels
Q’ty
55 Nm (5.5 m • kg, 40 ft • Ib)
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the rear wheels.
Place the vehicle on a level surface.
WARNING
_
Securely support the vehicle so there
is no danger of it falling over.
1
2
3
Rear wheel
Wheel cap
Rear wheel axle nut
1
1
1
8-3
Refer to “INSTALLING THE WHEELS”.
Refer to “INSTALLING THE WHEEL
HUBS”.
FRONT AND REAR WHEELS
CHAS
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
R.
LT
260 Nm (26.0 m • kg, 190 ft • lb)
1
2
6
5
4
3 New
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
R.
Order
4
5
6
Job/Part
Rear brake caliper assembly
Rear wheel hub
Rear brake disc
55 Nm (5.5 m • kg, 40 ft • Ib)
Q’ty
Remarks
1
NOTE:
Do not squeeze the rear brake lever and
brake pedal when the brake caliper is off
of the brake disc as the brake pads will
be forced shut.
1
1
8-4
Refer to “INSTALLING THE BRAKE
DISCS”.
For installation, reverse the removal procedure.
FRONT AND REAR WHEELS
CHAS
EBS00383
CHECKING THE WHEELS
1. Check:
• wheels
2. Measure:
• wheel runout
Over the specified limit → Replace the
wheel or check the wheel bearing play 1.
Wheel runout limit
Front
Radial 2: 2.0 mm (0.08 in)
Lateral 3: 2.0 mm (0.08 in)
Rear
Radial 2: 2.0 mm (0.08 in)
Lateral 3: 2.0 mm (0.08 in)
3. Check:
• wheel balance
Out of balance → Adjust.
WARNING
_
After replacing the tire, ride conservatively
to allow the tire to be properly seated in the
rim. Failure to do so may cause an accident
resulting in vehicle damage and possible
operator injury.
EBS00385
2
CHECKING THE WHEEL HUBS
1. Check:
• wheel hubs 1
Cracks/damage → Replace.
• splines (wheel hub) 2
Wear/damage → Replace the wheel hub.
1
8-5
FRONT AND REAR WHEELS
CHAS
EBS00389
CHECKING THE BRAKE DISCS
1. Check:
• brake discs
Galling/damage → Replace.
2. Measure:
• brake disc deflection
Out of specification → Check the wheel
runout.
Brake disc maximum deflection
Front: 0.1 mm (0.004 in)
Rear: 0.1 mm (0.004 in)
• brake disc thickness a
Out of specification → Replace.
Brake disc minimum thickness
Front: 3.0 mm (0.12 in)
Rear: 3.0 mm (0.12 in)
INSTALLING THE BRAKE DISCS
1. Install:
• brake discs
T.
R.
Brake disc bolt
30 Nm (3.0 m · kg, 22 ft · lb)
LOCTITE®
NOTE:
Install the brake discs with their spot-faced
side facing the bolt heads.
INSTALLING THE WHEEL HUBS
1. Install:
• wheel axle nut New
T.
R.
260 Nm (26.0 m · kg, 190 ft · lb)
NOTE:
• Do not apply oil to the seat of the nut.
• After tightening the nut, stake the collar of
the nut into the notch of the shaft.
8-6
FRONT AND REAR WHEELS
CHAS
EBS00392
INSTALLING THE WHEELS
1. Install:
• wheels
NOTE:
The arrow mark 1 on the tire must point in the
direction of rotation È of the wheel.
_
2. Tighten:
• wheel nuts 1
T.
R.
55 Nm (5.5 m · kg, 40 ft · lb)
WARNING
Tapered wheel nuts 1 are used for both the
front and rear wheels. Install each nut with
its tapered side towards the wheel.
8-7
FRONT AND REAR BRAKES
CHAS
EBS00400
FRONT AND REAR BRAKES
FRONT BRAKE PADS
4
5
T.
R.
5 Nm (0.5 m • kg, 3.6 ft • Ib)
T.
R.
17 Nm (1.7 m • kg, 12 ft • Ib)
3
2
1
T.
R.
Order
1
2
3
4
5
30 Nm (3.0 m • kg, 22 ft • Ib)
Job/Part
Removing the front brake pads
Front wheel
Front brake caliper bolt
Brake pad holding bolt plug
Brake pad holding bolt
Front brake pad
Brake pad spring
Q’ty
2
1
1
2
1
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
Refer to “FRONT AND REAR WHEELS”.
Refer to “REPLACING THE FRONT
AND REAR BRAKE PADS”.
For installation, reverse the removal procedure.
8-8
FRONT AND REAR BRAKES
CHAS
EBS00401
REAR BRAKE PADS
T.
R.
5 Nm (0.5 m • kg, 3.6 ft • Ib)
5
4
1
2
T.
R.
T.
R.
Order
1
2
3
4
5
3
30 Nm (3.0 m • kg, 22 ft • Ib)
17 Nm (1.7 m • kg, 12 ft • Ib)
Job/Part
Removing the rear brake pads
Rear wheel
Rear brake caliper bolt
Brake pad holding bolt plug
Brake pad holding bolt
Rear brake pad
Brake pad spring
Q’ty
2
1
1
2
1
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the rear brake calipers.
Refer to “FRONT AND REAR WHEELS”.
Refer to “REPLACING THE FRONT
AND REAR BRAKE PADS”.
For installation, reverse the removal procedure.
8-9
FRONT AND REAR BRAKES
CHAS
EBS00402
CAUTION:
_
Disc brake components rarely require disassembly.
DO NOT:
• disassemble components unless absolutely necessary;
• use solvents on internal brake components;
• use spent brake fluid for cleaning; (use
only clean brake fluid)
• allow brake fluid to come in contact with
the eyes, as this may cause eye injury;
• splash brake fluid onto painted surfaces
or plastic parts, as this may cause damage;
• disconnect any hydraulic connection, as
this would require the entire brake system to be disassembled, drained,
cleaned, properly filled and bled after
reassembly.
EBS00404
REPLACING THE FRONT AND REAR
BRAKE PADS
NOTE:
It is not necessary to disassemble the brake
calipers and brake hoses to replace the brake
pads.
_
a
1. Remove:
• brake pads
Brake pad wear limit a
Front: 1.0 mm (0.04 in)
Rear: 1.0 mm (0.04 in)
NOTE:
Replace the brake pads as a set if either is
found to be worn to the wear limit.
_
8 - 10
FRONT AND REAR BRAKES
CHAS
2. Install:
• brake pad spring
• brake pads
NOTE:
Always install new brake pads and brake pad
spring as a set.
_
1
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a suitable hose 1 tightly to the
brake caliper bleed screw 2. Put the other
end of this hose into an open container.
b. Loosen the brake caliper bleed screw and,
using a finger, push the caliper piston into
the brake caliper.
c. Tighten the brake caliper bleed screw.
T.
Brake caliper bleed screw
5 Nm (0.5 m · kg, 3.6 ft · lb)
R.
d. Install new brake pads and a new brake pad
spring.
e. Install the holding bolt, holding bolt plug and
brake caliper.
T.
R.
Brake pad holding bolt
17 Nm (1.7 m · kg, 12 ft · lb)
Brake caliper bolt
30 Nm (3.0 m · kg, 22 ft · lb)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
4. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
8 - 11
FRONT AND REAR BRAKES
CHAS
EBS00407
FRONT BRAKE MASTER CYLINDER
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
11
2
3
12
7 New
T.
R.
6 Nm (0.6 m • kg, 4.3 ft • Ib)
∗
6
9
5
10
8
4
T.
R.
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.
R.
27 Nm (2.7 m • kg, 19 ft • Ib)
* Apply silicone grease.
Order
1
2
3
4
5
Job/Part
Removing the front brake master
cylinder
Brake fluid
On-command four-wheel-drive motor
switch and differential gear lock switch
Brake fluid reservoir cap
Brake fluid reservoir diaphragm holder
Brake fluid reservoir diaphragm
Front brake lever cover
Brake lever
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
Refer to “HANDLEBAR”.
1
1
1
1
1
8 - 12
FRONT AND REAR BRAKES
CHAS
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
11
2
3
12
7 New
T.
R.
6 Nm (0.6 m • kg, 4.3 ft • Ib)
∗
6
9
5
10
8
4
T.
R.
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.
R.
27 Nm (2.7 m • kg, 19 ft • Ib)
* Apply silicone grease.
Order
6
7
8
9
10
11
12
Job/Part
Union bolt
Copper washer
Front brake hose
Front brake light switch connector
Front brake light switch
Front brake master cylinder holder
Front brake master cylinder
Q’ty
Remarks
1
2
1
Disconnect. Refer to “INSTALLING
2
Disconnect. THE FRONT BRAKE
MASTER CYLINDER”.
1
1
1
For installation, reverse the removal procedure.
8 - 13
FRONT AND REAR BRAKES
CHAS
EBS00409
3 New
2 New
1
Order
1
2
3
Job/Part
Disassembling the front brake master cylinder
Dust boot
Circlip
Brake master cylinder kit
Q’ty
1
1
1
8 - 14
Remarks
Remove the parts in the order listed.
Refer to “ASSEMBLING THE FRONT
AND REAR BRAKE MASTER CYLINDERS”.
For assembly, reverse the disassembly
procedure.
CHAS
FRONT AND REAR BRAKES
EBS00410
REAR BRAKE MASTER CYLINDER
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
14
2
3
15
New 10
T.
R.
6 Nm (0.6 m • kg, 4.3 ft • Ib)
∗
9
12
∗
11
7
LS
13
6
T
.
R.
6 Nm (0.6 m • kg, 4.3 ft • Ib)
8
New
5
4
LS
* Apply silicone grease.
27 Nm (2.7 m kg, 19 ft Ib)
T.
•
R.
Order
1
2
3
4
5
6
7
8
•
Job/Part
Q’ty
Remarks
Removing the rear brake master cylRemove the parts in the order listed.
inder
Brake fluid
Drain.
Brake fluid reservoir cap
1
Brake fluid reservoir diaphragm holder
1
Brake fluid reservoir diaphragm
1
Rear brake lever cover
1
Shift control cable
1
Disconnect.
Rear brake cable
1
Disconnect.
Brake lever
1
Brake lever bracket
1
8 - 15
CHAS
FRONT AND REAR BRAKES
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
1
14
2
3
15
New 10
T.
R.
6 Nm (0.6 m • kg, 4.3 ft • Ib)
∗
9
12
∗
11
7
LS
13
6
T
.
R.
6 Nm (0.6 m • kg, 4.3 ft • Ib)
8
New
5
4
LS
* Apply silicone grease.
T.
R.
27 Nm (2.7 m kg, 19 ft Ib)
Order
9
10
11
12
13
14
15
•
•
Job/Part
Union bolt
Copper washer
Rear brake hose
Rear brake light switch connector
Rear brake light switch
Rear brake master cylinder holder
Rear brake master cylinder
Q’ty
Remarks
1
2
1
Disconnect. Refer to “INSTALLING
2
Disconnect. THE REAR BRAKE MASTER CYLINDER”.
1
1
1
For installation, reverse the removal procedure.
8 - 16
FRONT AND REAR BRAKES
CHAS
EBS00411
3 New
2 New
1
Order
1
2
3
Job/Part
Disassembling the rear brake master cylinder
Dust boot
Circlip
Brake master cylinder kit
Q’ty
1
1
1
8 - 17
Remarks
Remove the parts in the order listed.
Refer to “ASSEMBLING THE FRONT
AND REAR BRAKE MASTER CYLINDERS”.
For assembly, reverse the disassembly
procedure.
FRONT AND REAR BRAKES
CHAS
EBS00413
CHECKING THE MASTER CYLINDERS
1. Check:
• brake master cylinder
Wear/scratches → Replace the brake master cylinder assembly.
• brake master cylinder body
Cracks/damage → Replace.
• brake fluid delivery passage
(brake master cylinder body)
Blockage → Blow out with compressed air.
2. Check:
• brake master cylinder kit
Scratches/wear/damage → Replace as a
set.
3. Check:
• brake master cylinder reservoir
• brake master cylinder reservoir diaphragm
Cracks/damage → Replace.
EBS00415
ASSEMBLING THE FRONT AND REAR
BRAKE MASTER CYLINDERS
WARNING
_
• All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.
Recommended brake fluid
DOT 4
• Whenever a master cylinder is disassembled, replace the piston seals and dust
seals.
8 - 18
FRONT AND REAR BRAKES
CHAS
EBS00418
INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. Install:
• brake master cylinder 1
• brake master cylinder holder 2
2
1
er
Low
UP
T.
R.
a
b
7 Nm (0.7 m · kg, 5.1 ft · lb)
NOTE:
• Align the end of the brake master cylinder
holder with the punch mark a on the handlebar.
• The “UP” mark b on the brake master cylinder holder should face up.
_
Install:
brake hose
copper washers New
27 Nm (2.7 m · kg, 19 ft · lb)
union bolt
T.
R.
2.
•
•
•
NOTE:
• Tighten the union bolt while holding the
brake hose as shown.
• Turn the handlebar to the left and to the right
to check that the brake hose does not touch
other parts (throttle cable, wire harness,
leads, etc.). Correct if necessary.
_
60˚
WARNING
_
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING” in chapter 2.
8 - 19
FRONT AND REAR BRAKES
CHAS
3. Fill:
• brake fluid reservoir
Recommended brake fluid
DOT 4
CAUTION:
_
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.
WARNING
_
• Use only the designated quality brake
fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid:
mixing brake fluids may result in a harmful reaction and lead to poor brake performance.
• Be careful that water does not enter the
brake master cylinder when refilling.
Water will significantly lower the boiling
point of the brake fluid and may result in
vapor lock.
4. Air bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:
• brake fluid level
Brake fluid level is under the “LOWER” level
line → Fill up.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
8 - 20
FRONT AND REAR BRAKES
CHAS
EBS00418
INSTALLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
• brake master cylinder 1
• brake master cylinder holder 2
1
R.
2
a
T.
UP
NOTE:
• Align the end of the brake master cylinder
holder with the punch mark a on the handlebar.
• The “UP” mark b on the brake master cylinder holder should face up.
_
b
Install:
brake hose
copper washers New
27 Nm (2.7 m · kg, 19 ft · lb)
union bolt
T.
R.
2.
•
•
•
60˚
7 Nm (0.7 m · kg, 5.1 ft · lb)
NOTE:
• Tighten the union bolt while holding the
brake hose as shown.
• Turn the handlebar to the left and to the right
to check that the brake hose does not touch
other parts (throttle cable, wire harness,
leads, etc.). Correct if necessary.
_
WARNING
_
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING” in chapter 2.
8 - 21
FRONT AND REAR BRAKES
CHAS
3. Fill:
• brake fluid reservoir
Recommended brake fluid
DOT 4
CAUTION:
_
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.
WARNING
_
• Use only the designated quality brake
fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid:
mixing brake fluids may result in a harmful chemical reaction and lead to poor
brake performance.
• Be careful that water does not enter the
brake master cylinder when refilling.
Water will significantly lower the boiling
point of the brake fluid and may result in
vapor lock.
4. Air bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:
• brake fluid level
Brake fluid level is under the “LOWER” level
line → Fill up.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
6. Check:
• brake pedal free play
Refer to “ADJUSTING THE REAR BRAKE”
in chapter 3.
7. Check:
• select lever movement
Refer to “ADJUSTING THE SELECT
LEVER CONTROL CABLE AND SHIFT
ROD” in chapter 3.
8 - 22
FRONT AND REAR BRAKES
CHAS
EBS00421
FRONT BRAKE CALIPERS
T.
R.
17 Nm (1.7 m • kg, 12 ft • Ib)
5
4
3
6
T.
R.
T.
R.
Order
1
2
3
4
5
6
7
1
27 Nm (2.7 m • kg, 19 ft • Ib)
2 New
30 Nm (3.0 m • kg, 22 ft • Ib)
Job/Part
Removing the front brake calipers
Brake fluid
Front wheel
Union bolt
Copper washer
Front brake hose
Brake pad holding bolt plug
Brake pad holding bolt
Front brake caliper bolt
Front brake caliper assembly
7
Q’ty
1
2
1
1
1
2
1
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
Drain.
Refer to “FRONT AND REAR WHEELS”.
Disconnect.
Loosen.
Refer to “INSTALLING
THE FRONT AND REAR
BRAKE CALIPERS”.
For installation, reverse the removal procedure.
8 - 23
CHAS
FRONT AND REAR BRAKES
EBS00423
2
4
T.
R.
5 Nm (0.5 m • kg, 3.6 ft • Ib)
∗
8
3
T.
R.
17 Nm (1.7 m • kg, 12 ft • Ib)
5
6 New
7 New
∗
1
* Apply silicone grease.
Order
Job/Part
Disassembling the front brake calipers
Q’ty
1
2
3
4
5
6
7
Brake pad holding bolt
Front brake pad
Brake pad spring
Front brake caliper bracket
Caliper piston
Dust seal
Caliper piston seal
1
2
1
1
1
1
1
8
Bleed screw
1
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
Refer to “DISASSEMBLING THE
FRONT AND REAR BRAKE CALIPERS” and “ASSEMBLING THE
FRONT AND REAR BRAKE CALIPERS”.
For assembly, reverse the disassembly
procedure.
8 - 24
FRONT AND REAR BRAKES
CHAS
EBS00424
REAR BRAKE CALIPERS
T.
6
R.
17 Nm (1.7 m • kg, 12 ft • Ib)
7
4
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
5
3
T.
R.
27 Nm (2.7 m • kg, 19 ft • Ib)
1
2 New
Order
1
2
3
4
5
6
7
Job/Part
Removing the rear brake calipers
Brake fluid
Rear wheel
Union bolt
Copper washer
Rear brake hose
Brake pad holding bolt plug
Brake pad holding bolt
Rear brake caliper bolt
Rear brake caliper assembly
Q’ty
1
2
1
1
1
2
1
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the rear brake calipers.
Drain.
Refer to “FRONT AND REAR WHEELS”.
Disconnect.
Loosen.
For installation, reverse the removal procedure.
8 - 25
FRONT AND REAR BRAKES
CHAS
EBS00425
T.
R.
5 Nm (0.5 m • kg, 3.6 ft • Ib)
8
2
1
3
T.
R.
17 Nm (1.7 m • kg, 12 ft • Ib)
∗
New 7
4
New 6
5
∗
* Apply silicone grease.
Order
Job/Part
Disassembling the rear brake calipers
Q’ty
1
2
3
4
5
6
7
Brake pad holding bolt
Rear brake pad
Brake pad spring
Rear brake caliper bracket
Caliper piston
Dust seal
Caliper piston seal
1
2
1
1
1
1
1
8
Bleed screw
1
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the rear brake calipers.
Refer to “DISASSEMBLING THE
FRONT AND REAR BRAKE CALIPERS” and “ASSEMBLING THE
FRONT AND REAR BRAKE CALIPERS”.
For assembly, reverse the disassembly
procedure.
8 - 26
FRONT AND REAR BRAKES
CHAS
EBS00427
È
DISASSEMBLING THE FRONT AND REAR
BRAKE CALIPERS
1. Remove:
• brake caliper piston 1
• dust seal 2
• caliper piston seal 3
3
1
2
È Front
É Rear
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the hose joint
opening a to force out the caliper piston
from the brake caliper body.
É
WARNING
_
3
1
2
• Never try to pry out the caliper piston.
