YX70 MPNE | YX70 MPHE | YX70 MPE | YX70 MNE | YX70 MHE | YXM700 DE | YXM700 PHE | Yamaha YX70 ME, MHE, MNE, MPE, MPHE, MPNE, YXM700 PE, PHE, DE ATV 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

A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

NOTICE

A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property.

TIP

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

3

4

5

6

EAS25061

CLUTCH

Removing the clutch

T.R

190 Nm (19 m

•

kgf, 137 ft

•

lbf)

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

2

New

1

4

3

(7)

3

5

M

E

E

LS

3

4

1

2

5

Order Job/Parts to remove

Drive belt case

C l u t c h h o u s i n g a s s e m b l y

Clutch housing assembly gasket

D o w e l p i n

C l u t c h c a r r i e r a s s e m b l y n u t

C l u t c h c a r r i e r a s s e m b l y

5-60

Q’ty Remarks

Refer to “PRIMARY AND SECONDARY

SHEAVES” on page 5-50.

2

1

1

1

1

L e f t h a n d t h r e a d s

For installation, reverse the removal procedure.

EAS25070

REMOVING T HE CLUTCH

1. Remove:

• Clutch housing assembly

TIP

Working in crisscross pattern, loosen each bolt

1/4 of a turn. Remove them after all of them are loosened.

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.

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 clut ch 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 a

1

EAS1XD1102

CHECKING THE CLUTCH

1. Check:

• Clutch housing

Damage/wear

→

Replace.

2

EAS28990

CHECKING THE CLUTCH SHOE

1. Check:

• Clutch shoe

Damage/wear

→

Replace.

Glazed areas

→

Sand with coarse sandpaper.

TIP

After sanding the glazed areas, clean the clutch with a cloth.

2. Measure:

• Clutch shoe thickness

Out of specification

→

Replace.

Clutch shoe thickness

1.5 mm (0.06 in)

Limit

1.0 mm (0.04 in)

5-62

7

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 DEFINITION

Serviceable with engine mounted Gear oil

G

Filling fluid Molybdenum disulfide oil

M

Lubricant Brake fluid

BF

Special tool

B

Wheel bearing grease

LS

Lithium-soap-based grease

.

T

R

.

Tightening torque

Wear limit, clearance

M

Molybdenum disulfide grease

Engine speed

Electrical data

E

Engine oil

S

Silicone grease

LT

Apply locking agent (LOCTITE®).

New

Replace the part with a new one.

EAS20110

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND

ADJUSTMENTS

CHASSIS

ENGINE

COOLING SYSTEM

FUEL SYSTEM

DRIVE TRAIN

ELECTRICAL SYSTEM

TROUBLESHOOTING

7

8

5

6

1

2

3

4

9

10


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

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

IDENTIFICATION

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 6 7,8,9,10

1. Lean angle sensor

2. ECU (engine control unit)

3. Fuel injection system relay

4. Engine trouble warning light

5. Ignition coil

6. Air cut-off valve

7. ISC (idle speed control) unit

8. Intake air pressure sensor

9. Fuel injector

16 15 14 13 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

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.

15

1

13

A

14

B

12

11

2

10

C

3

7

4

9

5

6

8

1. Fuel pump

2. Fuel injector

3. Ignition coil


5. Speed sensor



8. Catalytic converter



11. Throttle body


13. Throttle position sensor


15. Air filter case

A. Fuel system

B. Air system

C. Control system

1-3

1-4

FEATURES

FEATURES

EAS1XD1055

OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)

1 f

6 e

7

4

2 d

5 c

3 a

5 b

1-5

FEATURES

1. Speed information from speed sensor

2. Engine RPM information from ECU

3. Battery

4. EPS control unit

5. EPS unit

6. EPS motor

7. Torque sensor a. Operates steering b. Twists torsion bar c. Sends the torque sensor signal d. EPS control unit calculates assist power e. Electricity output switched by EPS control unit f.

Activates EPS motor

ECA1XD1027

NOTICE

To prevent accidental damage to the EPS unit, it must not be disassembled.

