2014-2015 Yamaha Viking Service Manual

2014-2015 Yamaha Viking Service Manual
2014
SERVICE MANUAL
YX70ME
YX70MHE
YX70MNE
YX70MPE
YX70MPHE
YX70MPNE
YXM700PE
YXM700PHE
YXM700DE
1XD-F8197-E0
EAS20071
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is 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 of 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.
TIP
Designs and specifications are subject to change without notice.
EAS20081
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to
avoid possible injury or death.
WARNING
NOTICE
TIP
A WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
EAS20090
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step.
• Numbers “5” enclosed in parentheses indicate the quantities of parts.
• Symbols “6” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “7” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
• Jobs “8” requiring more information (such as special tools and technical data) are described sequentially.
1
CLUTCH
CLUTCH
EAS25061
EAS25070
CLUTCH
REMOVING T HE CLUTCH
1. Remove:
• Clutch housing assembly
Removing the clutch
• One-way clutch bearing
Chafing/wear/damage → Replace.
TIP
• Replace the one-way clutch bearing and clutch
housing as a set.
• The one-way clutch bearing must be installed
with the flange side facing inward.
TIP
Working in crisscross pattern, loosen each bolt
1/4 of a turn. Remove them after all of them are
loosened.
3
2. Check:
• One-way clutch operation
T.R.
190 Nm (19 m•kgf, 137 ft •lbf)
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
“A”, it should turn freely; otherwise, the oneway clutch assembly is faulty and must be replaced.
c. When turning the clutch housing counterclockwise “B”, the clutch housing and crankshaft should engage; otherwise, the one-way
clutch assembly is faulty and must be replaced.
5
T.R.
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)
2
4
4
New
1
2. Straighten:
• Punched portion “a” of the clutch carrier assembly nut “1”
3. Remove:
• Clutch carrier assembly nut “1”
3
3
(7)
M
E
ECA1XD1019
7
NOTICE
The clutch carrier assembly nut has lefthand threads. To loosen the clut ch carrier
assembly nut, turn it clockwise .
E
TIP
5
6
Use a clutch holding tool “2” to hold the clutch
carrier assembly.
LS
Order
Job/Parts to remove
Q’ty
1
Clutch housing assembly
1
2
Clutch housing assembly gasket
1
3
Universal clutch holder
90890-04086
YM-91042
Remarks
Refer to “PRIMARY AND SECONDARY
SHEAVES” on page 5-50.
Drive belt case
Dowel pin
2
4
Clutch carrier assembly nut
1
5
Clutch carrier assembly
1
EAS28990
CHECKING THE CLUTCH SHOE
1. Check:
• Clutch shoe
Damage/wear → Replace.
Glazed areas → Sand with coarse sandpaper.
2
a
Left-hand threads
TIP
After sanding the glazed areas, clean the clutch
with a cloth.
For installation, reverse the removal procedure.
2. Measure:
• Clutch shoe thickness
Out of specification → Replace.
1
EAS1XD1102
CHECKING THE CLUTCH
1. Check:
• Clutch housing
Damage/wear → Replace.
5-60
Clutch shoe thickness
1.5 mm (0.06 in)
Limit
1.0 mm (0.04 in)
5-62
2
EAS20100
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL
DEFINITION
SYMBOL
Serviceable with engine mounted
DEFINITION
Gear oil
G
Filling fluid
Molybdenum disulfide oil
M
Lubricant
Brake fluid
BF
B
Wheel bearing grease
Tightening torque
LS
Lithium-soap-based grease
Wear limit, clearance
M
Molybdenum disulfide grease
Engine speed
S
Silicone grease
T.
Special tool
R.
Electrical data
Engine oil
E
LT
New
Apply locking agent (LOCTITE®).
Replace the part with a new one.
EAS20110
TABLE OF CONTENTS
GENERAL INFORMATION
1
SPECIFICATIONS
2
PERIODIC CHECKS AND
ADJUSTMENTS
3
CHASSIS
4
ENGINE
5
COOLING SYSTEM
6
FUEL SYSTEM
7
DRIVE TRAIN
8
ELECTRICAL SYSTEM
9
TROUBLESHOOTING
10
GENERAL INFORMATION
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
(for EPS models) ......................................................................................1-5
INSTRUMENT FUNCTIONS ..................................................................... 1-7
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 ..................................... 1-9
BEARINGS AND OIL SEALS .................................................................. 1-10
CIRCLIPS ................................................................................................1-10
RUBBER PARTS.....................................................................................1-10
BASIC SERVICE INFORMATION.................................................................1-11
QUICK FASTENERS............................................................................... 1-11
ELECTRICAL SYSTEM...........................................................................1-12
SPECIAL TOOLS .......................................................................................... 1-16
1
IDENTIFICATION
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the frame.
1
EAS20150
MODEL LABEL
The model label “1” is affixed to the frame under
the driver seat. This information will be needed
to order spare parts.
1
1-1
FEATURES
EAS20170
FEATURES
EAS30340
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 by 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 airfuel 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
5
16
1.
2.
3.
4.
5.
6.
7.
8.
9.
15
14
6
13
7,8,9,10
11,12
10. Throttle position sensor
11. Spark plug
12. Coolant temperature sensor
13. Speed sensor
14. Crankshaft position sensor
15. Intake air temperature sensor
16. Fuel pump
Lean angle sensor
ECU (engine control unit)
Fuel injection system relay
Engine trouble warning light
Ignition coil
Air cut-off valve
ISC (idle speed control) unit
Intake air pressure sensor
Fuel injector
1-2
FEATURES
EAS1XD1054
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 a certain level. 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
C
1
4
6
2
7
A
3
13
15
8
B
14
12
11
10
9
13. Throttle position sensor
14. Intake air temperature sensor
15. Air filter case
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. Catalytic converter
9. Crankshaft position sensor
10. Intake air pressure sensor
11. Throttle body
12. ISC (idle speed control) unit
A. Fuel system
B. Air system
C. Control system
1-3
FEATURES
1-4
FEATURES
EAS1XD1055
OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
2
1
d
3
4
e
c
5
f
a
6
7
5
1-5
b
FEATURES
1.
2.
3.
4.
5.
6.
7.
a.
b.
c.
d.
e.
f.
Speed information from speed sensor
Engine RPM information from ECU
Battery
EPS control unit
EPS unit
EPS motor
Torque sensor
Operates steering
Twists torsion bar
Sends the torque sensor signal
EPS control unit calculates assist power
Electricity output switched by EPS control unit
Activates EPS motor
ECA1XD1027
NOTICE
To prevent accidental damage to the EPS unit, it must not be disassembled.
1-6
FEATURES
Pushing the “SELECT” button switches the display between the odometer mode “ODO” and
the tripmeter modes “TRIP A” and “TRIP 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
enables you to plan future fuel stops.
EAS1XD1056
INSTRUMENT FUNCTIONS
Multi-function meter unit
4
5
3
2
1
TIP
7
1.
2.
3.
4.
5.
6.
7.
To switch the display between “mph” and “km/h”,
turn the key to “ ” (off), then push and hold the
“SELECT” button while turning the key to “ ”
(on).
6
“CLOCK” button
“RESET” button
“SELECT” button
Speedometer
Fuel meter
Clock/Hour meter/Voltage display
Odometer/Tripmeter A/Tripmeter B
Clock, hour meter and voltage display
modes
The multi-function meter unit is equipped with
the following:
• a speedometer
• an odometer
• 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
engine has been running)
• a voltage display (which shows the battery voltage)
• a fuel meter
• a self-diagnosis device
1
2
3
4
1.
2.
3.
4.
“SELECT” button
“RESET” button
“CLOCK” button
Clock/Hour meter/Voltage display
Pushing the “CLOCK” button switches the display between the clock mode “CLOCK”, the hour
meter mode “HOUR”, and the voltage display
mode “
” 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.
Odometer and tripmeter modes
1
2
3
1. “SELECT” button
2. “RESET” button
3. Odometer/Tripmeter A/Tripmeter B
1-7
FEATURES
Voltage display mode
TIP
This fuel meter is equipped with a self-diagnosis
system. If a problem is detected in an electrical
circuit, all the display segments and fuel level
warning indicator start flashing. If this occurs,
check the electrical circuit.
Refer to “SIGNALING SYSTEM” on page 9-19.
Self-diagnosis device
1
2
This display shows the battery voltage.
“
” appears for 1 second when the voltage
display mode is first selected, and then “ ” appears and the battery voltage is displayed.
If the battery voltage is less than 10 volts, “LO” is
displayed, and if the voltage is above 16 volts,
“HI” is displayed.
ECA1XD1054
NOTICE
If the voltage display indicates “LO” or “HI”,
there may be trouble with the battery charging circuit or the battery may be faulty. If this
occurs, check or repair the vehicle.
Refer to “CHARGING SYSTEM” on page
9-11.
1. Fault code display
2. Engine trouble warning light “
”
This model is equipped with a self-diagnosis device for various electrical circuits.
If a problem is detected in any of those circuits,
the engine trouble warning light comes on or
flashes, and the multi-function display indicates
a fault code.
If the multi-function display indicates a fault
code, note the code number, and then check the
fuel injection system.
Refer to “FUEL INJECTION SYSTEM” on page
9-33.
Fuel meter
1
2
ECA1XD1055
NOTICE
3
If the multi-function display indicates a fault
code, the vehicle should be checked as soon
as possible in order to avoid engine damage.
1. Fuel level warning indicator
2. Fuel meter
3. “E” segment
The fuel meter indicates the amount of fuel in the
fuel tank. The display segments of the fuel meter
disappear from “F” (full) towards “E” (empty) as
the fuel level decreases. When the “E” segment
disappears and the fuel level warning indicator
flashes, refuel as soon as possible.
1-8
IMPORTANT INFORMATION
EAS20180
IMPORTANT INFORMATION
EAS20190
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
EAS20210
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.
2. Use only the proper tools and cleaning equipment.
Refer to “SPECIAL TOOLS” on page 1-16.
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.
1.
2.
3.
4.
Oil
Lip
Spring
Grease
EAS20220
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.
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.
EAS20200
REPLACEMENT PARTS
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.
1-9
IMPORTANT INFORMATION
EAS20230
EAS1XD1131
BEARINGS AND OIL SEALS
Install bearings “1” and oil seals “2” so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
RUBBER PARTS
Check rubber parts for deterioration during inspection. Some of the rubber parts are sensitive
to gasoline, flammable oil, grease, etc. Do not allow any items other than the specified one to
contact the parts.
ECA13300
NOTICE
Do not spin the bearing with compressed air
because this will damage the bearing surfaces.
EAS20240
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.
1-10
BASIC SERVICE INFORMATION
EAS30380
BASIC SERVICE INFORMATION
EAS30390
QUICK FASTENERS
Rivet type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, push its pin with a
screwdriver, then pull the fastener out.
Screw type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, loosen the screw
with a screwdriver, then pull the fastener out.
2. Install:
• Quick fastener
TIP
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the part to be secured and push
the pin in with a screwdriver. Make sure that the
pin is flush with the fastener’s head.
2. Install:
• Quick fastener
TIP
To install the quick fastener, insert the fastener
into the part to be secured and tighten the screw.
1-11
BASIC SERVICE INFORMATION
ECA16760
EAS30402
NOTICE
ELECTRICAL SYSTEM
Be sure to connect the battery leads to the
correct battery terminals. Reversing the battery lead connections could damage the
electrical components.
Electrical parts handling
ECA16600
NOTICE
Never disconnect a battery lead while the engine is running; otherwise, the electrical
components could be damaged.
ECA16771
NOTICE
When connecting the battery leads to the
battery, be sure to connect the positive battery lead first, then the negative battery lead.
If the negative battery lead is connected first
and a tool or similar item contacts the vehicle while the positive battery lead is being
connected, a spark could be generated,
which is extremely dangerous.
ECA16751
NOTICE
When disconnecting the battery leads from
the battery, be sure to disconnect the negative battery lead first, then the positive battery lead. If the positive battery lead is
disconnected first and a tool or similar item
contacts the vehicle, a spark could be generated, which is extremely dangerous.
ECA16610
NOTICE
Turn the main switch to “OFF” before disconnecting or connecting an electrical component.
TIP
If a battery lead is difficult to disconnect due to
rust on the battery terminal, remove the rust using hot water.
1-12
BASIC SERVICE INFORMATION
ECA16620
NOTICE
Checking the electrical system
Handle electrical components with special
care, and do not subject them to strong
shocks.
TIP
Before checking the electrical system, make
sure that the battery voltage is at least 12 V.
ECA14371
ECA16630
NOTICE
NOTICE
Electrical components are very sensitive to
and can be damaged by static electricity.
Therefore, never touch the terminals and be
sure to keep the contacts clean.
Never insert the tester probes into the coupler terminal slots. Always insert the probes
from the opposite end “a” of the coupler, taking care not to loosen or damage the leads.
a
ECA16640
TIP
NOTICE
When resetting the ECU by turning the main
switch to “OFF”, be sure to wait approximately 5
seconds before turning the main switch back to
“ON”.
For waterproof couplers, never insert the
tester probes directly into the coupler. When
performing any checks using a waterproof
coupler, use the specified test harness or a
suitable commercially available test harness.
1-13
BASIC SERVICE INFORMATION
2. Check:
• Lead
• Coupler
• Connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect several times.
Checking the connections
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• Lead
• Coupler
• Connector
ECA16780
NOTICE
• When disconnecting a coupler, release the
coupler lock, hold both sections of the coupler securely, and then disconnect the coupler.
• There are many types of coupler locks;
therefore, be sure to check the type of coupler lock before disconnecting the coupler.
3. Connect:
• Lead
• Coupler
• Connector
TIP
• When connecting a coupler or connector, push
both sections of the coupler or connector together until they are connected securely.
• Make sure all connections are tight.
ECA16790
NOTICE
When disconnecting a connector, do not pull
the leads. Hold both sections of the connector securely, and then disconnect the connector.
1-14
BASIC SERVICE INFORMATION
TIP
The resistance values shown were obtained at
the standard measuring temperature of 20 °C
(68 °F). If the measuring temperature is not 20
°C (68 °F), the specified measuring conditions
will be shown.
Intake air temperature sensor resistance
5.40–6.60 kΩ at 0 °C (32 °F)
290–390 Ω at 80 °C (176 °F)
4. Check:
• Continuity
(with the pocket tester)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
TIP
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
5. Check:
• Resistance
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
1-15
SPECIAL TOOLS
EAS20260
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
TIP
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, “YS-”, “YK-”, or “ACC-”.
• For others, use part number starting with “90890-”.
Tool name/Tool No.
Reference
pages
Illustration
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
1-15, 9-89,
9-90, 9-91,
9-93, 9-95,
9-98, 9-99,
9-100, 9-101,
9-102, 9-104,
9-105, 9-106,
9-107, 9-108
Thickness gauge
90890-03079
Narrow gauge set
YM-34483
3-4
Tappet adjusting tool
90890-01311
Six piece tappet set
YM-A5970
3-4
YM-A5970
ø8
ø9
ø10
ø3
ø4
Yamaha diagnostic tool
90890-03215
3-6, 9-37
Oil filter wrench
90890-01426
YU-38411
3-13
1-16
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Reference
pages
Boots band installation tool
90890-01526
YM-01526
4-54, 8-9, 8-11,
8-23, 8-25
Ball joint remover
90890-01474
YM-01474
4-58, 4-62
Ball joint remover adapter set
90890-01477
YM-01477
4-58, 4-62
Base plate 35mm
90890-01553
YM-01553
45mm
4-58, 4-62
ø35
110mm
12mm
Ball joint installer attachment 39mm
90890-01555
YS-01881-A
4-58, 4-62
ø39
Compression gauge
90890-03081
Engine compression tester
YU-33223
5-14
Slide hammer bolt
90890-01083
Slide hammer bolt 6 mm
YU-01083-1
5-17, 5-19
Weight
90890-01084
YU-01083-3
5-17
YU-01083-3
1-17
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Reference
pages
Valve spring compressor
90890-04019
YM-04019
5-21, 5-26
Valve spring compressor attachment
90890-01243
Valve spring compressor adapter (26 mm)
YM-01253-1
5-21, 5-26
Valve guide remover (ø6)
90890-04064
Valve guide remover (6.0 mm)
YM-04064-A
5-22
Valve guide installer (ø6)
90890-04065
Valve guide installer (6.0 mm)
YM-04065-A
5-22
Valve guide reamer (ø6)
90890-04066
Valve guide reamer (6.0 mm)
YM-04066
5-22
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
5-28
YU-01304
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
5-34, 5-35,
5-36, 5-53,
5-58
Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B
5-34
1-18
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Reference
pages
Yamaha bond No. 1215
90890-85505
(Three Bond No.1215®)
5-36, 5-69,
8-27
Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927
5-39, 7-13,
9-101, 9-103
Sheave fixed block
90890-04135
Sheave fixed bracket
YM-04135
5-53, 5-57
Locknut wrench
90890-01348
YM-01348
5-53, 5-57
Sheave spring compressor
90890-04134
YM-04134
5-53, 5-57
1-19
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Reference
pages
Universal clutch holder
90890-04086
YM-91042
5-62, 5-63
Crankcase separating tool
90890-01135
Crankcase separator
YU-01135-B
5-73
Crankshaft installer pot
90890-01274
Installing pot
YU-90058
5-75
YU-90058/YU-90059
Crankshaft installer bolt
90890-01275
Bolt
YU-90060
5-75
Adapter (M16)
90890-04130
Adapter #13
YM-04059
5-75
1-20
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044
Reference
pages
5-75
YM-91044
Spacer
90890-04167
YM-04167
ø70
5-75
Coupling gear/middle shaft tool
90890-01229
Gear holder
YM-01229
5-87, 5-90
Bearing retainer wrench
90890-04128
Middle gear bearing retainer
YM-04128
5-88, 5-89
Ring nut wrench
90890-01430
YM-38404
5-88, 5-89
Final gear backlash band
90890-01511
Middle drive gear lash tool
YM-01230
5-91
1-21
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Radiator cap tester
90890-01325
Mityvac cooling system tester kit
YU-24460-A
Reference
pages
6-6
YU-24460-A
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984
6-6
YU-33984
Mechanical seal installer
90890-04132
Water pump seal installer
YM-33221-A
6-14
Middle driven shaft bearing driver
90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058
6-14
Pressure gauge
90890-03153
YU-03153
7-4
Fuel pressure adapter
90890-03176
YM-03176
7-4
1-22
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Reference
pages
Test harness- TPS (3P)
90890-03204
YU-03204
7-13
Universal joint holder
90890-04062
YM-04062
8-11, 8-14
Ring gear fix bolt (M10)
90890-01527
YM-01527
8-15
M10×P1.25
Gear lash measurement tool
90890-01475
Middle drive gear lash tool
YM-01475
8-15
Coupling gear holding tool (35)
90890-01571
YM-01571
8-25, 8-28
Ring gear fix bolt (M10 x 1.5)
90890-01572
YM-01572
8-26
M10×P1.50
Gear lash measurement tool
90890-01467
YM-01467
8-26
Ignition checker
90890-06754
Oppama pet-4000 spark checker
YM-34487
9-99
1-23
SPECIAL TOOLS
Tool name/Tool No.
Illustration
Reference
pages
Test harness-lean angle sensor (3P)
90890-03213
YU-03213
9-100
Test harness- speed sensor (3P)
90890-03208
YU-03208
9-102
Test harness S- pressure sensor 5S7 (3P)
90890-03211
YU-03211
9-105
1-24
SPECIAL TOOLS
1-25
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................2-2
CHASSIS SPECIFICATIONS ..........................................................................2-9
ELECTRICAL SPECIFICATIONS .................................................................2-12
TIGHTENING TORQUES .............................................................................. 2-14
GENERAL TIGHTENING TORQUE SPECIFICATIONS......................... 2-14
ENGINE TIGHTENING TORQUES......................................................... 2-15
CHASSIS TIGHTENING TORQUES.......................................................2-19
LUBRICATION AND SEALING POINTS ......................................................2-27
ENGINE................................................................................................... 2-27
LUBRICATION SYSTEM CHART AND DIAGRAMS.................................... 2-29
ENGINE OIL LUBRICATION CHART .....................................................2-29
LUBRICATION DIAGRAMS .................................................................... 2-31
COOLING SYSTEM DIAGRAMS .................................................................. 2-35
CABLE ROUTING ......................................................................................... 2-41
2
GENERAL SPECIFICATIONS
EAS29110
GENERAL SPECIFICATIONS
Model
Model
1XD2 (YX70ME [for CDN])
1XD5 (YX70MHE [for sun top models for CDN])
1XD7 (YX70MNE [for sun top models for CDN])
1XP2 (YX70MPE [for EPS models for CDN])
1XPA (YX70MPHE [for EPS/sun top models for
CDN])
1XPD (YX70MPNE [for EPS/sun top models for
CDN])
1XP3 (YXM700PE [for EPS models for CDN])
1XPB (YXM700PHE [for EPS/sun top models
for CDN])
1XD3 (YXM700DE [for sun top models for
CDN])
1XP4 (YXM700PE [for EPS/sun top models for
CDN])
Dimensions
Overall length
Overall width
Overall height
3100 mm (122.0 in)
1570 mm (61.8 in)
1880 mm (74.1 in)
(YX70ME/YX70MPE/YXM700DE/YXM700PE
[for Oceania])
1925 mm (75.8 in)
(YX70MHE/YX70MNE/YX70MPHE/YX70MPN
E/YXM700PE [for Europe]/YXM700PHE)
793 mm (31.2 in)
2135 mm (84.1 in)
300 mm (11.8 in)
4500 mm (177 in)
Seat height
Wheelbase
Ground clearance
Minimum turning radius
Weight
Curb weight
609.0 kg (1342 lb) (YX70ME/YXM700DE)
615.0 kg (1356 lb) (YX70MPE/YXM700PE [for
Oceania])
617.0 kg (1360 lb) (YX70MHE/YX70MNE)
623.0 kg (1373 lb)
(YX70MPHE/YX70MPNE/YXM700PE [for
Europe]/YXM700PHE)
445 kg (981 lb)
(Total weight of rider, passengers, cargo,
accessories, and tongue)
Maximum loading limit
2-1
ENGINE SPECIFICATIONS
EAS29120
ENGINE SPECIFICATIONS
Engine
Engine type
Displacement
Cylinder arrangement
Bore × stroke
Compression ratio
Standard compression pressure (at sea level)
Minimum–maximum
Starting system
Liquid cooled 4-stroke, SOHC
686 cm³
Single cylinder
102.0 × 84.0 mm (4.02 × 3.31 in)
10.00 : 1
500 kPa (5.0 kgf/cm², 71.1 psi)
440–560 kPa (4.4–5.6 kgf/cm², 62.6–79.6 psi)
Electric starter
Fuel
Recommended fuel
Fuel tank capacity
Regular unleaded gasoline only
36.7 L (9.70 US gal, 8.07 Imp.gal)
Engine oil
Lubrication system
Recommended brand
Type
Wet sump
YAMALUBE
SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W40 or 20W-50
API service SG type or higher, JASO standard
MA
Recommended engine oil grade
Engine oil quantity
Total amount
Without oil filter cartridge replacement
With oil filter cartridge replacement
2.60 L (2.75 US qt, 2.29 Imp.qt)
2.20 L (2.33 US qt, 1.94 Imp.qt)
2.30 L (2.43 US qt, 2.02 Imp.qt)
Final gear oil
Type
Total amount
Quantity
SAE 80 API GL-4 Hypoid gear oil
0.45 L (0.47 US qt, 0.40 Imp.qt)
0.40 L (0.42 US qt, 0.35 Imp.qt)
Differential gear oil
Type
Total amount
Quantity
SAE 80 API GL-4 Hypoid gear oil
0.20 L (0.21 US qt, 0.18 Imp.qt)
0.18 L (0.19 US qt, 0.16 Imp.qt)
Oil filter
Oil filter type
Cartridge
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip clearance
Limit
Outer-rotor-to-oil-pump-housing clearance
Limit
Oil-pump-housing-to-inner-and-outer-rotor
clearance
Limit
Pressure check location
Trochoid
Less than 0.12 mm (0.0047 in)
0.20 mm (0.0079 in)
0.090–0.170 mm (0.0035–0.0067 in)
0.24 mm (0.0094 in)
0.03–0.10 mm (0.0012–0.0039 in)
0.17 mm (0.0067 in)
Cylinder head
2-2
ENGINE SPECIFICATIONS
Cooling system
Radiator capacity (including all routes)
2.74 L (2.90 US qt, 2.41 Imp.qt)
Coolant reservoir capacity (up to the maximum level
mark)
0.28 L (0.30 US qt, 0.25 Imp.qt)
From low to full level
0.17 L (0.18 US qt, 0.15 Imp.qt)
Radiator cap opening pressure
107.9–137.3 kPa (1.1–1.4 kgf/cm², 15.6–19.9
psi)
Thermostat
Valve opening temperature
69–73 °C (156–163 °F)
Valve full open temperature
85 °C (185 °F)
Valve lift (full open)
8.0 mm (0.31 in)
Radiator core
Width
400.0 mm (15.75 in)
Height
253.4 mm (9.98 in)
Depth
28.0 mm (1.10 in)
Water pump
Water pump type
Single suction centrifugal pump
Reduction ratio
32/31 (1.032)
Impeller shaft tilt limit
0.15 mm (0.006 in)
Spark plug
Manufacturer/model
Spark plug gap
NGK/CPR7EA-9
0.8–0.9 mm (0.031–0.035 in)
Cylinder head
Combustion chamber volume
Warpage limit
57.60–61.20 cm³ (3.51–3.73 cu.in)
0.03 mm (0.0012 in)
Camshaft
Drive system
Camshaft lobe dimensions
Intake A
Limit
Intake B
Limit
Exhaust A
Limit
Exhaust B
Limit
Chain drive (right)
42.985–43.085 mm (1.6923–1.6963 in)
42.885 mm (1.6884 in)
36.950–37.050 mm (1.4547–1.4587 in)
36.850 mm (1.4572 in)
43.490–43.590 mm (1.7122–1.7161 in)
43.390 mm (1.7083 in)
36.950–37.050 mm (1.4547–1.4587 in)
36.850 mm (1.4572 in)
A
B
2-3
ENGINE SPECIFICATIONS
Camshaft runout limit
0.015 mm (0.0006 in)
Timing chain
Tensioning system
Automatic
Rocker arm/rocker arm shaft
Rocker arm inside diameter
Rocker arm shaft outside diameter
Rocker-arm-to-rocker-arm-shaft clearance
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)
Valve, valve seat, valve guide
Valve clearance (cold)
Intake
Exhaust
Valve dimensions
Valve head diameter A (intake)
Valve head diameter A (exhaust)
0.09–0.13 mm (0.0035–0.0051 in)
0.16–0.20 mm (0.0063–0.0079 in)
37.90–38.10 mm (1.4921–1.5000 in)
31.90–32.10 mm (1.2559–1.2638 in)
A
Valve face width B (intake)
Valve face width B (exhaust)
2.26 mm (0.0890 in)
2.26 mm (0.0890 in)
B
Valve seat width C (intake)
Limit
Valve seat width C (exhaust)
Limit
1.00–1.20 mm (0.0394–0.0472 in)
1.60 mm (0.0630 in)
1.00–1.20 mm (0.0394–0.0472 in)
1.60 mm (0.0630 in)
C
Valve margin thickness D (intake)
Limit
Valve margin thickness D (exhaust)
Limit
0.80–1.20 mm (0.0315–0.0472 in)
0.4 mm (0.016 in)
0.80–1.20 mm (0.0315–0.0472 in)
0.4 mm (0.016 in)
D
Valve stem diameter (intake)
Limit
5.975–5.990 mm (0.2352–0.2358 in)
5.945 mm (0.2341 in)
2-4
ENGINE SPECIFICATIONS
Valve stem diameter (exhaust)
Limit
Valve guide inside diameter (intake)
Limit
Valve guide inside diameter (exhaust)
Limit
Valve-stem-to-valve-guide clearance (intake)
Limit
Valve-stem-to-valve-guide clearance (exhaust)
Limit
Valve stem runout
5.960–5.975 mm (0.2346–0.2352 in)
5.930 mm (0.2335 in)
6.000–6.012 mm (0.2362–0.2367 in)
6.050 mm (0.2382 in)
6.000–6.012 mm (0.2362–0.2367 in)
6.050 mm (0.2382 in)
0.010–0.037 mm (0.0004–0.0015 in)
0.080 mm(0.0031 in)
0.025–0.052 mm (0.0010–0.0020 in)
0.100 mm(0.0039 in)
0.040 mm (0.0016 in)
Cylinder head valve seat width (intake)
Cylinder head valve seat width (exhaust)
1.00–1.20 mm (0.0394–0.0472 in)
1.00–1.20 mm (0.0394–0.0472 in)
Valve spring
Free length (intake)
Limit
Free length (exhaust)
Limit
Installed length (intake)
Installed length (exhaust)
Spring rate K1 (intake)
Spring rate K2 (intake)
Spring rate K1 (exhaust)
Spring rate K2 (exhaust)
Installed compression spring force (intake)
Spring tilt (intake)
Spring tilt (exhaust)
40.38 mm (1.59 in)
38.36 mm (1.51 in)
40.38 mm (1.59 in)
38.36 mm (1.51 in)
35.00 mm (1.38 in)
35.00 mm (1.38 in)
34.18 N/mm (3.49 kgf/mm, 195.16 lbf/in)
44.14 N/mm (4.50 kgf/mm, 252.04 lbf/in)
34.18 N/mm (3.49 kgf/mm, 195.16 lbf/in)
44.14 N/mm (4.50 kgf/mm, 252.04 lbf/in)
171.00–197.00 N (17.44–20.09 kgf, 38.44–
44.29 lbf)
171.00–197.00 N (17.44–20.09 kgf, 38.44–
44.29 lbf)
2.5°/1.8 mm (2.5°/0.07 in)
2.5°/1.8 mm (2.5°/0.07 in)
Winding direction (intake)
Winding direction (exhaust)
Clockwise
Clockwise
Installed compression spring force (exhaust)
Cylinder
Cylinder bore
Wear limit
Taper limit
Out of round limit
102.000–102.010 mm (4.0157–4.0161 in)
102.080 mm (4.0189 in)
0.05 mm (0.002 in)
0.05 mm (0.002 in)
2-5
ENGINE SPECIFICATIONS
Piston
Piston-to-cylinder clearance
Piston skirt diameter D
Height H
0.030–0.055 mm (0.0012–0.0022 in)
101.955–101.970 mm (4.0140–4.0146 in)
10.0 mm (0.39 in)
H
D
Offset
Offset direction
Piston pin bore inside diameter
Limit
Piston pin outside diameter
Limit
Piston-pin-to-piston-pin-bore clearance
Limit
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)
Piston ring
Top ring
Ring type
Dimensions (B × T)
Barrel
1.20 × 3.80 mm (0.05 × 0.15 in)
B
T
End gap (installed)
Limit
Ring side clearance
Limit
2nd ring
Ring type
Dimensions (B × T)
0.20–0.35 mm (0.008–0.014 in)
0.60 mm (0.024 in)
0.030–0.070 mm (0.0012–0.0028 in)
0.12 mm (0.0047 in)
Taper
1.20 × 4.00 mm (0.05 × 0.16 in)
B
T
End gap (installed)
Limit
Ring side clearance
Limit
Oil ring
Dimensions (B × T)
0.75–0.90 mm (0.03–0.04 in)
1.25 mm (0.049 in)
0.030–0.070 mm (0.0012–0.0028 in)
0.13 mm (0.0051 in)
2.50 × 2.80 mm (0.10 × 0.11 in)
B
T
End gap (installed)
0.20–0.70 mm (0.01–0.03 in)
2-6
ENGINE SPECIFICATIONS
Crankshaft
Width A
Runout limit C
Big end side clearance D
C
74.92–75.00 mm (2.950–2.953 in)
0.030 mm (0.0012 in)
0.350–0.650 mm (0.0138–0.0256 in)
C
D
A
Balancer
Balancer drive method
Gear
Automatic centrifugal clutch
Clutch type
Clutch shoe thickness
Limit
Clutch housing inside diameter
Clutch-in revolution
Clutch-stall revolution
Wet, centrifugal automatic
1.5 mm (0.06 in)
1.0 mm (0.04 in)
150.0 mm (5.91 in)
1950–2050 r/min
3550–3650 r/min
V-belt
V-belt width
Limit
33.0–33.6 mm (1.30–1.32 in)
32.5 mm (1.28 in)
Transmission
Transmission type
Primary reduction system
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratio
Low range
High range
Reverse gear
Drive axle runout limit
V-belt automatic
V-belt
Shaft drive
41/21 × 17/12 × 33/9 (10.142)
Right hand operation
2.554–0.705 : 1
31/16 (1.938)
30/21 (1.429)
23/14 × 28/23 (2.000)
0.06 mm (0.0024 in)
Shifting mechanism
Shift mechanism type
Shift fork thickness
Shift drum and guide bar
5.76–5.89 mm (0.2268–0.2319 in)
Decompression device
Device type
Auto decomp
Air filter
Air filter element
Air filter oil grade
Wet element
Foam air filter oil or equivalent oil
2-7
ENGINE SPECIFICATIONS
Fuel pump
Pump type
Electrical
Fuel injector
Model/quantity
Fuel injector resistance
EAT291/1
11.5–12.5 Ω
Throttle body
Type/quantity
ID mark
Throttle valve size
44EHS/1
1XD1 00
#100
Throttle position sensor
Resistance
2.64–6.16 kΩ
Fuel injection sensor
Crankshaft position sensor resistance
Intake air pressure sensor output voltage
Intake air temperature sensor resistance
408.0–612.0 Ω
3.594–3.684 V at 101 kPa (1.01 kgf/cm², 14 psi)
5.40–6.60 kΩ at 0 °C (32 °F)
290–390 Ω at 80 °C (176 °F)
2.32–2.59 kΩ at 20 °C (68 °F)
310–326 Ω at 80 °C (176 °F)
Coolant temperature sensor resistance
Idling condition
Engine idling speed
Intake vacuum
Water temperature
Oil temperature
Accelerator pedal free play
CO% (air induction system ON)
CO% (air induction system OFF)
1550–1650 r/min
32.7 kPa (245 mmHg, 9.7 inHg)
75–85 °C (167–185 °F)
55–65 °C (131–149 °F)
12.0–32.0 mm (0.47–1.26 in)
1%
5.5–6.5 %
Air induction system
Solenoid resistance
20–24 Ω
Drive train
Middle gear backlash
Final gear backlash
Differential gear backlash
0.10–0.30 mm (0.004–0.012 in)
0.13–0.23 mm (0.005–0.009 in)
0.05–0.25 mm (0.002–0.0010 in)
2-8
CHASSIS SPECIFICATIONS
EAS29130
CHASSIS SPECIFICATIONS
Chassis
Frame type
Caster angle
Camber angle
Kingpin angle
Kingpin offset
Trail
Tread rear (STD)
Tread front (STD)
Toe-in (with tires touching the ground)
Steel tube frame
3.7°
0.4°
12.7°
7.7 mm (0.30 in)
19.0 mm (0.75 in)
1304.0 mm (51.34 in)
1320.0 mm (51.97 in)
5.0–15.0 mm (0.20–0.59 in)
Front wheel
Wheel type
Rim size
Wheel material
Wheel travel
Radial wheel runout limit
Lateral wheel runout limit
Panel wheel
12 × 6.0AT
Steel
205 mm (8.1 in)
2.0 mm (0.08 in)
2.0 mm (0.08 in)
Rear wheel
Wheel type
Rim size
Wheel material
Wheel travel
Radial wheel runout limit
Lateral wheel runout limit
Panel wheel
12 × 7.5AT
Steel
205 mm (8.1 in)
2.0 mm (0.08 in)
2.0 mm (0.08 in)
Front tire
Type
Size
Manufacturer/model
Wear limit (front)
Tubeless
25 × 8–12NHS
MAXXIS/MU09
3.0 mm (0.12 in)
Rear tire
Type
Size
Manufacturer/model
Wear limit (rear)
Tubeless
25 × 10–12NHS
MAXXIS/MU10
3.0 mm (0.12 in)
Tire air pressure (measured on cold tires)
Recommended
Vehicle load
Front
Rear
Vehicle load
Front
Rear
Minimum
Vehicle load
Front
0–300 kg (0–661 lb)
75.0 kPa (0.750 kgf/cm², 11 psi)
90.0 kPa (0.900 kgf/cm², 13 psi)
300–445 kg (661–981 lb)
75.0 kPa (0.750 kgf/cm², 11 psi)
125.0 kPa (1.250 kgf/cm², 18 psi)
0–300 kg (0–661 lb)
70.0 kPa (0.700 kgf/cm², 10 psi)
2-9
CHASSIS SPECIFICATIONS
Rear
Vehicle load
Front
Rear
85.0 kPa (0.850 kgf/cm², 12 psi)
300–445 kg (661–981 lb)
70.0 kPa (0.700 kgf/cm², 10 psi)
120.0 kPa (1.200 kgf/cm², 17 psi)
Front brake
Type
Operation
Front disc brake
Disc outside diameter × thickness
Brake disc thickness limit
Brake disc deflection limit
Brake pad lining thickness (inner)
Limit
Brake pad lining thickness (outer)
Limit
Master cylinder inside diameter
Caliper cylinder inside diameter
Specified brake fluid
Disc brake
Unified brake
207.0 × 4.0 mm (8.15 × 0.16 in)
3.5 mm (0.14 in)
0.1 mm (0.004 in)
4.5 mm (0.18 in)
1.0 mm (0.04 in)
4.5 mm (0.18 in)
1.0 mm (0.04 in)
17.46 mm (0.69 in)
32.03 mm × 2 (1.26 in × 2)
DOT 4
Rear brake
Type
Operation
Brake pedal free play
Rear disc brake
Disc outside diameter × thickness
Brake disc thickness limit
Brake disc deflection limit
Brake pad lining thickness (inner)
Limit
Brake pad lining thickness (outer)
Limit
Caliper cylinder inside diameter
Specified brake fluid
207.0 × 4.0 mm (8.15 × 0.16 in)
3.5 mm (0.14 in)
0.1 mm (0.004 in)
4.3 mm (0.17 in)
1.0 mm (0.04 in)
4.3 mm (0.17 in)
1.0 mm (0.04 in)
27.00 mm × 2
DOT 4
Parking brake
Type
Disc outside diameter × thickness
Brake disc thickness limit
Brake pad lining thickness-inner
Limit
Brake pad lining thickness-outer
Limit
Disc
200.0 × 3.5 mm (7.87 × 0.14 in)
3.0 mm (0.12 in)
3.2 mm (0.13 in)
1.0 mm (0.04 in)
3.2 mm (0.13 in)
1.0 mm (0.04 in)
Front suspension
Type
Spring/shock absorber type
Wheel travel
Shock absorber travel
Spring free length
Installed length
Spring rate K1
Spring stroke K1
Double wishbone
Coil spring/gas-oil damper
205 mm (8.1 in)
123.0 mm (4.84 in)
334.0 mm (13.15 in)
277.0 mm (10.91 in)
28.00 N/mm (2.86 kgf/mm, 159.88 lbf/in)
0.0–123.0 mm (0.00–4.84 in)
Disc brake
Unified brake
0 mm (0 in)
2-10
CHASSIS SPECIFICATIONS
Rear suspension
Type
Spring/shock absorber type
Wheel travel
Rear shock absorber assembly travel
Spring free length
Installed length
Spring rate K1
Spring rate K2
Spring stroke K1
Spring stroke K2
Double wishbone
Coil spring/gas-oil damper
205 mm (8.1 in)
112.0 mm (4.41 in)
381.2 mm (15.01 in)
316.2 mm (12.45 in)
36.00 N/mm (3.67 kgf/mm, 205.56 lbf/in)
115.00 N/mm (11.73 kgf/mm, 656.65 lbf/in)
0.0–75.0 mm (0.00–2.95 in)
75.0–112.0 mm (2.95–4.41 in)
2-11
ELECTRICAL SPECIFICATIONS
EAS29140
ELECTRICAL SPECIFICATIONS
Voltage
System voltage
12 V
Ignition system
Ignition system
Advancer type
Ignition timing (B.T.D.C.)
TCI
Digital
5.0°/1600 r/min
Engine control unit
Model/manufacturer
F8T85871/MITSUBISHI
Ignition coil
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
6.0 mm (0.24 in)
2.16–2.64 Ω
8.64–12.96 kΩ
Spark plug cap
Material
Resistance
Resin
7.5–12.5 kΩ
AC magneto
Standard output
Stator coil resistance
14.0 V, 36.4 A at 5000 r/min
0.09–0.13 Ω
Rectifier/regulator
Regulator type
Regulated voltage (DC)
Rectifier capacity (DC)
Withstand voltage
Semi conductor-short circuit
14.3–14.7 V
50.0 A
40.0 V
Battery
Model
Voltage, capacity
Manufacturer
Ten hour rate charging current
U1-H11L
12 V, 28.0 Ah
GS
2.8 A
Headlight
Bulb type
Halogen bulb
Bulb voltage, wattage × quantity
Headlight
Tail/brake light
12 V, 35.0/35.0 W × 2
12 V, 5.0/21.0 W × 2
Indicator and warning lights
Neutral indicator light
LED
Reverse indicator light
LED
Coolant temperature warning light
LED
Parking brake indicator light
LED
On-Command four-wheel-drive/differential gear lock
indicator
LCD
2-12
ELECTRICAL SPECIFICATIONS
Engine trouble warning light
EPS warning light
High-range indicator light
Low-range indicator light
Differential gear lock indicator light
Helmet/seat belt indicator light
LED
LED (for EPS models)
LED
LED
LED
14 V, 0.85 W × 2
Electric starting system
System type
Constant mesh
Starter motor
Power output
Armature coil resistance
Brush overall length
Limit
Brush spring force
Commutator diameter
Limit
Mica undercut (depth)
0.80 kW
0.025–0.035 Ω
12.5 mm (0.49 in)
5.00 mm (0.20 in)
7.65–10.01 N (780–1021 gf, 27.54–36.03 oz)
28.0 mm (1.10 in)
27.0 mm (1.06 in)
0.70 mm (0.03 in)
Starter relay
Amperage
Coil resistance
180.0 A
4.18–4.62 Ω
Horn (for Europe and Oceania)
Horn type
Quantity
Maximum amperage
Plane
1 pc
1.0 A
Fuel sender unit
Sender unit resistance (full)
Sender unit resistance (empty)
19.0–21.0 Ω
139.0–141.0 Ω
EPS torque sensor
Coil resistance
0.875–1.625 kΩ (for EPS models)
Auxiliary DC output
Jack capacity
12 V, 10.0 A (120 W)
Fuses
Main fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan motor fuse
Auxiliary DC jack fuse
Fuel injection system fuse
Backup fuse
Differential motor fuse
EPS fuse
Spare fuse
Spare fuse
Spare fuse
40.0 A
15.0 A
10.0 A
10.0 A
25.0 A
10.0 A
10.0 A
10.0 A
10.0 A
40.0 A (for EPS models)
25.0 A
15.0 A
10.0 A × 2
2-13
TIGHTENING TORQUES
EAS20320
TIGHTENING TORQUES
EAS20330
GENERAL TIGHTENING TORQUE
SPECIFICATIONS
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
A (nut) B (bolt)
General tightening
torques
Nm
m·kgf
ft·lbf
10 mm
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
2-14
TIGHTENING TORQUES
EAS20340
ENGINE TIGHTENING TORQUES
Item
Thread
Q’ty
size
Tightening torque
Exhaust pipe nut
M8
2
20 Nm (2.0 m·kgf, 14 ft·lbf)
Muffler bolt
M8
1
23 Nm (2.3 m·kgf, 17 ft·lbf)
Muffler mount shaft
M8
1
17 Nm (1.7 m·kgf, 12 ft·lbf)
Spark arrester bolt
M6
4
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Intake air pressure sensor screw
M5
1
3.6 Nm (0.36 m·kgf, 2.6 ft·lbf)
Throttle position sensor screw
M5
2
3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Injector fuel rail screw
M6
2
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Throttle cable locknut (throttle
body end, air intake silencer side)
M7
1
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Throttle cable locknut (throttle
body end, throttle body side)
M6
1
0.8 Nm (0.08 m·kgf, 0.6 ft·lbf)
Throttle cable housing cover
screw
M4
3
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Cylinder head stud bolt (exhaust
pipe)
M8
2
15 Nm (1.5 m·kgf, 11 ft·lbf)
Reed valve cover bolt
M6
2
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head bolt
M9
4
35 Nm (3.5 m·kgf, 25 ft·lbf)
Remarks
LT
LT
l = 135
mm
(5.31 in),
l = 145
mm
(5.71 in)
M
Cylinder head bolt
M9
2
38 Nm (3.8 m·kgf, 27 ft·lbf)
l = 39 mm
(1.54 in)
E
Cylinder head bolt
M6
2
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tappet cover bolt
M6
8
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Camshaft sprocket cover bolt
M6
2
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Thermostat cover bolt
M6
2
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Thermostat cover air bleed bolt
M6
1
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil check bolt
M8
1
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Camshaft sprocket bolt
M7
2
20 Nm (2.0 m·kgf, 14 ft·lbf)
Decompression assembly bolt
M7
2
20 Nm (2.0 m·kgf, 14 ft·lbf)
Valve adjusting screw locknut
M6
4
14 Nm (1.4 m·kgf, 10 ft·lbf)
Bearing retainer bolt (camshaft)
M6
2
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder bolt
M10
4
See TIP.
Cylinder bolt
M6
2
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing chain guide (intake side)
bolt
M6
2
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing chain tensioner cap bolt
M16
1
20 Nm (2.0 m·kgf, 14 ft·lbf)
2-15
LT
E
LT
TIGHTENING TORQUES
Item
Thread
Q’ty
size
Tightening torque
Remarks
Timing chain tensioner bolt
M6
2
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pipe (crankcase to cylinder
head) union bolt
M10
1
20 Nm (2.0 m·kgf, 14 ft·lbf)
Oil pipe (crankcase to cylinder
head) union bolt
M14
2
35 Nm (3.5 m·kgf, 25 ft·lbf)
Oil pipe (crankcase to cylinder
head) bolt
M6
1
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pipe union bolt (AC magneto
cover)
M8
2
18 Nm (1.8 m·kgf, 13 ft·lbf)
Thermostat outlet hose guide
bolt
M10
1
48 Nm (4.8 m·kgf, 35 ft·lbf)
Crankcase bolt
M8
3
26 Nm (2.6 m·kgf, 19 ft·lbf)
Crankcase bolt
M6
13
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Dipstick guide bolt
M6
1
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Engine oil drain bolt
M14
1
30 Nm (3.0 m·kgf, 22 ft·lbf)
Crankcase plug
M16
1
8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Crankcase plug
M14
1
18 Nm (1.8 m·kgf, 13 ft·lbf)
Oil filter cartridge
M20
1
17 Nm (1.7 m·kgf, 12 ft·lbf)
Oil filter cartridge union bolt
M20
1
30 Nm (3.0 m·kgf, 22 ft·lbf)
Timing chain stopper guide (lower) bolt
M6
2
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LT
Bearing retainer bolt (crankcase)
M6
2
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LT
Oil pump bolt
M6
3
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pump housing cover screw
M5
1
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Water jacket joint bolt
M6
2
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Water pump outlet hose clamp
screw
M5
2
1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Water pump housing bolt
M6
3
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant drain bolt
M6
1
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Water pump air bleed bolt
M6
1
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Water pump outlet pipe bolt
M6
1
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankshaft end accessing screw
M36
1
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Timing mark accessing screw
M14
1
1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Drive select lever shift cable
bracket bolt (engine side)
M6
1
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
AC magneto cover bolt
M6
11
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
AC magneto rotor nut
M16
1
60 Nm (6.0 m·kgf, 43 ft·lbf)
AC magneto/crankshaft position
sensor lead holder bolt
M5
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
LT
Starter clutch bolt
M8
3
30 Nm (3.0 m·kgf, 22 ft·lbf)
LT
2-16
LS
E
E
TIGHTENING TORQUES
Item
Oil pump driven sprocket nut
Balancer driven gear nut
Thread
Q’ty
size
M10
M18
1
1
Tightening torque
Remarks
22 Nm (2.2 m·kgf, 16 ft·lbf)
Use a
lock
washer.
85 Nm (8.5 m·kgf, 61 ft·lbf)
Use a
lock
washer.
E
Drive belt cover bolt
M6
11
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Bearing housing bolt (primary
sheave assembly)
M6
4
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Bearing retainer bolt (bearing
housing)
M6
1
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Primary sheave assembly nut
M16
1
190 Nm (19 m·kgf, 137 ft·lbf)
Primary sheave cap screw
M4
8
3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Secondary sheave assembly nut
M16
1
100 Nm (10 m·kgf, 72 ft·lbf)
Secondary sheave spring retaining nut
M36
1
90 Nm (9.0 m·kgf, 65 ft·lbf)
Drive belt case bolt
M6
8
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Clutch housing assembly bolt
M6
9
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Clutch carrier assembly nut
M22
1
190 Nm (19 m·kgf, 137 ft·lbf)
Left-hand
threads
Stake.
M
Drive select lever unit bolt
M6
5
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Drive select lever shift cable
bracket bolt (drive select lever
side)
M8
2
16 Nm (1.6 m·kgf, 12 ft·lbf)
Drive select lever shift cable locknut
M14
1
39 Nm (3.9 m·kgf, 28 ft·lbf)
Shift arm bolt
M6
1
14 Nm (1.4 m·kgf, 10 ft·lbf)
Shift lever cover bolt
M6
4
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Shift lever 2 bolt
M6
1
14 Nm (1.4 m·kgf, 10 ft·lbf)
Shift drum stopper bolt
M14
1
18 Nm (1.8 m·kgf, 13 ft·lbf)
Middle drive pinion gear nut
M22
1
190 Nm (19 m·kgf, 137 ft·lbf)
Middle drive shaft bearing housing bolt
M8
4
32 Nm (3.2 m·kgf, 23 ft·lbf)
Middle drive shaft bearing retainer bolt
M8
4
29 Nm (2.9 m·kgf, 21 ft·lbf)
Front drive shaft yoke nut (middle
gear side)
M16
1
190 Nm (19 m·kgf, 137 ft·lbf)
Middle driven shaft bearing retainer
M55
1
80 Nm (8.0 m·kgf, 58 ft·lbf)
Stake.
LT
Stake.
LT
LT
Left-hand
threads
LT
2-17
TIGHTENING TORQUES
Item
Thread
Q’ty
size
Tightening torque
Middle driven pinion gear bearing
housing bolt
M8
4
25 Nm (2.5 m·kgf, 18 ft·lbf)
Middle driven pinion gear bearing
retainer
M60
1
130 Nm (13 m·kgf, 94 ft·lbf)
Remarks
Left-hand
threads
LT
Rear drive shaft yoke nut (middle
gear side)
M16
1
190 Nm (19 m·kgf, 137 ft·lbf)
Starter motor bolt
M6
2
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Starter motor cover bolt
M5
2
4.9 Nm (0.49 m·kgf, 3.5 ft·lbf)
Brush set bolt
M6
1
11 Nm (1.1 m·kgf, 8.0 ft·lbf)
Starter motor lead nut
M6
1
4.9 Nm (0.49 m·kgf, 3.5 ft·lbf)
Negative battery lead bolt
M6
1
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Spark plug
M10
1
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Stator coil assembly bolt
M6
3
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
LT
Crankshaft position sensor bolt
M5
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
LT
Coolant temperature sensor
M12
1
18 Nm (1.8 m·kgf, 13 ft·lbf)
Gear position switch bolt
M6
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Reverse switch
M10
1
17 Nm (1.7 m·kgf, 12 ft·lbf)
Speed sensor bolt
M6
1
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LT
TIP
Cylinder bolt
Temporarily tighten the cylinder bolts to 15 Nm (1.5 m·kgf, 11 ft·lbf), and then tighten them to 50 Nm
(5.0 m·kgf, 36 ft·lbf).
TIP
Cylinder head bolt
Tighten the cylinder head bolts to specification in the proper tightening sequence.
Cylinder head tightening sequence:
4
2
1
6
7
8
5
3
2-18
TIGHTENING TORQUES
EAS20350
CHASSIS TIGHTENING TORQUES
Item
Thread
Q’ty
size
Tightening torque
Engine mounting bolt
M10
4
42 Nm (4.2 m·kgf, 30 ft·lbf)
Engine mounting bolt
M6
4
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Engine bracket nut
M10
4
42 Nm (4.2 m·kgf, 30 ft·lbf)
Front fender and front grill bolt
M6
6
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Radiator bracket bolt
M6
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Radiator fan bolt
M6
4
8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Radiator pipe holder bolt
M6
4
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front fender and electrical components tray bolt
M6
4
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Front grill and front guard bolt
M6
2
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Front guard bolt
M10
4
48 Nm (4.8 m·kgf, 35 ft·lbf)
Front guard cover screw
M6
4
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Front grill and frame bolt
M6
2
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Headlight screw
M5
6
1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Front fender and frame bolt
M6
2
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Electrical components tray and
frame bolt
M6
4
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Muffler heat protector plate bolt
M8
2
17 Nm (1.7 m·kgf, 12 ft·lbf)
Side panel bolt
M6
6
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
ECU nut
M6
1
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Lean angle sensor bolt
M5
2
3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Starter relay lead bolt
M6
2
3.6 Nm (0.36 m·kgf, 2.6 ft·lbf)
Positive battery lead nut
M8
1
1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Negative battery lead nut
M8
1
1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
EPS control unit bolt (for EPS
models)
M6
1
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
V-belt cooling intake duct joint 1
clamp screw (V-belt cooling intake duct side)
M4
1
1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
V-belt cooling intake duct joint 1
clamp screw (drive belt cover
side)
M6
1
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
V-belt cooling intake duct joint 2
clamp screw
M4
2
1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
V-belt cooling exhaust duct joint
clamp screw (V-belt cooling exhaust duct side)
M4
1
1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
V-belt cooling exhaust duct joint
clamp screw (drive belt cover
side)
M6
1
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Fuel tank retainer bolt
M8
2
16 Nm (1.6 m·kgf, 12 ft·lbf)
2-19
Remarks
LT
TIGHTENING TORQUES
Item
Thread
Q’ty
size
Tightening torque
Remarks
Fuel tank bolt
M6
3
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bracket bolt
M6
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank breather hose joint bolt
M6
1
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel pump nut
M6
6
See TIP.
Throttle body joint clamp screw
M5
2
2.8 Nm (0.28 m·kgf, 2.0 ft·lbf)
Air intake silencer joint clamp
screw (throttle body side)
M5
1
3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Air intake silencer joint clamp
screw (air intake silencer side)
M6
1
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Air filter case joint clamp screw
M6
2
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Air intake duct joint clamp screw
M6
2
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Air filter case bolt
M6
3
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Coolant reservoir bolt
M6
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Door hinge nut
M6
8
1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Door hinge bolt
M6
4
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Door handle latch nut
M6
6
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front skid plate bolt
M6
4
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear skid plate bolt
M6
4
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Lower panel and floor board bolt
M6
2
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Lower panel and frame bolt
M6
4
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Frame cross member bolt
M8
4
17 Nm (1.7 m·kgf, 12 ft·lbf)
Exhaust pipe heat protector plate
bolt
M8
2
17 Nm (1.7 m·kgf, 12 ft·lbf)
Exhaust pipe heat protector plate
bolt
M6
2
8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Front wheel axle nut
M24
2
350 Nm (35 m·kgf, 253 ft·lbf)
Front wheel nut
M12
8
75 Nm (7.5 m·kgf, 54 ft·lbf)
Rear wheel axle nut
M24
2
350 Nm (35 m·kgf, 253 ft·lbf)
Rear wheel nut
M12
8
75 Nm (7.5 m·kgf, 54 ft·lbf)
Front brake disc guard bolt
M6
6
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Front brake caliper bolt
M10
4
48 Nm (4.8 m·kgf, 35 ft·lbf)
Front brake disc bolt
M8
8
30 Nm (3.0 m·kgf, 22 ft·lbf)
LT
Front brake caliper retaining pin
nut
M8
2
22 Nm (2.2 m·kgf, 16 ft·lbf)
LT
Front brake pad bolt
M10
4
17 Nm (1.7 m·kgf, 12 ft·lbf)
Front brake caliper guide pin
M8
2
17 Nm (1.7 m·kgf, 12 ft·lbf)
Front brake caliper bleed screw
M8
2
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Rear brake disc guard bolt
M6
4
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Rear brake disc cleaning plate
bolt
M6
4
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
2-20
Stake.
Stake.
TIGHTENING TORQUES
Item
Thread
Q’ty
size
Tightening torque
Rear brake disc bolt
M8
8
30 Nm (3.0 m·kgf, 22 ft·lbf)
Rear brake caliper bolt
M10
4
48 Nm (4.8 m·kgf, 35 ft·lbf)
Rear brake caliper retaining pin
nut
M8
2
22 Nm (2.2 m·kgf, 16 ft·lbf)
Rear brake pad bolt
M10
4
17 Nm (1.7 m·kgf, 12 ft·lbf)
Rear brake caliper guide pin
M8
2
17 Nm (1.7 m·kgf, 12 ft·lbf)
Rear brake caliper bleed screw
M8
2
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Brake pipe flare nut
M10
4
19 Nm (1.9 m·kgf, 14 ft·lbf)
Front brake hose joint bolt
M6
1
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear brake hose joint bolt
M6
1
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Front brake hose holder bolt
M6
4
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear brake hose holder bolt
M6
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front brake hose union bolt
M10
2
27 Nm (2.7 m·kgf, 20 ft·lbf)
Rear brake hose union bolt
M10
2
27 Nm (2.7 m·kgf, 20 ft·lbf)
Brake master cylinder reservoir
cap
—
1
3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Brake master cylinder reservoir
clamp screw
M6
1
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Parking brake cable holder bolt
M6
2
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Parking brake caliper guide pin
M8
1
17 Nm (1.7 m·kgf, 12 ft·lbf)
Parking brake caliper retaining
pin nut
M8
1
22 Nm (2.2 m·kgf, 16 ft·lbf)
Parking brake pad bolt
M8
2
17 Nm (1.7 m·kgf, 12 ft·lbf)
Parking brake caliper arm nut
M8
1
17 Nm (1.7 m·kgf, 12 ft·lbf)
Brake master cylinder bolt
M8
2
16 Nm (1.6 m·kgf, 12 ft·lbf)
Pedal assembly bolt
M8
3
16 Nm (1.6 m·kgf, 12 ft·lbf)
Brake pedal rod locknut
M8
1
17 Nm (1.7 m·kgf, 12 ft·lbf)
Throttle cable locknut (accelerator pedal end)
M6
1
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Parking brake lever bolt
M6
2
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Parking brake caliper bolt
M10
2
40 Nm (4.0 m·kgf, 29 ft·lbf)
Parking brake disc nut
M6
3
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Parking brake cable locknut
M6
2
16 Nm (1.6 m·kgf, 12 ft·lbf)
Front arm nut
M10
8
45 Nm (4.5 m·kgf, 33 ft·lbf)
Front shock absorber assembly
nut
M10
4
45 Nm (4.5 m·kgf, 33 ft·lbf)
Steering knuckle nut
M12
4
30 Nm (3.0 m·kgf, 22 ft·lbf)
Front arm protector bolt
M6
4
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Steering wheel nut
M12
1
35 Nm (3.5 m·kgf, 25 ft·lbf)
2-21
Remarks
LT
LT
LT
LS
TIGHTENING TORQUES
Item
Thread
Q’ty
size
Tightening torque
Steering column bolt (except for
EPS models)
M8
4
21 Nm (2.1 m·kgf, 15 ft·lbf)
EPS unit bolt (for EPS models)
M8
4
21 Nm (2.1 m·kgf, 15 ft·lbf)
EPS unit bracket bolt (for EPS
models)
M6
2
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Steering joint bolt
M8
2
27 Nm (2.7 m·kgf, 20 ft·lbf)
Steering assembly bolt
M10
4
See TIP.
Tie-rod end locknut
M12
2
40 Nm (4.0 m·kgf, 29 ft·lbf)
Steering knuckle and tie-rod end
nut
M12
2
39 Nm (3.9 m·kgf, 28 ft·lbf)
Rear arm nut
M10
4
45 Nm (4.5 m·kgf, 33 ft·lbf)
Rear shock absorber assembly
nut
M12
4
82 Nm (8.2 m·kgf, 59 ft·lbf)
Stabilizer joint nut
M10
4
60 Nm (6.0 m·kgf, 43 ft·lbf)
Stabilizer holder bolt
M10
4
85 Nm (8.5 m·kgf, 61 ft·lbf)
Rear knuckle nut
M12
2
85 Nm (8.5 m·kgf, 61 ft·lbf)
Rear arm protector bolt
M6
4
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear knuckle grease nipple
M6
4
3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Differential gear oil filler bolt
M14
1
23 Nm (2.3 m·kgf, 17 ft·lbf)
Differential gear oil drain bolt
M10
1
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Differential motor bolt
M6
3
11 Nm (1.1 m·kgf, 8.0 ft·lbf)
Front drive shaft yoke nut
M14
1
62 Nm (6.2 m·kgf, 45 ft·lbf)
Differential case bolt
M8
5
24 Nm (2.4 m·kgf, 17 ft·lbf)
Front drive shaft universal joint
yoke nut
M16
1
150 Nm (15 m·kgf, 108 ft·lbf)
Differential assembly nut
M12
1
105 Nm (10.5 m·kgf, 76 ft·lbf)
Differential assembly bolt
M10
2
60 Nm (6.0 m·kgf, 43 ft·lbf)
Differential assembly bracket nut
M10
1
60 Nm (6.0 m·kgf, 43 ft·lbf)
Support bearing bracket bolt
M8
2
18 Nm (1.8 m·kgf, 13 ft·lbf)
Final gear oil filler bolt
M10
1
23 Nm (2.3 m·kgf, 17 ft·lbf)
Final gear oil drain bolt
M10
1
23 Nm (2.3 m·kgf, 17 ft·lbf)
Final drive assembly bracket bolt
M8
6
33 Nm (3.3 m·kgf, 24 ft·lbf)
Final drive assembly nut
M12
3
105 Nm (10.5 m·kgf, 76 ft·lbf)
Rear drive shaft yoke nut (final
drive assembly side)
M14
1
97 Nm (9.7 m·kgf, 70 ft·lbf)
Final drive pinion gear bearing
housing bolt
M8
4
26 Nm (2.6 m·kgf, 19 ft·lbf)
Ring gear stopper nut
M8
1
16 Nm (1.6 m·kgf, 12 ft·lbf)
Final drive case cover bolt
M10
8
52 Nm (5.2 m·kgf, 38 ft·lbf)
Driver seat frame bolt
M8
4
23 Nm (2.3 m·kgf, 17 ft·lbf)
2-22
Remarks
LS
LT
LT
LT
TIGHTENING TORQUES
Item
Thread
Q’ty
size
Tightening torque
Center passenger seat frame bolt
M8
4
23 Nm (2.3 m·kgf, 17 ft·lbf)
Outer passenger seat frame bolt
M8
4
23 Nm (2.3 m·kgf, 17 ft·lbf)
Seat back bolt
M6
9
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Headrest bolt
M6
9
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Seat belt bolt
M12
6
59 Nm (5.9 m·kgf, 43 ft·lbf)
Seat belt buckle bolt
M12
3
59 Nm (5.9 m·kgf, 43 ft·lbf)
Seat belt guide bolt
M11
3
59 Nm (5.9 m·kgf, 43 ft·lbf)
Passenger handhold bracket bolt
M8
2
16 Nm (1.6 m·kgf, 12 ft·lbf)
Passenger handhold stopper nut
M6
1
3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Left floor board and frame bolt
M6
6
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Center floor board and frame bolt
M6
2
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Right floor board and frame bolt
M6
6
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Center floor board and left floor
board bolt
M6
4
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Center floor board and right floor
board bolt
M6
5
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Instrument panel bolt
M6
8
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Meter assembly nut
M5
3
3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Meter assembly bracket bolt
M6
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Glove compartment latch plate
screw
M4
1
1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Gas spring assembly ball stud
nut
M8
2
16 Nm (1.6 m·kgf, 12 ft·lbf)
Tail/brake light nut
M6
4
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Cargo bed release lever bolt
M6
4
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Cargo bed release lever holder
bolt
M6
4
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Cargo hook nut
M6
8
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Tailgate shaft bolt
M6
3
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Tailgate cable bolt
M6
4
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Tailgate cable bracket bolt
M6
4
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Cargo bed heat protector plate
bolt
M6
5
8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Left side frame nut (front)
M10
2
65 Nm (6.5 m·kgf, 47 ft·lbf)
Left side frame nut (rear)
M10
1
48 Nm (4.8 m·kgf, 35 ft·lbf)
Right side frame nut (front)
M10
2
65 Nm (6.5 m·kgf, 47 ft·lbf)
Right side frame nut (rear)
M10
1
48 Nm (4.8 m·kgf, 35 ft·lbf)
Front top frame bolt
M10
4
48 Nm (4.8 m·kgf, 35 ft·lbf)
Rear top frame bolt
M10
4
48 Nm (4.8 m·kgf, 35 ft·lbf)
Rear center frame bolt
M10
4
48 Nm (4.8 m·kgf, 35 ft·lbf)
2-23
Remarks
TIGHTENING TORQUES
Thread
Q’ty
size
Item
Tightening torque
Rear left frame bolt
M10
4
48 Nm (4.8 m·kgf, 35 ft·lbf)
Rear right frame bolt
M10
4
48 Nm (4.8 m·kgf, 35 ft·lbf)
Sun top front bracket screw (for
sun top models)
M6
8
3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Sun top rear bracket screw (for
sun top models)
M6
8
3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Sun top lower bracket bolt (for
sun top models)
M6
4
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Sun top lower bracket nut (for sun
top models)
M6
4
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Intake air temperature sensor
screw
M5
1
1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Rectifier/regulator bolt
M6
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Ground lead bolt
M6
1
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Ignition coil bolt
M6
2
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Horn lead nut (for Europe and
Oceania)
—
2
2.3 Nm (023 m·kgf, 1.7 ft·lbf)
Horn nut (for Europe and Oceania)
M6
1
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Remarks
TIP
Enclosure bolt and nut
Tighten the enclosure bolts and nuts to specification in the proper tightening sequence.
Enclosure tightening sequence:
2
2
2
1
5
1
1
1
2
3
4
5
4
3
TIP
Steering assembly bolt
Tighten the steering assembly bolts to 48 Nm (4.8 m·kgf, 35 ft·lbf) in the proper tightening sequence.
2-24
TIGHTENING TORQUES
Steering assembly tightening sequence:
FWD
4
2
1
3
TIP
Fuel pump nut
Tighten the fuel pump nuts to 7 Nm (0.7 m·kgf, 5.1 ft·lbf) in the proper tightening sequence.
Fuel pump tightening sequence:
2
4
5
6
1
3
TIP
Fuel tank bolt
Tighten the fuel tank bolts and fuel tank retainer bolts to specification in the proper tightening sequence.
Fuel tank tightening sequence:
3
4
5
2
1
TIP
Final drive assembly bolt and nut
Tighten the final drive assembly bolts and nuts to specification in the proper tightening sequence.
2-25
TIGHTENING TORQUES
Final drive assembly tightening sequence:
6
3
4
5
7
9 8
FWD
1
2
2-26
LUBRICATION AND SEALING POINTS
EAS20360
LUBRICATION AND SEALING POINTS
EAS20370
ENGINE
Lubrication point
Oil seal lips
Lubricant/Sealant
LS
Bearings
E
O-rings
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 rings and ring grooves
E
Valve stems and stem ends (intake and exhaust)
M
Valve stem seals (intake and exhaust)
M
Rocker arm shafts
E
Camshaft lobes
M
Decompressor lever pin
E
Decompressor lever
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
M
Reverse idle gear shaft
E
Reverse idle gear
E
2-27
LUBRICATION AND SEALING POINTS
Lubrication point
Lubricant/Sealant
Middle driven shaft splines
M
Shift drum
E
Shift forks and shift fork guide bar
E
Shift drum stopper ball
E
Shift lever 1 and shift lever 2
E
AC magneto lead grommet
Yamaha bond
No.1215 (Three bond
No.1215®)
Crankcase mating surface
Yamaha bond
No.1215 (Three bond
No.1215®)
2-28
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20390
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20400
ENGINE OIL LUBRICATION CHART
9
9
6
11
10
8
7
5
4
3
1
2-29
2
LUBRICATION SYSTEM CHART AND DIAGRAMS
1. Oil pan
2. Oil strainer
3. Oil pump assembly
4. Relief valve assembly
5. Oil cooler
6. Oil filter cartridge
7. Drive axle
8. Reverse idle gear shaft
9. Oil pipe (crankcase to cylinder head)
10. Crankshaft
11. Cylinder head
2-30
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20410
LUBRICATION DIAGRAMS
6
1
5
7
4
3
2
8
3
9
2-31
2
LUBRICATION SYSTEM CHART AND DIAGRAMS
1.
2.
3.
4.
5.
6.
7.
8.
9.
Oil pipe (crankcase to cylinder head)
Oil filter cartridge
Oil cooler
Oil strainer
Oil pump
Oil pipe (AC magneto cover)
Reverse idle gear shaft
Drive axle
Relief valve assembly
2-32
LUBRICATION SYSTEM CHART AND DIAGRAMS
1
2
5
2-33
4
3
LUBRICATION SYSTEM CHART AND DIAGRAMS
1.
2.
3.
4.
5.
Camshaft
Crankshaft
Oil strainer
Oil pump
Oil pump driven sprocket
2-34
COOLING SYSTEM DIAGRAMS
EAS20420
COOLING SYSTEM DIAGRAMS
1
6
2
3
5
4
1
2
5
4
2-35
COOLING SYSTEM DIAGRAMS
1.
2.
3.
4.
5.
6.
Radiator
Radiator outlet hose
Radiator outlet pipe
Radiator inlet pipe
Radiator inlet hose
Radiator cap
2-36
COOLING SYSTEM DIAGRAMS
1
2
5
4
3
3
5
2
4
2-37
6
COOLING SYSTEM DIAGRAMS
1.
2.
3.
4.
5.
6.
Radiator outlet pipe
Water pump inlet hose
Thermostat outlet hose
Oil cooler outlet hose
Radiator inlet pipe
Thermostat
2-38
COOLING SYSTEM DIAGRAMS
1
2
3
4
4
5
9
6
8
4
7
2-39
COOLING SYSTEM DIAGRAMS
1.
2.
3.
4.
5.
6.
7.
8.
9.