• Cover the caliper piston with a rag. Be
careful not to get injured when the piston
is expelled from the caliper cylinder.
b. Remove the dust seal and the caliper piston
seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a
EBS00429
CHECKING THE FRONT AND REAR BRAKE
CALIPERS
Recommended brake component
replacement schedule:
8 - 27
Brake pads
As required
Piston seals, dust
seals
Every two years
Brake hoses
Every four years
Brake fluid
Replace when
brakes are
disassembled.
FRONT AND REAR BRAKES
CHAS
WARNING
_
All internal brake components should be
cleaned in new brake fluid only. Do not use
solvents as they will cause seals to swell
and distort.
È
3
2
1
É
3
1. Check:
• brake caliper piston 1
Scratches/rust/wear → Replace the brake
caliper assembly.
• brake caliper cylinder 2
Wear/scratches → Replace the brake caliper assembly.
• brake caliper body 3
Cracks/damage → Replace.
• brake fluid delivery passage
(brake caliper body)
Blockage → Blow out with compressed air.
WARNING
_
Replace the caliper piston seal and dust
seal whenever the brake caliper is disassembled.
2
1
È Front
É Rear
EBS00431
ASSEMBLING THE FRONT AND REAR
BRAKE CALIPERS
WARNING
_
• All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.
Recommended brake fluid
DOT 4
• Replace the caliper piston seal whenever
a brake caliper is disassembled.
1. Install:
• caliper piston seal 1 New
• dust seal 2 New
1 New
2 New
8 - 28
FRONT AND REAR BRAKES
CHAS
2. Install:
• brake caliper piston 1
1
È
EBS00434
1
INSTALLING THE FRONT AND REAR
BRAKE CALIPERS
1. Install:
• brake caliper assembly
• brake caliper bolts 1
2
a
T.
R.
3 New
1
4
30 Nm (3.0 m · kg, 22 ft · lb)
• brake hose 2
• copper washers 3 New
27 Nm (2.7 m · kg, 19 ft · lb)
• union bolt 4
T.
R.
CAUTION:
É
_
2
1
4
New 3
When installing the brake hose on the
brake caliper, make sure that the brake
pipe touches the projection a on the brake
caliper.
a
WARNING
_
1
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING” in chapter 2.
È Front
É Rear
2. Fill:
• brake master cylinder reservoir
Recommended brake fluid
DOT 4
CAUTION:
_
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.
8 - 29
FRONT AND REAR BRAKES
CHAS
WARNING
_
• Use only the designated quality brake
fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid:
mixing brake fluids may result in a harmful chemical reaction and lead to poor
brake performance.
• Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
brake fluid and may result in vapor lock.
3. Air bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4. Check:
• brake fluid level
Brake fluid level is below the “LOWER”
level line → Add the recommended brake
fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
8 - 30
STEERING SYSTEM
CHAS
EBS00444
STEERING SYSTEM
HANDLEBAR
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
5
15
15
1
3
8
9
11
6
14
16
12
7
13
10
14
2
4
2
T.
R.
Order
1
2
3
4
5
6
7
8
9
Job/Part
Removing the handlebar
Handlebar cover
Plastic band
On-command four-wheel-drive motor
switch and differential gear lock switch
Throttle lever assembly holder
Throttle lever assembly
Front brake light switch connector
Front brake master cylinder holder
Front brake master cylinder
Rear brake light switch connector
Q’ty
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
Remove the parts in the order listed.
1
4
1
1
1
2
1
1
2
8 - 31
Refer to “INSTALLING THE THROTTLE LEVER ASSEMBLY”.
Disconnect.
Refer to “INSTALLING THE FRONT
BRAKE MASTER CYLINDER”.
Disconnect.
STEERING SYSTEM
T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
CHAS
5
15
15
1
3
8
9
11
6
14
16
12
7
13
10
14
2
4
2
T.
R.
Order
10
11
12
13
14
15
16
Job/Part
Rear brake master cylinder holder
Rear brake master cylinder
Spacer
Left handlebar switch
Handlebar grip
Handlebar holder
Handlebar
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Q’ty
Remarks
1
1
Refer to “INSTALLING THE REAR
BRAKE
MASTER CYLINDER”.
1
1
2
Refer to “REMOVING THE HANDLEBAR
GRIPS” and “INSTALLING THE HANDLEBAR GRIPS”.
2
Refer to “INSTALLING THE HANDLEBAR”.
1
For installation, reverse the removal procedure.
8 - 32
STEERING SYSTEM
CHAS
EBS00447
REMOVING THE HANDLEBAR GRIPS
1. Remove:
• handlebar grips 1
NOTE:
Blow compressed air between the handlebar
and handlebar grip, and gradually push the
grip off the handlebar.
_
EBS00448
CHECKING THE HANDLEBAR
1. Check:
• handlebar
Bends/cracks/damage → Replace.
WARNING
_
Do not attempt to straighten a bent handlebar as this may dangerously weaken the
handlebar.
EBS00449
INSTALLING THE HANDLEBAR
1. Install:
• handlebar
• handlebar holders
T.
R.
20 Nm (2.0 m · kg, 14 ft · lb)
NOTE:
• Install the handlebar within 15° from the horizontal line shown in the illustration.
• The upper handlebar holders should be
installed with the punched mark 1 forward
2.
_
CAUTION:
_
First tighten the bolts 3 on the front side of
the handlebar holders, and then tighten the
bolts 4 on the rear side.
8 - 33
STEERING SYSTEM
CHAS
EBS00450
INSTALLING THE HANDLEBAR GRIPS
1. Install:
• handlebar grip 1
NOTE:
• Before applying adhesive, wipe off grease or
oil on the handlebar surface a with a lacquer
thinner.
• Install the handlebar grips to the handlebar
so that arrow mark L faces up on the left handlebar grip and the arrow mark R faces up on
the right handlebar.
_
EBS00453
1
UP
2
a
INSTALLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
• left handlebar switch
• spacer
• rear brake master cylinder 1
• rear brake master cylinder holder 2
T.
b
R.
7 Nm (0.7 m · kg, 5.1 ft · lb)
NOTE:
• Align the end of the brake master cylinder
holder with the punch mark a on the handlebar.
• The “UP” mark b on the brake master cylinder holder should face up.
_
8 - 34
STEERING SYSTEM
CHAS
EBS00453
2
1
er
Low
UP
T.
R.
a
INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. Install:
• front brake master cylinder 1
• front brake master cylinder holder 2
b
7 Nm (0.7 m · kg, 5.1 ft · lb)
NOTE:
• Align the end of the brake master cylinder
holder with the punch mark a on the handlebar.
• The “UP” mark b on the brake master cylinder holder should face up.
_
1
b
a
INSTALLING THE THROTTLE LEVER
ASSEMBLY
1. Install:
• throttle lever assembly 1
• throttle lever assembly holder
NOTE:
Align the projection a on the throttle lever
assembly with the end of the brake master cylinder holder b.
8 - 35
STEERING SYSTEM
CHAS
EBS00454
STEERING STEM
T.
10
R.
T.
R.
5 New
23 Nm (2.3 m • kg, 17 ft • Ib)
LS
New 1
2
50 Nm (5.0 m • kg, 36 ft • Ib)
4
3
LS
20
3
LT
5 New
LS
13
T.
R.
50 Nm (5.0 m • kg, 36 ft • Ib)
T.
125 Nm (12.5 m • kg, 90 ft • lb)
R.
12
17
14
LT
11
15
16
18
T.
30 Nm (3.0 m • kg, 22 ft • Ib)
R.
15
New
(4)
6
6
LT
7
19
Handlebar
Electrical components tray
1
2
3
4
5
6
7
Lock washer
Cable guide
Steering stem bushing
Collar
Oil seal
Tie rod end nut
Tie rod
1
1
2
2
2
2
2
8 - 36
25 Nm (2.5 m • kg, 18 ft • Ib)
210 Nm (21.0 m • kg, 150 ft • lb)
Q’ty
Air filter case
R.
Job/Part
Removing the steering stem
Front fender
R.
R.
Order
8
T.
T.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
9
Remarks
Remove the parts in the order listed.
Refer to “ENGINE SKID PLATES, SEAT,
CARRIERS AND FENDERS” in chapter
3.
Refer to “AIR FILTER CASE” in chapter
3.
Refer to “HANDLEBAR”.
Refer to “ELECTRICAL COMPONENTS
TRAY” in chapter 3.
Refer to “INSTALLING THE STEERING
STEM”.
Disconnect.
STEERING SYSTEM
T.
10
R.
T.
R.
LS
New 1
2
50 Nm (5.0 m • kg, 36 ft • Ib)
5 New
23 Nm (2.3 m • kg, 17 ft • Ib)
4
3
CHAS
LS
20
3
LT
5 New
LS
13
T.
R.
50 Nm (5.0 m • kg, 36 ft • Ib)
T.
125 Nm (12.5 m • kg, 90 ft • lb)
R.
12
17
14
LT
11
15
16
18
T.
30 Nm (3.0 m • kg, 22 ft • Ib)
R.
15
New
(4)
6
6
LT
7
19
25 Nm (2.5 m • kg, 18 ft • Ib)
210 Nm (21.0 m • kg, 150 ft • lb)
Q’ty
1
1
1
1
1
1
1
2
1
1
1
1
1
8 - 37
R.
Job/Part
Pitman arm nut
Pitman arm
Steering stem
Collar
Bearing nut
Collar
Steering stem bearing
Steering stem joint bolt
Steering stem joint
EPS breather hose
EPS motor cover
EPS unit
Steering stem bracket
R.
R.
Order
8
9
10
11
12
13
14
15
16
17
18
19
20
8
T.
T.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
9
Remarks
Refer to “INSTALLING THE PITMAN
ARM”.
Refer to “INSTALLING THE STEERING
STEM”.
Refer to “INSTALLING THE STEERING
STEM”.
For installation, reverse the removal procedure.
STEERING SYSTEM
CHAS
EBS00456
CHECKING THE STEERING STEM
1. Check:
• steering stem
Bends → Replace.
WARNING
_
Do not attempt to straighten a bent stem;
this may dangerously weaken the stem.
2. Check:
• oil seals
• steering stem bushings
Wear/damage → Replace.
3. Check:
• steering stem joint
Cracks/damage → Replace.
3
A
8
9
H
5
7
6
D
4
7 B G
T.
H
E
2
F
R.
C
0
9
INSTALLING THE STEERING STEM
1. Install:
• EPS unit 1
• washers
• EPS unit bolts 2
EPS unit bolt
30 Nm (3.0 m · kg, 22 ft · lb)
LOCTITE®
Install:
steering stem 3
steering stem bearing 4
collar 5
bearing nut 6
3.
•
•
•
•
•
•
•
Install:
oil seals 7 New
collars 8
steering stem bushings 9
cable guide 0
lock washer A New
steering stem bracket B
steering stem bolts C
(temporarily tighten)
T.
2.
•
•
•
•
R.
(4)
1
125 Nm (12.5 m · kg, 90 ft · lb)
NOTE:
Apply lithium-soap-based grease to the oil
seals and steering stem bushings.
8 - 38
STEERING SYSTEM
b
a
d
c
4.
•
•
•
CHAS
Install:
collar D
steering stem joint E
steering stem joint bolts F
(temporarily tighten)
NOTE:
• Apply LOCTITE® to the steering stem joint
bolts.
• Align the spline a on the steering stem with
the groove b in the steering stem joint.
• Align the punch mark c on the EPS unit with
the groove d in the steering stem joint.
5. Tighten:
• steering stem bracket bolts G
T.
R.
50 Nm (5.0 m · kg, 36 ft · lb)
NOTE:
Apply LOCTITE® to the steering stem bracket
bolts.
• steering stem bearing bolts H
T.
R.
50 Nm (5.0 m · kg, 36 ft · lb)
NOTE:
Apply LOCTITE® to the steering stem bearing
bolts.
• steering stem joint bolts F
T.
R.
30 Nm (3.0 m · kg, 22 ft · lb)
6. Tighten:
• steering stem bolts C
T.
R.
e
e
23 Nm (2.3 m · kg, 17 ft · lb)
NOTE:
• Bend the lock washer tab e along a flat side
of the bolt.
• Pass the cable and hoses through the cable
guide. Refer to “CABLE ROUTING” in chapter 2.
8 - 39
STEERING SYSTEM
INSTALLING THE PITMAN ARM
1. Install:
• pitman arm 1
• washer
• pitman arm nut
1
T.
R.
a
CHAS
210 Nm (21.0 m · kg, 150 ft · lb)
• clip
b
NOTE:
Align the punch mark b on the EPS unit with
the groove a in the pitman arm.
8 - 40
STEERING SYSTEM
CHAS
EBS00460
TIE-RODS AND STEERING KNUCKLES
T.
R.
25 Nm (2.5 m • kg, 18 ft • Ib)
New
3
2
LS
6
New
T.
R.
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
4
11 New
T.
R.
10 New
30 Nm (3.0 m • kg, 22 ft • Ib)
New
T.
R.
25 Nm (2.5 m kg, 18 ft Ib)
•
25 Nm (2.5 m • kg, 18 ft • Ib)
•
5
9 New
7
New
1
8
LS
T.
R.
Order
Job/Part
Removing the tie-rods and steering
knuckles
Q’ty
1
2
3
4
5
6
Front wheel/brake disc
Brake disc guard
Front arm protector
Tie-rod
Nut
Nut
Steering knuckle
1
1
1
1
1
1
7
8
9
Circlip
Rubber boot
Ball joint
1
1
1
8 - 41
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the tie-rods and steering knuckles.
Refer to “FRONT WHEELS”.
Refer to “INSTALLING THE TIE-RODS”.
Refer to “REMOVING THE STEERING
KNUCKLES”.
STEERING SYSTEM
CHAS
T.
R.
25 Nm (2.5 m • kg, 18 ft • Ib)
New
3
2
LS
6
New
T.
R.
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
4
11 New
T.
R.
10 New
30 Nm (3.0 m • kg, 22 ft • Ib)
New
T.
R.
25 Nm (2.5 m kg, 18 ft Ib)
•
25 Nm (2.5 m • kg, 18 ft • Ib)
•
New
5
9 New
7
1
8
LS
T.
R.
Order
10
11
Job/Part
Circlip
Bearing
Q’ty
1
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
For installation, reverse the removal procedure.
8 - 42
STEERING SYSTEM
CHAS
EBS00461
REMOVING THE STEERING KNUCKLES
1. Remove:
• steering knuckle 1
NOTE:
Use a general puller to separate the ball joint
2 from the steering knuckle 1 or the front
lower arm 3.
_
EBS00462
CHECKING THE TIE-RODS
1. Check:
• tie-rod free play and movement
Free play → Replace the tie-rod end.
Turns roughly → Replace the tie-rod end.
2. Check:
• tie-rod
Bends/damage → Replace.
EBS00463
CHECKING THE STEERING KNUCKLES
1. Check:
• steering knuckle
Damage/pitting → Replace.
2. Check:
• ball joints
Damage/pitting → Replace the ball joint.
Free play → Replace the ball joint.
Turns roughly → Replace the ball joint.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the steering knuckle.
b. Remove the clip 1, circlip 2 and rubber
boot 3.
1
3
2
8 - 43
STEERING SYSTEM
CHAS
c. Remove the ball joint.
2
3
NOTE:
Use a remover attachment 3 to separate the
ball joint 1 from the steering knuckle 2.
1
d. Measure the ball joint bore inside diameter
a.
Out of specification → Replace the steering
knuckle.
Ball joint bore inside diameter
32.00 ~ 32.05 mm
(1.260 ~ 1.280 in)
a
e. Install the new ball joint.
Use the ball joint remover/installer set.
Ball joint remover
90890-01474, YM-01474
Ball joint remover attachment set
90890-01480
Ball joint adapter set
YM-01480
Ball joint remover short shaft set
90890-01514
8 - 44
3
Remover
attachment
90890-01474
YM-01474
4
Installer spacer
90890-01480
YM-01480
5
Installer washer
90890-01474
YM-01474
6
Base
90890-01480
YM-01480
7
Body
90890-01480
YM-01480
8
Ball joint remover
short shaft set
90890-01514
STEERING SYSTEM
CHAS
f. Attach the ball joint remover/installer, new
ball joint (with rubber boot and retaining
ring) 1, installer spacer 6 and installer
washer 2 to the steering knuckle 3.
213 4
5
NOTE:
Do not tap or damage the top of the ball joint.
6
g. Hold the body 4 in place while turning in
the bolt 5 to install the new ball joint 1 into
the steering knuckle 3.
h. Remove the ball joint remover/installer.
i. Install a new ball joint.
NOTE:
Always use a new ball joint set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2
3. Check:
• front wheel bearing 1
Bearings allow play in the wheel hubs or the
wheel turns roughly → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
a. Clean the outside of the steering knuckle.
b. Remove the circlip 2.
c. Drive out the bearing.
WARNING
_
Eye protection is recommended when
using striking tools.
d. Apply lithium-soap-based grease to the
outer side of the bearing.
e. Install the new bearing.
CAUTION:
_
Do not strike the center race or balls of the
bearing. Should be made only with the
outer race.
f. Install the new circlip.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8 - 45
STEERING SYSTEM
CHAS
EBS00465
INSTALLING THE TIE-RODS
1. Install:
• tie-rods (left and right)
T.
R.
25 Nm (2.5 m · kg, 18 ft · lb)
NOTE:
The tie-rod side which must be installed on the
out side has grooves 1.
_
2. Adjust:
• toe-in
Refer to “ADJUSTING THE TOE-IN” in
chapter 3.
8 - 46
FRONT ARMS AND FRONT SHOCK ABSORBER
ASSEMBLIES
CHAS
EBS00468
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES
T.
6
T.
R.
45 Nm (4.5 m • kg, 32 ft • Ib)
R.
45 Nm (4.5 m • kg, 32 ft • Ib)
6
3
8
8
LS
8
8
13
9
13
16
New
3
10
10
LS
10
14
10
New
12
15
5
7
12
6
New
17
1
6
17
T.
R.
T
2
.R
.
New
Job/Part
Removing the front arms and front
shock absorber assemblies
Front wheel/brake disc
Front brake caliper assembly
Brake disc guard
Front arm protector
Front brake hose holder
Nut
Nut
Nut/bolt
Front shock absorber assembly
Nut/bolt
Front upper arm
7 Nm (0.7 m • kg, 5.1 ft • Ib)
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
45 Nm (4.5 m • kg, 32 ft • Ib)
T.
R.
1
2
3
4
5
6
7
8
9
4
R.
T.
Order
T.
11
25 Nm (2.5 m • kg, 18 ft • Ib)
Q’ty
1
1
2
1
1
2/2
1
2/2
1
8 - 47
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front arms and front shock
absorber assemblies.
Refer to “FRONT AND REAR WHEELS”.
Refer to “FRONT AND REAR BRAKES”.
Refer to “REMOVING THE FRONT
ARMS” and “INSTALLING THE FRONT
ARMS AND FRONT SHOCK ABSORBERS”.
FRONT ARMS AND FRONT SHOCK ABSORBER
ASSEMBLIES
T.
6
T.
R.
45 Nm (4.5 m • kg, 32 ft • Ib)
CHAS
R.
45 Nm (4.5 m • kg, 32 ft • Ib)
6
3
8
8
LS
8
8
13
9
13
16
New
3
10
10
LS
10
14
10
New
12
15
5
7
12
6
New
17
1
6
17
T.
R.
T
2
.R
.
45 Nm (4.5 m • kg, 32 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
New
T.
R.
R.
Job/Part
Nut/bolt
Front lower arm
Dust cover
Bushing
Circlip
Rubber boot
Ball joint
Bushing
4
R.
T.