1-6

FEATURES

EAS1XD1056

INSTRUMENT FUNCTIONS

Multi-function meter unit

3

2

1

4 5

7 6

1. “CLOCK” button

2. “RESET” button

3. “SELECT” button

4. Speedometer

5. Fuel meter

6. Clock/Hour meter/Voltage display

7. Odometer/Tripmeter A/Tripmeter B

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

Odometer and tripmeter modes

1

2

3



3. Odometer/Tripmeter A/Tripmeter B

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 “SE-

LECT” 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.

TIP

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).

Clock, hour meter and voltage display modes

1

2

3

4



3. “CLOCK” button

4. 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.

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.

Fuel meter

1

2

3

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.

ECA1XD1055

NOTICE

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


EAS20190

PREPARATION FOR REMOVAL AND

DISASSEMBLY

1. Before removal and disassembly, remove all dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning 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.

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.

1. Oil

2. Lip

3. Spring

4. 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


EAS20230

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.

ECA13300

NOTICE

Do not spin the bearing with compressed air because this will damage the bearing surfaces.

EAS1XD1131

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.

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


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


EAS30402


Electrical parts handling

ECA16600

NOTICE

Never disconnect a battery lead while the engine is running; otherwise, the electrical components could be damaged.

ECA16760

NOTICE

Be sure to connect the battery leads to the correct battery terminals. Reversing the battery lead connections could damage the electrical components.

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.

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.

TIP

If a battery lead is difficult to disconnect due to rust on the battery terminal, remove the rust using hot water.

1-12

ECA16610

NOTICE

Turn the main switch to “OFF” before disconnecting or connecting an electrical component.


ECA16620

NOTICE

Handle electrical components with special care, and do not subject them to strong shocks.

Checking the electrical system

TIP

Before checking the electrical system, make sure that the battery voltage is at least 12 V.

ECA16630

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.

ECA14371

NOTICE

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

TIP

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”.

ECA16640

NOTICE

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


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.

2. Check:

• Lead

• Coupler

• Connector

Moisture

→

Dry with an air blower.

Rust/stains

→

Connect and disconnect several times.

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

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.


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 k

Ω

at 0 °C (32 °F)

290–390

Ω

at 80 °C (176 °F)

5. Check:

• Resistance

Pocket tester

90890-03112


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.

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

Illustration

Reference pages

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

3-4

Thickness gauge

90890-03079

Narrow gauge set

YM-34483

Tappet adjusting tool

90890-01311

Six piece tappet set

YM-A5970

3-4

Yamaha diagnostic tool

90890-03215

YM-A5970

ø8 ø9 ø10

ø3 ø4

3-6, 9-37

Oil filter wrench

90890-01426

YU-38411

3-13

1-16


Boots band installation tool

90890-01526

YM-01526

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

Compression gauge

90890-03081

Engine compression tester

YU-33223

Slide hammer bolt

90890-01083

Slide hammer bolt 6 mm

YU-01083-1

Weight

90890-01084

YU-01083-3

YU-01083-3

1-17

Illustration

SPECIAL TOOLS

Reference pages

4-54, 8-9, 8-11,

8-23, 8-25

4-58, 4-62

4-58, 4-62

45mm ø35

110mm

12mm

4-58, 4-62

4-58, 4-62

ø39

5-14

5-17, 5-19

5-17


Valve spring compressor

90890-04019

YM-04019

Valve spring compressor attachment

90890-01243

Valve spring compressor adapter (26 mm)

YM-01253-1

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

Piston pin puller set

90890-01304

Piston pin puller

YU-01304

YU-01304

Illustration

SPECIAL TOOLS

Reference pages

5-21, 5-26

5-21, 5-26

5-22

5-22

5-22

5-28

Sheave holder

90890-01701

Primary clutch holder

YS-01880-A

Flywheel puller

90890-01362

Heavy duty puller

YU-33270-B

5-34, 5-35,

5-36, 5-53,

5-58

5-34

1-18


Yamaha bond No. 1215

90890-85505

(Three Bond No.1215®)