Thermostat outlet hose
Water pump inlet hose
Water pump
Water pump outlet pipe
Oil cooler inlet hose
Oil cooler
Oil cooler outlet hose
Water pump outlet hose
Water jacket joint
2-40
CABLE ROUTING
EAS20430
CABLE ROUTING
Radiator view (right side)
1
2
A
B
3
4
13
I
5
12
C
11
10
6
9
D
8
H
G
E
F
7
2-41
CABLE ROUTING
1. Horn lead (for Europe and Oceania)
2. Wire harness
3. Radiator fan motor breather hose
4. Differential assembly breather hose
5. Coolant reservoir breather hose
6. Radiator outlet hose
7. Differential motor lead
8. Coolant reservoir hose
9. Radiator fan motor lead
10. Drive select lever shift cable
11. Parking brake cable
12. Ground lead
13. Auxiliary DC jack lead
A. Route the wire harness, starter motor lead,
negative battery lead, and horn lead (for Europe
and Oceania) into the electrical components tray.
B. Make sure that there is no slack in the coolant
reservoir breather hose in the area shown in the
illustration.
C. Fasten the coolant reservoir breather hose to the
radiator outlet hose with the plastic band. Align the
plastic band with the portion of the radiator outlet
hose where the hose begins to bend.
D. Fasten the differential assembly breather hose with
the holder on the radiator.
E. Fasten the coolant reservoir hose to the radiator
outlet hose with the plastic band. Align the plastic
band with the portion of the radiator outlet hose
where the hose begins to bend.
F. Fasten the radiator fan motor lead to the radiator
outlet hose with the plastic band.
G. Insert the projection on the wire harness holder
into the hole in the frame from the inside of the
frame.
H. Fasten the wire harness, starter motor lead,
negative battery lead, drive select lever shift cable,
and parking brake cable with the plastic band.
I. Fasten the wire harness, starter motor lead, and
negative battery lead with the plastic band.
Position the plastic band at the section of the wire
harness where the leads branch off from the
harness.
2-42
CABLE ROUTING
Radiator view (left side)
B C
10
11
12
13
2
13
D
2
5
6
4
3
1
2
4
5
6
4
3
7
8
9
9
A
3 E
9
3 F
2-43
CABLE ROUTING
1. Coolant reservoir hose
2. Wire harness
3. Throttle cable
4. Brake light switch lead
5. EPS motor lead (for EPS models)
6. EPS torque sensor lead (for EPS models)
7. Drive select lever shift cable
8. Parking brake cable
9. Radiator inlet hose
10. Differential assembly breather hose
11. Coolant reservoir breather hose
12. Radiator fan motor breather hose
13. Horn lead (for Europe and Oceania)
A. Fasten the coolant reservoir hose with the holder
on the radiator.
B. Route the right headlight lead and horn lead (for
Europe and Oceania) into the electrical
components tray, and then fasten the lead with the
holder on the electrical components tray.
C. Route the differential assembly breather hose,
coolant reservoir breather hose, and radiator fan
motor breather hose through the hole in the
electrical components tray. Make sure that the end
of each breather hose protrudes out of the
electrical components tray.
D. Fasten the right headlight lead and horn lead (for
Europe and Oceania) with the holder on the
electrical components tray.
E. Fasten the throttle cable to the radiator inlet hose
with the plastic band. Be sure to route the throttle
cable to the outside of the radiator inlet hose and
install the plastic band around the hose protector
of the radiator inlet hose, not the hose itself.
F. Fasten the throttle cable to the radiator inlet hose
with the plastic band. Be sure to route the throttle
cable to the inside of the radiator inlet hose and
install the plastic band around the hose protector
of the radiator inlet hose, not the hose itself.
2-44
CABLE ROUTING
Radiator view (top)
3
4
N
3
4
6
5
7
7
6
4
C
1
3
D
5
5
6
7
E
E
2
B
A
F
M
L
17
H
11
12
13
K
I
14
J
15
16
2-45
10 9 G 8
G
CABLE ROUTING
1. Right headlight lead
2. Horn lead (for Europe and Oceania)
3. Wire harness
4. Negative battery lead
5. Starter motor lead
6. Parking brake cable
7. Drive select lever shift cable
8. Throttle cable
9. Meter assembly lead
10. Indicator light assembly lead
11. Parking brake switch lead
12. Main switch lead
13. EPS motor lead (for EPS models)
14. EPS torque sensor lead (for EPS models)
15. Light switch lead
16. On-Command four-wheel-drive switch lead
17. Left headlight lead
A. Fasten the right headlight lead and horn lead (for
Europe and Oceania) to the frame with the plastic
band.
B. To the electrical components tray
C. Fasten the wire harness with the plastic band.
Position the plastic band at the section of the wire
harness before the leads branch off from the
harness.
D. Fasten the wire harness and horn lead (for Europe
and Oceania) at the white mark on the harness
with the plastic band.
E. Fasten the wire harness, starter motor lead,
negative battery lead, drive select lever shift cable,
and parking brake cable with the plastic band.
F. To the horn switch (for Europe and Oceania)
G. Fasten the throttle cable with the plastic band.
H. Fasten the parking brake switch lead with the
plastic band.
I. Route the EPS torque sensor lead through the
frame, and then connect the coupler to the EPS
torque sensor. (For EPS models)
J. Fasten the wire harness with the plastic band.
Position the plastic band at the section of the wire
harness before the leads branch off from the
harness.
K. Fasten the wire harness and EPS motor lead (for
EPS models) with the plastic band. Position the
plastic band at the section of the wire harness
before the leads branch off from the harness.
L. Route the EPS torque sensor lead and EPS motor
lead through the hole in the electrical components
tray, and then connect the couplers to the EPS
control unit. (For EPS models)
M. Fasten the left headlight lead to the frame with the
plastic band.
N. Insert the projection on the holder into the second
hole from the right in the frame, and then fasten the
wire harness with the holder.
2-46
CABLE ROUTING
Engine view (right side)
8
9
H
J
I
K 2
6
G 1
1
A
2
B
2
C
6
D
E
B
F
9
8
7
6
5
2-47
4
3
CABLE ROUTING
1.
2.
3.
4.
5.
6.
7.
8.
9.
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
Wire harness
Final drive assembly breather hose
Drive select lever shift cable
Intake air temperature sensor lead
Speed sensor lead
Parking brake cable
AC magneto lead
Negative battery lead
Starter motor lead
Route the final drive assembly breather hose
through the hole in the frame.
Fasten the final drive assembly breather hose with
the holder.
Fasten the wire harness with the plastic band.
Position the plastic band to the front of the split in
the wire harness.
Fasten the negative battery lead and starter motor
lead with the holder.
Fasten the wire harness to the frame with the
plastic band. Be sure to position the plastic band
above the bracket.
Route the wire harness in front of the frame, and
then fasten the wire harness to the frame with the
plastic band. Be sure to position the plastic band
under the bracket.
Route the wire harness to the inside of the frame.
Fasten the negative battery lead and starter motor
lead with the plastic band.
10–30°
50–60 mm (1.97–2.36 in)
Align the holder with the white mark on the final
drive assembly breather hose.
2-48
CABLE ROUTING
Engine view (left side)
D
5
4
10
2
1
B
6 E
11
C
A
2-49
3
4
5
6
7
8
9
CABLE ROUTING
1. Seat belt switch lead
2. Gear position switch lead
3. Reverse switch lead
4. Throttle cable
5. Cylinder head breather hose
6. Throttle body breather hose
7. ISC unit lead
8. Coolant temperature sensor lead
9. Air induction system solenoid lead
10. Spark plug lead
11. Wire harness
A. Fasten the seat belt switch lead with the holder.
B. Route the seat belt switch lead to the left side of
the frame.
C. To the seat belt switch
D. Fasten the wire harness with the plastic band.
Position the plastic band near the ignition coil
bracket and at the section of the wire harness
before the leads branch off from the harness.
E. Make sure that the throttle body breather hose is
not pinched.
2-50
CABLE ROUTING
Engine view (top)
*A
*B
*D
*C
9
9
*E
*F
10
9
10
10
9
1
2
3
4 B 5
6
C
7
D
8
*A
A
L
*A
E
17
16
K
J
I
H
G
15 14
13
12
*B
*B
*C
*C
*D
*D
*D
*D
*D
*D
*E
*E
*D
*D
11
F
12
11
*F
*F
10
1 M
13
13
2-51
CABLE ROUTING
1.
2.
3.
4.
5.
6.
7.
8.
Wire harness
Parking brake cable
Drive select lever shift cable
Fuel pump lead
Fuel hose
TPS lead
Intake air pressure sensor lead
Air induction system hose (air cut-off valve to reed
valve cover)
9. Right tail/brake light lead
10. Left tail/brake light lead
11. Spark plug lead
12. Air induction system solenoid lead
13. Air induction system hose (air intake silencer to air
cut-off valve)
14. Thermostat outlet hose
15. ISC unit lead
16. Throttle cable
17. Seat belt switch lead
A. To the fuel pump
B. Fasten the wire harness with the holder.
C. Fasten the hose protector of the fuel hose with the
holder.
D. Insert the projection on the holder into the hole in
the frame cross member from under the member,
and then fasten the wire harness with the holder.
E. Connect the right tail/brake light connectors. Make
sure that there is no slack in the lead between the
holders in the area shown in the illustration. Place
the slack in the lead to the outside of the outermost
holder.
F. Connect the left tail/brake light connectors. Make
sure that there is no slack in the lead between the
holders in the area shown in the illustration. Place
the slack in the lead to the outside of the outermost
holder.
G. Route the wire harness between the air induction
system hose (air intake silencer to air cut-off valve)
and the thermostat outlet hose.
H. Fasten the air induction system solenoid lead with
the holder under the frame cross member. Position
the holder at the section of the lead after the lead
branches off from the wire harness.
I. Fasten the spark plug lead to the air induction
system hose (air intake silencer to air cut-off valve)
with the holder. Align the holder with the portion of
the air induction system hose (air intake silencer to
air cut-off valve) where the hose begins to bend.
J. Route the spark plug lead above the air induction
system hose (air intake silencer to air cut-off valve)
and wire harness.
K. Fasten the wire harness with the holder. Position
the holder at the section of the wire harness before
the leads branch off from the harness.
L. Fasten the throttle cable at the white paint mark to
the hose protector of the thermostat outlet hose
with the plastic band. Align the plastic band with
the portion of the thermostat outlet hose where the
hose begins to bend.
M. Route the wire harness under the frame. Make
sure that the wire harness is not pinched between
the frame and the air intake silencer.
2-52
CABLE ROUTING
Final drive assembly view
4
2
4
D F
E
D
2
C
1
A
2
1
A
3
B
2-53
CABLE ROUTING
1.
2.
3.
4.
A.
B.
C.
D.
E.
F.
Wire harness
Final drive assembly breather hose
Parking brake cable
Rear brake hose
Fasten the wire harness with the holder.
Fasten the final drive assembly breather hose with
the holder.
Insert the projection on the holder into the hole in
the cargo bed, and then fasten the wire harness
with the holder.
Fasten the rear brake hose with the holder.
Fasten the rear brake hose and final drive
assembly breather hose with the holder. Position
the holder to the right of the centerline between the
holders securing the brake hose.
Centerline
2-54
CABLE ROUTING
Fuel tank view
A
1
B
1
2
A
1
3
4
4
C
4
D
D
3
D
2-55
A
CABLE ROUTING
1. Fuel hose
2. Fuel pump lead
3. Fuel tank breather hose (fuel tank to fuel tank
breather hose joint)
4. Fuel tank breather hose (fuel tank breather hose
joint to air)
A. Fasten the grommet on the fuel hose with the
holder.
B. Fasten the fuel pump lead with the holder.
C. Insert the fuel tank breather hose (fuel tank
breather hose joint to air) into the hole in the frame.
D. 0–3.0 mm (0–0.12 in)
2-56
CABLE ROUTING
Front brake caliper view (left side)
2
B
1
2
3
2
A
2-57
CABLE ROUTING
1.
2.
3.
A.
Front brake pipe
Front brake hose
Rear brake pipe
Connect the front brake hose end that has a
projection to the left front brake caliper.
B. Fasten the front brake hose with the holder.
2-58
CABLE ROUTING
Front brake caliper view (top)
A
1
3
B
2
C
2-59
CABLE ROUTING
1.
2.
3.
A.
B.
Front brake hose
Front brake pipe
Rear brake pipe
Face the paint mark upward.
Route the front brake hose under the front upper
arm.
C. Fasten the front brake hose with the holder.
2-60
CABLE ROUTING
Rear brake caliper view (left side)
B
2
B
C
1
A
2
A
1
B
2-61
CABLE ROUTING
1.
2.
A.
B.
C.
Rear brake pipe
Rear brake hose
Fasten the rear brake pipe with the holder.
Fasten the rear brake hose with the holder.
Face the paint mark forward.
2-62
CABLE ROUTING
Rear brake caliper view (top)
A
1
A
B
2
B
C
D
2
B
2
2-63
CABLE ROUTING
1.
2.
A.
B.
C.
D.
Rear brake pipe
Rear brake hose
Fasten the rear brake pipe with the holder.
Fasten the rear brake hose with the holder.
Right side
Connect the rear brake hose end that has a
projection to the right rear brake caliper.
2-64
CABLE ROUTING
Parking brake view
1
A
1
B
1
1
2-65
CABLE ROUTING
1. Parking brake cable
A. Fit the parking brake cable into the slit in the
parking brake lever.
B. Fit the parking brake cable into the holder on the
parking brake caliper.
2-66
CABLE ROUTING
Electrical components tray view
2
A
B 3 4 5 6
7 8
1
24
8
7
23
17
23
22
21
1
20
1
19
9
18
17
10
9
11
16
12
D
15
C
13
14
15
14
13
E
2-67
CABLE ROUTING
1. Wire harness
2. Right headlight lead
3. Load control relay
4. Differential motor relay 2
5. Fuel injection system relay
6. Differential motor relay 1
7. Radiator fan motor relay
8. Headlight relay
9. Main fuse lead
10. Fuel injection system fuse
11. Battery
12. EPS control unit (for EPS models)
13. EPS motor lead (for EPS models)
14. Left headlight lead
15. EPS torque sensor lead (for EPS models)
16. Lean angle sensor lead
17. Negative battery lead
18. Starter relay lead
19. Positive battery lead
20. EPS fuse (for EPS models)
21. ECU (engine control unit) lead
22. Main fuse
23. Starter motor lead
24. Fuse box
A. Fasten the right headlight lead with the holder on
the electrical components tray.
B. Fasten the wire harness and main fuse lead with a
plastic band, making sure to align the band with
the white tape on the harness.
C. Fasten the left headlight lead, EPS motor lead (for
EPS models), and EPS torque sensor lead (for
EPS models) with the holder on the electrical
components tray.
D. Place the slack in the leads in the electrical
components tray.
E. Connect the EPS motor coupler and EPS torque
sensor coupler, and then insert the projection on
each coupler into the hole in the electrical
components tray. (For EPS models)
2-68
CABLE ROUTING
2-69
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE ............................................................................3-1
INTRODUCTION .......................................................................................3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM ................................................................................ 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART .......................3-1
CHECKING THE FUEL LINE .................................................................... 3-3
ADJUSTING THE VALVE CLEARANCE .................................................. 3-3
CHECKING THE SPARK PLUG ............................................................... 3-5
CHECKING THE BREATHER HOSES .....................................................3-6
CHECKING THE EXHAUST SYSTEM......................................................3-6
ADJUSTING THE EXHAUST GAS VOLUME
(for Europe and Oceania) ......................................................................... 3-6
CLEANING THE SPARK ARRESTER ......................................................3-6
CHECKING THE AIR INDUCTION SYSTEM............................................3-7
CHECKING THE COOLING SYSTEM ......................................................3-7
CHECKING THE COOLANT LEVEL.........................................................3-8
CHANGING THE COOLANT..................................................................... 3-8
CLEANING THE AIR FILTER ELEMENT................................................ 3-10
CHECKING THE ENGINE OIL LEVEL....................................................3-12
CHANGING THE ENGINE OIL ...............................................................3-13
CHECKING THE FINAL GEAR OIL LEVEL ............................................3-14
CHANGING THE FINAL GEAR OIL........................................................ 3-15
CHECKING THE DIFFERENTIAL GEAR OIL LEVEL............................. 3-15
CHANGING THE DIFFERENTIAL GEAR OIL ........................................ 3-16
CHECKING THE FRONT BRAKE PADS ................................................ 3-16
CHECKING THE BRAKE FLUID LEVEL................................................. 3-16
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-17
CHECKING THE BRAKE HOSES AND BRAKE PIPES ......................... 3-18
ADJUSTING THE BRAKE PEDAL .......................................................... 3-19
LUBRICATING THE BRAKE PEDAL AND
ACCELERATOR PEDAL ........................................................................3-19
CHECKING THE REAR BRAKE PADS .................................................. 3-20
CHECKING THE PARKING BRAKE PADS ............................................3-20
ADJUSTING THE PARKING BRAKE LEVER.........................................3-20
CHECKING AND LUBRICATING THE CABLES .................................... 3-21
ADJUSTING THE ACCELERATOR PEDAL FREE PLAY ......................3-21
CHECKING THE V-BELT........................................................................3-22
REPLACING THE V-BELT ...................................................................... 3-23
CHECKING THE WHEELS ..................................................................... 3-23
CHECKING THE TIRES..........................................................................3-24
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES ............. 3-25
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................ 3-25
CHECKING THE STEERING SYSTEM .................................................. 3-26
ADJUSTING THE TOE-IN....................................................................... 3-26
LUBRICATING THE STEERING SHAFT ................................................ 3-27
CHECKING THE STABILIZER BUSHINGS ............................................3-27
LUBRICATING THE REAR KNUCKLE PIVOTS ..................................... 3-28
LUBRICATING THE DRIVE SHAFT UNIVERSAL JOINTS ....................3-28
CHECKING THE ENGINE MOUNT ........................................................ 3-28
CHECKING THE CONSTANT VELOCITY SHAFT ASSEMBLY
DUST BOOTS ........................................................................................ 3-28
CHECKING THE FASTENERS...............................................................3-29
3
PERIODIC MAINTENANCE
EAS20450
PERIODIC MAINTENANCE
EAS20460
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. 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.
EVU01640
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
• For vehicles not equipped with an odometer or hour meter, follow the month maintenance intervals.
• For vehicles equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance
intervals. However, keep in mind that if the vehicle 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
month
NO.
ITEM
CHECK OR MAINTENANCE
JOB
Whichever
comes first km (mi)
hours
1
3
6
6
12
320
(200)
1200
(750)
2400
(1500)
2400
(1500)
4800
(3000)
20
75
150
150
300
√
√
√
√
√
√
√
√
√
1
*
Fuel line
• Check fuel hose for cracks or damage.
• Replace if necessary.
2
*
Valves
• Check valve clearance.
• Adjust if necessary.
√
Spark plug
• Check condition.
• Adjust gap and clean.
• Replace if necessary.
√
3
EVERY
√
4
*
Crankcase breather
system
• Check breather hose for cracks or damage.
• Replace if necessary.
√
√
√
5
*
Exhaust system
• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.
√
√
√
Spark arrester
• Clean.
√
√
√
Air induction system
• Check the air cut-off valve, reed valve, and hose for
damage.
• Replace any damaged parts if necessary.
√
√
√
6
7
*
√
√
EVU01650
GENERAL MAINTENANCE AND LUBRICATION CHART
INITIAL
month
NO.
ITEM
CHECK OR MAINTENANCE
JOB
Whichever
comes first km (mi)
hours
EVERY
1
3
6
6
12
320
(200)
1200
(750)
2400
(1500)
2400
(1500)
4800
(3000)
20
75
150
150
300
√
√
√
√
√
Cooling system
• Check coolant leakage.
• Repair if necessary.
• Replace coolant every 24 months.
Air filter element
• Clean.
• Replace if necessary.
3
Engine oil
• Replace (warm engine before draining).
√
√
4
Engine oil filter cartridge
• Replace.
√
√
1
2
*
Every 20–40 hours
(more often in wet or dusty areas.)
3-1
√
√
√
PERIODIC MAINTENANCE
INITIAL
month
NO.
ITEM
CHECK OR MAINTENANCE
JOB
Whichever
comes first km (mi)
hours
5
Final gear oil
6
Differential gear oil
EVERY
1
3
6
6
12
320
(200)
1200
(750)
2400
(1500)
2400
(1500)
4800
(3000)
20
75
150
150
300
• Check oil level/oil leakage.
• Replace.
√
√
7
*
Front brake
• Check operation/brake pad wear/fluid leakage.
• Correct if necessary. Replace pads if worn to the limit.
√
√
√
√
√
8
*
Rear brake
• Check operation/brake pad wear/fluid leakage.
• Correct if necessary. Replace pads if worn to the limit.
√
√
√
√
√
9
*
Parking brake
• Check operation and free play/brake pad wear.
• Correct if necessary. Replace pads if worn to the limit.
√
√
√
√
√
10
*
Brake fluid
• Replace.
11
*
Accelerator pedal
• Check operation and free play.
√
√
√
√
√
√
Every 2 years
√
√
12
*
V-belt
• Check operation.
• Check for wear, cracks, or damage.
13
*
Wheels
• Check balance/damage/runout.
• Repair if necessary.
√
√
√
√
14
*
Wheel bearings
• Check bearing assemblies for looseness/damage.
• Replace if damaged.
√
√
√
√
15
*
Front and rear suspension
• Check operation and for leakage.
• Correct if necessary.
16
*
Steering system
• Check operation and for looseness/Replace if damaged.
• Check toe-in/Adjust if necessary.
17
*
Stabilizer bushes
18
*
19
√
√
√
√
√
√
√
• Check for cracks or other damage, and replace if
necessary.
√
√
√
Rear upper and lower
knuckle pivots
• Lubricate with lithium-soap-based grease.
√
√
√
*
Drive shaft universal
joint
• Lubricate with lithium-soap-based grease.
√
√
√
20
*
Engine mount
• Check for cracks or damage.
• Check bolt tightness.
√
√
√
21
*
Front and rear axle
boots
• Check for cracks or other damage, and replace if
necessary.
√
22
*
Fittings and fasteners
• Check all chassis fittings and fasteners.
• Correct if necessary.
√
√
√
√
√
√
TIP
• Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy
or muddy areas, or at full throttle.
• Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-2
PERIODIC MAINTENANCE
EAS21030
CHECKING THE FUEL LINE
1. Lift the cargo bed.
2. Remove:
• Outer passenger seat frame
• Right passenger compartment panel
Refer to “GENERAL CHASSIS” on page 4-1.
3. Check:
• Fuel hose “1”
Cracks/damage → Replace.
Loose connection → Connect properly.
2
3
4
1
5. Disconnect:
• Spark plug cap
6. Remove:
• Spark plug
1
ECA13330
NOTICE
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from falling
into the cylinder.
7. Remove:
• Crankshaft end accessing screw “1”
• Timing mark accessing screw “2”
4. Install:
• Right passenger compartment panel
• Outer passenger seat frame
Refer to “GENERAL CHASSIS” on page 4-1.
5. Lower the cargo bed.
2
EAS20520
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
1
TIP
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
8. Measure:
• Valve clearance
Out of specification → Adjust.
1. Lift the cargo bed.
2. Remove:
• Frame cross member
• Right rear panel
Refer to “GENERAL CHASSIS” on page 4-1.
• Exhaust pipe heat protector plate
Refer to “ENGINE REMOVAL” on page 5-1.
3. Disconnect:
• Cylinder head breather hose “1”
4. Remove:
• Intake tappet cover “2”
• Exhaust tappet cover “3”
• Camshaft sprocket cover “4”
Valve clearance (cold)
Intake
0.09–0.13 mm (0.0035–0.0051 in)
Exhaust
0.16–0.20 mm (0.0063–0.0079 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
b. When the piston is at 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.
3-3
PERIODIC MAINTENANCE
c. Turn the adjusting screw “3” in direction “a” or
“b” with the tappet adjusting tool “4” until the
specified valve clearance is obtained.
Tappet adjusting tool
90890-01311
Six piece tappet set
YM-A5970
a
b
Direction “a”
Valve clearance is increased.
Direction “b”
Valve clearance is decreased.
TIP
To position the piston at 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.
d
b
4
3
c
1
a
2
• Hold the adjusting screw to prevent it from
moving and tighten the locknut to specification.
c. Measure the valve clearance with the thickness gauge “1”.
Out of specification → Adjust.
T.
R.
Thickness gauge
90890-03079
Narrow gauge set
YM-34483
Valve adjusting screw locknut
14 Nm (1.4 m·kgf, 10 ft·lbf)
d. Measure the valve clearance again.
e. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is
obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
10.Install:
• O-ring New
• Timing mark accessing screw
• O-ring New
• Crankshaft end accessing screw
1
T.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
R.
9. Adjust:
• Valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Timing mark accessing screw
1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Crankshaft end accessing screw
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
11.Install:
• Spark plug
a. Loosen the locknut “1”.
b. Insert the thickness gauge “2” between the
end of the adjusting screw and the valve tip.
3-4
PERIODIC MAINTENANCE
ECA13330
TIP
NOTICE
Before installing the spark plug, clean the spark
plug and gasket surface.
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from falling
into the cylinder.
T.
R.
Spark plug
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
4. Check:
• Spark plug type
Incorrect → Change.
12.Connect:
• Spark plug cap
13.Install:
Manufacturer/model
NGK/CPR7EA-9
• O-ring New
• Camshaft sprocket cover
5. Check:
• Electrodes “1”
Damage/wear → Replace the spark plug.
• Insulator “2”
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
• Spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
• Spark plug gap “a”
(with a wire thickness gauge)
Out of specification → Regap.
• O-ring “1” New
• Intake tappet cover
• O-ring New
• Exhaust tappet cover
T.
R.
Camshaft sprocket cover bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tappet cover bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Spark plug gap
0.8–0.9 mm (0.031–0.035 in)
1 New
14.Connect:
• Cylinder head breather hose
15.Install:
• Exhaust pipe heat protector plate
Refer to “ENGINE REMOVAL” on page 5-1.
• Right rear panel
• Frame cross member
Refer to “GENERAL CHASSIS” on page 4-1.
16.Lower the cargo bed.
8. Install:
• Spark plug
EAS20690
T.
CHECKING THE SPARK PLUG
1. Lift the cargo bed.
2. Disconnect:
• Spark plug cap
3. Remove:
• Spark plug
R.
Spark plug
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
TIP
Before installing the spark plug, clean the spark
plug and gasket surface.
9. Connect:
• Spark plug cap
3-5
PERIODIC MAINTENANCE
10.Lower the cargo bed.
5
3
EAS1XD1057
CHECKING THE BREATHER HOSES
1. Lift the cargo bed.
2. Remove:
• Frame cross member
Refer to “GENERAL CHASSIS” on page 4-1.
3. Check:
• Cylinder head breather hose “1”
• Throttle body breather hose “2”
Cracks/damage → Replace.
Loose connection → Connect properly.
5 4
1
2
4. Lower the cargo bed.
EAS1XD2005
ECA1XD1016
ADJUSTING THE EXHAUST GAS VOLUME
(for Europe and Oceania)
NOTICE
Make sure the cylinder head breather hose
and throttle body breather hose are routed
correctly.
TIP
• Be sure to set the CO density level to standard,
and then adjust the exhaust gas volume.
• To adjust the exhaust gas volume, use the CO
adjustment mode of the Yamaha diagnostic
tool. For more information, refer to the operation manual of the Yamaha diagnostic tool.
1
2
1. Connect the Yamaha diagnostic tool to the
coupler. For information about connecting the
Yamaha diagnostic tool, refer to “YAMAHA
DIAGNOSTIC TOOL” on page 9-37.
Yamaha diagnostic tool
90890-03215
4. Install:
• Frame cross member
Refer to “GENERAL CHASSIS” on page 4-1.
5. Lower the cargo bed.
EAS1XD2001
CLEANING THE SPARK ARRESTER
1. Clean:
• Spark arrester
EAS21080
CHECKING THE EXHAUST SYSTEM
1. Lift the cargo bed.
2. Check:
• Exhaust pipe “1”
• Muffler “2”
• Muffler mount “3”
• Springs “4”
Cracks/damage → Replace.
• Gaskets “5”
Exhaust gas leaks → Replace.
3. Check:
• Tightening torque
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EWA1XD1004
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.
a. Remove the bolts “1”.
b. Remove the tailpipe “2” by pulling it out of the
muffler and gasket “3”.
T.
R.
Exhaust pipe nut
20 Nm (2.0 m·kgf, 14 ft·lbf)
Muffler bolt
23 Nm (2.3 m·kgf, 17 ft·lbf)
Muffler mount shaft
17 Nm (1.7 m·kgf, 12 ft·lbf)
3-6
PERIODIC MAINTENANCE
1
2. Lift the cargo bed.
3. Check:
• Radiator “1”
• Coolant reservoir hose “2”
• Coolant reservoir “3”
• Radiator outlet hose “4”
• Radiator inlet hose “5”
• Radiator outlet pipe “6”
• Radiator inlet pipe “7”
• Thermostat outlet hose “8”
• Thermostat cover “9”
• Water pump inlet hose “10”
• Water pump housing “11”
• Water pump outlet pipe “12”
• Water pump outlet hose “13”
• Water jacket joint “14”
• Oil cooler inlet hose “15”
• Oil cooler “16”
• Oil cooler outlet hose “17”
Cracks/damage → Replace.
Coolant leakage → Replace any damaged
hose and pipe
Refer to “OIL COOLER” on page 6-1, “RADIATOR” on page 6-4, “THERMOSTAT” on
page 6-8 and “WATER PUMP” on page 6-11.
1
2
2
3
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 the inner
contact surfaces of the muffler.
d. Install a new gasket, and then insert the
tailpipe into the muffler and align the bolt
holes.
e. Install the bolts “1” and tighten them.
7
T.
R.
Spark arrester bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
5
6
4
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
2
3
EAS1XD1013
CHECKING THE AIR INDUCTION SYSTEM
Refer to “CHECKING THE AIR INDUCTION
SYSTEM” on page 7-19.
8
9
EAS21120
CHECKING THE COOLING SYSTEM
1. Remove:
• Sun top (for sun top models)
• Side frames
• Hood
• Front fender
• Instrument panel
• Center passenger seat frame
• Center passenger compartment panel
• Center floor board
Refer to “GENERAL CHASSIS” on page 4-1.
• Air filter case
Refer to “AIR FILTER CASE” on page 7-5.
3-7
PERIODIC MAINTENANCE
17
a
14
12
13
16
10
b
15
11
3. If the coolant is at or below the minimum level
mark, remove the reservoir cap “1”, add coolant or distilled water to the maximum level
mark “a”, install the reservoir cap.
4. Lower the cargo bed.
5. Install:
• Air filter case
Refer to “AIR FILTER CASE” on page 7-5.
• Center floor board
• Center passenger compartment panel
• Center passenger seat frame
• Instrument panel
• Front fender
• Hood
• Side frames
• Sun top (for sun top models)
Refer to “GENERAL CHASSIS” on page 4-1.
Coolant reservoir capacity (up to
the maximum level mark)
0.28 L (0.30 US qt, 0.25 Imp.qt)
1
a
EAS21110
CHECKING THE COOLANT LEVEL
1. Place the vehicle on a level surface.
TIP
The coolant level must be checked on a cold engine since the level varies with engine temperature.
EAS21130
CHANGING THE COOLANT
1. Remove the hood.
2. Lift the cargo bed.
3. Remove:
• Right rear panel
Refer to “GENERAL CHASSIS” on page 4-1.
4. Remove:
• Coolant reservoir cap “1”
5. Disconnect:
• Coolant reservoir hose “2”
2. Check:
• Coolant level
The coolant level should be between the
maximum level mark “a” and minimum level
mark “b”.
Below the minimum level mark → Add the
recommended coolant to the proper level.
ECA13470
NOTICE
• 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.
1
2
6. Drain:
• Coolant
(from the coolant reservoir)
3-8
PERIODIC MAINTENANCE
T.
7. Connect:
• Coolant reservoir hose
8. Remove:
• Radiator cap “1”
R.
Coolant drain bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
12.Fill:
• Cooling system
(with the specified amount of the recommended coolant)
EWA13030
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.
Recommended antifreeze
High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Radiator capacity (including all
routes)
2.74 L (2.90 US qt, 2.41 Imp.qt)
Coolant reservoir capacity (up to
the maximum level mark)
0.28 L (0.30 US qt, 0.25 Imp.qt)
1
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
EWA13040
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.
9. Remove:
• Coolant drain bolt “1”
(along with the copper washer)
TIP
ECA13480
Place a container under the engine, and then remove the coolant drain bolt.
NOTICE
• 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.
1
10.Drain:
• Coolant
(from the engine and radiator)
11.Install:
• Coolant drain bolt
13.Install:
• Radiator cap
(along with the copper washer New )
3-9
PERIODIC MAINTENANCE
14.Fill:
• Coolant reservoir
(with the recommended coolant to the maximum level mark “a”)
15.Install:
• Coolant reservoir cap “1”
d. When coolant begins to flow out of the bolt
hole, tighten the thermostat cover air bleed
bolt to specification.
T.
R.
Thermostat cover air bleed bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
17.Start the engine, warm it up for ten minutes,
and then rev the engine five times.
18.Pour the recommended coolant into the radiator until it is full.
19.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.
20.Check:
• Coolant level
Refer to “CHECKING THE COOLANT LEVEL” on page 3-8.
21.Start the engine, and then check for coolant
leakage.
22.Install:
• Right rear panel
Refer to “GENERAL CHASSIS” on page 4-1.
23.Lower the cargo bed.
24.Install the hood.
1
a
16.Bleed:
• Cooling system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the water pump air bleed bolt “1”,
without removing it, to allow all of the air to escape from the air bleed bolt hole.
1
EAS20951
CLEANING THE AIR FILTER ELEMENT
1. Check:
• Check hoses “1”
2. Remove:
• Center passenger seat cushion
Refer to “GENERAL CHASSIS” on page 4-1.
b. When coolant begins to flow out of the bolt
hole, tighten the water pump air bleed bolt to
specification.
T.
Water pump air bleed bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
TIP
R.
There are check hoses “1” at the bottom of the
air filter case and on the air intake duct. If dust
and/or water collects in these hoses, clean the
air filter element, filter frame, and air filter case.
c. Loosen the thermostat cover air bleed bolt
“2”, without removing it, to allow all of the air
to escape from the air bleed bolt hole.
È
1
2
3-10
PERIODIC MAINTENANCE
É
3
2
1
1
6. Check:
• Air filter element
• Air filter element frame
• Air filter element holder
Damage → Replace.
7. Clean:
• Air filter element
A. Air filter case check hose
B. Air intake duct check hose
3. Remove:
• Air filter case cover “1”
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Carefully wash the air filter element in solvent.
EWA13020
WARNING
Never use low flash point solvents, such as
gasoline, to clean the air filter element. Such
solvents may cause a fire or an explosion.
4. Remove:
• Air filter element “1”
1
b. After cleaning, squeeze the air filter element
to remove the excess solvent.
5. Disassemble:
• Air filter element holder “1”
• Air filter element “2”
• Air filter element frame “3”
ECA13430
NOTICE
Do not twist the air filter element when
squeezing it.
ECA1XD1028
NOTICE
The engine should never be run without the
air filter; excessive piston and/or cylinder
wear may result.
c. Properly dispose of the used solvent.
3-11
PERIODIC MAINTENANCE
d. Carefully wash the air filter element in soap
water.
11.Install:
• Center passenger seat cushion
Refer to “GENERAL CHASSIS” on page 4-1.
EAS28910
CHECKING THE ENGINE OIL LEVEL
1. Place the vehicle on a level surface.
2. Check the engine oil level on a cold engine.
TIP
If the engine was started before the oil level was
checked, be sure to warm up the engine sufficiently, and then wait at least 10 minutes until
the oil settles for an accurate reading.
e. Thoroughly rinse the air filter element with
water, and then let it dry.
3. Lift the cargo bed.
4. Check:
• Engine oil level
The engine oil level should be between the
minimum level mark “a” and maximum level
mark “b”.
Below the minimum level mark → Add the
recommended engine oil to the proper level.
ECA1XD1029
NOTICE
Do not twist the air filter element when rinsing it.
f. Pour the recommended oil into a storage bag
large enough for the air filter element.
Air filter oil grade
Foam air filter oil or equivalent
oil
g. Place the air filter element into the storage
bag and repeatedly squeeze the element until the air filter element is saturated with oil.
ECA1XD1030
NOTICE
Do not allow foreign materials to enter the
crankcase.
TIP
Insert the dipstick completely into the oil filler
hole, and then remove it again to check the oil
level.
TIP
The air filter element should be wet but not dripping.
b
a
Recommended brand
YAMALUBE
Type
SAE 5W-30, 10W-30, 10W-40,
15W-40, 20W-40 or 20W-50
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Assemble:
• Air filter element frame
• Air filter element
• Air filter element holder
9. Install:
• Air filter element assembly
10.Install:
• Air filter case cover
3-12
PERIODIC MAINTENANCE
0
10 30 50 70 90 110 130 ˚F
SAE 5W-30
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 20W-40
2
SAE 20W-50
–20 –10 0
10 20 30 40 50 ˚C
ECA1XD1031
6. Drain:
• Engine oil
(completely from the crankcase)
7. If the oil filter cartridge is also to be replaced,
perform the following procedure.
NOTICE
• Engine oil also lubricates the clutch and the
wrong oil types or additives could cause
clutch slippage. Therefore, do not add any
chemical additives or use engine oils with a
grade of “CD” or higher and do not use oils
labeled “ENERGY CONSERVING II”.
• Do not allow foreign materials to enter the
crankcase.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the oil filter cartridge “1” with the oil
filter wrench “2”.
Oil filter wrench
90890-01426
YU-38411
5. Check the engine oil level again.
ECA1XD1032
NOTICE
Be sure the engine oil is at the correct level,
otherwise engine damage may result.
1
6. Lower the cargo bed.
2
EAS20780
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several minutes, and then turn it off.
2. Lift the cargo bed.
3. Remove:
• Right rear panel
Refer to “GENERAL CHASSIS” on page 4-1.
4. Place a container under the engine oil drain
bolt.
5. Remove:
• Dipstick “1”
• Engine oil drain bolt “2”
(along with the gasket)
b. Lubricate the O-ring “3” of a new oil filter cartridge with a thin coat of engine oil.
ECA13390
NOTICE
Make sure the O-ring “3” is positioned correctly in the groove of the oil filter cartridge.
1
c. Tighten the new oil filter cartridge to specification with the oil filter wrench.
3-13
PERIODIC MAINTENANCE
T.
R.
b. Start the engine and keep it idling until engine
oil starts to seep from the oil check 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” on page 5-71.
d. Start the engine after solving the problems
and check the engine oil pressure again.
e. Tighten the oil check bolt to specification.
Oil filter cartridge
17 Nm (1.7 m·kgf, 12 ft·lbf)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Install:
• Engine oil drain bolt
(along with the gasket New )
T.
R.
Engine oil drain bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
9. Fill:
• Crankcase
(with the specified amount of the recommended engine oil)
R.
Oil check bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
15.Install:
• Right rear panel
Refer to “GENERAL CHASSIS” on page 4-1.
16.Lower the cargo bed.
Engine oil quantity
Total amount
2.60 L (2.75 US qt, 2.29 Imp.qt)
Without oil filter cartridge replacement
2.20 L (2.33 US qt, 1.94 Imp.qt)
With oil filter cartridge replacement
2.30 L (2.43 US qt, 2.02 Imp.qt)
EAS21460
CHECKING THE FINAL GEAR OIL LEVEL
1. Place the vehicle on a level surface.
2. Remove:
• Final gear oil filter bolt “1”
(along with the gasket)
3. Check:
• Final gear oil level
The final gear oil level should be up to the
brim “2” of the hole.
Below the brim → Add the recommended final gear oil to the proper level.
10.Install:
• Dipstick
11.Start the engine, warm it up for several minutes, and then turn it off.
12.Check:
• Engine
(for engine oil leaks)
13.Check:
• Engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-12.
14.Check:
• Engine oil pressure
Type
SAE 80 API GL-4 Hypoid gear
oil
ECA1XD1017
NOTICE
Do not allow foreign material to enter the final drive case.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slightly loosen the oil check bolt “1”.
1
1
2
3-14
PERIODIC MAINTENANCE
4. Check:
• Final gear oil filler bolt gasket
Damage → Replace.
5. Install:
• Final gear oil filler bolt
(along with the gasket)
6. Check:
• Oil level
Refer to “CHECKING THE FINAL GEAR OIL
LEVEL” on page 3-14.
7. Install:
• Final gear oil filler bolt
(along with the gasket)
T.
R.
Final gear oil filler bolt
23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
Final gear oil filler bolt
23 Nm (2.3 m·kgf, 17 ft·lbf)
EAS21470
CHANGING THE FINAL GEAR OIL
1. Place the vehicle on a level surface.
2. Place a container under the final drive case.
3. Remove:
• Final gear oil level check bolt “1”
(along with the gasket)
• Final gear oil drain bolt “2”
(along with the gasket)
Completely drain the final drive case of its oil.
EAS1XD1014
CHECKING THE DIFFERENTIAL GEAR OIL
LEVEL
1. Place the vehicle on a level surface.
2. Remove:
• Differential gear oil filler bolt “1”
(along with the gasket)
3. Check:
• Differential gear oil level
The differential gear oil level should be up to
the brim “2” of the hole.
Below the brim → Add the recommended differential gear oil to the proper level.
1
Type
SAE 80 API GL-4 Hypoid gear
oil
2
ECA1XD1007
NOTICE
4. Install:
• Final gear oil drain bolt
Do not allow foreign material to enter the differential case.
(along with the gasket New )
1
T.
R.
Final gear oil drain bolt
23 Nm (2.3 m·kgf, 17 ft·lbf)
5. Fill:
• Final drive case
(with the specified amount of the recommended final gear oil)
2
Type
SAE 80 API GL-4 Hypoid gear
oil
Total amount
0.45 L (0.47 US qt, 0.40 Imp.qt)
Quantity
0.40 L (0.42 US qt, 0.35 Imp.qt)
4. Check:
• Differential gear oil filler bolt gasket
Damage → Replace.
5. Install:
• Differential gear oil filler bolt
(along with the gasket)
ECA1XD1017
NOTICE
T.
R.
Do not allow foreign material to enter the final drive case.
3-15
Differential gear oil filler bolt
23 Nm (2.3 m·kgf, 17 ft·lbf)
PERIODIC MAINTENANCE
EAS1XD1015
ECA1XD1007
CHANGING THE DIFFERENTIAL GEAR OIL
1. Place the vehicle on a level surface.
2. Place a container under the differential case.
3. Remove:
• Differential gear oil filler bolt “1”
(along with the gasket)
• Differential gear oil drain bolt “2”
(along with the gasket)
Completely drain the differential case of its
oil.
NOTICE
Do not allow foreign material to enter the differential case.
6. Check:
• Oil level
Refer to “CHECKING THE DIFFERENTIAL
GEAR OIL LEVEL” on page 3-15.
7. Install:
• Differential gear oil filler bolt
(along with the gasket)
T.
Differential gear oil filler bolt
23 Nm (2.3 m·kgf, 17 ft·lbf)
R.
EAS21250
CHECKING THE FRONT BRAKE PADS
The following procedure applies to all of the front
brake pads.
1. Remove:
• Front wheels
Refer to “FRONT AND REAR WHEELS” on
page 4-25.
2. Operate the brake.
3. Check:
• Front brake pads
Wear indicator grooves “a” have almost disappeared → Replace the brake pads and
brake pad spring as a set.
Refer to “FRONT AND REAR BRAKES” on
page 4-29.
1
2
4. Install:
• Differential gear oil drain bolt
a
(along with the gasket New )
T.
R.
Differential gear oil drain bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
5. Fill:
• Differential case
(with the specified amount of the recommended differential gear oil)
Type
SAE 80 API GL-4 Hypoid gear
oil
Total amount
0.20 L (0.21 US qt, 0.18 Imp.qt)
Quantity
0.18 L (0.19 US qt, 0.16 Imp.qt)
4. Install:
• Front wheels
Refer to “FRONT AND REAR WHEELS” on
page 4-25.
EAS21240
CHECKING THE BRAKE FLUID LEVEL
1. Place the vehicle on a level surface.
TIP
When checking the brake fluid level, make sure
that the top of the brake master cylinder reservoir is horizontal.
3-16
PERIODIC MAINTENANCE
2. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the
specified brake fluid to the proper level.
• brake operation is faulty.
TIP
• Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir to overflow.
• 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.
Specified brake fluid
DOT 4
a
1. Remove:
• Front wheels
• Rear wheels
Refer to “FRONT AND REAR WHEELS” on
page 4-25.
2. Bleed:
• Hydraulic brake system
EWA1XD1001
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reservoir. Water will significantly lower the boiling point of the brake fluid and could cause
vapor lock.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the brake master cylinder reservoir to the
proper level with the specified brake fluid.
b. Install the diaphragm (brake master cylinder
reservoir).
c. Connect a clear plastic hose “1” tightly to the
bleed screw “2”.
È
2
1
ECA13540
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
TIP
In order to ensure a correct reading of the brake
fluid level, make sure the top of the brake master
cylinder reservoir is horizontal.
É
2
1
EAS21350
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
EWA13100
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.
A. Front brake
B. Rear brake
3-17
PERIODIC MAINTENANCE
d. Place the other end of the hose into a container.
e. Slowly apply the brake several times.
f. Fully depress the brake pedal and hold it in
position.
g. Loosen the bleed screw.
3. Check:
• Front brake pipe “2”
Cracks/damage → Replace.
4. Check:
• Rear brake pipe “3”
Cracks/damage → Replace.
5. Check:
• Rear brake hoses “4”
Cracks/damage/wear → Replace.
TIP
Loosening the bleed screw will release the pressure and cause the brake pedal to fully extend.
h. Tighten the bleed screw, and then release
the 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.
1
1
T.
R.
Bleed screw
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
k. Fill the brake master cylinder reservoir to the
proper level with the specified brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-16.
3
EWA13110
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
2
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3. Install:
• Rear wheels
• Front wheels
Refer to “FRONT AND REAR WHEELS” on
page 4-25.
3
EAS1XD1048
CHECKING THE BRAKE HOSES AND
BRAKE PIPES
1. Remove:
• Sun top (for sun top models)
• Side frames
• Hood
• Front fender
• Instrument panel
• Center passenger seat frame
• Center floor board
• Left rear panel
Refer to “GENERAL CHASSIS” on page 4-1.
• Air filter case
Refer to “AIR FILTER CASE” on page 7-5.
2. Check:
• Front brake hoses “1”
Cracks/damage/wear → Replace.
3
3-18
PERIODIC MAINTENANCE
a
4
4
2
1
2. Adjust:
• Brake pedal free play
6. Check:
• Brake hose holders
Loose → Tighten the holder bolts.
Damage → Replace.
7. Place the vehicle in an upright position and
apply the brake several times.
8. Check:
• Brake hoses
• Brake pipe
Brake fluid leakage → Replace any damaged
hose and pipe.
Refer to “FRONT AND REAR BRAKES” on
page 4-29.
9. Install:
• Air filter case
Refer to “AIR FILTER CASE” on page 7-5.
• Left rear panel
• Center floor board
• Center passenger seat frame
• Instrument panel
• Front fender
• Hood
• Side frames
• Sun top (for sun top models)
Refer to “GENERAL CHASSIS” on page 4-1.
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a. Loosen the locknut “1”.
b. Turn the brake pedal rod “2” in direction “a” or
“b” until the correct free play is obtained.
Direction “a”
Brake pedal free play is increased.
Direction “b”
Brake pedal free play is decreased.
b
1
a
2
c. Tighten the locknut to specification.
T.
R.
Brake pedal rod locknut
17 Nm (1.7 m·kgf, 12 ft·lbf)
EWA1XD1005
EAS29190
ADJUSTING THE BRAKE PEDAL
1. Check:
• Brake pedal free play “a”
Out of specification → Adjust.
WARNING
After this adjustment is performed, lift the
front and rear wheels off the ground by placing a block under the frame, and spin the
front and rear wheels to ensure there is no
brake drag. If any brake drag is noticed perform the above steps again.
TIP
The end of the brake pedal rod “1” should lightly
contact the brake master cylinder “2”.
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Brake pedal free play
0 mm (0 in)
EAS1XD1058
LUBRICATING THE BRAKE PEDAL AND
ACCELERATOR PEDAL
Lubricate the pivoting point and metal-to-metal
moving parts of the pedal.
Recommended lubricant
Lithium-soap-based grease
3-19
PERIODIC MAINTENANCE
a
EAS21260
EAS29210
CHECKING THE REAR BRAKE PADS
The following procedure applies to all of the rear
brake pads.
1. Remove:
• Rear wheels
Refer to “FRONT AND REAR WHEELS” on
page 4-25.
2. Operate the brake.
3. Check:
• Rear brake pads
Wear indicator grooves “a” have almost disappeared → Replace the brake pads and
brake pad spring as a set.
Refer to “FRONT AND REAR BRAKES” on
page 4-29.
ADJUSTING THE PARKING BRAKE LEVER
1. Shift the drive select lever into low gear “L”.
2. Check:
• Parking brake lever free play “a”
The maximum free play is equal to one click
of the parking brake lever.
Incorrect → Adjust.
a
a
3. Adjust:
• Parking brake lever free play
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a.
b.
c.
d.
4. Install:
• Rear wheels
Refer to “FRONT AND REAR WHEELS” on
page 4-25.
Release the parking brake lever.
Slide back the rubber cover “1”.
Loosen the locknut “2”.
Turn the adjusting nut “3” in direction “a” or “b”
until the correct free play is obtained.
Direction “a”
Parking brake cable free play is increased.
Direction “b”
Parking brake cable free play is decreased.
EAS1XD1059
CHECKING THE PARKING BRAKE PADS
1. Operate the brake.
2. Check:
• Parking brake pads
A wear indicator groove “a” has almost appeared → Replace the brake pads and brake
pad spring as a set.
Refer to “PARKING BRAKE” on page 4-42.
a
1
2
3
3-20
b
PERIODIC MAINTENANCE
e. Tighten the locknut to specification.
T.
R.
Parking brake cable locknut
16 Nm (1.6 m·kgf, 12 ft·lbf)
f. Slide the rubber cover to its original position.
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EAS21690
CHECKING AND LUBRICATING THE
CABLES
The following procedure applies to all of the inner and outer cables.
a
2. Lift the cargo bed.
3. Remove:
• Frame cross member
Refer to “GENERAL CHASSIS” on page 4-1.
4. Adjust:
• Accelerator pedal free play
EWA13270
WARNING
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Replace damaged outer cable and inner cables
as soon as possible.
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a. Remove the throttle cable housing cover “1”.
1. Check:
• Outer cable
Damage → Replace.
2. Check:
• Cable operation
Rough movement → Lubricate.
1
Recommended lubricant
Engine oil or a suitable cable lubricant
b. Slide back the rubber cover “2”.
c. Loosen the locknut “3”.
d. Turn the adjusting nut “4” in direction “a” or “b”
until the specified accelerator pedal free play
is obtained.
TIP
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suitable lubricating device.
3. Apply:
• Lithium-soap-based grease
(onto end of the throttle cable and drive select
lever shift cable)
Direction “a”
Accelerator pedal free play is increased.
Direction “b”
Accelerator pedal free play is decreased.
EAS20660
ADJUSTING THE ACCELERATOR PEDAL
FREE PLAY
1. Check:
• Accelerator pedal free play “a”
Out of specification → Adjust.
2
b
4
Accelerator pedal free play
12.0–32.0 mm (0.47–1.26 in)
a
3
3-21
PERIODIC MAINTENANCE
TIP
T.
If length “c” is 8.5 mm (0.33 in) or more, loosen
locknut “5” and turn the adjusting nut “6” in direction “d” or “e” until the specified accelerator pedal free play is obtained.
R.
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5. Install:
• Frame cross member
Refer to “GENERAL CHASSIS” on page 4-1.
6. Lower the cargo bed.
Direction “d”
Accelerator pedal free play is increased.
Direction “e”
Accelerator pedal free play is decreased.
EAS1XD1060
CHECKING THE V-BELT
1. Lift the cargo bed.
2. Remove:
• Frame cross member
• Left rear panel
• V-belt cooling ducts
Refer to “GENERAL CHASSIS” on page 4-1.
3. Remove:
• Drive belt cover
Refer to “PRIMARY AND SECONDARY
SHEAVES” on page 5-50.
4. Check:
• V-belt “1”
Cracks/damage/wear → Replace.
Grease/oil → Clean the primary and secondary sheaves.
Refer to “REPLACING THE V-BELT” on
page 3-23.
5. Measure:
• V-belt width “a”
Out of specification → Replace.
Refer to “REPLACING THE V-BELT” on
page 3-23.
5
6
e
c
Throttle cable housing cover
screw
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
d
e. Tighten the locknuts to specification.
T.
Throttle cable locknut (air intake
silencer side)
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Throttle cable locknut (throttle
body side)
0.8 Nm (0.08 m·kgf, 0.6 ft·lbf)
R.
f. Slide the rubber cover to its original position.
g. Check the throttle valve pulley stopper gap.
TIP
V-belt width
33.0–33.6 mm (1.30–1.32 in)
Limit
32.5 mm (1.28 in)
When the accelerator pedal is fully depressed
(throttle valve fully open), the gap “f” between
the throttle valve pulley “7” and the pulley stopper “8” should be 1 mm (0.04 in) or less.
f
8
7
6. Install:
• Drive belt cover
Refer to “PRIMARY AND SECONDARY
SHEAVES” on page 5-50.
h. Install the throttle cable housing cover.
3-22
PERIODIC MAINTENANCE
7. Install:
• V-belt cooling ducts
• Left rear panel
• Frame cross member
Refer to “GENERAL CHASSIS” on page 4-1.
8. Lower the cargo bed.
TIP
Install the new V-belt so that its arrow faces the
direction shown in the illustration.
EAS1XD1061
REPLACING THE V-BELT
1. Lift the cargo bed.
2. Remove:
• Frame cross member
• Left rear panel
• V-belt cooling ducts
Refer to “GENERAL CHASSIS” on page 4-1.
3. Remove:
• Bearing housing
Refer to “PRIMARY AND SECONDARY
SHEAVES” on page 5-50.
4. Replace:
• V-belt
d. Remove the bolts.
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EAS29350
CHECKING THE WHEELS
The following procedure applies to all of the
wheels.
1. Check:
• Wheel “1”
Damage/bends → Replace.
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a. Install the bolts “1” (90101-06016) into the
secondary fixed sheave holes.
EWA14990
TIP
WARNING
Tightening the bolts “1” will push the secondary
sliding sheave away, causing the gap between
the secondary fixed and sliding sheaves to widen.
• Never attempt even small repairs to the
wheel.
• Ride conservatively after installing a tire to
allow it to seat itself properly on the rim.
1
1
b. Remove the V-belt “2” from the primary
sheave and secondary sheave.
2. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to “CHECKING THE WHEELS” on
page 4-26.
3. Check:
• Wheel bearings
Refer to “CHECKING THE STEERING
KNUCKLES AND FRONT WHEEL BEARINGS” on page 4-57 and “CHECKING THE
REAR KNUCKLES AND REAR WHEEL
BEARINGS” on page 4-66.
c. Install a new V-belt.
3-23
PERIODIC MAINTENANCE
EAS29340
CHECKING THE TIRES
The following procedure applies to all of the
tires.
Tire air pressure (measured on
cold tires)
Recommended
Vehicle load
0–300 kg (0–661 lb)
Front
75.0 kPa (0.750 kgf/cm², 11 psi)
Rear
90.0 kPa (0.900 kgf/cm², 13 psi)
Vehicle load
300–445 kg (661–981 lb)
Front
75.0 kPa (0.750 kgf/cm², 11 psi)
Rear
125.0 kPa (1.250 kgf/cm², 18
psi)
Minimum
Vehicle load
0–300 kg (0–661 lb)
Front
70.0 kPa (0.700 kgf/cm², 10 psi)
Rear
85.0 kPa (0.850 kgf/cm², 12 psi)
Vehicle load
300–445 kg (661–981 lb)
Front
70.0 kPa (0.700 kgf/cm², 10 psi)
Rear
120.0 kPa (1.200 kgf/cm², 17
psi)
EWA14940
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
EWA14950
WARNING
Tire characteristics influence the handling of
vehicles. 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.
Front tire
Type
Tubeless
Size
25 × 8–12NHS
Manufacturer/model
MAXXIS/MU09
Rear tire
Type
Tubeless
Size
25 × 10–12NHS
Manufacturer/model
MAXXIS/MU10
Maximum loading limit
EWA14970
WARNING
Be extra careful of the vehicle balance and
stability when towing a trailer.
Maximum loading limit
445 kg (981 lb)
(Total weight of rider, passengers, cargo, accessories, and
tongue)
Cargo bed
272 kgf (600 lbf)
Trailer hitch
Pulling load (total weight of
trailer and cargo)
680 kgf (1500 lbf)
Tongue weight (vertical weight
on trailer hitch point)
50 kgf (110 lbf)
Tire pressure
EWA1XD1023
WARNING
• Tire pressure below the minimum specification could cause the tire to dislodge from
the rim under severe riding conditions.
• Use no more than the following pressures
when seating the tire beads.
Front
250 kPa (2.5 kgf/cm², 36 psi)
Rear
250 kPa (2.5 kgf/cm², 36 psi)
Higher pressures and fast inflation may
cause a tire to burst. Inflate the tires very
slowly and carefully.
1. Measure:
• Tire pressure
Out of specification → Adjust.
3-24
PERIODIC MAINTENANCE
• 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.
Tire air pressure (measured on
cold tires)
Recommended
Vehicle load
0–300 kg (0–661 lb)
Front
75.0 kPa (0.750 kgf/cm², 11 psi)
Rear
90.0 kPa (0.900 kgf/cm², 13 psi)
Vehicle load
300–445 kg (661–981 lb)
Front
75.0 kPa (0.750 kgf/cm², 11 psi)
Rear
125.0 kPa (1.250 kgf/cm², 18
psi)
Minimum
Vehicle load
0–300 kg (0–661 lb)
Front
70.0 kPa (0.700 kgf/cm², 10 psi)
Rear
85.0 kPa (0.850 kgf/cm², 12 psi)
Vehicle load
300–445 kg (661–981 lb)
Front
70.0 kPa (0.700 kgf/cm², 10 psi)
Rear
120.0 kPa (1.200 kgf/cm², 17
psi)
2. Check:
• Tire surfaces
Wear/damage → Replace.
Wear limit (front)
3.0 mm (0.12 in)
Wear limit (rear)
3.0 mm (0.12 in)
EWA1XD1006
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit
“a”, replace the tire immediately.
EAS29300
CHECKING THE FRONT SHOCK ABSORBER
ASSEMBLIES
The following procedure applies to both of the
front shock absorber assemblies.
1. Place the vehicle on a level place.
2. Check:
• Front shock absorber assembly
Refer to “CHECKING THE FRONT SHOCK
ABSORBER ASSEMBLIES” on page 4-61.
3. Check:
• Operation
Pump the front shock absorber assembly up
and down several times.
Unsmooth operation → Replace front shock
absorber assembly.
Refer to “FRONT ARMS AND FRONT
SHOCK ABSORBER ASSEMBLIES” on
page 4-59.
TIP
• Two tire pressure gauges are included as standard equipment. Use the lower range tire pressure gauge “1” for the front wheels and the
higher range tire pressure gauge for the rear
wheels.
• In order to insure an accurate reading, make
sure that the gauge is clean before use.
1
EAS29320
EWA14980
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLIES
The following procedure applies to both of the
rear shock absorber assemblies.
WARNING
Uneven or improper tire pressure may adversely affect the handling of this vehicle
and may cause loss of control.
3-25
PERIODIC MAINTENANCE
1. Place the vehicle on a level place.
2. Check:
• Rear shock absorber assembly
Refer to “CHECKING THE REAR SHOCK
ABSORBER ASSEMBLIES” on page 4-69.
3. Check:
• Operation
Pump the rear shock absorber assembly up
and down several times.
Unsmooth operation → Replace rear shock
absorber assembly.
Refer to “REAR ARMS AND REAR SHOCK
ABSORBER ASSEMBLIES” on page 4-67.
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4. Raise the front end of the vehicle so that
there is no weight on the front wheels.
5. Check:
• Ball joints and wheel bearings
Move the wheels laterally back and forth.
Excessive free play → Replace the front
arms (upper and lower) and/or wheel bearings.
EAS29280
CHECKING THE STEERING SYSTEM
1. Place the vehicle on a level surface.
2. Check:
• Steering column (except for EPS models)
• EPS unit (for EPS models)
• Steering wheel nut
Move the steering wheel up and down, and
back and forth.
Excessive play → Check that the steering
column bolts, EPS unit bolts, or steering
wheel nut are tightened to specification.
Refer to “STEERING SYSTEM” on page
4-52.
EAS29290
ADJUSTING THE TOE-IN
1. Place the vehicle on a level surface.
2. Measure:
• Toe-in
Out of specification → Adjust.
3. Check:
• Tie-rod ends
Free play → Replace the tie-rod end.
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Toe-in (with tires touching the
ground)
5.0–15.0 mm (0.20–0.59 in)
TIP
Before measuring the toe-in, make sure that the
tire pressure is correct.
a. Turn the steering wheel left until it stops.
b. Move the steering wheel slightly to the right
and left.
c. Check for play in the tie-rod ends.
d. Turn the steering wheel right until it stops.
e. Move the steering wheel slightly to the left
and right.
f. Check for play in the tie-rod ends.
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a.
b.
c.
d.
Mark both front tire tread centers.
Face the steering wheel straight ahead.
Measure the width “A” between the marks.
Rotate the front tires 180° until the marks are
exactly opposite one another.
e. Measure the width “B” between the marks.
f. Calculate the toe-in using the formula given
below.
3-26
PERIODIC MAINTENANCE
Toe-in = “B” – “A”
2
1
2
1
g. If the toe-in is incorrect, adjust it.
d. Tighten the tie-rod end locknuts to specification.
T.
R.
Tie-rod end locknut
40 Nm (4.0 m·kgf, 29 ft·lbf)
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4. Check:
• Steering wheel
TIP
After adjusting the toe-in, the steering wheel
should be centered.
Refer to “INSTALLING THE STEERING
WHEEL” on page 4-15.
C. Forward
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EAS1XD1062
LUBRICATING THE STEERING SHAFT
Lubricate the pivoting point and metal-to-metal
moving parts of the shaft.
3. Adjust:
• Toe-in
EWA1XD1007
WARNING
Recommended lubricant
Lithium-soap-based grease
• Be sure that both tie-rods are turned the
same amount. If not, the vehicle will drift
right or left even though the steering wheel
is 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 steering
wheel and check that the steering wheel responds correctly. If not, turn either the right
or left tie-rod within the toe-in specification.
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a. Mark both tie-rods ends.
This reference point will be needed during
adjustment.
b. Loosen the tie-rod end locknuts “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 tie-rods the same.
EAS1XD1063
CHECKING THE STABILIZER BUSHINGS
1. Check:
• Stabilizer bushings
Damage/wear → Replace.
Refer to “REAR KNUCKLES AND STABILIZER” on page 4-64.
3-27
PERIODIC MAINTENANCE
EAS1XD1064
LUBRICATING THE REAR KNUCKLE
PIVOTS
1. Remove:
• Rear arm protectors
2. Lubricate:
• Rear knuckle pivots
Recommended lubricant
Lithium-soap-based grease
EAS1XD1065
CHECKING THE ENGINE MOUNT
1. Check:
• Engine brackets
Cracks/damage → Replace.
• Engine mounting bolts
• Engine bracket nuts
Loosen → Tighten.
Refer to “ENGINE REMOVAL” on page 5-1.
EAS29270
CHECKING THE CONSTANT VELOCITY
SHAFT ASSEMBLY DUST BOOTS
1. Check:
• Dust boots “1”
Damage → Replace.
Refer to “FRONT CONSTANT VELOCITY
SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT” on
page 8-3 and “REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE
ASSEMBLY AND REAR DRIVE SHAFT” on
page 8-17.
EAS1XD1016
LUBRICATING THE DRIVE SHAFT
UNIVERSAL JOINTS
1. Remove:
• Center passenger seat frame
Refer to “GENERAL CHASSIS” on page 4-1.
• Air filter case
Refer to “AIR FILTER CASE” on page 7-5.
2. Lubricate:
• Drive shaft universal joint
Recommended lubricant
Lithium-soap-based grease
A
1
3-28
1
PERIODIC MAINTENANCE
B
1
1
A. Front
B. Rear
EAS1XD1066
CHECKING THE FASTENERS
1. Check:
• Fasteners
Damage/pitting → Replace.
Refer to “GENERAL CHASSIS” on page 4-1.
3-29
CHASSIS
GENERAL CHASSIS.......................................................................................4-1
INSTALLING THE DOOR..........................................................................4-3
REMOVING THE SEATS ..........................................................................4-5
ADJUSTING THE DRIVER SEAT POSITION...........................................4-5
INSTALLING THE SEATS......................................................................... 4-5
INSTALLING THE SEAT BELTS............................................................... 4-8
INSTALLING THE ENCLOSURE ............................................................ 4-11
REMOVING THE STEERING WHEEL....................................................4-15
INSTALLING THE STEERING WHEEL .................................................. 4-15
INSTALLING THE V-BELT COOLING DUCTS....................................... 4-21
DISASSEMBLING THE CARGO BED ....................................................4-24
ASSEMBLING THE CARGO BED .......................................................... 4-24
FRONT AND REAR WHEELS ...................................................................... 4-25
REMOVING THE WHEELS..................................................................... 4-26
REMOVING THE WHEEL HUBS ............................................................ 4-26
CHECKING THE WHEELS ..................................................................... 4-26
CHECKING THE WHEEL HUBS............................................................. 4-27
INSTALLING THE BRAKE DISCS .......................................................... 4-27
INSTALLING THE WHEEL HUBS........................................................... 4-27
INSTALLING THE WHEELS ................................................................... 4-28
FRONT AND REAR BRAKES....................................................................... 4-29
INTRODUCTION .....................................................................................4-36
CHECKING THE BRAKE DISCS ............................................................ 4-36
REPLACING THE BRAKE PADS............................................................ 4-37
DISASSEMBLING THE BRAKE CALIPERS ...........................................4-38
CHECKING THE BRAKE CALIPERS .....................................................4-38
ASSEMBLING THE BRAKE CALIPERS ................................................. 4-38
INSTALLING THE BRAKE CALIPERS ...................................................4-39
CHECKING THE BRAKE MASTER CYLINDER ..................................... 4-40
CHECKING THE BRAKE PIPES............................................................. 4-40
INSTALLING THE BRAKE MASTER CYLINDER ................................... 4-40
PARKING BRAKE......................................................................................... 4-42
REMOVING THE PARKING BRAKE CALIPER ...................................... 4-47
CHECKING THE PARKING BRAKE CALIPER....................................... 4-47
CHECKING THE PARKING BRAKE DISC ............................................. 4-47
REPLACING THE PARKING BRAKE PADS ..........................................4-47
INSTALLING THE PARKING BRAKE CALIPER..................................... 4-48
INSTALLING THE PARKING BRAKE LEVER ........................................ 4-48
PEDAL ASSEMBLY ......................................................................................4-49
INSTALLING THE PEDAL ASSEMBLY .................................................. 4-51
4
STEERING SYSTEM .....................................................................................4-52
CHECKING THE STEERING JOINT.......................................................4-54
CHECKING THE TIE-ROD ENDS........................................................... 4-54
INSTALLING THE STEERING SYSTEM ................................................ 4-54
STEERING KNUCKLES................................................................................ 4-56
REMOVING THE STEERING KNUCKLES ............................................. 4-57
CHECKING THE STEERING KNUCKLES AND
FRONT WHEEL BEARINGS .................................................................. 4-57
CHECKING THE STEERING KNUCKLE BALL JOINTS ........................ 4-57
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES ............. 4-59
CHECKING THE FRONT ARMS............................................................. 4-61
HANDLING THE FRONT SHOCK ABSORBER ASSEMBLIES.............. 4-61
DISPOSING OF A FRONT SHOCK ABSORBER ASSEMBLY............... 4-61
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES ............. 4-61
CHECKING THE FRONT ARM BALL JOINTS ....................................... 4-62
INSTALLING THE FRONT ARMS AND FRONT SHOCK
ABSORBER ASSEMBLIES .................................................................... 4-63
REAR KNUCKLES AND STABILIZER ......................................................... 4-64
CHECKING THE REAR KNUCKLES AND REAR WHEEL
BEARINGS ............................................................................................. 4-66
CHECKING THE STABILIZER................................................................4-66
INSTALLING THE STABILIZER..............................................................4-66
REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES ................. 4-67
CHECKING THE REAR ARMS ...............................................................4-69
HANDLING THE REAR SHOCK ABSORBER ASSEMBLIES ................ 4-69
DISPOSING OF A REAR SHOCK ABSORBER ASSEMBLY ................. 4-69
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................ 4-69
INSTALLING THE REAR ARMS AND REAR SHOCK
ABSORBER ASSEMBLIES .................................................................... 4-70
GENERAL CHASSIS
EAS21830
GENERAL CHASSIS
Removing the skid plates
1
2
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
.
T.R
Order
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
Job/Parts to remove
Q’ty
1
Front skid plate
1
2
Rear skid plate
1
Remarks
For installation, reverse the removal procedure.
4-1
GENERAL CHASSIS
Removing the doors and side panels
.
T.R
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
.
T.R
1.3 Nm (0.13 m•kgf, 0.94 ft•Ibf)
T.R
.
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
4
5
(4)
3
6
(4)
1
2
.
T.R
Order
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
Job/Parts to remove
Q’ty
Remarks
The following procedure applies to both of
the doors.
1
Door hinge
1
2
Door
1
3
Door handle latch
1
4
Rubber damper
1
5
Fuel tank cap
1
6
Side panel
1
Right side only.
Lift the cargo bed.
For installation, reverse the removal procedure.
4-2
GENERAL CHASSIS
EAS1XD1019
INSTALLING THE DOOR
The following procedure applies to both of the
doors.
1. Install:
• Door hinge “1”
1
2
T.
R.
Door hinge nut
1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
1
1
2. Install:
• Door “1”
TIP
Fit the tab “a” on the door hinge with the slot “b”
in the frame.
T.
R.
Door hinge bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
1
a
b
3. Install:
• Door handle latch “1”
TIP
Adjust the position of the door latch so that it fully
engages the bar “2” on the frame when the door
is closed.
Make sure that the spring force of the door hinge
can close the door without latching it when the
door is opened less than 60°.
T.
R.
Door handle latch nut
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
4-3
GENERAL CHASSIS
Removing the seats
.
T.R
6 Nm (0.6 m•kgf, 4.3 ft•Ibf)
5
.