Order
10
11
12
13
14
15
16
17
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
11
25 Nm (2.5 m • kg, 18 ft • Ib)
Q’ty
2/2
1
2
2
1
1
1
2
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
Refer to “REMOVING THE FRONT
ARMS” and “INSTALLING THE FRONT
ARMS AND FRONT SHOCK ABSORBERS”.
For installation, reverse the removal procedure.
8 - 48
FRONT ARMS AND FRONT SHOCK ABSORBER
ASSEMBLIES
CHAS
EBS00469
REMOVING THE FRONT ARMS
1. Check:
• front arm free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the front arm side play È by moving
it from side to side.
If side play is noticeable, check the bushings.
b. Check the front arm vertical movement É
by moving it up and down.
If the vertical movement is tight or rough, or
if there is binding, check the bushings.
È
È
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Remove:
• front arms
É
É
EBS00470
CHECKING THE FRONT ARMS
1. Check:
• front arms
Bends/damage → Replace.
2. Check:
• bushings
Wear/damage → Replace.
3. Check:
• ball joint
Damage/pitting → Replace the ball joint.
Free play → Replace the ball joint.
Turns roughly → Replace the ball joint.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3
2
a. Clean the outside of the front upper arm.
b. Remove the circlip 1, boot retaining ring 2
and rubber boot 3.
Use the ball joint remover and installer set.
1
8 - 49
FRONT ARMS AND FRONT SHOCK ABSORBER
ASSEMBLIES
CHAS
Ball joint remover
90890-01474, YM-01474
Ball joint remover attachment set
90890-01480
Ball joint adapter set
YM-01480
5
4
7
4
Body
5
Long bolt
6
Base
90890-01480
YM-01480
7
Remover
attachment
90890-01474
YM-01474
8
Installer spacer
90890-01480
YM-01480
9
Installer washer
90890-01474
YM-01474
0
A
6
90890-01474
YM-01474
c. Install the body 4, long bolt 5, base 6 and
attachment 7 onto ball joint.
d. Hold the body 4 in place while turning in
the long bolt 5 to remove the ball joint 0
from the front upper arm A.
e. Remove the ball joint remover.
f. Attach the assembled ball joint remover/
installer, new ball joint (with rubber boot and
retaining ring) B, installer spacer 8 and
installer washer 9 to the front upper arm
A.
NOTE:
• Do not tap or damage the top of the ball joint.
• Installer washer 9 must be aligned with the
projection on the head of the ball joint B.
_
g. Remove the ball joint remover.
h. Install a new circlip.
NOTE:
Always use a new ball joint set.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8 - 50
FRONT ARMS AND FRONT SHOCK ABSORBER
ASSEMBLIES
CHAS
EBS00471
CHECKING THE FRONT SHOCK
ABSORBERS
1. Check:
• shock absorber assembly
Oil leaks → Replace the shock absorber
assembly.
• spring
Fatigue → Replace the shock absorber
assembly.
Move the spring up and down.
EBS00475
INSTALLING THE FRONT ARMS AND
FRONT SHOCK ABSORBERS
1. Install:
• front arms
• front shock absorber
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
67
a. Install the front upper arm 1 and front lower
arm 2.
5
NOTE:
• Lubricate the bolts 3 with lithium-soapbased grease.
• Be sure to position the bolts 3 so that the
bolt head faces forward.
• Temporarily tighten the nuts 4.
_
1
34
8
b. Install the front shock absorber 5 and bolts
6.
T.
67
Nut 7
45 Nm (4.5 m · kg, 32 ft · lb)
R.
2
9
c. Install the steering knuckle.
T.
R.
Nut 8
25 Nm (2.5 m · kg, 18 ft · lb)
Nut 9
30 Nm (3.0 m · kg, 22 ft · lb)
d. Install the new cotter pins.
e. Tighten the nuts 4.
T.
Nut 4
45 Nm (4.5 m · kg, 32 ft · lb)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8 - 51
REAR KNUCKLES AND STABILIZER
CHAS
EBS01023
REAR KNUCKLES AND STABILIZER
T.
R.
T.
50 Nm (5.0 m • kg, 36 ft • Ib)
R.
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
12
13
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
12
11
13
4
7 Nm (0.7 m • kg, 5.1 ft • Ib)
14
5
11
LS
LS
.
7
3
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
7
R
8
T.
7
New 9
LS
T.
10
R.
6
7
R.
8
T.
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
50 Nm (5.0 m • kg, 36 ft • Ib)
45 Nm (4.5 m • kg, 32 ft • Ib)
2
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Q’ty
Remarks
Removing the rear knuckles and staRemove the parts in the order listed.
bilizer
The following procedure applies to both
of the rear knuckles.
Rear wheel hubs
Refer to “FRONT AND REAR WHEELS”.
Brake disc guard
1
Plate
1
Rear arm protector
1
Rear brake hose protector
1
Rear brake hose holder
1
Rear knuckle
1
Spacer cover
4
Spacer
2
Circlip
1
Bearing
1
Stabilizer joint
2
8 - 52
REAR KNUCKLES AND STABILIZER
T.
R.
T.
50 Nm (5.0 m • kg, 36 ft • Ib)
R.
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
12
13
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
12
11
13
4
CHAS
14
5
11
LS
LS
.
7
3
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
7
R
8
T.
7
New 9
LS
T.
10
R.
6
7
R.
8
T.
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
50 Nm (5.0 m • kg, 36 ft • Ib)
45 Nm (4.5 m • kg, 32 ft • Ib)
2
Order
12
13
14
Job/Part
Stabilizer holder
Bushing
Stabilizer
Q’ty
2
2
1
Remarks
For installation, reverse the removal procedure.
8 - 53
REAR KNUCKLES AND STABILIZER
CHAS
EBS01024
CHECKING THE REAR KNUCKLES
1. Check:
• rear knuckle
Damage/pitting → Replace.
2. Check:
• rear wheel bearing 1
Bearing allow play in the wheel hub or the
wheel turns roughly → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the rear knuckle.
b. Remove the circlip 2.
c. Drive out the bearing.
2
WARNING
_
1
Eye protection is recommended when
using striking tools.
d. Apply lithium-soap-based grease to the
outer side of the bearing.
e. Install the new bearing.
CAUTION:
_
Do not strike the center race or balls of the
bearing. Should be made only with the
outer race.
f. Install the new circlip.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS01025
CHECKING THE STABILIZER
1. Check:
• stabilizer
Bends/cracks/damage → Replace.
8 - 54
REAR ARMS AND REAR SHOCK ABSORBER
ASSEMBLIES
CHAS
EBS00476
REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES
T.
R.
2
T.
R.
45 Nm (4.5 m • kg, 32 ft • Ib)
4
45 Nm (4.5 m • kg, 32 ft • Ib)
2
LS
7
4
7
4
6
10
LS
7
1
10
7
5
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
9
10
3
9
T.
R.
45 Nm (4.5 m • kg, 32 ft • Ib)
10
2
2
8
T.
R.
Order
45 Nm (4.5 m • kg, 32 ft • Ib)
Job/Part
Removing the rear arms and rear
shock absorber assemblies
Q’ty
Rear knuckle/stabilizer
1
2
3
4
5
6
7
8
9
Rear brake hose guide
Nut/washer/bolt
Rear shock absorber assembly
Nut/bolt
Rear upper arm
Dust cover
Nut/bolt
Rear lower arm
Dust cover
2
2/1/2
1
2/2
1
1
2/2
1
2
8 - 55
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the rear arms and rear shock absorber
assemblies.
Refer to “REAR KNUCKLES AND STABILIZER”.
Refer to “INSTALLING THE REAR
ARMS AND REAR SHOCK ABSORBER
ASSEMBLIES”.
REAR ARMS AND REAR SHOCK ABSORBER
ASSEMBLIES
T.
R.
2
T.
R.
45 Nm (4.5 m • kg, 32 ft • Ib)
4
CHAS
45 Nm (4.5 m • kg, 32 ft • Ib)
2
LS
7
4
7
4
6
10
LS
7
1
10
7
5
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
9
10
3
9
T.
R.
45 Nm (4.5 m • kg, 32 ft • Ib)
10
2
2
8
T.
R.
Order
10
45 Nm (4.5 m • kg, 32 ft • Ib)
Job/Part
Bushing
Q’ty
4
8 - 56
Remarks
Refer to “INSTALLING THE REAR
ARMS AND REAR SHOCK ABSORBER
ASSEMBLIES”.
For installation, reverse the removal procedure.
REAR ARMS AND REAR SHOCK ABSORBER
ASSEMBLIES
CHAS
CHECKING THE REAR ARMS
1. Check:
• rear arms
Bends/damage → Replace.
2. Check:
• bushings
Wear/damage → Replace.
EBS00478
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLIES
1. Check:
• shock absorber assemblies
Oil leaks → Replace the shock absorber
assembly.
• spring
Fatigue → Replace the shock absorber
assemblies.
Move the spring up and down.
8 - 57
REAR ARMS AND REAR SHOCK ABSORBER
ASSEMBLIES
CHAS
EBS01027
INSTALLING THE REAR ARMS AND REAR
SHOCK ABSORBER ASSEMBLIES
1. Install:
• rear arms
• rear shock absorber assemblies
67
5
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the rear upper arm 1 and rear lower
arm 2.
34
1
8
67
8
NOTE:
• Lubricate the bolts 3 with lithium-soapbased grease.
• Be sure to position the bolts 3 so that the
bolt head faces outward.
• Temporarily tighten the nuts 4.
_
b. Install the rear shock absorber assembly 5
and bolts 6.
2
T.
Nut 7
45 Nm (4.5 m · kg, 32 ft · lb)
R.
c. Install the rear knuckle.
T.
Nut 8
45 Nm (4.5 m · kg, 32 ft · lb)
R.
d. Tighten the nuts 4.
T.
Nut 4
45 Nm (4.5 m · kg, 32 ft · lb)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8 - 58
ELECTRICAL COMPONENTS
ELEC
–
+
EBS00500
ELECTRICAL
ELECTRICAL COMPONENTS
1 Four-wheel-drive motor relay 3
2 Rear brake relay
3 Four-wheel-drive motor relay 2
4 Four-wheel-drive motor relay 1
5 Headlight relay
6 Fuel injection system fuse
7 Starter relay
1
2
3
8 EPS fuse
9 Main fuse
0 Fuse box (ignition, headlights, four-wheel-drive
motor, radiator fan motor, signaling system, auxiliary DC jack)
A Radiator fan motor circuit breaker
B Rectifier/regulator
4
5
6
7
0
8
9
J
A
H
B
I
C
F
D
G
E
9-1
9
ELECTRICAL COMPONENTS
ELEC
–
+
C Reverse switch
D Gear position switch
E Auxiliary DC jack
F Main switch
G Differential gear motor
H EPS motor
I EPS torque sensor
J Radiator fan motor
1
2
3
4
5
6
7
0
8
9
J
A
H
B
I
C
F
D
G
E
9-2
ELECTRICAL COMPONENTS
1 Lean angle sensor
2 Radiator fan motor relay
3 Fuel injection system relay
4 Starting circuit cut-off relay
5 Front brake light switch
6 Rear brake light switch
7 Intake air temperature sensor
8 Intake air pressure sensor
9 TPS (throttle position sensor)
0 Fuel pump
A Speed sensor
1
ELEC
–
+
B Crankshaft position sensor
C Coolant temperature sensor
D Ignition coil
E Battery
F ECU (engine control unit)
G EPS (electric power steering) control unit
2
3
4
5
6
8
7
G
9
F
E
0
D
A
C
B
9-3
CHECKING SWITCH CONTINUITY
ELEC
–
+
EBS01028
CHECKING SWITCH CONTINUITY
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.
CAUTION:
_
Never insert the tester probes into the coupler terminal slots 1. Always insert the
probes from the opposite end of the coupler, taking care not to loosen or damage
the leads.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NOTE:
• Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back
and forth between the switch positions a few
times.
_
The terminal connections for switches (e.g.,
main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
The switch positions a are shown in the far
left column and the switch lead colors b are
shown in the top row in the switch illustration.
NOTE:
“
” indicates a continuity of electricity
between switch terminals (i.e., a closed circuit
at the respective switch position).
_
The example illustration on the left shows
that:
There is continuity between red and brown/
blue when the switch is set to “ON”.
9-4
ELEC
CHECKING THE SWITCHES
–
+
EBS01029
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear → Repair or replace.
Improperly connected → Properly connect.
Incorrect continuity reading → Replace the switch.
A
0
Br/Y
Br/Y
1
R Br/L
ON
R Br/L
OFF
(GRAY)
Y
2
R/Y L
Y/W
Y
OFF
3
R/W R/B
R/Y Y
L
L/B Lg B
4
L/B B
R/B R/W
(GRAY)
5
Lg
B
OFF
PUSH
6
9
L/B L/G L/R Sb Br Gy G/R B
2WD
4WD
LOCK
G/W
8
7
L
G/R Gy
B
Br
(LIGHT GRAY)
P
Gy W
L/R L/G
Sb L/B
(BLACK)
9-5
CHECKING THE SWITCHES
1 Main switch
2 Light switch
3 Engine stop switch
4 Start switch
5 Override switch
6 On-command four-wheel-drive motor switch and differential gear lock switch
7 Four-wheel-drive motor switch
8 Gear position switch
9 Reverse switch
0 Rear brake light switch
A Front brake light switch
9-6
ELEC
–
+
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
EBS01030
CHECKING THE BULBS AND
BULB SOCKETS
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 both.
Improperly connected → Properly connect.
No continuity → Repair or replace the bulb,
bulb socket or both.
TYPES OF BULBS
The bulbs used on this vehicle are shown in
the illustration on the left.
• Bulbs a and b are used for the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The
majority of these types of bulbs can be
removed from their respective socket by
turning them counterclockwise.
• Bulbs c is used for turn signal and tail/
brake lights and can be removed from the
socket by pushing and turning the bulb
counterclockwise.
• Bulbs d and e are used for meter and indicator lights and can be removed from their
respective socket by carefully pulling them
out.
9-7
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:
• bulb
WARNING
_
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
CAUTION:
_
• Be sure to hold the socket firmly when
removing the bulb. Never pull the lead,
otherwise it may be pulled out of the terminal in the coupler.
• Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the
life of the bulb, and the luminous flux will
be adversely affected. If the headlight
bulb gets soiled, thoroughly clean it with
a cloth moistened with alcohol or lacquer
thinner.
2. Check:
• bulb (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
_
9-8
CHECKING THE BULBS AND BULB SOCKETS
ELEC
–
+
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2, and check the continuity.
b. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 3, and check the continuity.
c. If either of the readings indicate no continuity, replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the
bulb sockets.
1. Check:
• bulb socket (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NOTE:
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
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any
of the readings indicate no continuity,
replace the bulb socket.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9-9
5
B/L
Gy
G
B
B
2
B
B
R
R
B
Y
W Sb Gy Br Y/B Y/L Y/W B/L R/B O
R/B
Gy
O/W
G/W
B
B
W
G/R
O/W
L/B
L
(BLACK)
3
P Y/G G/Y Br/W L
L/W W/B B/R Gy/G W/R G/W Lg G/R R/L L/R Y/R O/W Y/W B/W L/B B
R
(BLACK)
W
W
W
W
W
W
B
W R G B R
G
R/B
1
G/Y B
R
W
W R G B R
R
R
R/B
B
Br
R/B
D
W W W
R
(GRAY)
R
6
7
O/W Br L/B
R
G W G/R
G/R W
R/B
(BLACK)
R
R
R
J
(BLACK)
R
Br
L/W
Br/B
R
L/W
Br/B
4
ON
}
(BLACK)
R/B
Br
L/B
Br/W
O
B/L
Br/W
Sb L/B
L/R
B/Y
G/Y B/L
B/Y
Y/W
Y/W
I
H
A
B
B B
G
F
B
B
B
L/W
L/W
B
B
B
Br/L R
R/L
R/B R/B
Br/B
B/Y
Br
Br
0
Br/L
R/B R/B
L/W
L/W
(BLACK)
B
(GRAY)
R/L
Br/B
L/B
L/W Br
9
8
R Br/L
OFF
N
Br/W B/L
~
R/W
R/W
(GRAY)
R/B
R/B
(BLACK)
M
R/L R/B
G/W
L
B
R
L
O
E
L/B
L
L/B Br O
O
R/L
Sb B/Y
L/R
K
(GREEN)
G/Y
P
L/B
Sb
L/R
R/L
B
Lg
Y/R
Y/B
G/R
W/B
B/R
Gy/G
W/R
Y/L
R/L
R/B
|
Br/L
Br/L
c
j
s
L
L
B
B/L
Y
L
L
P
B/L
P
L/B
Y/G
S
L
B/L
P
L
B/W
L
T
B/W
Br/R
Br/Y
Y
(BLACK)
B/Y
P
B/L
Y/G
B/L
L
Br/R
P
Br/L
R
Q
(BLACK)
Br
t
{
R/L B B/W G/Y
(GRAY)
i
B
Br/L
L
b
B/L
Y/G B/L
(GRAY)
B
Br/R B L/R
u
B
Br/B
k
Br/L
R/Y
e
Br/R B L/G
G W/B
Br
B
Br/Y
P
B
(BLACK)
Gy
Br/R
l
w
v
Y
R/Y
Br
m
R/B
L/B
n
B/Y
L/B Sb
V
L/R B
L/G B
p
Br/R
Y/B
Br
Gy
W
OFF
PUSH
L
R/B R/W
L/B Lg B
(GRAY)
R/Y Y
B
q
Y
G
(GRAY)
L/G L/R
L/R L/G
L/Y Sb
Sb L/B
(BLACK)
(BLACK)
L/R G/R
G/R Gy
Gy
L
B
X
B
(GRAY)
B
g
Y
2WD
4WD
LOCK
Y/L Br B/W
(BLACK)
Z
Br
[
(LIGHT GRAY)
Y L
L/Y
(BLACK)
B
Y/WB/Y
Sb Gy
B
G
B
\
]
Y/W B/Y
B
Y G
Y G
r
B B
Sb B/Y W/B
L/Y Br Br/B B/R
r
B
Br L/Y W/B B/R B Sb Br/B B/Y
Y G
B
G
G
Y
B
Y
B
(GRAY)
_
a
h
L
P
G/R
B
–
B
Y G
B
W/R Gy/G
ELEC
Y
Br R/B
Y
L
G/R
L/R
G/Y G/R Br/B
L Y R/Y
B Lg L/B
Y
L/R
L/G
L/B W/R
Gy/G
Gy W
Y/L
B/W
G/Y
Br
Br/B
Y/W
Y
L Y
Sb
U
Lg
o
OFF
Y/W
(BLACK)
d
Br/B
Br/Y
Y
Y/W
(BLACK)
Y/B
f
B
+
1 Crankshaft position
sensor
y
4 Main switch
6 Main fuse
8 Battery
K ECU (engine control
unit)
x
z
L Ignition coil
M Spark plug
T Lean angle sensor
n Engine stop switch
s Ignition fuse
Br/R
Br/R
Br/R
Br/R
Br/R
IGNITION SYSTEM
9 - 10
Y/R
L Y/R
B
G/Y
W L/Y
L
W
B/L
Y
L
L W
B/L
B/L
G/Y
L
W
B/L
R/B Br
Br
EBS00503
B/L Gy
W
IGNITION SYSTEM
B
R
B
CIRCUIT DIAGRAM
C
B
G
ELEC
IGNITION SYSTEM
–
+
EBS01043
EBS01045
TROUBLESHOOTING
1. Main and ignition fuses
The ignition system fails to operate (no
spark or intermittent spark).