Digital circuit tester

90890-03174

Model 88 Multimeter with tachometer

YU-A1927

Sheave fixed block

90890-04135

Sheave fixed bracket

YM-04135

Illustration

SPECIAL TOOLS

Reference pages

5-36, 5-69,

8-27

5-39, 7-13,

9-101, 9-103

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


Universal clutch holder

90890-04086

YM-91042

Illustration

SPECIAL TOOLS

Reference pages

5-62, 5-63

Crankcase separating tool

90890-01135

Crankcase separator

YU-01135-B

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

YU-90058/YU-90059

5-73

5-75

5-75

5-75

1-20


Spacer (crankshaft installer)

90890-04081

Pot spacer

YM-91044

Spacer

90890-04167

YM-04167

Coupling gear/middle shaft tool

90890-01229

Gear holder

YM-01229

Bearing retainer wrench

90890-04128

Middle gear bearing retainer

YM-04128

Ring nut wrench

90890-01430

YM-38404

Final gear backlash band

90890-01511

Middle drive gear lash tool

YM-01230

YM-91044

Illustration

SPECIAL TOOLS

Reference pages

5-75

ø70

5-75

5-87, 5-90

5-88, 5-89

5-88, 5-89

5-91

1-21


Radiator cap tester

90890-01325

Mityvac cooling system tester kit

YU-24460-A

YU-24460-A

Radiator cap tester adapter

90890-01352

Pressure tester adapter

YU-33984

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

Pressure gauge

90890-03153

YU-03153

Fuel pressure adapter

90890-03176

YM-03176

YU-33984

Illustration

SPECIAL TOOLS

Reference pages

6-6

6-6

7-4

7-4

6-14

6-14

1-22


Test harness- TPS (3P)

90890-03204

YU-03204

Universal joint holder

90890-04062

YM-04062

Illustration

SPECIAL TOOLS

Reference pages

7-13

8-11, 8-14

Ring gear fix bolt (M10)

90890-01527

YM-01527

Gear lash measurement tool

90890-01475

Middle drive gear lash tool

YM-01475

Coupling gear holding tool (35)

90890-01571

YM-01571

Ring gear fix bolt (M10 x 1.5)

90890-01572

YM-01572

Gear lash measurement tool

90890-01467

YM-01467

Ignition checker

90890-06754

Oppama pet-4000 spark checker

YM-34487

1-23

8-15

M10×P1.25

8-15

8-25, 8-28

8-26

M10×P1.50

8-26

9-99


Test harness-lean angle sensor (3P)

90890-03213

YU-03213

Test harness- speed sensor (3P)

90890-03208

YU-03208

Test harness S- pressure sensor 5S7 (3P)

90890-03211

YU-03211

Illustration

SPECIAL TOOLS

Reference pages

9-100

9-102

9-105

1-24

1-25

SPECIAL TOOLS

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

Dimensions

Overall length

Overall width

Overall height

Seat height

Wheelbase

Ground clearance

Minimum turning radius

Weight

Curb weight

Maximum loading limit

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])

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)

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)

2-1

ENGINE SPECIFICATIONS

EAS29120


Engine

Engine type

Displacement

Cylinder arrangement

Bore

×

stroke

Compression ratio

Standard compression pressure (at sea level)

Minimum–maximum

Starting system

Fuel

Recommended fuel

Fuel tank capacity

Engine oil

Lubrication system

Recommended brand

Type

Recommended engine oil grade

Engine oil quantity

Total amount

Without oil filter cartridge replacement

With oil filter cartridge replacement

Final gear oil

Type

Total amount

Quantity

Differential gear oil

Type

Total amount

Quantity

Oil filter

Oil filter type

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

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

Regular unleaded gasoline only

36.7 L (9.70 US gal, 8.07 Imp.gal)

Wet sump

YAMALUBE

SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-

40 or 20W-50

API service SG type or higher, JASO standard

MA

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)

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)

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)

Cartridge

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


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

Radiator cap opening pressure

0.17 L (0.18 US qt, 0.15 Imp.qt)

107.9–137.3 kPa (1.1–1.4 kgf/cm², 15.6–19.9 psi)

Thermostat

Valve opening temperature

Valve full open temperature

69–73 °C (156–163 °F)

85 °C (185 °F)

8.0 mm (0.31 in) Valve lift (full open)

Radiator core

Width

Height

400.0 mm (15.75 in)

253.4 mm (9.98 in)