T.R
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
7
6
(3)
1
(3)
(3)
(3)
(3)
(3)
(3)
(4)
(3)
(4)
New
(4)
New
3
6
2
4
T.R
.
Order
Job/Parts to remove
Q’ty
1
Seat cushion
2
Center passenger seat frame
1
3
Driver seat frame
1
4
Outer passenger seat frame
1
5
Seat back
3
23 Nm (2.3 m•kgf, 17 ft•Ibf)
Remarks
3
6
Shoulder holster
2
7
Headrest
3
For installation, reverse the removal procedure.
4-4
GENERAL CHASSIS
EAS1XD1017
REMOVING THE SEATS
The following procedure applies to all of the
seats.
1. Remove:
• Seat cushion “1”
2
b
c
d
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Lift the front of the seat cushion.
b. Pull the cushion off.
a
b. Forward position
c. Center position
d. Rear position
1
c. Install the driver seat frame bolts, and then
tighten the bolts to specification.
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1XD1049
Driver seat frame bolt
23 Nm (2.3 m·kgf, 17 ft·lbf)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ADJUSTING THE DRIVER SEAT POSITION
The driver seat can be adjusted to one of three
positions to suit the driver’s preference.
1. Remove:
• Driver seat cushion
Refer to “REMOVING THE SEATS” on page
4-5.
2. Adjust:
• Driver seat position
3. Install:
• Driver seat cushion
Refer to “INSTALLING THE SEATS” on page
4-5.
EAS1XD1018
INSTALLING THE SEATS
The following procedure applies to all of the
seats.
1. Install:
• Seat cushion “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the driver seat frame bolts “1”.
EWA1XD1008
WARNING
1
A loose seat could cause the operator to lose
control, or cause the operator or passengers
to fall.
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Insert the projections “a” on the rear of the
seat cushion under the seat frame.
b. Insert the projection “b” on the front of the
cushion into the grommet while pushing the
cushion downward.
b. Move the driver seat frame “2” to the desired
position and align the bolt holes in the seat
frame with the bolt holes “a” in the vehicle
frame.
TIP
Make sure the seats are properly secured before
riding.
4-5
GENERAL CHASSIS
1
a
b
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-6
GENERAL CHASSIS
Removing the seat belts
T.R
.
2
59 Nm (5.9 m•kgf, 43 ft•Ibf)
4
3
7
6
5
1
T.R
.
59 Nm (5.9 m•kgf, 43 ft•Ibf)
T.R
.
59 Nm (5.9 m•kgf, 43 ft•Ibf)
Order
Job/Parts to remove
Q’ty
Refer to “Removing the doors and side panels”.
Side panels
1
Remarks
Set belt switch coupler
1
2
Driver seat belt
1
3
Driver seat belt buckle
1
4
Center passenger seat belt
1
5
Center passenger seat belt buckle
1
6
Outer passenger seat belt
1
7
Outer passenger seat belt buckle
1
Disconnect.
For installation, reverse the removal procedure.
4-7
GENERAL CHASSIS
EAS1XD1067
INSTALLING THE SEAT BELTS
1. Install:
• Seat belts
T.
R.
Seat belt bolt
59 Nm (5.9 m·kgf, 43 ft·lbf)
Seat belt buckle bolt
59 Nm (5.9 m·kgf, 43 ft·lbf)
TIP
• Install the seat belt anchor plates “1” so that
they contact the stoppers “a”.
• Fit the projection “b” on each seat belt “2” into
the holes “c” in the frame.
a
1
2
c
b
4-8
GENERAL CHASSIS
Removing the sun top (for sun top models)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
5
T.R
.
1
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
2 New
1
6
2 New
1
(4)
(4)
1
New 2
(4)
7 New
(4)
3
(4)
(4)
(4)
4
(4)
T.R
.
1
.
.
Order
T.R
T.R
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)
Job/Parts to remove
Q’ty
Sun top lower bracket
2
2
Damper
4
3
Sun top rear bracket
4
4
Sun top front bracket
4
5
Sun top
1
6
Damper
4
7
Damper
4
Remarks
For installation, reverse the removal procedure.
4-9
GENERAL CHASSIS
Removing the enclosure
.
T.R
48 Nm (4.8 m•kgf, 35 ft•Ibf)
T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf)
1
2
4
T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf)
6
3
5
7
T.R
48 Nm (4.8 m•kgf, 35 ft•Ibf)
.
.
.
Order
T.R
T.R
48 Nm (4.8 m•kgf, 35 ft•Ibf)
Job/Parts to remove
Q’ty
Headrests
65 Nm (6.5 m•kgf, 47 ft•Ibf)
Remarks
Refer to “Removing the seats”.
Seat belts
Refer to “Removing the seat belts”.
Sun top
For sun top models
Refer to “Removing the sun top (for sun top
models)”.
1
Rear top frame
1
2
Front top frame
1
3
Rear right frame
1
4
Rear left frame
1
5
Right side frame
1
6
Left side frame
1
7
Rear center frame
1
For installation, reverse the removal procedure.
4-10
GENERAL CHASSIS
EAS1XD1068
INSTALLING THE ENCLOSURE
1. Install:
• Rear center frame “1”
• Right side frame “2”
• Left side frame “3”
• Rear right frame “4”
• Rear left frame “5”
• Front top frame “6”
• Rear top frame “7”
7
6
TIP
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Do not fully tighten the bolts and nuts.
2. Tighten:
• Rear right frame bolts
• Rear left frame bolts
• Front top frame bolts
• Rear top frame bolts
• Right side frame nuts (front)
• Left side frame nuts (front)
• Rear center frame bolts
• Right side frame nut (rear)
• Left side frame nut (rear)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the rear center frame “1”.
1
TIP
Tighten the bolts and nuts in the proper sequence as shown ( 1, 2, and so on).
b. Install the right side frame “2” and left side
frame “3”.
3
T.
R.
2
Rear right frame bolt
48 Nm (4.8 m·kgf, 35 ft·lbf)
Rear left frame bolt
48 Nm (4.8 m·kgf, 35 ft·lbf)
Front top frame bolt
48 Nm (4.8 m·kgf, 35 ft·lbf)
Rear top frame bolt
48 Nm (4.8 m·kgf, 35 ft·lbf)
Right side frame nut (front)
65 Nm (6.5 m·kgf, 47 ft·lbf)
Left side frame nut (front)
65 Nm (6.5 m·kgf, 47 ft·lbf)
Rear center frame bolt
48 Nm (4.8 m·kgf, 35 ft·lbf)
Right side frame nut (rear)
48 Nm (4.8 m·kgf, 35 ft·lbf)
Left side frame nut (rear)
48 Nm (4.8 m·kgf, 35 ft·lbf)
c. Install the rear right frame “4” and rear left
frame “5”.
5
4
2
2
2
1
5
1
d. Install the front top frame “6” and rear top
frame “7”.
1
1
4
4-11
3
4
5
2
3
GENERAL CHASSIS
Removing the hood and battery
.
.
T.R
T.R
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
.
T.R
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
1
2
5
4
10
3
6
9
9
.
T.R
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
7
.
T.R
2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)
T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf)
Order
8
Job/Parts to remove
Q’ty
Front skid plate
Remarks
Refer to “Removing the skid plates”.
1
Hood
1
2
Air intake duct cover
1
Disconnect.
ECA1XD1033
3
Negative battery lead
1
NOTICE
First disconnect the negative battery
lead, then disconnect the positive lead.
4
Positive battery lead
1
5
Battery band
2
6
Battery
1
7
Front guard
1
8
Front guard cover
2
9
Headlight coupler
2
10
Front grill
1
Disconnect.
Disconnect.
For installation, reverse the removal procedure.
4-12
GENERAL CHASSIS
Removing the front fender and instrument panel
T.R
.
3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf)
.
T.R
.
T.R
35 Nm (3.5 m•kgf, 25 ft•Ibf)
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
4
3
5
7
.
T.R
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
11
6
.
T.R
(7)
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
8
12
(6)
1
9
(6)
10
2
.
T.R
3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)
(4)
(4)
.
T.R
16 Nm (1.6 m•kgf, 12 ft•Ibf)
T.R
.
2.3 Nm (0.23 m•kgf, 1.7 ft•Ibf)
.
T.R
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
Order
Job/Parts to remove
Q’ty
Remarks
Sun top
For sun top models
Refer to “Removing the sun top (for sun top
models)”.
Side frames
Refer to “Removing the enclosure”.
Hood
Refer to “Removing the hood and battery”.
1
Front fender
1
2
Passenger handhold
1
3
Steering wheel cover
1
4
Steering wheel
1
5
Meter assembly
1
6
Meter assembly bracket
1
7
Parking brake lever rubber cover
1
8
On-Command four-wheel-drive switch
1
9
Light switch
1
10
Main switch
1
11
Indicator light assembly
1
12
Auxiliary DC jack
1
4-13
GENERAL CHASSIS
Removing the front fender and instrument panel
.
T.R
.
T.R
35 Nm (3.5 m•kgf, 25 ft•Ibf)
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.
3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf)
.
T.R
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
14
.
T.R
(7)
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
(6)
(6)
13
.
T.R
3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)
(4)
(4)
.
T.R
16 Nm (1.6 m•kgf, 12 ft•Ibf)
T.R
.
2.3 Nm (0.23 m•kgf, 1.7 ft•Ibf)
.
T.R
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
Order
Job/Parts to remove
Q’ty
13
Horn switch
1
14
Instrument panel
1
Remarks
For Europe and Oceania
For installation, reverse the removal procedure.
4-14
GENERAL CHASSIS
EAS1XD1069
REMOVING THE STEERING WHEEL
1. Turn the steering wheel so that it is straight
and the front wheels are pointing straight
ahead.
2. Remove:
• Steering wheel cover “1”
1
TIP
While pushing the ends of the projections “a” together, remove the steering wheel cover from
the steering wheel.
2. Operate the vehicle at low speeds and make
sure that the steering wheel is straight when
the vehicle is advancing straight ahead.
a
1
3. Remove:
• Steering wheel “1”
TIP
Use a general puller “2” to separate the steering
wheel and steering column.
1
2
EAS1XD1070
INSTALLING THE STEERING WHEEL
1. Install:
• Steering wheel “1”
T.
R.
Steering wheel nut
35 Nm (3.5 m·kgf, 25 ft·lbf)
TIP
Install the steering wheel onto the steering column so that it is centered as shown in the illustration.
4-15
GENERAL CHASSIS
Removing the floor boards and panels
.
T.R
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
(2)
(7)
4
(2)
2
(9)
1
3
(4)
(7)
.
T.R
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
6
5
(5)
(4)
.
T.R
Order
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
Job/Parts to remove
Q’ty
Remarks
Seat frames
Refer to “Removing the seats”.
Side panels
Refer to “Removing the doors and side panels”.
Seat belts
Refer to “Removing the seat belts”.
Sun top
For sun top models
Refer to “Removing the sun top (for sun top
models)”.
Side frames
Refer to “Removing the enclosure”.
Hood
Refer to “Removing the hood and battery”.
Instrument panel
Refer to “Removing the front fender and instrument panel”.
1
Rubber cover
1
2
Center floor board
1
3
Left floor board
1
4
Right floor board
1
5
Left lower panel
1
6
Right lower panel
1
4-16
GENERAL CHASSIS
Removing the floor boards and panels
.
T.R
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
(2)
(7)
(2)
7
(9)
(4)
9
8
(7)
.
T.R
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
(5)
(4)
.
T.R
Order
10
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
Job/Parts to remove
Q’ty
7
Center passenger compartment panel
1
8
Left passenger compartment panel
1
9
Right passenger compartment panel
1
10
Left rear panel
1
11
Right rear panel
1
11
Remarks
For installation, reverse the removal procedure.
4-17
GENERAL CHASSIS
Removing the electrical components tray
5
.
T.R
9
4
3.6 Nm (0.36 m•kgf, 2.6 ft•Ibf)
.
T.R
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.
2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)
7
8
3
6
(4)
2
1
1
.
T.R
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
.
T.R
3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf)
FW
Order
Job/Parts to remove
Q’ty
D
Remarks
Sun top
For sun top models
Refer to “Removing the sun top (for sun top
models)”.
Side frames
Refer to “Removing the enclosure”.
Hood
Refer to “Removing the hood and battery”.
Instrument panel
Refer to “Removing the front fender and instrument panel”.
1
Headlight coupler
2
2
Lean angle sensor
1
3
Starter relay
1
4
Main fuse
1
5
EPS fuse
1
6
ECU (engine control unit)
1
7
EPS (electronic power steering) control unit
1
8
Fuse box
1
9
Differential motor relay 2
1
4-18
Disconnect.
For EPS models
For EPS models
GENERAL CHASSIS
Removing the electrical components tray
10
.
T.R
11
.
T.R
14
T.R
13 12
3.6 Nm (0.36 m•kgf, 2.6 ft•Ibf)
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
.
2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)
(4)
1
.
T.R
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
.
T.R
3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf)
15
Order
Job/Parts to remove
Q’ty
10
Differential motor relay 1
11
Headlight relay
1
12
Load control relay
1
13
Fuel injection system relay
1
14
Radiator fan motor relay
1
15
Electrical components tray
1
FW
D
Remarks
1
For installation, reverse the removal procedure.
4-19
GENERAL CHASSIS
Removing the V-belt cooling ducts
T.R
.
59 Nm (5.9 m•kgf, 43 ft•Ibf)
.
T.R
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
3
4
6
1
5
2
.
T.R
.
T.R
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
.
T.R
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
.
T.R
Order
Job/Parts to remove
Q’ty
Frame cross member
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
Remarks
Refer to “Removing the cargo bed”.
1
V-belt cooling exhaust duct
1
2
V-belt cooling exhaust duct joint
1
3
Outer passenger seat belt bolt
1
4
V-belt cooling intake duct
1
5
V-belt cooling intake duct joint 1
1
6
V-belt cooling intake duct joint 2
1
For installation, reverse the removal procedure.
4-20
GENERAL CHASSIS
EAS1XD1020
INSTALLING THE V-BELT COOLING DUCTS
1. Install:
• V-belt cooling intake duct joint 2 “1”
• V-belt cooling intake duct joint 1 “2”
• V-belt cooling exhaust duct joint “3”
TIP
• Align the projection “a” on V-belt cooling intake
duct joint 2 with the lib on the crankcase.
• Fit the projection “b” on the V-belt cooling intake duct joints and V-belt cooling exhaust duct
joint between the projections on the V-belt
cooling intake duct and V-belt cooling exhaust
duct.
• Align the slit “c” in V-belt cooling intake duct
joint 1 and V-belt cooling exhaust duct joint
with the projection on the drive belt cover.
1
a
1
2
b
3
2
c
3
4-21
GENERAL CHASSIS
Removing the cargo bed
5
T.R
.
16 Nm (1.6 m•kgf, 12 ft•Ibf)
T.R
.
17 Nm (1.7 m•kgf, 12 ft•Ibf)
(4)
1
3
2
4
2
T.R
.
Order
16 Nm (1.6 m•kgf, 12 ft•Ibf)
Job/Parts to remove
Q’ty
Remarks
1
Frame cross member
1
Lift the cargo bed.
2
Tail/brake light connector
6
Disconnect.
3
Gas spring assembly
1
4
Pin
2
5
Cargo bed assembly
1
TIP
Install the gas spring assembly so that the
cylinder end is pointing upward.
For installation, reverse the removal procedure.
4-22
GENERAL CHASSIS
Disassembling the cargo bed
.
T.R
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
(7)
8
2
3
3
4
3
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
3
(7)
5
1
5
6
7
4
T.R
.
(5)
.
9
T.R
.
Order
1
.
T.R
T.R
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
9 Nm (0.9 m•kgf, 6.5 ft•Ibf)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
Job/Parts to remove
Q’ty
Cargo bed left panel
1
2
Cargo bed right panel
1
3
Cargo hook
4
4
Tail/brake light
2
5
Tailgate cable
2
6
Tailgate
1
7
Tailgate shaft
1
8
Cargo bed release lever
1
9
Cargo bed heat protector plate
1
Remarks
For assembly, reverse the disassembly procedure.
4-23
GENERAL CHASSIS
EAS1XD1021
DISASSEMBLING THE CARGO BED
1. Remove:
• Tailgate “1”
25˚
TIP
1
Align the slot “a” in the left end of the tailgate
shaft with the flat portions of the projection “b” on
the cargo bed, and then lift the left end of the tailgate.
b
c
25˚
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Tailgate cables “1”
1
Tailgate cable bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
a
R.
TIP
b
Connect the straight end “a” of each tailgate cable to the tailgate “2”, and the offset end “b” to
the cargo bed “3”.
EAS1XD1022
ASSEMBLING THE CARGO BED
1. Install:
• Tailgate shaft “1”
3
1
T.
Tailgate shaft bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
R.
a
TIP
Install the tailgate shaft so that the end with the
slot “a” is pointing to the left.
a
a
2
1
2. Install:
• Tailgate “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the right end of the tailgate shaft onto the
projection “a” on the cargo bed.
b. Align the slot “b” in the left end of the tailgate
shaft with the flat portions of the projection “c”
on the cargo bed, and then fit the tailgate
shaft onto the projection.
4-24
b
FRONT AND REAR WHEELS
EAS21870
FRONT AND REAR WHEELS
Removing the wheels and brake discs
T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf)
4
T.R
.
30 Nm (3.0 m•kgf, 22 ft•Ibf)
6
5
LT
New 3
2
.
T.R
350 Nm (35.0 m•kgf, 253 ft•lbf)
1
D
FW
T.R
.
Order
Job/Parts to remove
75 Nm (7.5 m•kgf, 54 ft•Ibf)
Q’ty
Remarks
The following procedure applies to all of the
wheels.
1
Wheel
1
2
Wheel cap
1
3
Wheel axle nut
1
TIP
4
Brake caliper
1
5
Wheel hub
1
6
Brake disc
1
Do not apply the brake pedal when the
brake caliper is off of the brake disc as the
brake pads will be forced shut.
For installation, reverse the removal procedure.
4-25
FRONT AND REAR WHEELS
• Wheel
Refer to “CHECKING THE TIRES” on page
3-24 and “CHECKING THE WHEELS” on
page 3-23.
EAS21890
REMOVING THE WHEELS
1. Place the vehicle on a level surface.
2. Elevate:
• Wheels
EWA15000
WARNING
TIP
Place the vehicle on a suitable stand so that the
wheels are elevated.
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 injury.
EAS1XD1023
REMOVING THE WHEEL HUBS
The following procedure applies to all of the
wheel hubs.
1. Straighten the wheel axle nut rib “a”.
a
2. Measure:
• Radial wheel runout “1”
• Lateral wheel runout “2”
Over the specified limit → Replace the wheel
or check the wheel bearing play.
Refer to “CHECKING THE STEERING
KNUCKLES AND FRONT WHEEL BEARINGS” on page 4-57 and “CHECKING THE
REAR KNUCKLES AND REAR WHEEL
BEARINGS” on page 4-66.
2. Remove:
• Wheel axle nut
3. Remove:
• Brake caliper
TIP
Do not apply the brake pedal when removing the
brake caliper.
4. Remove:
• Wheel hub “1”
Radial wheel runout limit
2.0 mm (0.08 in)
Lateral wheel runout limit
2.0 mm (0.08 in)
TIP
Use a general puller “2” to separate the wheel
hub and constant velocity shaft.
2
1
EAS29380
CHECKING THE WHEELS
The following procedure applies to all of the
wheels.
1. Check:
• Tire
4-26
FRONT AND REAR WHEELS
TIP
Install the brake disc so that the recessed portion of the bolt hole faces away from the hub.
EAS29410
INSTALLING THE WHEEL HUBS
The following procedure applies to all of the
wheel hubs.
1. Install:
• Wheel hub “1”
TIP
Tap lightly on the wheel hub with a plastic hammer until five threads on the end of the constant
velocity shaft will be exposed when the washer
is installed.
EAS29390
CHECKING THE WHEEL HUBS
The following procedure applies to all of the
wheel hubs.
1. Check:
• Wheel hub “1”
Cracks/damage → Replace.
• Splines (wheel hub) “2”
Wear/damage → Replace the wheel hub.
1
1
2
2. Install:
• Wheel axle nut New
T.
R.
EAS1XD1071
INSTALLING THE BRAKE DISCS
The following procedure applies to all of the
brake discs.
1. Install:
• Brake disc
Wheel axle nut
350 Nm (35 m·kgf, 253 ft·lbf)
TIP
• Do not apply oil to the threads of the nut.
• After tightening the nut, stake the collar of the
nut into the notch of the shaft.
T.
R.
Brake disc bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
LOCTITE®
4-27
FRONT AND REAR WHEELS
3. Check:
• Brake disc
Refer to “CHECKING THE BRAKE DISCS”
on page 4-36.
EAS29420
INSTALLING THE WHEELS
The following procedure applies to all of the
wheels.
1. Tighten:
• Wheel nuts “1”
T.
R.
Wheel nut
75 Nm (7.5 m·kgf, 54 ft·lbf)
EWA1XD1009
WARNING
Tapered wheel nuts “1” are used for both the
front and rear wheels. Install each nut with
its tapered side towards the wheel.
1
4-28
FRONT AND REAR BRAKES
EAS22210
FRONT AND REAR BRAKES
Removing the front brake pads
FW
D
48 Nm (4.8 m•kgf, 35 ft•Ibf)
T.R
.
1
1
3
.
T.R
17 Nm (1.7 m•kgf, 12 ft•Ibf)
2
4
Order
Job/Parts to remove
Q’ty
Remarks
The following procedure applies to both of
the front brake calipers.
Refer to “FRONT AND REAR WHEELS” on
page 4-25.
Front wheel
1
Brake caliper bolt
2
2
Brake pad bolt
2
3
Brake pad
2
4
Brake pad spring
1
For installation, reverse the removal procedure.
4-29
FRONT AND REAR BRAKES
Removing the rear brake pads
D
T.R
.
FW
48 Nm (4.8 m•kgf, 35 ft•Ibf)
1
3
1
2
Order
.
T.R
4
Job/Parts to remove
Q’ty
17 Nm (1.7 m•kgf, 12 ft•Ibf)
Remarks
The following procedure applies to both of
the rear brake calipers.
Refer to “FRONT AND REAR WHEELS” on
page 4-25.
Rear wheel
1
Brake caliper bolt
2
2
Brake pad bolt
2
3
Brake pad
2
4
Brake pad spring
1
For installation, reverse the removal procedure.
4-30
FRONT AND REAR BRAKES
Removing the front brake calipers
.
T.R
FW
48 Nm (4.8 m•kgf, 35 ft•Ibf)
D
5
5
6
.
T.R
17 Nm (1.7 m•kgf, 12 ft•Ibf)
3
4
New 2
2 New
T.R
1
.
Order
Job/Parts to remove
27 Nm (2.7 m•kgf, 20 ft•Ibf)
Q’ty
Remarks
The following procedure applies to both of
the front brake calipers.
Front wheel
Refer to “FRONT AND REAR WHEELS” on
page 4-25.
Brake fluid
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-17.
1
Union bolt
1
2
Copper washer
2
3
Brake hose
1
Disconnect.
4
Brake pad bolt
2
Loosen.
5
Brake caliper bolt
2
6
Brake caliper
1
For installation, reverse the removal procedure.
4-31
FRONT AND REAR BRAKES
Removing the rear brake calipers
T.R
.
FW
48 Nm (4.8 m•kgf, 35 ft•Ibf)
D
5
T.R
.
17 Nm (1.7 m•kgf, 12 ft•Ibf)
5
4
3
.
T.R
6
Order
1
2 New
Job/Parts to remove
27 Nm (2.7 m•kgf, 20 ft•Ibf)
Q’ty
Remarks
The following procedure applies to both of
the rear brake calipers.
Rear wheel
Refer to “FRONT AND REAR WHEELS” on
page 4-25.
Brake fluid
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-17.
1
Union bolt
1
2
Copper washer
2
3
Brake hose
1
Disconnect.
4
Brake pad bolt
2
Loosen.
5
Brake caliper bolt
2
6
Brake caliper
1
For installation, reverse the removal procedure.
4-32
FRONT AND REAR BRAKES
Disassembling the front brake calipers
T.R
.
22 Nm (2.2 m•kgf, 16 ft•Ibf)
T.R
.
17 Nm (1.7 m•kgf, 12 ft•Ibf)
4
S
5
6
LT
7
S
8 New
2
9 New
S
BF
3
10
1
T.R
.
5 Nm (0.5 m•kgf, 3.6 ft•Ibf)
.
T.R
Order
Job/Parts to remove
17 Nm (1.7 m•kgf, 12 ft•Ibf)
Q’ty
Remarks
The following procedure applies to both of
the front brake calipers.
1
Brake pad bolt
2
2
Brake pad
2
3
Brake pad spring
1
4
Brake caliper bracket
1
5
Brake caliper guide pin
1
6
Brake caliper retaining pin
1
7
Brake caliper piston
2
8
Brake caliper piston dust seal
2
9
Brake caliper piston seal
2
10
Bleed screw
1
For assembly, reverse the disassembly procedure.
4-33
FRONT AND REAR BRAKES
Disassembling the rear brake calipers
T.R
.
22 Nm (2.2 m•kgf, 16 ft•Ibf)
T.R
.
17 Nm (1.7 m•kgf, 12 ft•Ibf)
4
S
5
6
LT
7
S
2
8 New
9 New
S
3
BF
10
1
T.R
.
5 Nm (0.5 m•kgf, 3.6 ft•Ibf)
T.R
.
Order
17 Nm (1.7 m•kgf, 12 ft•Ibf)
Job/Parts to remove
Q’ty
Remarks
The following procedure applies to both of
the rear brake calipers.
1
Brake pad bolt
2
2
Brake pad
2
3
Brake pad spring
1
4
Brake caliper bracket
1
5
Brake caliper guide pin
1
6
Brake caliper retaining pin
1
7
Brake caliper piston
2
8
Brake caliper piston dust seal
2
9
Brake caliper piston seal
2
10
Bleed screw
1
For assembly, reverse the disassembly procedure.
4-34
FRONT AND REAR BRAKES
Removing the brake master cylinder
T.R
.
T.R
.
3.5 Nm (0.35 m•kgf, 2.5 ft•Ibf)
19 Nm (1.9 m•kgf, 14 ft•Ibf)
1
3
2
5
4
7
6
T.R
.
16 Nm (1.6 m•kgf, 12 ft•Ibf)
FW
D
Order
Job/Parts to remove
Q’ty
Remarks
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-17.
Brake fluid
1
Brake master cylinder reservoir cap
1
2
Brake master cylinder reservoir diaphragm
1
3
Brake master cylinder reservoir diaphragm holder
1
4
Brake master cylinder reservoir float
1
5
Rear brake pipe
1
Disconnect.
6
Front brake pipe
1
Disconnect.
7
Brake master cylinder
1
For installation, reverse the removal procedure.
4-35
FRONT AND REAR BRAKES
EAS22220
INTRODUCTION
EWA14100
WARNING
Disc brake components rarely require disassembly. Therefore, always follow these preventive measures:
• Never disassemble brake components unless absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reassembly.
• Never use solvents on internal brake components.
• Use only clean or new brake fluid for cleaning brake components.
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
• FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get immediate medical attention.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Measure:
• Brake disc thickness “a”
Measure the brake disc thickness at a few different locations.
Out of specification → Replace.
Brake disc thickness limit
3.5 mm (0.14 in)
EAS22240
5. Adjust:
• Brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
T.
R.
CHECKING THE BRAKE DISCS
The following procedure applies to all of the
brake discs.
1. Remove:
• Wheels
Refer to “FRONT AND REAR WHEELS” on
page 4-25.
2. Check:
• Brake disc
Damage/galling → Replace.
3. Measure:
• Brake disc deflection
Out of specification → Correct the brake disc
deflection or replace the brake disc.
Brake disc bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
LOCTITE®
TIP
Install the brake disc so that the recessed portion of the bolt hole faces away from the hub.
Brake disc deflection limit
0.1 mm (0.004 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the dial gauge at a right angle against
the brake disc surface.
b. Measure the deflection 3.0 mm (0.12 in) below the edge of the brake disc.
4-36
FRONT AND REAR BRAKES
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• Wheels
Refer to “FRONT AND REAR WHEELS” on
page 4-25.
2. Install:
• Brake pad spring
• Brake pads
EAS22250
REPLACING THE BRAKE PADS
The following procedure applies to all of the
brake calipers.
TIP
Always install new brake pads and brake pad
spring as a set.
TIP
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose “1” tightly to the
bleed screw “2”. Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with your
finger.
1. Measure:
• Brake pad wear limit “a”
Out of specification → Replace the brake
pads as a set.
1
Front brake
Brake pad lining thickness (inner)
4.5 mm (0.18 in)
Limit
1.0 mm (0.04 in)
Brake pad lining thickness (outer)
4.5 mm (0.18 in)
Limit
1.0 mm (0.04 in)
Rear brake
Brake pad lining thickness (inner)
4.3 mm (0.17 in)
Limit
1.0 mm (0.04 in)
Brake pad lining thickness (outer)
4.3 mm (0.17 in)
Limit
1.0 mm (0.04 in)
2
c. Tighten the bleed screw.
T.
R.
Bleed screw
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
d. Install the brake pad spring and brake pads.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Brake pad bolts
• Brake caliper
T.
R.
Brake pad bolt
17 Nm (1.7 m·kgf, 12 ft·lbf)
Brake caliper bolt
48 Nm (4.8 m·kgf, 35 ft·lbf)
4. Check:
• Brake fluid level
Below the minimum level mark → Add the
specified brake fluid to the proper level.
4-37
FRONT AND REAR BRAKES
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-16.
5. Check:
• Brake pedal operation
Soft or spongy feeling → Bleed the brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-17.
b. Remove the brake caliper piston dust seals
and piston seals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22390
CHECKING THE BRAKE CALIPERS
The following procedure applies to all of the
brake calipers.
Recommended brake component replacement schedule
EAS22350
DISASSEMBLING THE BRAKE CALIPERS
The following procedure applies to all of the
brake calipers.
TIP
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
• Brake caliper pistons “1”
• Brake caliper piston dust seals “2”
• Brake caliper piston seals “3”
If necessary
Piston seals, piston
dust seals
Every two years
Brake hoses
Every four years
Brake fluid
Every two years and
whenever the brake
is disassembled
1. Check:
• Brake caliper pistons “1”
Rust/scratches/wear → Replace the brake
caliper pistons.
• Brake caliper cylinders “2”
Scratches/wear → Replace the brake caliper.
• Brake caliper body “3”
Cracks/damage → Replace the brake caliper.
• Brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed air.
3
2
3
1
Brake pads
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EWA1XD1010
a. Blow compressed air into the brake hose joint
opening “a” to force out the pistons from the
brake caliper.
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals and
brake caliper piston dust seals.
EWA13550
WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the piston is expelled from the brake caliper.
• Never try to pry out the brake caliper piston.
2
1
3
2
EAS22410
ASSEMBLING THE BRAKE CALIPERS
The following procedure applies to all of the
brake calipers.
a
4-38
FRONT AND REAR BRAKES
• When installing the right rear brake hose
onto the right rear brake caliper, make sure
that the projection “d” on the brake hose
contacts the rib on the brake caliper.
EWA1XD1011
WARNING
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake components as they will cause the brake caliper
piston seals and brake caliper piston dust
seals to swell and distort.
• Whenever a brake caliper is disassembled,
replace the brake caliper piston seals and
brake caliper piston dust seals.
È
2
3
a
1
Specified brake fluid
DOT 4
É
EAS22440
INSTALLING THE BRAKE CALIPERS
The following procedure applies to all of the
brake calipers.
1. Install:
• Brake caliper “1”
(temporarily)
2
b
3
• Copper washers New
• Brake hose “2”
• Brake hose union bolt “3”
1
Ê
T.
R.
Brake hose union bolt
27 Nm (2.7 m·kgf, 20 ft·lbf)
2
c
EWA1XD1022
WARNING
Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE
ROUTING” on page 2-41.
3
1
ECA1XD1008
NOTICE
Ë
• When installing the left front brake hose
onto the left front brake caliper, fit the projection “a” on the brake hose into the slot in
the brake caliper.
• When installing the right front brake hose
onto the right front brake caliper, make
sure that the pipe section “b” on the end of
the brake hose contacts the rib on the
brake caliper.
• When installing the left rear brake hose
onto the left rear brake caliper, fit the pipe
section “c” on the end of the brake hose
into the slot in the brake caliper.
2
d
3
1
A.
B.
C.
D.
Left front brake
Right front brake
Left rear brake
Right rear brake
2. Remove:
• Brake caliper
4-39
FRONT AND REAR BRAKES
3. Install:
• Brake pads
• Brake pad spring
• Brake pad bolts
• Brake caliper
Refer to “REPLACING THE BRAKE PADS”
on page 4-37.
7. Check:
• Brake pedal operation
Soft or spongy feeling → Bleed the brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-17.
EAS1XD1072
T.
R.
CHECKING THE BRAKE MASTER
CYLINDER
1. Check:
• Brake master cylinder
Damage/scratches/wear → Replace.
• Brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed air.
2. Check:
• Brake master cylinder reservoir
Cracks/damage → Replace the brake master
cylinder.
• Brake master cylinder reservoir diaphragm
• Brake master cylinder reservoir diaphragm
holder
Cracks/damage → Replace.
3. Check:
• Brake pipes
Cracks/damage → Replace.
Brake pad bolt
17 Nm (1.7 m·kgf, 12 ft·lbf)
Brake caliper bolt
48 Nm (4.8 m·kgf, 35 ft·lbf)
4. Fill:
• Brake master cylinder reservoir
(with the specified amount of the specified
brake fluid)
Specified brake fluid
DOT 4
EWA1XD1021
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reservoir. Water will significantly lower the boiling point of the brake fluid and could cause
vapor lock.
EAS1XD1050
CHECKING THE BRAKE PIPES
The following procedure applies to both of the
brake pipes.
1. Check:
• Brake pipe end (flare nut)
Damage → Replace the brake master cylinder, brake pipes, and related parts as a set.
ECA13540
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
5. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-17.
6. Check:
• Brake fluid level
Below the minimum level mark → Add the
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-16.
EAS1XD1073
INSTALLING THE BRAKE MASTER
CYLINDER
1. Install:
• Brake master cylinder
• Brake pipes
4-40
FRONT AND REAR BRAKES
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-17.
T.
R.
Brake master cylinder bolt
16 Nm (1.6 m·kgf, 12 ft·lbf)
Brake pipe flare nut
19 Nm (1.9 m·kgf, 14 ft·lbf)
EWA1XD1012
WARNING
Proper brake pipe routing is essential to insure safe vehicle operation. Refer to “CABLE
ROUTING” on page 2-41.
2. Fill:
• Brake master cylinder reservoir
(with the specified amount of the specified
brake fluid)
Specified brake fluid
DOT 4
EWA13540
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reservoir. Water will significantly lower the boiling point of the brake fluid and could cause
vapor lock.
ECA13540
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
3. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-17.
4. Check:
• Brake fluid level
Below the minimum level mark → Add the
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-16.
5. Check:
• Brake pedal operation
Soft or spongy feeling → Bleed the brake system.
4-41
PARKING BRAKE
EAS1XD1074
PARKING BRAKE
Removing the parking brake pads
FW
D
6
7
1
5
2
9
5
8
T.R
.
40 Nm (4.0 m•kgf, 29 ft•Ibf)
T.R
.
17 Nm (1.7 m•kgf, 12 ft•Ibf)
4
3
T.R
.
Order
Job/Parts to remove
Q’ty
17 Nm (1.7 m•kgf, 12 ft•Ibf)
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
Rear skid plate
1
Parking brake caliper bolt
2
2
Parking brake caliper
1
3
Parking brake cable (parking brake caliper end)
1
4
Spring
1
5
Parking brake pad bolt
2
6
Parking brake pad
2
7
Brake pad spring
1
8
Parking brake caliper arm nut
1
9
Parking brake caliper arm
1
Disconnect.
For installation, reverse the removal procedure.
4-42
PARKING BRAKE
Removing the parking brake caliper
FW
D
2
1
1
3
T.R
.
40 Nm (4.0 m•kgf, 29 ft•Ibf)
Order
Job/Parts to remove
Q’ty
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
Rear skid plate
1
Parking brake caliper bolt
2
2
Parking brake caliper
1
3
Parking brake cable (parking brake caliper end)
1
Disconnect.
For installation, reverse the removal procedure.
4-43
PARKING BRAKE
Disassembling the parking brake caliper
T.R
.
17 Nm (1.7 m•kgf, 12 ft•Ibf)
T.R
.
17 Nm (1.7 m•kgf, 12 ft•Ibf)
S
2
10
New
7
11
8
S
14 New
S
LT
13
12
T.R
.
22 Nm (2.2 m•kgf, 16 ft•Ibf)
4
New
3
1
9
S
.
T.R
6
12 Nm (1.2 m•kgf, 8.7 ft•Ibf)
5
T.R
.
Order
1
Job/Parts to remove
Q’ty
Spring
1
2
Parking brake pad bolt
2
3
Parking brake pad
2
4
Brake pad spring
1
5
Parking brake caliper arm nut
1
6
Parking brake caliper arm
1
7
Brake caliper piston
1
8
Push rod
1
9
Parking brake caliper arm shaft
1
10
Brake caliper bracket
1
11
Parking brake caliper guide pin
1
12
Parking brake caliper retaining pin
1
13
Parking brake cable holder
1
14
Brake caliper piston seal
1
17 Nm (1.7 m•kgf, 12 ft•Ibf)
Remarks
Left-hand threads
For assembly, reverse the disassembly procedure.
4-44
PARKING BRAKE
Removing the parking brake lever
2
1
T.R
.
13 Nm (1.3 m•kgf, 9.4 ft•Ibf)
3
T.R
.
Order
16 Nm (1.6 m•kgf, 12 ft•Ibf)
Job/Parts to remove
Q’ty
Sun top/Side frames/Hood/Front fender/Instrument panel
1
Parking brake switch
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
1
2
Parking brake lever
1
3
Parking brake cable (parking brake lever end)
1
Disconnect.
For installation, reverse the removal procedure.
4-45
PARKING BRAKE
Removing the parking brake disc
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)
1
Order
Job/Parts to remove
Q’ty
Refer to “REAR CONSTANT VELOCITY
SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT” on
page 8-17.
Final drive assembly
1
Remarks
Parking brake disc
1
For installation, reverse the removal procedure.
4-46
PARKING BRAKE
EAS1XD1075
REMOVING THE PARKING BRAKE CALIPER
1. Move the parking brake lever to the released
position, and then loosen the parking brake
cable adjuster so that the parking brake cable
is slack.
Brake pad lining thickness-inner
3.2 mm (0.13 in)
Limit
1.0 mm (0.04 in)
Brake pad lining thickness-outer
3.2 mm (0.13 in)
Limit
1.0 mm (0.04 in)
EAS1XD1076
CHECKING THE PARKING BRAKE CALIPER
1. Check:
• Brake caliper piston
Scratches/rust/wear → Replace.
• Brake caliper body
Cracks/damage → Replace the parking
brake caliper.
a
EAS1XD1077
CHECKING THE PARKING BRAKE DISC
1. Check:
• Brake disc
Galling/damage → Replace.
2. Measure:
• Brake disc deflection
• Brake disc thickness “a”
Out of specification → Replace.
T.
R.
Brake disc deflection limit
0.10 mm (0.004 in)
Brake disc thickness limit
3.0 mm (0.12 in)
2. Install:
• Brake pad spring
• Parking brake pads
• Parking brake pad bolts
Parking brake pad bolt
17 Nm (1.7 m·kgf, 12 ft·lbf)
TIP
Always install new brake pads and brake pad
spring as a set.
TIP
Measure the deflection 3.0 mm (0.12 in) below
the edge of the brake disc.
3. Adjust:
• Brake pad clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a
a. Fully turn in the parking brake caliper arm
shaft “1”.
1
EAS1XD1078
REPLACING THE PARKING BRAKE PADS
1. Measure:
• Brake pad wear limit “a”
Out of specification → Replace the brake
pads and brake pad spring as a set.
TIP
The parking brake arm shaft has left hand
threads. To turn in the shaft, turn it counterclockwise.
b. Install the parking brake caliper arm “2” onto
the parking brake caliper arm shaft, and then
rotate the arm until it contacts the stopper “a”.
4-47
PARKING BRAKE
2. Adjust:
• Parking brake cable free play
Refer to “ADJUSTING THE PARKING
BRAKE LEVER” on page 3-20.
2
a
EAS1XD1051
INSTALLING THE PARKING BRAKE LEVER
1. Install:
• Parking brake lever
T.
c. Install the parking brake caliper arm nut “3”,
and then temporarily tighten it.
R.
Parking brake lever bolt
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
2. Adjust:
• Parking brake lever free play
Refer to “ADJUSTING THE PARKING
BRAKE LEVER” on page 3-20.
3
d. Insert a suitable tool “4” with a thickness of
4.7 mm (0.19 in) between the brake pads “5”,
and then finger tighten the push rod “6”.
6
5
4
5
e. Tighten the parking brake caliper arm nut.
T.
R.
Parking brake caliper arm nut
17 Nm (1.7 m·kgf, 12 ft·lbf)
f. Install the spring.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1XD1079
INSTALLING THE PARKING BRAKE
CALIPER
1. Install:
• Parking brake caliper
T.
R.
Parking brake caliper bolt
40 Nm (4.0 m·kgf, 29 ft·lbf)
4-48
PEDAL ASSEMBLY
EAS1XD1080
PEDAL ASSEMBLY
Removing the pedal assembly
FW
D
T.R
.
2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)
2
3
1
T.R
.
Order
16 Nm (1.6 m•kgf, 12 ft•Ibf)
Job/Parts to remove
Q’ty
Remarks
Sun top/Side frames/Hood/Front fender/Instrument panel
Refer to “GENERAL CHASSIS” on page
4-1.
Brake fluid
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-17.
Brake master cylinder
Refer to “FRONT AND REAR BRAKES” on
page 4-29.
Steering joint
Refer to “STEERING SYSTEM” on page
4-52.
1
Brake light switch
1
2
Throttle cable
1
3
Pedal assembly
1
Disconnect.
For installation, reverse the removal procedure.
4-49
PEDAL ASSEMBLY
Disassembling the pedal assembly
11
LS
New 8
10
LS
3
9
9
2
1
New
LS
7
5
New 4
5
T.R
.
17 Nm (1.7 m•kgf, 12 ft•Ibf)
Order
1
6
Job/Parts to remove
Q’ty
Pin
1
2
Brake pedal rod
1
3
Spring
1
4
Circlip
1
5
Washer
2
6
Brake pedal
1
7
Spring
1
8
Circlip
1
9
Washer
2
10
Accelerator pedal
1
11
Pedal assembly bracket
1
Remarks
For assembly, reverse the disassembly procedure.
4-50
PEDAL ASSEMBLY
EAS1XD1052
INSTALLING THE PEDAL ASSEMBLY
1. Adjust:
• Throttle cable length “a”
1
Throttle cable length
5.5–6.5 mm (0.22–0.26 in)
2
b
a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting nut “1” until the specified
length is obtained.
b. Tighten the locknut “2” to specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
T.
R.
Throttle cable locknut
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
a
2
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• Accelerator pedal free play
Refer to “ADJUSTING THE ACCELERATOR
PEDAL FREE PLAY” on page 3-21.
3. Adjust:
• Brake pedal free play
Refer to “ADJUSTING THE BRAKE PEDAL”
on page 3-19.
4. Adjust:
• Brake light operation timing
TIP
Adjustment is correct when the brake light
comes on by depressing the brake pedal less
than 5.0–10.0 mm (0.20–0.39 in).
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the main body “1” of the brake light
switch so that it does not rotate and turn the
adjusting nut “2” in direction “a” or “b” until the
brake light comes on at the proper time.
Direction “a”
Brake light comes on sooner.
Direction “b”
Brake light comes on later.
4-51
STEERING SYSTEM
EAS1XD1081
STEERING SYSTEM
Removing the steering assembly
T.R
.
.
T.R
21 Nm (2.1 m•kgf, 15 ft•Ibf)
27 Nm (2.7 m•kgf, 20 ft•Ibf)
3
.
T.R
40 Nm (4.0 m•kgf, 29 ft•Ibf)
(4)
4
2
5
1
6
1
New
(4)
New
T.R
.
27 Nm (2.7 m•kgf, 20 ft•Ibf)
.
T.R
New
40 Nm (4.0 m•kgf, 29 ft•Ibf)
.
T.R
48 Nm (4.8 m•kgf, 35 ft•Ibf)
.
T.R
39 Nm (3.9 m•kgf, 28 ft•Ibf)
T.R
.
Order
39 Nm (3.9 m•kgf, 28 ft•Ibf)
Job/Parts to remove
Q’ty
Sun top/Side frames/Hood/Front fender/Instrument panel
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
1
Steering joint bolt
2
2
Steering column
1
Except for EPS models
3
EPS motor coupler
1
Disconnect.
For EPS models
4
EPS torque sensor coupler
1
Disconnect.
For EPS models
For EPS models
ECA1XD1009
5
EPS unit
1
NOTICE
The EPS unit should not be disassembled.
6
Steering joint
1
4-52
STEERING SYSTEM
Removing the steering assembly
.
.
T.R
40 Nm (4.0 m•kgf, 29 ft•Ibf)
T.R
.
T.R
21 Nm (2.1 m•kgf, 15 ft•Ibf)
27 Nm (2.7 m•kgf, 20 ft•Ibf)
(4)
9
7
7
9
New
(4)
10
New
T.R
8
.
27 Nm (2.7 m•kgf, 20 ft•Ibf)
.
T.R
New
40 Nm (4.0 m•kgf, 29 ft•Ibf)
.
T.R
48 Nm (4.8 m•kgf, 35 ft•Ibf)
.
T.R
39 Nm (3.9 m•kgf, 28 ft•Ibf)
T.R
.
Order
39 Nm (3.9 m•kgf, 28 ft•Ibf)
Job/Parts to remove
10
Q’ty
7
Tie-rod end locknut
2
8
Steering assembly
1
9
Tie-rod end
2
10
Dust boot
2
Remarks
For installation, reverse the removal procedure.
4-53
STEERING SYSTEM
b. Crimp the portion “c” of the boot band with the
boots band installation tool “2”.
EAS1XD1082
CHECKING THE STEERING JOINT
1. Check:
• Steering joint
Rough movement → Replace.
Boots band installation tool
90890-01526
YM-01526
2
c
EAS1XD1083
CHECKING THE TIE-ROD ENDS
The following procedure applies to both of the
tie-rod ends.
1. Check:
• Tie-rod end free play and movement
Rough movement → Replace the tie-rod end.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
• Steering assembly “1”
T.
R.
Steering assembly bolt
48 Nm (4.8 m·kgf, 35 ft·lbf)
TIP
Tighten the steering assembly bolts in the proper tightening sequence as shown.
FWD
4
2. Check:
• Tie-rod end
Bends/damage → Replace.
Rubber boot damage → Replace the tie-rod
end.
1
1
2
3
3. Install:
• Steering joint “1”
• Steering column “2” (except for EPS models)
• EPS unit “2” (for EPS models)
EAS29650
INSTALLING THE STEERING SYSTEM
1. Install:
• Dust boots
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
T.
a. Fit the tabs “a” into the holes “b” in the boot
band “1”.
R.
a
1
b
4-54
Steering column bolt (except for
EPS models)
21 Nm (2.1 m·kgf, 15 ft·lbf)
EPS unit bolt (for EPS models)
21 Nm (2.1 m·kgf, 15 ft·lbf)
Steering joint bolt
27 Nm (2.7 m·kgf, 20 ft·lbf)
STEERING SYSTEM
TIP
• Align the alignment mark “a” on the steering
assembly shaft and the alignment mark “b” on
the steering joint with the alignment mark “c” on
the steering assembly housing.
• Fit the steering joint onto the steering column
shaft or EPS unit shaft so that the bolt hole “d”
in the joint is aligned with the area “e” on the
shaft that does not have splines.
c
a
1
b
2
1
d
e
4. Adjust:
• Toe-in
Refer to “ADJUSTING THE TOE-IN” on page
3-26.
4-55
STEERING KNUCKLES
EAS1XD1084
STEERING KNUCKLES
Removing the steering knuckles
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
2
T.R
.
39 Nm (3.9 m•kgf, 28 ft•Ibf)
3
7
New
8
9
1
New
T.R
.
30 Nm (3.0 m•kgf, 22 ft•Ibf)
LS
New
New 5
4
8
New
LS
T.R
.
30 Nm (3.0 m•kgf, 22 ft•Ibf)
6 New
T.R
.
Order
Job/Parts to remove
Q’ty
7 New
9 Nm (0.9 m•kgf, 6.5 ft•Ibf)
Remarks
The following procedure applies to both of
the steering knuckles.
Refer to “FRONT AND REAR WHEELS” on
page 4-25.
Front wheel hub
1
Brake disc guard
1
2
Tie-rod end
1
3
Front brake hose holder
1
4
Steering knuckle
1
5
Circlip
1
6
Ball joint
1
7
Oil seal
2
8
Bearing
2
9
Spacer
1
Disconnect.
For installation, reverse the removal procedure.
4-56
STEERING KNUCKLES
e. Apply lithium-soap-based grease to the spacer, new bearings and oil seals.
f. Install the spacer to the steering knuckle.
g. Install the new bearings.
EAS29670
REMOVING THE STEERING KNUCKLES
The following procedure applies to both of the
steering knuckles.
1. Remove:
• Steering knuckle “1”
TIP
Install the wheel side bearing first.
TIP
ECA1XD1010
Use a general puller to separate the ball joints
“2” from the steering knuckle “1” or the front lower arm “3”.
NOTICE
Do not strike the inner race or balls of the
bearing. Contact should be made only with
the outer race.
h. Install the new oil seals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1XD1086
CHECKING THE STEERING KNUCKLE BALL
JOINTS
The following procedure applies to both of the
steering knuckle ball joints.
1. Check:
• Ball joint (steering knuckle)
Damage/pitting → Replace the ball joint.
Rubber boot damage → Replace the ball
joint.
Rough movement → Replace the ball joint.
EAS1XD1085
CHECKING THE STEERING KNUCKLES
AND FRONT WHEEL BEARINGS
The following procedure applies to both of the
steering knuckles and front wheel bearings.
1. Check:
• Steering knuckle
Damage/pitting → Replace.
2. Check:
• Front wheel bearings “1”
Rough movement/excessive free play → Replace.
• Oil seals “2”
Damage → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the surface of the steering knuckle.
b. Remove the oil seals.
c. Drive out the bearings.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the surface of the steering knuckle.
b. Remove the circlip “1”.
EWA15040
WARNING
Eye protection is recommended when using
striking tools.
d. Remove the spacer “3”.
3
1
2
2
c. Remove the ball joint “2”.
TIP
Use a suitable socket “3” to separate the ball
joint “2” from the steering knuckle “4”.
1
4-57
STEERING KNUCKLES
4
3
2
d. Measure the ball joint bore inside diameter
“a”.
Out of specification → Replace the steering
knuckle.
No.
Tool name
6
Long bolt
7
Body
8
Guide bolt
9
Installer washer
90890-01477
YM-01477
10
Base plate 35 mm
90890-01553
YM-01553
11
Ball joint installer attachment 39 mm
90890-01555
YS-01881-A
90890-01474
YM-01474
11
8
7
Ball joint bore inside diameter
32.90–32.95 mm (1.295–1.297 in)
Tool No.
9
6
8
6
7
9
8
10
11 5 10
a
e. Attach the special tools and a new ball joint
“5” to the steering knuckle “4”.
TIP
• Always use a new ball joint.
• Do not tap or damage the top of the ball joint or
rubber boot.
8
4
f. Hold the base plate “10” in place while turning
in the long bolt “6” to install the new ball joint
“5” into the steering knuckle “4”.
g. Remove the special tools.
h. Install a new circlip.
Ball joint remover
90890-01474
YM-01474
Ball joint remover adapter set
90890-01477
YM-01477
Base plate 35mm
90890-01553
YM-01553
Ball joint installer attachment
39mm
90890-01555
YS-01881-A
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-58
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES
EAS29710
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES
Removing the front arms and front shock absorber assemblies
7
5
.
7
T.R
LS
5
45 Nm (4.5 m•kgf, 33 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
LS
7
2
LS
9
9
6
LS
8
New
5
4
5
T.R
3
.
30 Nm (3.0 m•kgf, 22 ft•Ibf)
T.R
.
45 Nm (4.5 m•kgf, 33 ft•Ibf)
1
T.R
.
30 Nm (3.0 m•kgf, 22 ft•Ibf)
New
D
FW
4
T.R
.
Order
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
Job/Parts to remove
Q’ty
Remarks
The following procedure applies to both of
the front upper arms, front lower arms, and
front shock absorber assemblies.
Refer to “FRONT AND REAR WHEELS” on
page 4-25.
Front wheel
1
Front arm protector
1
2
Front brake hose holder
1
3
Front brake hose holder
1
4
Nut
2
5
Nut/Bolt (front shock absorber assembly)
6
Front shock absorber assembly
2/2
1
7
Nut/Bolt (front upper arm)
8
Front upper arm
2/2
1
9
Dust cover
2
4-59
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES
Removing the front arms and front shock absorber assemblies
T.R
LS
.
45 Nm (4.5 m•kgf, 33 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
LS
LS
10
13
13
10
10
LS
14 New
New
12
T.R
12 16
.
30 Nm (3.0 m•kgf, 22 ft•Ibf)
16
11
T.R
15 New
.
T.R
.
30 Nm (3.0 m•kgf, 22 ft•Ibf)
New
D
FW
T.R
.
Order
10
45 Nm (4.5 m•kgf, 33 ft•Ibf)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
Job/Parts to remove
Q’ty
Nut/Bolt (front lower arm)
Remarks
2/2
11
Front lower arm
1
12
Dust cover
2
13
Bushing
2
14
Circlip
1
15
Ball joint
1
16
Bushing
2
For installation, reverse the removal procedure.
4-60
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES
damage or personal injury that may result
from improper handling of the front shock
absorber assemblies.
• Do not tamper or attempt to open the front
shock absorber assemblies.
• Do not subject the front shock absorber assemblies to an open flame or any other
source of high heat. High heat can cause an
explosion due to excessive gas pressure.
• Do not deform or damage the front shock
absorber assemblies in any way. If the front
shock absorber assemblies are damaged,
damping performance will suffer.
EAS29730
CHECKING THE FRONT ARMS
The following procedure applies to both of the
front upper arms and front lower arms.
1. Check:
• Front arm free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the front arm side play “A” by moving
it from side to side.
If side play is noticeable, check the bushings.
A
EAS1XD1088
DISPOSING OF A FRONT SHOCK
ABSORBER ASSEMBLY
Gas pressure must be released before disposing of a front shock absorber assembly. To release the gas pressure, drill a 2–3 mm (0.08–
0.12 in) hole through the front shock absorber at
a point 60–70 mm (2.4–2.8 in) from its end as
shown.
A
b. Check the front arm vertical movement “B” by
moving it up and down.
If the vertical movement is tight or rough, or if
there is binding, check the bushings.
EWA1XD1014
WARNING
Oil and metal chips may be expelled together
with the gas from the shock absorber assembly; therefore, wear eye protection to prevent
eye damage.
B
B
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Front upper arm
• Front lower arm
Bends/damage → Replace.
3. Check:
• Bushings
Wear/damage → Replace.
EAS29760
CHECKING THE FRONT SHOCK ABSORBER
ASSEMBLIES
The following procedure applies to both of the
front shock absorber assemblies.
1. Check:
• Front shock absorber assembly
Oil leaks/gas leaks → Replace the front
shock absorber assembly.
• Front shock absorber rod
Bends/damage → Replace the front shock
absorber assembly.
• Spring
Move the spring up and down.
EAS1XD1087
HANDLING THE FRONT SHOCK ABSORBER
ASSEMBLIES
EWA1XD1013
WARNING
These front shock absorber assemblies contain highly compressed nitrogen gas. Before
handling the front shock absorber assemblies, read and make sure you understand
the following information. The manufacturer
cannot be held responsible for property
4-61
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES
Fatigue → Replace the front shock absorber
assembly.
TIP
• Always use a new ball joint.
• Do not tap or damage the top of the ball joint or
rubber boot.
EAS29770
CHECKING THE FRONT ARM BALL JOINTS
The following procedure applies to both of the
front arm ball joints.
1. Check:
• Ball joint (front upper arm)
Damage/pitting → Replace the ball joint.
Rubber boot damage → Replace the ball
joint.
Rough movement → Replace the ball joint.
Ball joint remover
90890-01474
YM-01474
Ball joint remover adapter set
90890-01477
YM-01477
Base plate 35mm
90890-01553
YM-01553
Ball joint installer attachment
39mm
90890-01555
YS-01881-A
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the surface of the front upper arm.
b. Remove the circlip “1”.
No.
Tool name
Tool No.
6
Long bolt
7
Body
8
Guide bolt
9
Installer washer
90890-01477
YM-01477
10
Base plate 35 mm
90890-01553
YM-01553
11
Ball joint installer attachment 39 mm
90890-01555
YS-01881-A
90890-01474
YM-01474
1
11
8
7
9
6
c. Remove the ball joint “2”.
TIP
Use a suitable socket “3” to separate the ball
joint “2” from the front upper arm “4”.
8
10
3
6
7
8
9
11
10
4
2
4
d. Attach the special tools and a new ball joint
“5” to the front upper arm “4”.
4-62
8
5
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES
e. Hold the base plate “10” in place while turning
in the long bolt “6” to install the new ball joint
“5” into the front upper arm “4”.
f. Remove the special tools.
g. Install a new circlip.
6,7
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS29790
INSTALLING THE FRONT ARMS AND
FRONT SHOCK ABSORBER ASSEMBLIES
The following procedure applies to both of the
front upper arms, front lower arms, and front
shock absorber assemblies.
1. Install:
• Front upper arm
• Front lower arm
• Front shock absorber assembly
5
1
6,7
3,4
8
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the front upper arm “1” and front lower
arm “2”.
2
8
TIP
• Lubricate the front upper and lower arm bolts
“3” with lithium-soap-based grease.
• Be sure to position the front upper and lower
arm bolts “3” so that the bolt heads face forward.
• Temporarily tighten the front upper and lower
arm nuts “4”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Install the front shock absorber assembly “5”,
bolts “6”, and nuts “7”.
T.
R.
Front shock absorber assembly
nut
45 Nm (4.5 m·kgf, 33 ft·lbf)
TIP
• Install the front shock absorber assembly so
that the warning label is facing out.
• Be sure to position the front shock absorber
bolts “6” so that the bolt heads face forward.
c. Install the steering knuckle and nuts “8”.
T.
R.
Steering knuckle nut
30 Nm (3.0 m·kgf, 22 ft·lbf)
d. Install new cotter pins.
e. Tighten the front upper and lower arm nuts
“4” to specification.
T.
R.
Front arm nut
45 Nm (4.5 m·kgf, 33 ft·lbf)
4-63
REAR KNUCKLES AND STABILIZER
EAS29800
REAR KNUCKLES AND STABILIZER
Removing the rear knuckles and stabilizer
FW
D
R.
T.
85 Nm (8.5 m•kgf, 61 ft •Ibf)
9
9
R.
T.
60 Nm (6.0 m•kgf, 43 ft •Ibf)
New 6
LS
R.
T.
9 Nm (0.9 m•kgf, 6.5 ft •Ibf)
4
New 6
5
7 3
4
8
5
1
4
LS
T.
R.
Order
2
4
7
Job/Parts to remove
Q’ty
85 Nm (8.5 m•kgf, 61 ft •Ibf)
Remarks
The following procedure applies to both of
the rear knuckles.
Refer to “FRONT AND REAR WHEELS” on
page 4-25.
Rear wheel hub
1
Rear brake disc cleaning plate
1
2
Brake disc guard
1
3
Rear knuckle
1
4
Spacer cover
4
5
Spacer
2
6
Oil seal
2
7
Bearing
2
8
Spacer
1
9
Stabilizer joint
2
4-64
REAR KNUCKLES AND STABILIZER
Removing the rear knuckles and stabilizer
FW
D
R.
T.
85 Nm (8.5 m•kgf, 61 ft •Ibf)
10 11
12
10 11
R.
T.
60 Nm (6.0 m•kgf, 43 ft •Ibf)
LS
R.
T.
9 Nm (0.9 m•kgf, 6.5 ft •Ibf)
LS
T.
R.
Order
Job/Parts to remove
Q’ty
10
Stabilizer holder
2
11
Bushing
2
12
Stabilizer
1
85 Nm (8.5 m•kgf, 61 ft •Ibf)
Remarks
For installation, reverse the removal procedure.
4-65
REAR KNUCKLES AND STABILIZER
EAS1XD1089
EAS29830
CHECKING THE REAR KNUCKLES AND
REAR WHEEL BEARINGS
The following procedure applies to both of the
rear knuckles and rear wheel bearings.
1. Check:
• Rear knuckle
Damage/pitting → Replace.
2. Check:
• Rear wheel bearings “1”
Rough movement/excessive free play → Replace.
• Oil seals “2”
Damage → Replace.
INSTALLING THE STABILIZER
1. Install:
• Stabilizer “1”
• Bushing “2”
• Stabilizer holder “3”
T.
Stabilizer holder bolt
85 Nm (8.5 m·kgf, 61 ft·lbf)
R.
TIP
Install the bushing with its slit “a” facing downward.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the surface of the rear knuckle.
b. Remove the oil seals.
c. Drive out the bearings.
2
3
1
EWA15040
WARNING
a
Eye protection is recommended when using
striking tools.
d. Remove the spacer “3”.
1
2
2
3
e. Apply lithium-soap-based grease to the spacer, new bearings and oil seals.
f. Install the spacer to the rear knuckle.
g. Install the new bearings.
TIP
Install the wheel side bearing first.
ECA1XD1010
NOTICE
Do not strike the inner race or balls of the
bearing. Contact should be made only with
the outer race.
h. Install the new oil seals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS29820
CHECKING THE STABILIZER
1. Check:
• Stabilizer
Bends/cracks/damage → Replace.
4-66
REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES
EAS29840
REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES
Removing the rear arms and rear shock absorber assemblies
3
R.
T.
FW
82 Nm (8.2 m•kgf, 59 ft •Ibf)
D
3
LS
8
6
5
7
LS
6
8
LS
6
5
2
T.
R.
7 Nm (0.7 m•kgf, 5.1 ft •Ibf)
T.R
.
85 Nm (8.5 m•kgf, 61 ft•Ibf)
3
T.
R.
R.
T.
T.R
.
3
45 Nm (4.5 m•kgf, 33 ft •Ibf)
82 Nm (8.2 m•kgf, 59 ft •Ibf)
4
85 Nm (8.5 m•kgf, 61 ft•Ibf)
1
T.
R.
Order
7 Nm (0.7 m•kgf, 5.1 ft •Ibf)
Job/Parts to remove
Q’ty
Remarks
The following procedure applies to both of
the rear upper arms, rear lower arms, and
rear shock absorber assemblies.
Rear wheel
Refer to “FRONT AND REAR WHEELS” on
page 4-25.
Stabilizer joint
Refer to “REAR KNUCKLES AND STABILIZER” on page 4-64.
1
Rear arm protector
1
2
Rear brake hose holder
1
3
Nut/Bolt (rear shock absorber)
4
Rear shock absorber
2/2
5
Nut/Bolt (rear upper arm – rear knuckle)
1/1
6
Nut/Bolt (rear upper arm – frame)
2/2
7
Rear upper arm
1
8
Dust cover
2
1
4-67
REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES
Removing the rear arms and rear shock absorber assemblies
R.
T.
FW
82 Nm (8.2 m•kgf, 59 ft •Ibf)
D
LS
13
LS
13
LS
10
10
T.
R.
7 Nm (0.7 m•kgf, 5.1 ft •Ibf)
10
T.R
.
85 Nm (8.5 m•kgf, 61 ft•Ibf)
12
10
13
13
T.
12
R.
R.
T.
T.R
9
.
11
82 Nm (8.2 m•kgf, 59 ft •Ibf)
85 Nm (8.5 m•kgf, 61 ft•Ibf)
9
T.
R.
Order
45 Nm (4.5 m•kgf, 33 ft •Ibf)
7 Nm (0.7 m•kgf, 5.1 ft •Ibf)
Job/Parts to remove
Q’ty
9
Nut/Bolt (rear lower arm – rear knuckle)
1/1
10
Nut/Bolt (rear lower arm – frame)
2/2
11
Rear lower arm
1
12
Dust cover
2
13
Bushing
4
Remarks
For installation, reverse the removal procedure.
4-68
REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES
damage or personal injury that may result
from improper handling of the rear shock absorber assemblies.
• Do not tamper or attempt to open the rear
shock absorber assemblies.
• Do not subject the rear shock absorber assemblies to an open flame or any other
source of high heat. High heat can cause an
explosion due to excessive gas pressure.
• Do not deform or damage the rear shock
absorber assemblies in any way. If the rear
shock absorber assemblies are damaged,
damping performance will suffer.
EAS29850
CHECKING THE REAR ARMS
The following procedure applies to both of the
rear upper arms and rear lower arms.
1. Check:
• Rear arm free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the rear arm side play “A” by moving it
from side to side.
If side play is noticeable, check the bushings.
A
EAS1XD1091
DISPOSING OF A REAR SHOCK ABSORBER
ASSEMBLY
Gas pressure must be released before disposing of a rear shock absorber assembly. To release the gas pressure, drill a 2–3 mm (0.08–
0.12 in) hole through the rear shock absorber at
a point 40–50 mm (1.6–2.0 in) from its end as
shown.
A
b. Check the rear arm vertical movement “B” by
moving it up and down.
If the vertical movement is tight or rough, or if
there is binding, check the bushings.
EWA1XD1016
WARNING
Oil and metal chips may be expelled together
with the gas from the shock absorber assembly; therefore, wear eye protection to prevent
eye damage.
B
B
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Rear upper arm
• Rear lower arm
Bends/damage → Replace.
3. Check:
• Bushings
Wear/damage → Replace.
EAS29860
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLIES
The following procedure applies to both of the
rear shock absorber assemblies.
1. Check:
• Rear shock absorber assembly
Oil leaks/gas leaks → Replace the rear shock
absorber assembly.
• Rear shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
• Spring
Move the spring up and down.
EAS1XD1090
HANDLING THE REAR SHOCK ABSORBER
ASSEMBLIES
EWA1XD1015
WARNING
These rear shock absorber assemblies contain highly compressed nitrogen gas. Before
handling the rear shock absorber assemblies, read and make sure you understand
the following information. The manufacturer
cannot be held responsible for property
4-69
REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES
Fatigue → Replace the rear shock absorber
assembly.
EAS29870
INSTALLING THE REAR ARMS AND REAR
SHOCK ABSORBER ASSEMBLIES
The following procedure applies to both of the
rear upper arms, rear lower arms, and rear
shock absorber assemblies.
1. Install:
• Rear upper arm
• Rear lower arm
• Rear shock absorber assembly
6,7
5
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3,4
a. Install the rear upper arm “1” and rear lower
arm “2”.
8,9
TIP
• Lubricate the rear upper and lower arm bolts
“3” with lithium-soap-based grease.
• Be sure to position the rear upper and lower
arm bolts “3” so that the bolt heads face forward.
• Temporarily tighten the rear upper and lower
arm nuts “4”.
6,7
3,4
2
8,9
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Install the rear shock absorber assembly “5”,
bolts “6”, and nuts “7”.
T.
R.
Rear shock absorber assembly
nut
82 Nm (8.2 m·kgf, 59 ft·lbf)
TIP
• Install the rear shock absorber assembly so
that the warning label is facing rearward.
• Be sure to position the rear shock absorber
bolts “6” so that the bolt heads face forward.
c. Install the rear knuckle bolts “8”, and nuts “9”.
T.
R.
Rear knuckle nut
85 Nm (8.5 m·kgf, 61 ft·lbf)
d. Tighten the rear upper and lower arm nuts “4”
to specification.
T.
R.