Check:
1. main and ignition fuses
2. battery
3. spark plug
4. ignition spark gap
5. spark plug cap resistance
6. ignition coil resistance
7. main switch
8. engine stop switch
9. crankshaft position sensor resistance
10.lean angle sensor
11.wiring connections (of the entire ignition
system)
• Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and ignition fuses OK?
YES
NO
Replace the fuse(s).
EBS01044
2. Battery
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. battery cover
3. right side panel
4. V-belt cooling duct 2
• Troubleshoot with the following special
tool(s).
_
Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
9 - 11
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
YES
NO
• Clean the battery
terminals.
• Recharge or replace the battery.
IGNITION SYSTEM
ELEC
–
+
EBS01034
EBS01032
3. Spark plug
4. Ignition spark gap
• Check the condition of the spark plug.
• Check the spark plug type.
• Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUG”
in chapter 3.
Standard spark plug
CR8E (NGK)
Spark plug gap
0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
• Disconnect the spark plug cap from the
spark plug.
• Connect the ignition checker 1 as shown.
2 Spark plug cap
• Set the main switch to “ON”.
• Measure the ignition spark gap a.
• Crank the engine by pushing the start
switch and gradually increase the spark
gap until a misfire occurs.
• Is the spark plug in good condition, is it of
the correct type, and is its gap within specification?
YES
NO
Re-gap or replace
the spark plug.
Minimum ignition spark gap
6.0 mm (0.24 in)
• Is there a spark and is the spark gap within
specification?
NO
YES
The ignition system
is OK.
9 - 12
EBS01036
–
ELEC
IGNITION SYSTEM
+
EBS01038
5. Spark plug cap resistance
6. Ignition coil resistance
• Remove the spark plug cap from the spark
plug lead.
• Connect the pocket tester (Ω × 1k) to the
spark plug cap as shown.
• Measure the spark plug cap resistance.
• Disconnect the ignition coil connectors
from the ignition coil terminals.
• Connect the pocket tester (Ω × 1) to the
ignition coil as shown.
Positive tester probe →
red/black lead terminal 1
Negative tester probe →
orange lead terminal 2
Spark plug cap resistance
10.0 kΩ at 20 °C (68 °F)
• Is the spark plug cap OK?
• Measure the primary coil resistance.
NO
YES
Replace the
plug cap.
Primary coil resistance
3.4 ~ 4.6 Ω at 20 °C (68 °F)
spark
• Connect the pocket tester (Ω × 1k) to the
ignition coil as shown.
Positive tester probe →
red/black lead terminal 1
Negative tester probe → spark plug lead 2
• Measure the secondary coil resistance.
Secondary coil resistance
10.4 ~ 15.6 kΩ at 20 °C (68 °F)
• Is the ignition coil OK?
YES
NO
Replace the ignition
coil.
9 - 13
ELEC
IGNITION SYSTEM
–
+
EBS01040
EBS01041
7. Main switch
9. Crankshaft position sensor resistance
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
• Disconnect the crankshaft position sensor
coupler from the wire harness.
• Connect the pocket tester (Ω × 100) to the
crankshaft position sensor coupler as
shown.
NO
YES
Replace
switch.
the
main
Positive tester probe → green/yellow 1
Negative tester probe → black 2
EBS01042
8. Engine stop switch
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
YES
NO
G/ Y B
1
2
• Measure the crankshaft position sensor
resistance.
Replace the left handlebar switch.
Crankshaft position sensor resistance
459 ~ 561 Ω at 20 °C (68 °F)
• Is the crankshaft position sensor OK?
YES
NO
Replace the crankshaft position sensor/
stator assembly.
9 - 14
IGNITION SYSTEM
• Remove the lean angle sensor.
• Connect the pocket tester (DC 20 V) to the
lean angle sensor coupler as shown.
• Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the ignition system’s wiring properly
connected and without defects?
YES
Replace the ECU.
65˚
L Y/G B/L
1
2
• Set the main switch to “ON”.
• Turn the lean angle sensor to 65°.
• Measure the lean angle sensor output voltage.
Lean angle sensor voltage
Less than 65° ± 5° →
3.55 ~ 4.45 V
More than 65° ± 5° →
0.65 ~ 1.35 V
• Is the lean angle sensor OK?
YES
+
11.Wiring
Positive tester probe → yellow/green 1
Negative tester probe → black/blue 2
UP
–
EBS01047
10.Lean angle sensor
65˚
ELEC
NO
Replace the
angle sensor.
lean
9 - 15
NO
Properly connect or
repair the ignition
system’s wiring.
5
B/L
Gy
G
B
B
B
B
R
R
B
Y
W Sb Gy Br Y/B Y/L Y/W B/L R/B O
R/B
Gy
O/W
G/W
B
B
W
G/R
O/W
L/B
L
(BLACK)
3
P Y/G G/Y Br/W L
L/W W/B B/R Gy/G W/R G/W Lg G/R R/L L/R Y/R O/W Y/W B/W L/B B
R
(BLACK)
W
W
W
W
W
W
2
B
W R G B R
G
R/B
1
G/Y B
R
W
W R G B R
R
R
R/B
B
Br
R/B
D
W W W
R
(GRAY)
R
6
7
O/W Br L/B
G W G/R
G/R W
R/B
(BLACK)
R
R
R
J
(BLACK)
R
Br
L/W
Br/B
R
Br/B
4
ON
9
8
R Br/L
(BLACK)
R/B
B B
Br
L/B
B/Y
L/R
O
B/L
Br/W
G/Y B/L
B/Y
Y/W
Y/W
I
R/L
Br/W
Sb L/B
H
A
B
R/B R/B
Br/B
B/Y
G
F
L/W
B
B
B
L/W
B
B
B
Br/L R
R/L
Br
Br
0
Br/L
L/B
R/B R/B
L/W
L/W
(BLACK)
B
(GRAY)
Br/B
R/L
(GREEN)
G/Y
Sb B/Y
L/R
K
P
L/B
Sb
L/R
R/L
B
B/L
Y
L
Y
R/L
Lg
Y/R
Y/B
G/R
W/B
B/R
Gy/G
W/R
Y/L
R/B
|
L
9 - 16
Y/R
Br/L
Br/L
c
L Y/R
j
s
L
L
L
B
R/L B B/W G/Y
(GRAY)
i
P
L/B
Y/G
S
B/L
Y
L
B/L
P
L
(BLACK)
B/W
L
T
B/W
Br/R
Br/Y
Q
Y/G
B/L
L
B/Y
P
B/L
(BLACK)
Br/R
P
Br/L
R
L
P
B/L
Br
t
{
b
B
Br/L
B
G/Y
W L/Y
L
W
B/L
L
W
B/L
R/B Br
Br
L W
B/L
B/L
G/Y
Y/G B/L
(GRAY)
B
Br/R B L/R
u
B
Br/B
k
Br/L
R/Y
e
Br/R B L/G
G W/B
Br
B
Br/Y
P
B
(BLACK)
Gy
Br/R
l
w
v
R/Y
Br
m
R/B
L/B
n
B/Y
L/B Sb
V
L/R B
L/G B
p
U
Br/R
Y/B
Br
Gy
W
OFF
PUSH
G/Y
Br
Br/B
Y/W
Y
L
R/B R/W
L/B Lg B
(GRAY)
R/Y Y
y
L Y
B
L
G
Br R/B
L/G L/R
L/R L/G
(GRAY)
L/Y Sb
Sb L/B
(BLACK)
(BLACK)
L/R G/R
G/R Gy
Y
q
Y
Y
L/R
L/G
Gy
L
B
G/R
L/R
B
(GRAY)
B
(LIGHT GRAY)
Sb Gy
B
G
Y G
Y G
r
Sb B/Y W/B
L/Y Br Br/B B/R
r
B
Br L/Y W/B B/R B Sb Br/B B/Y
Y G
B
G
G
Y
B
Y
B
B
Y G
B
(GRAY)
Y/L Br B/W
(BLACK)
Br
x
B B
Y/L
B/W
h
B
G/R
+
I Diode 2
U Gear position switch
n Engine stop switch
o Start switch
s Ignition fuse
t Signaling system fuse
v Rear brake light switch
z Rear brake relay
–
B
[
4 Main switch
\
6 Main fuse
]
8 Battery
_
0 Starter relay
a
A Starter motor
F Diode 1
G Starting circuit cut-off
relay
ELEC
z
B
P
Z
L/Y
Y/WB/Y
B
L
Gy W
Y
2WD
4WD
LOCK
(BLACK)
Y/W B/Y
W/R Gy/G
X
g
Y L
B
L/B W/R
Gy/G
G/Y G/R Br/B
L Y R/Y
B Lg L/B
Y
Sb
Lg
o
OFF
Y/W
Y
d
Br/B
Br/Y
Y
(BLACK)
(BLACK)
Y/B
f
Y/W
Br/R
Br/R
Br/R
Br/R
Br/R
ELECTRIC STARTING SYSTEM
OFF
}
L/W Br
L/W
N
Br/W B/L
~
R/W
R/W
(GRAY)
R/B
R/B
(BLACK)
M
R/L R/B
G/W
L
B
R
L
O
E
L/B
L
L/B Br O
R
O
EBS00506
B/L Gy
W
ELECTRIC STARTING SYSTEM
B
R
B
CIRCUIT DIAGRAM
C
B
G
ELECTRIC STARTING SYSTEM
ELEC
–
+
EBS00507
STARTING CIRCUIT OPERATION
The starting circuit on this model consists of
the starter motor, starter relay, starting circuit
cut-off relay, rear brake light switch, rear brake
relay and gear position switch. If the main
switch is on and the engine stop switch is in
the RUN position, the starter motor can be
operated only if:
E
D
1
2
• The transmission is in neutral (the neutral
switch circuit of the gear position switch is
closed).
or
• The transmission is in park (the park
switch circuit of the gear position switch is
closed).
or
• You pull in the rear brake lever or push
down on the brake pedal (the rear brake
light switch circuit is closed).
C
3
6
4
7
5
A
8
9
0
B
The starting circuit cut-off relay prevents the
starter from operating when the select lever is
in gear or in reverse and the rear brake lever
and brake pedal is free. In this instance, the
starting circuit cut-off relay is off so that current
cannot reach the starter motor.
1 Battery
2 Main fuse
3 Main switch
4 Ignition fuse
5 Engine stop switch
6 Signaling system fuse
7 Rear brake light switch
8 Rear brake relay
9 Diode 2
0 Gear position switch
A Starting circuit cut-off relay
B Start switch
C Diode 1
D Starter relay
E Starter motor
9 - 17
ELECTRIC STARTING SYSTEM
ELEC
–
+
EBS01044
EBS01048
TROUBLESHOOTING
2. Battery
The starter motor fails to turn.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main, ignition and signaling system fuses
2. battery
3. starter motor
4. starting circuit cut-off relay
5. starter relay
6. Rear brake relay
7. Diode 2
8. main switch
9. engine stop switch
10.start switch
11.rear brake light switch
12.gear position switch
13.wiring connections
(of the entire starting system)
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
NO
YES
• Clean the battery
terminals.
• Recharge or
replace the battery.
EBS01051
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. battery cover
3. side covers
• Troubleshoot with the following special
tool(s).
3. Starter motor
_
• Connect the positive battery terminal 1
and starter motor lead 2 with a jumper
lead 3.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
EBS01043
WARNING
_
1. Main, ignition and signaling system fuses
• Check the main, ignition and signaling system fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, ignition and signaling system fuses OK?
YES
• A wire that is used as a jumper lead
must have at least the same capacity or
more as that of the battery lead, otherwise the jumper lead may burn.
• This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.
NO
• Does the starter motor turn?
YES
NO
Replace the fuse(s).
Repair or replace the
starter motor.
9 - 18
ELECTRIC STARTING SYSTEM
EBS01052
ELEC
–
+
EBS01054
5. Starter relay
4. Starting circuit cut-off relay
• Remove the starting circuit cut-off relay
from the wire harness.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the starting circuit cut-off
relay as shown.
Positive battery terminal → red/black 1
Negative battery terminal →
black/yellow 2
• Remove the starter relay from the wire
harness.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the starter relay as shown.
Positive battery terminal → brown 1
Negative battery terminal → blue/white 2
Positive tester probe → red 3
Negative tester probe → black 4
Positive tester probe → blue/white 3
Negative tester probe → blue/black 4
3
R
3
4
Br/B
+
2
L/W Br
B
1
R/B
B/Y
1 2
4
L /B
• Does the starter relay have continuity
between red and black?
L/W
• Does the starting circuit cut-off relay have
continuity between blue/white and blue/
black?
YES
YES
NO
Replace the starter
relay.
NO
Replace the starting
circuit cut-off relay.
9 - 19
ELEC
ELECTRIC STARTING SYSTEM
–
+
EBS01053
EBS01054
6. Rear brake relay
7. Diode 2
• Remove the rear brake relay from the wire
harness.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the rear brake relay as
shown.
• Remove the diode 2 from the wire harness.
• Connect the pocket tester (Ω × 1) to the
diode 2 as shown.
• Measure the diode 2 for continuity as follows.
Positive battery terminal →
yellow/white 1
Negative battery terminal → black 2
Positive tester probe → black/yellow 3
Negative tester probe → black 4
2
1
Positive tester probe →
black/yellow 1
Continuity
Negative tester probe →
blue/black 3
Y/W B/Y
B
• Does the rear brake relay have continuity
between black/yellow and black?
YES
_
Positive tester probe →
black/yellow 1
Continuity
Negative tester probe →
sky blue 2
4
3
B
NOTE:
The pocket tester 90890-03112 and the analog pocket tester YU-03112-C readings are
shown in the following table.
NO
Replace the
brake relay.
rear
Positive tester probe →
sky blue 2 No
Negative tester probe →
continuity
black/yellow 1
Positive tester probe →
blue/black 3 No
Negative tester probe →
continuity
black/yellow 1
1
3
2
Sb L/B
B/Y
• Are the testing readings correct?
YES
NO
Replace the diode 2.
9 - 20
ELEC
ELECTRIC STARTING SYSTEM
EBS01041
–
+
11.Rear brake light switch
8. Main switch
• Check the rear brake light switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the rear brake light switch OK?
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
NO
YES
Replace
switch.
the
YES
main
EBS01042
NO
Replace the rear
brake light switch.
EBS01058
9. Engine stop switch
12.Gear position switch
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
YES
• Check the gear position switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the gear position switch OK?
NO
YES
Replace the left handlebar switch.
EBS01057
NO
Replace the gear
position switch.
EBS01059
10.Start switch
13.Wiring
• Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the start switch OK?
YES
• Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the starting system’s wiring properly
connected and without defects?
NO
YES
Replace the left handlebar switch.
The starting system
circuit is OK.
9 - 21
NO
Properly connect or
repair the starting
system’s wiring.
STARTER MOTOR
ELEC
–
+
EBS01061
STARTER MOTOR
Order
1
2
3
1
2
3
4
5
6
Job/Part
Removing the starter motor
Muffler
Starter motor lead
Ground lead
Starter motor
Disassembling the starter motor
Starter motor front cover
Lock washer
Oil seal
Bearing
Shim
Starter motor rear cover
Q’ty
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “ENGINE REMOVAL” in chapter
4.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
Remove the parts in the order listed.
1
1
1
1
*
1
9 - 22
Refer to “ASSEMBLING THE STARTER
MOTOR”.
STARTER MOTOR
Order
7
8
9
0
A
Job/Part
Bushing
Shim
Brush holder set
Armature assembly
Starter motor yoke
Q’ty
1
*
1
1
1
ELEC
–
+
Remarks
Refer to “ASSEMBLING THE STARTER
MOTOR”.
For assembly, reverse the disassembly
procedure.
9 - 23
STARTER MOTOR
ELEC
–
+
EBS01064
a
CHECKING THE STARTER MOTOR
1. Check:
• commutator
Dirt → Clean with 600-grit sandpaper.
2. Measure:
• commutator diameter a
Out of specification → Replace the starter
motor.
Commutator wear limit
27 mm (1.06 in)
3. Measure:
• mica undercut a
Out of specification → Scrape the mica to
the proper measurement with a hacksaw
blade that has been grounded to fit the
commutator.
Mica undercut
0.70 mm (0.03 in)
NOTE:
The mica of the commutator must be undercut
to ensure proper operation of the commutator.
_
4. Measure:
• armature assembly resistances
(commutator and insulation)
Out of specification → Replace the starter
motor.
9 - 24
STARTER MOTOR
ELEC
–
+
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the armature assembly resistances with the pocket tester.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Armature coil
Commutator resistance 1
0.0250 ~ 0.0350 Ω at
20 °C (68 °F)
Insulation resistance 2
Above 1 MΩ at 20 °C (68 °F)
b. If any resistance is out of specification,
replace the starter motor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
• brush length a
Out of specification → Replace the brushes
as a set.
Brush length wear limit
5.00 mm (0.20 in)
6. Measure:
• brush spring force
Out of specification → Replace the brush
springs as a set.
Brush spring force
7.65 ~ 10.01 N (780 ~ 1021 gf,
27.54 ~ 36.03 oz)
7. Check:
• gear teeth
Damage/wear → Replace the gear.
8. Check:
• bearing
• oil seal
Damage/wear → Replace the defective
part(s).
9 - 25
STARTER MOTOR
ELEC
–
+
EBS00515
ASSEMBLING THE STARTER MOTOR
1. Install:
• brush holder set 1
NOTE:
Align the projection a on the brush holder set
with the slot b in the starter motor yoke.
_
a
b
b
2.
•
•
•
NOTE:
Align the match marks a on the starter motor
yoke with the match marks b on the starter
motor front and rear covers.
_
3
2
1
Install:
starter motor yoke 1
starter motor front cover 2
starter motor rear cover 3
9 - 26
ELEC
CHARGING SYSTEM
–
EBS00516
CHARGING SYSTEM
CIRCUIT DIAGRAM
B
B/L Gy
G/Y B
Gy
5
B/L
1
B
W
W
W
2
R
(BLACK)
W
W
W
3
R
R
R/B
W W W
R
(GRAY)
R
6
R
7
R/B
B
R
R
R
R
~
R/W
R
Br/B
R
R/W
Br/B
4
ON
8
R Br/L
OFF
(BLACK)
B
}
(GRAY)
0
Br/L
B
B
Br/L R
(BLACK)
R/B
B
Br
L/W
B
B
B
L/W Br
9
B
B B
A
B
R/B Br
R/B
|
L
Br
Y/R
L Y/R
s
L
Br/L
B
L
L
B
{
Br
t
Br/L
Br/Y
u
B
Br/L
R/Y
2 AC magneto
3 Rectifier/regulator
6 Main fuse
8 Battery
9 - 27
+
CHARGING SYSTEM
ELEC
–
+
EBS01044
EBS01065
TROUBLESHOOTING
2. Battery
The battery is not being charged.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main fuse
2. battery
3. charging voltage
4. stator coil resistance
5. wiring connections
(of the entire charging system)
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
YES
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. battery cover
3. right side cover
4. V-belt cooling duct 2
• Troubleshoot with the following special
tool(s).
NO
_
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
EBS01043
1. Main fuse
• Check the main fuse for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Is the main fuse OK?
NO
YES
Replace
fuse.
the
main
9 - 28
• Clean the battery
terminals.
• Recharge or replace the battery.
CHARGING SYSTEM
ELEC
–
+
EBS01100
EBS01066
3. Charging voltage
4. Stator coil resistance
• Connect the engine tachometer to the
spark plug lead.