28.0 mm (1.10 in) Depth

Water pump

Water pump type

Reduction ratio

Impeller shaft tilt limit

Single suction centrifugal pump

32/31 (1.032)

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

A

B

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)

2-3


0.015 mm (0.0006 in) Camshaft runout limit

Timing chain

Tensioning system

Rocker arm/rocker arm shaft

Rocker arm inside diameter

Rocker arm shaft outside diameter

Rocker-arm-to-rocker-arm-shaft clearance

Valve, valve seat, valve guide

Valve clearance (cold)

Intake

Exhaust

Valve dimensions

Valve head diameter A (intake)

Valve head diameter A (exhaust)

Automatic

12.000–12.018 mm (0.4724–0.4731 in)

11.981–11.991 mm (0.4717–0.4721 in)

0.009–0.037 mm (0.0004–0.0015 in)

0.09–0.13 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)

B

Valve seat width C (intake)

Limit

Valve seat width C (exhaust)

Limit

C

Valve margin thickness D (intake)

Limit

Valve margin thickness D (exhaust)

Limit

D

Valve stem diameter (intake)

Limit

2.26 mm (0.0890 in)

2.26 mm (0.0890 in)

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)

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)

2-4

5.975–5.990 mm (0.2352–0.2358 in)

5.945 mm (0.2341 in)


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)

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)

Installed compression spring force (exhaust)

Spring tilt (intake)

Spring tilt (exhaust)

1.00–1.20 mm (0.0394–0.0472 in)

1.00–1.20 mm (0.0394–0.0472 in)

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)

Cylinder

Cylinder bore

Wear limit

Taper limit

Out of round limit

2-5

Clockwise

Clockwise

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)

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

Piston ring

Top ring

Ring type

Dimensions (B

×

T)

B

T

End gap (installed)

Limit

Ring side clearance

Limit

2nd ring

Ring type

Dimensions (B

×

T)

B

T

End gap (installed)

Limit

Ring side clearance

Limit

Oil ring

Dimensions (B

×

T)

B

T

End gap (installed)

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)

Barrel

1.20

×

3.80 mm (0.05

×

0.15 in)

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)

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)

2-6

0.20–0.70 mm (0.01–0.03 in)

Crankshaft

Width A

Runout limit C

Big end side clearance D

C C

D

A

Balancer

Balancer drive method

Automatic centrifugal clutch

Clutch type

Clutch shoe thickness

Limit

Clutch housing inside diameter

Clutch-in revolution

Clutch-stall revolution

V-belt

V-belt width

Limit

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

Shifting mechanism

Shift mechanism type

Shift fork thickness

Decompression device

Device type

Air filter

Air filter element

Air filter oil grade


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)

Gear

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

33.0–33.6 mm (1.30–1.32 in)

32.5 mm (1.28 in)

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)

2-7

Shift drum and guide bar

5.76–5.89 mm (0.2268–0.2319 in)

Auto decomp

Wet element

Foam air filter oil or equivalent oil


Fuel pump

Pump type

Fuel injector

Model/quantity

Fuel injector resistance

Throttle body

Type/quantity

ID mark

Throttle valve size

Throttle position sensor

Resistance

Fuel injection sensor

Crankshaft position sensor resistance

Intake air pressure sensor output voltage

Intake air temperature sensor resistance

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)

Air induction system

Solenoid resistance

Drive train

Middle gear backlash

Final gear backlash

Differential gear backlash

Electrical

EAT291/1

11.5–12.5

Ω

44EHS/1

1XD1 00

#100

2.64–6.16 k

Ω

408.0–612.0

Ω

3.594–3.684 V at 101 kPa (1.01 kgf/cm², 14 psi)

5.40–6.60 k

Ω

at 0 °C (32 °F)

290–390

Ω

at 80 °C (176 °F)

2.32–2.59 k

Ω

at 20 °C (68 °F)

310–326

Ω

at 80 °C (176 °F)

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 %

20–24

Ω

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

Frame type

Caster angle

Camber angle

Kingpin angle

Kingpin offset

Trail

Tread rear (STD)

Tread front (STD)

Toe-in (with tires touching the ground)