Rear arm nut
45 Nm (4.5 m·kgf, 33 ft·lbf)
4-70
REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES
4-71
ENGINE
ENGINE REMOVAL ........................................................................................5-1
INSTALLING THE EXHAUST PIPE AND MUFFLER................................5-2
INSTALLING THE ENGINE....................................................................... 5-7
CYLINDER HEAD............................................................................................ 5-8
REMOVING THE CYLINDER HEAD.......................................................5-10
CHECKING THE CYLINDER HEAD .......................................................5-10
CHECKING THE CAMSHAFT SPROCKET............................................5-11
CHECKING THE TAPPET COVERS AND CAMSHAFT
SPROCKET COVER .............................................................................. 5-11
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-11
INSTALLING THE CYLINDER HEAD .....................................................5-12
MEASURING THE COMPRESSION PRESSURE..................................5-14
ROCKER ARMS AND CAMSHAFT ..............................................................5-16
REMOVING THE ROCKER ARMS AND CAMSHAFT............................ 5-17
CHECKING THE CAMSHAFT.................................................................5-17
CHECKING THE DECOMPRESSION SYSTEM..................................... 5-18
CHECKING THE ROCKER ARMS AND ROCKER ARM
SHAFTS .................................................................................................5-18
INSTALLING THE CAMSHAFT AND ROCKER ARMS .......................... 5-18
VALVES AND VALVE SPRINGS.................................................................. 5-20
REMOVING THE VALVES...................................................................... 5-21
CHECKING THE VALVES AND VALVE GUIDES ..................................5-21
CHECKING THE VALVE SEATS ............................................................ 5-23
CHECKING THE VALVE SPRINGS........................................................ 5-24
INSTALLING THE VALVES .................................................................... 5-25
CYLINDER AND PISTON.............................................................................. 5-27
REMOVING THE PISTON ...................................................................... 5-28
CHECKING THE CYLINDER AND PISTON ...........................................5-28
CHECKING THE PISTON RINGS........................................................... 5-29
CHECKING THE PISTON PIN ................................................................5-30
INSTALLING THE PISTON AND CYLINDER .........................................5-30
AC MAGNETO AND STARTER CLUTCH ....................................................5-32
REMOVING THE AC MAGNETO ROTOR.............................................. 5-34
REMOVING THE STARTER CLUTCH ...................................................5-34
CHECKING THE STARTER CLUTCH ....................................................5-35
CHECKING THE TORQUE LIMITER......................................................5-35
INSTALLING THE STARTER CLUTCH .................................................. 5-35
INSTALLING THE AC MAGNETO ROTOR ............................................5-35
ELECTRIC STARTER ...................................................................................5-37
CHECKING THE STARTER MOTOR .....................................................5-39
ASSEMBLING THE STARTER MOTOR................................................. 5-40
5
BALANCER GEARS AND OIL PUMP GEARS ............................................5-41
REMOVING THE BALANCER DRIVEN GEAR AND
OIL PUMP DRIVEN SPROCKET ........................................................... 5-43
CHECKING THE OIL PUMP GEARS......................................................5-43
CHECKING THE BALANCER GEARS ...................................................5-43
INSTALLING THE BALANCER DRIVE GEAR, BALANCER
DRIVEN GEAR, AND OIL PUMP DRIVEN SPROCKET........................ 5-43
SHIFT LEVER................................................................................................5-45
CHECKING THE STOPPER LEVER ......................................................5-48
CHECKING THE SHIFT LEVERS........................................................... 5-48
INSTALLING THE SHIFT LEVERS......................................................... 5-48
ADJUSTING THE DRIVE SELECT LEVER SHIFT CABLE ....................5-48
PRIMARY AND SECONDARY SHEAVES....................................................5-50
REMOVING THE PRIMARY AND SECONDARY SHEAVES ................. 5-53
DISASSEMBLING THE SECONDARY SHEAVE.................................... 5-53
CHECKING THE V-BELT........................................................................5-54
CHECKING THE PRIMARY SHEAVE ....................................................5-54
CHECKING THE PRIMARY SHEAVE WEIGHTS................................... 5-54
CHECKING THE PRIMARY SHEAVE SLIDERS .................................... 5-54
CHECKING THE SECONDARY SHEAVE .............................................. 5-54
ASSEMBLING THE PRIMARY SHEAVE ................................................ 5-55
ASSEMBLING THE SECONDARY SHEAVE..........................................5-56
INSTALLING THE PRIMARY AND SECONDARY SHEAVES................ 5-57
CLUTCH ........................................................................................................5-60
REMOVING THE CLUTCH ..................................................................... 5-62
CHECKING THE CLUTCH...................................................................... 5-62
CHECKING THE CLUTCH SHOE........................................................... 5-62
ASSEMBLING THE CLUTCH HOUSING................................................ 5-63
INSTALLING THE CLUTCH.................................................................... 5-63
CRANKCASE ................................................................................................5-65
SEPARATING THE CRANKCASE.......................................................... 5-68
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE............. 5-68
CHECKING THE RELIEF VALVE ........................................................... 5-68
CHECKING THE BEARINGS.................................................................. 5-68
CHECKING THE CRANKCASE ..............................................................5-69
ASSEMBLING THE CRANKCASE.......................................................... 5-69
CRANKSHAFT AND OIL PUMP ................................................................... 5-71
REMOVING THE CRANKSHAFT ........................................................... 5-73
CHECKING THE OIL PUMP ................................................................... 5-73
CHECKING THE OIL STRAINER ........................................................... 5-74
CHECKING THE CRANKSHAFT ............................................................ 5-74
ASSEMBLING THE OIL PUMP...............................................................5-74
INSTALLING THE CRANKSHAFT .......................................................... 5-75
TRANSMISSION............................................................................................ 5-76
REMOVING THE TRANSMISSION ........................................................ 5-80
DISASSEMBLING THE DRIVE AXLE.....................................................5-80
CHECKING THE SHIFT FORKS............................................................. 5-80
CHECKING THE SHIFT DRUM ..............................................................5-80
CHECKING THE TRANSMISSION ......................................................... 5-81
CHECKING THE SECONDARY SHAFT................................................. 5-81
ASSEMBLING THE DRIVE AXLE ASSEMBLY ...................................... 5-81
ASSEMBLING THE SHIFT FORK ASSEMBLY ...................................... 5-81
INSTALLING THE SHIFT FORKS AND SHIFT DRUM........................... 5-82
MIDDLE GEAR ..............................................................................................5-83
REMOVING THE MIDDLE DRIVE SHAFT ............................................. 5-87
REMOVING THE MIDDLE DRIVEN SHAFT...........................................5-87
CHECKING THE PINION GEARS .......................................................... 5-88
INSTALLING THE BEARING AND OIL SEALS ...................................... 5-89
INSTALLING THE MIDDLE DRIVEN SHAFT .........................................5-89
INSTALLING THE MIDDLE DRIVE SHAFT ............................................5-90
MEASURING THE MIDDLE GEAR BACKLASH..................................... 5-91
ALIGNING THE MIDDLE GEAR ............................................................. 5-92
ENGINE REMOVAL
EAS23711
ENGINE REMOVAL
Removing the muffler and exhaust pipe
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
T.R
.
T.R
.
17 Nm (1.7 m•kgf, 12 ft•Ibf)
1
T.R
2
.
6
20 Nm (2.0 m•kgf, 14 ft•Ibf)
New 8
5
3
LT
7
T.R
.
17 Nm (1.7 m•kgf, 12 ft•Ibf)
T.R
.
23 Nm (2.3 m•kgf, 17 ft•Ibf)
Order
4
Job/Parts to remove
Q’ty
1
Exhaust pipe heat protector plate
1
2
Muffler heat protector plate
1
3
Spring
2
4
Muffler
1
5
Gasket
1
6
Muffler mount
1
7
Exhaust pipe
1
8
Gasket
1
Remarks
Lift the cargo bed.
For installation, reverse the removal procedure.
5-1
ENGINE REMOVAL
EAS1XD1025
INSTALLING THE EXHAUST PIPE AND
MUFFLER
1. Install:
1
• Gasket “1” New
(muffler side)
ECA1XD1012
NOTICE
Be careful not to damage the muffler contact
surface of the gasket.
1
TIP
Install the gasket completely onto the exhaust
pipe “2” by pushing the side “a” of the gasket. If
the gasket is difficult to install, tap lightly on the
gasket with a soft-face hammer.
New 1
2
a
2. Install:
• Muffler mount “1”
Installed length “a”
34 mm (1.34 in)
1
a
3. Install:
• Springs “1”
TIP
Install the springs so that the spring ends are
pointing inward as shown in the illustration.
5-2
ENGINE REMOVAL
Disconnecting the couplers and leads
.
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
.
T.R
4.9 Nm (0.49 m•kgf, 3.5 ft•Ibf)
Order
Job/Parts to remove
Q’ty
Remarks
Cargo bed/Frame cross member/Seat
frames/Rear panels/Center passenger compartment panel/V-belt cooling ducts
Refer to “GENERAL CHASSIS” on page
4-1.
Drive select lever shift cable
Disconnect.
Refer to “SHIFT LEVER” on page 5-45.
Coolant
Drain.
Refer to “CHANGING THE COOLANT” on
page 3-8.
Thermostat outlet hose
Disconnect.
Refer to “THERMOSTAT” on page 6-8.
Water pump inlet hose
Disconnect.
Refer to “WATER PUMP” on page 6-11.
Oil cooler outlet hose
Disconnect.
Refer to “OIL COOLER” on page 6-1.
Air induction system hose (air cut-off valve to
reed valve cover)
Disconnect.
Refer to “AIR INDUCTION SYSTEM” on
page 7-15.
5-3
ENGINE REMOVAL
Disconnecting the couplers and leads
.
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
.
T.R
4.9 Nm (0.49 m•kgf, 3.5 ft•Ibf)
1
2
3
5
4
6
8
7
9
Order
Job/Parts to remove
Q’ty
Remarks
Air intake silencer
Refer to “THROTTLE BODY” on page 7-8.
Rear drive shaft
Refer to “REAR CONSTANT VELOCITY
SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT” on
page 8-17.
1
Spark plug cap
1
Disconnect.
2
Coolant temperature sensor coupler
1
Disconnect.
3
Reverse switch coupler
1
Disconnect.
4
Gear position switch coupler
1
Disconnect.
5
Engine ground lead
1
Disconnect.
6
Starter motor lead
1
Disconnect.
7
Speed sensor coupler
1
Disconnect.
8
Crankshaft position sensor coupler
1
Disconnect.
9
AC magneto coupler
2
Disconnect.
For installation, reverse the removal procedure.
5-4
ENGINE REMOVAL
Removing the engine
4
1
2
LT
7
6
LT
5
3
2
1
7
LT
LT
.
.
.
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
T.R
Order
T.R
T.R
42 Nm (4.2 m•kgf, 30 ft•Ibf)
Job/Parts to remove
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
42 Nm (4.2 m•kgf, 30 ft•Ibf)
Q’ty
1
Engine mounting bolt (front)
2
2
Engine mounting bolt (front)
2
3
Engine bracket nut (rear)
2
Remarks
ECA1XD1034
NOTICE
4
Engine
1
Make sure that the engine does not strike
the brake pipe when removing it.
TIP
Remove the engine from the top of the vehicle.
5
Engine bracket nut (front)
2
6
Engine bracket (front)
2
7
Engine mounting bolt (rear)
2
5-5
ENGINE REMOVAL
Removing the engine
8
LT
9
LT
8
LT
LT
.
.
.
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
T.R
Order
T.R
T.R
42 Nm (4.2 m•kgf, 30 ft•Ibf)
Job/Parts to remove
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
42 Nm (4.2 m•kgf, 30 ft•Ibf)
Q’ty
8
Engine mounting bolt (rear)
2
9
Engine bracket (rear)
2
Remarks
For installation, reverse the removal procedure.
5-6
ENGINE REMOVAL
EAS23720
INSTALLING THE ENGINE
1. Install:
• Engine brackets (rear) “1”
(onto the engine)
• Engine mounting bolts (rear) (M10) “2”
• Engine mounting bolts (rear) (M6) “3”
6
TIP
Before installing the engine, tighten the engine
mounting bolts (rear) to specification.
2
9
T.
R.
Engine mounting bolt (rear) (M10)
42 Nm (4.2 m·kgf, 30 ft·lbf)
Engine mounting bolt (rear) (M6)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
8
3
5
7 9 8
2. Install:
• Engine brackets (front) “4”
(onto the frame)
• Engine bracket nuts (front) “5”
• Engine “6”
• Engine bracket nuts (rear) “7”
• Engine mounting bolts (front) (M10) “8”
• Engine mounting bolts (front) (M6) “9”
ECA1XD1011
NOTICE
Make sure that the engine does not strike the
brake pipe when installing it.
TIP
Do not fully tighten the bolts and nuts.
3. Tighten:
• Engine bracket nuts (front) “5”
• Engine bracket nuts (rear) “7”
• Engine mounting bolts (front) (M10) “8”
• Engine mounting bolts (front) (M6) “9”
T.
R.
Engine bracket nuts (front)
42 Nm (4.2 m·kgf, 30 ft·lbf)
Engine bracket nuts (rear)
42 Nm (4.2 m·kgf, 30 ft·lbf)
Engine mounting bolt (front)
(M10)
42 Nm (4.2 m·kgf, 30 ft·lbf)
Engine mounting bolt (front) (M6)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
5-7
4 2
3
1
CYLINDER HEAD
EAS24100
CYLINDER HEAD
Removing the cylinder head
.
T.R
13 Nm (1.3 m•kgf, 9.4 ft•Ibf)
.
T.R
.
T.R
35 Nm (3.5 m•kgf, 25 ft•Ibf)
20 Nm (2.0 m•kgf, 14 ft•Ibf)
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
M
.
T.R
1
20 Nm (2.0 m•kgf, 14 ft•Ibf)
(4)
2
3
LS
New
LS
New
New
(4)
New
LS
E
.
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
.
T.R
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
LS
New
E
Job/Parts to remove
.
T.R
.
T.R
Order
38 Nm (3.8 m•kgf, 27 ft•Ibf)
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
Q’ty
Remarks
Right rear panel/Frame cross member
Refer to “GENERAL CHASSIS” on page
4-1.
Exhaust pipe
Refer to “ENGINE REMOVAL” on page 5-1.
Engine oil
Disconnect.
Refer to “CHANGING THE ENGINE OIL” on
page 3-13.
Oil pipe (crankcase to cylinder head)
Refer to “OIL COOLER” on page 6-1.
Coolant
Drain.
Refer to “CHANGING THE COOLANT” on
page 3-8.
Thermostat/Coolant temperature sensor
Refer to “THERMOSTAT” on page 6-8.
Throttle body assembly
Refer to “THROTTLE BODY” on page 7-8.
Reed valve assembly
Refer to “AIR INDUCTION SYSTEM” on
page 7-15.
1
Spark plug cap
1
2
Spark plug
1
3
Cylinder head breather hose
1
5-8
Disconnect.
Disconnect.
CYLINDER HEAD
Removing the cylinder head
T.R
.
13 Nm (1.3 m•kgf, 9.4 ft•Ibf)
T.R
.
.
T.R
35 Nm (3.5 m•kgf, 25 ft•Ibf)
20 Nm (2.0 m•kgf, 14 ft•Ibf)
.
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
M
.
T.R
20 Nm (2.0 m•kgf, 14 ft•Ibf)
(4)
5
LS
New
6
11
10
LS
7
New
New
48
5
9
14
(4)
12
New
LS
E
.
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
.
T.R
13 New
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
LS
New
E
Job/Parts to remove
.
T.R
.
T.R
Order
38 Nm (3.8 m•kgf, 27 ft•Ibf)
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
Q’ty
4
Camshaft sprocket cover
5
Tappet cover
2
6
Oil check bolt
1
7
Timing chain tensioner cap bolt
1
8
Timing chain tensioner
1
Remarks
1
9
Timing chain tensioner gasket
1
10
Camshaft sprocket
1
11
Decompressor assembly
1
12
Cylinder head
1
13
Cylinder head gasket
1
14
Dowel pin
2
For installation, reverse the removal procedure.
5-9
CYLINDER HEAD
4. Remove:
• Timing chain tensioner
(along with the gasket)
• Camshaft sprocket
• Timing chain
EAS24130
REMOVING THE CYLINDER HEAD
1. Align:
• “I” mark “a” on the AC magneto rotor
(with the stationary pointer “b” on the AC
magneto cover)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
TIP
a. Turn the crankshaft counterclockwise.
To prevent the timing chain from falling into the
crankcase, fasten it with a wire.
5. Remove:
• Cylinder head
a
TIP
• Loosen the bolts in the proper sequence as
shown.
• Loosen each bolt 1/2 of a turn at a time. After
all of the bolts are fully loosened, remove them.
b
b. When the piston is at TDC on the compression stroke, align the “I” mark “c” on the camshaft sprocket with the stationary pointer “d”
on the cylinder head.
1
2
3
4
d
c
×2
×2
×2
×2
4
2
6
7
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
2. Loosen:
• Camshaft sprocket bolts “1”
• Decompressor assembly bolts “2”
8
5
3
TIP
While holding the AC magneto rotor nut with a
wrench, loosen the camshaft sprocket bolts and
decompressor assembly bolts.
Cylinder head bolts “1”
Length: 135 mm (5.31 in)
Cylinder head bolts “2”
Length: 145 mm (5.71 in)
Cylinder head bolts “3”
Length: 39 mm (1.54 in)
Cylinder head bolts “4”
Length: 30 mm (1.18 in)
1
EAS24160
CHECKING THE CYLINDER HEAD
1. Eliminate:
• Combustion chamber carbon deposits
(with a rounded scraper)
2
3. Loosen:
• Timing chain tensioner cap bolt
5-10
CYLINDER HEAD
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.
ECA1XD1035
NOTICE
Do not use a sharp instrument; otherwise,
the following may be damaged or scratched:
• Spark plug bore threads
• Valve seats
TIP
To ensure an even surface, rotate the cylinder
head several times.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1XD1092
CHECKING THE CAMSHAFT SPROCKET
1. Check:
• Camshaft sprocket
More than 1/4 tooth wear “a” → Replace the
camshaft sprocket and the timing chain as a
set.
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.
Warpage limit
0.03 mm (0.0012 in)
a.
b.
1.
2.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge “1” and a thickness
gauge “2” across the cylinder head.
1/4 tooth
Correct
Timing chain roller
Camshaft sprocket
EAS23940
CHECKING THE TAPPET COVERS AND
CAMSHAFT SPROCKET COVER
The following procedure applies to both of the
tappet covers.
1. Check:
• Tappet cover
• Camshaft sprocket cover
Damage/wear → Replace.
EAS24190
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
Damage/wear → Replace.
1
2
b. Measure the warpage.
5-11
CYLINDER HEAD
• Spring
• One-way cam
• Timing chain tensioner rod
Damage/wear → Replace the timing chain
tensioner.
1
2
×2
4
3
×2
2
4
×2
3
×2
1
5
7
1
8
4
EAS24230
INSTALLING THE CYLINDER HEAD
1. Install:
• Dowel pins
4
• Cylinder head gasket New
2. Install:
• Cylinder head
• Cylinder head bolts
3
2
6
2
3
1
3. Install:
• Decompressor assembly
• Camshaft sprocket
(onto the camshaft)
T.
R.
Cylinder head bolt “1”
35 Nm (3.5 m·kgf, 25 ft·lbf)
Cylinder head bolt “2”
35 Nm (3.5 m·kgf, 25 ft·lbf)
Cylinder head bolt “3”
38 Nm (3.8 m·kgf, 27 ft·lbf)
Cylinder head bolt “4”
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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. Align the “I” mark “c” on the camshaft sprocket with the stationary pointer “d” on the cylinder head.
e. Install the timing chain “2” onto the camshaft
sprocket “3”, and install the camshaft sprocket onto the camshaft, and then finger tighten
the camshaft sprocket bolts “4”.
Cylinder head bolts “1”
Length: 135 mm (5.31 in)
Cylinder head bolts “2”
Length: 145 mm (5.71 in)
Cylinder head bolts “3”
Length: 39 mm (1.54 in)
Cylinder head bolts “4”
Length: 30 mm (1.18 in)
TIP
• Lubricate the threads and mating surface of
the cylinder head bolts “1” and “2” with molybdenum disulfide grease.
• Lubricate the threads and mating surface of
the cylinder head bolts “3” with engine oil.
• Tighten the cylinder head bolts in the proper
tightening sequence as shown ( 1, 2, and
so on) and torque them in two stages.
a
b
5-12
CYLINDER HEAD
d. Install the spring “5”, a new copper washer
“6”, and the timing chain tensioner cap bolt
“7”.
d
2
4
c
1
T.
R.
4
Timing chain tensioner cap bolt
20 Nm (2.0 m·kgf, 14 ft·lbf)
6 New
3
7
5
3
TIP
4 New
When installing the camshaft sprocket, be sure
to keep the timing chain as tight as possible on
the exhaust side.
ECA1XD1036
NOTICE
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Turn:
• Crankshaft
(several turns counterclockwise)
6. Check:
• “I” mark “a”
Align the “I” mark on the AC magneto rotor
with the stationary pointer “b” on the AC magneto cover.
• “I” mark “c”
Align the “I” mark on the camshaft sprocket
with the stationary pointer “d” on the cylinder
head.
Out of alignment → Correct.
Refer to the installation steps above.
f. Remove the wire from the timing chain.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• Timing chain tensioner
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the timing chain tensioner cap bolt,
copper washer, and spring.
b. Release the timing chain tensioner one-way
cam “1” and push the timing chain tensioner
rod “2” all the way into the timing chain tensioner housing.
1
a
b
2
c. Install the timing chain tensioner housing “3”
and a new gasket “4” onto the cylinder.
d
T.
R.
Timing chain tensioner bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
c
TIP
Install the gasket with its beaded side facing the
timing chain tensioner.
5-13
CYLINDER HEAD
7. Tighten:
• Camshaft sprocket bolts “1”
• Decompressor assembly bolts “2”
EAS20710
MEASURING THE COMPRESSION
PRESSURE
TIP
T.
R.
Camshaft sprocket bolt
20 Nm (2.0 m·kgf, 14 ft·lbf)
Decompressor assembly bolt
20 Nm (2.0 m·kgf, 14 ft·lbf)
Insufficient compression pressure will result in a
loss of performance.
1. Measure:
• Valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE CLEARANCE” on page 3-3.
2. Start the engine, warm it up for several minutes, and then turn it off.
3. Lift the cargo bed.
4. Disconnect:
• Spark plug cap
5. Remove:
• Spark plug
ECA1XD1026
NOTICE
Be sure to tighten the camshaft sprocket
bolts to specification to avoid the possibility
of the bolts coming loose and damaging the
engine.
TIP
• 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.
ECA1XD1037
NOTICE
Before removing the spark plug, use compressed air to blow away any dirt accumulated in the spark plug well to prevent it from
falling into the cylinder.
1
6. Attach:
• Compression gauge “1”
Compression gauge
90890-03081
Engine compression tester
YU-33223
2
1
7. Measure:
• Compression pressure
Out of specification → Refer to steps (b) and
(c).
8. Measure:
• Valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE CLEARANCE” on page 3-3.
Standard compression pressure
(at sea level)
500 kPa (5.0 kgf/cm², 71.1 psi)
Minimum–maximum
440–560 kPa (4.4–5.6 kgf/cm²,
62.6–79.6 psi)
5-14
CYLINDER HEAD
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. With the throttle wide open, crank the engine
until the reading on the compression gauge
stabilizes.
EWA1XD1017
WARNING
To prevent sparking, ground the spark plug
lead before cranking the engine.
b. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces and piston crown for
carbon deposits.
Carbon deposits → Eliminate.
c. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore 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 ring(s) possibly defective → Repair.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Install:
• Spark plug
T.
R.
Spark plug
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
TIP
Before installing the spark plug, clean the spark
plug and gasket surface.
9. Connect:
• Spark plug cap
10.Lower the cargo bed.
5-15
ROCKER ARMS AND CAMSHAFT
EAS1XD1093
ROCKER ARMS AND CAMSHAFT
Removing the rocker arms and camshaft
.
T.R
5
6
.
T.R
14 Nm (1.4 m•kgf, 10 ft•Ibf)
14 Nm (1.4 m•kgf, 10 ft•Ibf)
5
3
6
5
M
5
2
6
6
E
4
E
M
10
.
T.R
9
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
7
M
E
1
E
2
8
E
E
Order
Job/Parts to remove
Q’ty
Cylinder head
LT
Remarks
Refer to “CYLINDER HEAD” on page 5-8.
1
Bearing retainer
1
2
Rocker arm shaft
2
3
Intake rocker arm
1
4
Exhaust rocker arm
1
5
Locknut
4
6
Valve adjusting screw
4
ECA1XD1038
NOTICE
7
Camshaft
1
8
Decompressor lever
1
9
Decompressor lever pin
1
10
Bearing
1
Do not disassemble the camshaft assembly.
For installation, reverse the removal procedure.
5-16
ROCKER ARMS AND CAMSHAFT
EAS23770
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
Camshaft lobe dimensions
Intake A
42.985–43.085 mm (1.6923–
1.6963 in)
Limit
42.885 mm (1.6884 in)
Intake B
36.950–37.050 mm (1.4547–
1.4587 in)
Limit
36.850 mm (1.4572 in)
Exhaust A
43.490–43.590 mm (1.7122–
1.7161 in)
Limit
43.390 mm (1.7083 in)
Exhaust B
36.950–37.050 mm (1.4547–
1.4587 in)
Limit
36.850 mm (1.4572 in)
TIP
Remove the rocker arm shafts with the slide
hammer bolt “1” and weight “2”.
Slide hammer bolt
90890-01083
Slide hammer bolt 6 mm
YU-01083-1
Weight
90890-01084
YU-01083-3
2
1
EAS23840
CHECKING THE CAMSHAFT
1. Check:
• Camshaft lobes
Blue discoloration/pitting/scratches → Replace the camshaft.
2. Measure:
• Camshaft lobe dimensions “a” and “b”
Out of specification → Replace the camshaft.
3. Measure:
• Camshaft runout
Out of specification → Replace the camshaft.
Camshaft runout limit
0.015 mm (0.0006 in)
5-17
ROCKER ARMS AND CAMSHAFT
Rocker arm inside diameter
12.000–12.018 mm (0.4724–
0.4731 in)
EAS1XD1094
CHECKING THE DECOMPRESSION SYSTEM
1. Check:
• Decompression system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
4. Measure:
• Rocker arm shaft outside diameter
Out of specification → Replace.
a. Check the decompression system with the
camshaft sprocket installed on the decompressor lever and the decompressor lever pin
“1” 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.
Rocker arm shaft outside diameter
11.981–11.991 mm (0.4717–
0.4721 in)
1
2
5. Calculate:
• Rocker-arm-to-rocker-arm-shaft clearance
Out of specification → Replace the defective
part(s).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS23880
CHECKING THE ROCKER ARMS AND
ROCKER ARM SHAFTS
The following procedure applies to all 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-to-rocker-arm-shaft
clearance
0.009–0.037 mm (0.0004–0.0015
in)
TIP
Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker
arm inside diameter.
EAS24040
INSTALLING THE CAMSHAFT AND ROCKER
ARMS
1. Install:
• Bearing “1”
(into the cylinder head “2”)
5-18
ROCKER ARMS AND CAMSHAFT
TIP
TIP
• Apply engine oil to the bearing.
• Install the bearing so that the seal “a” is facing
the camshaft.
Install the camshaft so that the pins “a” become
horizontal.
1
Installed depth
0 mm (0 in)
2
a
1
5. Lubricate:
• Rocker arms
• Rocker arm shafts
a
b
Recommended lubricant
Rocker arm inner surface
Molybdenum disulfide grease
Rocker arm shaft
Engine oil
b. Installed depth
2. Lubricate:
• Camshaft
• Decompressor lever pin
• Decompressor lever
Recommended lubricant
Camshaft
Molybdenum disulfide oil
Camshaft bearing, decompressor
lever pin, decompressor lever
Engine oil
6. Install:
• Exhaust rocker arm “1”
• Exhaust rocker arm shaft “2”
• Intake rocker arm
• Intake rocker arm shaft
TIP
• Use a slide hammer bolt “3” to install the rocker
arm shaft.
• Make sure the rocker arm shafts are completely pushed into the cylinder head.
3. Install:
• Decompressor lever pin “1”
• Decompressor lever “2”
TIP
Slide hammer bolt
90890-01083
Slide hammer bolt 6 mm
YU-01083-1
Install the decompressor lever pin and decompressor lever into the camshaft “3” as shown in
the illustration.
3
1
2
3
2
1
4. Install:
• Camshaft “1”
5-19
VALVES AND VALVE SPRINGS
EAS24270
VALVES AND VALVE SPRINGS
Removing the valves and valve springs
1
3
3
2
3
M
6
M
New
7
6
New
M
1
2
2
2
6
3
New
7
6
New
M
7
7
8
8
5
4
4
5
M
Order
Job/Parts to remove
Q’ty
Remarks
Cylinder head
Refer to “CYLINDER HEAD” on page 5-8.
Camshaft
Refer to “ROCKER ARMS AND CAMSHAFT” on page 5-16.
1
Valve cotter
8
2
Valve spring retainer
4
3
Valve spring
4
4
Exhaust valve
2
5
Intake valve
2
6
Valve stem seal
4
7
Valve spring seat
4
8
Valve guide
4
For installation, reverse the removal procedure.
5-20
VALVES AND VALVE SPRINGS
EAS24280
REMOVING THE VALVES
The following procedure applies to all of the
valves and related components.
TIP
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal.
1. Check:
• Valve sealing
Leakage at the valve seat → Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”
on page 5-23.
3. Remove:
• Valve spring retainer “1”
• Valve spring “2”
• Valve “3”
• Valve stem seal “4”
• Valve spring seat “5”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pour a clean solvent “a” into the intake and
exhaust ports.
b. Check that the valves properly seal.
TIP
Identify the position of each part very carefully so
that it can be reinstalled in its original place.
TIP
There should be no leakage at the valve seat “1”.
EAS24290
CHECKING THE VALVES AND VALVE
GUIDES
The following procedure applies to all of the
valves and valve guides.
1. Measure:
• Valve-stem-to-valve-guide clearance
Out of specification → Replace the valve
guide.
• Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” Valve stem diameter “b”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Remove:
• Valve cotters
TIP
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
“1” and the valve spring compressor attachment
“2”.
Valve spring compressor
90890-04019
YM-04019
Valve spring compressor attachment
90890-01243
Valve spring compressor adapter (26 mm)
YM-01253-1
5-21
VALVES AND VALVE SPRINGS
b. Install a new valve guide with the valve guide
installer “2” and valve guide remover “1”.
Valve-stem-to-valve-guide clearance (intake)
0.010–0.037 mm (0.0004–0.0015
in)
Limit
0.080 mm(0.0031 in)
Valve-stem-to-valve-guide clearance (exhaust)
0.025–0.052 mm (0.0010–0.0020
in)
Limit
0.100 mm(0.0039 in)
Valve guide position
12.7–13.1 mm (0.50–0.52 in)
a. Valve guide position
c. After installing the valve guide, bore the valve
guide with the valve guide reamer “3” to obtain the proper valve-stem-to-valve-guide
clearance.
b
TIP
After replacing the valve guide, reface the valve
seat.
2. Replace:
• Valve guide
TIP
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
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100 °C (212 °F) in an oven.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide with the valve guide
remover “1”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
5-22
VALVES AND VALVE SPRINGS
4. Check:
• Valve face
Pitting/wear → Grind the valve face.
• Valve stem end
Mushroom shape or diameter larger than the
body of the valve stem → Replace the valve.
5. Measure:
• Valve margin thickness “a”
Out of specification → Replace the valve.
EAS24300
CHECKING THE VALVE SEATS
The following procedure applies to all of the
valves and valve seats.
1. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
2. Check:
• Valve seat
Pitting/wear → Replace the cylinder head.
3. Measure:
• Valve seat width C “a”
Out of specification → Replace the cylinder
head.
Valve margin thickness D (intake)
0.80–1.20 mm (0.0315–0.0472 in)
Limit
0.4 mm (0.016 in)
Valve margin thickness D (exhaust)
0.80–1.20 mm (0.0315–0.0472 in)
Limit
0.4 mm (0.016 in)
Valve seat width C (intake)
1.00–1.20 mm (0.0394–0.0472 in)
Limit
1.60 mm (0.0630 in)
Valve seat width C (exhaust)
1.00–1.20 mm (0.0394–0.0472 in)
Limit
1.60 mm (0.0630 in)
6. Measure:
• Valve stem runout
Out of specification → Replace the valve.
TIP
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always replace the valve stem seal.
a. Apply blue layout fluid “b” onto the valve face.
Valve stem runout
0.040 mm (0.0016 in)
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 impression.
d. Measure the valve seat width.
5-23
VALVES AND VALVE SPRINGS
TIP
Where the valve seat and valve face contacted
one another, the blue layout fluid will have been
removed.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Lap:
• Valve face
• Valve seat
TIP
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from the
valve face and valve seat.
g. Apply blue layout fluid “b” onto the valve face.
After replacing the cylinder head or replacing the
valve and valve guide, the valve seat and valve
face should be lapped.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound “a” to the
valve face.
ECA13790
NOTICE
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impression.
j. Measure the valve seat width “c” again. If the
valve seat width is out of specification, reface
and lap the valve seat.
b. Apply molybdenum disulfide oil onto 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 lapping compound.
EAS24310
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the
valve springs.
1. Measure:
• Valve spring free length “a”
Out of specification → Replace the valve
spring.
TIP
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth between your hands.
5-24
VALVES AND VALVE SPRINGS
Free length (intake)
40.38 mm (1.59 in)
Limit
38.36 mm (1.51 in)
Free length (exhaust)
40.38 mm (1.59 in)
Limit
38.36 mm (1.51 in)
Spring tilt (intake)
2.5°/1.8 mm (2.5°/0.07 in)
Spring tilt (exhaust)
2.5°/1.8 mm (2.5°/0.07 in)
a
EAS24340
INSTALLING THE VALVES
The following procedure applies to all of the
valves and related components.
1. Deburr:
• Valve stem end
(with an oil stone)
2. Measure:
• Compressed valve spring force “a”
Out of specification → Replace the valve
spring.
Installed compression spring
force (intake)
171.00–197.00 N (17.44–20.09
kgf, 38.44–44.29 lbf)
Installed compression spring
force (exhaust)
171.00–197.00 N (17.44–20.09
kgf, 38.44–44.29 lbf)
Installed length (intake)
35.00 mm (1.38 in)
Installed length (exhaust)
35.00 mm (1.38 in)
2. Lubricate:
• Valve stem “1”
• Valve stem seal “2” New
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
b. Installed length
3. Measure:
• Valve spring tilt “a”
Out of specification → Replace the valve
spring.
3. Install:
• Valve spring seat “1”
• Valve stem seal “2” New
5-25
VALVES AND VALVE SPRINGS
• Valve “3”
• Valve spring “4”
• Valve spring retainer “5”
(into the cylinder head)
TIP
• Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch “a”
facing up.
5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a soft-face
hammer.
ECA13800
NOTICE
Hitting the valve tip with excessive force
could damage the valve.
b. Smaller pitch
4. Install:
• Valve cotters
TIP
Install the valve cotters by compressing the
valve spring with the valve spring compressor
“1” and the valve spring compressor attachment
“2”.
Valve spring compressor
90890-04019
YM-04019
Valve spring compressor attachment
90890-01243
Valve spring compressor adapter (26 mm)
YM-01253-1
5-26
CYLINDER AND PISTON
EAS24350
CYLINDER AND PISTON
Removing the cylinder and piston
T.R
.
E
E
1st 15 Nm (1.5 m•kgf, 11 ft•lbf)
2nd 50 Nm (5.0 m•kgf, 36 ft•lbf)
1
.
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
2
E
E
7
8
3 New
9
10
4
New 5
4
6
New 5
E
Order
Job/Parts to remove
Q’ty
Cylinder head
Remarks
Refer to “CYLINDER HEAD” on page 5-8.
Water jacket joint
Refer to “WATER PUMP” on page 6-11.
1
Timing chain guide (exhaust side)
1
2
Cylinder
1
3
Cylinder gasket
1
4
Dowel pin
2
5
Piston pin clip
2
6
Piston pin
1
7
Piston
1
8
Top ring
1
9
2nd ring
1
10
Oil ring
1
For installation, reverse the removal procedure.
5-27
CYLINDER AND PISTON
EAS24380
REMOVING THE PISTON
1. Remove:
• Piston pin clips “1”
• Piston pin “2”
• Piston “3”
TIP
When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring
over the piston crown.
ECA13810
NOTICE
Do not use a hammer to drive the piston pin
out.
TIP
• Before removing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
the piston pin 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”.
EAS24400
CHECKING THE CYLINDER AND PISTON
1. Check:
• Piston wall
• Cylinder wall
Vertical scratches → Replace the cylinder,
and replace the piston and piston rings as a
set.
2. Measure:
• Piston-to-cylinder clearance
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the cylinder bore with the cylinder
bore gauge.
2
1
3
TIP
Measure the cylinder bore by taking side-to-side
and front-to-back measurements of the cylinder.
Then, find the average of the measurements.
Cylinder bore
102.000–102.010 mm (4.0157–
4.0161 in)
Wear limit
102.080 mm (4.0189 in)
Taper limit
0.05 mm (0.002 in)
Out of round limit
0.05 mm (0.002 in)
2. Remove:
• Top ring
• 2nd ring
• Oil ring
5-28
CYLINDER AND PISTON
Cylinder bore = maximum of D1–D6
TIP
Taper limit = maximum of D1 or D2 - maximum of D5 or D6
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
ring grooves and piston rings.
Out of round limit = maximum of D1, D3 or D5
- minimum of D2, D4 or D6
Top ring
Ring side clearance
0.030–0.070 mm (0.0012–0.0028
in)
Limit
0.12 mm (0.0047 in)
2nd ring
Ring side clearance
0.030–0.070 mm (0.0012–0.0028
in)
Limit
0.13 mm (0.0051 in)
b. If out of specification, replace the cylinder,
and replace the piston and piston rings as a
set.
c. Measure piston skirt diameter “a” with a micrometer.
Piston skirt diameter D
101.955–101.970 mm (4.0140–
4.0146 in)
b. 10.0 mm (0.39 in) from the bottom edge of the
piston
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 Piston skirt diameter
2. Install:
• Piston ring
(into the cylinder)
TIP
Level the piston ring into the cylinder with the
piston crown.
Piston-to-cylinder clearance
0.030–0.055 mm (0.0012–0.0022
in)
f. If out of specification, replace the cylinder,
and replace the piston and piston rings as a
set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. 50 mm (1.97 in)
EAS24430
3. Measure:
• Piston ring end gap
Out of specification → Replace the piston
ring.
CHECKING THE PISTON RINGS
1. Measure:
• Piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
5-29
CYLINDER AND PISTON
TIP
The oil ring expander end gap cannot be measured. If the oil ring rail gap is excessive, replace
all three piston rings.
Top ring
End gap (installed)
0.20–0.35 mm (0.008–0.014 in)
Limit
0.60 mm (0.024 in)
2nd ring
End gap (installed)
0.75–0.90 mm (0.03–0.04 in)
Limit
1.25 mm (0.049 in)
Oil ring
End gap (installed)
0.20–0.70 mm (0.01–0.03 in)
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-pin-bore
clearance
0.004–0.024 mm (0.0002–0.0009
in)
Limit
0.074 mm (0.0029 in)
EAS24440
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)
EAS24450
INSTALLING THE PISTON AND CYLINDER
1. Install:
• Lower oil ring rail “1”
• Oil ring expander “2”
• Upper oil ring rail “3”
• 2nd ring “4”
• Top ring “5”
TIP
Be sure to install the piston rings so that the
manufacturer marks or numbers face up.
3. Measure:
• Piston pin bore 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)
2. Install:
• Piston “1”
• Piston pin “2”
• Piston pin clips “3” New
TIP
• Apply engine oil to the piston pin.
5-30
CYLINDER AND PISTON
• Pass the timing chain and timing chain guide
(exhaust side) through the timing chain cavity.
• 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.
1
1
a
2
7. Install:
• Cylinder bolts “1”
• Cylinder bolts (timing chain side) “2”
3 New
3. Install:
TIP
• Cylinder gasket New
• Dowel pins
4. Lubricate:
• Piston
• Piston rings
• Cylinder
(with the recommended lubricant)
• Lubricate the threads and mating surface of
the cylinder bolts “1” with engine oil.
• Finger tighten the bolts.
8. Tighten:
• Cylinder bolts “1”
• Cylinder bolts (timing chain side) “2”
T.
Recommended lubricant
Engine oil
R.
5. Offset:
• Piston ring end gaps
a
Cylinder bolt
1st
15 Nm (1.5 m·kgf, 11 ft·lbf)
2nd
50 Nm (5.0 m·kgf, 36 ft·lbf)
Cylinder bolt (timing chain side)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
135˚
45˚
e
2
b
45˚
45˚
45˚ 45˚
E
c
d
1
1
A
a.
b.
c.
d.
e.
A.
2
Upper oil ring rail
Top ring
Oil ring expander
Lower oil ring rail
2nd ring
Exhaust side
6. Install:
• Cylinder “1”
• Timing chain guide (exhaust side)
TIP
• While compressing the piston rings with one
hand, install the cylinder with the other hand.
5-31
E
AC MAGNETO AND STARTER CLUTCH
EAS1XD1095
AC MAGNETO AND STARTER CLUTCH
Removing the AC magneto and starter clutch
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
.
T.R
.
m•kgf,
18 Nm (1.8
13 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
1
4
2
7
LT
(3)
LT
New
New
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
(11)
LT
6
New
E
5 New
3
LS
E
T.R
.
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
T.R
.
(3)
6
LT
T.R
.
E
E
.
T.R
Order
Job/Parts to remove
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
30 Nm (3.0 m•kgf, 22 ft•Ibf)
60 Nm (6.0 m•kgf, 43 ft•Ibf)
Q’ty
Remarks
Right rear panel
Refer to “GENERAL CHASSIS” on page
4-1.
Engine oil
Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-13.
Coolant
Drain.
Refer to “CHANGING THE COOLANT” on
page 3-8.
Water pump housing
Refer to “WATER PUMP” on page 6-11.
1
Stator coil coupler
2
Disconnect.
2
Crankshaft position sensor coupler
1
Disconnect.
3
AC magneto cover
1
4
Oil pipe (AC magneto cover)
1
5
AC magneto cover gasket
1
6
Dowel pin
2
7
Lead holder
1
5-32
AC MAGNETO AND STARTER CLUTCH
Removing the AC magneto and starter clutch
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
.
T.R
.
m•kgf,
18 Nm (1.8
13 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
LT
LT
(3)
New
8
New
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
LT
(11)
9
New
E
18 New
10
12
15
11
.
.
LT
T.R
16
.
E
E
.
T.R
Order
Job/Parts to remove
8
Crankshaft position sensor
Q’ty
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
T.R
14 18 New
13
(3)
T.R
17
LS
E
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
30 Nm (3.0 m•kgf, 22 ft•Ibf)
60 Nm (6.0 m•kgf, 43 ft•Ibf)
Remarks
1
9
Stator coil
1
10
Torque limiter
1
11
Starter idle gear
1
12
Starter idle gear shaft
1
13
AC magneto rotor
1
14
Starter clutch
1
15
Woodruff key
1
16
Starter wheel gear
1
17
Washer
1
18
Bushing
2
For installation, reverse the removal procedure.
5-33
AC MAGNETO AND STARTER CLUTCH
EAS24490
ECA13880
REMOVING THE AC MAGNETO ROTOR
1. Remove:
• AC magneto cover
NOTICE
To protect the end of the crankshaft, place an
appropriate sized socket between the flywheel puller set center bolt and the crankshaft.
TIP
Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
TIP
• Use the flywheel puller “2”.
• Make sure the flywheel puller is centered over
the AC magneto rotor.
Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B
1
2. Remove:
• AC magneto rotor nut “1”
• Washer
2
TIP
• Hold the AC magneto rotor “2” with the sheave
holder “3” while loosening the AC magneto rotor nut.
• Do not allow the sheave holder to touch the
projection on the rotor.
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
EAS24560
REMOVING THE STARTER CLUTCH
1. Remove:
• Starter clutch bolts “1”
TIP
• Hold the AC magneto rotor “2” with the sheave
holder “3” while removing the starter clutch
bolts.
• Do not allow the sheave holder to touch the
projection on the AC magneto rotor.
3
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
1
2
3. Remove:
• AC magneto rotor “1”
(with the starter clutch)
• Woodruff key
1
3
5-34
2
AC MAGNETO AND STARTER CLUTCH
EAS24570
CHECKING THE STARTER CLUTCH
1. Check:
• Starter clutch rollers
Damage/wear → Replace.
2. Check:
• Starter idle gear
• Starter wheel gear
Burrs/chips/roughness/wear → Replace the
defective part(s).
3. Check:
• Starter clutch gear contact surfaces
Damage/pitting/wear → Replace the defective part(s).
4. Check:
• Starter clutch operation
TIP
• Be sure to install the starter clutch (outer ring)
so that its side with the arrow mark “a” is facing
outward.
• While holding the AC magneto rotor “2” with
the sheave holder “3”, tighten the starter clutch
bolts.
• Do not allow the sheave holder to touch the
projection on the AC magneto rotor.
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter wheel gear onto the starter
clutch, and then hold the starter clutch.
b. When turning the starter wheel gear counterclockwise “A”, the starter clutch and the starter wheel gear should engage; otherwise, the
starter clutch is faulty and must be replaced.
c. When turning the starter wheel gear clockwise “B”, it should turn freely; otherwise, the
starter clutch is faulty and must be replaced.
1
3
B
2
a
A
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1XD1097
TIP
INSTALLING THE AC MAGNETO ROTOR
1. Install:
• Woodruff key
• AC magneto rotor
• Washer
• AC magneto rotor nut
Do not disassemble the torque limiter.
TIP
EAS1XD1096
CHECKING THE TORQUE LIMITER
1. Check:
• Torque limiter
Damage/wear → Replace.
• Clean the tapered portion of the crankshaft and
the AC magneto rotor hub.
• When installing the AC magneto rotor, make
sure the woodruff key is properly seated in the
keyway of the crankshaft.
• Lubricate the threads of the crankshaft with engine oil.
EAS24600
INSTALLING THE STARTER CLUTCH
1. Install:
• Starter clutch
• Starter clutch bolts “1”
T.
R.
Starter clutch bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
LOCTITE®
5-35
AC MAGNETO AND STARTER CLUTCH
T.
R.
• After installing the AC magneto rotor, check
that the AC magneto rotor rotates smoothly. If
not, reinstall the woodruff key and AC magneto
rotor.
AC magneto cover bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
TIP
2. Tighten:
• AC magneto rotor nut “1”
T.
• Align the slot “a” in the impeller shaft “1” with
the projection “b” on the oil pump shaft “2”.
• Tighten the AC magneto cover bolts in stages,
using a crisscross pattern.
R.
AC magneto rotor nut
60 Nm (6.0 m·kgf, 43 ft·lbf)
TIP
2
• Hold the AC magneto rotor “2” with the sheave
holder “3” while tightening the AC magneto rotor nut.
• Do not allow the sheave holder to touch the
projection on the AC magneto rotor.
b
a
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
3
1
2
3. Apply:
• Sealant
(onto the crankshaft position sensor/stator
assembly lead grommet)
Yamaha bond No. 1215
90890-85505
(Three Bond No.1215®)
4. Install:
• AC magneto cover
5-36
1
ELECTRIC STARTER
EAS24780
ELECTRIC STARTER
Removing the starter motor
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
.
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
4.9 Nm (0.49 m•kgf, 3.5 ft•Ibf)
1
2
3
FW
Order
Job/Parts to remove
Q’ty
D
Remarks
Frame cross member
Refer to “GENERAL CHASSIS” on page
4-1.
Air intake silencer
Refer to “THROTTLE BODY” on page 7-8.
1
Negative battery lead
1
Disconnect.
2
Starter motor lead
1
Disconnect.
3
Starter motor
1
For installation, reverse the removal procedure.
5-37
ELECTRIC STARTER
Disassembling the starter motor
T.R
.
4.9 Nm (0.49 m•kgf, 3.5 ft•Ibf)
2
3
5
6
4
3
New
New
Order
1
Job/Parts to remove
Q’ty
1
Starter motor front cover
1
2
Starter motor rear cover
1
3
Washer kit
1
4
Armature assembly
1
5
Brush set
1
6
Starter motor yoke
1
Remarks
For assembly, reverse the disassembly procedure.
5-38
ELECTRIC STARTER
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EAS24790
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.
a. Measure the armature assembly resistances
with the digital circuit tester.
Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927
Commutator diameter
28.0 mm (1.10 in)
Limit
27.0 mm (1.06 in)
Armature coil
Commutator resistance “1”
0.0250–0.0350 Ω
Insulation resistance “2”
Above 1 MΩ
b. If any resistance is out of specification, replace the starter motor.
a
3. Measure:
• Mica undercut “a”
Out of specification → Cut the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commutator.
Mica undercut (depth)
0.70 mm (0.03 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
• Brush length “a”
Out of specification → Replace the brush set.
Brush overall length
12.5 mm (0.49 in)
Limit
5.00 mm (0.20 in)
TIP
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.
6. Measure:
• Brush spring force
Out of specification → Replace the brush set.
5-39
ELECTRIC STARTER
Brush spring force
7.65–10.01 N (780–1021 gf,
27.54–36.03 oz)
TIP
Align the match marks “a” on the starter motor
yoke with the match marks “b” on the starter motor front and rear covers.
a
b
2
7. Check:
• Gear teeth
Damage/wear → Replace the armature assembly.
8. Check:
• Bushing
• Bearing
• Oil seal
Damage/wear → Replace the starter motor.
EAS24800
ASSEMBLING THE STARTER MOTOR
1. Install:
• Brush set “1”
TIP
Align the tab “a” on the brush set with the slot “b”
in the starter motor yoke.
2. Install:
• Starter motor yoke “1”
• Starter motor front cover “2”
• Starter motor rear cover “3”
T.
R.
Starter motor cover bolt
4.9 Nm (0.49 m·kgf, 3.5 ft·lbf)
5-40
b
3
1
BALANCER GEARS AND OIL PUMP GEARS
EAS1XD1098
BALANCER GEARS AND OIL PUMP GEARS
Removing the balancer gears and oil pump gears
T.R
.
85 Nm (8.5 m•kgf, 61 ft•Ibf)
E
4
2
1 New
5
3 New
E
New
T.R
.
Order
Job/Parts to remove
Q’ty
22 Nm (2.2 m•kgf, 16 ft•Ibf)
Remarks
Right rear panel
Refer to “GENERAL CHASSIS” on page
4-1.
Engine oil
Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-13.
Coolant
Drain.
Refer to “CHANGING THE COOLANT” on
page 3-8.
Water pump housing
Refer to “WATER PUMP” on page 6-11.
Starter wheel gear
Refer to “AC MAGNETO AND STARTER
CLUTCH” on page 5-32.
1
Lock washer
1
2
Balancer driven gear
1
3
Lock washer
1
4
Oil pump drive gear
1
5
Oil pump driven sprocket
1
5-41
BALANCER GEARS AND OIL PUMP GEARS
Removing the balancer gears and oil pump gears
7
.
E
T.R
8
E
6
10
11
12
9
New
T.R
.
Order
85 Nm (8.5 m•kgf, 61 ft•Ibf)
Job/Parts to remove
Q’ty
6
Chain
7
Straight key
1
8
Spacer
1
9
Plate
1
10
Balancer drive gear
1
11
Spring
8
12
Pin
4
22 Nm (2.2 m•kgf, 16 ft•Ibf)
Remarks
1
For installation, reverse the removal procedure.
5-42
BALANCER GEARS AND OIL PUMP GEARS
EAS1XD1026
REMOVING THE BALANCER DRIVEN GEAR
AND OIL PUMP DRIVEN SPROCKET
1. Straighten the lock washer tabs.
2. Loosen:
• Balancer driven gear nut “1”
• Oil pump driven sprocket nut “2”
TIP
Place a aluminum plate “3” between the teeth of
the balancer drive gear “4” and balancer driven
gear “5”, and then loosen the nuts.
2. Install:
• Spacer
• Oil pump drive gear
• Oil pump driven sprocket “1”
• Chain “2”
1
3
4
5
TIP
Install the oil pump driven sprocket with the
“3B4” mark “a” facing out.
2
2
EAS1XD1053
CHECKING THE OIL PUMP GEARS
1. Check:
• Oil pump drive gear
• Oil pump driven sprocket
Cracks/wear/damage → Replace.
1
a
EAS1XD1027
CHECKING THE BALANCER GEARS
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.
3. Install:
• Balancer driven gear “1”
TIP
Align the punch mark “a” on the balancer drive
gear “2” with the punch mark “b” on the balancer
driven gear.
b
EAS1XD1028
a
INSTALLING THE BALANCER DRIVE GEAR,
BALANCER DRIVEN GEAR, AND OIL PUMP
DRIVEN SPROCKET
1. Install:
• Balancer drive gear
(onto the buffer boss)
• Pins
• Springs
2
4. Install:
• Oil pump driven sprocket nut “1”
• Balancer driven gear nut “2”
TIP
• Align the punch mark “a” on the balancer drive
gear with the hole “b” in the buffer boss.
• Be sure to install a pin to every other spring.
• Lock washers New
5-43
1
BALANCER GEARS AND OIL PUMP GEARS
T.
Oil pump driven sprocket nut
22 Nm (2.2 m·kgf, 16 ft·lbf)
Balancer driven gear nut
85 Nm (8.5 m·kgf, 61 ft·lbf)
R.
TIP
• Apply the engine oil to the threads of shafts
and nuts.
• Place a aluminum plate “3” between the teeth
of the balancer drive gear “4” and balancer
driven gear “5”, and then tighten the nuts.
5
2
4
3
1
5. Bend the lock washer tabs along the balancer
driven gear nut and oil pump driven sprocket
nut.
5-44
SHIFT LEVER
EAS1XD1029
SHIFT LEVER
Removing the drive select lever unit and drive select lever shift cable
T.R
2
.
13 Nm (1.3 m•kgf, 9.4 ft•Ibf)
T.R
.
13 Nm (1.3 m•kgf, 9.4 ft•Ibf)
LS
T.R
.
39 Nm (3.9 m•kgf, 28 ft•Ibf)
1
FW
3
T.R
.
Order
Job/Parts to remove
Q’ty
Sun top/Side frames/Hood/Front fender/Instrument panel
1
D
16 Nm (1.6 m•kgf, 12 ft•Ibf)
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
Drive select lever shift cable
1
2
Drive select lever unit
1
3
Drive select lever shift cable bracket
1
Disconnect.
For installation, reverse the removal procedure.
5-45
SHIFT LEVER
Disassembling the drive select lever unit
T.R
.
1
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
2
3
6
4
LS
5
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
LS
7
Order
1
Job/Parts to remove
Q’ty
Drive select lever knob
1
2
Drive select lever guide
1
3
Dust cover
1
4
Drive select lever
1
5
Spring
1
6
Shift arm
1
7
Drive select lever unit housing
1
Remarks
For installation, reverse the removal procedure.
5-46
SHIFT LEVER
Removing the shift levers and stopper lever
T.R
.
E
14 Nm (1.4 m•kgf, 10 ft•Ibf)
5 New
7
New
4
LS
1
6
2
3
E
.
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
LS
10
E
8
14 Nm (1.4 m•kgf, 10 ft•Ibf)
Job/Parts to remove
.
T.R
.
T.R
Order
9
Q’ty
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
Right rear panel
1
Drive select lever shift cable
1
2
Shift arm
1
3
Drive select lever shift cable bracket
1
4
Shift lever cover
1
5
Shift lever cover gasket
1
6
Dowel pin
1
7
Shift lever 1
1
8
Stopper lever spring
1
9
Shift lever 2
1
10
Stopper lever
1
Disconnect.
For installation, reverse the removal procedure.
5-47
SHIFT LEVER
3. Install:
EAS25430
CHECKING THE STOPPER LEVER
1. Check:
• Stopper lever
Damage/wear → Replace.
• Stopper lever spring
Damage/wear → Replace.
• Oil seal “1” New
(into the shift lever cover “2”)
Installed depth “a”
1.0–1.5 mm (0.04–0.06 in)
EAS25440
CHECKING THE SHIFT LEVERS
1. Check:
• Shift lever 1
• Shift lever 2
Damage/wear → Replace.
New 1
a
2
EAS1XD1030
INSTALLING THE SHIFT LEVERS
1. Install:
• Shift lever 2 assembly “1”
T.
Shift lever 2 bolt
14 Nm (1.4 m·kgf, 10 ft·lbf)
4. Install:
• Shift arm “1”
R.
TIP
Align the slit “a” in the shift arm with the projection “b” on shift lever 1.
TIP
Align the projection “a” on the shift drum with the
slit “b” in the stopper lever.
b
1
a
1
a
b
EAS1XD1031
ADJUSTING THE DRIVE SELECT LEVER
SHIFT CABLE
2. Install:
• Shift lever 1 “1”
EWA1XD1002
WARNING
TIP
Before moving the drive select lever, bring
the vehicle to a complete stop and take your
foot off the accelerator pedal. Otherwise the
transmission may be damaged.
When installing shift lever 1, align the alignment
mark “a” on shift lever 1 with the punch marks “b”
on shift lever 2 “2”.
a
1. Check:
• Drive select lever free play “a”
Out of specification → Adjust the drive select
lever shift cable.
1
Drive select lever free play
Less than 4 mm (0.16 in)
b
2
5-48
SHIFT LEVER
b
a
a
a
1
5
4
2. Check:
• Drive select lever shift cable length “a”
Out of specification → Adjust.
3
L
2
H
Drive select lever shift cable
length
165 mm (6.50 in)
N
L
H
N
R R
TIP
When checking the drive select lever shift cable
length, shift the drive select lever into “N” (neutral).
e. Tighten the locknut to specification.
T.
R.
Drive select lever shift cable locknut
39 Nm (3.9 m·kgf, 28 ft·lbf)
f. Tighten the drive select lever shift cable
bracket bolts to specification.
a
T.
R.
Drive select lever shift cable
bracket bolt
16 Nm (1.6 m·kgf, 12 ft·lbf)
g. Turn the main switch to “ ” (on), and then
check that the drive select lever can be shifted to each shift position and that the appropriate indicator light comes on when the lever is
in each position.
3. Adjust:
• Drive select lever shift cable length
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the drive select lever shift cable
bracket bolts “1”.
b. Set the drive select lever “2” and shift lever “3”
in “N” (neutral) position.
c. Loosen the locknut “4”.
d. Turn the adjusting nut “5” in direction “a” or “b”
until the specified cable length is obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Direction “a”
Shift cable length is increased.
Direction “b”
Shift cable length is decreased.
5-49
PRIMARY AND SECONDARY SHEAVES
EAS1XD1099
PRIMARY AND SECONDARY SHEAVES
Removing the primary and secondary sheaves
New 10
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
.
9
New 11
.
T.R
100 Nm (10.0 m•kgf, 72 ft•Ibf)
6
8
T.R
(8)
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
New
LS
7
E
4
4
5
3
(11)
T.R
.
190 Nm (19 m•kgf, 137 ft•lbf)
1
Order
New 2
Job/Parts to remove
Q’ty
Frame cross member/Left rear panel/V-belt
cooling ducts
1
Drive belt cover
.
T.R
.
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
1
2
Rubber gasket
1
3
Bearing housing
1
4
Dowel pin
2
5
Primary sheave assembly
1
6
V-belt
1
7
Primary fixed sheave
1
8
Secondary sheave assembly
1
9
Drive belt case
1
10
Rubber gasket
1
11
Rubber gasket
1
For installation, reverse the removal procedure.
5-50
PRIMARY AND SECONDARY SHEAVES
Disassembling the primary sheave
Order
Job/Parts to remove
Q’ty
1
Primary sheave cap
1
2
Primary sheave slider
4
3
Primary sheave cam
1
4
Primary sheave weight
8
5
Spacer
1
6
Oil seal
2
7
Primary sliding sheave
1
8
O-ring
1
Remarks
For assembly, reverse the disassembly procedure.
* Apply Yamaha Grizzly grease or Yamaha grease F.
5-51
PRIMARY AND SECONDARY SHEAVES
Disassembling the secondary sheave
Order
Job/Parts to remove
Q’ty
1
Secondary sheave spring retaining nut
1
2
Upper spring seat
1
3
Compression spring
1
4
Lower spring seat
1
5
Guide pin
4
6
Secondary sliding sheave
1
7
O-ring
2
8
Secondary fixed sheave
1
9
Oil seal
2
Remarks
For assembly, reverse the disassembly procedure.
* Apply Yamaha grease H or POLYREX EM®
5-52
PRIMARY AND SECONDARY SHEAVES
EAS1XD1100
REMOVING THE PRIMARY AND
SECONDARY SHEAVES
1. Loosen:
• Primary sheave assembly nut “1”
Sheave fixed block
90890-04135
Sheave fixed bracket
YM-04135
Locknut wrench
90890-01348
YM-01348
Sheave spring compressor
90890-04134
YM-04134
TIP
Use the sheave holder “2” to hold the primary
sheave.
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
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 secondary sheave spring retaining nut “1” with the locknut wrench “3”.
e. Remove the secondary sheave spring retaining nut “1”.
f. Remove the sheave spring compressor and
locknut wrench.
1
2
4
2. Loosen:
• Secondary sheave assembly nut “1”
5
1
3
TIP
Shift the transmission into “R” (reverse), set the
parking brake, and then loosen the secondary
sheave assembly nut.
1
2
EAS24640
DISASSEMBLING THE SECONDARY
SHEAVE
1. Remove:
• Secondary sheave spring retaining nut “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Attach the sheave fixed block “2”, locknut
wrench “3” and sheave spring compressor “4”
to the secondary sheave assembly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-53
PRIMARY AND SECONDARY SHEAVES
1. Check:
• Primary sheave weight
Cracks/damage/wear → Replace.
2. Measure:
• Primary sheave weight outside diameter “a”
Out of specification → Replace.
EAS24670
CHECKING THE V-BELT
1. Check:
• V-belt “1”
Cracks/damage/wear → Replace.
Grease/oil → Clean the primary and secondary sheaves.
2. Measure:
• V-belt width “a”
Out of specification → Replace.
Primary sheave weight outside
diameter
30 mm (1.18 in)
Limit
29.5 mm (1.16 in)
V-belt width
33.0–33.6 mm (1.30–1.32 in)
Limit
32.5 mm (1.28 in)
EAS24700
CHECKING THE PRIMARY SHEAVE
SLIDERS
The following procedure applies to all of the primary sheave sliders.
1. Check:
• Primary sheave slider
Cracks/damage/wear → Replace.
EAS24680
CHECKING THE PRIMARY SHEAVE
1. Check:
• Primary sliding sheave splines
Wear/cracks/damage → Replace.
• Primary sheave cam
Cracks/damage → Replace.
EAS24710
CHECKING THE SECONDARY SHEAVE
1. Check:
• Secondary fixed sheave
• Secondary sliding sheave
Cracks/damage/wear → Replace the secondary fixed and sliding sheaves as a set.
2. Check:
• Torque cam grooves “1”
Damage/wear → Replace the secondary
fixed and sliding sheaves as a set.
3. Check:
• Guide pins “2”
Damage/wear → Replace the secondary
fixed and sliding sheaves as a set.
2. Check:
• Primary sliding sheave
• Primary fixed sheave
Cracks/damage → Replace.
EAS24690
CHECKING THE PRIMARY SHEAVE
WEIGHTS
The following procedure applies to all of the primary sheave weights.
5-54
PRIMARY AND SECONDARY SHEAVES
2. Install:
• Oil seals “1” New
(into the primary sliding sheaver “2”)
Installed depth “a”
0 mm (0 in)
New 1
4. Check:
• Secondary sheave spring
Damage → Replace.
5. Measure:
• Secondary sheave spring free length “a”
Out of specification → Replace the secondary sheave spring.
a
a
2
1 New
3. Lubricate:
• Spacer inner surface
• Primary sliding sheave inner surface
Free length
130.6 mm (5.14 in)
Limit
128.0 mm (5.04 in)
Recommended lubricant
Yamaha Grizzly grease or
Yamaha grease F
TIP
• Apply Yamaha Grizzly grease or Yamaha
grease F (2.5 g) to the inner surface of the
spacer.
• Apply Yamaha Grizzly grease or Yamaha
grease F (2.5 g) to the inner surface of the primary sliding sheave.
EAS24720
ASSEMBLING THE PRIMARY SHEAVE
1. Clean:
• Primary sliding sheave “1”
• Spacer “2”
• Primary sheave weights “3”
• Primary sheave cam
TIP
Remove any excess grease.
4. Install:
• Primary sheave weights “1”
TIP
Apply Yamaha Grizzly grease or Yamaha
grease F (90 g) to the whole outer surface of the
weights and install.
5-55
PRIMARY AND SECONDARY SHEAVES
3. Install:
• Secondary sliding sheave
4. Install:
• Guide pins “1”
EAS24730
ASSEMBLING THE SECONDARY SHEAVE
1. Install:
• Oil seals “1” New
(into the secondary sliding sheave “2”)
5. Lubricate:
• Guide pin grooves “1”
(with the recommended lubricant)
Installed depth “a”
0 mm (0 in)
Recommended lubricant
Yamaha grease H or POLYREX
EM®
2
1 New
TIP
a
Apply Yamaha grease H or POLYREX EM® (5.0
g) to the guide pin grooves.
a
New 1
2. Lubricate:
• Secondary sliding sheave “1”
• Secondary fixed sheave “2”
(with the recommended lubricant)
Recommended lubricant
Yamaha grease H or POLYREX
EM®
6. Install:
• Lower spring seat “1”
• Compression spring “2”
• Upper spring seat “3”
• Secondary sheave spring retaining nut “4”
TIP
Apply Yamaha grease H or POLYREX EM® (15
g) to the inner surfaces of the secondary
sheaves.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Attach the sheave fixed block “5”, locknut
wrench “6” and sheave spring compressor “7”
to the secondary sheave.
5-56
PRIMARY AND SECONDARY SHEAVES
a
Sheave fixed block
90890-04135
Sheave fixed bracket
YM-04135
Locknut wrench
90890-01348
YM-01348
Sheave spring compressor
90890-04134
YM-04134
4
e. Remove the sheave spring compressor, locknut wrench, and sheave fixed block.
b. Place the sheave fixed block in a vise and secure it.
c. Tighten the sheave spring compressor nut “8”
and compress the spring.
d. Install the secondary sheave spring retaining
nut “4” and tighten it to specification using the
locknut wrench.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1XD1101
T.
R.
INSTALLING THE PRIMARY AND
SECONDARY SHEAVES
1. Install:
• Secondary sheave
• V-belt
• Primary fixed sheave
• Primary sheave
Secondary sheave spring retaining nut
90 Nm (9.0 m·kgf, 65 ft·lbf)
TIP
TIP
• Be sure to push in the primary sheave cam “1”
when installing the primary sheave so that the
primary sheave weights “2” will be properly positioned “a”.
• Tightening the bolts “3” (90101-06016) 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 points in the
direction of rotation as shown in the illustration.
Install the secondary sheave spring retaining nut
“4” with its tapered side “a” facing the secondary
sheaves.
7
8
4
6
1
3
2
1
2
a
5
3
5-57
PRIMARY AND SECONDARY SHEAVES
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
2. Check:
• Primary sheave weights position
Out of specification → Repeat step (1).
2
1
TIP
To check that the primary sheave weights “1”
are installed correctly, make sure that the secondary sheave “2”, primary sheave “3”, and Vbelt “4” are positioned as shown in the illustration.
4. Tighten:
• Secondary sheave assembly nut “1”
T.
R.
Secondary sheave assembly nut
100 Nm (10.0 m·kgf, 72 ft·lbf)
A
TIP
Shift the transmission into “L” (low) or “H” (high),
set the parking brake, and then tighten the secondary sheave assembly nut.
2
4
3
1
B
2
1
4
5. Lubricate:
• Bearing housing oil seal inner surface
(with the recommended lubricant)
3
1
Recommended lubricant
Lithium-soap-based grease
A. Correct position
B. Incorrect position
3. Tighten:
• Primary sheave assembly nut “1”
TIP
T.
R.
Apply 2.3 g or more of lithium-soap-based
grease to the groove in the oil seal as shown in
the illustration.
Primary sheave assembly nut
190 Nm (19 m·kgf, 137 ft·lbf)
TIP
Use the sheave holder “2” to hold the primary
sheave.
5-58
PRIMARY AND SECONDARY SHEAVES
LS
5-59
CLUTCH
EAS25061
CLUTCH
Removing the clutch
T.R
.
190 Nm (19 m•kgf, 137 ft•lbf)
5
.
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
2
4
New
1
3
3
(7)
M
E
E
LS
Order
Job/Parts to remove
Q’ty
Remarks
Refer to “PRIMARY AND SECONDARY
SHEAVES” on page 5-50.
Drive belt case
1
Clutch housing assembly
1
2
Clutch housing assembly gasket
1
3
Dowel pin
2
4
Clutch carrier assembly nut
1
5
Clutch carrier assembly
1
Left-hand threads
For installation, reverse the removal procedure.
5-60
CLUTCH
Disassembling the clutch housing assembly
6 New
7
9
8
E
Order
1
Job/Parts to remove
Q’ty
Oil seal
1
2
Circlip
1
3
Bearing housing
1
4
Circlip
1
5
Bearing
1
6
Seal ring
1
7
One-way clutch bearing
1
8
Bearing
1
9
Clutch housing
1
Remarks
For assembly, reverse the disassembly procedure.
5-61
CLUTCH
• One-way clutch bearing
Chafing/wear/damage → Replace.
EAS25070
REMOVING THE CLUTCH
1. Remove:
• Clutch housing assembly
TIP
• Replace the one-way clutch bearing and clutch
housing as a set.
• The one-way clutch bearing must be installed
with the flange side facing inward.
TIP
Working in crisscross pattern, loosen each bolt
1/4 of a turn. Remove them after all of them are
loosened.
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
“A”, it should turn freely; otherwise, the oneway clutch assembly is faulty and must be replaced.
c. When turning the clutch housing counterclockwise “B”, the clutch housing and crankshaft should engage; otherwise, the one-way
clutch assembly is faulty and must be replaced.
2. Straighten:
• Punched portion “a” of the clutch carrier assembly nut “1”
3. Remove:
• Clutch carrier assembly nut “1”
ECA1XD1019
NOTICE
The clutch carrier assembly nut has lefthand threads. To loosen the clutch carrier
assembly nut, turn it clockwise.
TIP
Use a clutch holding tool “2” to hold the clutch
carrier assembly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Universal clutch holder
90890-04086
YM-91042
EAS28990
CHECKING THE CLUTCH SHOE
1. Check:
• Clutch shoe
Damage/wear → Replace.
Glazed areas → Sand with coarse sandpaper.
2
a
TIP
After sanding the glazed areas, clean the clutch
with a cloth.
2. Measure:
• Clutch shoe thickness
Out of specification → Replace.
1
EAS1XD1102
CHECKING THE CLUTCH
1. Check:
• Clutch housing
Damage/wear → Replace.
Clutch shoe thickness
1.5 mm (0.06 in)
Limit
1.0 mm (0.04 in)
5-62
CLUTCH
a
1 New
2
a. Clutch shoe wear limit
EAS1XD1104
INSTALLING THE CLUTCH
1. Install:
• Clutch carrier assembly
EAS1XD1103
ASSEMBLING THE CLUTCH HOUSING
1. Install:
• Bearing “1”
(into the clutch housing “2”)
• Clutch carrier assembly nut “1” New
T.
Installed depth “a”
2.5–2.7 mm (0.10–0.11 in)
R.
Clutch carrier assembly nut
190 Nm (19 m·kgf, 137 ft·lbf)
ECA1XD1020
NOTICE
a
The clutch carrier assembly nut has lefthand threads. To tighten the clutch carrier
assembly nut, turn it counterclockwise.
2
TIP
• Lubricate the threads of the clutch carrier assembly nut with molybdenum disulfide grease.
• Use a clutch holding tool “2” to hold the clutch
carrier assembly.
1
2. Install:
• One-way clutch bearing
Universal clutch holder
90890-04086
YM-91042
TIP
The one-way clutch bearing should be installed
in the clutch housing with the “OUT SIDE” mark
“a” facing the clutch housing.
2. Lock the threads with a drift punch.
2
1 New
3. Install:
• Dowel pins
3. Install:
• Gasket New
• Clutch housing assembly
• Oil seal “1” New
(into the bearing housing “2”)
T.
Installed depth “a”
0 mm (0 in)
R.
5-63
Clutch housing assembly bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
CLUTCH
TIP
• Tighten the bolts in stages, using a crisscross
pattern.
• After tightening the bolts, check that the clutch
housing assembly rotates smoothly.
5-64
CRANKCASE
EAS25540
CRANKCASE
Separating the crankcase
.
.
T.R
LS
18 Nm (1.8 m•kgf, 13 ft•Ibf)
T.R
.
T.R
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
17 Nm (1.7 m•kgf, 12 ft•Ibf)
E
New
New
.
T.R
.
T.R
.
T.R
LS
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
26 Nm (2.6 m•kgf, 19 ft•Ibf)
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf)
LT
(3)
LS
New
LT
New
New
T.R
.
30 Nm (3.0 m•kgf, 22 ft•Ibf)
T.R
.
42 Nm (4.2 m•kgf, 30 ft•Ibf)
1
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
New
LT
LT
2
LS
LT
LT
.