• Connect the pocket tester (DC 20 V) to the
battery as shown.
Positive tester probe →
positive battery terminal 1
Negative tester probe →
negative battery terminal 2
• Disconnect the AC magneto coupler from
the wire harness.
• Connect the pocket tester (Ω × 1) to the
stator coils.
Positive tester probe → white terminal 1
Negative tester probe → white terminal 2
Positive tester probe → white terminal 1
Negative tester probe → white terminal 3
Positive tester probe → white terminal 2
Negative tester probe → white terminal 3
W W W
• Start the engine and let it run at approximately 1,000 r/min.
• Measure the charging voltage.
1 23
• Measure the stator coil resistance.
Charging voltage
14 V at 5,000 r/min
Stator coil resistance
0.108 ~ 0.132 Ω at 20 °C (68 °F)
NOTE:
Make sure the battery is fully charged.
_
YES
• Is the charging voltage within specification?
NO
Replace the crankshaft position sensor/
stator assembly.
YES
The charging circuit
is OK.
NO
5. Wiring
• Check the entire charging system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the charging system’s wiring properly
connected and without defects?
YES
Replace the rectifier/
regulator.
9 - 29
NO
Properly connect or
repair the charging
system’s wiring.
LIGHTING SYSTEM
–
ELEC
+
EBS00518
LIGHTING SYSTEM
CIRCUIT DIAGRAM
4 Main switch
6 Main fuse
8 Battery
m Light switch
q Headlight relay
r Headlight
u Headlight fuse
x Tail/brake light
B
B/L Gy
5
B/L
Gy
R
B
W
R
G
W
B
B
W R G B
W R G B
B
B
(BLACK)
W
W
W
W
W
W
2
R
B
G
R/B
1
G/Y B
G
(BLACK)
3
R
R/B
B
Br
R/B
R
D
W W W
R
(GRAY)
R
6
R
7
R/B
B
R
R
R
R
~
R/W
R
Br/B
R
R/W
L/W
Br/B
4
ON
8
R Br/L
OFF
(GRAY)
Br/L
B
Br/L R
B
B
B
A
(BLACK)
R/B
L/W
B B
G
F
L/W
B
B
B
Br
Br
0
R/B R/B
L/W
L/W
(BLACK)
B
}
L/B
L/W Br
9
Br
L/B
B/Y
B
R/B Br
R/B
|
L
Br
Y/R
Br/L
Br/L
L Y/R
j
s
L
Br/L
B
L
L
B
P
Br/L
Br/Y
u
B
k
Br/L
R/Y
G W/B
B
Br/Y
l
v
R/Y
Br
Y
R/B
L/B
Lg
n
o
p
OFF
Y
Br
OFF
PUSH
Y/W
Y
L
R/B R/W
L/B Lg B
(GRAY)
R/Y Y
y
L Y
B
L Y R/Y
B Lg L/B
Y
Y
L
q
Y
Y
G
L
B
Y L
(BLACK)
B
Y/WB/Y
Y/W B/Y
B
z
B
B
Br/R
m
Y/W
(BLACK)
P
Br/Y
w
Y/W
Br/R
P
t
{
i
Br
G
x
Y G
Y G
r
B B
r
B
Y G
B
G
G
Y
B
B
9 - 30
Y
B
B
Y G
B
Br R/B
(GRAY)
LIGHTING SYSTEM
–
ELEC
+
EBS01044
EBS01067
TROUBLESHOOTING
2. Battery
Any of the following fail to light: headlight, tail/brake light.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main and headlight fuses
2. battery
3. main switch
4. light switch
5. wiring connections
(of the entire lighting system)
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
NO
YES
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. battery cover
3. tail/brake light cover
• Troubleshoot with the following special
tool(s).
• Clean the battery
terminals.
• Recharge or replace the battery.
_
EBS01041
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NO
YES
EBS01043
Replace
switch.
1. Main and headlight fuses
• Check the main and headlight fuses for
continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and headlight fuses OK?
YES
the
main
EBS01068
4. Light switch
NO
• Check the light switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the light switch OK?
YES
NO
Replace the fuse(s).
Replace the left handlebar switch.
9 - 31
ELEC
LIGHTING SYSTEM
EBS01069
–
+
2. Headlight relay
5. Wiring
• Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the lighting system wiring properly connected and without defects?
Check the condition
of each of the lighting
system circuits.
Refer to “CHECKING THE LIGHTING
SYSTEM”.
È high beam
É low beam
Positive battery terminal → yellow 1
Negative battery terminal → black 2
NO
YES
• Remove the headlight relay.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the headlight relay as shown.
Properly connect or
repair the lighting
system’s wiring.
Positive tester probe → blue 3
Negative tester probe →
yellow 4 or green 5
È
3
4
2
EBS01070
CHECKING THE LIGHTING SYSTEM
1. The headlights fail to come on.
1
B
G
Y
Y
1. Headlight bulb and socket
L
• Check the headlight bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the headlight bulb and socket OK?
YES
É
3
5
NO
B
G
Y
Y
Replace the headlight bulb, socket or
both.
L
• Does the headlight relay have continuity
between blue and yellow? È
• Does the headlight relay have continuity
between blue and green? É
YES
NO
Replace the headlight relay.
9 - 32
LIGHTING SYSTEM
3. Voltage
ELEC
–
+
2. Voltage
• Connect the pocket tester (DC 20 V) to the
headlight couplers as shown.
• Connect the pocket tester (DC 20 V) to the
tail/brake light connectors as shown.
È When the light switch is set to “LO”
É When the light switch is set to “HI”
Tail/brake light connectors (wire harness
side)
Headlight coupler (wire harness side)
Positive tester probe → blue 1
Negative tester probe → black 2
Headlight
Positive tester probe →
yellow 1 or green 2
Negative tester probe → black 3
È
1
2
DC20V
Y G
G
B
É
Y
B
3
• Set the main switch to “ON”.
• Set the light switch to “LO” or “HI”.
• Measure the voltage (DC 12 V) of blue 1
on the tail/brake light connectors (wire harness side).
• Is the voltage within specification?
• Set the main switch to “ON”.
• Set the light switch to “LO” or “HI”.
• Measure the voltage (DC 12 V) of yellow
1 or green 2 on the headlight coupler
(wire harness side).
• Is the voltage within specification?
This circuit is OK.
This circuit is OK.
NO
YES
YES
The wiring circuit
from the main switch
to the headlight coupler is faulty and
must be repaired.
2. The taillight fails to come on.
1. Taillight bulb and socket
• Check the taillight bulb and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the taillight bulb and socket OK?
YES
NO
Replace the taillight
bulb, socket or both.
9 - 33
NO
The wiring circuit
from the main switch
to the tail/brake light
connectors are faulty
and
must
be
repaired.
5
B/L
Gy
G
B
B
2
B
B
R
R
B
Y
W Sb Gy Br Y/B Y/L Y/W B/L R/B O
R/B
Gy
O/W
G/W
B
B
W
G/R
O/W
L/B
L
(BLACK)
3
P Y/G G/Y Br/W L
L/W W/B B/R Gy/G W/R G/W Lg G/R R/L L/R Y/R O/W Y/W B/W L/B B
R
(BLACK)
W
W
W
W
W
W
B
W R G B R
G
R/B
1
G/Y B
R
W
W R G B R
R
R
R/B
B
Br
R/B
D
W W W
R
(GRAY)
R
6
7
O/W Br L/B
R
G W G/R
G/R W
R/B
(BLACK)
R
R
R
J
(BLACK)
R
Br
L/W
Br/B
R
L/W
Br/B
4
ON
}
(BLACK)
R/B
Br
L/B
Br/W
O
B/L
Br/W
Sb L/B
L/R
B/Y
G/Y B/L
B/Y
Y/W
Y/W
I
H
A
B
B B
G
F
B
B
B
L/W
L/W
B
B
B
Br/L R
R/L
R/B R/B
Br/B
B/Y
Br
Br
0
Br/L
R/B R/B
L/W
L/W
(BLACK)
B
(GRAY)
R/L
Br/B
L/B
L/W Br
9
8
R Br/L
OFF
N
Br/W B/L
~
R/W
R/W
(GRAY)
R/B
R/B
(BLACK)
M
R/L R/B
G/W
L
B
R
L
O
E
L/B
L
L/B Br O
O
R/L
Sb B/Y
L/R
K
(GREEN)
G/Y
P
L/B
Sb
L/R
R/L
B
Lg
Y/R
Y/B
G/R
W/B
B/R
Gy/G
W/R
Y/L
R/L
R/B
|
Br/L
Br/L
c
j
s
L
L
B
B/L
Y
L
L
P
B/L
P
L/B
Y/G
S
L
B/L
P
L
B/W
L
T
B/W
Br/R
Br/Y
Y
(BLACK)
B/Y
P
B/L
Y/G
B/L
L
Br/R
P
Br/L
R
Q
(BLACK)
Br
t
{
R/L B B/W G/Y
(GRAY)
i
B
Br/L
L
b
B/L
Y/G B/L
(GRAY)
B
Br/R B L/R
u
B
Br/B
k
Br/L
R/Y
e
Br/R B L/G
G W/B
Br
B
Br/Y
P
B
(BLACK)
Gy
Br/R
l
w
v
R/Y
Br
m
R/B
L/B
n
B/Y
L/B Sb
Y/W
V
L/R B
L/G B
p
Br/R
Y/B
Br
Gy
W
OFF
PUSH
L
R/B R/W
L/B Lg B
(GRAY)
R/Y Y
y
B
q
Y
G
(GRAY)
L/G L/R
L/R L/G
L/Y Sb
Sb L/B
(BLACK)
(BLACK)
L/R G/R
G/R Gy
Gy
L
B
X
B
(GRAY)
B
g
Y
2WD
4WD
LOCK
Y/L Br B/W
(BLACK)
Z
Br
[
(LIGHT GRAY)
Y L
L/Y
(BLACK)
B
Y/WB/Y
Y/W B/Y
B
z
B
Sb Gy
B
G
x
\
]
Y G
Y G
r
B B
Sb B/Y W/B
L/Y Br Br/B B/R
r
B
Br L/Y W/B B/R B Sb Br/B B/Y
Y G
B
G
G
Y
B
Y
B
(GRAY)
_
a
h
L
P
G/R
B
–
B
Y G
B
W/R Gy/G
ELEC
Y
Br R/B
Y
L
G/R
L/R
G/Y G/R Br/B
L Y R/Y
B Lg L/B
Y
L/R
L/G
L/B W/R
Gy/G
Gy W
Y/L
B/W
G/Y
Br
Br/B
Y/W
Y
L Y
Sb
U
Lg
o
OFF
Y
d
Br/B
Br/Y
Y
(BLACK)
(BLACK)
Y/B
f
Y/W
Br/R
Br/R
Br/R
Br/R
Br/R
SIGNALING SYSTEM
9 - 34
Y/R
L Y/R
B
G/Y
W L/Y
L
W
B/L
Y
L
L W
B/L
B/L
G/Y
L
W
B/L
R/B Br
Br
EBS00521
B/L Gy
W
SIGNALING SYSTEM
B
R
B
CIRCUIT DIAGRAM
C
B
G
B
+
SIGNALING SYSTEM
4 Main switch
6 Main fuse
8 Battery
J Reverse switch
K ECU (engine control unit)
P Coolant temperature sensor
Q Speed sensor
U Gear position switch
W Multifunction meter
Y Coolant temperature warning light
Z Park indicator light
[ Reverse indicator light
\ Neutral indicator light
] High-range indicator light
_ Low-range indicator light
b Fuel sender
h Differential gear motor
p Override switch
s Ignition fuse
t Signaling system fuse
v Rear brake light switch
w Front brake light switch
x Tail/brake light
y Diode 3
9 - 35
ELEC
–
+
SIGNALING SYSTEM
–
ELEC
+
EBS01044
EBS01073
TROUBLESHOOTING
2. Battery
Any of the following fail to light: warning
light, brake light or an indicator light.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main, signaling system and ignition fuses
2. battery
3. main switch
4. wiring connections
(of the entire signaling system)
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
NO
YES
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. battery cover
3. side panels
4. V-belt cooling duct 2
5. rear fender
• Troubleshoot with the following special
tool(s).
_
• Clean the battery
terminals.
• Recharge or replace the battery.
EBS01041
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NO
YES
Replace
switch.
EBS01043
the
main
1. Main, signaling system and ignition fuses
• Check the main, signaling system and
ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, signaling system and ignition fuses OK?
YES
EBS01074
4. Wiring
• Check the entire signal system wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the signaling system wiring properly
connected and without defects?
NO
Replace the fuse(s).
YES
Check the condition
of each of the signaling system circuits.
Refer to “CHECKING THE SIGNALING SYSTEM”.
9 - 36
NO
Properly connect or
repair the signaling
system wiring.
ELEC
SIGNALING SYSTEM
–
+
EBS01053
EBS01075
CHECKING THE SIGNALING SYSTEM
3. Diode 3
EBS01076
1. The brake light fails to come on.
• Remove the diode 3 from the wire harness.
• Connect the pocket tester (Ω × 1) to the
diode 3 as shown.
• Measure the diode 3 for continuity as follows.
1. Brake light bulb and bulb socket
• Check the brake light bulb and bulb socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the brake light bulb and bulb socket
OK?
YES
NO
Replace the brake
light
bulb,
bulb
socket or both.
2. Brake light switches
• Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the brake light switch OK?
YES
NOTE:
The pocket tester 90890-03112 and the analog pocket tester YU-03112-C readings are
shown in the following table.
_
Positive tester probe →
yellow/white 1
Continuity
Negative tester probe →
yellow 2
Positive tester probe →
yellow 2 No
continuity
Negative tester probe →
yellow/white 1
1
NO
2
Replace the brake
light switch.
Y
Y/W
• Are the testing readings correct?
YES
NO
Replace the diode 3.
9 - 37
SIGNALING SYSTEM
ELEC
–
+
EBS01078
4. Voltage
• Connect the pocket tester (DC 20 V) to the
tail/brake light connectors (wire harness
side) as shown.
2. The neutral, park, high-range, and/or lowrange indicator light fails to come on.
1. Gear position switch
• Check the gear position switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the gear position switch OK?
Positive tester probe → yellow 1
Negative tester probe → black 2
NO
YES
Replace the gear
position switch.
2. Voltage
• Set the main switch to “ON”.
• Pull in the brake lever or push down on the
brake pedal.
• Measure the voltage (DC 12 V) of yellow
1 on the tail/brake light connector (wire
harness side).
• Is the voltage within specification?
YES
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler as shown.
Positive tester probe → brown 1
Negative tester probe → black/white 2
NO
G/Y G/R Br/B
This circuit is OK.
The wiring circuit
from the main switch
to the tail/brake light
connector is faulty
and
must
be
repaired.
Y/L Br B/W
1
2
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of brown
1 and black/white 2 at the meter assembly coupler.
• Is the voltage within specification?
YES
Replace the meter
assembly or ECU.
9 - 38
NO
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and
must
be
repaired.
SIGNALING SYSTEM
ELEC
–
+
EBS01079
EBS01081
3. The reverse indicator light fails to come on.
4. The differential gear lock indicator light and/
or four-wheel-drive motor indicator light fails
to come on.
1. Reverse switch
• Check the reverse switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the reverse switch OK?
1. Four-wheel-drive motor switch (differential
gear motor)
• Check the four-wheel-drive motor switch
for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the four-wheel-drive motor switch OK?
NO
YES
Replace the reverse
switch.
NO
YES
2. Voltage
Replace the differential gear motor.
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler as shown.
Positive tester probe → brown 1
Negative tester probe → black/white 2
2. Voltage
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler as shown.
Positive tester probe → brown 1
Negative tester probe → black/white 2
G/Y G/R Br/B
Y/L Br B/W
1
2
G/Y G/R Br/B
• Set the main switch to “ON”.
• Measure the voltage (12 V) of brown 1
and black/white 2 at the meter assembly
coupler.
• Is the voltage within specification?
YES
Replace the meter
assembly or ECU.
Y/L Br B/W
1
• Set the main switch to “ON”.
• Measure the voltage (12 V) of brown 1
and black/white 2 at the meter assembly
coupler.
• Is the voltage within specification?
NO
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and must be repaired.
2
YES
Replace the meter
assembly or ECU.
9 - 39
NO
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and
must
be
repaired.
SIGNALING SYSTEM
5. While the override switch is pushed, the
segments of the speedometer digits will not
appear as shown in the illustration.
ELEC
–
+
2. Voltage
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler as shown.
Positive tester probe → brown 1
Negative tester probe → black/white 2
G/Y G/R Br/B
1. Override switch
Y/L Br B/W
• Check the override switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the override switch OK?
YES
1
2
• Set the main switch to “ON”.
• Measure the voltage (12 V) of brown 1
and black/white 2 at the meter assembly
coupler.
• Is the voltage within specification?
NO
Replace the left handlebar switch.
YES
Replace the meter
assembly or ECU.
9 - 40
NO
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and
must
be
repaired.
SIGNALING SYSTEM
ELEC
–
+
EBS01083
6. The coolant temperature warning light does
not come on when the main switch is set to
“ON”, or if the coolant temperature warning
light does not come on when the temperature is high (more than 112 °C (233.6 °F)).
EBS00812
1. Coolant temperature sensor
• Remove the coolant temperature sensor
from the cylinder head.
• Connect the pocket tester (Ω × 100) to the
coolant temperature sensor 1 as shown.
• Immerse the coolant temperature sensor
in a container filled with coolant 2.
NOTE:
Make sure the coolant temperature sensor
terminals do not get wet.
_
• Place a thermometer 3 in the coolant.
• Slowly heat the coolant, and then let it cool
to the specified temperature indicated in
the table.
• Measure the coolant temperature sensor
resistance.
• Does the coolant temperature sensor
operate properly?
YES
NO
Replace the coolant
temperature sensor.
Coolant temperature sensor
resistance
290 ~ 354 Ω at 80 °C (176 °F)
WARNING
_
• Handle the coolant temperature sensor
with special care.
• Never subject the coolant temperature
sensor to strong shocks. If the coolant
temperature sensor is dropped, replace
it.
T.
Coolant temperature sensor
18 Nm (1.8 m · kg, 13 ft · lb)
R.
9 - 41
ELEC
SIGNALING SYSTEM
2. Voltage
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler as shown.
–
+
7. The fuel level indicator light fails to come
on.
1. Fuel sender
• Drain the fuel from the fuel tank and then
remove the fuel pump assembly (fuel
sender) from the fuel tank.
• Connect the pocket tester (Ω × 10) to the
fuel pump terminals as shown.
Positive tester probe → brown 1
Negative tester probe → black/white 2
Positive tester probe → green/yellow 1
Negative tester probe → black/white 2
G/Y G/R Br/B
• Move the fuel sender float to the minimum
3 and maximum 4 level positions.
• Measure the fuel sender resistance.
Y/L Br B/W
1
2
Fuel sender resistance
Minimum 3: 139.0 ~ 141.0 Ω
Maximum 4: 19.0 ~ 21.0 Ω
• Set the main switch to “ON”.
• Measure the voltage (12 V) of brown 1
and black/white 2 at the meter assembly
coupler.
• Is the voltage within specification?
YES
NO
R/L B B/W G/Y
Replace the meter
assembly or ECU.
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and
must
be
repaired.
1 2
4
3
• Is the fuel sender OK?
YES
NO
Replace the fuel
pump assembly.
9 - 42
–
ELEC
SIGNALING SYSTEM
+
8. The speedometer fails to come on.
2. Voltage
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler as shown.
1. Speed sensor
• Connect the pocket tester (DC 20 V) to the
speed sensor coupler (wire harness side)
as shown.
Positive tester probe → brown 1
Negative tester probe → black/white 2
Positive tester probe → white 1
Negative tester probe → black/blue 2
1
G/Y G/R Br/B
Y/L Br B/W
1
2
• Set the main switch to “ON”.
• Measure the voltage (12 V) of brown 1
and black/white 2 at the meter assembly
coupler.
• Is the voltage within specification?
YES
Replace the meter
assembly.
NO
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and
must
be
repaired.
9 - 43
W L/Y
L W
B/ L
B /L
2
• Turn the main switch to “ON”.
• Elevate the rear wheels and slowly rotate
them.
• Measure the voltage 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.
• Is the speed sensor OK?
YES
NO
Replace the speed
sensor.
SIGNALING SYSTEM
2. Voltage
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler as shown.
Positive tester probe → brown 1
Negative tester probe → black/white 2
G/Y G/R Br/B
Y/L Br B/W
1
2
• Set the main switch to “ON”.
• Measure the voltage (12 V) of brown 1
and black/white 2 at the meter assembly
coupler.
• Is the voltage within specification?
YES
Replace the meter
assembly or ECU.
NO
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and
must
be
repaired.
9 - 44
ELEC
–
+
5
B/L
Gy
G
B
B
2
B
B
R
R
B
Y
W Sb Gy Br Y/B Y/L Y/W B/L R/B O
R/B
Gy
O/W
G/W
B
B
W
G/R
O/W
L/B
L
(BLACK)
3
P Y/G G/Y Br/W L
L/W W/B B/R Gy/G W/R G/W Lg G/R R/L L/R Y/R O/W Y/W B/W L/B B
R
(BLACK)
W
W
W
W
W
W
B
W R G B R
G
R/B
1
G/Y B
R
W
W R G B R
R
R
R/B
B
Br
R/B
D
W W W
R
(GRAY)
R
6
7
O/W Br L/B
R
G W G/R
G/R W
R/B
(BLACK)
R
R
R
J
(BLACK)
R
Br
L/W
Br/B
R
L/W
Br/B
4
ON
}
(BLACK)
R/B
Br
L/B
Br/W
O
B/L
Br/W
Sb L/B
L/R
B/Y
G/Y B/L
B/Y
Y/W
Y/W
I
H
A
B
B B
G
F
B
B
B
L/W
L/W
B
B
B
Br/L R
R/L
R/B R/B
Br/B
B/Y
Br
Br
0
Br/L
R/B R/B
L/W
L/W
(BLACK)
B
(GRAY)
R/L
Br/B
L/B
L/W Br
9
8
R Br/L
OFF
N
Br/W B/L
~
R/W
R/W
(GRAY)
R/B
R/B
(BLACK)
M
R/L R/B
G/W
L
B
R
L
O
E
L/B
L
L/B Br O
O
R/L
Sb B/Y
L/R
K
(GREEN)
G/Y
P
L/B
Sb
L/R
R/L
B
Lg
Y/R
Y/B
G/R
W/B
B/R
Gy/G
W/R
Y/L
R/L
R/B
|
Br/L
Br/L
c
j
s
L
L
B
B/L
Y
L
L
P
B/L
P
L/B
Y/G
S
L
B/L
P
L
B/W
L
T
B/W
Br/R
Br/Y
Y
(BLACK)
B/Y
P
B/L
Y/G
B/L
L
Br/R
P
Br/L
R
Q
(BLACK)
Br
t
{
R/L B B/W G/Y
(GRAY)
i
B
Br/L
L
b
B/L
Y/G B/L
(GRAY)
B
Br/R B L/R
u
B
Br/B
k
Br/L
R/Y
e
Br/R B L/G
G W/B
Br
B
Br/Y
P
B
(BLACK)
Gy
Br/R
l
w
v
R/Y
Br
m
R/B
L/B
n
Y/W
p
L/B Sb
y
L Y
Y/W B/Y
B
B
B B
B
Y/B
Br
Gy
W
R/B R/W
B
L/B Lg B
(GRAY)
q motor
{ Radiator fan
| Radiator fan motor
relay
} Radiator fan motor
r
r
circuit breaker
~ Radiator fan motor
fuse
Br R/B
(GRAY)
L/G L/R
L/R L/G
L/Y Sb
Sb L/B
(BLACK)
(BLACK)
L/R G/R
G/R Gy
Gy
Y
G
L
B
B
(GRAY)
B
Y G
B
G
G
Y
Y
B
Y/L Br B/W
(BLACK)
Z
Br
[
(LIGHT GRAY)
L/Y
Sb Gy
B
\
]
Y G
B
Sb B/Y W/B
L/Y Br Br/B B/R
Br L/Y W/B B/R B Sb Br/B B/Y
Y G
B
(GRAY)
_
a
h
L
P
G/R
B
–
B
Y
2WD
4WD
LOCK
G
Y G
Y/L
B/W
X
g
(BLACK)
B
G/R
L/R
W/R Gy/G
Gy W
G/Y G/R Br/B
L Y R/Y
Y
L
Y
L/R
L/G
L/B W/R
Gy/G
ELEC
Y/WB/Y
Br/R
G/Y
Br
Br/B
L
B Lg L/B
Y
Sb
U
Y/W
R/Y Y
Y L
V
OFF
PUSH
Y
B
+
4 Main switch
6 Main fuse
x
8 Batteryz
K ECU (engine control
unit)
P Coolant temperature
sensor
s Ignition fuse
B/Y
L/R B
L/G B
Lg
o
OFF
Y
d
Br/B
Br/Y
Y
(BLACK)
(BLACK)
Y/B
f
Y/W
Br/R
Br/R
Br/R
Br/R
Br/R
COOLING SYSTEM
9 - 45
Y/R
L Y/R
B
G/Y
W L/Y
L
W
B/L
Y
L
L W
B/L
B/L
G/Y
L
W
B/L
R/B Br
Br
EBS00532
B/L Gy
W
COOLING SYSTEM
B
R
B
CIRCUIT DIAGRAM
C
B
G
COOLING SYSTEM
–
ELEC
+
EBS01044
EBS01085
TROUBLESHOOTING
2. Battery
The radiator fan motor fails to turn.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main, ignition, and radiator fan motor fuses
2. battery
3. main switch
4. radiator fan motor
5. radiator fan motor relay
6. radiator fan motor circuit breaker
7. coolant temperature sensor
8. wiring connections
(the entire cooling system)
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. battery cover
3. side panels
4. front fenders
• Troubleshoot with the following special
tool(s).
• Clean the battery
terminals.
• Recharge or replace the battery.
_
EBS01041
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
NO
YES
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Replace
switch.
EBS01043
1. Main, ignition, and radiator fan motor fuses
• Check the main, ignition, and radiator fan
motor fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, ignition, and radiator fan
motor fuses OK?
YES
NO
YES
NO
Replace the fuse(s).
9 - 46
the
main
COOLING SYSTEM
EBS01086
ELEC
–
+
5. Radiator fan motor relay
4. Radiator fan motor
• Remove the radiator fan motor relay from
the wire harness.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the radiator fan motor relay
terminal as shown.
• Check the radiator fan motor relay of continuity.
• Disconnect the radiator fan motor coupler
from the wire harness.
• Connect the battery (12 V) as shown.
Positive battery lead → blue 1
Negative battery lead → black 2
Positive battery lead → brown 1
Negative battery lead → yellow/red 2
Positive tester probe → red/black 3
Negative tester probe → blue 4
• Does the radiator fan motor turn?
YES
NO
The
radiator
fan
motor is faulty and
must be replaced.
• Does the radiator fan motor relay have
continuity between red/black and blue?
YES
NO
The
radiator
fan
motor relay is faulty
and
must
be
replaced.
9 - 47
COOLING SYSTEM
6. Radiator fan motor circuit breaker
• Remove the radiator fan motor circuit
breaker from the wire harness.
NOTE:
The radiator fan motor circuit breaker 1 is
attached to the wire harness with black tape
near the tail/brake light connectors 2.
1
2
• Connect the pocket tester (Ω × 1) to the
radiator fan motor circuit breaker.
Radiator fan motor circuit breaker
resistance
Zero Ω at 20 °C (68 °F)
YES
NO
Replace the radiator
fan motor circuit
breaker.
9 - 48
ELEC
–
+
COOLING SYSTEM
ELEC
–
+
EBS00812
7. Coolant temperature sensor
• Remove the coolant temperature sensor
from the cylinder head.
• Connect the pocket tester (Ω × 100) to the
coolant temperature sensor 1 as shown.
• Immerse the coolant temperature sensor
in a container filled with coolant 2.
NOTE:
Make sure the coolant temperature sensor
terminals do not get wet.
_
• Place a thermometer 3 in the coolant.
• Slowly heat the coolant, and then let it cool
to the specified temperature indicated in
the table.
• Measure the coolant temperature sensor
resistance.
Coolant temperature sensor
resistance
290 ~ 354 Ω at 80 °C (176 °F)
• Does the coolant temperature sensor
operate properly?
YES
NO
WARNING
_
• Handle the coolant temperature sensor
with special care.
• Never subject the coolant temperature
sensor to strong shocks. If the coolant
temperature sensor is dropped, replace
it.
Replace the coolant
temperature sensor.
EBS01090
8. Wiring
T.
• Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the cooling system’s wiring properly
connected and without defects?
Coolant temperature sensor
18 Nm (1.8 m · kg, 13 ft · lb)
R.
YES
Replace the ECU.
9 - 49
NO
Properly connect or
repair the cooling
system’s wiring.
B/L Gy
5
B/L
Gy
R
G
W
B
B
2
B
W R G B R
B
B
R
R
B
Y
W Sb Gy Br Y/B Y/L Y/W B/L R/B O
R/B
Gy
O/W
G/W
B
B
W
G/R
O/W
L/B
L
(BLACK)
3
P Y/G G/Y Br/W L
L/W W/B B/R Gy/G W/R G/W Lg G/R R/L L/R Y/R O/W Y/W B/W L/B B
R
(BLACK)
W
W
W
W
W
W
W R G B R
G
R/B
1
G/Y B
W
R
R
R/B
B
Br
R/B
D
W W W
R
(GRAY)
R
6
7
O/W Br L/B
R
G W G/R
G/R W
R/B
(BLACK)
R
R
R
J
(BLACK)
R
Br
L/W
Br/B
R
L/W
Br/B
4
ON
}
(BLACK)
R/B
F
B
B
B B
Br
L/B
Br/W
O
B/L
Br/W
Sb L/B
L/R
B/Y
G/Y B/L
B/Y
Y/W
Y/W
I
H
G
A
B
B
L/W
L/W
B
B
B
Br/L R
R/L
R/B R/B
Br/B
B/Y
Br
Br
0
Br/L
R/B R/B
L/W
L/W
(BLACK)
B
(GRAY)
R/L
Br/B
L/B
L/W Br
9
8
R Br/L
OFF
N
Br/W B/L
~
R/W
R/W
(GRAY)
R/B
R/B
(BLACK)
M
R/L R/B
G/W
L
B
R
L
O
E
L/B
L
L/B Br O
O
R/L
Sb B/Y
L/R
K
(GREEN)
G/Y
P
L/B
Sb
L/R
R/L
B
Lg
Y/R
Y/B
G/R
W/B
B/R
Gy/G
W/R
Y/L
R/L
R/B
|
Br/L
Br/L
c
j
s
L
L
B
B/L
Y
L
L
P
B/L
P
L/B
Y/G
S
L
B/L
P
L
B/W
L
T
B/W
Br/R
Br/Y
Y
(BLACK)
B/Y
P
B/L
Y/G
B/L
L
Br/R
P
Br/L
R
Q
(BLACK)
Br
t
{
R/L B B/W G/Y
(GRAY)
i
B
Br/L
L
b
B/L
Y/G B/L
(GRAY)
B
Br/R B L/R
u
B
Br/B
k
Br/L
R/Y
e
Br/R B L/G
G W/B
Br
B
Br/Y
P
B
(BLACK)
Gy
Br/R
l
w
v
R/Y
Br
m
R/B
L/B
n
B/Y
L/B Sb
Y/W
V
L/R B
L/G B
p
Br/R
Y/B
Br
Gy
W
OFF
PUSH
G/Y
Br
Br/B
Y/W
Y
L
R/B R/W
L/B Lg B
(GRAY)
R/Y Y
y
L Y
B
q
Y
Y
G
Br R/B
(GRAY)
L/G L/R
L/R L/G
L/Y Sb
Sb L/B
(BLACK)
(BLACK)
L/R G/R
G/R Gy
Y
L
Gy
L
B
G/R
L/R
Y/L
B/W
X
B
(GRAY)
B
g
Y
2WD
4WD
LOCK
Y/L Br B/W
(BLACK)
Z
Br
[
(LIGHT GRAY)
Y L
L/Y
(BLACK)
B
Y/WB/Y
Sb Gy
B
G
B
\
]
Y/W B/Y
B
Y G
Y G
r
B B
Sb B/Y W/B
L/Y Br Br/B B/R
r
B
Br L/Y W/B B/R B Sb Br/B B/Y
Y G
B
G
G
Y
B
Y
B
(GRAY)
_
a
h
L
P
G/R
B
–
B
Y G
B
W/R Gy/G
Gy W
G/Y G/R Br/B
L Y R/Y
B Lg L/B
Y
L/R
L/G
L/B W/R
Gy/G
ELEC
B
+
4 Main switch
6 Main fuse
8 Battery
9 Fuel injection x
system fuse
z
H Fuel injection system relay
K ECU (engine control unit)
c Fuel pump
n Engine stop switch
s Ignition fuse
Sb
U
Lg
o
OFF
Y
d
Br/B
Br/Y
Y
(BLACK)
(BLACK)
Y/B
f
Y/W
Br/R
Br/R
Br/R
Br/R
Br/R
FUEL PUMP SYSTEM
9 - 50
Y/R
L Y/R
B
G/Y
W L/Y
L
W
B/L
Y
L
L W
B/L
B/L
G/Y
L
W
B/L
R/B Br
Br
FUEL PUMP SYSTEM
B
R
B
CIRCUIT DIAGRAM
C
B
G
FUEL PUMP SYSTEM
TROUBLESHOOTING
+
EBS01044
2. Battery
The fuel pump fails to operate.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main, ignition, and fuel injection system
fuses
2. battery
3. main switch
4. engine stop switch
5. fuel injection system relay
6. fuel pump
7. wiring connections
(the entire fuel pump system)
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. battery cover
3. rear fender
• Troubleshoot with the following special
tool(s).
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
NO
YES
• Clean the battery
terminals.
• Recharge or
replace the battery.
_
EBS01041
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NO
YES
Replace
switch.
EBS01043
1. Main, ignition, and fuel injection system
fuses
the
main
4. Engine stop switch
• Check the main, ignition, and fuel injection
system fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main, ignition, and fuel injection
system fuses OK?
YES
–
ELEC
NO
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
YES
NO
Replace the left handlebar switch.
Replace the fuse(s).
9 - 51
FUEL PUMP SYSTEM
5. Fuel injection system relay
–
+
6. Fuel pump
• Remove the fuel injection system relay
from the wire harness.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the fuel injection system
relay terminal as shown.
• Check the fuel injection system relay of
continuity.
• Check the condition of the fuel pump.
Refer to “CHECKING THE FUEL PUMP
BODY” in chapter 6.
YES
NO
Replace the fuel
pump assembly.
Positive battery lead → red/black 1
Negative battery lead → blue/red 2
7. Wiring
Positive tester probe → brown/black 3
Negative tester probe → red/blue 4
• Check the entire fuel pump system wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the fuel pump system wiring properly
connected and without defects?
YES
Replace the ECU.
• Does the fuel injection system relay have
continuity between brown/black and red/
blue?
YES
ELEC
NO
The fuel injection
system relay is faulty
and
must
be
replaced.
9 - 52
NO
Properly connect or
repair the fuel pump
system wiring.
5
B/L
Gy
G
B
B
2
B
B
R
R
B
Y
W Sb Gy Br Y/B Y/L Y/W B/L R/B O
R/B
Gy
O/W
G/W
B
B
W
G/R
O/W
L/B
L
(BLACK)
3
P Y/G G/Y Br/W L
L/W W/B B/R Gy/G W/R G/W Lg G/R R/L L/R Y/R O/W Y/W B/W L/B B
R
(BLACK)
W
W
W
W
W
W
B
W R G B R
G
R/B
1
G/Y B
R
W
W R G B R
R
R
R/B
B
Br
R/B
D
W W W
R
(GRAY)
R
6
7
O/W Br L/B
R
G W G/R
G/R W
R/B
(BLACK)
R
R
R
J
(BLACK)
R
Br
L/W
Br/B
R
L/W
Br/B
ON
}
(BLACK)
R/B
F
B
B
B B
Br
L/B
O
B/L
Br/W
Sb L/B
L/R
B/Y
G/Y B/L
B/Y
Y/W
Y/W
I
H
G
A
B
B
L/W
L/W
B
B
B
Br/L R
R/L
R/B R/B
Br/B
B/Y
Br
Br
0
Br/L
R/B R/B
L/W
L/W
(BLACK)
B
(GRAY)
Br/W
Br/B
L/B
L/W Br
9
8
R Br/L
OFF
R/L
R/L
(GREEN)
G/Y
Sb B/Y
L/R
K
P
L/B
B
B/L
Y
L
Y
Lg
Y/R
Y/B
G/R
W/B
B/R
Gy/G
W/R
Y/L
R/L
R/B
|
L
9 - 53
Y/R
Br/L
Br/L
c
L Y/R
j
s
L
L
L
B
R/L B B/W G/Y
(GRAY)
i
S
B/L
Y
L
B/L
P
L
(BLACK)
B/W
L
T
B/W
Br/R
Br/Y
Q
Y/G
B/L
L
B/Y
P
Br/L
R
L
P
B/L
P
L/B
Y/G
Br/R
P
B/L
(BLACK)
Br
t
{
b
B
Br/L
B
G/Y
W L/Y
L
W
B/L
Sb
L/R
R/L
R/B Br
Br
L W
B/L
B/L
G/Y
L
W
B/L
Y/G B/L
(GRAY)
B
Br/R B L/R
u
B
Br/B
k
Br/L
R/Y
e
Br/R B L/G
G W/B
Br
B
Br/Y
P
B
(BLACK)
Gy
Br/R
l
w
v
R/Y
Br
m
R/B
L/B
n
B/Y
L/B Sb
Y/W
p
Br/R
Y/B
Br
Gy
W
OFF
PUSH
G/Y
Br
Br/B
Y/W
Y
B
Y
L/B Lg B
(GRAY)
L/R
L/G
q
Br R/B
(GRAY)
L/G L/R
L/R L/G
L/Y Sb
Sb L/B
(BLACK)
(BLACK)
L/R G/R
G/R Gy
Gy
L
B
G/R
L/R
Y/L
B/W
X
B
(GRAY)
B
g
Y
2WD
4WD
LOCK
Y/L Br B/W
(BLACK)
Z
Br
[
(LIGHT GRAY)
Y L
L/Y
(BLACK)
B
Y/WB/Y
Sb Gy
B
G
B
B
Y G
Y G
Sb B/Y W/B
L/Y Br Br/B B/R
r
B B
B
Y G
B
G
\
]
Y/W B/Y
Br L/Y W/B B/R B Sb Br/B B/Y
G
Y
B
Y
B
(GRAY)
_
a
h
W/R Gy/G
L
P
G/R
B
–
B
Y G
B
L/B W/R
Gy/G
Gy W
G/Y G/R Br/B
L Y R/Y
Y
Y
G
R/B R/W
B Lg L/B
L
Y
L
R/Y Y
L Y
Sb
U
ELEC
B
+
4 Main switch
6 Main fuse
y
8 Battery
K ECU (engine control unit)
d Four-wheel-drive motor relay 1
e Four-wheel-drive motor relay 2
f Four-wheel-drive
motor relay 3
x
z
g On-command four-wheel-drive
r
motor switch and differential gear
lock switch
h Differential gear motor
i Four-wheel-drive motor fuse
V
L/R B
L/G B
Lg
o
OFF
Y
d
Br/B
Br/Y
Y
(BLACK)
(BLACK)
Y/B
f
Y/W
Br/R
Br/R
Br/R
Br/R
Br/R
2WD/4WD SELECTING SYSTEM
4
N
Br/W B/L
~
R/W
R/W
(GRAY)
R/B
R/B
(BLACK)
M
R/L R/B
G/W
L
B
R
L
O
E
L/B
L
L/B Br O
O
EBS00535
B/L Gy
W
2WD/4WD SELECTING SYSTEM
B
R
B
CIRCUIT DIAGRAM
C
B
G
2WD/4WD SELECTING SYSTEM
–
ELEC
+
EBS01043
EBS01095
TROUBLESHOOTING
1. Main and four-wheel-drive motor fuses
The four-wheel-drive motor indicator
light fails to come on.