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
42 Nm (4.2 m•kgf, 30 ft•Ibf)
T.R
.
Order
Job/Parts to remove
Q’ty
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
Remarks
Engine
Refer to “ENGINE REMOVAL” on page 5-1.
Oil cooler
Refer to “OIL COOLER” on page 6-1.
Cylinder head
Refer to “CYLINDER HEAD” on page 5-8.
Piston
Refer to “CYLINDER AND PISTON” on page
5-27.
Starter wheel gear
Refer to “AC MAGNETO AND STARTER
CLUTCH” on page 5-32.
Starter motor
Refer to “ELECTRIC STARTER” on page
5-37.
Balancer gears/Oil pump gears
Refer to “BALANCER GEARS AND OIL
PUMP GEARS” on page 5-41.
Shift levers
Refer to “SHIFT LEVER” on page 5-45.
Drive belt case
Refer to “PRIMARY AND SECONDARY
SHEAVES” on page 5-50.
Clutch carrier assembly
Refer to “CLUTCH” on page 5-60.
1
Timing chain guide (intake side)
1
2
Timing chain stopper guide (lower)
1
5-65
CRANKCASE
Separating the crankcase
18 Nm (1.8 m•kgf, 13 ft•Ibf)
T.R
.
T.R
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
.
.
T.R
8
7
9
LS
5
17 Nm (1.7 m•kgf, 12 ft•Ibf)
E
New
New
.
T.R
.
T.R
11
.
T.R
LS
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
26 Nm (2.6 m•kgf, 19 ft•Ibf)
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf)
12
LT
LS
12
(3)
New
4
LT
New
10
New
T.R
.
30 Nm (3.0 m•kgf, 22 ft•Ibf)
T.R
.
42 Nm (4.2 m•kgf, 30 ft•Ibf)
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
13
6
.
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
New
LT
LT
10
LS
LT
LT
.
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
42 Nm (4.2 m•kgf, 30 ft•Ibf)
T.R
.
Order
3
Job/Parts to remove
Q’ty
Timing chain
1
4
Speed sensor
1
5
Dipstick
1
6
Relief valve assembly
1
7
Reverse switch
1
8
Gear position switch
1
9
Thermostat outlet hose guide
1
10
Engine bracket
2
11
Left crankcase
1
12
Dowel pin
2
13
Right crankcase
1
3
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
Remarks
For installation, reverse the removal procedure.
5-66
CRANKCASE
Removing the crankcase bearings
New
LS
LS
1
E
2
4
LT
LT
New 3
.
T.R
7
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
LT
.
7
E
7
7
6
5
7
E
E
7
7
E
7
E
Order
Job/Parts to remove
Q’ty
E
Remarks
Crankshaft/Oil pump
Refer to “CRANKSHAFT AND OIL PUMP”
on page 5-71.
Transmission
Refer to “TRANSMISSION” on page 5-76.
Middle drive shaft/Middle driven shaft
Refer to “MIDDLE GEAR” on page 5-83.
1
Collar
1
2
O-ring
1
3
Oil seal
1
4
Bearing retainer
1
5
Spacer
1
6
Crankshaft seal
2
7
Bearing
9
For installation, reverse the removal procedure.
5-67
CRANKCASE
EAS25560
SEPARATING THE CRANKCASE
1. Remove:
• Crankcase bolts
TIP
Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
A
2. Check:
• Timing chain guide (intake side)
Damage/wear → Replace.
EAS1XD1105
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).
B
4
3
2
1
A. Right crankcase
B. Left crankcase
2. Remove:
• Left crankcase
• Dowel pins
EAS1XD1106
CHECKING THE BEARINGS
1. Check:
• Bearings
Clean and lubricate, then rotate the inner
race with a finger.
Roughness → Replace.
ECA13900
NOTICE
Tap on one side of the crankcase with a softface hammer. Tap only on reinforced portions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure the crankcase halves separate evenly.
EAS24180
CHECKING THE TIMING CHAIN AND TIMING
CHAIN GUIDE
1. Check:
• Timing chain
Damage/stiffness → Replace the timing
chain and camshaft sprocket as a set.
5-68
CRANKCASE
EAS25580
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:
• Crankcase
Cracks/damage → Replace.
• Oil delivery passages
Obstruction → Blow out with compressed air.
a
1
2
2
5. Fit the left crankcase onto the right crankcase. Tap lightly on the crankcase with a soft
hammer.
EAS25700
ASSEMBLING THE CRANKCASE
1. Install:
ECA1XD1021
NOTICE
• Oil seal “1” New
(into the left crankcase “2”)
Before installing and torquing the crankcase
bolts, be sure to check whether the transmission is functioning properly by manually rotating the shift drum in both directions.
Installed depth “a”
1.0–1.5 mm (0.04–0.06 in)
6. Install:
• Crankcase bolts
7. Tighten:
• Crankcase bolts
1 New
a
T.
2
R.
2. Thoroughly clean the crankcase mating surfaces.
3. Apply:
• Sealant “1”
(onto the crankcase mating surfaces)
Crankcase bolt “1”
26 Nm (2.6 m·kgf, 19 ft·lbf)
Crankcase bolt “2”, “3”
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
M8 × 40 mm “1”
M6 × 60 mm “2”
M6 × 30 mm “3”
TIP
Tighten the bolts in stages, using a crisscross
pattern.
Yamaha bond No. 1215
90890-85505
(Three Bond No.1215®)
TIP
• Apply two coats of sealant to the area “a”
shown in the illustration.
• Do not allow any sealant to come into contact
with the oil gallery.
4. Install:
• Dowel pins “2”
5-69
CRANKCASE
A
2
3
×2
×3
2
3
3
B
1
2
×3
3
×2
×6
3
3
2
1
3
2
3
A. Left crankcase
B. Right crankcase
8. Apply:
• 4-stroke engine oil
(onto the crankshaft pin, bearings and oil delivery hole)
9. Check:
• Crankshaft and transmission operation
Rough operation → Repair.
5-70
CRANKSHAFT AND OIL PUMP
EAS1XD1107
CRANKSHAFT AND OIL PUMP
Removing the crankshaft and oil pump
3
4
2 New
1
.
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
.
T.R
Order
Job/Parts to remove
Q’ty
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
Remarks
Separate.
Refer to “CRANKCASE” on page 5-65.
Crankcase
1
Oil pump
1
2
Oil pump gasket
1
3
Balancer
1
4
Crankshaft
1
For installation, reverse the removal procedure.
5-71
CRANKSHAFT AND OIL PUMP
Disassembling the oil pump
6
3
2
5
4
1
E
E
.
T.R
Order
5 Nm (0.5 m•kgf, 3.6 ft•Ibf)
Job/Parts to remove
Q’ty
1
Oil pump housing cover
2
Pin
1
3
Oil pump shaft
1
4
Oil pump inner rotor
1
5
Oil pump outer rotor
1
6
Oil pump housing
1
Remarks
1
For assembly, reverse the disassembly procedure.
5-72
CRANKSHAFT AND OIL PUMP
EAS1XD1108
REMOVING THE CRANKSHAFT
1. Remove:
• Crankshaft “1”
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-andouter-rotor clearance
0.03–0.10 mm (0.0012–0.0039 in)
Limit
0.17 mm (0.0067 in)
TIP
• Remove the crankshaft with the crankcase
separating tool “2”.
• Make sure the crankcase separating tool is
centered over the crankshaft.
ECA1XD1039
NOTICE
• To protect the end of the crankshaft, place
an appropriate sized socket between the
crankcase separating tool bolt and the
crankshaft.
• Do not tap on the crankshaft.
Crankcase separating tool
90890-01135
Crankcase separator
YU-01135-B
2
1
EAS24960
CHECKING THE OIL PUMP
1. Check:
• Oil pump
Cracks/damage/wear → Replace the oil
pump.
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
3. Check:
• Oil pump operation
Rough movement → Replace the oil pump.
5-73
CRANKSHAFT AND OIL PUMP
c
b
b
EAS24990
CHECKING THE OIL STRAINER
1. Check:
• Oil strainer
Damage → Replace the oil pump.
Contaminants → Clean with solvent.
EAS1XD1109
a
CHECKING THE CRANKSHAFT
1. Measure:
• Crankshaft width A “a”
Out of specification → Replace the crankshaft.
4. Check:
• Crankshaft sprocket
Damage/wear → Replace the crankshaft.
• Bearing
Cracks/damage/wear → Replace the crankshaft.
5. Check:
• Crankshaft journal
Scratches/wear → Replace the crankshaft.
• Crankshaft journal oil passage
Obstruction → Blow out with compressed air.
Width A
74.92–75.00 mm (2.950–2.953 in)
2. Measure:
• Crankshaft runout C “b”
Out of specification → Replace the crankshaft.
Runout limit C
0.030 mm (0.0012 in)
EAS25010
ASSEMBLING THE OIL PUMP
1. Lubricate:
• Inner rotor
• Outer rotor
• Oil pump shaft
(with the recommended lubricant)
3. Measure:
• Big end side clearance D “c”
Out of specification → Replace the crankshaft.
Big end side clearance D
0.350–0.650 mm (0.0138–0.0256
in)
Recommended lubricant
Engine oil
2. Install:
• Oil pump housing “1”
• Oil pump outer rotor “2”
• Oil pump inner rotor “3”
• Oil pump shaft “4”
• Pin “5”
TIP
To install the oil pump shaft “4”, align the pin “5”
with the groove “a” in the inner rotor “3”.
5-74
CRANKSHAFT AND OIL PUMP
ECA1XD1040
2
1
NOTICE
Apply engine oil to each bearing to protect
the crankshaft against scratches and to
make installation easier.
3
a
a
TIP
Hold the connecting rod at top dead center
(TDC) with one hand while turning the nut of the
crankshaft installer bolt with the other. Turn the
crankshaft installer bolt until the crankshaft assembly bottoms against the bearing.
4
5
3. Check:
• Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-73.
EAS1XD1110
INSTALLING THE CRANKSHAFT
1. Install:
• Crankshaft “1”
TIP
Install the crankshaft with the crankshaft installer
pot “2”, crankshaft installer bolt “3”, adapter
(M16) “4”, spacer (crankshaft installer) “5”, and
spacer “6”.
Crankshaft installer pot
90890-01274
Installing pot
YU-90058
Crankshaft installer bolt
90890-01275
Bolt
YU-90060
Adapter (M16)
90890-04130
Adapter #13
YM-04059
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044
Spacer
90890-04167
YM-04167
6
5
4
1
2
3
5-75
TRANSMISSION
EAS26241
TRANSMISSION
Removing the transmission, shift drum and shift forks
1
T.R
2
.
3
18 Nm (1.8 m•kgf, 13 ft•Ibf)
New
E
4
E
10
E
New
E
9
8
7
E
6
New
E
5
Order
E
Job/Parts to remove
Q’ty
Remarks
Crankcase
Separate.
Refer to “CRANKCASE” on page 5-65.
Middle driven gear
Refer to “MIDDLE GEAR” on page 5-83.
1
Bolt
1
2
Spring
1
3
Ball
1
4
Shift drum
1
5
Shift fork assembly
1
6
Shift fork “R”
1
7
Spring
1
8
Shift fork “L”
1
9
Shift fork guide bar
1
10
Secondary shaft
1
5-76
TRANSMISSION
Removing the transmission, shift drum and shift forks
T.R
.
18 Nm (1.8 m•kgf, 13 ft•Ibf)
New
E
E
E
15
14
New
E
13
12
E
11
New
E
E
Order
Job/Parts to remove
Q’ty
11
Drive axle assembly
1
12
Collar
1
13
Reverse idle gear
1
14
Bearing
1
15
Reverse idle gear shaft
1
Remarks
For installation, reverse the removal procedure.
5-77
TRANSMISSION
Disassembling the drive axle assembly
9
8
New 6
7
5
4
3
M
2
M
1
M
M
M
16
M
M
15
14
12
10
Order
1
13 New
11 New
Job/Parts to remove
Q’ty
Washer
1
2
Collar
1
3
High wheel gear
1
4
Washer
1
5
Clutch dog
1
6
Circlip
1
7
Washer
1
8
Collar
1
9
Low wheel gear
1
10
Washer
1
11
Circlip
1
12
Middle drive gear
1
13
Circlip
1
14
Washer
1
15
Bearing
1
16
Reverse wheel gear
1
5-78
Remarks
TRANSMISSION
Disassembling the drive axle assembly
M
M
17
M
18
M
M
M
M
Order
Job/Parts to remove
Q’ty
17
Collar
1
18
Drive axle
1
Remarks
For assembly, reverse the disassembly procedure.
5-79
TRANSMISSION
EAS26250
REMOVING THE TRANSMISSION
1. Remove:
• Shift drum “1”
• Shift fork assembly “2”
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pull out the guide bar from the right crankcase, and then remove the shift fork cam followers.
b. Remove the shift drum.
c. Remove the shift fork assembly.
2
2. Check:
• Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends → Replace.
EWA12840
WARNING
Do not attempt to straighten a bent shift fork
guide bar.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1XD1133
DISASSEMBLING THE DRIVE AXLE
1. Remove:
• Collar “1”
• Drive axle “2”
TIP
Press the drive axle end and remove the collar.
3. Check:
• Shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift forks
and shift fork guide bar as a set.
1
2
EAS26260
CHECKING THE SHIFT FORKS
The following procedure applies to both of the
shift forks.
1. Check:
• Shift fork cam follower “1”
• Shift fork pawl “2”
Bends/damage/scoring/wear → Replace the
shift fork.
4. Check:
• Spring
Cracks/damage → Replace.
EAS1XD1111
CHECKING THE SHIFT DRUM
1. Check:
• Shift drum grooves
Damage/scratches/wear → Replace the shift
drum.
5-80
TRANSMISSION
4. Check:
• Transmission gear movement
Rough movement → Replace the defective
part(s).
5. Check:
• Circlips
Bends/damage/looseness → Replace.
EAS1XD1112
CHECKING THE SECONDARY SHAFT
1. Check:
• Gear teeth
Blue discoloration/pitting/wear → Replace.
EAS26300
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)
EAS1XD1113
ASSEMBLING THE DRIVE AXLE ASSEMBLY
1. Install:
• Washer “1”
• Circlip “2” New
TIP
• Be sure the circlip sharp-edged corner “a” is
positioned opposite side to the washer and
gear.
• Be sure the circlip ends “b” are positioned at
axle spline groove “c”.
b
New 2
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).
c
a
1
EAS1XD1114
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
TIP
Install the shift forks with the “28P” mark “a” and
“5B4” mark “b” facing each other.
3. Check:
• Transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission
axle assemblies.
5-81
TRANSMISSION
New 5
1
2
3
b
New 5
a
4
EAS1XD1115
INSTALLING THE SHIFT FORKS AND SHIFT
DRUM
1. Install:
• Reverse idle gear “1”
• Drive axle assembly “2”
• Secondary shaft “3”
• Shift fork assembly “4”
• Shift drum “5”
TIP
Install the shift fork assembly “4” with the “L”
mark “a” facing the right crankcase.
3
2
4
5
1
4
a
2. Check:
• Shift operation
Rough operation → Repair.
TIP
• Oil each gear and bearing thoroughly.
• Before assembling the crankcase, make sure
that the transmission is in neutral and that the
gears turn freely.
5-82
MIDDLE GEAR
EAS25711
MIDDLE GEAR
Removing the middle drive shaft
.
T.R
190 Nm (19 m•kgf, 137 ft•lbf)
T.R
.
32 Nm (3.2 m•kgf, 23 ft•Ibf)
LT
LT
9
LT
5
10
New
6
8
11
7
12
E
10
1
New
LT
LT
LT
LT
T.R
.
29 Nm (2.9 m•kgf, 21 ft•Ibf)
Order
Job/Parts to remove
Q’ty
Separate.
Refer to “CRANKCASE” on page 5-65.
Crankcase
1
Remarks
Middle drive shaft/bearing housing assembly
1
2
Middle drive pinion gear nut
1
3
Middle drive pinion gear
1
4
Middle drive pinion gear shim
5
Middle drive shaft assembly
1
6
Middle driven gear
1
7
Circlip
1
8
Middle drive shaft
1
9
Middle drive shaft bearing housing assembly
1
10
Bearing retainer
2
11
Bearing
1
12
Washer
1
Refer to “ALIGNING THE MIDDLE GEAR”
on page 5-92.
5-83
MIDDLE GEAR
Removing the middle drive shaft
.
T.R
190 Nm (19 m•kgf, 137 ft•lbf)
T.R
.
32 Nm (3.2 m•kgf, 23 ft•Ibf)
LT
LT
LT
New
13
E
New
LT
LT
T.R
.
29 Nm (2.9 m•kgf, 21 ft•Ibf)
Order
13
LT
LT
Job/Parts to remove
Q’ty
Bearing housing
Remarks
1
For installation, reverse the removal procedure.
5-84
MIDDLE GEAR
Removing the middle driven shaft
.
T.R
190 Nm (19 m•kgf, 137 ft•lbf)
LT
.
T.R
25 Nm (2.5 m•kgf, 18 ft•Ibf)
T.R
.
80 Nm (8.0 m•kgf, 58 ft•Ibf)
5
T.R
.
130 Nm (13 m•kgf, 94 ft•lbf)
6
9
4
12
T.R
.
10
11
190 Nm (19 m•kgf, 137 ft•lbf)
8
4
7
Order
Job/Parts to remove
Q’ty
Remarks
Separate.
Refer to “CRANKCASE” on page 5-65.
Crankcase
1
Rear drive shaft yoke nut (middle gear side)
1
2
Rear drive shaft yoke (middle gear side)
1
3
Middle driven pinion gear assembly
1
4
Middle driven pinion gear shim
5
Front drive shaft yoke nut (middle gear side)
1
6
Front drive shaft yoke (middle gear side)
1
Refer to “ALIGNING THE MIDDLE GEAR”
on page 5-92.
7
Middle driven pinion gear
1
8
Bearing
1
9
Oil seal
1
10
Middle driven pinion gear bearing retainer
1
11
Bearing
1
12
O-ring
1
5-85
Left-hand threads
MIDDLE GEAR
Removing the middle driven shaft
.
T.R
190 Nm (19 m•kgf, 137 ft•lbf)
LT
15
17
16
.
T.R
25 Nm (2.5 m•kgf, 18 ft•Ibf)
14
T.R
.
80 Nm (8.0 m•kgf, 58 ft•Ibf)
T.R
.
130 Nm (13 m•kgf, 94 ft•lbf)
13
T.R
.
Order
Job/Parts to remove
Q’ty
13
Bearing housing
1
14
Oil seal
1
15
Middle driven shaft bearing retainer
1
16
Bearing
1
17
Middle driven shaft
1
190 Nm (19 m•kgf, 137 ft•lbf)
Remarks
Left-hand threads
For installation, reverse the removal procedure.
5-86
MIDDLE GEAR
EAS1XD1116
REMOVING THE MIDDLE DRIVE SHAFT
1. Straighten:
• Punched portion of the middle drive pinion
gear nut
2. Loosen:
• Middle drive pinion gear nut “1”
Coupling gear/middle shaft tool
90890-01229
Gear holder
YM-01229
TIP
Wrap the middle drive shaft in a folded rag, and
then secure it in a vise.
2
1
3
2. Remove:
• Front drive shaft yoke nut “1”
• Washer
• Front drive shaft yoke “2”
TIP
3. Remove:
• Middle drive pinion gear nut
• Middle drive pinion gear
• Shim(s)
4. Remove:
• Middle driven gear “1”
• Circlip
• Middle drive shaft “2”
Use the coupling gear/middle shaft tool “3” to
hold the front drive shaft coupling sleeve.
Coupling gear/middle shaft tool
90890-01229
Gear holder
YM-01229
TIP
Press the middle drive shaft end and remove the
middle driven gear.
2
1
1
3
2
3. Remove:
• Bearing housing assembly “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the surface of the bearing housing assembly.
b. Place the bearing housing assembly onto a
hydraulic press.
EAS1XD1117
REMOVING THE MIDDLE DRIVEN SHAFT
1. Remove:
• Rear drive shaft yoke nut “1”
• Washer
• Rear drive shaft yoke “2”
ECA1XD1041
NOTICE
• 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.
TIP
Use the coupling gear/middle shaft tool “3” to
hold the rear drive shaft coupling sleeve.
5-87
MIDDLE GEAR
• Install a suitable socket “2” on the middle
driven pinion gear end to protect the thread
from damage.
Ring nut wrench
90890-01430
YM-38404
c. Press the middle driven pinion gear end and
remove the bearing housing.
ECA1XD1023
NOTICE
The middle driven shaft bearing retainer has
left-hand threads. To loosen the retainer turn
it clockwise.
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Remove:
• Middle driven pinion gear bearing retainer
• Bearing
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wrap the bearing housing in a folded rag “1”,
and then secure the bearing housing edge in
a vise.
b. Attach the bearing retainer wrench “2”.
Bearing retainer wrench
90890-04128
Middle gear bearing retainer
YM-04128
3
ECA1XD1022
6. Remove:
• Middle driven shaft “1”
(with bearing)
NOTICE
The middle driven pinion gear bearing retainer has left-hand threads. To loosen the retainer, turn it clockwise.
1
2
1
EAS1XD1118
CHECKING THE PINION GEARS
1. Check:
• Drive pinion gear teeth
• Driven pinion gear teeth
Pitting/galling/wear → Replace.
2. Check:
• O-ring
Damage → Replace.
c. Remove the bearing retainer and bearing.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Remove:
• Oil seal “1”
• Middle driven shaft bearing retainer “2”
TIP
Attach the ring nut wrench “3”.
5-88
MIDDLE GEAR
• Bearings
Pitting/damage → Replace.
Ring nut wrench
90890-01430
YM-38404
EAS1XD1119
INSTALLING THE BEARING AND OIL SEALS
1. Install:
• Bearing “1”
ECA1XD1024
NOTICE
The middle driven shaft bearing retainer has
left-hand threads. To tighten the retainer turn
it counterclockwise.
• Oil seal “2” New
(into the bearing housing “3”)
Installed depth “a” of bearing
0.9–1.4 mm (0.035–0.055 in)
Installed depth “b” of oil seal
1.0–1.5 mm (0.039–0.059 in)
a
1
1
3
2 New
b
2. Install:
• Oil seal “1” New
(into the crankcase “2”)
Installed depth “a” of oil seal
1.0–1.5 mm (0.039–0.059 in)
2
2. Install:
• Middle driven pinion gear bearing retainer “1”
1 New
a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wrap the bearing housing in a folded rag, and
then secure the bearing housing edge in a
vise.
b. Attach the bearing retainer wrench “2”.
2
Bearing retainer wrench
90890-04128
Middle gear bearing retainer
YM-04128
EAS1XD1120
INSTALLING THE MIDDLE DRIVEN SHAFT
1. Install:
• Middle driven shaft bearing retainer “1”
c. Tighten the bearing retainer.
T.
R.
T.
R.
Middle driven shaft bearing retainer
80 Nm (8.0 m·kgf, 58 ft·lbf)
LOCTITE®
TIP
Attach the ring nut wrench “2”.
5-89
Middle driven pinion gear bearing
retainer
130 Nm (13 m·kgf, 94 ft·lbf)
LOCTITE®
MIDDLE GEAR
ECA1XD1025
NOTICE
The middle driven pinion gear bearing retainer has left-hand threads. To tighten the retainer turn it counterclockwise.
1
2
1
3
5. Install:
• Rear drive shaft yoke “1”
• Washer
• Rear drive shaft yoke nut “2”
2
T.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
R.
3. Install:
• Middle driven pinion gear shim(s) “1”
• Bearing housing
Rear drive shaft yoke nut (middle
gear side)
190 Nm (19 m·kgf, 137 ft·lbf)
LOCTITE®
TIP
TIP
Install the shim(s) so that the tabs are positioned
as shown in the illustration.
Use the coupling gear/middle shaft tool “3” to
hold the rear drive shaft yoke.
Coupling gear/middle shaft tool
90890-01229
Gear holder
YM-01229
1
1
1
4. Install:
• Front drive shaft yoke “1”
• Washer
• Front drive shaft yoke nut “2”
2
3
T.
R.
Front drive shaft yoke nut (middle gear side)
190 Nm (19 m·kgf, 137 ft·lbf)
LOCTITE®
EAS1XD1121
INSTALLING THE MIDDLE DRIVE SHAFT
1. Install:
• Circlip
• Middle driven gear “1”
(onto the middle drive shaft “2”)
TIP
Use the coupling gear/middle shaft tool “3” to
hold the front drive shaft yoke.
Installed depth “a” of middle
driven gear
24.7–24.9 mm (0.972–0.980 in)
Coupling gear/middle shaft tool
90890-01229
Gear holder
YM-01229
5-90
MIDDLE GEAR
EAS25890
a
MEASURING THE MIDDLE GEAR
BACKLASH
1. Measure:
• Middle gear backlash
Out of specification → Adjust.
Refer to “ALIGNING THE MIDDLE GEAR” on
page 5-92.
2
1
Middle gear backlash
0.10–0.30 mm (0.004–0.012 in)
2. Tighten:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Bearing retainer bolts “1” New
a. Temporarily install the right crankcase.
b. Wrap a rag “1” around a screwdriver “2”, and
then insert it into the installation hole “a” of the
right crankcase speed sensor to hold the middle driven gear.
T.
Middle drive shaft bearing retainer bolt
29 Nm (2.9 m·kgf, 21 ft·lbf)
LOCTITE®
R.
TIP
Stake the bearing retainer bolts at the cutouts “a”
in the bearing retainers “2”.
New 1
a
a
2
2
c. Attach the final gear backlash band “3” and
dial gauge “4”.
1 New
New 1
a
Final gear backlash band
90890-01511
Middle drive gear lash tool
YM-01230
3. Tighten:
• Middle drive pinion gear nut “1” New
T.
R.
Middle drive pinion gear nut
190 Nm (19 m·kgf, 137 ft·lbf)
4
TIP
• Wrap the middle drive shaft in a folded rag, and
then secure it in a vise.
• Lock the threads with a drift punch.
3
b
a
a. 39.3 mm (1.55 in)
b. 25.3 mm (1.00 in)
d. Measure the gear lash while rotating the middle driven shaft back and forth.
TIP
Measure the gear lash at 4 positions. Rotate the
middle driven gear 90° each time.
5-91
MIDDLE GEAR
e. If the gear lash is incorrect, adjust the gear
lash by middle driven pinion gear shim(s).
a
k
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS25930
ALIGNING THE MIDDLE GEAR
TIP
Aligning the middle gear is necessary when any
of the following parts are replaced:
• Crankcase
• Middle drive pinion gear
• Middle driven pinion gear
• Middle driven shaft bearing housing
• Middle drive shaft bearing housing
e
b
1. Select:
• Middle drive pinion gear shim(s) “1”
• Middle driven pinion gear shim(s) “2”
d
c
A
1
2
g
i
h
f
j
B
2
A. Middle drive pinion gear shim thickness
B. Middle driven pinion gear shim thickness
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Position the middle gears with the appropriate shim(s) that has had its respective thickness calculated from information marked on
the crankcase, bearing housings, and pinion
gears.
b. To find middle drive pinion gear shim thickness “A”, use the following formula.
Middle drive pinion gear shim thickness
“A” = “e” + “d” + “a” - “c” - “b” - “k”
“a” = a numeral (usually a decimal number)
on the bearing housing is either added to or
subtracted from “0.9”
“b” = 17.0
“c” = 55.0
“d” = a numeral (usually a decimal number)
on the left crankcase specifies a thickness of
“65.0”
5-92
MIDDLE GEAR
“e” = a numeral (usually a decimal number)
on the right crankcase specifies a thickness
of “9.0”
“k” = 1.5
Example:
If the bearing housing is marked “+01”,
“a” is 0.91
Hundredth
Rounded value
0, 1, 2
0
3, 4, 5, 6, 7
5
8, 9
10
Shims are supplied in the following thicknesses.
Middle drive pinion gear shim
Thickness (mm)
0.50 0.55 0.60 0.70 0.80 0.90 1.00
c. To find middle driven pinion gear shim thickness “B”, use the following formula.
Middle driven pinion gear shim thickness
“B” = “f” - “g” + “h” - “i” - “j”
a
“b” is 17.0
“c” is 55.0
If the left crankcase is marked “64.96”,
“d” is 64.96
“f” = a numeral (usually a decimal number) on
the bearing housing is either added to or subtracted from “89.5”
TIP
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.
d
If the right crankcase is marked “9.01”,
“e” is 9.01
f
“g” = a numeral (usually a decimal number)
on the middle driven pinion gear is either added to or subtracted from “61.0”
“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 right crankcase specifies a thickness of
“99.98”
“j” = a numeral (usually a decimal number) on
the left crankcase specifies a thickness of
“8.12”
Example:
If the bearing housing is marked “+03”,
“f” is 89.53
e
“k” is 1.5
Therefore, “A” is 1.38.
“A” = 9.01 + 64.96 + 0.91 - 55.0 - 17.0 - 1.5
= 1.38
Round off hundredths digit and select appropriate shim(s).
In the above example, the calculated shim
thickness is 1.38 mm. The following chart instructs you, however, to round off 8 to 10.
5-93
MIDDLE GEAR
f
j
Therefore, “B” is 0.93.
“B” = 89.53 - 61.02 + 80.52 - 99.98 - 8.12 =
0.93
Round off hundredth digit and select appropriate shim(s).
In the above example, the calculated shim
thickness is 0.93 mm. The chart instructs
you, however, to round off 3 to 5.
If the driven pinion gear is marked “+02”,
“g” is 61.02
g
If the driven pinion gear is marked “+02”,
“h” is 80.52
Hundredth
Rounded value
0, 1, 2
0
3, 4, 5, 6, 7
5
8, 9
10
Shims are supplied in the following thicknesses.
Middle driven pinion gear shim
Thickness (mm)
0.10 0.15 0.20 0.30 0.40 0.50 0.60
TIP
h
• If the specified middle gear backlash cannot be
obtained with a calculated shim thickness, increase or decrease the shim thickness.
• If the shim thickness is increased, the actual
middle gear backlash will increase and, if the
shim thickness is decreased, the actual middle
gear backlash will decrease.
If the right crankcase is marked “99.98”,
“i” is 99.98
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
i
If the left crankcase is marked “8.12”,
“j” is 8.12
5-94
MIDDLE GEAR
5-95
COOLING SYSTEM
OIL COOLER...................................................................................................6-1
CHECKING THE OIL COOLER ................................................................6-3
INSTALLING THE OIL COOLER .............................................................. 6-3
RADIATOR ...................................................................................................... 6-4
CHECKING THE RADIATOR.................................................................... 6-6
INSTALLING THE RADIATOR..................................................................6-6
INSTALLING THE HORN (for Europe and Oceania) ................................6-6
THERMOSTAT ................................................................................................6-8
CHECKING THE THERMOSTAT.............................................................. 6-9
INSTALLING THE THERMOSTAT............................................................ 6-9
WATER PUMP...............................................................................................6-11
DISASSEMBLING THE WATER PUMP.................................................. 6-13
CHECKING THE WATER PUMP ............................................................ 6-13
ASSEMBLING THE WATER PUMP........................................................ 6-13
INSTALLING THE AC MAGNETO COVER ............................................6-14
6
OIL COOLER
EAS26410
OIL COOLER
Removing the oil cooler
.
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
.
T.R
20 Nm (2.0 m•kgf, 14 ft•Ibf)
T.R
.
18 Nm (1.8 m•kgf, 13 ft•Ibf)
New
New
New
New
T.R
.
35 Nm (3.5 m•kgf, 25 ft•Ibf)
New
New
2
1
4
LS
T.R
.
3
18 Nm (1.8 m•kgf, 13 ft•Ibf)
E
LS
.
T.R
T.R
17 Nm (1.7 m•kgf, 12 ft•Ibf)
.
Order
30 Nm (3.0 m•kgf, 22 ft•Ibf)
Job/Parts to remove
Q’ty
Remarks
Rear skid plate/Right rear panel/Center passenger compartment panel
Refer to “GENERAL CHASSIS” on page
4-1.
Air filter case
Refer to “AIR FILTER CASE” on page 7-5.
Engine oil
Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-13.
Coolant
Drain.
Refer to “CHANGING THE COOLANT” on
page 3-8.
Water pump outlet pipe/Oil cooler inlet hose
Refer to “WATER PUMP” on page 6-11.
1
Oil filter cartridge
1
2
Oil filter cartridge union bolt
1
3
Oil cooler
1
4
Oil cooler outlet hose
1
6-1
OIL COOLER
Removing the oil cooler
.
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
.
T.R
20 Nm (2.0 m•kgf, 14 ft•Ibf)
T.R
.
18 Nm (1.8 m•kgf, 13 ft•Ibf)
New
5
New
6
New
New
T.R
.
35 Nm (3.5 m•kgf, 25 ft•Ibf)
New
New
LS
T.R
.
18 Nm (1.8 m•kgf, 13 ft•Ibf)
E
LS
.
T.R
T.R
17 Nm (1.7 m•kgf, 12 ft•Ibf)
.
Order
30 Nm (3.0 m•kgf, 22 ft•Ibf)
Job/Parts to remove
Q’ty
5
Oil pipe (crankcase to cylinder head)
1
6
Oil pipe (AC magneto cover)
1
Remarks
For installation, reverse the removal procedure.
6-2
OIL COOLER
EAS26420
T.
CHECKING THE OIL COOLER
1. Check:
• Oil cooler
Cracks/damage → Replace.
2. Check:
• Oil cooler outlet hose
• Oil pipe (crankcase to cylinder head)
• Oil pipe (AC magneto cover)
Cracks/damage/wear → Replace.
R.
4. Fill:
• Cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-8.
• Crankcase
(with the specified amount of the recommended engine oil)
Refer to “CHANGING THE ENGINE OIL” on
page 3-13.
5. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
6. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-6.
EAS26430
INSTALLING THE OIL COOLER
1. Clean:
• Mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
2. Install:
• Oil cooler outlet hose “1”
(to the oil cooler)
TIP
Install the oil cooler outlet hose with the white
paint mark “a” facing in the direction shown in
the illustration.
a
1
3. Install:
• Gasket New
• Oil cooler “1”
• Oil filter cartridge union bolt “2”
TIP
Fit the projection “a” on the oil cooler between
the projections “b” on the crankcase.
a
b
b
Oil filter cartridge union bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
1
2
6-3
RADIATOR
EAS26380
RADIATOR
Removing the radiator
T.R
.
.
T.R
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
6
7
8
1
4
5
(4)
2
T.R
.
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
3
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
Order
Job/Parts to remove
Q’ty
Remarks
Side frames/Front fender/Instrument panel/Center passenger compartment panel/Center floor
board/Left floor board/Right floor board/Electrical components tray
Refer to “GENERAL CHASSIS” on page
4-1.
Air filter case
Refer to “AIR FILTER CASE” on page 7-5.
Coolant
Drain.
Refer to “CHANGING THE COOLANT” on
page 3-8.
1
Radiator cap
1
2
Coolant reservoir hose
1
3
Coolant reservoir breather hose
1
4
Coolant reservoir cap
1
5
Coolant reservoir
1
6
Radiator inlet hose
1
7
Radiator inlet pipe
1
8
Radiator outlet hose
1
6-4
RADIATOR
Removing the radiator
.
.
T.R
T.R
12
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
11
9
10
15
14
(4)
13
T.R
.
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
Order
Job/Parts to remove
Q’ty
Remarks
9
Radiator outlet pipe
1
10
Radiator fan motor coupler
1
Disconnect.
11
Horn
1
For Europe and Oceania
12
Radiator bracket
1
13
Radiator
1
14
Radiator fan
1
15
Radiator fan motor breather hose
1
For installation, reverse the removal procedure.
6-5
RADIATOR
EAS26390
CHECKING THE RADIATOR
1. Check:
• Radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the radiator.
Damage → Repair or replace.
TIP
Straighten any flattened fins with a thin, flat-head
screwdriver.
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” on page 9-29.
EAS26400
INSTALLING THE RADIATOR
1. Fill:
• Cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-8.
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” on
page 6-6.
2. Check:
• Radiator hoses
• Radiator pipes
Cracks/damage/wear → Replace.
3. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Radiator cap opening pressure
107.9–137.3 kPa (1.1–1.4
kgf/cm², 15.6–19.9 psi)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the radiator cap tester “1” and radiator
cap tester adapter “2” to the radiator cap “3”.
EAS1XD2002
INSTALLING THE HORN (for Europe and
Oceania)
1. Install:
• Horn “1”
T.
Radiator cap tester
90890-01325
Mityvac cooling system tester kit
YU-24460-A
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984
R.
Horn nut
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
TIP
Fit the slot “a” in the horn with the projection “b”
on the radiator bracket.
6-6
RADIATOR
b
a
1
6-7
THERMOSTAT
EAS26440
THERMOSTAT
Removing the thermostat
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
2
LS
New
3
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
New
4
5
T.R
.
1
Order
18 Nm (1.8 m•kgf, 13 ft•Ibf)
New
Job/Parts to remove
Q’ty
Remarks
Drain.
Refer to “CHANGING THE COOLANT” on
page 3-8.
Coolant
1
Thermostat outlet hose
1
2
Thermostat cover
1
3
Thermostat
1
4
Coolant temperature sensor coupler
1
5
Coolant temperature sensor
1
Disconnect.
For installation, reverse the removal procedure.
6-8
THERMOSTAT
• Thermostat housing (cylinder head)
• Thermostat outlet hose
Cracks/damage → Replace.
EAS26450
CHECKING THE THERMOSTAT
1. Check:
• Thermostat
Does not open at 69–73 °C (156–163°F) →
Replace.
EAS1XD1122
INSTALLING THE THERMOSTAT
1. Install:
• Copper washer New
• Coolant temperature sensor
T.
R.
Coolant temperature sensor
18 Nm (1.8 m·kgf, 13 ft·lbf)
ECA1XD1042
NOTICE
Use extreme care when handling the coolant
temperature sensor. Replace any part that
was dropped or subjected to a strong impact.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suspend the thermostat “1” in a container “2”
filled with water.
b. Slowly heat the water “3”.
c. Place a thermometer “4” in the water.
d. While stirring the water, observe the thermostat and thermometer indicated temperature.
2. Install:
• Thermostat “1”
• O-ring “2” New
• Thermostat cover “3”
T.
R.
Thermostat cover bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
TIP
Install the thermostat with its breather hole “a”
facing up.
2 New
a
1
3
7 mm
(0.28 in)
LS
71±2°C
(159±3°F)
85°C
(185°F)
3. Fill:
• Cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-8.
4. Check:
• Cooling system
Leak → Repair or replace any faulty part.
5. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
A. Fully closed
B. Fully open
TIP
If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause serious
overheating or overcooling.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Thermostat cover
6-9
THERMOSTAT
Refer to “CHECKING THE RADIATOR” on
page 6-6.
6-10
WATER PUMP
EAS26500
WATER PUMP
Removing the water pump
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
LS
1
LS
New
E
7
(11)
2
New
M
3
New
4
New 8
6
5
New
T.R
.
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
LS
New
.
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
Order
.
T.R
.
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
Job/Parts to remove
Q’ty
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
Remarks
Center compartment panel/Right side cover/Right rear cover/Rear skid plate
Refer to “GENERAL CHASSIS” on page
4-1.
Air filter case
Refer to “AIR FILTER CASE” on page 7-5.
Engine oil
Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-13.
Coolant
Drain.
Refer to “CHANGING THE COOLANT” on
page 3-8.
1
Water pump inlet hose
1
2
Water jacket joint
1
3
Water pump outlet hose
1
4
Water pump outlet pipe
1
5
Oil cooler inlet hose
1
6
Water pump breather hose
1
7
Water pump housing
1
8
Gasket
1
6-11
WATER PUMP
Removing the water pump
15
T.R
10
.
14 New
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
LS
16
20
13
21 New
11
15
12
19
LS
New
17
E
9
(11)
18
New
M
New
New
T.R
.
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
LS
New
.
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
Order
9
.
T.R
.
T.R
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
Job/Parts to remove
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
Q’ty
Dowel pin
Remarks
2
10
Drive select lever shift cable bracket
1
11
AC magneto coupler
2
Disconnect.
12
Crankshaft position sensor coupler
1
Disconnect.
13
AC magneto cover
1
14
AC magneto cover gasket
1
15
Dowel pin
2
16
Circlip
1
17
Impeller shaft
1
18
Mechanical seal (impeller side)
1
19
Mechanical seal (housing side)
1
20
Bearing
1
21
Oil seal
1
For installation, reverse the removal procedure.
6-12
WATER PUMP
EAS26510
EAS26540
DISASSEMBLING THE WATER PUMP
1. Remove:
• Mechanical seal (impeller side) “1”
(from the impeller, with a thin, flat-head
screwdriver)
CHECKING THE WATER PUMP
1. Check:
• Water pump housing cover
• AC magneto cover
• Impeller shaft
• Oil cooler inlet hose
• Water pump outlet pipe
• Water pump outlet hose
Cracks/damage/wear → Replace.
2. Check:
• Bearing
Rough movement → Replace.
TIP
Do not scratch the impeller shaft.
EAS26560
ASSEMBLING THE WATER PUMP
1. Install:
• Oil seal “1” New
(into the AC magneto cover)
2. Remove:
• Mechanical seal (housing side) “1”
TIP
• Before installing the oil seal, apply tap water or
coolant onto its outer surface.
• Install the oil seal with a socket that matches its
outside diameter.
TIP
Remove the mechanical seal (housing side)
from the inside of the AC magneto cover.
Installed depth of oil seal “a”
8.1–8.7 mm (0.32–0.34 in)
1 New
1
3. Remove:
• Bearing “1”
• Oil seal “2”
a
TIP
2. Install:
Remove the bearing and oil seal from the inside
of the AC magneto cover.
• Mechanical seal (housing side) “1” New
ECA1XD1056
NOTICE
Never lubricate the mechanical seal (housing side) surface with oil or grease.
TIP
Use the special tools and a press to press the
mechanical seal (housing side) straight in until it
touches the water pump housing.
2
1
6-13
WATER PUMP
Mechanical seal installer
90890-04132
Water pump seal installer
YM-33221-A
Middle driven shaft bearing driver
90890-04058
Middle drive bearing installer 40
& 50 mm
YM-04058
A
TIP
If the surface “a” of the mechanical seal (impeller
side) that contacts the mechanical seal (housing
side) is dirty, clean it.
Impeller shaft tilt limit
0.15 mm (0.006 in)
3
2
1 New
1. Straightedge
2. Impeller
5. Install:
• Impeller “1”
A. Push down
2. Mechanical seal installer
3. Middle driven shaft bearing driver
3. Install:
• Circlip New
TIP
After installation, check that the impeller shaft rotates smoothly.
• Mechanical seal (impeller side) “1” New
TIP
Before installing the mechanical seal (impeller
side), apply tap water or coolant onto its outer
surface.
1
EAS1XD1008
4. Measure:
• Impeller shaft tilt
Out of specification → Repeat steps (3) and
(4).
INSTALLING THE AC MAGNETO COVER
1. Install:
• Dowel pins “1”
• AC magneto cover gasket “2” New
• AC magneto cover “3”
TIP
Align the slit “a” on the impeller shaft with the
projection “b” on the oil pump driven sprocket.
ECA1XD1057
NOTICE
Make sure the mechanical seal (impeller
side) is flush with the impeller.
6-14
WATER PUMP
b
a
3
1
2 New
2. Install:
• Dowel pins “1”
• Gasket “2” New
• Water pump housing “3”
TIP
Install the bolt “4” to the water pump housing,
and then install the water pump housing to the
AC magneto cover.
1
2 New
3
4
3. Fill:
• Cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-8.
4. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
5. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-6.
6-15
FUEL SYSTEM
FUEL TANK..................................................................................................... 7-1
REMOVING THE FUEL TANK ..................................................................7-2
REMOVING THE FUEL PUMP .................................................................7-2
CHECKING THE FUEL PUMP BODY.......................................................7-2
CHECKING THE FUEL TANK BREATHER HOSE JOINT .......................7-2
INSTALLING THE FUEL PUMP................................................................7-3
INSTALLING THE FUEL TANK.................................................................7-3
CHECKING THE FUEL PRESSURE ........................................................7-4
AIR FILTER CASE .......................................................................................... 7-5
INSTALLING THE AIR FILTER CASE ......................................................7-7
THROTTLE BODY........................................................................................... 7-8
REMOVING THE THROTTLE BODY ASSEMBLY .................................7-11
CHECKING THE INJECTOR .................................................................. 7-11
CHECKING THE THROTTLE BODY ......................................................7-11
CHECKING THE THROTTLE BODY JOINT...........................................7-11
INSTALLING THE THROTTLE BODY ASSEMBLY................................7-11
ADJUSTING THE THROTTLE POSITION SENSOR..............................7-12
AIR INDUCTION SYSTEM ............................................................................7-15
CHECKING THE AIR INDUCTION SYSTEM..........................................7-19
INSTALLING THE AIR INDUCTION SYSTEM........................................ 7-19
7
FUEL TANK
EAS26620
FUEL TANK
Removing the fuel tank
.
T.R
16 Nm (1.6 m•kgf, 12 ft•Ibf)
T.R
.
.
T.R
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
4
5
(6)
1
11
2
3
6
1
New
7
7
9
10
8
T.R
.
T.R
.
Order
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
Job/Parts to remove
Q’ty
Outer passenger seat frame/Right side panel/Right rear cover
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
1
Fuel tank breather hose
2
2
Fuel tank breather hose joint
1
3
Fuel pump coupler
1
4
Fuel hose connector holder
1
5
Fuel hose
1
6
Fuel tank retainer
1
7
Damper
2
8
Fuel tank bracket
1
9
Fuel tank
1
10
Damper
2
11
Fuel pump
1
Disconnect.
For installation, reverse the removal procedure.
7-1
FUEL TANK
EAS26630
REMOVING THE FUEL TANK
1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Remove:
• Fuel hose connector holder
• Fuel hose
EWA15910
WARNING
Cover fuel hose connections with a cloth
when disconnecting them. Residual pressure in the fuel lines could cause fuel to
spurt out when removing the hose.
EAS26640
REMOVING THE FUEL PUMP
1. Remove:
• Fuel pump bracket
• Fuel pump
• Fuel pump gasket
ECA1XD1001
NOTICE
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.
ECA14720
NOTICE
• Do not drop the fuel pump or give it a
strong shock.
• Do not touch the base section of the fuel
sender.
TIP
• To disconnect the fuel hose from the fuel
pump, remove the fuel hose connector holder,
insert a slotted head screwdriver, etc., in the
slot part “a” of the fuel hose connector cover
“1”, slide the cover in the direction of the arrow,
and then disconnect the fuel hose.
• To disconnect the fuel hose from the injector
fuel rail, 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 disconnect the
hose.
• Before removing the hose, place a few rags in
the area under where it will be removed.
EAS26670
CHECKING THE FUEL PUMP BODY
1. Check:
• Fuel pump body
Obstruction → Clean.
Cracks/damage → Replace the fuel pump.
EAS1XD1005
CHECKING THE FUEL TANK BREATHER
HOSE JOINT
1. Check:
• Fuel tank breather hose joint
Damage/faulty → Replace.
TIP
• Check that air flows smoothly in the direction of
the arrow shown when the hose joint is positioned as shown in the illustration “A”.
• Check that air does not flow in the direction of
the arrow shown when the hose joint is positioned as shown in the illustration “B”.
7-2
FUEL TANK
È
a
É
a
2
4
a
5
6
a
3
a. upward
EAS1XD1006
INSTALLING THE FUEL TANK
1. Install:
• Dampers “1”
EAS26700
INSTALLING THE FUEL PUMP
1. Install:
TIP
• Fuel pump gasket “1” New
Fit the projections “a” on the dampers into the
holes “b” in the frame.
TIP
• Always use a new fuel pump gasket.
• Install the fuel pump gasket with the lip side “a”
facing upward.
New 1
1
b
a
1
a
1
b
1
2. Install:
• Fuel tank “1”
• Fuel tank bolts “2”
• Fuel tank retainer “3”
• Fuel tank retainer bolts “4”
2. Install:
• Fuel pump
• Fuel pump bracket
TIP
T.
Finger tighten the fuel tank bolts and fuel tank retainer bolts.
R.
Fuel pump nut
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
TIP
2
• Do not damage the installation surfaces of the
fuel tank when installing the fuel pump.
• Install the fuel pump in the direction shown in
the illustration.
• Install the fuel pump bracket by aligning the
projections “a” on the fuel pump with the projection “b” on the fuel tank.
• Tighten the nuts to specification in the proper
tightening sequence as shown.
4
3
4
1
2
3. Tighten:
• Fuel tank bolts “1”–“3”
• Fuel tank retainer bolts “4”, “5”
7-3
2
FUEL TANK
T.
R.
Fuel tank bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank retainer bolt
16 Nm (1.6 m·kgf, 12 ft·lbf)
TIP
Tighten the bolts in the proper tightening sequence as shown.
3
4
5
EAS1XD1123
CHECKING THE FUEL PRESSURE
1. Check:
• Fuel pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
a. Remove the frame cross member.
Refer to “GENERAL CHASSIS” on page 4-1.
b. Disconnect the fuel hose “1” from the injector
fuel rail.
Refer to “REMOVING THE THROTTLE
BODY ASSEMBLY” on page 7-11.
c. Connect the pressure gauge “2” and adapter
“3” to the fuel injector rail and fuel hose.
2
4. Install:
• Fuel hose
• Fuel hose connector holder “1”
• Fuel pump coupler
ECA1XD1053
Pressure gauge
90890-03153
YU-03153
Fuel pressure adapter
90890-03176
YM-03176
NOTICE
When installing 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 installed.
TIP
• 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 injector fuel
rail, slide the fuel hose connector cover “2” on
the end of the hose in direction of the arrow
shown.
2
3
1
d. Start the engine.
e. Measure the fuel pressure.
Out of specification → Replace the fuel
pump.
Fuel line pressure at idling
300–390 kPa (3.0–3.9 kgf/cm²,
42.7–55.5 psi)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-4
AIR FILTER CASE
EAS1XD1007
AIR FILTER CASE
Removing the air filter case and air intake duct
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
.
T.R
1
T.R
.
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
6
New
7
6
T.R
.
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
New
5
8
9
8
.
T.R
2
3
Order
Job/Parts to remove
.
T.R
4
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
Q’ty
Side frames/Front fender/Instrument panel/Side
panels/Center passenger compartment panel/Floor boards
Remarks
Refer to “GENERAL CHASSIS” on page
4-1.
1
Air filter case cover
1
2
Air filter element holder
1
3
Air filter element
1
4
Air filter element frame
1
5
Intake air temperature sensor coupler
1
Disconnect.
6
Air filter case joint clamp screw
2
Loosen.
7
Air filter case joint
1
8
Air intake duct joint clamp screw
2
9
Air intake duct joint
1
7-5
Loosen.
AIR FILTER CASE
Removing the air filter case and air intake duct
12
.
T.R
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
New
T.R
.
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
New
10
11
.
T.R
.
T.R
Order
10
Job/Parts to remove
Q’ty
Intake air temperature sensor
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
Remarks
1
11
Air filter case
1
12
Air intake duct
1
For installation, reverse the removal procedure.
7-6
AIR FILTER CASE
EAS1XD1124
INSTALLING THE AIR FILTER CASE
1. Install:
• Air filter case joint “1”
(to the air filter case)
• Air filter case
TIP
Align the projection “a” on the air filter case joint
with the slot “b” on the air intake silencer “2”.
b
2
a
1
7-7
THROTTLE BODY
EAS26970
THROTTLE BODY
Removing the throttle body
.
T.R
11
3.5 Nm (0.35 m•kgf, 2.5 ft•Ibf)
T.R
1
.
2.8 Nm (0.28 m•kgf, 2.0 ft•Ibf)
.
10
T.R
4
2.8 Nm (0.28 m•kgf, 2.0 ft•Ibf)
8
10
2
New
T.R
.
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
3
7
6
5
LS
9
T.R
.
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
.
T.R
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
Order
Job/Parts to remove
Q’ty
Refer to “GENERAL CHASSIS” on page
4-1.
Frame cross member
1
Remarks
Intake air pressure sensor coupler
1
Disconnect.
2
Throttle position sensor coupler
1
Disconnect.
3
Throttle body breather hose
1
4
Fuel injector coupler
1
Disconnect.
5
ISC unit coupler
1
Disconnect.
6
Throttle cable housing cover
1
7
Throttle cable
1
Disconnect.
8
Fuel hose
1
Disconnect.
9
Cylinder head breather hose
1
10
Air intake silencer joint clamp screw
2
11
Air intake silencer joint
1
7-8
Loosen.
THROTTLE BODY
Removing the throttle body
.
T.R
3.5 Nm (0.35 m•kgf, 2.5 ft•Ibf)
T.R
.
2.8 Nm (0.28 m•kgf, 2.0 ft•Ibf)
T.R
.
2.8 Nm (0.28 m•kgf, 2.0 ft•Ibf)
13
14
12
New
T.R
.
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
12
LS
17
T.R
.
16
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
15
.
T.R
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
Order
Job/Parts to remove
Q’ty
Remarks
12
Throttle body joint clamp screw
2
Loosen.
13
Throttle body assembly
1
14
Throttle body joint
1
15
Air induction system solenoid hose (air intake silencer to air induction system solenoid)
1
Disconnect.
16
Air filter case joint clamp screw
1
Loosen.
17
Air intake silencer
1
For installation, reverse the removal procedure.
7-9
THROTTLE BODY
Disassembling the throttle body assembly
.
T.R
3.6 Nm (0.36 m•kgf, 2.6 ft•Ibf)
1
T.R
.
5 Nm (0.5 m•kgf, 3.6 ft•Ibf)
4
T.R
.
3.5 Nm (0.35 m•kgf, 2.5 ft•Ibf)
New
2
3
5
New
LS
New
6
Order
1
Job/Parts to remove
Q’ty
Intake air pressure sensor
Remarks
1
2
Intake air pressure sensor hose
1
3
Throttle position sensor
1
4
Injector fuel rail
1
5
Fuel injector
1
ECA1XD1043
NOTICE
6
Throttle body
1
The throttle body should not be disassembled.
For assembly, reverse the disassembly procedure.
7-10
THROTTLE BODY
EAS1XD1125
EAS26990
REMOVING THE THROTTLE BODY
ASSEMBLY
1. Disconnect:
• Fuel hose
CHECKING THE THROTTLE BODY
1. Check:
• Throttle body
Cracks/damage → Replace the throttle body.
2. Check:
• Fuel passages
Obstructions → Clean.
EWA15910
WARNING
Cover fuel hose connections with a cloth
when disconnecting them. Residual pressure in the fuel lines could cause fuel to
spurt out when removing the hose.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the throttle body in a petroleum- based
solvent.
Do not use any caustic carburetor cleaning
solution.
b. Blow out all of the passages with compressed
air.
ECA1XD1018
NOTICE
• Be sure to disconnect the fuel hose (injector fuel rail side) 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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21020
CHECKING THE THROTTLE BODY JOINT
1. Check:
• Throttle body joint “1”
Cracks/damage → Replace.
TIP
• To disconnect the fuel hose from the injector
fuel rail, 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.
1
EAS1XD1126
INSTALLING THE THROTTLE BODY
ASSEMBLY
1. Install:
• Throttle body joint “1”
TIP
Align the projection “a” on the cylinder head with
the slot “b” in the throttle body joint.
1
EAS26980
CHECKING THE INJECTOR
1. Check:
• Injector:
Obstruction → Replace and check the fuel
pump/fuel supply system.
Deposit → Replace.
Damage → Replace.
2. Check:
• Injector resistance
Refer to “CHECKING THE FUEL INJECTOR” on page 9-106.
b
2. Install:
• Throttle body joint clamps “1”
7-11
a
THROTTLE BODY
TIP
Align the projections on the throttle body joint
with the gap in each throttle body joint clamp.
1
1
5. Install:
• Air intake silencer “1”
TIP
Align the projection “a” on the air filter case joint
“2” with the slot “b” on the air intake silencer.
3. Install:
• Throttle body assembly “1”
TIP
b
Align the projection “a” on the throttle body assembly between the tabs “b” on the throttle body
joint.
1
a
1
2
b
a
b
6. Install:
• Air intake silencer joint “1”
TIP
Align the projection “a” on the throttle body assembly between the tabs “b” on the air intake silencer joint.
4. Connect:
• Fuel hose
ECA1XD1044
NOTICE
1
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.
b
b
a
TIP
a
• Connect the fuel hose securely onto the injector fuel rail until a distinct “click” in heard.
• To connect the fuel hose onto the injector fuel
rail, slide the fuel hose connector cover “1” on
the end of the hose in direction of the arrow
shown.
EAS27030
ADJUSTING THE THROTTLE POSITION
SENSOR
EWA1XD1003
WARNING
• Handle the throttle position sensor with
special care.
• Never subject the throttle position sensor
to strong shocks. If the throttle position
sensor is dropped, replace it.
7-12
THROTTLE BODY
1. Check:
• Throttle position sensor
Refer to “CHECKING THE THROTTLE POSITION SENSOR” on page 9-104.
2. Adjust:
• Throttle position sensor angle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the test harness- TPS (3P) “1” to the
throttle position sensor and wire harness as
shown.
b. Connect the digital circuit tester (DC 20V) to
the test harness- TPS (3P).
Test harness- TPS (3P)
90890-03204
YU-03204
Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927
• Positive tester probe
yellow (wire harness color)
• Negative tester probe
black/blue (wire harness color)
c. Turn the main switch to “ ” (on).
d. Measure the throttle position sensor voltage.
e. Adjust the throttle position sensor angle so
that the voltage is within the specified range.
Throttle position sensor output
voltage
0.63–0.73 V
f. After adjusting the throttle position sensor angle, tighten the throttle position sensor
screws “2”.
T.
R.
Throttle position sensor screw
3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
2
1
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-13
THROTTLE BODY
7-14
AIR INDUCTION SYSTEM
EAS27040
AIR INDUCTION SYSTEM
2
3
4
1
5
7-15
AIR INDUCTION SYSTEM
1. Air intake silencer
2. Air induction system hose (air intake silencer
to air cut-off valve)
3. Air cut-off valve
4. Air induction system hose (air cut-off valve to
reed valve cover)
5. Reed valve
7-16
AIR INDUCTION SYSTEM
Removing the air cut-off valve
2
1
4
3
Order
Job/Parts to remove
Q’ty
1
Air induction system solenoid coupler
1
2
Air induction system hose (air cut-off valve joint
to reed valve cover)
1
3
Air induction system hose (air intake silencer to
air cut-off valve)
1
4
Air cut-off valve
1
Remarks
Disconnect.
For installation, reverse the removal procedure.
7-17
AIR INDUCTION SYSTEM
Removing the reed valve
3
2
LT
1
LT
.
T.R
Order
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
Job/Parts to remove
Q’ty
Air induction system hose (air cut-off valve to
reed valve cover)
Remarks
Disconnect.
Refer to “Removing the air cut-off valve”.
1
Reed valve cover
1
2
Reed valve assembly
1
3
Reed valve plate
1
For installation, reverse the removal procedure.
7-18
AIR INDUCTION SYSTEM
2. Check:
• Reed valve
• Reed valve stopper
• Reed valve seat
Cracks/damage → Replace the reed valve
assembly.
3. Check:
• Air cut-off valve
Cracks/damage → Replace.
4. Check:
• Air induction system solenoid
Refer to “CHECKING THE AIR INDUCTION
SYSTEM SOLENOID” on page 9-106.
EAS27060
CHECKING THE AIR INDUCTION SYSTEM
Air injection
The air induction system burns unburned exhaust gases by injecting fresh air (secondary air)
into the exhaust port, reducing the emission of
hydrocarbons. When there is negative pressure
at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port.
The required temperature for burning the unburned exhaust gases is approximately 600 to
700 °C (1112 to 1292 °F).
Air cut-off valve
The air cut-off valve is controlled by the signals
from the ECU in accordance with the combustion conditions. Ordinarily, the air cut-off valve
opens to allow the air to flow during idle and
closes to cut-off the flow when the vehicle is being driven. However, if the coolant temperature
is below the specified value, the air cut-off valve
remains open and allows the air to flow into the
exhaust pipe until the temperature becomes
higher than the specified value.
EAS27070
INSTALLING THE AIR INDUCTION SYSTEM
1. Install:
• Reed valve plate “1”
TIP
Align the notch “a” in the reed valve plate with
the projection “b” of the reed valve seat on the
cylinder head.
a
b
A
B
A
B
A. From the air intake silencer
B. To the reed valve
1. Check:
• Hoses
Loose connections → Connect properly.
Cracks/damage → Replace.
7-19
1
DRIVE TRAIN
TROUBLESHOOTING.....................................................................................8-1
CHECKING NOISES ................................................................................. 8-1
TROUBLESHOOTING CHART .................................................................8-2
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES,
DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT .......................... 8-3
DISASSEMBLING THE UNIVERSAL JOINTS.......................................... 8-9
DISASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES ........................................................................................... 8-9
CHECKING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-10
ASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-10
REMOVING THE FRONT DRIVE SHAFT YOKE.................................... 8-11
REMOVING THE DIFFERENTIAL GEAR ASSEMBLY........................... 8-12
CHECKING THE FRONT DRIVE SHAFT ............................................... 8-12
CHECKING THE DIFFERENTIAL ASSEMBLY ...................................... 8-12
CHECKING THE DIFFERENTIAL MOTOR OPERATION ......................8-12
ASSEMBLING THE DIFFERENTIAL ASSEMBLY ..................................8-13
ASSEMBLING THE UNIVERSAL JOINT ................................................ 8-14
MEASURING THE DIFFERENTIAL GEAR BACKLASH......................... 8-15
ADJUSTING THE DIFFERENTIAL GEAR BACKLASH .......................... 8-16
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE
ASSEMBLY AND REAR DRIVE SHAFT .....................................................8-17
DISASSEMBLING THE REAR CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-23
CHECKING THE REAR CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-23
ASSEMBLING THE REAR CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-24
DISASSEMBLING THE FINAL DRIVE PINION GEAR
ASSEMBLY ............................................................................................ 8-25
CHECKING THE REAR DRIVE SHAFT.................................................. 8-25
CHECKING THE FINAL DRIVE ASSEMBLY..........................................8-26
ADJUSTING THE RING GEAR STOPPER............................................. 8-26
MEASURING THE FINAL GEAR BACKLASH ........................................ 8-26
ADJUSTING THE FINAL GEAR BACKLASH .........................................8-27
ASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY............. 8-27
INSTALLING THE FINAL DRIVE ASSEMBLY........................................ 8-28
8
TROUBLESHOOTING
EAS29890
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 wheels.
A. Bearing damage.
B. Improper gear backlash.
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.
TIP
Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite subtle and
difficult to distinguish from normal vehicle operating noise. If there is reason to believe these components are damaged, remove the components and check them.
c. A slight “thunk” evident at low speed operation. This noise must be distinguished from
normal vehicle operation.
Diagnosis: Possible broken gear teeth.
EAS29900
CHECKING NOISES
1. Investigate any unusual noises.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EWA13790
The following “noises” may indicate a mechanical defect:
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.
Refer to “TROUBLESHOOTING CHART” on
page 8-2.
b. A “whining” noise that varies with acceleration and deceleration.
Diagnosis: Possible incorrect reassembly,
too little gear backlash.
Refer to “MEASURING THE DIFFERENTIAL
GEAR BACKLASH” on page 8-15 or “MEASURING THE FINAL GEAR BACKLASH” on
page 8-26.
WARNING
Stop riding immediately if broken gear teeth
are suspected. This condition could result in
the shaft drive assembly locking up, causing
a loss of control and possible injury to the
rider.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Drained oil
Drained oil shows large amounts of metal
particles → Check the bearing for seizure.
TIP
A small amount of metal particles in the oil is normal.
3. Check:
• Oil leakage
EWA13780
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
WARNING
a. Clean the entire vehicle thoroughly, then dry
it.
b. Apply a leak detection 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.
Insufficient gear backlash is extremely destructive to the gear teeth. If a test ride, following reassembly, indicates these
symptoms, stop riding immediately to minimize gear damage.
8-1
TROUBLESHOOTING
• Always clean the vehicle and recheck the suspected location of an apparent leakage.
TIP
• An apparent oil leak on a new or nearly new vehicle may be the result of a rust-preventative
coating or excessive seal lubrication.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS29910
TROUBLESHOOTING CHART
When basic conditions (a) and (b) described in “CHECKING NOISES” exist, check the following points:
YES →
Replace the wheel bearing. (Refer to
“STEERING KNUCKLES” on page 4-56
and “REAR KNUCKLES AND STABILIZER” on page 4-64.)
NO →
Torque to specification. (Refer to “FRONT
AND REAR WHEELS” on page 4-25.
NO →
Constant velocity shaft bearings and differential bearings are probably not damaged.
Repeat the test or remove the individual
components.
NO →
Adjust per instructions. (Refer to “ADJUSTING THE PARKING BRAKE LEVER”
on page 3-20.)
NO →
Constant velocity shaft bearings and final
gear bearings are probably not damaged.
Repeat the test or remove the individual
components.
1. Elevate and spin both wheels. Feel
for wheel bearing damage.
NO ↓
2. Check the wheel nuts and axle nuts
for tightness.
YES ↓
3. Check the front constant velocity
shaft assemblies. Feel for bearing
damage.
YES ↓
4. Check the parking brake adjustment.
YES ↓
5. Check the rear constant velocity
shaft assemblies. Feel for bearing
damage.
YES ↓
Remove the shaft drive components.
8-2
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
EAS1XD1132
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL
ASSEMBLY AND FRONT DRIVE SHAFT
Removing the front constant velocity shaft assemblies, differential assembly, and front drive shaft
.
T.R
.
T.R
18 Nm (1.8 m•kgf, 13 ft•Ibf)
60 Nm (6.0 m•kgf, 43 ft•Ibf)
.
T.R
150 Nm (15 m•kgf, 108 ft•lbf)
.
T.R
105 Nm (10.5 m•kgf, 76 ft•lbf)
LS
2
New
LS
New
1
New
LT
New
LS
LS
New
New
LS
LS
1
LS
4
New
3
LS
.
T.R
Order
Job/Parts to remove
60 Nm (6.0 m•kgf, 43 ft•Ibf)
Q’ty
Remarks
Sun top/Side frames/Front fender/Front
guard/Instrument panel/Center passenger compartment panel/Center floor board/Front skid
plate
Refer to “GENERAL CHASSIS” on page
4-1.
Air filter case
Refer to “AIR FILTER CASE” on page 7-5.
Steering knuckles
Refer to “STEERING KNUCKLES” on page
4-56.
Differential gear oil
Drain.
Refer to “CHANGING THE DIFFERENTIAL
GEAR OIL” on page 3-16.
1
Front constant velocity shaft assembly
2
2
Differential motor coupler
1
Disconnect.
3
Differential assembly breather hose
1
Disconnect.
4
Differential assembly
1
8-3
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
Removing the front constant velocity shaft assemblies, differential assembly, and front drive shaft
.
T.R
.
T.R
18 Nm (1.8 m•kgf, 13 ft•Ibf)
60 Nm (6.0 m•kgf, 43 ft•Ibf)
.
T.R
150 Nm (15 m•kgf, 108 ft•lbf)
.
T.R
105 Nm (10.5 m•kgf, 76 ft•lbf)
LS
New
9
LS
New
5
8
New
LT
New
6
LS
7
LS
9
8
LS
New
New
LS
10
New
LS
12 11
New 13
New 15
14 New
LS
.
T.R
Order
Job/Parts to remove
Q’ty
5
Support bearing bracket
1
6
Front drive shaft (differential side)
1
7
Dust seal
1
8
Universal joint
2
9
Universal joint yoke
2
10
Front drive shaft (middle gear side)
1
11
Support bearing housing
1
12
Support bearing rubber
1
13
Oil seal
1
14
Oil seal
1
15
Bearing
1
60 Nm (6.0 m•kgf, 43 ft•Ibf)
Remarks
For installation, reverse the removal procedure.
8-4
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
Disassembling the front constant velocity shaft assemblies
5
6 New
7
4 New
New 2
3
New 1
New 8
New 9
Order
Job/Parts to remove
Q’ty
Remarks
The following procedure applies to both of
the front constant velocity shaft assemblies.
1
Boot band
1
2
Boot band
1
3
Dust boot
1
4
Clip
1
5
Double offset joint
1
6
Circlip
1
7
Ball bearing
1
8
Boot band
1
9
Boot band
1
8-5
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
Disassembling the front constant velocity shaft assemblies
13
12 New
10
Order
10
Job/Parts to remove
Q’ty
Dust boot
1
11
Constant velocity joint
1
12
Clip
1
13
Constant velocity shaft
1
11
Remarks
For assembly, reverse the disassembly procedure.
A: Wheel side
B: Differential side
8-6
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
Disassembling the differential assembly
1
T.R
New
.
11 Nm (1.1 m•kgf, 8.0 ft•Ibf)
LS
T.R
.
62 Nm (6.2 m•kgf, 45 ft•Ibf)
LS
New
2
LS
5
3
New
10
*
LS
7
8
*
(3)
.
9
T.R
6
New
24 Nm (2.4 m•kgf, 17 ft•Ibf)
LS
New
T.R
.
4
New
T.R
.
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
Order
23 Nm (2.3 m•kgf, 17 ft•Ibf)
Job/Parts to remove
Q’ty
24 Nm (2.4 m•kgf, 17 ft•Ibf)
Remarks
ECA1XD1002
NOTICE
1
Differential motor
1
2
Front drive shaft yoke nut (differential case side)
1
3
Front drive shaft yoke (differential case side)
1
4
Bracket
1
5
Differential case cover
1
6
Differential gear assembly
1
7
Differential gear assembly shim
8
Bearing
1
9
Bearing
1
10
Oil seal
1
Do not disassemble the differential motor
or remove the differential motor pinion
gear.
Refer to “ADJUSTING THE DIFFERENTIAL GEAR BACKLASH” on page 8-16.
8-7
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
Disassembling the differential assembly
T.R
New
15
.
11 Nm (1.1 m•kgf, 8.0 ft•Ibf)
LS
T.R
62 Nm (6.2 m•kgf, 45 ft•Ibf)
.
LS
New
LS
New
11
13
*
12
14
16
LS
*
.
15
T.R
(3)
New
24 Nm (2.4 m•kgf, 17 ft•Ibf)
LS
New
T.R
.
23 Nm (2.3 m•kgf, 17 ft•Ibf)
New
T.R
Order
.
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
Job/Parts to remove
Q’ty
11
Clip
1
12
Differential pinion gear
1
13
Bearing
1
14
Bearing
1
15
Oil seal
2
16
Differential case
1
24 Nm (2.4 m•kgf, 17 ft•Ibf)
Remarks
For assembly, reverse the disassembly procedure.