Check:
1. main and four-wheel-drive motor fuses
2. battery
3. main switch
4. four-wheel-drive motor relay 1
5. four-wheel-drive motor relay 2
6. four-wheel-drive motor relay 3
7. on-command four-wheel-drive motor switch
and differential gear lock switch
8. differential gear motor
9. wiring connection
(the entire 2WD/4WD selecting system)
• Check the main and four-wheel-drive
motor fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.
• Are the main and four-wheel-drive motor
fuses OK?
NO
YES
Replace the fuse(s).
EBS01044
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. battery cover
• Troubleshoot with the following special
tool(s).
_
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
NO
YES
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
• Clean the battery
terminals.
• Recharge or replace the battery.
EBS01041
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
NO
YES
Replace
switch.
9 - 54
the
main
2WD/4WD SELECTING SYSTEM
ELEC
–
+
EBS01097
EBS01096
4. Four-wheel-drive motor relay 1
5. Four-wheel-drive motor relay 2
• Remove the four-wheel-drive motor relay
1 from the wire harness.
• Connect the pocket tester (Ω × 1) and the
battery (12 V) to the four-wheel-drive
motor relay 1 terminals.
• Remove the four-wheel-drive motor relay
2 from the wire harness.
• Connect the pocket tester (Ω × 1) and the
battery (12 V) to the four-wheel-drive
motor relay 2 terminals.
Positive tester probe → black/yellow 1
Negative tester probe → black 2
Positive tester probe → brown/black 1
Negative tester probe → black 2
Positive battery terminal → brown/red 3
Negative battery terminal → blue/red 4
Positive battery terminal → brown/red 3
Negative battery terminal → blue/green 4
Positive tester probe → black/yellow 1
Negative tester probe → brown/red 5
Positive tester probe → brown/black 1
Negative tester probe → brown/red 5
• Check the four-wheel-drive motor relay 1
for continuity.
YES
NO
• Check the four-wheel-drive motor relay 2
for continuity.
YES
Replace the fourwheel-drive
motor
relay 1.
9 - 55
NO
Replace the fourwheel-drive
motor
relay 2.
2WD/4WD SELECTING SYSTEM
ELEC
–
+
EBS01092
EBS01098
6. Four-wheel-drive motor relay 3
• Remove the four-wheel-drive motor relay
3 from the wire harness.
• Connect the pocket tester (Ω × 1) and the
battery (12 V) to the four-wheel-drive
motor relay 3 terminals.
7. On-command
four-wheel-drive
motor
switch and differential gear lock switch
Positive battery terminal → brown/red 1
Negative battery terminal →
yellow/black 2
• Check the on-command four-wheel-drive
motor switch and differential gear lock
switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the on-command four-wheel-drive motor
switch and differential gear lock switch
OK?
YES
Positive tester probe → brown 3
Negative tester probe → gray 4
NO
Replace the on-command
four-wheeldrive motor switch
and differential gear
lock switch.
• Check the four-wheel-drive motor relay 3
for continuity.
YES
NO
Replace the fourwheel-drive
motor
relay 3.
9 - 56
2WD/4WD SELECTING SYSTEM
–
+
EBS01094
8. Differential gear motor
• Disconnect the differential gear motor coupler.
• Remove the differential gear motor from
the differential gear case.
Refer to “FRONT CONSTANT VELOCITY
JOINTS AND DIFFERENTIAL GEAR” in
chapter 7.
• Connect two C size batteries to the differential gear motor terminals 1 (as shown
illustrations).
9. Wiring connection
• Check the connections of the entire 2WD/
4WD selecting system.
Refer to “CIRCUIT DIAGRAM”.
• Is the 2WD/4WD system wiring properly
connected and without defects?
YES
Replace the ECU.
È Check that the pinion gear 2 turns counterclockwise.
É Check that the pinion gear 2 turns clockwise.
È
3V
1
2
É
3V
2
1
• Make sure that the drive gear (shift fork
sliding gear) operates correctly.
NOTE:
When installing the differential gear motor,
refer to “FRONT CONSTANT VELOCITY
JOINTS AND DIFFERENTIAL GEAR” in
chapter 7.
YES
ELEC
NO
Replace the differential gear motor.
9 - 57
NO
Properly connect or
repair the 2WD/4WD
selecting system wiring.
G
B
B
2
B
R
R
B
Y
W Sb Gy Br Y/B Y/L Y/W B/L R/B O
R/B
Gy
O/W
G/W
B
B
W
G/R
O/W
L/B
L
(BLACK)
3
P Y/G G/Y Br/W L
L/W W/B B/R Gy/G W/R G/W Lg G/R R/L L/R Y/R O/W Y/W B/W L/B B
R
(BLACK)
W
W
W
W
W
W
B
G
R/B
1
G/Y B
R
W
B
W R G B R
R
R
R/B
B
Br
R/B
D
W W W
R
(GRAY)
R
6
7
O/W Br L/B
R
G W G/R
G/R W
R/B
(BLACK)
R
R
R
J
(BLACK)
R
Br
L/W
Br/B
R
L/W
Br/B
4
ON
}
(BLACK)
R/B
Br
L/B
Br/W
O
B/L
Br/W
Sb L/B
L/R
B/Y
G/Y B/L
B/Y
Y/W
Y/W
I
H
A
B
B B
G
F
B
B
B
L/W
L/W
B
B
B
Br/L R
R/L
R/B R/B
Br/B
B/Y
Br
Br
0
Br/L
R/B R/B
L/W
L/W
(BLACK)
B
(GRAY)
R/L
Br/B
L/B
L/W Br
9
8
R Br/L
OFF
N
Br/W B/L
~
R/W
R/W
(GRAY)
R/B
R/B
(BLACK)
M
R/L R/B
G/W
L
B
R
L
O
E
L/B
L
L/B Br O
O
R/L
(GREEN)
G/Y
Sb B/Y
L/R
K
P
L/B
B
B/L
Y
L
Y
Lg
Y/R
Y/B
G/R
W/B
B/R
Gy/G
W/R
Y/L
R/L
R/B
|
L
9 - 58
Y/R
Br/L
Br/L
c
L Y/R
j
s
L
L
L
B
R/L B B/W G/Y
(GRAY)
i
S
B/L
Y
L
B/L
P
L
(BLACK)
B/W
L
T
B/W
Br/R
Br/Y
Q
Y/G
B/L
L
B/Y
P
Br/L
R
L
P
B/L
P
L/B
Y/G
Br/R
P
B/L
(BLACK)
Br
t
{
b
B
Br/L
B
G/Y
W L/Y
L
W
B/L
Sb
L/R
R/L
R/B Br
Br
L W
B/L
B/L
G/Y
L
W
B/L
Y/G B/L
(GRAY)
B
Br/R B L/R
u
B
Br/B
k
Br/L
R/Y
e
Br/R B L/G
G W/B
Br
B
Br/Y
l
R/Y
Br
m
R/B
L/B
n
d
Br/B
B/Y
Y/B
L/B Sb
V
L/R B
L/G B
p
Br/R
Y/B
Br
Gy
W
OFF
PUSH
G/Y
Br
Br/B
Y/W
Y
L
R/B R/W
L/B Lg B
(GRAY)
R/Y Y
L Y
B
q
Y
(GRAY)
L/G L/R
L/R L/G
L/Y Sb
Sb L/B
(BLACK)
(BLACK)
L/R G/R
G/R Gy
Gy
L
B
G/R
L/R
Y/L
B/W
X
B
(GRAY)
B
g
Y
2WD
4WD
LOCK
Y/L Br B/W
(BLACK)
Z
Br
[
(LIGHT GRAY)
Y L
L/Y
(BLACK)
B
Y/WB/Y
Sb Gy
B
G
B
\
]
Y/W B/Y
B
Y G
Y G
r
B B
Sb B/Y W/B
L/Y Br Br/B B/R
r
B
Br L/Y W/B B/R B Sb Br/B B/Y
Y G
B
G
G
Y
B
Y
B
(GRAY)
_
a
h
L
P
G/R
B
–
B
Y G
B
W/R Gy/G
ELEC
G
Br R/B
Y
L
Y
L/R
L/G
L/B W/R
Gy/G
Gy W
G/Y G/R Br/B
L Y R/Y
B Lg L/B
Y
Sb
U
Lg
o
OFF
Y/W
Y
(BLACK)
Gy
Br/R
f
Y
(BLACK)
B
(BLACK)
Br/Y
B
+
4 Main switch
w
v
6 Main fuse
7 EPS fuse
8 Battery
y
B EPS torque sensor
C EPS motor
D EPS (electric power steering) control unit
E EPS self-diagnosis
signal
x
z
connectors
K ECU (engine control unit)
Q Speed sensor
a EPS warning light
s Ignition fuse
Y/W
P
Br/R
Br/R
Br/R
Br/R
Br/R
EPS (ELECTRIC POWER STEERING) SYSTEM
5
B/L
Gy
W R G B R
EBS00532
B/L Gy
W
EPS (ELECTRIC POWER STEERING) SYSTEM
B
R
B
CIRCUIT DIAGRAM
C
B
G
EPS (ELECTRIC POWER STEERING) SYSTEM
ELEC
–
+
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 malfunction has
occurred in the system. Once a malfunction has been detected, it becomes stored in the EPS control unit memory in the form of a fault code.
• The EPS warning light comes on when the
main switch is turned to “ON”, and then
goes off once the engine is started. If the
warning light remains on or comes on after
1
the engine is started, the EPS system may
be defective.
• The electrical circuit of the warning light can
be checked by turning the main switch to
“ON”. If the warning light does not come on,
the electrical circuit may be defective.
1 EPS warning light
NOTE:
• If the engine is stopped using the engine stop switch and the main switch is in the “ON” position,
the EPS warning light comes on to indicate that the power assistance for the steering is not functioning.
• If the steering usage is too heavy (i.e., excessive steering use when the vehicle is traveling at a
slow speed), the power assist is reduced to protect the EPS motor from overheating.
9 - 59
EPS (ELECTRIC POWER STEERING) SYSTEM
ELEC
–
+
EPS WARNING LIGHT DURING NORMAL OPERATION
The EPS warning light comes on initially for 2 seconds after the main switch is turned to “ON”. However, the warning light remains on until the engine is started.
In addition, if a malfunction is detected while the warning light comes on initially, the warning light
remains on.
Furthermore, the warning light comes on whenever a malfunction has occurred.
NOTE:
The EPS system does not operate while the EPS warning light is on.
a
d
e
g
b
f
i
g
c
f
h
a.
b.
c.
d.
e.
Main switch
EPS warning light (no malfunction detected)
EPS warning light (malfunction detected)
OFF
ON
f.
g.
h.
i.
9 - 60
Off
Comes on.
Initial lighting: 2 seconds
Goes off.
EPS (ELECTRIC POWER STEERING) SYSTEM
ELEC
–
+
DIAGNOSTIC MODE
Setting the diagnostic mode (present and
past malfunctions)
1. Turn the main switch to “ON”.
2. Disconnect the EPS self-diagnosis signal
connector 1.
1
2
NOTE:
Do not disconnect the EPS self-diagnosis signal connector before turning the main switch to
“ON”.
3. Select the signaling mode by grounding the
EPS self-diagnosis signal connector (male
side) to the EPS control unit 2 or disconnecting it from the unit as follows.
a) Present malfunction signaling mode
Ground the EPS self-diagnosis signal
connector within 5 seconds after turning the main switch to “ON”, and leave
it grounded. The signaling mode is activated after 5 seconds.
b) Past malfunction signaling mode
While the present malfunction mode is
activated, briefly disconnect the EPS
self-diagnosis signal connector, ground
it again, and leave it grounded. The signaling mode is activated after 5 seconds.
4. Turn the main switch to “OFF” to cancel the
diagnostic mode.
NOTE:
• The diagnostic mode can also be canceled
by riding the vehicle at speeds above 2 km/h.
• When the diagnostic mode is selected and
during the initial lighting of the EPS warning
light, the EPS control unit does not receive
input from the EPS self-diagnosis signal connector.
9 - 61
EPS (ELECTRIC POWER STEERING) SYSTEM
ELEC
–
+
Identifying fault codes
When the diagnostic mode is activated, the fault codes determined by the fail-safe specifications are
signaled by the EPS warning light as follows.
• Present malfunction signaling mode: Currently detected fault codes are signaled.
• Past malfunction signaling mode: Both previously detected fault codes and currently detected
fault codes are signaled.
Signaling method
Example 1: Fault code No. 23
a
d
g
g
k
j
h
b
5
i
d
∗2
e ∗1
c f
5
i
2
1
0.5 × 3
3
2
0.5 × 5
g. Grounded
a. EPS self-diagnosis signal connector
h. Normal mode (diagnostic mode not activated)
b. Diagnostic mode
i. Mode selection judgment
c. EPS warning light
j. Present malfunction signaling mode
d. Disconnected
k. Past malfunction signaling mode
e. On
f. Off
*1 The EPS warning light comes on for 5 seconds during the diagnostic mode selection judgment.
*2 Display of the present malfunctions stops when the past malfunction display mode is selected.
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 later.
When a fault code is signaled, the EPS warning light goes off for 1 second between the units of 10
and the units of 1 for the code. After a fault code is signaled, the warning light goes off for 3 seconds, and then the next code is signaled.
Example 2: No malfunctions are detected
a
c
d
f
∗1
b e
5
g
1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5
a. EPS self-diagnosis signal connector
e. Goes off.
b. EPS warning light
f. Grounded
g. Mode selection judgment
c. Disconnected
d. Comes on.
*1 The EPS warning light comes on for 5 seconds during the diagnostic mode selection judgment.
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 intervals.
9 - 62
EPS (ELECTRIC POWER STEERING) SYSTEM
ELEC
–
+
Deleting fault codes
To delete fault codes, ground the EPS self-diagnosis signal connector 3 or more times within 5 seconds while the present or past malfunction mode is activated. The currently selected mode remains
active after the fault codes of that mode are deleted.
b
a
c
T1
T1
T1
T1
T1
T2
a. EPS self-diagnosis signal connector
c. Grounded
b. Disconnected
T1: Connector grounded - - - - 0.1 ≤ T1 ≤ 1.6 seconds
T2: Fault codes deleted - - - - - Maximum 1.5 seconds required
9 - 63
EPS (ELECTRIC POWER STEERING) SYSTEM
ELEC
–
SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)
Fault
code No.
Item
Symptom
Probable cause of malfunction
11
13
15
16
EPS torque sensor
No normal signals are received from the
torque sensor.
• Open or short circuit in wire harness.
• Malfunction in torque sensor.
• Malfunction in EPS control unit.
21
Speed sensor
No normal signals are received from the
speed sensor.
• Open or short circuit in wire harness.
• Malfunction in speed sensor.
• Malfunction in EPS control unit.
22
Engine speed signal
No normal signals are received from the
ECU.
• Open or short circuit in wire harness.
• Malfunction in ECU.
• Malfunction in EPS control unit.
41
42
43
45
EPS motor
No normal signals are received from the
EPS motor.
• Open or short circuit in wire harness.
• Malfunction in EPS motor.
• Malfunction in EPS control unit.
52
EPS control unit
Relay contacts in the EPS control unit are
welded together.
Malfunction in EPS control unit.
53
EPS control unit
Battery voltage has dropped.
• Faulty battery.
• Malfunction in the charging system.
Refer to “CHARGING SYSTEM”.
• Malfunction in EPS control unit.
54
EPS control unit
Relay contacts in the EPS control unit are
welded together.
Malfunction in EPS control unit.
55
EPS control unit
Battery voltage has increased.
Abnormality exists between the EPS and
the ECU.
• Malfunction in the charging system.
Refer to “CHARGING SYSTEM”.
• Malfunction in EPS control unit.
9 - 64
+
EPS (ELECTRIC POWER STEERING) SYSTEM
ELEC
–
+
TROUBLESHOOTING DETAILS (EPS SYSTEM)
NOTE:
The malfunction history is stored even if the main switch is turned to “OFF”, therefore, be sure to
erase the history (present and past malfunction signaling modes) after repairing the cause of the
EPS system malfunction. The malfunction history must be erased in the diagnostic mode. Refer to
“DIAGNOSTIC MODE” and “Deleting fault codes”.
Fault code
No.
11, 13, Symptom EPS torque sensor: open or short circuit detected.
15, 16
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Connections
• EPS torque sensor coupler
• Check the coupler for any pins
that may have pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
Turning the
main switch to
“OFF”.
2
Defective EPS torque sensor.
• Replace if defective.
Refer to “CHECKING THE EPS
TORQUE SENSOR”.
3
Open or short circuit in EPS torque • Repair or replace if there is an
sensor lead.
open or short circuit.
• Between EPS torque sensor
coupler and EPS control unit
coupler.
(white–white)
(red–red)
(green–green)
(black–black)
9 - 65
EPS (ELECTRIC POWER STEERING) SYSTEM
Fault code No.
21
ELEC
Check or maintenance job
1
Connections
• Speed sensor coupler
• EPS control unit coupler at the
wire harness
• Check the coupler for any pins
that may have pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
2
Open or short circuit in wire harness.
•
•
Defective speed sensor.
•
•
Fault code No.
22
+
Symptom Speed sensor: open or short circuit detected.
Order Item/components and probable
cause
3
–
Reinstatement
method
Starting the
engine and activating the vehicle speed
sensor by operating the vehicle
above 5 km/h, or
turning the main
Repair or replace if there is an
switch to “OFF”,
open or short circuit.
then to “ON”,
Between speed sensor coupler
and then deletand EPS control unit coupler.
ing the fault
(white–white)
codes. Refer to
Execute the diagnostic mode.
“DIAGNOSTIC
(Code No.21)
MODE” and
Replace if defective.
“Deleting fault
Refer to “SIGNALING SYSTEM”. codes”.
Symptom No normal signals are received from the ECU.
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Connections
• EPS control unit coupler at the
wire harness
• ECU coupler at the wire harness
• Check the coupler for any pins
that may have pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
Turning the
main switch to
“OFF”.
2
Open or short circuit in wire harness.
• Repair or replace if there is an
open or short circuit.
• Between ECU coupler and EPS
control unit coupler.
(orange/white–orange/white)
3
Malfunction in ECU.
Replace the ECU.
9 - 66
EPS (ELECTRIC POWER STEERING) SYSTEM
Fault code
No.
ELEC
–
+
41, 42, Symptom EPS motor: open or short circuit detected.
43, 45
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Connections
• EPS motor coupler
• Check the coupler for any pins
that may have pulled out.
• Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler
securely.
Turning the
main switch to
“OFF”.
2
Open or short circuit in EPS motor
lead.
• Repair or replace if there is an
open or short circuit.
• Between EPS motor and EPS
control unit coupler.
(red–red)
(black–black)
3
Defective EPS motor.
Replace if defective.
Refer to “CHECKING THE EPS
MOTOR”.
Fault code No.
52
Symptom Relay contacts in the EPS control unit are welded
together.
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Replace the EPS control unit.
Turning the
main switch to
“OFF”.
Malfunction in EPS control unit.
Fault code No.
53
Symptom Power supply to the EPS control unit is not normal (low
battery voltage).
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Faulty battery.
Replace or charge the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” in
chapter 3.
Turning the
main switch to
“OFF”.
2
Malfunction in rectifier/regulator or
charging system.
Replace if defective.
Refer to “CHARGING SYSTEM”.
3
Malfunction in EPS control unit.
Replace the EPS control unit.
9 - 67
EPS (ELECTRIC POWER STEERING) SYSTEM
Fault code No.
54
ELEC
–
+
Symptom Relay contacts in the EPS control unit are welded
together.
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Replace the EPS control unit.
Turning the
main switch to
“OFF”.
Malfunction in EPS control unit.
Fault code No.
55
Symptom Power supply to the EPS control unit is not normal (High
battery voltage).
Malfunction in control unit.
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Faulty battery.
Replace the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” in
chapter 3.
Turning the
main switch to
“OFF”.
2
Malfunction in rectifier/regulator.
Replace if defective.
Refer to “CHARGING SYSTEM”.
3
Malfunction in EPS control unit.
Replace the EPS control unit.
9 - 68
EPS (ELECTRIC POWER STEERING) SYSTEM
ELEC
–
+
CHECKING THE EPS MOTOR
1. Remove:
• EPS unit
2. Check:
• EPS motor
Out of specification → Replace.
NOTE:
The pocket tester and the analog pocket tester
readings are shown in the following table.
2
Continuity
Positive tester probe → red 1
Negative tester probe → black 2
No continuity
Positive tester probe → red 1
Negative tester probe → EPS
motor body 3
No continuity
Positive tester probe → black 2
Negative tester probe → EPS
motor body 3
1
B
R
3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1) to the
EPS motor coupler terminal and EPS motor
body.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
b. Check the EPS motor for continuity.
c. Check the EPS motor for no continuity.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE EPS TORQUE SENSOR
1. Remove:
• EPS unit
2. Check:
• EPS torque sensor resistance
Out of specification → Replace.
EPS torque sensor resistance
1.00 ~ 1.50 kΩ
9 - 69
EPS (ELECTRIC POWER STEERING) SYSTEM
ELEC
–
+
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
2
G
R
B
W
a. Connect the pocket tester (Ω × 1k) to the
EPS torque sensor coupler terminal as
shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe → red 1
Negative tester probe → black 2
b. Measure the EPS torque sensor resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9 - 70
STARTING FAILURE/HARD STARTING
TRBL
SHTG
EBS00537
TROUBLESHOOTING
NOTE:
The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,
however, as a guide to troubleshooting. Refer to the relative procedure in this manual for check,
adjustment and replacement of parts.
_
STARTING FAILURE/HARD STARTING
FUEL SYSTEM
Fuel tank
• Empty
• Clogged fuel tank drain hose
• Deteriorated or contaminated fuel
Fuel pump
• Faulty fuel pump
• Faulty fuel injection system relay
ELECTRICAL SYSTEM
Spark plug
• Improper plug gap
• Worn electrodes
• Wire between terminals broken
• Improper heat range
• Faulty spark plug cap
Ignition coil
• Broken or shorted primary/secondary
• Faulty spark plug lead
• Broken body
Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
• Broken AC magneto rotor woodruff key
Throttle body
• Deteriorated or contaminated fuel
• Sucked-in air
Air filter
• Clogged air filter element
Switches and wiring
• Faulty main switch
• Faulty engine stop switch
• Broken or shorted wiring
• Faulty gear position switch
• Faulty start switch
• Faulty brake light switch
Starting system
• Faulty starter motor
• Faulty starter relay
• Faulty starter circuit cut-off relay
• Faulty starter clutch
Battery
• Faulty battery
Fuse(s)
• Blown, damaged or incorrect fuse
• Improperly installed fuse
10
10 - 1
STARTING FAILURE/HARD STARTING/POOR IDLE SPEED
PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE
COMPRESSION SYSTEM
Cylinder and cylinder head
• Loose spark plug
• Loose cylinder head or cylinder
• Broken cylinder head gasket
• Broken cylinder gasket
• Worn, damaged or seized cylinder
Valve, camshaft and crankshaft
• Improperly sealed valve
• Improperly contacted valve and valve seat
• Improper valve timing
• Broken valve spring
• Seized camshaft
• Seized crankshaft
TRBL
SHTG
Piston and piston rings
• Improperly installed piston ring
• Worn, fatigued or broken piston ring
• Seized piston ring
• Seized or damaged piston
Crankcase and crankshaft
• Improperly seated crankcase
• Seized crankshaft
Valve train
• Improperly adjusted valve clearance
• Improperly adjusted valve timing
EBS00538
POOR IDLE SPEED PERFORMANCE
POOR IDLE SPEED PERFORMANCE
Throttle body
• Damaged or loose throttle body joint
• Improperly adjusted idle speed (throttle stop
screw)
• Improper throttle cable play
• Flooded throttle body
Electrical system
• Faulty spark plug
• Faulty ECU
• Faulty crankshaft position sensor
• Faulty ignition coil
Valve train
• Improperly adjusted valve clearance
Air filter
• Clogged air filter element
EBS00539
POOR MEDIUM AND HIGH-SPEED PERFORMANCE
POOR MEDIUM AND HIGH-SPEED PERFORMANCE
Refer to “STARTING FAILURE/HARD STARTING” and “POOR IDLE SPEED PERFORMANCE”.
Fuel pump
Air filter
• Faulty fuel pump
• Clogged air filter element
10 - 2
FAULTY DRIVE TRAIN
TRBL
SHTG
EBS00540
FAULTY DRIVE TRAIN
The following conditions may indicate damaged shaft drive components:
Symptoms
Possible Causes
1. A pronounced hesitation or “jerky” movement during acceleration, deceleration, or
sustained speed. (This must not be confused with engine surging or transmission
characteristics.)
2. A “rolling rumble” noticeable at low speed; a
high-pitched whine; a “clunk” from a shaft
drive component or area.
3. A locked-up condition of the shaft drive
mechanism, no power transmitted from the
engine to the front and/or rear wheels.
A. Bearing damage.
B. Improper gear lash.
C. Gear tooth damage.
D. Broken drive shaft.
E. Broken gear teeth.
F. Seizure due to lack of lubrication.
G. Small foreign objects lodged between the
moving parts.
NOTE:
Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite subtle and
difficult to distinguish from normal vehicle operating noise. If there is reason to believe these components are damaged, remove the components and check them.
_
10 - 3
FAULTY GEAR SHIFTING/
FAULTY CLUTCH PERFORMANCE
TRBL
SHTG
EBS00542
FAULTY GEAR SHIFTING
HARD SHIFTING
Refer to “FAULTY CLUTCH PERFORMANCE”.
SHIFT LEVER DOES NOT MOVE
Shift drum, shift forks
• Groove jammed with impurities
• Seized shift fork
• Bent shift fork guide bar
Transmission
• Seized transmission gear
• Jammed impurities
• Incorrectly assembled transmission
Shift guide
• Broken shift guide
JUMPS OUT OF GEAR
Shift forks
• Worn shift fork
Shift drum
• Improper thrust play
• Worn shift drum groove
Transmission
• Worn gear dog
EBS00543
FAULTY CLUTCH PERFORMANCE
ENGINE OPERATES BUT VEHICLE WILL NOT MOVE
Transmission
V-belt
• Damaged transmission gears
• Bent, damaged or worn V-belt
• V-belt slips
Primary pulley cam and primary pulley
slider
• Damaged or worn primary pulley cam
• Damaged or worn primary pulley slider
CLUTCH SLIPPING
Clutch spring
• Damaged, loose or worn clutch shoe spring
Clutch shoe
• Damaged or worn clutch shoe
POOR STARTING PERFORMANCE
V-belt
• V-belt slips
• Oil or grease on the V-belt
Primary sliding sheave
• Faulty operation
• Worn pin groove
• Worn pin
Primary sliding sheave
• Seized primary sliding sheave
Clutch shoe
• Bent, damaged or worn clutch shoe
10 - 4
FAULTY CLUTCH PERFORMANCE/
OVERHEATING/OVERCOOLING/FAULTY BRAKE
POOR SPEED PERFORMANCE
V-belt
• Oil or grease on the V-belt
Primary pulley weight
• Faulty operation
• Worn primary pulley weight
Primary fixed sheave
• Worn primary fixed sheave
TRBL
SHTG
Primary sliding sheave
• Worn primary sliding sheave
Secondary fixed sheave
• Worn secondary fixed sheave
Secondary sliding sheave
• Worn secondary sliding sheave
EBS00546
OVERHEATING
OVERHEATING
Ignition system
• Improper spark plug gap
• Improper spark plug heat range
• Faulty ECU
Fuel system
• Faulty throttle body
• Damaged or loose throttle body joint
• Clogged air filter element
Compression system
• Heavy carbon build-up
Engine oil
• Improper oil level
• Improper oil viscosity
• Inferior oil quality
Brake
• Brake drag
Cooling system
• Low coolant level
• Clogged or damaged radiator
• Damaged or faulty water pump
• Faulty fan motor
• Faulty coolant temperature sensor
EBS00548
OVERCOOLING
COOLING SYSTEM
Thermostat
• Thermostat stays open
EBS00550
FAULTY BRAKE
POOR BRAKING EFFECT
Disc brake
• Worn brake pads
• Worn disc
• Air in brake fluid
• Leaking brake fluid
• Faulty master cylinder kit cup
• Faulty caliper kit seal
• Loose union bolt
• Broken brake hose and pipe
• Oily or greasy disc/brake pads
• Improper brake fluid level
10 - 5
SHOCK ABSORBER MALFUNCTION/
UNSTABLE HANDLING/LIGHTING SYSTEM
TRBL
SHTG
EBS00551
SHOCK ABSORBER MALFUNCTION
MALFUNCTION
• Bent or damaged damper rod
• Damaged oil seal lip
• Fatigued shock absorber spring
EBS00552
UNSTABLE HANDLING
UNSTABLE HANDLING
Handlebar
• Improperly installed or bent
Steering
• Incorrect toe-in
• Bent steering stem
• Improperly installed steering stem
• Damaged bearing or bearing race
• Bent tie-rods
• Deformed steering knuckles
Tires
• Uneven tire pressures on both sides
• Incorrect tire pressure
• Uneven tire wear
Wheels
• Deformed wheel
• Loose bearing
• Bent or loose wheel axle
• Excessive wheel runout
Frame
• Bent
• Damaged frame
EBS00553
LIGHTING SYSTEM
HEADLIGHT DOES NOT COME ON
• Improper bulb
• Too many electric accessories
• Hard charging (broken stator coil and/or
faulty rectifier/regulator)
• Incorrect connection
• Improperly grounded
• Poor contacts (main or light switch)
• Bulb life expired
BULB BURNT OUT
• Improper bulb
• Faulty battery
• Faulty rectifier/regulator
• Improperly grounded
• Faulty main and/or light switch
• Bulb life expired
10 - 6
TRBL
SHTG
10 - 7
YFM7FGPW 2007 WIRING DIAGRAM
1 Crankshaft position sensor
2 AC magneto
3 Rectifier/regulator
4 Main switch
5 Frame ground
6 Main fuse
7 EPS fuse
8 Battery
9 Fuel injection system fuse
0 Starter relay
A Starter motor
B EPS torque sensor
C EPS motor
D EPS (electric power steering)
control unit
E EPS self-diagnosis signal connectors
F Diode 1
G Starting circuit cut-off relay
H Fuel injection system relay
I Diode 2
J Reverse switch
K ECU (engine control unit)
L Ignition coil
M Spark plug
N Fuel injector
O Intake air temperature sensor
P Coolant temperature sensor
Q Speed sensor
R TPS (throttle position sensor)
S Intake air pressure sensor
T Lean angle sensor
U Gear position switch
V Meter assembly
W Multifunction meter
X Engine trouble warning light
Y Coolant temperature warning
light
Z Park indicator light
[ Reverse indicator light
\ Neutral indicator light
] High-range indicator light
_ Low-range indicator light
a EPS warning light
b Fuel sender
c Fuel pump
d Four-wheel-drive motor relay 1
e Four-wheel-drive motor relay 2
f Four-wheel-drive motor relay 3
g On-command four-wheel-drive
motor switch and differential
gear lock switch
h Differential gear motor
i Four-wheel-drive motor fuse
j Auxiliary DC jack fuse
k Auxiliary DC jack
l Left handlebar switch
m Light switch
n Engine stop switch
o Start switch
p Override switch
q Headlight relay
r Headlight
s Ignition fuse
t Signaling system fuse
u Headlight fuse
v Rear brake light switch
w Front brake light switch
x Tail/brake light
y Diode 3
z Rear brake relay
{ Radiator fan motor
| Radiator fan motor relay
} Radiator fan motor circuit
breaker
~ Radiator fan motor fuse
COLOR CODE
B............ Black
Br .......... Brown
G ........... Green
Gy ......... Gray
L ............ Blue
Lg .......... Light green
O ........... Orange
P............ Pink
R ........... Red
Sb.......... Sky blue
W........... White
Y............ Yellow
B/L......... Black/Blue
B/R ........ Black/Red
B/W ....... Black/White
B/Y ........ Black/Yellow
Br/B ....... Brown/Black
Br/L ....... Brown/Blue
Br/R ....... Brown/Red
Br/W ...... Brown/White
Br/Y ....... Brown/Yellow
G/R........ Green/Red
G/W ....... Green/White
G/Y ........ Green/Yellow
Gy/G...... Gray/Green
L/B......... Blue/Black
L/G ........ Blue/Green
L/R ........ Blue/Red
L/W........ Blue/White
L/Y......... Blue/Yellow
O/G ....... Orange/Green
O/W ....... Orange/White
R/B ........ Red/Black
R/L ........ Red/Blue
R/W ....... Red/White
R/Y ........ Red/Yellow
W/B ....... White/Black
W/L........ White/Blue
W/R ....... White/Red
Y/B ........ Yellow/Black
Y/G ........ Yellow/Green
Y/L......... Yellow/Blue
Y/R ........ Yellow/Red
Y/W ....... Yellow/White
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
PRINTED IN U.S.A.
YFM7FGPW 2007 WIRING DIAGRAM
C
B
B
B/L Gy
W
B
B
W R G B R
B
B
R
R
B
Y
W Sb Gy Br Y/B Y/L Y/W B/L R/B O
R/B
B
Gy
O/W
G/W
G
B
B
W
G/R
O/W
L/B
L
(BLACK)
3
P Y/G G/Y Br/W L
L/W W/B B/R Gy/G W/R G/W Lg G/R R/L L/R Y/R O/W Y/W B/W L/B B
R
(BLACK)
W
W
W
W
W
W
2
W R G B R
G
W
R/B
1
G/Y B
R
B
R
5
B/L
Gy
G
R
R/B
B
Br
R/B
R
D
W W W
R
(GRAY)
R
6
7
E
L/B
L
L/B Br O
O/W Br L/B
R
G W G/R
G/R W
R/B
(BLACK)
R
(BLACK)
J
R
R
(GRAY)
R/B
Br
L/W
Br/B
R
Br/B
4
ON
8
R Br/L
OFF
(GRAY)
B
Br/L R
(BLACK)
R/B
R/L
R/B R/B
L/W
R/B R/B
Br/B
B/Y
Br
L/B
B/Y
Br/W
O
B/L
Br/W
L/R
G/Y B/L
B/Y
Y/W
Y/W
I
R/L
R/L
Sb L/B
H
A
B
B B
L/B
G
F
B
B
B
L/W
L/W
B
B
Br/B
Br
Br
0
Br/L
L/W
(BLACK)
B
}
L/W Br
9
L/W
N
Br/W B/L
(BLACK)
R
M
R/L R/B
R/B
~
R/W
R/W
L
O
G/W
L
B
R
O
(GREEN)
G/Y
Sb B/Y
L/R
K
P
L/B
B
B/L
Y
L
Y
Lg
Y/R
Y/B
G/R
W/B
B/R
Gy/G
W/R
Y/L
R/B Br
R/L
|
L
Y/R
Br/L
Br/L
c
L Y/R
j
s
L
L
L
B
R/L B B/W G/Y
(GRAY)
i
P
L/B
Y/G
B/L
Y
L
S
B/L
P
L
Y/G
B/L
B/W
T
B/Y
B/W
Br/R
Br/Y
Q
(BLACK)
L
Br/R
P
B/L
(BLACK)
L
P
Br/L
R
L
P
B/L
Br
t
{
b
B
Br/L
B
G/Y
W L/Y
L
W
B/L
Sb
L/R
R/L
R/B
Br
L W
B/L
B/L
G/Y
L
W
B/L
Y/G B/L
(GRAY)
B
Br/R B L/R
u
B
Br/B
k
Br/L
R/Y
e
Br
B
Br/Y
P
B
(BLACK)
Gy
Br/R
l
w
v
R/Y
Br
m
Y
R/B
L/B
n
L/B Sb
V
L/R B
L/G B
p
Br/R
Y/B
Br
Gy
W
OFF
PUSH
L
R/B R/W
L/B Lg B
(GRAY)
R/Y Y
B
L/R
L/G
B Lg L/B
Br R/B
L/G L/R
L/R L/G
(GRAY)
L/Y Sb
Sb L/B
(BLACK)
Y
L
Y
G
(BLACK)
Y
L/R G/R
q
Y
Gy
L
B
G/R
L/R
X
G/Y G/R Br/B
L Y R/Y
B
(GRAY)
g
Y
2WD
4WD
LOCK
(BLACK)
G/R Gy
B
Y/L Br B/W
Z
Br
[
(LIGHT GRAY)
Y L
L/Y
(BLACK)
B
Y/WB/Y
Y/W B/Y
B
z
B
Sb Gy
B
G
x
\
]
Y G
Y G
r
B B
Sb B/Y W/B
L/Y Br Br/B B/R
r
B
Br L/Y W/B B/R B Sb Br/B B/Y
Y G
B
G
G
Y
B
Y
B
B
Y G
B
(GRAY)
_
a
h
G/R
B
B
L/B W/R
Gy/G
W/R Gy/G
L
P
Gy W
Y/L
B/W
G/Y
Br
Br/B
Y/W
Y
y
L Y
Sb
U
Lg
o
OFF
Y
B/Y
Y/B
Br/Y
Y/W
(BLACK)
(BLACK)
d
Br/B
f
Y/W
Br/R
Br/R
Br/R
Br/R
Br/R
Br/R B L/G
G W/B
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