* SAE 80 API GL-4 Hypoid gear oil
8-8
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
EAS1XD1036
A
DISASSEMBLING THE UNIVERSAL JOINTS
1. Remove:
• Universal joint
5
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the circlips “1”
b. Place the universal joint in a press.
c. With a suitable diameter pipe “2” beneath the
universal joint yoke “3”, press the bearing “4”
into the pipe as shown.
2
1
TIP
A
4
It may be necessary to lightly tap the universal
joint yoke with a punch.
3
A. Differential side
2. Remove:
• Boot band “1”
TIP
Use the boot band installation tool “2”.
Boots band installation tool
90890-01526
YM-01526
B
d. Repeat the steps for the opposite bearing.
e. Remove the universal joint.
2
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS29930
DISASSEMBLING THE FRONT CONSTANT
VELOCITY SHAFT ASSEMBLIES
The following procedure applies to both of the
front constant velocity shaft assemblies.
1. Remove:
• Boot bands
• Clip “1”
• Double offset joint “2”
• Circlip “3”
• Ball bearing “4”
• Dust boot “5”
B. Wheel side
3. Remove:
• Dust boot
• Constant velocity joint
• Clip
TIP
Secure the constant velocity shaft in a vise, and
then remove the constant velocity joint using
hammers.
TIP
Before removing the clip, slide the dust boot
away from the double offset joint.
8-9
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
B
A
New 1
3
A
B. Wheel side
3
EAS29960
CHECKING THE FRONT CONSTANT
VELOCITY SHAFT ASSEMBLIES
The following procedure applies to both of the
front constant velocity shaft assemblies.
1. Check:
• Double offset joint splines
• Constant velocity joint splines
• Constant velocity shaft splines
Wear/damage → Replace.
2. Check:
• Dust boots
Cracks/damage → Replace.
New 1
2
A
ECA1XD1006
NOTICE
Always use new boot bands.
3. Check:
• Balls and ball races
• Inner surface of double offset joint
Pitting/wear/damage → Replace.
A. Wheel side
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
• Dust boot
• Ball bearing “1”
EAS29990
ASSEMBLING THE FRONT CONSTANT
VELOCITY SHAFT ASSEMBLIES
The following procedure applies to both of the
front constant velocity shaft assemblies.
1. Install:
• Clip “1” New
• Constant velocity joint “2”
• Constant velocity shaft “3”
• Dust boot
• Circlip “2” New
• Double offset joint “3”
• Clip “4” New
TIP
• Securely install the circlip into the groove in the
constant velocity shaft.
• Securely install the clip into the groove in the
double offset joint.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a new clip.
b. Install the constant velocity joint.
TIP
• Install the clip into the groove in the constant
velocity shaft as shown.
• Secure the constant velocity joint in a vise, and
then fit the constant velocity shaft into the constant velocity joint using a plastic hammer.
8-10
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
B
a. Install the dust boots.
b. Install the dust boot bands “4” and “5”.
1
TIP
2 New
Use the boot band installation tool “6”.
Boots band installation tool
90890-01526
YM-01526
B
6
4
3
4 New
B. Differential side
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Apply:
• Molybdenum disulfide grease
(into the double offset joint, constant velocity
joint, and dust boots)
5. Check:
• Thrust movement free play
Excessive play → Replace the constant velocity shaft assembly.
Molybdenum disulfide grease
60–80 g (2.1–2.8 oz) per dust
boot (wheel side)
35–55 g (1.2–1.9 oz) per dust
boot (differential side)
TIP
Molybdenum disulfide grease is included in the
repair kit.
4. Install:
• Dust boots “1”
EAS1XD1035
REMOVING THE FRONT DRIVE SHAFT
YOKE
1. Remove:
• Front drive shaft yoke
• Boot bands “2”, “3”, “4”, “5” New
TIP
The dust boots should be fastened with the boot
bands “3” and “5” at the grooves in the constant
velocity shaft.
TIP
Use the universal joint holder “1” to hold the front
drive shaft yoke, then loosen the front drive shaft
yoke nut.
Universal joint holder
90890-04062
YM-04062
8-11
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
EAS1XD1047
CHECKING THE DIFFERENTIAL ASSEMBLY
1. Check:
• Differential case
• Differential case cover
Cracks/damage → Replace.
TIP
When the differential case and/or the differential
case cover are replaced, be sure to adjust the
shim of the differential gear assembly.
1
2. Check:
• Gear teeth
Pitting/galling/wear → Replace.
EAS1XD1046
REMOVING THE DIFFERENTIAL GEAR
ASSEMBLY
1. Remove:
• Differential gear assembly “1”
TIP
When the differential pinion gear and/or the differential assembly are replaced, be sure to adjust the shim of the differential gear assembly.
ECA1XD1003
NOTICE
The differential gear assembly is 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.
3. Check:
• Bearings
Damage → Replace.
EAS1XD1038
CHECKING THE DIFFERENTIAL MOTOR
OPERATION
1. Check:
• Differential motor operation
Does not operate → Replace.
1
ECA1XD1045
NOTICE
Do not disassemble the differential motor or
remove the differential motor pinion gear.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect two C-size batteries to the differential motor terminals “1” (as shown in the illustrations).
EAS1XD1127
CHECKING THE FRONT DRIVE SHAFT
1. Check:
• Drive shaft splines
• Coupling sleeve splines
Wear/damage → Replace.
ECA1XD1046
NOTICE
• Do not use a 12 V battery to operate the differential motor pinion gear.
• Do not connect the batteries to the differential motor when it is installed in the differential case.
• The differential motor should be checked
when it is removed from the differential
case.
EWA15060
WARNING
Do not attempt to straighten a bent shaft;
this may dangerously weaken it.
2. Check:
• Support bearing
Damage → Replace.
3. Check:
• Support bearing housing
• Support bearing rubber
Cracks/damage → Replace.
8-12
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
A
3V
3
1
a
2
2
B
3V
3. Differential case
4. Differential case cover
2. Measure:
• Gear backlash
Refer to “MEASURING THE DIFFERENTIAL
GEAR BACKLASH” on page 8-15.
3. Install:
• Differential motor
2
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
A. Check that the differential motor pinion gear
“2” turns counterclockwise.
B. Check that the differential motor pinion gear
“2” turns clockwise.
a. Slide the shift fork sliding gear “1”, which is installed to the differential case cover, to the
right front constant velocity shaft assembly
side as shown in the illustration to put it into
the 2WD mode.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1XD1039
ASSEMBLING THE DIFFERENTIAL
ASSEMBLY
1. Install:
• Oil seals “1”
• Oil seal “2”
1
Installed depth of oil seal “a”
-0.5–0.5 mm (-0.020–0.020 in)
3
a
a
b. Connect two C-size batteries to the differential motor terminal “2” to operate the differential motor pinion gear “3”. Operate the
differential motor pinion gear until the mark
“a” on the differential motor pinion gear is
aligned with the mark “b” on the differential
motor case.
4
ECA1XD1013
1
NOTICE
1
Do not use a 12 V battery to operate the differential motor pinion gear.
8-13
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
2
b
a
3
3V
5. Install:
• Front drive shaft yoke
• Washer
• Front drive shaft yoke nut
c. Insert 6 mm bolts “4” into the differential motor “5” and use them as a guide to set the motor on the differential case cover “6” so that
the shift fork sliding gear “7” does not move.
ECA1XD1047
NOTICE
R.
4
T.
If the position of the shift fork sliding gear is
moved, the position of the differential gear
assembly and the indicator light display may
differ, and the 2WD or differential lock mode
may not be activated.
Front drive shaft yoke nut
62 Nm (6.2 m·kgf, 45 ft·lbf)
TIP
• Apply locking agent (LOCTITE®) to the nut
threads.
• Use the universal joint holder “1” to hold the
front drive shaft yoke, then tighten the front
drive shaft yoke nut.
5
4
4
7
Universal joint holder
90890-04062
YM-04062
6
d. Remove the 6 mm bolts, and then install the
motor with the differential motor bolts.
T.
R.
Differential motor bolt
11 Nm (1.1 m·kgf, 8.0 ft·lbf)
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Differential assembly operation
Unsmooth operation → Replace the differential assembly.
Insert the double offset joint into the differential assembly, and turn the gears back and
forth.
EAS1XD1010
ASSEMBLING THE UNIVERSAL JOINT
1. Install:
• Universal joint
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the universal joint into the front drive
shaft yoke.
8-14
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
EAS1XD1040
MEASURING THE DIFFERENTIAL GEAR
BACKLASH
1. Secure the differential case in a vise or another supporting device.
2. Remove:
• Drain plug
• Gasket
3. Install:
• Ring gear fix bolt (M10) “1”
(into the drain plug hole)
b. Apply lithium-soap-based grease to the bearings.
c. Install the bearing “1” onto the front drive
shaft yoke.
Ring gear fix bolt (M10)
90890-01527
YM-01527
ECA1XD1015
NOTICE
ECA16250
NOTICE
Check each bearing. The needles can easily
fall out of their races. Slide the universal joint
back and forth on the bearings; the universal
joint will not go all the way onto a bearing if
a needle is out of place.
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
1
3
d. Press each bearing into the front drive shaft
yoke using a suitable socket.
2
TIP
The bearing must be inserted far enough into the
universal joint yoke and front drive shaft yoke so
that the circlip can be installed.
a
e. Install new circlips “2” into the groove of each
bearing.
a. Measuring point is 31.0 mm (1.22 in)
5. Measure:
• Gear backlash
Gently rotate the differential pinion gear from
engagement to engagement.
Differential gear backlash
0.05–0.25 mm (0.002–0.0010 in)
TIP
Measure the gear backlash at four positions. Rotate the differential pinion gear 90° each time.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-15
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT
EAS1XD1034
ADJUSTING THE DIFFERENTIAL GEAR
BACKLASH
1. Remove:
• Differential gear assembly shim(s) “1”
• Differential gear assembly “2”
1
2
2. Adjust:
• Gear backlash
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Select the suitable shims using the following
chart.
Differential gear backlash is
Thinner shim
increased.
Thicker shim
Differential gear backlash is
decreased.
Differential gear assembly shims
Thickness (mm)
0.1 0.2 0.3 0.4
b. Measure the differential gear backlash again.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-16
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
EAS1XD1024
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE
ASSEMBLY AND REAR DRIVE SHAFT
Removing the rear constant velocity shaft assemblies, final drive assembly, and rear drive shaft
T.R
.
105 Nm (10.5 m•kgf, 76 ft•lbf)
1
New
New
2
5
LS
(4)
LS
4
T.R
.
33 Nm (3.3 m•kgf, 24 ft•Ibf)
LS
3
T.R
.
33 Nm (3.3 m•kgf, 24 ft•Ibf)
New
1
T.R
.
Order
Job/Parts to remove
105 Nm (10.5 m•kgf, 76 ft•lbf)
Q’ty
Remarks
Rear skid plate
Refer to“GENERAL CHASSIS” on page 4-1.
Rear knuckles
Refer to “REAR KNUCKLES AND STABILIZER” on page 4-64.
Parking brake caliper
Refer to “PARKING BRAKE” on page 4-42.
Muffler
Refer to“ENGINE REMOVAL” on page 5-1.
Final gear oil
Drain.
Refer to “CHANGING THE FINAL GEAR
OIL” on page 3-15.
1
Rear constant velocity shaft assembly
2
2
Final drive assembly breather hose
1
3
Final drive assembly bracket (upper side)
1
4
Final drive assembly
1
5
Spring
1
8-17
Disconnect.
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
Removing the rear constant velocity shaft assemblies, final drive assembly, and rear drive shaft
T.R
.
105 Nm (10.5 m•kgf, 76 ft•lbf)
New
New
6
10
9
8 7
(4)
LS
LS
T.R
.
33 Nm (3.3 m•kgf, 24 ft•Ibf)
LS
T.R
.
33 Nm (3.3 m•kgf, 24 ft•Ibf)
11
New
T.R
.
Order
Job/Parts to remove
Q’ty
6
Rear drive shaft
7
Damper
1
8
Rear drive shaft coupling sleeve
1
9
Dust seal
1
10
Dust seal
1
11
Final drive assembly bracket (lower side)
1
105 Nm (10.5 m•kgf, 76 ft•lbf)
Remarks
1
For installation, reverse the removal procedure.
8-18
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
Disassembling the rear constant velocity shaft assemblies
5
6 New
7
4 New
New 2
3
New 1
12 New
New 8
10
11
New 9
Order
Job/Parts to remove
Q’ty
Remarks
The following procedure applies to both of
the rear constant velocity shaft assemblies.
1
Boot band
1
2
Boot band
1
3
Dust boot
1
4
Clip
1
5
Double offset joint
1
6
Circlip
1
7
Ball bearing
1
8
Boot band
1
9
Boot band
1
10
Dust boot
1
11
Constant velocity joint
1
12
Clip
1
8-19
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
Disassembling the rear constant velocity shaft assemblies
13
Order
13
Job/Parts to remove
Q’ty
Constant velocity shaft
Remarks
1
For assembly, reverse the disassembly procedure.
A: Wheel side
B: Final drive side
8-20
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
Disassembling the final drive assembly
T.R
.
23 Nm (2.3 m•kgf, 17 ft•Ibf)
New
LS
*
New
*
13
1
3
11 New
10
5
New 12
New
LS
8
New 6
LS
7
2
4
9
New
T.R
*
.
52 Nm (5.2 m•kgf, 38 ft•Ibf)
LT
.
T.R
LS
.
T.R
T.R
.
Order
16 Nm (1.6 m•kgf, 12 ft•Ibf)
(4)
LT
(8)
26 Nm (2.6 m•kgf, 19 ft•Ibf)
97 Nm (9.7 m•kgf, 70 ft•Ibf)
Job/Parts to remove
Q’ty
Parking brake disc
Remarks
Refer to “PARKING BRAKE” on page 4-42.
1
Final drive pinion gear assembly
1
2
Rear drive shaft yoke (final drive assembly side)
1
3
Final drive pinion gear
1
4
Final drive pinion gear shim
5
Collar
1
6
Oil seal
1
7
Bearing
1
8
Final drive pinion gear bearing housing
1
9
Ring gear stopper
1
10
Final drive case cover
1
11
Final drive case cover gasket
1
12
Oil seal
1
13
Final drive ring gear
1
8-21
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
Disassembling the final drive assembly
T.R
.
23 Nm (2.3 m•kgf, 17 ft•Ibf)
New
20
New 21
LS
19
New
*
*
15
17
18
16
14
19
New
LS
LS
New
T.R
*
.
52 Nm (5.2 m•kgf, 38 ft•Ibf)
.
T.R
16 Nm (1.6 m•kgf, 12 ft•Ibf)
(4)
LT
(8)
LT
LS
.
T.R
26 Nm (2.6 m•kgf, 19 ft•Ibf)
T.R
.
97 Nm (9.7 m•kgf, 70 ft•Ibf)
Order
Job/Parts to remove
Q’ty
14
Final drive ring gear shim (final drive case cover
side)
15
Final drive ring gear shim (final drive case side)
16
Bearing
1
17
Bearing
1
18
Bearing
1
19
Dowel pin
2
20
Final drive case
1
21
Oil seal
1
Remarks
For assembly, reverse the disassembly procedure.
* SAE 80 API GL-4 Hypoid gear oil
8-22
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
EAS30060
B
DISASSEMBLING THE REAR CONSTANT
VELOCITY SHAFT ASSEMBLIES
The following procedure applies to both of the
rear constant velocity shaft assemblies.
1. Remove:
• Boot bands
• Clip “1”
• Double offset joint “2”
• Circlip “3”
• Ball bearing “4”
• Dust boot “5”
2
1
B. Wheel side
3. Remove:
• Dust boot
• Constant velocity joint
• Clip
TIP
Before removing the clip, slide the dust boot
away from the double offset joint.
A
TIP
5
Secure the constant velocity shaft in a vise, and
then remove the constant velocity joint using
hammers.
2
B
1
A
4
3
B. Wheel side
EAS30330
CHECKING THE REAR CONSTANT
VELOCITY SHAFT ASSEMBLIES
The following procedure applies to both of the
rear constant velocity shaft assemblies.
1. Check:
• Double offset joint splines
• Constant velocity joint splines
• Constant velocity shaft splines
Wear/damage → Replace.
2. Check:
• Dust boots
Cracks/damage → Replace.
A. Final drive side
2. Remove:
• Boot bands “1”
Use the boot band installation tool “2”.
Boots band installation tool
90890-01526
YM-01526
ECA1XD1006
NOTICE
Always use new boot bands.
3. Check:
• Balls and ball races
• Inner surface of double offset joint
Pitting/wear/damage → Replace.
8-23
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
• Ball bearing “1”
EAS30070
ASSEMBLING THE REAR CONSTANT
VELOCITY SHAFT ASSEMBLIES
The following procedure applies to both of the
rear constant velocity shaft assemblies.
1. Install:
• Circlip “2” New
• Double offset joint “3”
• Clip “4” New
TIP
• Clip “1” New
• Constant velocity joint “2”
• Constant velocity shaft “3”
• Dust boot
• Securely install the circlip into the groove in the
constant velocity shaft.
• Securely install the clip into the groove in the
double offset joint.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the clip.
b. Install the constant velocity joint.
B
1
TIP
• Install the clip into the groove in the constant
velocity shaft as shown.
• Secure the constant velocity joint in a vise, and
then fit the constant velocity shaft into the constant velocity joint using a plastic hammer.
2 New
A
B
New 1
3
3
4 New
A
3
B. Final drive side
3. Apply:
• Molybdenum disulfide grease
(into the double offset joint, constant velocity
joint, and dust boots)
New 1
Molybdenum disulfide grease
60–80 g (2.1–2.8 oz) per dust
boot (wheel side)
55–75 g (1.9–2.6 oz) per dust
boot (final drive side)
2
A
TIP
Molybdenum disulfide grease is included in the
repair kit.
4. Install:
• Dust boots “1”
• Boot bands “2”, “3”, “4”, “5” New
A. Wheel side
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
• Dust boot
8-24
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
• Washer
• Rear drive shaft yoke “1”
TIP
The dust boots should be fastened with the boot
bands “3” and “5” at the grooves in the constant
velocity shaft.
TIP
• Secure the final drive assembly in a vise.
• Use the coupling gear holding tool (35) “2” to
hold the rear drive shaft yoke.
Coupling gear holding tool (35)
90890-01571
YM-01571
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the dust boots.
b. Install the dust boot bands “4” and “5”.
Use the boot band installation tool “6”.
2
Boots band installation tool
90890-01526
YM-01526
1
2. Remove:
• Final drive pinion gear “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside surface of the final drive
pinion gear.
b. Place the final drive gear in a hydraulic press.
6
ECA1XD1005
4
NOTICE
• Never directly press the gear end with a hydraulic press, this will result in damage to
the gear thread.
• Install a suitable socket “2” on the gear end
to protect the thread from damage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Check:
• Thrust movement free play
Excessive play → Replace the constant velocity shaft assembly.
c. Press the gear end and remove the final drive
pinion gear.
2
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30150
CHECKING THE REAR DRIVE SHAFT
1. Check:
• Drive shaft splines
• Coupling sleeve splines
Wear/damage → Replace.
EAS1XD1043
DISASSEMBLING THE FINAL DRIVE PINION
GEAR ASSEMBLY
1. Remove:
• Rear drive shaft yoke nut
8-25
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
b. Turn the ring gear stopper 120° counterclockwise.
EWA15060
WARNING
Do not attempt to straighten a bent shaft;
this may dangerously weaken it.
EAS1XD1044
CHECKING THE FINAL DRIVE ASSEMBLY
1. Check:
• Final drive case
• Final drive case cover
Cracks/damage → Replace.
TIP
When the final drive case and/or the final drive
case cover are replaced, be sure to adjust the
shim of the final drive pinion gear and/or ring
gear.
c. Tighten the ring gear stopper nut “3”.
T.
R.
2. Check:
• Gear teeth
Pitting/galling/wear → Replace the final drive
pinion gear and ring gear as a set.
Ring gear stopper nut
16 Nm (1.6 m·kgf, 12 ft·lbf)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1XD1033
MEASURING THE FINAL GEAR BACKLASH
1. Remove:
• Filler plug
• Gasket
2. Install:
• Ring gear fix bolt (M10 × 1.5) “1”
(into the drain plug hole)
TIP
When the final drive pinion gear and ring gear
are replaced, be sure to adjust the shim of the final drive pinion gear and/or ring gear.
3. Check:
• Bearings
Damage → Replace.
Ring gear fix bolt (M10 x 1.5)
90890-01572
YM-01572
EAS1XD1011
ADJUSTING THE RING GEAR STOPPER
1. Install:
• Ring gear stopper “1”
• Nut
EAS1XD1012
NOTICE
Finger tighten the bolt until if holds the ring
gear. Otherwise, the ring gear will be damaged.
TIP
• Apply Yamaha bond No.1215 to the ring gear
stopper threads.
• Apply LOCTITE® to the nut threads.
2. Adjust:
• Ring gear stopper clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Finger tighten the ring gear stopper until it
contacts the ring gear “2”.
1
2
3. Attach:
• Gear lash measurement tool “1”
• Dial gauge “2”
1
Gear lash measurement tool
90890-01467
YM-01467
3
8-26
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
Reduce the final drive ring gear shim (final
drive case cover side) “4” thickness by 0.2
mm (0.008 in) for every 0.2 mm (0.008 in) that
the final drive ring gear shim (final drive case
side) “2” and thrust washer “3” are increased.
c. If reduced by more than 0.2 mm (0.008 in):
Increase the final drive ring gear shim (final
drive case cover side) “4” thickness by 0.2
mm (0.008 in) for every 0.2 mm (0.008 in) that
the final drive ring gear shim (final drive case
side) “2” and thrust washer “3” are decreased.
2
1
a
a. Measuring point is 31.5 mm (1.24 in)
4. Measure:
• Gear backlash
Gently rotate the final drive pinion gear from
engagement to engagement.
Final gear backlash
0.13–0.23 mm (0.005–0.009 in)
Final drive ring gear shims (final
drive case cover side) “3”
Thickness (mm)
0.2 0.3
TIP
Be sure to use one of each of the final drive ring
gear shim (final drive case cover side) “3” and final drive ring gear shim (final drive case side) “4”
to obtain the shim thickness.
TIP
Measure the gear backlash at four positions. Rotate the final drive pinion gear 90° each time.
EAS30180
Final drive ring gear shims (final
drive case side) “4”
Thickness (mm)
0.2 0.3
ADJUSTING THE FINAL GEAR BACKLASH
1. Remove:
• Final drive ring gear “1”
• Bearings “2”
• Final drive ring gear shim (final drive case
cover side) “3”
• Final drive ring gear shim (final drive case
side) “4”
4
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1XD1130
ASSEMBLING THE FINAL DRIVE PINION
GEAR ASSEMBLY
1. Apply:
• Sealant
(onto the washer contact surface and splines
of the final drive pinion gear)
2
1
2
3
Yamaha bond No. 1215
90890-85505
(Three Bond No.1215®)
2. Adjust:
• Gear backlash
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Select a suitable shim(s) using the following
chart.
Final gear backlash is inThinner shim
creased.
Thicker shim
Final gear backlash is decreased.
b. If increased by more than 0.2 mm (0.008 in):
8-27
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
2. Install:
• Rear drive shaft yoke (final drive case side)
“1”
TIP
Tighten the bolts and nuts to specification in the
proper tightening sequence shown.
T.
R.
Rear drive shaft yoke nut (final
drive assembly side)
97 Nm (9.7 m·kgf, 70 ft·lbf)
LOCTITE®
6
3
3
1
5
4
7
9 8
TIP
• Secure the rear differential assembly in a vise.
• Use the coupling gear holding tool (35) “2” to
hold the rear drive shaft yoke.
FWD
1
2
2
Coupling gear holding tool (35)
90890-01571
YM-01571
2
1
EAS1XD1045
INSTALLING THE FINAL DRIVE ASSEMBLY
1. Install
• Final drive assembly bracket (upper side) “1”
T.
R.
Final drive assembly bracket (upper side) bolt
33 Nm (3.3 m·kgf, 24 ft·lbf)
• Final drive assembly “2”
T.
R.
Final drive assembly nut (upper
side)
105 Nm (10.5 m·kgf, 76 ft·lbf)
• Final drive assembly bracket (lower side) “3”
T.
R.
Final drive assembly bolt (lower
side)
105 Nm (10.5 m·kgf, 76 ft·lbf)
T.
R.
Final drive assembly bracket bolt
(lower side)
33 Nm (3.3 m·kgf, 24 ft·lbf)
8-28
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
8-29
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 9-1
CIRCUIT DIAGRAM .................................................................................. 9-1
TROUBLESHOOTING ..............................................................................9-3
ELECTRIC STARTING SYSTEM .................................................................... 9-5
CIRCUIT DIAGRAM .................................................................................. 9-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......................... 9-7
TROUBLESHOOTING ..............................................................................9-9
CHARGING SYSTEM....................................................................................9-11
CIRCUIT DIAGRAM ................................................................................ 9-11
TROUBLESHOOTING ............................................................................9-13
LIGHTING SYSTEM ......................................................................................9-15
CIRCUIT DIAGRAM ................................................................................ 9-15
TROUBLESHOOTING ............................................................................9-17
SIGNALING SYSTEM ...................................................................................9-19
CIRCUIT DIAGRAM (for CDN)................................................................9-19
CIRCUIT DIAGRAM (for Europe and Oceania)....................................... 9-21
TROUBLESHOOTING ............................................................................9-23
COOLING SYSTEM....................................................................................... 9-29
CIRCUIT DIAGRAM ................................................................................ 9-29
TROUBLESHOOTING ............................................................................9-31
FUEL INJECTION SYSTEM..........................................................................9-33
CIRCUIT DIAGRAM ................................................................................ 9-33
ECU SELF-DIAGNOSTIC FUNCTION....................................................9-35
TROUBLESHOOTING METHOD............................................................ 9-36
YAMAHA DIAGNOSTIC TOOL ...............................................................9-37
TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM) ............9-38
FUEL PUMP SYSTEM...................................................................................9-63
CIRCUIT DIAGRAM ................................................................................ 9-63
TROUBLESHOOTING ............................................................................9-65
2WD/4WD SELECTING SYSTEM.................................................................9-67
CIRCUIT DIAGRAM ................................................................................ 9-67
TROUBLESHOOTING ............................................................................9-69
9
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)...........9-71
CIRCUIT DIAGRAM ................................................................................ 9-71
EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION .....................9-73
EPS WARNING LIGHT DURING NORMAL OPERATION......................9-73
DIAGNOSTIC MODE .............................................................................. 9-74
SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)......................9-76
TROUBLESHOOTING DETAILS (EPS SYSTEM) ..................................9-77
ELECTRICAL COMPONENTS...................................................................... 9-81
CHECKING THE SWITCHES .................................................................9-87
CHECKING THE BULBS AND BULB SOCKETS ................................... 9-90
REPLACING THE HEADLIGHT BULBS ................................................. 9-91
ADJUSTING THE HEADLIGHT BEAMS................................................. 9-92
CHECKING THE FUSES ........................................................................9-92
CHECKING AND CHARGING THE BATTERY....................................... 9-93
CHECKING THE RELAYS ...................................................................... 9-95
CHECKING THE SPARK PLUG CAP .....................................................9-98
CHECKING THE IGNITION COIL ........................................................... 9-98
CHECKING THE IGNITION SPARK GAP............................................... 9-99
CHECKING THE CRANKSHAFT POSITION SENSOR.......................... 9-99
CHECKING THE LEAN ANGLE SENSOR............................................9-100
CHECKING THE STARTER MOTOR OPERATION .............................9-100
CHECKING THE STATOR COIL ..........................................................9-101
CHECKING THE RECTIFIER/REGULATOR ........................................9-101
CHECKING THE FUEL SENDER .........................................................9-101
CHECKING THE FUEL METER/FUEL LEVEL WARNING
LIGHT ...................................................................................................9-102
CHECKING THE SPEED SENSOR ......................................................9-102
CHECKING THE RADIATOR FAN MOTOR .........................................9-103
CHECKING THE RADIATOR FAN MOTOR CIRCUIT
BREAKER ............................................................................................9-103
CHECKING THE COOLANT TEMPERATURE SENSOR.....................9-103
CHECKING THE THROTTLE POSITION SENSOR .............................9-104
CHECKING THE INTAKE AIR PRESSURE SENSOR .........................9-105
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ..................9-105
CHECKING THE FUEL INJECTOR ......................................................9-106
CHECKING THE AIR INDUCTION SYSTEM SOLENOID ....................9-106
CHECKING THE DIFFERENTIAL MOTOR POSITION
SWITCH ...............................................................................................9-106
CHECKING THE EPS MOTOR (for EPS models) ................................9-107
CHECKING THE EPS TORQUE SENSOR (for EPS models) ..............9-107
9-1
L
B
R/L
B
64
L
R/W
B
(Gy)
W
(Gy)
W W
65
R/L
Y/R
Br/R
R
R/W
Y/R
B R/W
Br/R
R/L
R
66
(Gy)
W
(Gy)
W W
Gy
B/L Gy
1
Br/L
B
4
R
B
B/L
Br/R
2
Gy
B
R
Br/R
R/B
Br/L
Br/L
Br/R
R
W W
W W
W W
(Gy)
W W W
B
3
R
BB B
R
(B)
5
R/B Br/R
B
Br/Y
57
58
59
60
63
62
61
(B)
L/Y Br/R
R
Br/L
R
R/W
Br/Y
Br/Y
Br
W/B
Br/R R/B Br/R L/Y
(off)
(on)
(start)
6
B
Br/Y B
B
B
Y L
56
8
B
Y
55
9
56
Y LL
(B)
Br Y
(B)
7
B A B
R
Y Br/Y
R
R
(B)
R
Y
Br
B
54
W/B
W/B B
B
R/Y
L/Y
Br/Y
L
(B)
L
Br/Y
B
Y G
B
G
Y
Br
B
Y
53
Y
Y
Br/R
G
G
Y G
B
Y
L Y
L/R
Br/B
R/L
R/L
13
R/L
Br/B
14
L
L
L
Br
L/R
(B)
Br/Y R/W
68
Br/R
Br/Y
B G/W
52
(off)
51
Y G B
Y
L
(B)
Br/B
R/Y L/Y
11
10
Br/B
12
R
W
B
G W/B G
R
(B)
W
67
Br/Y
B
B
R
L Br/Y
A
B
Y G
Y
53
B
Y G
B
G
R/W
B
Br/Y L
G/W
Br/R
Br/B
50
Y/B B
(B)
Br/R B G/R
(B)
Br/R B Y/B
Br/R
B/Y
15
B/Y
O/L B/Y
P/W B/G
16
B/W
Y/W
(B)
P/L L/B Br/L
O
Br/R
G/R
B
Br/B
(Gy)
B
49
R/L
B
B/W
O/B
R/W
Br/Y
O/B
(Dg)
R/L B B/W O/B
48
(B)
W/R Sb
Gy/G
(B)
L W
Gy
17 L Gy W
Gy/G
Sb W/R
(B)
Br/L R/W P/L
W/G R/W R/G
W/R B/R L B/L L/W R/W
B/R
W/B
Br/B
(B)
Y/L Y
B/G P/W W/B B/R B O/L Br/B B/Y
Br/R
Br/R
Br/R
19
B/W R/W
Y/W
Lg G/Y R/L G/W Y L/Y
R/W
B
R/W L/B R/G G/R W/G Y/B R
Br/W W Gy P Y/G P/W Sb O/L Y/W B/G Gy/G W/B L/R B/W G/R Br/R
Y/R
R/Y
38
G/R L/W
B/W
(W)
B
L/W G/R
20
R/W
R/W
B
47
46
45
44
43
42
41
40
39
B/W
Y/L
B/W
(B)
R/W
Y/L Br/Y B/W
O/B
B L/B
L/R B
O
(B)
R
L
Br B
26
25
24
35
G/Y
Br/W
Br/R
B Br/Y
L/B
B
L/B
31
L/B
Y/G
L/B
Lg
P
B/L
Y
L
W
L/R
B/W B
21
G/Y
Br/W
2WD
4WD
DIFF LOCK
G/R
L/R
L/Y
Y
P/W
O/L
B/G
W/B
B/R
Sb
Gy/G
W/R
L/W
G/R
Y/L
R/W
R/Y
Y/R
Y/B
G/R
R/L
Y/W
W/G
Br/L
R/G
P/L
R/W
R
O
18
L/W
W/G
Br/L
R/G
P/L
Gy
Br/R
G/W
L
L/Y
B
36
Br
Br/Y
L
Y/G
B/L
L
P
B/L
L
Y
B/L
B/L
W
B/L
B/L
R/L
L/B
L
37
30
29
L W
B/L
(Gy)
L Y/G B/L
(B)
B/L P L
(B)
B/L Y L
W L/Y
B/L
28
(B)
G/Y B/L
(B)
Br/W B/L
(Gy)
R/L R
27
23
22
B
Lg
34
B
Lg
L
B
Lg
Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
L
L
L
L
L
R/W
R/W
R/W
R/W
R/W
R/W
L L L L
B/W
B/W
B/W
B/W
B/W
B/W
R/L
R/L
R/L
L/Y
L/Y
L/Y
33
G/W
G/W
G/W
Y
Y
Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
(B)
B/W B/W B/W B/W B/W B/W R/L R/L R/L L/Y L/Y L/Y
G/W G/W G/W Y Y
B/L
B/L
B/L
B/L
B/L
B/L
B/L
B/L
33
(B)
B/L B/L B/L B/L B/L B/L B/L B/L
R/W R/W R/W R/W R/W R/W
32
G/W
B
B
A
B
C
IGNITION SYSTEM
EAS27090
IGNITION SYSTEM
EAS27100
CIRCUIT DIAGRAM
IGNITION SYSTEM
1. Crankshaft position sensor
5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
21.ECU (engine control unit)
22.Ignition coil
23.Spark plug
30.Lean angle sensor
33.Joint coupler
59.Ignition fuse
B. Wire harness
C. Negative battery sub-wire harness
9-2
IGNITION SYSTEM
EAS27120
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Hood
2. Right side panel
3. Right rear panel
1. Check the fuses.
(Main and ignition)
Refer to “CHECKING THE FUSES” on page 9-92.
NG →
Replace the fuse(s).
OK ↓
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 9-93.
NG →
• Clean the battery terminals.
• Recharge or replace the battery.
OK ↓
3. Check the spark plug.
Refer to “CHECKING THE SPARK
PLUG” on page 3-5.
NG →
Re-gap or replace the spark plug.
OK ↓
4. Check the ignition spark gap.
Refer to “CHECKING THE IGNITION SPARK GAP” on page 9-99.
OK →
Ignition system is OK.
NG ↓
5. Check the spark plug cap.
Refer to “CHECKING THE SPARK
PLUG CAP” on page 9-98.
NG →
Replace the spark plug cap.
OK ↓
6. Check the ignition coil.
Refer to “CHECKING THE IGNITION COIL” on page 9-98.
NG →
Replace the ignition coil.
OK ↓
7. Check the crankshaft position sensor.
Refer to “CHECKING THE CRANKSHAFT POSITION SENSOR” on
page 9-99.
NG →
Replace the crankshaft position sensor/stator assembly.
OK ↓
8. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 9-87.
NG →
Replace the main switch.
OK ↓
9-3
IGNITION SYSTEM
9. Check the lean angle sensor.
Refer to “CHECKING THE LEAN
ANGLE SENSOR” on page 9-100.
NG →
Replace the lean angle sensor.
OK ↓
10.Check the entire ignition system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 9-1.
NG →
Properly connect or replace the wire harness.
OK ↓
Replace the ECU.
9-4
9-5
L
B
R/L
B
64
L
R/W
B
(Gy)
W
(Gy)
W W
65
R/L
Y/R
Br/R
R
R/W
Y/R
B R/W
Br/R
R/L
R
66
(Gy)
W
(Gy)
W W
Gy
B/L Gy
1
Br/L
B
4
R
B
B/L
Br/R
2
Gy
B
R
Br/R
R/B
Br/L
Br/L
Br/R
R
W W
W W
W W
(Gy)
W W W
B
3
R
BB B
R
(B)
5
R/B Br/R
B
Br/Y
57
58
59
60
63
62
61
(B)
L/Y Br/R
R
Br/L
R
R/W
Br/Y
Br/Y
Br
W/B
Br/R R/B Br/R L/Y
(off)
(on)
(start)
6
B
Br/Y B
B
B
Y L
56
8
B
Y
55
9
56
Y LL
(B)
Br Y
(B)
7
B A B
R
Y Br/Y
R
R
(B)
R
Y
Br
B
54
W/B
W/B B
B
R/Y
L/Y
Br/Y
L
(B)
L
Br/Y
B
Y G
B
G
Y
Br
B
Y
53
Y
Y
Br/R
G
G
Y G
B
Y
L Y
L/R
Br/B
R/L
R/L
13
R/L
Br/B
14
L
L
L
Br
L/R
(B)
Br/Y R/W
68
Br/R
Br/Y
B G/W
52
(off)
51
Y G B
Y
L
(B)
Br/B
R/Y L/Y
11
10
Br/B
12
R
W
B
G W/B G
R
(B)
W
67
Br/Y
B
B
R
L Br/Y
A
B
Y G
Y
53
B
Y G
B
G
R/W
B
Br/Y L
G/W
Br/R
Br/B
50
Y/B B
(B)
Br/R B G/R
(B)
Br/R B Y/B
Br/R
B/Y
15
B/Y
O/L B/Y
P/W B/G
16
B/W
Y/W
(B)
P/L L/B Br/L
O
Br/R
G/R
B
Br/B
(Gy)
B
49
R/L
B
B/W
O/B
R/W
Br/Y
O/B
(Dg)
R/L B B/W O/B
48
(B)
W/R Sb
Gy/G
(B)
L W
Gy
17 L Gy W
Gy/G
Sb W/R
(B)
Br/L R/W P/L
W/G R/W R/G
W/R B/R L B/L L/W R/W
B/R
W/B
Br/B
(B)
Y/L Y
B/G P/W W/B B/R B O/L Br/B B/Y
Br/R
Br/R
Br/R
19
B/W R/W
Y/W
Lg G/Y R/L G/W Y L/Y
R/W
B
R/W L/B R/G G/R W/G Y/B R
Br/W W Gy P Y/G P/W Sb O/L Y/W B/G Gy/G W/B L/R B/W G/R Br/R
Y/R
R/Y
38
G/R L/W
B/W
(W)
B
L/W G/R
20
R/W
R/W
B
47
46
45
44
43
42
41
40
39
B/W
Y/L
B/W
(B)
R/W
Y/L Br/Y B/W
O/B
B L/B
L/R B
O
(B)
R
L
Br B
26
25
24
35
G/Y
Br/W
Br/R
B Br/Y
L/B
B
L/B
31
L/B
Y/G
L/B
Lg
P
B/L
Y
L
W
L/R
B/W B
21
G/Y
Br/W
2WD
4WD
DIFF LOCK
G/R
L/R
L/Y
Y
P/W
O/L
B/G
W/B
B/R
Sb
Gy/G
W/R
L/W
G/R
Y/L
R/W
R/Y
Y/R
Y/B
G/R
R/L
Y/W
W/G
Br/L
R/G
P/L
R/W
R
O
18
L/W
W/G
Br/L
R/G
P/L
Gy
Br/R
G/W
L
L/Y
B
36
Br
Br/Y
L
Y/G
B/L
L
P
B/L
L
Y
B/L
B/L
W
B/L
B/L
R/L
L/B
L
37
30
29
L W
B/L
(Gy)
L Y/G B/L
(B)
B/L P L
(B)
B/L Y L
W L/Y
B/L
28
(B)
G/Y B/L
(B)
Br/W B/L
(Gy)
R/L R
27
23
22
B
Lg
34
B
Lg
L
B
Lg
Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
L
L
L
L
L
R/W
R/W
R/W
R/W
R/W
R/W
L L L L
B/W
B/W
B/W
B/W
B/W
B/W
R/L
R/L
R/L
L/Y
L/Y
L/Y
33
G/W
G/W
G/W
Y
Y
Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
(B)
B/W B/W B/W B/W B/W B/W R/L R/L R/L L/Y L/Y L/Y
G/W G/W G/W Y Y
B/L
B/L
B/L
B/L
B/L
B/L
B/L
B/L
33
(B)
B/L B/L B/L B/L B/L B/L B/L B/L
R/W R/W R/W R/W R/W R/W
32
G/W
B
B
A
B
C
ELECTRIC STARTING SYSTEM
EAS27160
ELECTRIC STARTING SYSTEM
EAS27170
CIRCUIT DIAGRAM
ELECTRIC STARTING SYSTEM
4. Load control relay
5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
11.Starter relay
12.Starter motor
17.Gear position switch
21.ECU (engine control unit)
33.Joint coupler
55.Brake light switch
59.Ignition fuse
61.Signaling system fuse
B. Wire harness
C. Negative battery sub-wire harness
9-6
ELECTRIC STARTING SYSTEM
EAS27180
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION
If the main switch is set to “ ” (start), the starter motor can only operate if at least one of the following
conditions is met:
• The transmission is in neutral (the neutral circuit of the gear position switch is closed).
• The brake pedal is pressed (the brake light switch circuit is closed).
11
10
1
2
5
3
6
4
7
8
9
9-7
ELECTRIC STARTING SYSTEM
1. Battery
2. Main fuse
3. Ignition fuse
4. Main switch
5. Load control relay
6. Signaling system fuse
7. Brake light switch
8. ECU (engine control unit)
9. Gear position switch
10.Starter relay
11.Starter motor
9-8
ELECTRIC STARTING SYSTEM
EAS27190
TROUBLESHOOTING
The starter motor fails to turn.
TIP
• Before troubleshooting, remove the following part(s):
1. Hood
2. Air intake silencer
1. Check the fuses.
(Main, ignition, and signaling system)
Refer to “CHECKING THE FUSES” on page 9-92.
NG →
Replace the fuse(s).
OK ↓
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 9-93.
NG →
• Clean the battery terminals.
• Recharge or replace the battery.
OK ↓
3. Check the starter motor operation.
Refer to “CHECKING THE STARTER MOTOR OPERATION” on page
9-100.
OK →
Starter motor is OK. Perform the electric
starting system troubleshooting, starting
with step 5.
NG ↓
4. Check the starter motor.
Refer to “CHECKING THE STARTER MOTOR” on page 5-39.
NG →
Repair or replace the starter motor.
OK ↓
5. Check the starter relay.
Refer to “CHECKING THE RELAYS” on page 9-95.
NG →
Replace the starter relay.
OK ↓
6. Check the load control relay.
Refer to “CHECKING THE RELAYS” on page 9-95.
NG →
Replace the load control relay.
OK ↓
7. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 9-87.
NG →
Replace the main switch.
OK ↓
8. Check the brake light switch.
Refer to “CHECKING THE
SWITCHES” on page 9-87.
NG →
Replace the brake light switch.
OK ↓
9-9
ELECTRIC STARTING SYSTEM
9. Check the gear position switch.
Refer to “CHECKING THE
SWITCHES” on page 9-87.
NG →
Replace the gear position switch.
OK ↓
10.Check the entire starting system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 9-5.
NG →
Properly connect or replace the wire harness.
OK ↓
Replace the ECU.
9-10
9-11
L
B
R/L
B
64
L
R/W
B
(Gy)
W
(Gy)
W W
65
R/L
Y/R
Br/R
R
R/W
Y/R
B R/W
Br/R
R/L
R
66
(Gy)
W
(Gy)
W W
Gy
B/L Gy
1
Br/L
B
4
R
B
B/L
Br/R
2
Gy
B
R
Br/R
R/B
Br/L
Br/L
Br/R
R
W W
W W
W W
(Gy)
W W W
B
3
R
BB B
R
(B)
5
R/B Br/R
B
Br/Y
57
58
59
60
63
62
61
(B)
L/Y Br/R
R
Br/L
R
R/W
Br/Y
Br/Y
Br
W/B
Br/R R/B Br/R L/Y
(off)
(on)
(start)
6
B
Br/Y B
B
B
Y L
56
8
B
Y
55
9
56
Y LL
(B)
Br Y
(B)
7
B A B
R
Y Br/Y
R
R
(B)
R
Y
Br
B
54
W/B
W/B B
B
R/Y
L/Y
Br/Y
L
(B)
L
Br/Y
B
Y G
B
G
Y
Br
B
Y
53
Y
Y
Br/R
G
G
Y G
B
Y
L Y
L/R
Br/B
R/L
R/L
13
R/L
Br/B
14
L
L
L
Br
L/R
(B)
Br/Y R/W
68
Br/R
Br/Y
B G/W
52
(off)
51
Y G B
Y
L
(B)
Br/B
R/Y L/Y
11
10
Br/B
12
R
W
B
G W/B G
R
(B)
W
67
Br/Y
B
B
R
L Br/Y
A
B
Y G
Y
53
B
Y G
B
G
R/W
B
Br/Y L
G/W
Br/R
Br/B
50
Y/B B
(B)
Br/R B G/R
(B)
Br/R B Y/B
Br/R
B/Y
15
B/Y
O/L B/Y
P/W B/G
16
B/W
Y/W
(B)
P/L L/B Br/L
O
Br/R
G/R
B
Br/B
(Gy)
B
49
R/L
B
B/W
O/B
R/W
Br/Y
O/B
(Dg)
R/L B B/W O/B
48
(B)
W/R Sb
Gy/G
(B)
L W
Gy
17 L Gy W
Gy/G
Sb W/R
(B)
Br/L R/W P/L
W/G R/W R/G
W/R B/R L B/L L/W R/W
B/R
W/B
Br/B
(B)
Y/L Y
B/G P/W W/B B/R B O/L Br/B B/Y
Br/R
Br/R
Br/R
19
B/W R/W
Y/W
Lg G/Y R/L G/W Y L/Y
R/W
B
R/W L/B R/G G/R W/G Y/B R
Br/W W Gy P Y/G P/W Sb O/L Y/W B/G Gy/G W/B L/R B/W G/R Br/R
Y/R
R/Y
38
G/R L/W
B/W
(W)
B
L/W G/R
20
R/W
R/W
47
46
45
44
43
42
41
40
39
2WD
4WD
DIFF LOCK
18
B
B/W
L/W
W/G
Br/L
R/G
P/L
G/R
(B)
R/W
Y/L Br/Y B/W
O/B
Y/L
B/W
L/R
L/Y
Y
P/W
O/L
B/G
W/B
B/R
Sb
Gy/G
W/R
L/W
G/R
Y/L
R/W
R/Y
Y/R
Y/B
G/R
R/L
Y/W
W/G
Br/L
R/G
P/L
R/W
Gy
Br/R
G/W
B/W B
21
B L/B
L/R B
31
L/B
Y/G
L/B
Lg
P
B/L
Y
L
W
O
(B)
R
L
Br B
26
25
24
35
G/Y
Br/W
Br/R
B Br/Y
L/B
B
L/R
L/B
G/Y
Br/W
R
O
L
L/Y
B
36
Br
Br/Y
L
Y/G
B/L
L
P
B/L
L
Y
B/L
B/L
W
B/L
B/L
R/L
L/B
L
37
30
29
L W
B/L
(Gy)
L Y/G B/L
(B)
B/L P L
(B)
B/L Y L
W L/Y
B/L
28
(B)
G/Y B/L
(B)
Br/W B/L
(Gy)
R/L R
27
23
22
B
Lg
34
B
Lg
L
B
Lg
Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
L
L
L
L
L
R/W
R/W
R/W
R/W
R/W
R/W
L L L L
B/W
B/W
B/W
B/W
B/W
B/W
R/L
R/L
R/L
L/Y
L/Y
L/Y
33
G/W
G/W
G/W
Y
Y
Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
(B)
B/W B/W B/W B/W B/W B/W R/L R/L R/L L/Y L/Y L/Y
G/W G/W G/W Y Y
B/L
B/L
B/L
B/L
B/L
B/L
B/L
B/L
33
(B)
B/L B/L B/L B/L B/L B/L B/L B/L
R/W R/W R/W R/W R/W R/W
32
G/W
B
B
A
B
C
CHARGING SYSTEM
EAS27200
CHARGING SYSTEM
EAS27210
CIRCUIT DIAGRAM
CHARGING SYSTEM
2.
3.
5.
8.
9.
B.
C.
AC magneto
Rectifier/regulator
Frame ground
Battery
Main fuse
Wire harness
Negative battery sub-wire harness
9-12
CHARGING SYSTEM
EAS27230
TROUBLESHOOTING
The battery is not being charged.
TIP
• Before troubleshooting, remove the following part(s):
1. Hood
2. Right side panel
3. Right rear panel
1. Check the fuse.
(Main)
Refer to “CHECKING THE FUSES” on page 9-92.
NG →
Replace the fuse.
OK ↓
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 9-93.
NG →
• Clean the battery terminals.
• Recharge or replace the battery.
OK ↓
3. Check the stator coil.
Refer to “CHECKING THE STATOR
COIL” on page 9-101.
NG →
Replace the crankshaft position sensor/stator assembly.
OK ↓
4. Check the rectifier/regulator.
Refer to “CHECKING THE RECTIFIER/REGULATOR” on page
9-101.
NG →
Replace the rectifier/regulator.
OK ↓
5. Check the entire charging system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 9-11.
NG →
Properly connect or replace the wire harness.
OK ↓
The charging system circuit is OK.
9-13
CHARGING SYSTEM
9-14
9-15
L
B
R/L
B
64
L
R/W
B
(Gy)
W
(Gy)
W W
65
R/L
Y/R
Br/R
R
R/W
Y/R
B R/W
Br/R
R/L
R
66
(Gy)
W
(Gy)
W W
Gy
B/L Gy
1
Br/L
B
4
R
B
B/L
Br/R
2
Gy
B
R
Br/R
R/B
Br/L
Br/L
Br/R
R
W W
W W
W W
(Gy)
W W W
B
3
R
BB B
R
(B)
5
R/B Br/R
B
Br/Y
57
58
59
60
63
62
61
(B)
L/Y Br/R
R
Br/L
R
R/W
Br/Y
Br/Y
Br
W/B
Br/R R/B Br/R L/Y
(off)
(on)
(start)
6
B
Br/Y B
B
B
Y L
56
8
B
Y
55
9
56
Y LL
(B)
Br Y
(B)
7
B A B
R
Y Br/Y
R
R
(B)
R
Y
Br
B
54
W/B
W/B B
B
R/Y
L/Y
Br/Y
L
(B)
L
Br/Y
B
Y G
B
G
Y
Br
B
Y
53
Y
Y
Br/R
G
G
Y G
B
Y
L Y
L/R
Br/B
R/L
R/L
13
R/L
Br/B
14
L
L
L
Br
L/R
(B)
Br/Y R/W
68
Br/R
Br/Y
B G/W
52
(off)
51
Y G B
Y
L
(B)
Br/B
R/Y L/Y
11
10
Br/B
12
R
W
B
G W/B G
R
(B)
W
67
Br/Y
B
B
R
L Br/Y
A
B
Y G
Y
53
B
Y G
B
G
R/W
B
Br/Y L
G/W
Br/R
Br/B
50
Y/B B
(B)
Br/R B G/R
(B)
Br/R B Y/B
Br/R
B/Y
15
B/Y
O/L B/Y
P/W B/G
16
B/W
Y/W
(B)
P/L L/B Br/L
O
Br/R
G/R
B
Br/B
(Gy)
B
49
R/L
B
B/W
O/B
R/W
Br/Y
O/B
(Dg)
R/L B B/W O/B
48
(B)
W/R Sb
Gy/G
(B)
L W
Gy
17 L Gy W
Gy/G
Sb W/R
(B)
Br/L R/W P/L
W/G R/W R/G
W/R B/R L B/L L/W R/W
B/R
W/B
Br/B
(B)
Y/L Y
B/G P/W W/B B/R B O/L Br/B B/Y
Br/R
Br/R
Br/R
19
B/W R/W
Y/W
Lg G/Y R/L G/W Y L/Y
R/W
B
R/W L/B R/G G/R W/G Y/B R
Br/W W Gy P Y/G P/W Sb O/L Y/W B/G Gy/G W/B L/R B/W G/R Br/R
Y/R
R/Y
38
G/R L/W
B/W
(W)
B
L/W G/R
20
R/W
R/W
47
46
45
44
43
42
41
40
39
2WD
4WD
DIFF LOCK
18
B
B/W
L/W
W/G
Br/L
R/G
P/L
G/R
(B)
R/W
Y/L Br/Y B/W
O/B
Y/L
B/W
L/R
L/Y
Y
P/W
O/L
B/G
W/B
B/R
Sb
Gy/G
W/R
L/W
G/R
Y/L
R/W
R/Y
Y/R
Y/B
G/R
R/L
Y/W
W/G
Br/L
R/G
P/L
R/W
Gy
Br/R
G/W
B/W B
21
B L/B
L/R B
31
L/B
Y/G
L/B
Lg
P
B/L
Y
L
W
O
(B)
R
L
Br B
26
25
24
35
G/Y
Br/W
Br/R
B Br/Y
L/B
B
L/R
L/B
G/Y
Br/W
R
O
L
L/Y
B
36
Br
Br/Y
L
Y/G
B/L
L
P
B/L
L
Y
B/L
B/L
W
B/L
B/L
R/L
L/B
L
37
30
29
L W
B/L
(Gy)
L Y/G B/L
(B)
B/L P L
(B)
B/L Y L
W L/Y
B/L
28
(B)
G/Y B/L
(B)
Br/W B/L
(Gy)
R/L R
27
23
22
B
Lg
34
B
Lg
L
B
Lg
Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
L
L
L
L
L
R/W
R/W
R/W
R/W
R/W
R/W
L L L L
B/W
B/W
B/W
B/W
B/W
B/W
R/L
R/L
R/L
L/Y
L/Y
L/Y
33
G/W
G/W
G/W
Y
Y
Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
(B)
B/W B/W B/W B/W B/W B/W R/L R/L R/L L/Y L/Y L/Y
G/W G/W G/W Y Y
B/L
B/L
B/L
B/L
B/L
B/L
B/L
B/L
33
(B)
B/L B/L B/L B/L B/L B/L B/L B/L
R/W R/W R/W R/W R/W R/W
32
G/W
B
B
A
B
C
LIGHTING SYSTEM
EAS27240
LIGHTING SYSTEM
EAS27250
CIRCUIT DIAGRAM
LIGHTING SYSTEM
4. Load control relay
5. Frame ground
6. Main switch
8. Battery
9. Main fuse
51.Light switch
52.Headlight relay
53.Headlight
56.Tail/brake light
59.Ignition fuse
62.Headlight fuse
B. Wire harness
C. Negative battery sub-wire harness
9-16
LIGHTING SYSTEM
EAS27260
TROUBLESHOOTING
Any of the following fail to light: headlight or taillight.
TIP
• Before troubleshooting, remove the following part(s):
1. Cargo bed left panel
2. Cargo bed right panel
3. Hood
1. Check the condition of each bulb
and bulb socket.
Refer to “CHECKING THE BULBS
AND BULB SOCKETS” on page
9-90.
NG →
Replace the bulb(s) and bulb socket(s).
OK ↓
2. Check the fuses.
(Main, ignition, and headlight)
Refer to “CHECKING THE FUSES” on page 9-92.
NG →
Replace the fuse(s).
OK ↓
3. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 9-93.
NG →
• Clean the battery terminals.
• Recharge or replace the battery.
OK ↓
4. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 9-87.
NG →
Replace the main switch.
OK ↓
5. Check the light switch.
Refer to “CHECKING THE
SWITCHES” on page 9-87.
NG →
Replace the light switch.
OK ↓
6. Check the headlight relay.
Refer to “CHECKING THE RELAYS” on page 9-95.
NG →
Replace the headlight relay.
OK ↓
7. Check the load control relay.
Refer to “CHECKING THE RELAYS” on page 9-95.
NG →
Replace the load control relay.
OK ↓
9-17
LIGHTING SYSTEM
8. Check the entire lighting system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 9-15.
NG →
Properly connect or replace the wire harness.
OK ↓
The lighting system circuit is OK.
9-18
9-19
L
B
R/L
B
64
L
R/W
B
(Gy)
W
(Gy)
W W
65
R/L
Y/R
Br/R
R
R/W
Y/R
B R/W
Br/R
R/L
R
66
(Gy)
W
(Gy)
W W
Gy
B/L Gy
1
Br/L
B
4
R
B
B/L
Br/R
2
Gy
B
R
Br/R
R/B
Br/L
Br/L
Br/R
R
W W
W W
W W
(Gy)
W W W
B
3
R
BB B
R
(B)
5
R/B Br/R
B
Br/Y
57
58
59
60
63
62
61
(B)
L/Y Br/R
R
Br/L
R
R/W
Br/Y
Br/Y
Br
W/B
Br/R R/B Br/R L/Y
(off)
(on)
(start)
6
B
Br/Y B
B
B
Y L
56
8
B
Y
55
9
56
Y LL
(B)
Br Y
(B)
7
B A B
R
Y Br/Y
R
R
(B)
R
Y
Br
B
54
W/B
W/B B
B
R/Y
L/Y
Br/Y
L
(B)
L
Br/Y
B
Y G
B
G
Y
Br
B
Y
53
Y
Y
Br/R
G
G
Y G
B
Y
L Y
L/R
Br/B
R/L
R/L
13
R/L
Br/B
14
L
L
L
Br
L/R
(B)
Br/Y R/W
68
Br/R
Br/Y
B G/W
52
(off)
51
Y G B
Y
L
(B)
Br/B
R/Y L/Y
11
10
Br/B
12
R
W
B
G W/B G
R
(B)
W
67
Br/Y
B
B
R
L Br/Y
A
B
Y G
Y
53
B
Y G
B
G
R/W
B
Br/Y L
G/W
Br/R
Br/B
50
Y/B B
(B)
Br/R B G/R
(B)
Br/R B Y/B
Br/R
B/Y
15
B/Y
O/L B/Y
P/W B/G
16
B/W
Y/W
(B)
P/L L/B Br/L
O
Br/R
G/R
B
Br/B
(Gy)
B
49
R/L
B
B/W
O/B
R/W
Br/Y
O/B
(Dg)
R/L B B/W O/B
48
(B)
W/R Sb
Gy/G
(B)
L W
Gy
17 L Gy W
Gy/G
Sb W/R
(B)
Br/L R/W P/L
W/G R/W R/G
W/R B/R L B/L L/W R/W
B/R
W/B
Br/B
(B)
Y/L Y
B/G P/W W/B B/R B O/L Br/B B/Y
Br/R
Br/R
Br/R
19
B/W R/W
Y/W
Lg G/Y R/L G/W Y L/Y
R/W
B
R/W L/B R/G G/R W/G Y/B R
Br/W W Gy P Y/G P/W Sb O/L Y/W B/G Gy/G W/B L/R B/W G/R Br/R
Y/R
R/Y
38
G/R L/W
B/W
(W)
B
L/W G/R
20
R/W
R/W
47
46
45
44
43
42
41
40
39
2WD
4WD
DIFF LOCK
18
B
B/W
L/W
W/G
Br/L
R/G
P/L
G/R
(B)
R/W
Y/L Br/Y B/W
O/B
Y/L
B/W
L/R
L/Y
Y
P/W
O/L
B/G
W/B
B/R
Sb
Gy/G
W/R
L/W
G/R
Y/L
R/W
R/Y
Y/R
Y/B
G/R
R/L
Y/W
W/G
Br/L
R/G
P/L
R/W
Gy
Br/R
G/W
B/W B
21
B L/B
L/R B
31
L/B
Y/G
L/B
Lg
P
B/L
Y
L
W
O
(B)
R
L
Br B
26
25
24
35
G/Y
Br/W
Br/R
B Br/Y
L/B
B
L/R
L/B
G/Y
Br/W
R
O
L
L/Y
B
36
Br
Br/Y
L
Y/G
B/L
L
P
B/L
L
Y
B/L
B/L
W
B/L
B/L
R/L
L/B
L
37
30
29
L W
B/L
(Gy)
L Y/G B/L
(B)
B/L P L
(B)
B/L Y L
W L/Y
B/L
28
(B)
G/Y B/L
(B)
Br/W B/L
(Gy)
R/L R
27
23
22
B
Lg
34
B
Lg
L
B
Lg
Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
L
L
L
L
L
R/W
R/W
R/W
R/W
R/W
R/W
L L L L
B/W
B/W
B/W
B/W
B/W
B/W
R/L
R/L
R/L
L/Y
L/Y
L/Y
33
G/W
G/W
G/W
Y
Y
Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
(B)
B/W B/W B/W B/W B/W B/W R/L R/L R/L L/Y L/Y L/Y
G/W G/W G/W Y Y
B/L
B/L
B/L
B/L
B/L
B/L
B/L
B/L
33
(B)
B/L B/L B/L B/L B/L B/L B/L B/L
R/W R/W R/W R/W R/W R/W
32
G/W
B
B
A
B
C
SIGNALING SYSTEM
EAS27270
SIGNALING SYSTEM
EAS1XD2004
CIRCUIT DIAGRAM (for CDN)
SIGNALING SYSTEM
4. Load control relay
5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
17.Gear position switch
21.ECU (engine control unit)
26.Coolant temperature sensor
27.Speed sensor
31.Parking brake switch
32.Reverse switch
33.Joint coupler
34.Seat belt switch
36.Helmet indicator light
37.Seat belt indicator light
39.Multi-function meter
41.Coolant temperature warning light
42.Park indicator light
43.Reverse indicator light
44.Neutral indicator light
45.High-range indicator light
46.Low-range indicator light
48.Fuel sender
55.Brake light switch
56.Tail/brake light
59.Ignition fuse
60.Backup fuse
61.Signaling system fuse
67.Backup light
68.Backup light relay
A. Optional
B. Wire harness
C. Negative battery sub-wire harness
9-20
9-21
L
B
R/L
B
64
L
R/W
B
(Gy)
W
(Gy)
W W
65
R/L
Y/R
Br/R
R
R/W
Y/R
B R/W
Br/R
R/L
R
66
(Gy)
W
(Gy)
W W
Gy
B/L Gy
1
Br/L
B
4
R
B
B/L
Br/R
2
Gy
B
R
Br/R
R/B
Br/L
Br/L
Br/R
R
W W
W W
W W
(Gy)
W W W
B
Br
B
3
R
BB B
R
(B)
5
Br
57
58
59
60
63
62
61
(B)
L/Y Br/R
P
R/B Br/R
B
Br/Y
R
Br/L
R
R/W
Br/Y
Br/Y
Br
W/B
Br/R R/B Br/R L/Y
(off)
(on)
(start)
6
B
Br/Y B
OFF
ON
67
B
B
Y L
56
68
8
B
Y
55
9
56
Y LL
(B)
Br Y
(B)
7
B A B
R
Y Br/Y
R
R
(B)
R
Y
Br
B
54
W/B
W/B B
B
R/Y
L/Y
Br/Y
L
(B)
L
Br/Y
B
Y G
B
G
Y
Br
B
Y
53
Y
Y
Br/R
G
G
Y G
B
Y
L Y
L/R
Br/B
R/L
R/L
13
R/L
Br/B
14
L
L
L
Br
L/R
(B)
Br/Y R/W
70
Br/R
Br/Y
B G/W
52
(off)
51
Y G B
Y
L
(B)
Br/B
R/Y L/Y
11
10
Br/B
12
R
W
B
G W/B G
R
(B)
W
69
Br/Y
B
B
R
L Br/Y
A
B
Y G
Y
53
B
Y G
B
G
R/W
B
Br/Y L
G/W
Br/R
Br/B
50
Y/B B
(B)
Br/R B G/R
(B)
Br/R B Y/B
Br/R
B/Y
15
B/Y
O/L B/Y
P/W B/G
16
B/W
Y/W
(B)
P/L L/B Br/L
O
Br/R
G/R
B
Br/B
(Gy)
B
49
R/L
B
B/W
O/B
R/W
Br/Y
O/B
(Dg)
R/L B B/W O/B
48
(B)
W/R Sb
Gy/G
(B)
L W
Gy
17 L Gy W
Gy/G
Sb W/R
(B)
Br/L R/W P/L
W/G R/W R/G
W/R B/R L B/L L/W R/W
B/R
W/B
Br/B
(B)
Y/L Y
B/G P/W W/B B/R B O/L Br/B B/Y
Br/R
Br/R
Br/R
19
B/W R/W
Y/W
Lg G/Y R/L G/W Y L/Y
R/W
B
R/W L/B R/G G/R W/G Y/B R
Br/W W Gy P Y/G P/W Sb O/L Y/W B/G Gy/G W/B L/R B/W G/R Br/R
Y/R
R/Y
38
G/R L/W
B/W
(W)
B
L/W G/R
20
R/W
R/W
47
46
45
44
43
42
41
40
39
2WD
4WD
DIFF LOCK
18
B
B/W
L/W
W/G
Br/L
R/G
P/L
G/R
(B)
R/W
Y/L Br/Y B/W
O/B
Y/L
B/W
L/R
L/Y
Y
P/W
O/L
B/G
W/B
B/R
Sb
Gy/G
W/R
L/W
G/R
Y/L
R/W
R/Y
Y/R
Y/B
G/R
R/L
Y/W
W/G
Br/L
R/G
P/L
R/W
Gy
Br/R
G/W
B/W B
21
B L/B
L/R B
31
L/B
Y/G
L/B
Lg
P
B/L
Y
L
W
O
(B)
R
L
Br B
26
25
24
35
G/Y
Br/W
Br/R
B Br/Y
L/B
B
L/R
L/B
G/Y
Br/W
R
O
L
L/Y
B
36
Br
Br/Y
L
Y/G
B/L
L
P
B/L
L
Y
B/L
B/L
W
B/L
B/L
R/L
L/B
L
37
30
29
L W
B/L
(Gy)
L Y/G B/L
(B)
B/L P L
(B)
B/L Y L
W L/Y
B/L
28
(B)
G/Y B/L
(B)
Br/W B/L
(Gy)
R/L R
27
23
22
B
Lg
34
B
Lg
L
B
Lg
Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
L
L
L
L
L
R/W
R/W
R/W
R/W
R/W
R/W
L L L L
B/W
B/W
B/W
B/W
B/W
B/W
R/L
R/L
R/L
L/Y
L/Y
L/Y
33
G/W
G/W
G/W
Y
Y
Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
(B)
B/W B/W B/W B/W B/W B/W R/L R/L R/L L/Y L/Y L/Y
G/W G/W G/W Y Y
B/L
B/L
B/L
B/L
B/L
B/L
B/L
B/L
33
(B)
B/L B/L B/L B/L B/L B/L B/L B/L
R/W R/W R/W R/W R/W R/W
32
G/W
B
B
A
B
C
SIGNALING SYSTEM
EAS1XD2003
CIRCUIT DIAGRAM (for Europe and Oceania)
SIGNALING SYSTEM
4. Load control relay
5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
17.Gear position switch
21.ECU (engine control unit)
26.Coolant temperature sensor
27.Speed sensor
31.Parking brake switch
32.Reverse switch
33.Joint coupler
34.Seat belt switch
36.Helmet indicator light
37.Seat belt indicator light
39.Multi-function meter
41.Coolant temperature warning light
42.Park indicator light
43.Reverse indicator light
44.Neutral indicator light
45.High-range indicator light
46.Low-range indicator light
48.Fuel sender
55.Brake light switch
56.Tail/brake light
59.Ignition fuse
60.Backup fuse
61.Signaling system fuse
67.Horn switch
68.Horn
69.Backup light
70.Backup light relay
A. Optional
B. Wire harness
C. Negative battery sub-wire harness
9-22
SIGNALING SYSTEM
EAS27290
TROUBLESHOOTING
• Any of the following fail to light: warning light, brake light or an indicator light.
• The horn fails to sound. (For Europe and Oceania)
• The fuel meter fails to come on.
• The speedometer fails to operate.
TIP
• Before troubleshooting, remove the following part(s):
1. Hood
2. Cargo bed left panel
3. Cargo bed right panel
4. Right/center passenger seat frame
5. Right/center passenger compartment panel
6. Right side panel
7. Right rear panel
8. Fuel tank
9. Air intake silencer
10.Sun top
11.Side frames
12.Front fender
1. Check the fuses.
(Main, ignition, signaling system,
and backup)
Refer to “CHECKING THE FUSES” on page 9-92.
NG →
Replace the fuse(s).
OK ↓
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 9-93.
NG →
• Clean the battery terminals.
• Recharge or replace the battery.
OK ↓
3. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 9-87.
NG →
Replace the main switch.
OK ↓
4. Check the load control relay.
Refer to “CHECKING THE RELAYS” on page 9-95.
NG →
Replace the load control relay.
OK ↓
9-23
SIGNALING SYSTEM
5. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM (for
CDN)” on page 9-19 and “CIRCUIT
DIAGRAM (for Europe and Oceania)” on page 9-21.
NG →
Properly connect or replace the wire harness.
OK ↓
Check the condition of each of the signaling system circuits. Refer to
“Checking the signaling system”.
Checking the signaling system
The tail/brake lights fail to come on.
1. Check the tail/brake light bulbs and
sockets.
Refer to “CHECKING THE BULBS
AND BULB SOCKETS” on page
9-90.
NG →
Replace the tail/brake light bulb, socket or
both.
OK ↓
2. Check the brake light switch.
Refer to “CHECKING THE
SWITCHES” on page 9-87.
NG →
Replace the brake light switch.
OK ↓
3. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM (for
CDN)” on page 9-19 and “CIRCUIT
DIAGRAM (for Europe and Oceania)” on page 9-21.
NG →
Properly connect or replace the wire harness.
OK ↓
This circuit is OK.
The neutral, high-range, and/or low-range indicator light fails to come on.
1. Check the gear position switch.
Refer to “CHECKING THE
SWITCHES” on page 9-87.
NG →
Replace the gear position switch.
OK ↓
9-24
SIGNALING SYSTEM
2. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM (for
CDN)” on page 9-19 and “CIRCUIT
DIAGRAM (for Europe and Oceania)” on page 9-21.
NG →
Properly connect or replace the wire harness.
OK ↓
Replace the meter assembly or ECU.
The reverse indicator light fails to come on.
1. Check the reverse switch.
Refer to “CHECKING THE
SWITCHES” on page 9-87.
NG →
Replace the reverse switch.
OK ↓
2. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM (for
CDN)” on page 9-19 and “CIRCUIT
DIAGRAM (for Europe and Oceania)” on page 9-21.
NG →
Properly connect or replace the wire harness.
OK ↓
Replace the meter assembly or ECU.
The park indicator light fails to come on.
1. Check the parking brake switch.
Refer to “CHECKING THE
SWITCHES” on page 9-87.
NG →
Replace the parking brake switch.
OK ↓
2. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM (for
CDN)” on page 9-19 and “CIRCUIT
DIAGRAM (for Europe and Oceania)” on page 9-21.
NG →
Properly connect or replace the wire harness.
OK ↓
Replace the meter assembly or ECU.
The coolant temperature warning light fails to come on.
1. Check the coolant temperature sensor.
Refer to “CHECKING THE COOLANT TEMPERATURE SENSOR”
on page 9-103.
NG →
Replace the coolant temperature sensor.
OK ↓
9-25
SIGNALING SYSTEM
2. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM (for
CDN)” on page 9-19 and “CIRCUIT
DIAGRAM (for Europe and Oceania)” on page 9-21.
NG →
Properly connect or replace the wire harness.
OK ↓
Replace the meter assembly or ECU.
The fuel meter fails to come on.
1. Check the fuel sender.
Refer to “CHECKING THE FUEL
SENDER” on page 9-101.
NG →
Replace the fuel pump assembly.
OK ↓
2. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM (for
CDN)” on page 9-19 and “CIRCUIT
DIAGRAM (for Europe and Oceania)” on page 9-21.
NG →
Properly connect or replace the wire harness.
OK ↓
Replace the meter assembly.
The speedometer fails to come on.
1. Check the speed sensor.
Refer to “ELECTRICAL COMPONENTS” on page 9-81.
NG →
Replace the speed sensor.
OK ↓
2. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM (for
CDN)” on page 9-19 and “CIRCUIT
DIAGRAM (for Europe and Oceania)” on page 9-21.
NG →
Properly connect or replace the wire harness.
OK ↓
Replace the meter assembly or ECU.
The helmet/seat belt indicator light fails to come on.
1. Check the seat belt switch.
Refer to “CHECKING THE
SWITCHES” on page 9-87.
NG →
Replace the driver seat belt buckle.
OK ↓
9-26
SIGNALING SYSTEM
2. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM (for
CDN)” on page 9-19 and “CIRCUIT
DIAGRAM (for Europe and Oceania)” on page 9-21.
NG →
Properly connect or replace the wire harness.
OK ↓
Replace the indicator light assembly or
ECU.
The horn fails to sound (for Europe and Oceania).
1. Check the horn switch.
Refer to “CHECKING THE
SWITCHES” on page 9-87.
NG →
Replace the horn switch.
OK ↓
2. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM (for
Europe and Oceania)” on page
9-21.
NG →
Properly connect or replace the wire harness.
OK ↓
Replace the horn.
9-27
SIGNALING SYSTEM
9-28
9-29
L
B
R/L
B
64
L
R/W
B
(Gy)
W
(Gy)
W W
65
R/L
Y/R
Br/R
R
R/W
Y/R
B R/W
Br/R
R/L
R
66
(Gy)
W
(Gy)
W W
Gy
B/L Gy
1
Br/L
B
4
R
B
B/L
Br/R
2
Gy
B
R
Br/R
R/B
Br/L
Br/L
Br/R
R
W W
W W
W W
(Gy)
W W W
B
3
R
BB B
R
(B)
5
R/B Br/R
B
Br/Y
57
58
59
60
63
62
61
(B)
L/Y Br/R
R
Br/L
R
R/W
Br/Y
Br/Y
Br
W/B
Br/R R/B Br/R L/Y
(off)
(on)
(start)
6
B
Br/Y B
B
B
Y L
56
8
B
Y
55
9
56
Y LL
(B)
Br Y
(B)
7
B A B
R
Y Br/Y
R
R
(B)
R
Y
Br
B
54
W/B
W/B B
B
R/Y
L/Y
Br/Y
L
(B)
L
Br/Y
B
Y G
B
G
Y
Br
B
Y
53
Y
Y
Br/R
G
G
Y G
B
Y
L Y
L/R
Br/B
R/L
R/L
13
R/L
Br/B
14
L
L
L
Br
L/R
(B)
Br/Y R/W
68
Br/R
Br/Y
B G/W
52
(off)
51
Y G B
Y
L
(B)
Br/B
R/Y L/Y
11
10
Br/B
12
R
W
B
G W/B G
R
(B)
W
67
Br/Y
B
B
R
L Br/Y
A
B
Y G
Y
53
B
Y G
B
G
R/W
B
Br/Y L
G/W
Br/R
Br/B
50
Y/B B
(B)
Br/R B G/R
(B)
Br/R B Y/B
Br/R
B/Y
15
B/Y
O/L B/Y
P/W B/G
16
B/W
Y/W
(B)
P/L L/B Br/L
O
Br/R
G/R
B
Br/B
(Gy)
B
49
R/L
B
B/W
O/B
R/W
Br/Y
O/B
(Dg)
R/L B B/W O/B
48
(B)
W/R Sb
Gy/G
(B)
L W
Gy
17 L Gy W
Gy/G
Sb W/R
(B)
Br/L R/W P/L
W/G R/W R/G
W/R B/R L B/L L/W R/W
B/R
W/B
Br/B
(B)
Y/L Y
B/G P/W W/B B/R B O/L Br/B B/Y
Br/R
Br/R
Br/R
19
B/W R/W
Y/W
Lg G/Y R/L G/W Y L/Y
R/W
B
R/W L/B R/G G/R W/G Y/B R
Br/W W Gy P Y/G P/W Sb O/L Y/W B/G Gy/G W/B L/R B/W G/R Br/R
Y/R
R/Y
38
G/R L/W
B/W
(W)
B
L/W G/R
20
R/W
R/W
47
46
45
44
43
42
41
40
39
2WD
4WD
DIFF LOCK
18
B
B/W
L/W
W/G
Br/L
R/G
P/L
G/R
(B)
R/W
Y/L Br/Y B/W
O/B
Y/L
B/W
L/R
L/Y
Y
P/W
O/L
B/G
W/B
B/R
Sb
Gy/G
W/R
L/W
G/R
Y/L
R/W
R/Y
Y/R
Y/B
G/R
R/L
Y/W
W/G
Br/L
R/G
P/L
R/W
Gy
Br/R
G/W
B/W B
21
B L/B
L/R B
31
L/B
Y/G
L/B
Lg
P
B/L
Y
L
W
O
(B)
R
L
Br B
26
25
24
35
G/Y
Br/W
Br/R
B Br/Y
L/B
B
L/R
L/B
G/Y
Br/W
R
O
L
L/Y
B
36
Br
Br/Y
L
Y/G
B/L
L
P
B/L
L
Y
B/L
B/L
W
B/L
B/L
R/L
L/B
L
37
30
29
L W
B/L
(Gy)
L Y/G B/L
(B)
B/L P L
(B)
B/L Y L
W L/Y
B/L
28
(B)
G/Y B/L
(B)
Br/W B/L
(Gy)
R/L R
27
23
22
B
Lg
34
B
Lg
L
B
Lg
Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
L
L
L
L
L
R/W
R/W
R/W
R/W
R/W
R/W
L L L L
B/W
B/W
B/W
B/W
B/W
B/W
R/L
R/L
R/L
L/Y
L/Y
L/Y
33
G/W
G/W
G/W
Y
Y
Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
(B)
B/W B/W B/W B/W B/W B/W R/L R/L R/L L/Y L/Y L/Y
G/W G/W G/W Y Y
B/L
B/L
B/L
B/L
B/L
B/L
B/L
B/L
33
(B)
B/L B/L B/L B/L B/L B/L B/L B/L
R/W R/W R/W R/W R/W R/W
32
G/W
B
B
A
B
C
COOLING SYSTEM
EAS27300
COOLING SYSTEM
EAS27310
CIRCUIT DIAGRAM
COOLING SYSTEM
5. Frame ground
6. Main switch
8. Battery
9. Main fuse
21.ECU (engine control unit)
26.Coolant temperature sensor
33.Joint coupler
57.Radiator fan motor fuse
59.Ignition fuse
64.Radiator fan motor
65.Radiator fan motor circuit breaker
66.Radiator fan motor relay
B. Wire harness
C. Negative battery sub-wire harness
9-30
COOLING SYSTEM
EAS27320
TROUBLESHOOTING
The radiator fan motor fails to turn.
TIP
• Before troubleshooting, remove the following part(s):
1. Hood
2. Front skid plate
3. Frame cross member
1. Check the fuses.
(Main, ignition, and radiator fan motor)
Refer to “CHECKING THE FUSES” on page 9-92.
NG →
Replace the fuse(s).
OK ↓
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 9-93.
NG →
• Clean the battery terminals.
• Recharge or replace the battery.
OK ↓
3. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 9-87.
NG →
Replace the main switch.
OK ↓
4. Check the radiator fan motor.
Refer to “CHECKING THE RADIATOR FAN MOTOR” on page 9-103.
NG →
Replace the radiator fan motor.
OK ↓
5. Check the radiator fan motor relay.
Refer to “CHECKING THE RELAYS” on page 9-95.
NG →
Replace the radiator fan motor relay.
OK ↓
6. Check the radiator fan motor circuit
breaker.
Refer to “CHECKING THE RADIATOR FAN MOTOR CIRCUIT
BREAKER” on page 9-103.
NG →
Replace the radiator fan motor circuit
breaker.
OK ↓
7. Check the coolant temperature sensor.
Refer to “CHECKING THE COOLANT TEMPERATURE SENSOR”
on page 9-103.
NG →
Replace the coolant temperature sensor.
OK ↓
9-31
COOLING SYSTEM
8. Check the entire cooling system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 9-29.
NG →
Properly connect or replace the wire harness.
OK ↓
Replace the ECU.
9-32
9-33
L
B
R/L
B
64
L
R/W
B
(Gy)
W
(Gy)
W W
65
R/L
Y/R
Br/R
R
R/W
Y/R
B R/W
Br/R
R/L
R
66
(Gy)
W
(Gy)
W W
Gy
B/L Gy
1
Br/L
B
4
R
B
B/L
Br/R
2
Gy
B
R
Br/R
R/B
Br/L
Br/L
Br/R
R
W W
W W
W W
(Gy)
W W W
B
3
R
BB B
R
(B)
5
R/B Br/R
B
Br/Y
57
58
59
60
63
62
61
(B)
L/Y Br/R
R
Br/L
R
R/W
Br/Y
Br/Y
Br
W/B
Br/R R/B Br/R L/Y
(off)
(on)
(start)
6
B
Br/Y B
B
B
Y L
56
8
B
Y
55
9
56
Y LL
(B)
Br Y
(B)
7
B A B
R
Y Br/Y
R
R
(B)
R
Y
Br
B
54
W/B
W/B B
B
R/Y
L/Y
Br/Y
L
(B)
L
Br/Y
B
Y G
B
G
Y
Br
B
Y
53
Y
Y
Br/R
G
G
Y G
B
Y
L Y
L/R
Br/B
R/L
R/L
13
R/L
Br/B
14
L
L
L
Br
L/R
(B)
Br/Y R/W
68
Br/R
Br/Y
B G/W
52
(off)
51
Y G B
Y
L
(B)
Br/B
R/Y L/Y
11
10
Br/B
12
R
W
B
G W/B G
R
(B)
W
67
Br/Y
B
B
R
L Br/Y
A
B
Y G
Y
53
B
Y G
B
G
R/W
B
Br/Y L
G/W
Br/R
Br/B
50
Y/B B
(B)
Br/R B G/R
(B)
Br/R B Y/B
Br/R
B/Y
15
B/Y
O/L B/Y
P/W B/G
16
B/W
Y/W
(B)
P/L L/B Br/L
O
Br/R
G/R
B
Br/B
(Gy)
B
49
R/L
B
B/W
O/B
R/W
Br/Y
O/B
(Dg)
R/L B B/W O/B
48
(B)
W/R Sb
Gy/G
(B)
L W
Gy
17 L Gy W
Gy/G
Sb W/R
(B)
Br/L R/W P/L
W/G R/W R/G
W/R B/R L B/L L/W R/W
B/R
W/B
Br/B
(B)
Y/L Y
B/G P/W W/B B/R B O/L Br/B B/Y
Br/R
Br/R
Br/R
19
B/W R/W
Y/W
Lg G/Y R/L G/W Y L/Y
R/W
B
R/W L/B R/G G/R W/G Y/B R
Br/W W Gy P Y/G P/W Sb O/L Y/W B/G Gy/G W/B L/R B/W G/R Br/R
Y/R
R/Y
38
G/R L/W
B/W
(W)
B
L/W G/R
20
R/W
R/W
47
46
45
44
43
42
41
40
39
2WD
4WD
DIFF LOCK
18
B
B/W
L/W
W/G
Br/L
R/G
P/L
G/R
(B)
R/W
Y/L Br/Y B/W
O/B
Y/L
B/W
L/R
L/Y
Y
P/W
O/L
B/G
W/B
B/R
Sb
Gy/G
W/R
L/W
G/R
Y/L
R/W
R/Y
Y/R
Y/B
G/R
R/L
Y/W
W/G
Br/L
R/G
P/L
R/W
Gy
Br/R
G/W
B/W B
21
B L/B
L/R B
31
L/B
Y/G
L/B
Lg
P
B/L
Y
L
W
O
(B)
R
L
Br B
26
25
24
35
G/Y
Br/W
Br/R
B Br/Y
L/B
B
L/R
L/B
G/Y
Br/W
R
O
L
L/Y
B
36
Br
Br/Y
L
Y/G
B/L
L
P
B/L
L
Y
B/L
B/L
W
B/L
B/L
R/L
L/B
L
37
30
29
L W
B/L
(Gy)
L Y/G B/L
(B)
B/L P L
(B)
B/L Y L
W L/Y
B/L
28
(B)
G/Y B/L
(B)
Br/W B/L
(Gy)
R/L R
27
23
22
B
Lg
34
B
Lg
L
B
Lg
Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
L
L
L
L
L
R/W
R/W
R/W
R/W
R/W
R/W
L L L L
B/W
B/W
B/W
B/W
B/W
B/W
R/L
R/L
R/L
L/Y
L/Y
L/Y
33
G/W
G/W
G/W
Y
Y
Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
(B)
B/W B/W B/W B/W B/W B/W R/L R/L R/L L/Y L/Y L/Y
G/W G/W G/W Y Y
B/L
B/L
B/L
B/L
B/L
B/L
B/L
B/L
33
(B)
B/L B/L B/L B/L B/L B/L B/L B/L
R/W R/W R/W R/W R/W R/W
32
G/W
B
B
A
B
C
FUEL INJECTION SYSTEM
EAS27330
FUEL INJECTION SYSTEM
EAS27340
CIRCUIT DIAGRAM
FUEL INJECTION SYSTEM
1. Crankshaft position sensor
4. Load control relay
5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
10.Fuel injection system fuse
13.Fuel injection system relay
14.Air induction system solenoid
17.Gear position switch
19.Yamaha diagnostic tool coupler
20.ISC (idle speed control) unit
21.ECU (engine control unit)
22.Ignition coil
23.Spark plug
24.Fuel injector
25.Intake air temperature sensor
26.Coolant temperature sensor
27.Speed sensor
28.TPS (throttle position sensor)
29.Intake air pressure sensor
30.Lean angle sensor
33.Joint coupler
39.Multi-function meter
40.Engine trouble warning light
49.Fuel pump
59.Ignition fuse
60.Backup fuse
61.Signaling system fuse
66.Radiator fan motor relay
B. Wire harness
C. Negative battery sub-wire harness
9-34
FUEL INJECTION SYSTEM
EAS27350
ECU SELF-DIAGNOSTIC FUNCTION
The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is
operating normally. If this function detects a malfunction in the system, it immediately operates the 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 warning light
comes on when the main switch is being turned 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.
• After the engine has been stopped, the lowest fault code number appears on the multi-function meter
display. 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 main switch
is turned to “ (on)”:
Fuel injector
12:
Crankshaft position sensor
39:
(open or short-circuit)
30:
Lean angle sensor
(latch up detected)
41:
Lean angle sensor
(open or short-circuit)
33:
Faulty ignition
50:
ECU internal malfunction
(faulty ECU memory)
Checking for a defective engine trouble warning light bulb
The engine trouble warning light comes on for around 2 seconds after the main switch has been turned
to “ (on)”. If the warning light does not come on under these conditions, the warning light (LED) may
be defective.
ECU detects an abnormal signal from a sensor
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.
9-35
FUEL INJECTION SYSTEM
5. Erase the malfunction history in the diagnostic mode (code No. 62). Refer to “SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC
CODE TABLE” on page 10-5.
EAS27400
TROUBLESHOOTING METHOD
The engine operation is not normal and the
engine trouble warning light comes on.
1. Check:
• Fault code number
TIP
Turning the main switch to “ ” (off) will not
erase the malfunction history.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the fault code number displayed on
the multi-function meter.
b. Identify the faulty system with the fault code.
c. Identify the probable cause of the malfunction.
The engine operation is not normal, but the
engine trouble warning light does not come
on.
1. Check the operation of the following sensors
and actuators in the diagnostic mode.
Refer to “TROUBLESHOOTING DETAILS
(FUEL INJECTION SYSTEM)” on page 9-38
and “SELF-DIAGNOSTIC FUNCTION AND
DIAGNOSTIC CODE TABLE” on page 10-5.
01: Throttle position sensor signal (throttle
angle)
30: Ignition coil
36: Injector
48: Air induction system solenoid
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check and repair the probable cause of malfunction.
Fault code No.
No fault code No.
Check and repair.
Check and repair.
Refer to “TROUBLESHOOTING DETAILS
(FUEL INJECTION
SYSTEM)” on page
9-38.
Monitor the operation of the sensors
and actuators in the
diagnostic mode.
Refer to “TROUBLESHOOTING DETAILS
(FUEL INJECTION
SYSTEM)” on page
9-38 and “SELF-DIAGNOSTIC FUNCTION AND
DIAGNOSTIC CODE
TABLE” on page
10-5.
If a malfunction is detected in the sensors or
actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors
and actuators, check and repair inner parts of
the engine.
3. Perform the reinstatement action for the fuel
injection system.
Refer to “Confirmation of service completion”
of table in “TROUBLESHOOTING DETAILS
(FUEL INJECTION SYSTEM)” on page 9-38.
4. Turn the main switch to “ ” (off) and back to
“ ” (on), then check that no fault code number is displayed.
TIP
If another fault code are displayed, repeat steps
(1) to (4) until no fault code number is displayed.
9-36
FUEL INJECTION SYSTEM
EAS1XD1003
YAMAHA DIAGNOSTIC TOOL
This model uses the Yamaha diagnostic tool to identify malfunctions.
For information about using the Yamaha diagnostic tool, refer to the operation manual that is
included with the tool.
Yamaha diagnostic tool
90890-03215
Features of the Yamaha diagnostic tool
You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional
methods.
By connecting the adapter interface, which is connected to the USB port of a computer, to a vehicle’s
ECU using the communication cable, you can display information that is necessary for identifying malfunctions and for maintenance to display on the computer. The displayed information includes the sensor output data and information recorded in the ECU.
Functions of the Yamaha diagnostic tool
Fault diagnosis mode:
Fault codes recorded on the ECU are read, and the contents are
displayed.
Function diagnostic mode:
Check the operation of the output value of each sensor and actuator.
Inspection mode:
Determine whether each sensor or actuator is functioning properly.
Monitoring mode:
Displays a graph of sensor output values for actual operating
conditions.
Logging mode:
Records and saves the sensor output value in actual driving conditions.
View log:
Displays the logging data.
ECU rewrite:
If necessary, the ECU is rewritten using ECU rewrite data provided by Yamaha.
Ignition timing adjustment, etc. cannot be changed from the vehicle’s original state.
However, the diagnostic tool cannot be used to freely change the basic vehicle functions, such as
adjusting the ignition timing.
Connecting the Yamaha diagnostic tool
Remove the protective cap, and then connect the Yamaha diagnostic tool to the coupler “1”.
1
TIP
When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter
and indicators will be different from the normal operation.
9-37
FUEL INJECTION SYSTEM
EAS1XD1032
TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM)
This section describes the measures per fault code number displayed on the multi-function meter display. 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 multi-function
meter display according to the “Confirmation of service completion”.
Fault code No.:
Fault code number displayed on the multi-function meter when the engine failed to work normally.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 10-5.
Fault code No.
12
Item
Crankshaft position sensor: no normal signals are received
from the crankshaft position sensor.
Fail-safe system
Unable to start engine
Unable to drive vehicle
Diagnostic code No.
—
Indicated
—
Procedure
—
Item
Probable cause of malfunction and check
Maintenance job
Confirmation of service
completion
1
Connection of crankshaft position sensor coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Crank the engine.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 2.
2
Connection of ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Crank the engine.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 3.
3
Wire harness continuity.
Open or short circuit → Replace the wire harness.
Between crankshaft position
sensor coupler and ECU
coupler.
gray–gray
Between crankshaft position
sensor coupler and joint coupler.
black/blue–black/blue
Between joint coupler and
ECU coupler.
black/blue–black/blue
Crank the engine.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 4.
9-38
FUEL INJECTION SYSTEM
Fault code No.
12
Item
Crankshaft position sensor: no normal signals are received
from the crankshaft position sensor.
4
Installed condition of crankshaft position sensor.
Check for looseness or
pinching.
Improperly installed sensor
→ Reinstall or replace the
sensor.
Crank the engine.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 5.
5
Defective crankshaft position sensor.
Check the crankshaft position sensor.
Refer to “CHECKING THE
CRANKSHAFT POSITION
SENSOR” on page 9-99.
Replace if defective.
Crank the engine.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 6.
6
Malfunction in ECU.
Replace the ECU.
Fault code No.
13
Item
Intake air pressure sensor: open or short circuit detected.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No.
03
Indicated
Displays the intake air pressure.
Procedure
Turn and hold the main switch in the “ ” (start) position, then
press the accelerator pedal. (If the display value changes, the performance is OK.)
Item
Probable cause of malfunction and check
Maintenance job
Confirmation of service
completion
1
Connection of intake air
pressure sensor coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 2.
2
Connection of ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 3.
9-39
FUEL INJECTION SYSTEM
Fault code No.
13
Item
Intake air pressure sensor: open or short circuit detected.
3
Wire harness continuity.
Open or short circuit → Replace the wire harness.
Between intake air pressure
sensor coupler and ECU
coupler.
pink–pink
Between intake air pressure
sensor coupler and joint coupler.
blue–blue
black/blue–black/blue
Between joint coupler and
ECU coupler.
blue–blue
black/blue–black/blue
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 4.
4
Installed condition of intake
air pressure sensor.
Check for looseness or
pinching.
Improperly installed sensor
→ Reinstall or replace the
sensor.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 5.
5
Defective intake air pressure
sensor.
Execute the diagnostic
mode. (Code No. 03)
When engine is stopped:
Atmospheric pressure at the
current altitude and weather
conditions is indicated.
At sea level: Approx. 101 kPa
(757.6 mmHg, 29.8 inHg)
1000 m (3300 ft) above sea
level: Approx. 90 kPa (675.1
mmHg, 26.6 inHg)
2000 m (6700 ft) above sea
level: Approx. 80 kPa (600.0
mmHg, 23.6 inHg)
3000 m (9800 ft) above sea
level: Approx. 70 kPa (525.0
mmHg, 20.7 inHg)
When engine is cranking:
Make sure that the indication
value changes.
The value does not change
when engine is cranking. →
Check the intake air pressure
sensor.
Replace if defective.
Refer to “CHECKING THE
INTAKE AIR PRESSURE
SENSOR” on page 9-105.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 6.
6
Malfunction in ECU.
Replace the ECU.
9-40
FUEL INJECTION SYSTEM
TIP
If fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number
“13” first.
Fault code No.
14
Item
Intake air pressure sensor: hose system malfunction (clogged
or detached hose).
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No.
03
Indicated
Displays the intake air pressure.
Procedure
Turn and hold the main switch in the “ ” (start) position, then
press the accelerator pedal. (If the display value changes, the performance is OK.)
Item
Probable cause of malfunction and check
Maintenance job
1
Condition of intake air pres- Clogged or detached hose
sure sensor hose.
→ Repair or replace the senCheck the intake air pressure sor hose.
sensor hose condition.
2
Defective intake air pressure
sensor.
Execute the diagnostic
mode. (Code No. 03)
When engine is stopped:
Atmospheric pressure at the
current altitude and weather
conditions is indicated.
At sea level: Approx. 101 kPa
(757.6 mmHg, 29.8 inHg)
1000 m (3300 ft) above sea
level: Approx. 90 kPa (675.1
mmHg, 26.6 inHg)
2000 m (6700 ft) above sea
level: Approx. 80 kPa (600.0
mmHg, 23.6 inHg)
3000 m (9800 ft) above sea
level: Approx. 70 kPa (525.0
mmHg, 20.7 inHg)
When engine is cranking:
Make sure that the indication
value changes.
The value does not change
when engine is cranking. →
Check the intake air pressure
sensor.
Replace if defective.
Refer to “CHECKING THE
INTAKE AIR PRESSURE
SENSOR” on page 9-105.
9-41
Confirmation of service
completion
Start the engine and let it idle
for approximately 5 seconds.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 2.
FUEL INJECTION SYSTEM
TIP
If fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number
“13” first.
Fault code No.
15
Item
Throttle position sensor: open or short circuit detected.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No.
01
Indicated
Throttle position sensor signal
• 14–20 (fully closed position)
Procedure
Check with throttle valve fully closed.
Item
Probable cause of malfunction and check
Maintenance job
Confirmation of service
completion
1
Connection of throttle position sensor coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 2.
2
Connection of ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 3.
3
Wire harness continuity.
Open or short circuit → Replace the wire harness.
Between throttle position
sensor coupler and ECU
coupler.
yellow–yellow
Between throttle position
sensor coupler and joint coupler.
blue–blue
black/blue–black/blue
Between joint coupler and
ECU coupler.
blue–blue
black/blue–black/blue
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 4.
4
Installed condition of throttle
position sensor.
Check for looseness or
pinching.
Improperly installed sensor
→ Reinstall or adjust the
sensor.
Refer to “ADJUSTING THE
THROTTLE POSITION
SENSOR” on page 7-12.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 5.
9-42
FUEL INJECTION SYSTEM
Fault code No.
15
Item
Throttle position sensor: open or short circuit detected.
5
Throttle position sensor resistance.
Measure the throttle position
sensor resistance.
Refer to “CHECKING THE
THROTTLE POSITION
SENSOR” on page 9-104.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 6.
6
Defective throttle position
sensor.
Check throttle position sensor signal.
Execute the diagnostic
mode. (Code No. 01)
When the throttle valve is fully closed:
A value of 14–20 is indicated.
An indicated value is out of
the specified range → Replace the throttle position
sensor.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 7.
7
Malfunction in ECU.
Replace the ECU.
TIP
If fault code numbers “15” and “16” are both indicated, take the actions specified for fault code number
“15” first.
Fault code No.
16
Item
Throttle position sensor: stuck throttle position sensor is detected.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No.
01
Indicated
Throttle position sensor signal
• 14–20 (fully closed position)
Procedure
Check with throttle valve fully closed.
Item
1
Probable cause of malfunction and check
Installed condition of throttle
position sensor.
Check for looseness or
pinching.
Maintenance job
Improperly installed sensor
→ Reinstall or adjust the
sensor.
Refer to “ADJUSTING THE
THROTTLE POSITION
SENSOR” on page 7-12.
9-43
Confirmation of service
completion
Turn the main switch to “ ”
(on), then press the accelerator pedal.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 2.
FUEL INJECTION SYSTEM
Fault code No.
16
Item
Throttle position sensor: stuck throttle position sensor is detected.
2
Defective throttle position
sensor.
Check throttle position sensor signal.
Execute the diagnostic
mode. (Code No. 01)
When the throttle valve is fully closed:
A value of 14–20 is indicated.
An indicated value is out of
the specified range → Replace the throttle position
sensor.
3
Malfunction in ECU.
Replace the ECU.
Turn the main switch to “ ”
(on), then operate the throttle.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 3.
TIP
• If fault code numbers “15” and “16” are both indicated, take the actions specified for fault code number
“15” first.
• If fault code numbers “16” and “37” are both indicated, take the actions specified for fault code number
“16” first.
Fault code No.
21
Item
Coolant temperature sensor: open or short circuit detected.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No.
06
Indicated
Displays the coolant temperature.
Procedure
Compare the actually measured coolant temperature with the
meter display value.
Item
Probable cause of malfunction and check
Maintenance job
Confirmation of service
completion
1
Connection of coolant temperature sensor coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 2.
2
Connection of ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 3.
9-44
FUEL INJECTION SYSTEM
Fault code No.
21
Item
Coolant temperature sensor: open or short circuit detected.
Open or short circuit → Replace the wire harness.
Between coolant temperature sensor coupler and ECU
coupler.
green/yellow–green/yellow
Between coolant temperature sensor coupler and joint
coupler.
black/blue–black/blue
Between joint coupler and
ECU coupler.
black/blue–black/blue
3
Wire harness continuity.
4
Installed condition of coolant Improperly installed sensor
temperature sensor.
→ Reinstall or replace the
Check for looseness or
sensor.
pinching.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 5.
5
Defective coolant temperature sensor.
Execute the diagnostic
mode. (Code No. 06)
When engine is cold:
Displayed temperature is
close to the ambient temperature.
The displayed temperature is
not close to the ambient temperature → Check the coolant temperature sensor.
Replace if defective.
Refer to “CHECKING THE
COOLANT TEMPERATURE
SENSOR” on page 9-103.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 6.
6
Malfunction in ECU.
Replace the ECU.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 4.
TIP
If fault code numbers “21” and “37” are both indicated, take the actions specified for fault code number
“21” first.
Fault code No.
22
Item
Intake air temperature sensor: open or short circuit detected.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No.
05
Indicated
Displays the intake air temperature.
Procedure
Compare the actually measured intake air temperature with the indicated value.
Item
Probable cause of malfunction and check
Maintenance job
9-45
Confirmation of service
completion
FUEL INJECTION SYSTEM
Fault code No.
22
Item
Intake air temperature sensor: open or short circuit detected.
1
Connection of intake air temperature sensor coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 2.
2
Connection of ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 3.
3
Wire harness continuity.
Open or short circuit → Replace the wire harness.
Between intake air temperature sensor coupler and ECU
coupler.
brown/white–brown/white
Between intake air temperature sensor coupler and joint
coupler.
black/blue–black/blue
Between joint coupler and
ECU coupler.
black/blue–black/blue
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 4.
4
Installed condition of intake
air temperature sensor.
Check for looseness or
pinching.
Improperly installed sensor
→ Reinstall or replace the
sensor.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 5.
5
Defective intake air tempera- Execute the diagnostic
ture sensor.
mode. (Code No. 05)
When engine is cold:
Displayed temperature is
close to the ambient temperature.
The displayed temperature is
not close to the ambient temperature. → Check the intake
air temperature sensor.
Replace if defective.
Refer to “CHECKING THE
INTAKE AIR TEMPERATURE SENSOR” on page
9-105.
6
Malfunction in ECU.
Replace the ECU.
9-46
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 6.
FUEL INJECTION SYSTEM
TIP
If fault code numbers “22” and “37” are both indicated, take the actions specified for fault code number
“22” first.
Fault code No.
30
Item
Latch up detected.
Fail-safe system
Unable to start engine
Unable to drive vehicle
Diagnostic code No.
08
Indicated
Lean angle sensor output voltage
• 3.6–4.4 (upright)
• 0.7–1.3 (overturned)
Procedure
Remove the lean angle sensor and incline it more than 65 degrees.
Item
Probable cause of malfunction and check
Maintenance job
Confirmation of service
completion
1
The vehicle has overturned.
Raise the vehicle upright.
Turn the main switch to “ ”
(on), then to “ ” (off), and
then back to “ ” (on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 2.
2
Installed condition of lean
angle sensor.
Check the installed direction
and condition of the sensor.
Turn the main switch to “ ”
(on), then to “ ” (off), and
then back to “ ” (on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 3.
3
Defective lean angle sensor.
Execute the diagnostic
mode. (Code No. 08)
An indicated value is out of
the specified range → Check
the lean angle sensor.
Replace if defective.
Refer to “CHECKING THE
LEAN ANGLE SENSOR” on
page 9-100.
Turn the main switch to “ ”
(on) then to “ ” (off), and
then back to “ ” (on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 4.
4
Malfunction in ECU.
Replace the ECU.
Fault code No.
33
Item
Ignition coil: open or short circuit detected in the primary lead
of the ignition coil.
Fail-safe system
Diagnostic code No.
Unable to start engine
Unable to drive vehicle
30
9-47
FUEL INJECTION SYSTEM
Fault code No.
33
Item
Ignition coil: open or short circuit detected in the primary lead
of the ignition coil.
Actuation
Actuates the ignition coil five times at one-second intervals.
The “CHECK” indicator and “
” on the Yamaha diagnostic tool
screen come on each time the ignition coil is actuated.
Procedure
Check that a spark is generated five times.
• Connect an ignition checker.
Item
Probable cause of malfunction and check
Maintenance job
Confirmation of service
completion
1
Connection of ignition coil
connector.
Check the locking condition
of the connector.
Disconnect the connector
and check the pins (bent or
broken terminals and locking condition of the pins).
Improperly connected →
Connect the connector securely or replace the wire
harness.
Start the engine and let it idle
for approximately 5 seconds.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 2.
2
Connection of ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Start the engine and let it idle
for approximately 5 seconds.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 3.
3
Wire harness continuity.
Open or short circuit → Replace the wire harness.
Between ignition coil connector and ECU coupler.
orange–orange
Start the engine and let it idle
for approximately 5 seconds.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 4.
4
Installed condition of ignition
coil.
Check for looseness or
pinching.
Improperly installed ignition
coil → Reinstall or replace
the ignition coil.
Start the engine and let it idle
for approximately 5 seconds.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 5.
5
Defective ignition coil.
Measure the primary coil resistance of the ignition coil.
Replace if out of specification.
Refer to “CHECKING THE
IGNITION COIL” on page
9-98.
Start the engine and let it idle
for approximately 5 seconds.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 6.
6
Malfunction in ECU.
Execute the diagnostic
mode. (Code No. 30)
No spark → Replace the
ECU.
9-48
FUEL INJECTION SYSTEM
Fault code No.
37
A
Component other than ISC (idle speed control) unit is defective (ISC operating sound is heard).
B
Defective ISC (idle speed control) unit (ISC operating sound is
not heard).
Item
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No.
54
Actuation
Actuates and fully closes the ISC valve, then opens it to the standby opening position when the engine is started.
This operation takes approximately 3 seconds until it is compleated.
The “CHECK” indicator and “
” on the Yamaha diagnostic tool
screen come on during the operation.
Procedure
The operating sound can be heard when ISC valve operates.
Item
Probable cause of malfunction and check
Maintenance job
Confirmation of service
completion
1
Locate the malfunction.
Execute the diagnostic
mode. (Code No. 54)
Fully closes the ISC (idle
speed control) valve, and
then fully opens the valve.
ISC operating sound is heard
→ Go to item 2.
ISC operating sound is not
heard → Go to item 2 in section B for the defective ISC
(idle speed control) unit.
2
Incorrect speed sensor signal.
Check the speed sensor.
Execute the diagnostic
mode. (Code No. 07)
Rotate the rear wheel by
hand and check that the indicated value increases.
Value does not increase →
Go to fault code No. 42.
Start the engine and let it idle
for approximately 10 seconds.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 3.
3
Throttle valve does not fully
close.
Check the throttle body.
Refer to “THROTTLE BODY”
on page 7-8.
Check the throttle cable.
Refer to “ADJUSTING THE
ACCELERATOR PEDAL
FREE PLAY” on page 3-21.
Start the engine and let it idle
for approximately 10 seconds.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 4.
4
ISC valve is not moving correctly.
Replace the throttle body as- Start the engine and let it idle
sembly.
for approximately 10 seconds.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 5.
5
Malfunction in ECU.
Replace the ECU.
9-49
FUEL INJECTION SYSTEM
TIP
• Do not remove the ISC (idle speed control) valve.
• If fault code numbers “21” and “37” are both indicated, take the actions specified for fault code number
“21” first.
• If fault code numbers “22” and “37” are both indicated, take the actions specified for fault code number
“22” first.
• If fault code numbers “37” and “46” are both indicated, take the actions specified for fault code number
“46” first.
• If fault code numbers “37” and “42” are both indicated, take the actions specified for fault code number
“42” first.
Fault code No.
37
A
Component other than ISC (idle speed control) unit is defective
(ISC operating sound is heard).
B
Defective ISC (idle speed control) unit (ISC operating
sound is not heard).
Item
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No.
54
Actuation
Actuates and fully closes the ISC valve, then opens it to the standby opening position when the engine is started.
This operation takes approximately 3 seconds until it is completed.
The “CHECK” indicator and “
” on the Yamaha diagnostic tool
screen come on during the operation.
Procedure
The operating sound can be heard when ISC valve operates.
Item
Probable cause of malfunction and check
Maintenance job
Confirmation of service
completion
1
Locate the malfunction.
Execute the diagnostic
mode. (Code No. 54)
Fully closes the ISC (idle
speed control) valve, and
then fully opens the valve.
ISC operating sound is heard
→ Go to item 2 in section A
for the component other than
ISC (idle speed control) unit
is defective.
ISC operating sound is not
heard → Go to item 2.
2
Connection of ISC (idle
speed control) unit coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Execute the diagnostic
mode. (Code No. 54)
ISC operating sound is heard
→ Go to item 8.
ISC operating sound is not
heard → Go to item 3.
3
Connection of ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Execute the diagnostic
mode. (Code No. 54)
ISC operating sound is heard
→ Go to item 8.
ISC operating sound is not
heard → Go to item 4.
9-50
FUEL INJECTION SYSTEM
Fault code No.
37
A
Component other than ISC (idle speed control) unit is defective
(ISC operating sound is heard).
B
Defective ISC (idle speed control) unit (ISC operating
sound is not heard).
Item
4
Wire harness continuity.
Open or short circuit → Replace the wire harness.
Between ISC (idle speed
control) unit coupler and
ECU coupler.
red/green–red/green
pink/blue–pink/blue
white/green–white/green
brown/blue–brown/blue
Between ISC (idle speed
control) unit coupler and joint
coupler.
red/white–red/white
red/white–red/white
Execute the diagnostic
mode. (Code No. 54)
ISC operating sound is heard
→ Go to item 8.
ISC operating sound is not
heard → Go to item 5.
5
Installed condition of ISC
(idle speed control) unit.
Check for looseness or
pinching.
Improperly installed ISC (idle
speed control) unit → Reinstall the ISC (idle speed control) unit.
Execute the diagnostic
mode. (Code No. 54)
ISC operating sound is heard
→ Go to item 8.
ISC operating sound is not
heard → Go to item 6.
6
ISC valve is not moving correctly.
Replace the throttle body as- Execute the diagnostic
sembly.
mode. (Code No. 54)
ISC operating sound is heard
→ Go to item 8.
ISC operating sound is not
heard → Go to item 7.
7
Malfunction in ECU.
Replace the ECU.
8
Delete the fault code.
Start the engine and let it idle
for approximately 10 seconds.
Check that the fault code
number is not displayed.
TIP
• Do not remove the ISC (idle speed control) valve.
• If fault code numbers “21” and “37” are both indicated, take the actions specified for fault code number
“21” first.
• If fault code numbers “22” and “37” are both indicated, take the actions specified for fault code number
“22” first.
• If fault code numbers “37” and “46” are both indicated, take the actions specified for fault code number
“46” first.
• If fault code numbers “37” and “42” are both indicated, take the actions specified for fault code number
“42” first.
9-51
FUEL INJECTION SYSTEM
Fault code No.
39
Item
Injector: open or short circuit detected.
Fail-safe system
Unable to start engine
Unable to drive vehicle
Diagnostic code No.
36
Actuation
Actuates injector five times at one-second intervals.
The “CHECK” indicator and “
” on the Yamaha diagnostic tool
screen come on each time the fuel injector is actuated.
Procedure
Check that injector is actuated five times by listening for the operating sound.
Item
Probable cause of malfunction and check
Maintenance job
Confirmation of service
completion
1
Connection of injector coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Execute the diagnostic
mode. (Code No. 36)
Operating sound → Go to
item 6.
No operating sound → Go to
item 2.
2
Defective injector.
Measure the injector resistance.
Replace if out of specification.
Refer to “CHECKING THE
FUEL INJECTOR” on page
9-106.
Execute the diagnostic
mode. (Code No. 36)
Operating sound → Go to
item 6.
No operating sound → Go to
item 3.
3
Connection of ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Execute the diagnostic
mode. (Code No. 36)
Operating sound → Go to
item 6.
No operating sound → Go to
item 4.
4
Wire harness continuity.
Open or short circuit → Replace the wire harness.
Between injector coupler and
ECU coupler.
red–red
Between injector coupler and
joint coupler.
red/blue–red/blue
Execute the diagnostic
mode. (Code No. 36)
Operating sound → Go to
item 6.
No operating sound → Go to
item 5.
5
Malfunction in ECU.
Replace the ECU.
6
Delete the fault code.
Start the engine and let it idle
for approximately 5 seconds.
Check that the fault code
number is not displayed.
9-52
FUEL INJECTION SYSTEM
Fault code No.
41
Item
Lean angle sensor: open or short circuit detected.
Fail-safe system
Unable to start engine
Unable to drive vehicle
Diagnostic code No.
08
Indicated
Lean angle sensor output voltage
• 3.6–4.4 (upright)
• 0.7–1.3 (overturned)
Procedure
Remove the lean angle sensor and incline it more than 65 degrees.
Item
Probable cause of malfunction and check
Maintenance job
Confirmation of service
completion
1
Connection of lean angle
sensor coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Turn the main switch to “ ”
(on), then to “ ” (off), and
then back to “ ” (on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 2.
2
Connection of ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Turn the main switch to “ ”
(on), then to “ ” (off), and
then back to “ ” (on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 3.
3
Wire harness continuity.
Open or short circuit → Replace the wire harness.
Between lean angle sensor
coupler and ECU coupler.
yellow/green–yellow/green
Between lean angle sensor
coupler and joint coupler.
blue–blue
black/blue–black/blue
Between joint coupler and
ECU coupler.
blue–blue
black/blue–black/blue
Turn the main switch to “ ”
(on), then to “ ” (off), and
then back to “ ” (on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 4.
4
Defective lean angle sensor.
Execute the diagnostic
mode. (Code No. 08)
An indicated value is out of
the specified range → Check
the lean angle sensor.
Replace if defective.
Refer to “CHECKING THE
LEAN ANGLE SENSOR” on
page 9-100.
Turn the main switch to “ ”
(on), then to “ ” (off), and
then back to “ ” (on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 5.
5
Malfunction in ECU.
Replace the ECU.
9-53
FUEL INJECTION SYSTEM
Fault code No.
42
Item
Speed sensor: no normal signals are received from the speed
sensor.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No.
07
Indicated
Vehicle speed pulse
0–999
Procedure
Check that the number increases when the rear wheels are rotated. The number is cumulative and does not reset each time the
wheel is stopped.
Item
Probable cause of malfunction and check
Maintenance job
Confirmation of service
completion
1
Connection of speed sensor
coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Turn the main switch to “ ”
(on), and then rotate the rear
wheel by hand.
Fault code number is not displayed → Go to item 6.
Fault code number is displayed → Go to item 2.
2
Connection of ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Turn the main switch to “ ”
(on), and then rotate the rear
wheel by hand.
Fault code number is not displayed → Go to item 6.
Fault code number is displayed → Go to item 3.
3
Wire harness continuity.
Open or short circuit → Replace the wire harness.
Between speed sensor coupler and ECU coupler.
white–white
Between speed sensor coupler and joint coupler.
blue–blue
black/blue–black/blue
Between joint coupler and
ECU coupler.
blue–blue
black/blue–black/blue
Turn the main switch to “ ”
(on), and then rotate the rear
wheel by hand.
Fault code number is not displayed → Go to item 6.
Fault code number is displayed → Go to item 4.
4
Defective speed sensor.
Execute the diagnostic
mode. (Code No. 07)
While the rear wheels and
stopped, check that the indicated value does not
change.
Rotate the rear wheel by
hand and check that the indicated value increases.
Malfunction → Replace the
speed sensor.
Turn the main switch to “ ”
(on), and then rotate the rear
wheel by hand.
Fault code number is not displayed → Go to item 6.
Fault code number is displayed → Go to item 5.
9-54
FUEL INJECTION SYSTEM
Fault code No.
42
Item
Speed sensor: no normal signals are received from the speed
sensor.
5
Malfunction in ECU.
6
Delete the fault code.
Replace the ECU.
Start the engine, and input
the vehicle speed signals by
operating the vehicle at 20 to
30 km/h (12 to 19 mph).
Check that the fault code
number is not displayed.
TIP
If fault code numbers “37” and “42” are both indicated, take the actions specified for fault code number
“42” first.
Fault code No.
43
Item
Fuel system voltage: incorrect voltage supplied to the fuel injector and fuel pump.
Fail-safe system
Diagnostic code No.
09, 50
Fuel system voltage (battery voltage)
Approximately 12.0
Procedure
Turn the main switch to “ ” (on), and then compare the actually
measured battery voltage with the display value. (If the actually
measured battery voltage is low, recharge the battery.)
Actuation
Actuates the fuel injection system relay five times at one-second
intervals.
The “CHECK” indicator and “
” on the Yamaha diagnostic tool
screen come on each time the relay is actuated.
(When the relay is on, the “CHECK” indicator and “
” on the
Yamaha diagnostic tool screen go off. When the relay is off, the
“CHECK” indicator and “
” on the Yamaha diagnostic tool
screen come on.)
Procedure
Check that the fuel injection system relay is actuated five times by
listening for the operating sound.
50
1
Able to drive vehicle
Indicated
09
Item
Able to start engine
Probable cause of malfunction and check
Connection of fuel injection
system relay coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Maintenance job
Improperly connected →
Connect the coupler securely or replace the wire harness.
9-55
Confirmation of service
completion
Start the engine and let it idle
for approximately 5 seconds.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 2.
FUEL INJECTION SYSTEM
Fault code No.
43
Item
Fuel system voltage: incorrect voltage supplied to the fuel injector and fuel pump.
2
Connection of ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Start the engine and let it idle
for approximately 5 seconds.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 3.
3
Wire harness continuity.
Open or short circuit → Replace the wire harness.
Between fuel injection system relay coupler and ECU
coupler.
blue/red–blue/red
Between fuel injection system relay coupler and joint
coupler.
red/blue–red/blue
Between joint coupler and
ECU coupler.
red/blue–red/blue
Between ECU coupler and
joint coupler.
red/white–red/white
Between joint coupler and
backup fuse.
red/white–red/white
Between main switch coupler
and ECU coupler.
brown/red–brown/red
Start the engine and let it idle
for approximately 5 seconds.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 4.
4
Defective fuel injection system relay.
Execute the diagnostic
mode. (Code No. 50)
No operating sound → Replace the fuel injection system relay.
Start the engine and let it idle
for approximately 5 seconds.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 5.
5
Defective fuel injection system relay.
Execute the diagnostic
mode. (Code No. 09)
Fuel system voltage is below 3 V → Replace the fuel
injection system relay.
Start the engine and let it idle
for approximately 5 seconds.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 6.
6
Malfunction in ECU.
Replace the ECU.
Fault code No.
44
Item
EEPROM fault code number: an error is detected while reading
or writing on EEPROM.
Fail-safe system
Diagnostic code No.
Able to start engine
Able to drive vehicle
60
9-56
FUEL INJECTION SYSTEM
Fault code No.
44
Item
EEPROM fault code number: an error is detected while reading
or writing on EEPROM.
Indicated
The fault code No. 44 detected EEPROM errors are indicated.
00 indication: Normal status
Procedure
—
Item
Probable cause of malfunction and check
Maintenance job
Confirmation of service
completion
1
Locate the malfunction.
Execute the diagnostic
mode. (Code No. 60)
01 indication: Go to item 2
—
2
“01” is indicated in diagnostic
mode (code No. 60). EEPROM data error for adjustment of CO concentration.
Change the CO concentration, and rewrite in EEPROM.
Refer to “ADJUSTING THE
EXHAUST GAS VOLUME
(for Europe and Oceania)”
on page 3-6.
After this adjustment is
made, the memory is not recovered when the main
switch is turned to “ ” (off).
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Repeat item 1. If
the same number is indicated, go to item 3.
3
Malfunction in ECU.
Replace the ECU.
Fault code No.
46
Item
Charging voltage is abnormal.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No.
—
Indicated
—
Procedure
—
Item
1
Probable cause of malfunction and check
Malfunction in charging system.
Maintenance job
Check the charging system.
Refer to “CHARGING SYSTEM” on page 9-11.
Defective rectifier/regulator
or AC magneto → Replace.
Defective connection in the
charging system circuit →
Properly connect or replace
the wire harness.
Confirmation of service
completion
Start the engine and let it idle
for approximately 5 seconds.
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Repeat the maintenance job.
TIP
If fault code numbers “37” and “46” are both indicated, take the actions specified for fault code number
“46” first.
9-57
FUEL INJECTION SYSTEM
Fault code No.
50
Item
Faulty ECU (engine control unit) memory. (When this malfunction is detected in the ECU, the fault code number might not
appear.)
Fail-safe system
Unable to start engine
Unable to drive vehicle
Diagnostic code No.
—
Indicated
—
Procedure
—
Item
1
Probable cause of malfunction and check
Malfunction in ECU.
Maintenance job
Replace the ECU.
Confirmation of service
completion
Turn the main switch to “ ”
(on).
Check that the fault code
number is not displayed.
Fault code No.
Er-1
Item
ECU (engine control unit) internal malfunction (output signal
error): signals cannot be transmitted between the ECU and the
multi-function meter.
Fail-safe system
Able to start engine (unable when ECU is malfunctioning)
Able to drive vehicle (unable when ECU is malfunctioning)
Diagnostic code No.
—
Indicated
—
Procedure
—
Item
Probable cause of malfunction and check
Maintenance job
Confirmation of service
completion
1
Connection of meter assembly coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 2.
2
Connection of ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 3.
3
Wire harness continuity.
Open or short circuit → Replace the wire harness.
Between meter assembly
coupler and ECU coupler.
yellow/blue–yellow/blue
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 4.
9-58
FUEL INJECTION SYSTEM
Fault code No.
Er-1
Item
ECU (engine control unit) internal malfunction (output signal
error): signals cannot be transmitted between the ECU and the
multi-function meter.
4
Defective meter assembly.
Replace the meter assembly. Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 5.
5
Malfunction in ECU.
Replace the ECU.
Fault code No.
Er-2
Item
ECU (engine control unit) internal malfunction (output signal
error): no signals are received from the ECU within the specified duration.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No.
—
Indicated
—
Procedure
—
Item
Probable cause of malfunction and check
Maintenance job
Confirmation of service
completion
1
Connection of meter assembly coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 2.
2
Connection of ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 3.
3
Wire harness continuity.
Open or short circuit → Replace the wire harness.
Between meter assembly
coupler and ECU coupler.
yellow/blue–yellow/blue
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 4.
4
Defective meter assembly.
Replace the meter assembly. Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 5.
9-59
FUEL INJECTION SYSTEM
Fault code No.
Er-2
Item
ECU (engine control unit) internal malfunction (output signal
error): no signals are received from the ECU within the specified duration.
5
Malfunction in ECU.
Replace the ECU.
Fault code No.
Er-3
Item
ECU (engine control unit) internal malfunction (output signal
error): data from the ECU cannot be received correctly.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No.
—
Indicated
—
Procedure
—
Item
Probable cause of malfunction and check
Maintenance job
Confirmation of service
completion
1
Connection of meter assembly coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 2.
2
Connection of ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 3.
3
Wire harness continuity.
Open or short circuit → Replace the wire harness.
Between meter assembly
coupler and ECU coupler.
yellow/blue–yellow/blue
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 4.
4
Defective meter assembly.
Replace the meter assembly. Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 5.
5
Malfunction in ECU.
Replace the ECU.
9-60
FUEL INJECTION SYSTEM
Fault code No.
Er-4
Item
ECU (engine control unit) internal malfunction (input signal error): non-registered data has been received from the meter assembly.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No.
—
Indicated
—
Procedure
—
Item
Probable cause of malfunction and check
Maintenance job
Confirmation of service
completion
1
Connection of meter assembly coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 2.
2
Connection of ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken terminals and locking
condition of the pins).
Improperly connected →
Connect the coupler securely or replace the wire harness.
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 3.
3
Wire harness continuity.
Open or short circuit → Replace the wire harness.
Between meter assembly
coupler and ECU coupler.
yellow/blue–yellow/blue
Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 4.
4
Defective meter assembly.
Replace the meter assembly. Turn the main switch to “ ”
(on).
Fault code number is not displayed → Service is finished.
Fault code number is displayed → Go to item 5.
5
Malfunction in ECU.
Replace the ECU.
9-61
FUEL INJECTION SYSTEM
9-62
9-63
L
B
R/L
B
64
L
R/W
B
(Gy)
W
(Gy)
W W
65
R/L
Y/R
Br/R
R
R/W
Y/R
B R/W
Br/R
R/L
R
66
(Gy)
W
(Gy)
W W
Gy
B/L Gy
1
Br/L
B
4
R
B
B/L
Br/R
2
Gy
B
R
Br/R
R/B
Br/L
Br/L
Br/R
R
W W
W W
W W
(Gy)
W W W
B
3
R
BB B
R
(B)
5
R/B Br/R
B
Br/Y
57
58
59
60
63
62
61
(B)
L/Y Br/R
R
Br/L
R
R/W
Br/Y
Br/Y
Br
W/B
Br/R R/B Br/R L/Y
(off)
(on)
(start)
6
B
Br/Y B
B
B
Y L
56
8
B
Y
55
9
56
Y LL
(B)
Br Y
(B)
7
B A B
R
Y Br/Y
R
R
(B)
R
Y
Br
B
54
W/B
W/B B
B
R/Y
L/Y
Br/Y
L
(B)
L
Br/Y
B
Y G
B
G
Y
Br
B
Y
53
Y
Y
Br/R
G
G
Y G
B
Y
L Y
L/R
Br/B
R/L
R/L
13
R/L
Br/B
14
L
L
L
Br
L/R
(B)
Br/Y R/W
68
Br/R
Br/Y
B G/W
52
(off)
51
Y G B
Y
L
(B)
Br/B
R/Y L/Y
11
10
Br/B
12
R
W
B
G W/B G
R
(B)
W
67
Br/Y
B
B
R
L Br/Y
A
B
Y G
Y
53
B
Y G
B
G
R/W
B
Br/Y L
G/W
Br/R
Br/B
50
Y/B B
(B)
Br/R B G/R
(B)
Br/R B Y/B
Br/R
B/Y
15
B/Y
O/L B/Y
P/W B/G
16
B/W
Y/W
(B)
P/L L/B Br/L
O
Br/R
G/R
B
Br/B
(Gy)
B
49
R/L
B
B/W
O/B
R/W
Br/Y
O/B
(Dg)
R/L B B/W O/B
48
(B)
W/R Sb
Gy/G
(B)
L W
Gy
17 L Gy W
Gy/G
Sb W/R
(B)
Br/L R/W P/L
W/G R/W R/G
W/R B/R L B/L L/W R/W
B/R
W/B
Br/B
(B)
Y/L Y
B/G P/W W/B B/R B O/L Br/B B/Y
Br/R
Br/R
Br/R
19
B/W R/W
Y/W
Lg G/Y R/L G/W Y L/Y
R/W
B
R/W L/B R/G G/R W/G Y/B R
Br/W W Gy P Y/G P/W Sb O/L Y/W B/G Gy/G W/B L/R B/W G/R Br/R
Y/R
R/Y
38
G/R L/W
B/W
(W)
B
L/W G/R
20
R/W
R/W
47
46
45
44
43
42
41
40
39
2WD
4WD
DIFF LOCK
18
B
B/W
L/W
W/G
Br/L
R/G
P/L
G/R
(B)
R/W
Y/L Br/Y B/W
O/B
Y/L
B/W
L/R
L/Y
Y
P/W
O/L
B/G
W/B
B/R
Sb
Gy/G
W/R
L/W
G/R
Y/L
R/W
R/Y
Y/R
Y/B
G/R
R/L
Y/W
W/G
Br/L
R/G
P/L
R/W
Gy
Br/R
G/W
B/W B
21
B L/B
L/R B
31
L/B
Y/G
L/B
Lg
P
B/L
Y
L
W
O
(B)
R
L
Br B
26
25
24
35
G/Y
Br/W
Br/R
B Br/Y
L/B
B
L/R
L/B
G/Y
Br/W
R
O
L
L/Y
B
36
Br
Br/Y
L
Y/G
B/L
L
P
B/L
L
Y
B/L
B/L
W
B/L
B/L
R/L
L/B
L
37
30
29
L W
B/L
(Gy)
L Y/G B/L
(B)
B/L P L
(B)
B/L Y L
W L/Y
B/L
28
(B)
G/Y B/L
(B)
Br/W B/L
(Gy)
R/L R
27
23
22
B
Lg
34
B
Lg
L
B
Lg
Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
L
L
L
L
L
R/W
R/W
R/W
R/W
R/W
R/W
L L L L
B/W
B/W
B/W
B/W
B/W
B/W
R/L
R/L
R/L
L/Y
L/Y
L/Y
33
G/W
G/W
G/W
Y
Y
Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
(B)
B/W B/W B/W B/W B/W B/W R/L R/L R/L L/Y L/Y L/Y
G/W G/W G/W Y Y
B/L
B/L
B/L
B/L
B/L
B/L
B/L
B/L
33
(B)
B/L B/L B/L B/L B/L B/L B/L B/L
R/W R/W R/W R/W R/W R/W
32
G/W
B
B
A
B
C
FUEL PUMP SYSTEM
EAS27550
FUEL PUMP SYSTEM
EAS27560
CIRCUIT DIAGRAM
FUEL PUMP SYSTEM
5. Frame ground
6. Main switch
8. Battery
9. Main fuse
10.Fuel injection system fuse
13.Fuel injection system relay
21.ECU (engine control unit)
33.Joint coupler
49.Fuel pump
59.Ignition fuse
B. Wire harness
C. Negative battery sub-wire harness
9-64
FUEL PUMP SYSTEM
EAS27570
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
• Before troubleshooting, remove the following part(s):
1. Outer passenger seat frame
2. Right passenger compartment panel
3. Right side panel
4. Right rear panel
5. Fuel tank
1. Check the fuses.
(Main, ignition, and fuel injection
system)
Refer to “CHECKING THE FUSES” on page 9-92.
NG →
Replace the fuse(s).
OK ↓
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 9-93.
NG →
• Clean the battery terminals.
• Recharge or replace the battery.
OK ↓
3. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 9-87.
NG →
Replace the main switch.
OK ↓
4. Check the fuel injection system relay.
Refer to “CHECKING THE RELAYS” on page 9-95.
NG →
Replace the fuel injection system relay.
OK ↓
5. Check the fuel pump.
Refer to “CHECKING THE FUEL
PUMP BODY” on page 7-2.
NG →
Replace the fuel pump assembly.
OK ↓
6. Check the entire fuel pump system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 9-63.
NG →
Properly connect or replace the wire harness.
OK ↓
Replace the ECU.
9-65
FUEL PUMP SYSTEM
9-66
9-67
L
B
R/L
B
64
L
R/W
B
(Gy)
W
(Gy)
W W
65
R/L
Y/R
Br/R
R
R/W
Y/R
B R/W
Br/R
R/L
R
66
(Gy)
W
(Gy)
W W
Gy
B/L Gy
1
Br/L
B
4
R
B
B/L
Br/R
2
Gy
B
R
Br/R
R/B
Br/L
Br/L
Br/R
R
W W
W W
W W
(Gy)
W W W
B
3
R
BB B
R
(B)
5
R/B Br/R
B
Br/Y
57
58
59
60
63
62
61
(B)
L/Y Br/R
R
Br/L
R
R/W
Br/Y
Br/Y
Br
W/B
Br/R R/B Br/R L/Y
(off)
(on)
(start)
6
B
Br/Y B
B
B
Y L
56
8
B
Y
55
9
56
Y LL
(B)
Br Y
(B)
7
B A B
R
Y Br/Y
R
R
(B)
R
Y
Br
B
54
W/B
W/B B
B
R/Y
L/Y
Br/Y
L
(B)
L
Br/Y
B
Y G
B
G
Y
Br
B
Y
53
Y
Y
Br/R
G
G
Y G
B
Y
L Y
L/R
Br/B
R/L
R/L
13
R/L
Br/B
14
L
L
L
Br
L/R
(B)
Br/Y R/W
68
Br/R
Br/Y
B G/W
52
(off)
51
Y G B
Y
L
(B)
Br/B
R/Y L/Y
11
10
Br/B
12
R
W
B
G W/B G
R
(B)
W
67
Br/Y
B
B
R
L Br/Y
A
B
Y G
Y
53
B
Y G
B
G
R/W
B
Br/Y L
G/W
Br/R
Br/B
50
Y/B B
(B)
Br/R B G/R
(B)
Br/R B Y/B
Br/R
B/Y
15
B/Y
O/L B/Y
P/W B/G
16
B/W
Y/W
(B)
P/L L/B Br/L
O
Br/R
G/R
B
Br/B
(Gy)
B
49
R/L
B
B/W
O/B
R/W
Br/Y
O/B
(Dg)
R/L B B/W O/B
48
(B)
W/R Sb
Gy/G
(B)
L W
Gy
17 L Gy W
Gy/G
Sb W/R
(B)
Br/L R/W P/L
W/G R/W R/G
W/R B/R L B/L L/W R/W
B/R
W/B
Br/B
(B)
Y/L Y
B/G P/W W/B B/R B O/L Br/B B/Y
Br/R
Br/R
Br/R
19
B/W R/W
Y/W
Lg G/Y R/L G/W Y L/Y
R/W
B
R/W L/B R/G G/R W/G Y/B R
Br/W W Gy P Y/G P/W Sb O/L Y/W B/G Gy/G W/B L/R B/W G/R Br/R
Y/R
R/Y
38
G/R L/W
B/W
(W)
B
L/W G/R
20
R/W
R/W
47
46
45
44
43
42
41
40
39
2WD
4WD
DIFF LOCK
18
B
B/W
L/W
W/G
Br/L
R/G
P/L
G/R
(B)
R/W
Y/L Br/Y B/W
O/B
Y/L
B/W
L/R
L/Y
Y
P/W
O/L
B/G
W/B
B/R
Sb
Gy/G
W/R
L/W
G/R
Y/L
R/W
R/Y
Y/R
Y/B
G/R
R/L
Y/W
W/G
Br/L
R/G
P/L
R/W
Gy
Br/R
G/W
B/W B
21
B L/B
L/R B
31
L/B
Y/G
L/B
Lg
P
B/L
Y
L
W
O
(B)
R
L
Br B
26
25
24
35
G/Y
Br/W
Br/R
B Br/Y
L/B
B
L/R
L/B
G/Y
Br/W
R
O
L
L/Y
B
36
Br
Br/Y
L
Y/G
B/L
L
P
B/L
L
Y
B/L
B/L
W
B/L
B/L
R/L
L/B
L
37
30
29
L W
B/L
(Gy)
L Y/G B/L
(B)
B/L P L
(B)
B/L Y L
W L/Y
B/L
28
(B)
G/Y B/L
(B)
Br/W B/L
(Gy)
R/L R
27
23
22
B
Lg
34
B
Lg
L
B
Lg
Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
L
L
L
L
L
R/W
R/W
R/W
R/W
R/W
R/W
L L L L
B/W
B/W
B/W
B/W
B/W
B/W
R/L
R/L
R/L
L/Y
L/Y
L/Y
33
G/W
G/W
G/W
Y
Y
Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
(B)
B/W B/W B/W B/W B/W B/W R/L R/L R/L L/Y L/Y L/Y
G/W G/W G/W Y Y
B/L
B/L
B/L
B/L
B/L
B/L
B/L
B/L
33
(B)
B/L B/L B/L B/L B/L B/L B/L B/L
R/W R/W R/W R/W R/W R/W
32
G/W
B
B
A
B
C
2WD/4WD SELECTING SYSTEM
EAS30200
2WD/4WD SELECTING SYSTEM
EAS30210
CIRCUIT DIAGRAM
2WD/4WD SELECTING SYSTEM
4. Load control relay
5. Frame ground
6. Main switch
8. Battery
9. Main fuse
15.Differential motor relay 1
16.Differential motor
18.On-Command four-wheel-drive switch
21.ECU (engine control unit)
33.Joint coupler
39.Multi-function meter
50.Differential motor relay 2
58.Differential motor fuse
59.Ignition fuse
61.Signaling system fuse
B. Wire harness
C. Negative battery sub-wire harness
9-68
2WD/4WD SELECTING SYSTEM
EAS30220
TROUBLESHOOTING
• The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential
gear lock indicator fails to come on.
• The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential
gear lock indicator flashes.
TIP
• Before troubleshooting, remove the following part(s):
1. Hood
2. Front skid plate
The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential gear
lock indicator fails to come on.
1. Check the fuses.
(Main, ignition, signaling system,
and differential motor)
Refer to “CHECKING THE FUSES” on page 9-92.
NG →
Replace the fuse(s).
OK ↓
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 9-93.
NG →
• Clean the battery terminals.
• Recharge or replace the battery.
OK ↓
3. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 9-87.
NG →
Replace the main switch.
OK ↓
4. Check the On-Command fourwheel-drive switch.
Refer to“CHECKING THE
SWITCHES” on page 9-87.
NG →
Replace the On-Command four-wheeldrive switch.
OK ↓
5. Check the differential motor relay 1.
Refer to “CHECKING THE RELAYS” on page 9-95.
NG →
Replace the differential motor relay 1.
OK ↓
6. Check the differential motor relay 2.
Refer to “CHECKING THE RELAYS” on page 9-95.
NG →
Replace the differential motor relay 2.
OK ↓
7. Check the load control relay.
Refer to “CHECKING THE RELAYS” on page 9-95.
NG →
Replace the load control relay.
OK ↓
9-69
2WD/4WD SELECTING SYSTEM
8. Check the differential motor operation.
Refer to “CHECKING THE DIFFERENTIAL MOTOR OPERATION”
on page 8-12.
NG →
Replace the differential motor.
OK ↓
9. Check the entire 2WD/4WD selecting system wiring.
Refer to “CIRCUIT DIAGRAM” on
page 9-67.
NG →
Properly connect or replace the 2WD/4WD
selecting system wiring.
OK ↓
Replace the meter assembly or ECU.
The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential gear
lock indicator flashes.
1. Check the differential motor position switch.
Refer to “CHECKING THE DIFFERENTIAL MOTOR POSITION
SWITCH” on page 9-106.
NG →
Replace the differential motor.
OK ↓
2. Check the entire 2WD/4WD selecting system wiring.
Refer to “CIRCUIT DIAGRAM” on
page 9-67.
NG →
Properly connect or replace the 2WD/4WD
selecting system wiring.
OK ↓
Replace the ECU.
9-70
9-71
L
B
R/L
B
71
L
R/W
B
(Gy)
W
(Gy)
W W
72
R/L
Y/R
Br/R
R
R/W
Y/R
B R/W
Br/R
R/L
R
73
(Gy)
W
(Gy)
W W
Gy
B/L Gy
1
Br/L
B
4
R
B
B/L
Br/R
2
Gy
B
R
Br/R
R/B
Br/L
Br/L
Br/R
R
W W
W W
W W
(Gy)
W W W
B
3
R
BB B
R
(B)
5
R/B Br/R
B
Br/Y
64
65
66
67
70
69
68
(B)
L/Y Br/R
R
Br/L
R
R/W
Br/Y
Br/Y
Br
W/B
Br/R R/B Br/R L/Y
(off)
(on)
(start)
6
B
Br/Y B
B
B
Y L
63
8
B
Y
62
9
63
Y LL
(B)
Br Y
(B)
7
B A B
R
Y Br/Y
R
R
(B)
R
Y
Br
B
13
61
W/B
W/B B
B
R/Y
L/Y
(B)
L
Br/Y
B
Y G
B
G
Y
Br
B
Y
60
Y
Y
Br/R
G
G
Y G
B
Y
L Y
L/R
Br/B
R/L
R/L
14
R/L
Br/B
15
L
L
L
Br
L/R
(B)
Br/Y R/W
75
Br/R
Br/Y
B G/W
59
(off)
58
Y G B
Y
L
(B)
R/B
R/B
R
Br/Y
L
Br/B
R/Y L/Y
12
11
R
R Br/B
R
10
W
B
G W/B G
R
(B)
W
74
Br/Y
B
B
R
L Br/Y
A
B
Y G
Y
60
B
Y G
B
G
R/W
B
Br/Y L
G/W
Br/R
Br/B
57
Y/B B
(B)
Br/R B G/R
(B)
Br/R B Y/B
Br/R
B/Y
16
B/Y
O/L B/Y
P/W B/G
17
B/W
Y/W
(B)
P/L L/B Br/L
O
Br/R
G/R
B
Br/B
(Gy)
B
56
R/L
B
B/W
O/B
R/W
Br/Y
O/B
(Dg)
R/L B B/W O/B
55
(B)
W/R Sb
Gy/G
(B)
L W
Gy
18 L Gy W
Gy/G
Sb W/R
(B)
Br/L R/W P/L
W/G R/W R/G
W/R B/R L B/L L/W R/W
B/R
W/B
Br/B
(B)
Y/L Y
B/G P/W W/B B/R B O/L Br/B B/Y
Br/R
Br/R
Br/R
20
B/W R/W
Y/W
Lg G/Y R/L G/W Y L/Y
R/W
B
Br/W W Gy P Y/G P/W Sb O/L Y/W B/G Gy/G W/B L/R B/W G/R Br/R
Y/R
R/Y O/W R/W L/B R/G G/R W/G Y/B R
44
G/R L/W
B/W
(W)
B
L/W G/R
21
R/W
R/W
54
53
52
51
50
49
48
47
46
B
G/R
B/W
L/W
45
2WD
4WD
DIFF LOCK
19
W/G
Br/L
R/G
P/L
G/R
(B)
Y/L Br/Y B/W
O/B G/R R/W
Y/L
B/W
L/R
L/Y
Y
P/W
O/L
B/G
W/B
B/R
Sb
Gy/G
W/R
L/W
G/R
Y/L
R/W
R/Y
Y/R
Y/B
G/R
R/L
Y/W
W/G
Br/L
O/W
R/G
P/L
R/W
Gy
Br/R
G/W
(Gy)
R/B
R
B
R/B
B/W B
22
B
(Gy)
G
G
Br
R G
W B
L/B
B
L/R
O
(B)
B Br/Y
L/B
39
R
27
26
25
L
Br B
41
L/B Br O
G W G/R
(B)
O
R B
B
G/Y
Br/W
GR B WR
B L/B
L/R B
32
L/B
Y/G
L/B
Lg
P
B/L
Y
L
W
G/Y
Br/W
R
O
Br/R
L
L
Y/G
B/L
B
Br
Br/Y
42
(B)
O/W R L/B
G/R W
W
G/R
O/W
L/B
L/Y
L
P
B/L
L
Y
B/L
B/L
W
B/L
B/L
R/L
L/B
L
43
L/B
W/B
31
30
L W
B/L
38
(Gy)
L Y/G B/L
(B)
B/L P L
(B)
B/L Y L
W L/Y
B/L
29
(B)
G/Y B/L
(B)
Br/W B/L
(Gy)
R/L R
28
24
23
B
Lg
40
B
Lg
L
L L L L
B
Lg
(Gy)
G R
B W
G
34
37
R B
36
(Gy)
B R
Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
R B W
L
L
L
L
L
R/W
R/W
R/W
R/W
R/W
R/W
B/W
B/W
B/W
B/W
B/W
B/W
R/L
R/L
R/L
L/Y
L/Y
L/Y
34
G/W
G/W
G/W
Y
Y
Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
(B)
B/W B/W B/W B/W B/W B/W R/L R/L R/L L/Y L/Y L/Y
G/W G/W G/W Y Y
35
W
W
W
B/L
B/L
B/L
B/L
B/L
B/L
B/L
B/L
(B)
B/L B/L B/L B/L B/L B/L B/L B/L W W W
R/W R/W R/W R/W R/W R/W
33
G/W
B
C
B
D
(B)
C
B
B
A
(B)
B
B
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
EAS30230
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
EAS30240
CIRCUIT DIAGRAM
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
4. Load control relay
5. Frame ground
6. Main switch
8. Battery
9. Main fuse
10.EPS fuse
22.ECU (engine control unit)
28.Speed sensor
34.Joint coupler
35.EPS unit
36.EPS motor
37.EPS torque sensor
38.EPS self-diagnosis signal connector
39.EPS (electric power steering) control unit
54.EPS warning light
66.Ignition fuse
68.Signaling system fuse
B. Wire harness
C. Negative battery sub-wire harness
D. EPS (electric power steering) control unit
9-72
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
EAS30250
EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION
The EPS control unit is equipped with a self-diagnostic function. If this function detects a malfunction in
the EPS system, it lights the EPS warning light to alert the rider that a 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 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
1. EPS warning light
TIP
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.
EAS30260
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.
TIP
The EPS system does not operate while the EPS warning light is on.
9-73
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
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)
“
“
f.
g.
h.
i.
” (off)
” (on)
Off
Comes on.
Initial lighting: 2 seconds
Goes off.
EAS30270
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”.
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.
1
2
• Present malfunction signaling mode
Ground the EPS self-diagnosis signal connector within 5 seconds after setting the main switch to
“ ” (on), and leave it grounded. The signaling mode is activated after 5 seconds.
• 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.
TIP
• The diagnostic mode can also be canceled by riding the vehicle at speeds above 2 km/h (1.2 mi/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.
5. Connect the EPS self-diagnosis signal connector.
9-74
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
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
k
j
h
b
5
i
d
g
B
e A
c f
5
i
a.
b.
c.
d.
e.
f.
g.
h.
2
1
0.5 × 3
3
2
0.5 × 5
i. Mode selection judgment
j. Present malfunction signaling mode
k. Past malfunction signaling mode
EPS self-diagnosis signal connector
Diagnostic mode
EPS warning light
Disconnected
On
Off
Grounded
Normal mode (diagnostic mode not activated)
A. The EPS warning light comes on for 5
seconds during the diagnostic mode selection
judgment.
B. 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
f
d A
b e
5
g
a.
b.
c.
d.
e.
f.
1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5
g. Mode selection judgment
EPS self-diagnosis signal connector
EPS warning light
Disconnected
Comes on
Goes off
Grounded
A. The EPS warning light comes on for 5
seconds during the diagnostic mode selection
judgment.
9-75
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
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.
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
a. EPS self-diagnosis signal connector
b. Disconnected
T1
T2
c. Grounded
T1: Connector grounded - - - - 0.1 ≤ T1 ≤ 1.6 seconds
T2: Fault codes deleted - - - - - Maximum 1.5 seconds required
EAS30280
SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)
Fault
code No.
11
13
15
16
21
22
Item
EPS torque sensor
Speed sensor
Engine speed signal
Symptom
Probable cause of malfunction
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.
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.
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.
9-76
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
Fault
code No.
Item
Symptom
Probable cause of malfunction
53
EPS control unit
Battery voltage has dropped.
• Faulty battery.
• Malfunction in the
charging system.
Refer to “CHARGING
SYSTEM” on page
9-11.
• Malfunction in EPS control unit.
54
EPS control unit
Relay contacts in the EPS control
unit are welded together.
Malfunction in EPS control unit.
Battery voltage has increased.
Abnormality exists between the
EPS and the ECU.
• Malfunction in the
charging system.
Refer to “CHARGING
SYSTEM” on page
9-11.
• Malfunction in EPS control unit.
55
EPS control unit
EAS30290
TROUBLESHOOTING DETAILS (EPS SYSTEM)
TIP
The malfunction history is stored even if the main switch is turned to “ ” (off), therefore, be sure to
erase the history (present and past malfunction signaling modes) after repairing the cause of the EPS
system malfunction. The malfunction history must be erased in the diagnostic mode. Refer to “DIAGNOSTIC MODE” on page 9-74.
Fault code No. 11,
Symptom EPS torque sensor: open or short circuit detected.
13,
15, 16
Order Item/components and probable
cause
Check or maintenance job
1
Connections
• EPS torque sensor coupler
• Check the coupler for any pins Turning the
that may have pulled out.
main switch to
• Check the locking condition of
“ ” (off).
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
2
Defective EPS torque sensor.
• Replace if defective.
Refer to “CHECKING THE EPS
TORQUE SENSOR (for EPS
models)” on page 9-107.
3
Open or short circuit in EPS torque
sensor lead.
• Replace if there is an open or
short circuit.
• Between EPS torque sensor
coupler and EPS control unit
coupler.
white–white
red–red
green–green
black–black
9-77
Reinstatement
method
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
Fault code No. 21
Symptom Speed sensor: open or short circuit detected.
Order Item/components and probable
cause
Check or maintenance job
1
Connections
• Check the coupler for any pins
• Speed sensor coupler
that may have pulled out.
• EPS control unit coupler at the wire • Check the locking condition of
harness
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
2
Open or short circuit in wire harness. • Replace if there is an open or
short circuit.
• Between speed sensor coupler
and joint coupler.
white–white
• Between joint coupler and EPS
control unit coupler.
white–white
3
Defective speed sensor.
Fault code No. 22
• Replace if defective.
Refer to “CHECKING THE
SPEED SENSOR” on page
9-102.
Reinstatement
method
Starting the engine and activating the
vehicle speed
sensor by operating the vehicle above 5
km/h (3 mi/h),
or turning the
main switch to
“ ” (off), then
to “ ” (on), and
then deleting
the fault codes.
Refer to “DIAGNOSTIC
MODE” on
page 9-74.
Symptom No normal signals are received from the ECU.
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
Connections
• Check the coupler for any pins Turning the
• EPS control unit coupler at the wire
that may have pulled out.
main switch to
harness
• Check the locking condition of
“ ” (off).
• ECU coupler at the wire harness
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
2
Open or short circuit in wire harness. • 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.
9-78
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
Fault code No. 41,
Symptom EPS motor: open or short circuit detected.
42,
43, 45
Order Item/components and probable
cause
Check or maintenance job
1
Connections
• EPS motor coupler
• Check the coupler for any pins Turning the
that may have pulled out.
main switch to
• Check the locking condition of
“ ” (off).
the coupler.
• If there is a malfunction, repair it
and connect the coupler securely.
2
Open or short circuit in EPS motor
lead.
• 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 (for EPS models)” on
page 9-107.
Fault code No. 52
Reinstatement
method
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” on
page 9-93.
Turning the
main switch to
“ ” (off).
2
Malfunction in rectifier/regulator or
charging system.
Replace if defective.
Refer to “CHECKING THE RECTIFIER/REGULATOR” on page
9-101.
3
Malfunction in EPS control unit.
Replace the EPS control unit.
9-79
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
Fault code No. 54
Symptom Relay contacts in the EPS control unit are welded together.
Order Item/components and probable
cause
Check or maintenance job
Reinstatement
method
1
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” on
page 9-93.
Turning the
main switch to
“ ” (off).
2
Malfunction in rectifier/regulator.
Replace if defective.
Refer to “CHECKING THE RECTIFIER/REGULATOR” on page
9-101.
3
Malfunction in EPS control unit.
Replace the EPS control unit.
9-80
ELECTRICAL COMPONENTS
EAS27972
ELECTRICAL COMPONENTS
7
6
5
4
9
8
3
10
2
11
12
1
13
20
14
19
18
17
9-81
16
15
ELECTRICAL COMPONENTS
1. Radiator fan motor
2. Lean angle sensor
3. Parking brake switch
4. Ignition coil
5. Intake air pressure sensor
6. TPS (throttle position sensor)
7. Fuel injector
8. ISC (idle speed control)
9. Air induction system solenoid
10. Coolant temperature sensor
11. Reverse switch
12. Gear position switch
13. Speed sensor
14. Crankshaft position sensor
15. Intake air temperature sensor
16. Fuel sender
17. Fuel pump
18. Seat belt switch
19. Brake light switch
20. Differential motor
9-82
ELECTRICAL COMPONENTS
3
4
2
5
6
7
1
9
8
14
13
11
10
12
9-83
ELECTRICAL COMPONENTS
1. Auxiliary DC jack
2. Battery
3. Meter assembly
4. Indicator light assembly
5. Main switch
6. On-Command four-wheel-drive switch
7. Light switch
8. EPS torque sensor (for EPS models)
9. EPS motor (for EPS models)
10. EPS (electric power steering) control unit (for
EPS models)
11. Radiator fan motor circuit breaker
12. Horn (for Europe and Oceania)
13. ECU (engine control unit)
14. Rectifier/regulator
9-84
ELECTRICAL COMPONENTS
3
2
1
4
5
6
8
19 18
17 16
15 14
10
13
7
11
8
12
9
12
9-85
ELECTRICAL COMPONENTS
1. Load control relay
2. Fuel injection system relay
3. Radiator fan motor relay
4. Headlight relay
5. Differential motor relay 1
6. Differential motor relay 2
7. Fuel injection system fuse
8. Spare fuse
9. Starter relay
10. EPS fuse (for EPS models)
11. Main fuse
12. Fuse box
13. Radiator fan motor fuse
14. Headlight fuse
15. Signaling system fuse
16. Auxiliary DC jack fuse
17. Differential motor fuse
18. Ignition fuse
19. Backup fuse
9-86
ELECTRICAL COMPONENTS
EAS27980
CHECKING THE SWITCHES
4
L/W B G/R
2
3
1
Br/R R/B L/Y Br/R
Br Y
(B)
2WD
4WD
DIFF LOCK
(off)
(on)
(start)
L/R B
L/W G/R
B
5
G/W
9
8
Br
OFF
ON
7
Br
P
L
6
Y
(off)
L
B
L
W
Gy
(B)
9-87
ELECTRICAL COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
Brake light switch
Parking brake switch
Main switch
On-Command four-wheel-drive switch
Reverse switch
Gear position switch
Seat belt switch
Light switch
Horn switch (for Europe and Oceania)
9-88
ELECTRICAL COMPONENTS
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.
ECA14370
NOTICE
Never insert the tester probes into the coupler terminal slots “a”. 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
TIP
• 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 switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated by
“
”. There is continuity between the brown/red and red/black leads when the switch is set to
“ ” (on).
b
Br/R R/B L/Y Br/R
a
(off)
(on)
(start)
Br/R R/B
L/Y Br/R
9-89
ELECTRICAL COMPONENTS
EAS27990
EWA1XD1018
CHECKING THE BULBS AND BULB
SOCKETS
WARNING
Since headlight bulbs get extremely hot,
keep flammable products and your hands
away from them until they have cooled
down.
TIP
Do not check any of the lights that use LEDs.
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continuity
between the terminals.
Damage/wear → Repair or replace the bulb,
bulb socket or both.
Improperly connected → Properly connect.
No continuity → Repair or replace the bulb, bulb
socket or both.
ECA1XD1048
NOTICE
• 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 a 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.
Types of bulbs
The bulbs used on this vehicle are shown in the
illustration.
• 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” are used for tail/brake lights and can
be removed from the socket by pushing and
turning the bulb counterclockwise.
2. Check:
• Bulb (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
TIP
Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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 bulbs
The following procedure applies to all of the
bulbs.
1. Remove:
• Bulb
9-90
ELECTRICAL COMPONENTS
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.
3. Disconnect:
• Headlight coupler “1”
1
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
4. Remove:
• Headlight bulb holder “1”
• Headlight bulb “2”
TIP
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
EWA13320
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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.
TIP
Unhook the headlight bulb holder, and then remove the defective bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21790
REPLACING THE HEADLIGHT BULBS
The following procedure applies to both of the
headlight bulbs.
1. Remove:
• Headlight rear cover “1”
1
2
1
5. Install:
• Headlight bulb New
Secure the new headlight bulb with the headlight bulb holder.
ECA13690
NOTICE
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. Remove:
• Headlight bulb holder cover “1”
1
6. Install:
• Headlight bulb holder
7. Connect:
• Headlight coupler
9-91
ELECTRICAL COMPONENTS
8. Install:
• Headlight bulb holder cover
EAS28000
CHECKING THE FUSES
The following procedure applies to all of the fuses.
ECA1XD1049
NOTICE
ECA1XD1050
Make sure the headlight bulb holder cover is
securely fitted over the bulb holder and seated properly.
NOTICE
To avoid a short circuit, always turn the main
switch to “ ” (off) when checking or replacing a fuse.
TIP
Pass the headlight lead “1” through the slot “a” in
the headlight unit as shown, and then reinstall
the bulb holder cover.
1. Remove:
• Hood
Refer to “GENERAL CHASSIS” on page 4-1.
2. Check:
• Fuse
No.
1
a
9. Install:
• Headlight rear cover
EAS21810
ADJUSTING THE HEADLIGHT BEAMS
The following procedure applies to both of the
headlights.
1. Adjust:
• Headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw “1” in direction “a” or
“b”.
1
EPS (for EPS models)
40.0 A
1
2
Main
40.0 A
1
3
Radiator fan motor
25.0 A
1
4
Headlight
15.0 A
1
5
Backup
10.0 A
1
6
Fuel injection system
10.0 A
1
7
Ignition
10.0 A
1
8
Differential motor
10.0 A
1
9
Signaling system
10.0 A
1
10
Auxiliary DC jack
10.0 A
1
11
Spare
25.0 A
1
12
Spare
15.0 A
1
Spare
10.0 A
2
13
14
Direction “a”
Headlight beam is raised.
Direction “b”
Headlight beam is lowered.
Amperage
Q’ty
rating
Fuses
2
11
13
1
3
12
6
14
5 7 8 10 9 4
a
b
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and
check the continuity.
1
TIP
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Set the pocket tester selector to “Ω × 1”.
9-92
ELECTRICAL COMPONENTS
• 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.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
b. If the pocket tester indicates “∞”, replace the
fuse.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Replace:
• Blown fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the main switch to “ ” (off).
b. Install a new fuse of the correct amperage
rating.
c. Set on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
ECA1XD1051
NOTICE
• This is a VRLA (Valve Regulated Lead Acid)
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 a VRLA battery are different from those of conventional batteries.
The VRLA battery should be charged according to the appropriate charging method. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery.
EWA13310
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:
• Hood
Refer to “GENERAL CHASSIS” on page 4-1.
TIP
Since VRLA 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.
EAS28030
CHECKING AND CHARGING THE BATTERY
EWA13290
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.
1. Remove:
• Hood
Refer to “GENERAL CHASSIS” on page 4-1.
2. Disconnect:
• Battery leads
(from the battery terminals)
ECA13640
NOTICE
First, disconnect the negative battery lead
“1”, and then positive battery lead “2”.
9-93
ELECTRICAL COMPONENTS
D. These values vary with the temperature, the
condition of the battery plates, and the
electrolyte level.
2
1
3. Remove:
• Battery
4. Check:
• Battery charge
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
A. Open-circuit voltage (V)
B. Charging condition of the battery (%)
C. Ambient temperature 20 °C (68 °F)
a. Connect a pocket tester to the battery terminals.
• Positive tester probe →
positive battery terminal
• Negative tester probe →
negative battery terminal
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Charge:
• Battery
(refer to the appropriate charging method)
TIP
EWA13300
WARNING
• The charge state of a VRLA (Valve Regulated
Lead Acid) battery can be checked by measuring its open-circuit voltage (i.e., the voltage
when the positive battery terminal is disconnected).
• No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
Do not quick charge a battery.
ECA1XD1052
NOTICE
• 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.
b. Check the charge of the battery, as shown in
the charts and the following example.
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20–30%
A. Open-circuit voltage (V)
B. Charging time (hours)
C. Relationship between the open-circuit voltage
and the charging time at 20 °C (68 °F)
9-94
ELECTRICAL COMPONENTS
• 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 a VRLA (Valve Regulated Lead Acid) battery stabilizes about
30 minutes after charging has been completed. Therefore, wait 30 minutes after
charging is completed before measuring
the open-circuit voltage.
TIP
Set the charging time at 20 hours (maximum).
e. Measure the battery open-circuit voltage after
leaving the battery unused for more than 30
minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• Battery
7. Connect:
• Battery leads
(to the battery terminals)
ECA13630
NOTICE
First, connect the positive battery lead “1”,
and then the negative battery lead “2”.
1
A.
B.
C.
D.
E.
Open-circuit voltage (V)
Time (minutes)
Charging
Ambient temperature 20 °C (68 °F)
Check the open-circuit voltage.
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
8. Check:
• Battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
9. Install:
• Hood
Refer to “GENERAL CHASSIS” on page 4-1.
Charging method using a constant voltage charger
a. Measure the open-circuit voltage prior to
charging.
TIP
Voltage should be measured 30 minutes after
the engine is stopped.
EAS28040
b. Connect a charger and ammeter to the battery and start charging.
c. Make sure that the current is higher than the
standard charging current written on the battery.
CHECKING THE RELAYS
Check each switch for continuity with the pocket
tester. If the continuity reading is incorrect, replace the relay.
TIP
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
If the current is lower than the standard charging
current written on the battery, this type of battery
charger cannot charge the VRLA (Valve Regulated Lead Acid) battery. A variable voltage
charger is recommended.
1. Disconnect the relay from the wire harness.
2. Connect the pocket tester (Ω × 1) and battery
(12 V) to the relay terminal as shown.
Check the relay operation.
Out of specification → Replace.
d. Charge the battery until the battery’s charging voltage is 15 V.
9-95
ELECTRICAL COMPONENTS
Starter relay
Headlight relay
First step:
3
1
R
3
Br/B
2
R/Y L/Y
B
B
2 1
G
Y
Y
4
1.
2.
3.
4.
L
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
1. Positive tester probe
2. Negative tester probe
3. Negative tester probe
Result
Continuity
(between “3” and “4”)
Result
Continuity
(between “1” and “2”)
No continuity
(between “1” and “3”)
Load control relay
Second step:
3
4
3
+
2
5
4
1
+
2
1
Br/R
B
Br/L
B
R
G
Y
Y
L
1.
2.
3.
4.
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
1.
2.
3.
4.
5.
Result
Continuity
(between “3” and “4”)
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
Negative tester probe
Result
No continuity
(between “3” and “4”)
Continuity
(between “3” and “5”)
9-96
ELECTRICAL COMPONENTS
Radiator fan motor relay
Differential motor relay 1
First step:
1
3
Br/R
2
R/L
R
Y/B B Br/R
Br/R
B/Y
1.
2.
3.
4.
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
1. Positive tester probe
2. Negative tester probe
3. Negative tester probe
Result
Continuity
(between “3” and “4”)
Result
Continuity
(between “1” and “2”)
No continuity
(between “1” and “3”)
Fuel injection system relay
3
Second step:
3
5
4
4
2
1
+
2
1
Br/R
Y/B B Br/R
Br/R
B/Y
1.
2.
3.
4.
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
1.
2.
3.
4.
5.
Result
Continuity
(between “3” and “4”)
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
Negative tester probe
Result
No continuity
(between “3” and “4”)
Continuity
(between “3” and “5”)
9-97
ELECTRICAL COMPONENTS
Differential motor relay 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the spark plug cap from the spark
plug lead.
b. Connect the pocket tester (Ω × 1k) to the
spark plug cap as shown.
First step:
1
3
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
2
G/R B Br/R
Br/R
Br/B
1. Positive tester probe
2. Negative tester probe
3. Negative tester probe
Result
Continuity
(between “1” and “2”)
No continuity
(between “1” and “3”)
c. Measure the spark plug cap resistance.
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Second step:
EAS28090
3
5
4
CHECKING THE IGNITION COIL
1. Check:
• Primary coil resistance
Out of specification → Replace.
+
2
1
Primary coil resistance
2.16–2.64 Ω
G/R B Br/R
Br/R
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Br/B
1.
2.
3.
4.
5.
a. Disconnect the ignition coil connectors from
the ignition coil terminals.
b. Connect the pocket tester (Ω × 1) to the ignition coil as shown.
Positive battery terminal
Negative battery terminal
Positive tester probe
Negative tester probe
Negative tester probe
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Result
No continuity
(between “3” and “4”)
Continuity
(between “3” and “5”)
• Positive tester probe →
brown/red “1”
• Negative tester probe →
orange “2”
EAS28060
CHECKING THE SPARK PLUG CAP
1. Check:
• Spark plug cap resistance
Out of specification → Replace.
Resistance
7.5–12.5 kΩ
9-98
ELECTRICAL COMPONENTS
Refer to “TROUBLESHOOTING” on page
9-3.
Minimum ignition spark gap
6.0 mm (0.24 in)
TIP
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
c. Measure the primary coil resistance.
a. Disconnect the spark plug cap from the spark
plug.
b. Connect the ignition checker “1” as shown.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Secondary coil resistance
Out of specification → Replace.
Ignition checker
90890-06754
Oppama pet–4000 spark checker
YM-34487
Secondary coil resistance
8.64–12.96 kΩ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the ignition coil.
b. Connect the pocket tester (Ω × 1k) to the ignition coil as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
2. Spark plug cap
• Positive tester probe →
brown/red “1”
• Negative tester probe →
Spark plug lead “2”
c. Measure the ignition spark gap “a”.
d. Crank the engine by turning the main switch
to “ ” (start) and gradually increase the
spark gap until a misfire occurs.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28120
CHECKING THE CRANKSHAFT POSITION
SENSOR
1. Disconnect:
• Crankshaft position sensor coupler
(from the wire harness)
2. Check:
• Crankshaft position sensor resistance
Out of specification → Replace the crankshaft position sensor/stator assembly.
c. Measure the secondary coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Crankshaft position sensor resistance
408.0–612.0 Ω
EAS28930
CHECKING THE IGNITION SPARK GAP
1. Check:
• Ignition spark gap
Out of specification → Perform the ignition
system troubleshooting, starting with step 5.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 100) to the
crankshaft position sensor coupler as shown.
9-99
ELECTRICAL COMPONENTS
• Positive tester probe →
yellow/green (wire harness color)
• Negative tester probe →
black/blue (wire harness color)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
1
• Positive tester probe →
gray “1”
• Negative tester probe →
black “2”
Gy
1
65˚
65˚
c. Turn the main switch to “ ” (on).
d. Turn the lean angle sensor to 65°.
e. Measure the lean angle sensor output voltage.
B
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Measure the crankshaft position sensor resistance.
EAS28940
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28130
CHECKING THE LEAN ANGLE SENSOR
1. Remove:
• Lean angle sensor
2. Check:
• Lean angle sensor output voltage
Out of specification → Replace.
CHECKING THE STARTER MOTOR
OPERATION
1. Check:
• Starter motor operation
Does not operate → Perform the electric
starting system troubleshooting, starting with
step 4.
Refer to “TROUBLESHOOTING” on page
9-9.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Lean angle sensor output voltage
Less than 65°: 3.55–4.45 V
More than 65°: 0.65–1.35 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the test harness- lean angle sensor
(3P) “1” between the lean angle sensor and
wire harness as shown.
b. Connect the pocket tester (DC 20 V) to the
test harness- lean angle sensor (3P).
a. Connect the positive battery terminal “1” and
starter motor lead “2” with a jumper lead “3”.
EWA13810
WARNING
• A wire that is used as a jumper lead must
have at least the same capacity of the battery lead, otherwise the jumper lead may
burn.
• This check is likely to produce sparks,
therefore, make sure no flammable gas or
fluid is in the vicinity.
Test harness-lean angle sensor
(3P)
90890-03213
YU-03213
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
9-100
ELECTRICAL COMPONENTS
b. Check the starter motor operation.
EAS28170
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28150
CHECKING THE STATOR COIL
1. Disconnect:
• Stator coil couplers
(from the wire harness)
2. Check:
• Stator coil resistance
Out of specification → Replace the crankshaft position sensor/stator assembly.
CHECKING THE RECTIFIER/REGULATOR
1. Check:
• Charging voltage
Out of specification → Replace the rectifier/regulator.
Charging voltage
above 14 V at 5000 r/min
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the engine tachometer to the spark
plug lead.
b. Connect the pocket tester (DC 20 V) to the
battery as shown.
Stator coil resistance
0.09–0.13 Ω
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the digital circuit tester to the stator
coil coupler as shown.
Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927
• Positive tester probe →
positive battery terminal “1”
• Negative tester probe →
negative battery terminal “2”
• Positive tester probe →
white “1”
• Negative tester probe →
white “2”
1
2
• Positive tester probe →
white “1”
• Negative tester probe →
white “3”
• Positive tester probe →
white “2”
• Negative tester probe →
white “3”
c. Start the engine and let it run at approximately 5000 r/min.
d. Measure the charging voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28230
W
3
W
W
2
1
b. Measure the stator coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE FUEL SENDER
1. Disconnect:
• Fuel pump coupler
(from the wire harness)
2. Remove:
• Fuel pump assembly
(from the fuel tank)
3. Check:
• Fuel sender resistance
Out of specification → Replace the fuel pump
assembly.
9-101
ELECTRICAL COMPONENTS
c. Measure the fuel sender resistance.
Sender unit resistance (full)
19.0–21.0 Ω
Sender unit resistance (empty)
139.0–141.0 Ω
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS29040
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 10 or Ω × 100)
to the fuel sender terminals as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
• Positive tester probe →
orange/black “1”
• Negative tester probe →
black/white “2”
CHECKING THE FUEL METER/FUEL LEVEL
WARNING LIGHT
This model is equipped with a self-diagnosis device for the fuel level detection circuit.
1. Check:
• Fuel meter/fuel level warning light “1”
(Turn the main switch to “ ” [on].)
Warning light comes on for a few seconds,
then goes off → Warning light is OK.
Warning light does not come on → Replace
the meter assembly.
Warning light flashes eight times, then goes
off for 3 seconds in a repeated cycle (malfunction detected in fuel sender) → Replace
the fuel pump assembly.
1
R/L B B/W O/B
1
2
b. Move the fuel sender float to minimum “3”
and maximum “4” level positions.
EAS28240
CHECKING THE SPEED SENSOR
1. Check:
• Speed sensor output voltage
Out of specification → Replace.
Output voltage reading cycle
0.6 V–4.8 V–0.6 V–4.8 V–0.6 V
4
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the test harness- speed sensor (3P)
“1” between the speed sensor coupler and
wire harness as shown.
b. Connect the pocket tester (DC 20 V) to the
test harness- speed sensor (3P).
Test harness- speed sensor (3P)
90890-03208
YU-03208
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
3
9-102
ELECTRICAL COMPONENTS
• Positive tester probe →
white (wire harness color)
• Negative tester probe →
black/blue (wire harness color)
EAS1XD1128
CHECKING THE RADIATOR FAN MOTOR
CIRCUIT BREAKER
1. Remove:
• Radiator fan motor circuit breaker
(from the wire harness)
1
c. Turn the main switch to “ ” (on).
d. Elevate the rear wheels and slowly rotate
them.
e. Measure the voltage (DC 20 V) of white and
black/blue. With each full rotation of the rear
wheels, the voltage reading should cycle
from 0.6 V to 4.8 V to 0.6 V to 4.8 V.
2. Check:
• Radiator fan motor circuit breaker resistance
Out of specification → Replace the radiator
fan motor circuit breaker.
Radiator fan motor circuit breaker resistance
0–0.05 Ω at 25 °C (77 °F)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28250
CHECKING THE RADIATOR FAN MOTOR
1. Check:
• Radiator fan motor
Faulty/rough movement → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the digital circuit tester to the radiator fan motor circuit breaker as shown.
Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the radiator fan motor coupler
from the wire harness.
b. Connect the battery (DC 12 V) as shown.
• Positive battery terminal →
blue “1”
• Negative battery terminal →
black “2”
b. Measure the radiator fan motor circuit breaker resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Check the radiator fan motor movement.
EAS28260
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE COOLANT TEMPERATURE
SENSOR
1. Remove:
• Coolant temperature sensor
9-103
ELECTRICAL COMPONENTS
EWA14130
EAS28300
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.
2. Check:
• Coolant temperature sensor resistance
Out of specification → Replace.
CHECKING THE THROTTLE POSITION
SENSOR
1. Remove:
• Throttle position sensor
(from the throttle body)
EWA1XD1019
WARNING
• Handle the throttle position sensor with
special care.
• Never subject the throttle position sensor
to strong shocks. If the throttle position
sensor is dropped, replace it.
Coolant temperature sensor resistance
2.32–2.59 kΩ at 20 °C (68 °F)
310–326 Ω at 80 °C (176 °F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1k or Ω × 100)
to the coolant temperature sensor terminals
as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
2. Check:
• Throttle position sensor maximum resistance
Out of specification → Replace the throttle
position sensor.
Resistance
2.64–6.16 kΩ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1k) to the
throttle position sensor terminals as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
b. Immerse the coolant temperature sensor “1”
in a container filled with coolant “2”.
TIP
Make sure the coolant temperature sensor terminals do not get wet.
• Positive tester probe →
blue “1”
• Negative tester probe →
black/blue “2”
c. Place a thermometer “3” in the coolant.
3
1
2
d. Heat the coolant or let it cool down to the
specified temperatures.
e. Measure the coolant temperature sensor resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Coolant temperature sensor
b. Measure the throttle position sensor maximum resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Throttle position sensor
T.
R.
Coolant temperature sensor
18 Nm (1.8 m·kgf, 13 ft·lbf)
9-104
ELECTRICAL COMPONENTS
TIP
When installing the throttle position sensor, adjust its angle properly. Refer to “ADJUSTING
THE THROTTLE POSITION SENSOR” on page
7-12.
1
EAS28410
CHECKING THE INTAKE AIR PRESSURE
SENSOR
EWA1XD1020
WARNING
• Handle the intake air pressure sensor with
special care.
• Never subject the intake air pressure sensor to strong shocks. If the intake air pressure sensor is dropped, replace it.
1. Check:
• Intake air pressure sensor output voltage
Out of specification → Replace.
Intake air pressure sensor output
voltage
3.594–3.684 V at 101 kPa (1.01
kgf/cm², 14 psi)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the test harness S- pressure sensor
5S7 (3P) “1” between the intake air pressure
sensor and wire harness as shown.
b. Connect the pocket tester (DC 20 V) to the
test harness S- pressure sensor 5S7 (3P).
Test harness S- pressure sensor
5S7 (3P)
90890-03211
YU-03211
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
c. Turn the main switch to “ ” (on).
d. Measure the intake air pressure sensor output voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28420
CHECKING THE INTAKE AIR
TEMPERATURE SENSOR
1. Remove:
• Intake air temperature sensor
(from the air filter case.)
EWA14110
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
5.40–6.60 kΩ at 0 °C (32 °F)
290–390 Ω at 80 °C (176 °F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1k or Ω × 100)
to the intake air temperature sensor terminals
as shown.
• Positive tester probe →
pink (wire harness color)
• Negative tester probe →
black/blue (wire harness color)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
b. Immerse the intake air temperature sensor
“1” in a container filled with water “2”.
TIP
Make sure that the intake air temperature sensor
terminals do not get wet.
c. Place a thermometer “3” in the water.
9-105
ELECTRICAL COMPONENTS
EAS28370
CHECKING THE AIR INDUCTION SYSTEM
SOLENOID
1. Check:
• Air induction system solenoid resistance
Out of specification → Replace.
3
1
Solenoid resistance
20–24 Ω
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
d. Heat the water or let it cool down to the specified temperatures.
e. Measure the intake air temperature sensor
resistance.
a. Disconnect the air induction system solenoid
coupler from the wire harness.
b. Connect the pocket tester (Ω × 1) to the air induction system solenoid terminals as shown.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
EAS1XD1004
CHECKING THE FUEL INJECTOR
1. Check:
• Fuel injector resistance
Out of specification → Replace the fuel injector.
• Positive tester probe →
Air induction system solenoid terminal “1”
• Negative tester probe →
Air induction system solenoid terminal “2”
Fuel injector resistance
11.5–12.5 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2
a. Disconnect the fuel injector coupler from wire
harness.
b. Connect the pocket tester (Ω × 1) to the fuel
injector terminals as shown.
1
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
c. Measure the air induction system solenoid resistance.
• Positive tester probe
Injector terminal “1”
• Negative tester probe
Injector terminal “2”
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1XD1037
CHECKING THE DIFFERENTIAL MOTOR
POSITION SWITCH
1. Check:
• Differential motor position switch
Out of specification → Replace.
2
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
c. Measure the fuel injector resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9-106
ELECTRICAL COMPONENTS
TIP
TIP
Check the differential motor position switch for
continuity between the terminals “1” and “3” and
between the terminals “2” and “3” when the OnCommand four-wheel-drive switch is set to the
“2WD”, “4WD”, and “DIFF LOCK” positions.
The pocket tester and the analog pocket tester
readings are shown in the following table.
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”
2WD position
No continuity
(between “1” and “3”)
(between “2” and “3”)
4WD position
Continuity
(between “2” and “3”)
No continuity
(between “1” and “3”)
DIFF LOCK position
Continuity
(between “1” and “3”)
No continuity
(between “2” and “3”)
2
1
B
3
R
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 2
a. Connect the pocket tester (Ω × 1) to the EPS
motor coupler terminal and EPS motor body.
3
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the main switch to “ ” (on).
b. Set the On-Command four-wheel-drive
switch to “2WD”, “4WD”, or “DIFF LOCK” position.
c. Turn the main switch to “ ” (off).
d. Disconnect the differential motor coupler.
e. Connect the pocket tester (Ω × 1) to the differential motor terminals.
f. Check the differential motor position switch
continuity.
g. Check the differential motor position switch
no continuity.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30300
CHECKING THE EPS MOTOR (for EPS
models)
1. Remove:
• EPS unit
2. Check:
• EPS motor
Out of specification → Replace the EPS unit.
b. Check the EPS motor for continuity.
c. Check the EPS motor for no continuity.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30310
CHECKING THE EPS TORQUE SENSOR (for
EPS models)
1. Remove:
• EPS unit
ECA1XD1014
NOTICE
Make sure do not remove the torque sensor
and its protector from the EPS unit.
2. Check:
• EPS torque sensor resistance
Out of specification → Replace the steering
column.
9-107
ELECTRICAL COMPONENTS
EPS torque sensor
Coil resistance
0.875–1.625 kΩ (for EPS models)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1k) to the EPS
torque sensor coupler terminals as shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
• Positive tester probe →
red “1”
• Negative tester probe →
black “2”
1
2
G
R
B
W
b. Measure the EPS torque sensor resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9-108
ELECTRICAL COMPONENTS
9-109
TROUBLESHOOTING
TROUBLESHOOTING...................................................................................10-1
GENERAL INFORMATION ..................................................................... 10-1
STARTING FAILURES............................................................................10-1
INCORRECT ENGINE IDLING SPEED .................................................. 10-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......................... 10-2
FAULTY DRIVE TRAIN ...........................................................................10-2
FAULTY GEAR SHIFTING...................................................................... 10-2
SHIFT LEVER DOES NOT MOVE .......................................................... 10-2
JUMPS OUT OF GEAR...........................................................................10-2
FAULTY CLUTCH ...................................................................................10-3
OVERHEATING ......................................................................................10-3
OVERCOOLING......................................................................................10-4
POOR BRAKING PERFORMANCE........................................................ 10-4
FAULTY SHOCK ABSORBER ASSEMBLY............................................10-4
UNSTABLE HANDLING ..........................................................................10-4
FAULTY LIGHTING OR SIGNALING SYSTEM ...................................... 10-4
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE..........10-5
10
TROUBLESHOOTING
Electrical system
1. Battery
• Discharged battery
• Faulty battery
2. Fuse(s)
• Blown, damaged or incorrect fuse
• Improperly installed fuse
3. Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
4. Ignition coil
• Cracked or broken ignition coil body
• Broken or shorted primary or secondary coils
• Faulty spark plug lead
5. Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
• Broken generator rotor woodruff key
6. Switches and wiring
• Faulty main switch
• Broken or shorted wiring
• Faulty gear position switch
• Improperly grounded circuit
• Loose connections
• Faulty brake light switch
7. Starting system
• Faulty starter motor
• Faulty starter relay
• Faulty starter clutch
EAS28451
TROUBLESHOOTING
EAS28460
GENERAL INFORMATION
TIP
The following guide for troubleshooting does not
cover all the possible causes of trouble. It should
be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this
manual for checks, adjustments, and replacement of parts.
EAS28470
STARTING FAILURES
Engine
1. Cylinder and cylinder head
• Loose spark plug
• Loose cylinder head or cylinder
• Damaged cylinder head gasket
• Damaged cylinder gasket
• Worn or damaged cylinder
• Incorrect valve clearance
• Improperly sealed valve
• Incorrect valve-to-valve-seat contact
• Incorrect valve timing
• Faulty valve spring
• Seized valve
2. Piston and piston ring(s)
• Improperly installed piston ring
• Damaged, worn or fatigued piston ring
• Seized piston ring
• Seized or damaged piston
3. Air filter
• Improperly installed air filter
• Clogged air filter element
4. Crankcase and crankshaft
• Improperly assembled crankcase
• Seized crankshaft
EAS28490
INCORRECT ENGINE IDLING SPEED
Engine
1. Cylinder and cylinder head
• Incorrect valve clearance
• Damaged valve train components
2. Air filter
• Clogged air filter element
Fuel system
1. Fuel tank
• Empty fuel tank
• Clogged fuel tank breather hose joint
• Clogged fuel tank breather hose joint hose
• Deteriorated or contaminated fuel
2. Fuel pump
• Faulty fuel pump
• Faulty fuel injection system relay
• Clogged or damaged fuel hose
3. Throttle body
• Deteriorated or contaminated fuel
• Sucked-in air
Fuel system
1. Throttle body
• Damaged or loose throttle body joint
• Improper throttle cable free play
• Flooded throttle body
• Faulty air induction system
Electrical system
1. Battery
• Discharged battery
10-1
TROUBLESHOOTING
• Faulty battery
2. Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
3. Ignition coil
• Broken or shorted primary or secondary coils
• Faulty spark plug lead
• Cracked or broken ignition coil
4. Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
• Broken generator rotor woodruff key
EAS28520
POOR MEDIUM-AND-HIGH-SPEED
PERFORMANCE
Refer to “STARTING FAILURES” on page 10-1.
Engine
1. Air filter
• Clogged air filter element
Fuel system
1. Fuel pump
• Faulty fuel pump
EAS30320
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 backlash.
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.
TIP
Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite subtle and
difficult to distinguish from normal vehicle operating noise. If there is reason to believe these components are damaged, remove the components and check them.
EAS28530
EAS28550
FAULTY GEAR SHIFTING
JUMPS OUT OF GEAR
Shifting is difficult
Refer to “FAULTY CLUTCH” on page 10-3.
Shift forks
• Worn shift fork
EAS1XD1001
Shift drum
• Incorrect axial play
• Worn shift drum groove
SHIFT LEVER DOES NOT MOVE
Shift drum and shift forks
• Foreign object in a shift drum groove
• Seized shift fork
• Bent shift fork guide bar
Transmission
• Worn gear dog
Transmission
• Seized transmission gear
• Foreign object between transmission gears
• Improperly assembled transmission
10-2
TROUBLESHOOTING
EAS28580
EAS28600
FAULTY CLUTCH
OVERHEATING
Engine operates but vehicle will not move
1. V-belt
• Bent, damaged or worn V-belt
• Slipping V-belt
2. Primary pulley cam and primary pulley slider
• Damaged or worn primary pulley cam
• Damaged or worn primary pulley slider
3. Clutch spring(s)
• Damaged clutch spring
4. Transmission gear(s)
• Damaged transmission gear
Engine
1. Clogged coolant passages
2. Cylinder head and piston
• Heavy carbon buildup
3. Engine oil
• Incorrect oil level
• Incorrect oil viscosity
• Inferior oil quality
Cooling system
1. Coolant
• Low coolant level
2. Radiator
• Damaged or leaking radiator
• Faulty radiator cap
• Bent or damaged radiator fin
3. Water pump
• Damaged or faulty water pump
4. Thermostat
• Thermostat stays closed
5. Oil cooler
• Clogged or damaged oil cooler
6. Hose(s) and pipe(s)
• Damaged hose
• Improperly connected hose
• Damaged pipe
• Improperly connected pipe
Clutch slips
1. Clutch spring(s)
• Damaged, loose or worn clutch spring
2. Clutch shoe(s)
• Damaged or worn clutch shoe
3. Primary sliding sheave
• Seized primary sliding sheave
Poor starting performance
1. V-belt
• V-belt slips
• Oil or grease on the V-belt
2. Primary sliding sheave
• Faulty operation
• Worn pin groove
• Worn pin
3. Clutch shoe
• Bent, damaged or worn clutch shoe
Fuel system
1. Throttle body
• Faulty throttle body
• Damaged or loose throttle body joint
2. Air filter
• Clogged air filter element
Poor speed performance
1. V-belt
• Oil or grease on the V-belt
2. Primary pulley weight(s)
• Faulty operation
• Worn primary pulley weight
3. Primary fixed sheave
• Worn primary fixed sheave
4. Primary sliding sheave
• Worn primary sliding sheave
5. Secondary fixed sheave
• Worn secondary fixed sheave
6. Secondary sliding sheave
• Worn secondary sliding sheave
Chassis
1. Brake(s)
• Dragging brake
Electrical system
1. Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
2. Ignition system
• Faulty ECU
3. Radiator fan
• Faulty fan motor
• Disconnected circuit breaker terminal
• Faulty coolant temperature sensor
10-3
TROUBLESHOOTING
6. Frame
• Bent frame
• Damaged frame
EAS28610
OVERCOOLING
Cooling system
1. Thermostat
• Thermostat stays open
EAS28710
FAULTY LIGHTING OR SIGNALING SYSTEM
Headlight does not come on
• Wrong headlight bulb
• Too many electrical accessories
• Hard charging
• Incorrect connection
• Improperly grounded circuit
• Poor contacts (main or light switch)
• Burnt-out headlight bulb
EAS28620
POOR BRAKING PERFORMANCE
• Worn brake pad
• Worn brake disc
• Air in hydraulic brake system
• Leaking brake fluid
• Faulty brake caliper kit
• Faulty brake caliper seal
• Loose union bolt
• Damaged brake hose
• Oil or grease on the brake disc
• Oil or grease on the brake pad
• Incorrect brake fluid level
Headlight bulb burnt out
• Wrong headlight bulb
• Faulty battery
• Faulty rectifier/regulator
• Improperly grounded circuit
• Faulty main switch
• Faulty light switch
• Headlight bulb life expired
EAS1XD1129
FAULTY SHOCK ABSORBER ASSEMBLY
Leaking oil
• Bent, damaged or rusty damper rod
• Cracked or damaged shock absorber
• Damaged oil seal lip
Tail/brake light does not come on
• Wrong tail/brake light bulb
• Too many electrical accessories
• Incorrect connection
• Burnt-out tail/brake light bulb
Malfunction
• Fatigued or damaged shock absorber spring
• Bent or damaged damper rod
Tail/brake light bulb burnt out
• Wrong tail/brake light bulb
• Faulty battery
• Faulty brake light switch
• Tail/brake light bulb life expired
• Faulty rectifier/regulator
• Improperly grounded circuit
EAS28670
UNSTABLE HANDLING
1. Steering wheel
• Bent or improperly installed steering wheel
2. Steering components
• Incorrect toe-in
• Bent steering shaft
• Improperly installed steering shaft
• Damaged bearing or bearing race
• Bent tie-rods
• Deformed steering knuckles
3. Shock absorber assembly(-ies)
• Faulty shock absorber spring
• Leaking oil or gas
4. Tire(s)
• Uneven tire pressures (left and right)
• Incorrect tire pressure
• Uneven tire wear
5. Wheel(s)
• Incorrect wheel balance
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout
10-4
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EAS1XD1002
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
Self-diagnostic function table
Fault
code No.
Item
Reference
pages
12
Crankshaft position sensor: no normal signals are received from the
crankshaft position sensor.
9-38
13
Intake air pressure sensor: open or short circuit detected.
9-39
14
Intake air pressure sensor: hose system malfunction (clogged or detached hose).
9-41
15
Throttle position sensor: open or short circuit detected.
9-42
16
Throttle position sensor: stuck throttle position sensor is detected.
9-43
21
Coolant temperature sensor: open or short circuit detected.
9-44
22
Intake air temperature sensor: open or short circuit detected.
9-45
30
Latch up detected.
9-47
33
Ignition coil: open or short circuit detected in the primary lead of the
ignition coil.
9-47
Component other than ISC (idle speed control) unit is defective (ISC
operating sound is heard).
9-49
Defective ISC (idle speed control) unit (ISC operating sound is not
heard).
9-50
39
Injector: open or short circuit detected.
9-52
41
Lean angle sensor: open or short circuit detected.
9-53
42
Speed sensor: no normal signals are received from the speed sensor.
9-54
43
Fuel system voltage: incorrect voltage supplied to the fuel injector and
fuel pump.
9-55
44
EEPROM fault code number: an error is detected while reading or
writing on EEPROM.
9-56
46
Charging voltage is abnormal.
9-57
50
Faulty ECU (engine control unit) memory. (When this malfunction is
detected in the ECU, the fault code number might not appear.)
9-58
37
10-5
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
Communication error with the meter
Fault
code No.
Item
Reference
pages
Er-1
ECU (engine control unit) internal malfunction (output signal error):
signals cannot be transmitted between the ECU and the multi-function
meter.
9-58
Er-2
ECU (engine control unit) internal malfunction (output signal error): no
signals are received from the ECU within the specified duration.
9-59
Er-3
ECU (engine control unit) internal malfunction (output signal error):
data from the ECU cannot be received correctly.
9-60
Er-4
ECU (engine control unit) internal malfunction (input signal error):
non-registered data has been received from the meter.
9-61
Diagnostic code: sensor operation table
TIP
The diagnostic code numbers cannot be displayed on the multi-function meter. To display the diagnostic code numbers, use the Yamaha diagnostic tool.
Diagnostic
code No.
01
Item
Display
Procedure
Throttle position sensor
signal
• Fully closed position
14–20
Check with throttle valve
fully closed.
03
Intake air pressure
Displays the intake air
pressure.
Turn and hold the main
switch in the “ ” (start)
position, then press the
accelerator pedal. (If the
display value changes, the
performance is OK.)
05
Intake air temperature
When engine is cold: Displays temperature closer
to ambient temperature.
When engine is hot: Displays ambient temperature
20 °C (68 °F).
Compare the actually
measured intake air temperature with the display
value.
06
Coolant temperature
When engine is cold: Displays temperature closer
to ambient temperature.
When engine is hot: Displays current coolant temperature.
Compare the actually
measured coolant temperature with the display value.
07
Vehicle speed pulse
0–999
Check that the number increases when the rear
wheels are rotated. The
number is cumulative and
does not reset each time
the wheel is stopped.
10-6
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
Diagnostic
code No.
08
Item
Display
Procedure
Lean angle sensor
Lean angle sensor output
voltage
• Upright
3.6–4.4
Remove the lean angle
sensor and incline it more
than 65 degrees.
• Overturned
0.7–1.3
Fuel system voltage (battery voltage)
Approximately 12.0
09
21
60
61
Gear position switch
Turn the main switch to
“ ” (on), and then compare the actually measured battery voltage with
the display value. (If the
actually measured battery
voltage is low, recharge
the battery.)
Shift the transmission.
• Transmission is in neutral
ON
• Transmission is in gear
OFF
EEPROM fault code display
• No history
00
—
• No malfunctions detected (If the fault code 44 is
indicated, the ECU is defective.)
• History exists
01 (Cylinder fault code)
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.)
—
10-7
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
Diagnostic
code No.
62
70
Item
Display
Procedure
Malfunction history code
erasure
• No history
00
—
• History exists
• Displays the total number of malfunctions, including the current
malfunction, that have
occurred since the history was last erased. (For
example, if there have
been three malfunctions, “03” is displayed.)
Save the malfunction history to the computer, and
then delete the fault
codes.
Control number
0–254 [-]
—
Diagnostic code: actuator operation table
Diagnostic
code No.
Item
Actuation
Procedure
30
Ignition coil
Actuates the ignition coil
Check that a spark is genfive times at one-second
erated five times.
intervals.
• Connect an ignition
The “CHECK” indicator
checker.
and “
” on the Yamaha
diagnostic tool screen
come on each time the ignition coil is actuated.
36
Injector
Actuates the injector five
times at one-second intervals.
The “CHECK” indicator
and “
” on the Yamaha
diagnostic tool screen
come on each time the
fuel injector is actuated.
Check that the injector is
actuated five times by listening for the operating
sound.
48
Air induction system solenoid
Actuates the air induction
system solenoid five times
at one-second intervals.
The “CHECK” indicator
and “
” on the Yamaha
diagnostic tool screen
come on each time the air
induction system solenoid
is actuated.
Check that the air induction system solenoid is actuated five times by
listening for the operating
sound.
10-8
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
Diagnostic
code No.
Item
Actuation
Procedure
50
Fuel injection system relay Actuates the fuel injection
system relay five times at
one-second intervals.
The “CHECK” indicator
and “
” on the Yamaha
diagnostic tool screen
come on each time the relay is actuated.
(When the relay is on, the
“CHECK” indicator and
“
” on the Yamaha diagnostic tool screen go off.
When the relay is off, the
“CHECK” indicator and
“
” on the Yamaha diagnostic tool screen come
on.)
Check that the fuel injection system relay unit is
actuated five times by listening for the operating
sound.
51
Radiator fan motor relay
Actuates the radiator fan
motor relay five times at
five-second intervals. (2
seconds on, 3 seconds
off)
The “CHECK” indicator
and “
” on the Yamaha
diagnostic tool screen
come on each time the relay is actuated.
(When the relay is on, the
“CHECK” indicator and
“
” on the Yamaha diagnostic tool screen go off.
When the relay is off, the
“CHECK” indicator and
“
” on the Yamaha diagnostic tool screen come
on.)
Check that the radiator fan
motor relay is actuated
five times by listening for
the operating sound.
54
ISC valve
Actuates and fully closes The operating sound can
the ISC valve, then opens be heard when ISC valve
it to the stand-by opening operates.
position when the engine
is started.
This operation takes approximately 3 seconds until it is completed.
The “CHECK” indicator
and “
” on the Yamaha
diagnostic tool screen
come on during the operation.
10-9
EAS28740
WIRING DIAGRAM
YX70ME/YX70MHE/YX70MNE/
YXM700DE 2014
1. Crankshaft position sensor
2. AC magneto
3. Rectifier/regulator
4. Load control relay
5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
10. Fuel injection system fuse
11. Starter relay
12. Starter motor
13. Fuel injection system relay
14. Air induction system solenoid
15. Differential motor relay 1
16. Differential motor
17. Gear position switch
18. On-Command four-wheel-drive
switch
19. Yamaha diagnostic tool coupler
20. ISC (idle speed control) unit
21. ECU (engine control unit)
22. Ignition coil
23. Spark plug
24. Fuel injector
25. Intake air temperature sensor
26. Coolant temperature sensor
27. Speed sensor
28. TPS (throttle position sensor)
29. Intake air pressure sensor
30. Lean angle sensor
31. Parking brake switch
32. Reverse switch
33. Joint coupler
34. Seat belt switch
35. Indicator light assembly
36. Helmet indicator light
37. Seat belt indicator light
38. Meter assembly
39. Multi-function meter
40. Engine trouble warning light
41. Coolant temperature warning
light
42. Parking brake indicator light
43. Reverse indicator light
44. Neutral indicator light
45. High-range indicator light
46. Low-range indicator light
47. On-Command differential gear
lock indicator light
48. Fuel sender
49. Fuel pump
50. Differential motor relay 2
51. Light switch
52. Headlight relay
53. Headlight
54. Auxiliary DC jack
55. Brake light switch
56. Tail/brake light
57. Radiator fan motor fuse
58. Differential motor fuse
59. Ignition fuse
60. Backup fuse
61. Signaling system fuse
62. Headlight fuse
63. Auxiliary DC jack fuse
64. Radiator fan motor
65. Radiator fan motor circuit
breaker
66. Radiator fan motor relay
67. Horn switch (for Europe and
Oceania)
68. Horn (for Europe and Oceania)
69. Backup light
70. Backup light relay
A. Optional
B. Wire harness
C. Negative battery sub-wire harness
EAS28750
COLOR CODE
B
Br
G
Gy
L
Lg
O
P
R
Sb
W
Y
B/G
B/L
B/R
B/W
B/Y
Br/B
Br/L
Br/R
Br/W
Br/Y
G/R
G/W
G/Y
Gy/G
L/B
L/R
L/W
L/Y
O/B
O/L
P/L
P/W
R/B
R/G
R/L
R/W
R/Y
W/B
W/G
W/R
Y/B
Y/G
Y/L
Y/R
Y/W
Black
Brown
Green
Gray
Blue
Light green
Orange
Pink
Red
Sky blue
White
Yellow
Black/Green
Black/Blue
Black/Red
Black/White
Black/Yellow
Brown/Black
Brown/Blue
Brown/Red
Brown/White
Brown/Yellow
Green/Red
Green/White
Green/Yellow
Gray/Green
Blue/Black
Blue/Red
Blue/White
Blue/Yellow
Orange/Black
Orange/Blue
Pink/Blue
Pink/White
Red/Black
Red/Green
Red/Blue
Red/White
Red/Yellow
White/Black
White/Green
White/Red
Yellow/Black
Yellow/Green
Yellow/Blue
Yellow/Red
Yellow/White
EAS1XD1041
WIRING DIAGRAM
YX70MPE/YX70MPHE/
YX70MPNE/YXM700PE/
YXM700PHE 2014
1. Crankshaft position sensor
2. AC magneto
3. Rectifier/regulator
4. Load control relay
5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
10. EPS fuse
11. Fuel injection system fuse
12. Starter relay
13. Starter motor
14. Fuel injection system relay
15. Air induction system solenoid
16. Differential motor relay 1
17. Differential motor
18. Gear position switch
19. On-Command four-wheel-drive
switch
20. Yamaha diagnostic tool coupler
21. ISC (idle speed control) unit
22. ECU (engine control unit)
23. Ignition coil
24. Spark plug
25. Fuel injector
26. Intake air temperature sensor
27. Coolant temperature sensor
28. Speed sensor
29. TPS (throttle position sensor)
30. Intake air pressure sensor
31. Lean angle sensor
32. Parking brake switch
33. Reverse switch
34. Joint coupler
35. EPS unit
36. EPS motor
37. EPS torque sensor
38. EPS self-diagnosis signal connector
39. EPS (electric power steering)
control unit
40. Seat belt switch
41. Indicator light assembly
42. Helmet indicator light
43. Seat belt indicator light
44. Meter assembly
45. Multi-function meter
46. Engine trouble warning light
47. Coolant temperature warning
light
48. Parking brake indicator light
49. Reverse indicator light
50. Neutral indicator light
51. High-range indicator light
52. Low-range indicator light
53. On-Command differential gear
lock indicator light
54. EPS warning light
55. Fuel sender
56. Fuel pump
57. Differential motor relay 2
58. Light switch
59. Headlight relay
60. Headlight
61. Auxiliary DC jack
62. Brake light switch
63. Tail/brake light
64. Radiator fan motor fuse
65. Differential motor fuse
66. Ignition fuse
67. Backup fuse
68. Signaling system fuse
69. Headlight fuse
70. Auxiliary DC jack fuse
71. Radiator fan motor
72. Radiator fan motor circuit
breaker
73. Radiator fan motor relay
74. Horn switch (for Europe and
Oceania)
75. Horn (for Europe and Oceania)
76. Backup light
77. Backup light relay
A. Optional
B. Wire harness
C. Negative battery sub-wire harness
D. EPS (electric power steering)
control unit
EAS1XD1042
COLOR CODE
B
Br
G
Gy
L
Lg
O
P
R
Sb
W
Y
B/G
B/L
B/R
B/W
B/Y
Br/B
Br/L
Br/R
Br/W
Br/Y
G/R
G/W
G/Y
Gy/G
L/B
L/R
L/W
L/Y
O/B
O/L
O/W
P/L
P/W
R/B
R/G
R/L
R/W
R/Y
W/B
W/G
W/R
Y/B
Y/G
Y/L
Y/R
Y/W
Black
Brown
Green
Gray
Blue
Light green
Orange
Pink
Red
Sky blue
White
Yellow
Black/Green
Black/Blue
Black/Red
Black/White
Black/Yellow
Brown/Black
Brown/Blue
Brown/Red
Brown/White
Brown/Yellow
Green/Red
Green/White
Green/Yellow
Gray/Green
Blue/Black
Blue/Red
Blue/White
Blue/Yellow
Orange/Black
Orange/Blue
Orange/White
Pink/Blue
Pink/White
Red/Black
Red/Green
Red/Blue
Red/White
Red/Yellow
White/Black
White/Green
White/Red
Yellow/Black
Yellow/Green
Yellow/Blue
Yellow/Red
Yellow/White
YX70ME/YX70MHE/YX70MNE/
YXM700DE 2014 WIRING DIAGRAM
YX70ME/YX70MHE/
YX70MNE/YXM700DE 2014
SCHÉMA DE CÂBLAGE
A
67
68
OFF
ON
B
Br
A
P
W
L Br/Y
Br
B
B
L
W
Br/Y
(B)
(B)
Br/Y
Br/Y B
Br/Y L
69
Br/Y
L
R/W L/B R/G G/R W/G Y/B R
R/Y
70
B G/W
B
Y/R
B
P/L L/B Br/L
O
(B)
22
Br/R
B/L Gy
Gy
B/L
O
G/W
Gy
B
W W
W W
(Gy)
(Gy)
W
W
(Gy)
(Gy)
W W W
1
R
B
B
(Gy)
W W
W W
W W
2
Br/Y R/W
R
3
Lg G/Y R/L G/W Y L/Y
Y/L Y
W/R B/R L B/L L/W R/W
20
Br/L R/W P/L
B/W R/W
Y/W
(B)
R/G
P/L
R/G
P/L
W/G
Br/L
W/G
Br/L
4
Y/W
B
Br/L
R
R
Br/B
8
B
R
Br/R
Br/B
10
Br/L
Br/R
R/L
Br/R
R
5
L/R
13
Br/R
Br/R
L/Y
B
11
B
R/B Br/R
B
15
B
A
(off)
(on)
(start)
12
B
Br/R
L/W
L W
Gy
B
Br/R
Br/R B Y/B
L/Y Br/R
(B)
G/R
B/L
32
G/Y B/L
L
L/W G/R
B
W/R Sb
Gy/G
Y/R
27
W L/Y
B/L
L W
B/L
B/L
R/W R/W R/W R/W R/W R/W
Y
28
Y
(B)
(B)
L
P
B/L
29
33
B/L P L
L
Y/G
B/L
Y/G
L/B
B/W B
31
R/W
R/W
R/W
R/W
R/W
R/W
(B)
L/B
L L L L
B/L Y L
L
P
B/L
Lg
L
B/L B/L B/L B/L B/L B/L B/L B/L
B/L
30
B/L
B/L
B/L
B/L
B/L
B/L
B/L
B/L
L Y/G B/L
(Gy)
L
L
L
L
L
L/R
B
(W)
(Gy)
L/Y
W
L
L/B
2WD
4WD
DIFF LOCK
(B)
B/G P/W W/B B/R B O/L Br/B B/Y
(B)
G/Y
W
21
18
Y/B B
B/Y
Br/R R/B Br/R L/Y
R/L
Y/R
B/R
16
7
R
Br/B
17 L Gy W
R/L
R/L
(B)
66
R/L
O/L B/Y
L/R
Br/B
R/Y L/Y
Gy/G
Sb W/R
W/B
B/Y
6
Br/R
R
P/W B/G
R/Y
G/W
Br/W B/L
(B)
L/R
L/Y
Y
P/W
O/L
B/G
W/B
B/R
Sb
Gy/G
W/R
L/W
G/R
Y/L
Br/B
R
25
(B)
R/L
R/W
R/Y
Y/R
Y/B
G/R
R
B/L
Y/W
9
BB B
R/L R
Br/W
G/Y
B/W
R
R
24
Br/W
26
19
R/W
Br/R
R
R/L
(Gy)
W/G R/W R/G
14
B
R
R/W
R/W
Br/Y
23
R
R/W
R/W
(B)
(B)
O
Gy
Br/R
Br/W W Gy P Y/G P/W Sb O/L Y/W B/G Gy/G W/B L/R B/W G/R Br/R
(B)
L/R B
B/W
G/R L/W
B/W
B L/B
B
(B)
R/L
Br/L
W/B
R/W
63
62
61
R/W
60
65
G/W G/W G/W Y Y
Br/Y
R/B
R
(B)
Br/L
Br Y
55
(B)
R
Y
54
W/B B
R/W
Br/Y
O/B
Br/R B G/R
Y
Y
Y
B
L
Y
52
R/L
40
O/B
(B)
41
49
L
Y G B
O/B
48
42
L
(B)
B
Y/L
B/W
B
Br/R
B
B
G
G
43
B/W
R/L B B/W O/B
(Dg)
Y LL
Y G
Y
Y L
56
56
53
G
Y
B
Y G
B
B
B
44
35
(B)
Br/Y
Lg
Y
B
47
Y G
B
B
B
Lg
Br B
L
34
(B)
36
B
46
Lg
Br
B Br/Y
L/B
45
B
B
R/W
Y/L Br/Y B/W
Y G
53
G
33
B/W
B/W
B/W
B/W
B/W
B/W
R/L
R/L
R/L
L/Y
L/Y
L/Y
Br/B
G/R
L Y
(B)
39
50
L
(off)
G W/B G
Y
B
B R/W
Br
Br/B
57
L
Br/R
51
Br/Y
Br
58
R
38
Br/R
Br
Y Br/Y
59
Br/R
Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
B/W B/W B/W B/W B/W B/W R/L R/L R/L L/Y L/Y L/Y
Br/Y
R/W
L
64
Br
W/B
B
B
B
C
B
G/W
L
L/B
37
B
G/W
G/W
G/W
Y
Y
Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
YX70ME/YX70MHE/YX70MNE/
YXM700DE 2014 WIRING DIAGRAM
YX70ME/YX70MHE/
YX70MNE/YXM700DE 2014
SCHÉMA DE CÂBLAGE
A
67
OFF
ON
A
68
69
(B)
B
(B)
70
(B)
22
23
1
(Gy)
(Gy)
(Gy)
2
(B)
(Gy)
25
20
14
(Gy)
(Gy)
24
(B)
(B)
3
(B)
(B)
32
26
19
(B)
21
27
9
4
28
5
(B)
(B)
8
10
29
13
11
15
A
6
30
17
12
(off)
(on)
(start)
(Gy)
18
16
2WD
4WD
DIFF LOCK
(B)
66
33
(B)
7
31
(B)
(W)
(B)
(Gy)
(B)
(B)
65
63
62
61
38
60
51
(B)
59
64
54
58
(B)
(B)
33
39
50
(off)
55
57
40
(B)
49
52
41
48
42
(B)
43
(Dg)
56
56
35
(B)
53
53
44
45
46
47
34
(B)
36
37
C
YX70MPE/YX70MPHE/YX70MPNE/
YXM700PE/YXM700PHE
2014 WIRING DIAGRAM
YX70MPE/YX70MPHE/YX70MPNE/
YXM700PE/YXM700PHE 2014
SCHÉMA DE CÂBLAGE
A
B
B
74
75
OFF
ON
B
Br
A
P
W
L Br/Y
Br
B
B
G/W
B
B
L
W
Br/Y
Br/Y
L
R/Y O/W R/W L/B R/G G/R W/G Y/B R
77
B G/W
B
Y/R
B
P/L L/B Br/L
O
(B)
23
Br/R
B/L Gy
Gy
B/L
O
G/W
Gy
B
W W
W W
(Gy)
(Gy)
W
W
(Gy)
(Gy)
W W W
1
R
B
B
(Gy)
W W
W W
W W
2
Br/Y R/W
R
Lg G/Y R/L G/W Y L/Y
Y/L Y
W/R B/R L B/L L/W R/W
W/G R/W R/G
15
B
21
Br/L R/W P/L
B/W R/W
Y/W
(B)
O/W
R/G
P/L
W/G
Br/L
W/G
Br/L
R
R
4
9
BB B
Y/W
R
R
Br/L
R
R
R Br/B
8
B
R
Br/R
Br/B
11
Br/L
Br/R
R/L
Br/R
R
L/R
14
Br/R
Br/R
L/Y
B
12
B
R/B Br/R
B
16
B
A
(off)
(on)
(start)
13
B
Br/R
L/W
L W
Gy
B
Br/R
Br/R B Y/B
L/Y Br/R
(B)
G/R
G/Y
B/L
33
G/Y B/L
W
22
L
L/W G/R
B
W/R Sb
Gy/G
Y/R
28
W L/Y
B/L
L W
B/L
B/L
R/W R/W R/W R/W R/W R/W
Y
29
Y
(B)
(B)
L
P
B/L
30
34
B/L P L
(B)
L/B
L
Y/G
B/L
Y/G
L/B
B/W B
32
L L L L
B/L Y L
L
P
B/L
Lg
L
B/L B/L B/L B/L B/L B/L B/L B/L W W W
B/L
31
R/W
R/W
R/W
R/W
R/W
R/W
W
W
W
B/L
B/L
B/L
B/L
B/L
B/L
B/L
B/L
L Y/G B/L
(Gy)
L
L
L
L
L
L/R
B
(W)
(Gy)
L/Y
W
L
L/B
2WD
4WD
DIFF LOCK
(B)
B/G P/W W/B B/R B O/L Br/B B/Y
(B)
G/W
Br/W B/L
(B)
19
Y/B B
B/Y
Br/R R/B Br/R L/Y
R/L
Y/R
B/R
17
7
R
Br/B
18 L Gy W
R/L
R/L
(B)
73
R/L
O/L B/Y
L/R
Br/B
R/Y L/Y
Gy/G
Sb W/R
W/B
B/Y
6
Br/R
R
P/W B/G
R/Y
26
L/R
L/Y
Y
P/W
O/L
B/G
W/B
B/R
Sb
Gy/G
W/R
L/W
G/R
Y/L
Br/B
B
5
(Gy)
B/L
(B)
R/L
R/W
R/Y
Y/R
Y/B
G/R
R/B
R/L R
Br/W
Y/W
R/B
R
10
R
25
Br/W
G/Y
B/W
Br/R
R
R/L
27
20
R/W
R
R/W
R/G
P/L
R/W
Br/Y
24
R
R/W
R/W
(B)
(B)
O
Gy
Br/R
Br/W W Gy P Y/G P/W Sb O/L Y/W B/G Gy/G W/B L/R B/W G/R Br/R
(B)
3
L/R B
B/W
G/R L/W
B/W
B L/B
B
(B)
35
R/L
G R
B W
37
36
B R
(Gy)
(Gy)
G
R B W
R B
Br/L
W/B
R/W
70
69
68
R/W
67
72
R/B
Br
R G
W B
Br/Y
Br/Y
R
(B)
Br/L
Br Y
58
Br/Y
61
Br
62
(B)
R
Br/B
R/W
Br/Y
O/B
G/R
L Y
W/B B
45
57
L
(off)
G W/B G
Y
B
R B
B
Br/R B G/R
Y
Y
B
L
Y
59
G/W G/W G/W Y Y
Y G B
48
B
63
63
Y G
Y G
Y
60
G
Y G
B
B
B
B
Y/L Br/Y B/W
B
Y
53
Y G
B
41
(B)
Br/Y
Lg
B Br/Y
L/B
Lg
B
B
Lg
Br B
L
40
(B)
51
52
B
34
B/W
B/W
B/W
B/W
B/W
B/W
R/L
R/L
R/L
L/Y
L/Y
L/Y
(B)
O/B G/R R/W
50
60
G
Y
B
38
Br
(Dg)
Y LL
(Gy)
(B)
L/B
O/W R L/B
G/R W
B/W
R/L B B/W O/B
Y L
(Gy)
W/B
Y/L
B/W
49
G
G
G
O
L/B Br O
G W G/R
(B)
47
55
L
B
R/B
39
O/B
56
(B)
B
42
B
54
G/R
Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
B/W B/W B/W B/W B/W B/W R/L R/L R/L L/Y L/Y L/Y
W
G/R
O/W
L/B
46
R/L
(B)
L
G
Br
B
Br/R
Y
B R/W
Br
Br/B
64
L
Br/R
Y
R
B
44
Br/R
Br
W/B
Y Br/Y
65
R
B
R/B
66
Br/R
71
GR B WR
R/W
L
C
B
(B)
(B)
Br/Y
Br/Y B
Br/Y L
76
L
L/B
43
B
G/W
G/W
G/W
Y
Y
Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
Br/Y
B
B
(B)
(B)
D
C
YX70MPE/YX70MPHE/YX70MPNE/
YXM700PE/YXM700PHE
2014 WIRING DIAGRAM
YX70MPE/YX70MPHE/YX70MPNE/
YXM700PE/YXM700PHE 2014
SCHÉMA DE CÂBLAGE
A
74
OFF
ON
A
75
76
B
C
B
(B)
(B)
77
(B)
23
24
1
(Gy)
(Gy)
(Gy)
2
(B)
(Gy)
26
21
15
(Gy)
(Gy)
25
(B)
(B)
3
(B)
(B)
33
27
20
(B)
22
28
9
4
10
29
5
(B)
(B)
8
11
30
14
12
16
A
6
31
18
13
(off)
(on)
(start)
(Gy)
19
17
2WD
4WD
DIFF LOCK
(B)
73
34
(B)
7
32
(B)
(W)
(B)
(Gy)
(B)
(B)
35
37
72
70
69
68
44
67
58
(B)
66
71
61
65
(B)
39
B
45
57
(B)
38
(Gy)
(Gy)
(B)
(off)
34
(B)
62
64
46
47
(B)
56
59
55
48
49
(B)
41
(B)
50
(Dg)
63
63
60
60
51
52
53
54
40
(B)
42
43
36
(Gy)
(Gy)
(B)
(B)
D
C
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