Front wheel

Wheel type

Rim size

Wheel material

Wheel travel

Radial wheel runout limit

Lateral wheel runout limit

Rear wheel

Wheel type

Rim size

Wheel material

Wheel travel

Radial wheel runout limit

Lateral wheel runout limit

Front tire

Type

Size

Manufacturer/model

Wear limit (front)

Rear tire

Type

Size

Manufacturer/model

Wear limit (rear)

Tire air pressure (measured on cold tires)

Recommended

Vehicle load

Front

Rear

Vehicle load

Front

Rear

Minimum

Vehicle load

Front

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)

Panel wheel

12

×

6.0AT

Steel

205 mm (8.1 in)

2.0 mm (0.08 in)

2.0 mm (0.08 in)

Panel wheel

12

×

7.5AT

Steel

205 mm (8.1 in)

2.0 mm (0.08 in)

2.0 mm (0.08 in)

Tubeless

25

×

8–12NHS

MAXXIS/MU09

3.0 mm (0.12 in)

Tubeless

25

×

10–12NHS

MAXXIS/MU10

3.0 mm (0.12 in)

2-9

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)

Rear

Vehicle load

Front

Rear

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

Rear brake

Type

Operation

Brake pedal free play

Rear disc brake


×

thickness


Brake disc deflection limit

Brake pad lining thickness (inner)

Limit

Brake pad lining thickness (outer)

Limit

Caliper cylinder inside diameter

Specified brake fluid

Parking brake

Type


×

thickness


Brake pad lining thickness-inner

Limit

Brake pad lining thickness-outer

Limit

Front suspension

Type

Spring/shock absorber type

Wheel travel

Shock absorber travel

Spring free length

Installed length

Spring rate K1

Spring stroke K1


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)

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

Disc brake

Unified brake

0 mm (0 in)

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

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)

2-10

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)

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


Voltage

System voltage

Ignition system

Ignition system

Advancer type

Ignition timing (B.T.D.C.)

12 V

TCI

Digital

5.0°/1600 r/min

Engine control unit

Model/manufacturer

Ignition coil

Minimum ignition spark gap

Primary coil resistance

Secondary coil resistance

Spark plug cap

Material

Resistance

F8T85871/MITSUBISHI

6.0 mm (0.24 in)

2.16–2.64

Ω

8.64–12.96 k

Ω

Resin

7.5–12.5 k

Ω

AC magneto

Standard output

Stator coil resistance

Rectifier/regulator

Regulator type

Regulated voltage (DC)

Rectifier capacity (DC)

Withstand voltage

Battery

Model

Voltage, capacity

Manufacturer

Ten hour rate charging current

14.0 V, 36.4 A at 5000 r/min

0.09–0.13

Semi conductor-short circuit

14.3–14.7 V

50.0 A

40.0 V

Ω

U1-H11L

12 V, 28.0 Ah

GS

2.8 A

Headlight

Bulb type

Bulb voltage, wattage

×

quantity

Headlight

Tail/brake light

Halogen bulb

12 V, 35.0/35.0 W

×

2

12 V, 5.0/21.0 W

×

2

Indicator and warning lights

Neutral indicator light

Reverse indicator light

Coolant temperature warning light

LED

LED

LED

Parking brake indicator light

On-Command four-wheel-drive/differential gear lock

LED indicator LCD

2-12

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

Electric starting system

System type

Starter motor

Power output

Armature coil resistance

Brush overall length

Limit

Brush spring force

Commutator diameter

Limit

Mica undercut (depth)

Starter relay

Amperage

Coil resistance

Horn (for Europe and Oceania)

Horn type

Quantity

Maximum amperage

Fuel sender unit

Sender unit resistance (full)

Sender unit resistance (empty)

EPS torque sensor

Coil resistance

Auxiliary DC output

Jack capacity

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


LED

LED (for EPS models)

LED

LED

LED

14 V, 0.85 W

×

2

Constant mesh

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)

180.0 A

4.18–4.62

Ω

Plane

1 pc

1.0 A

19.0–21.0

Ω

139.0–141.0

Ω

0.875–1.625 k

Ω

(for EPS models)

12 V, 10.0 A (120 W)

2-13

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

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

General tightening torques

A (nut) B (bolt)

Nm

10 mm 6 mm

12 mm 8 mm

14 mm 10 mm

6

15

30

17 mm 12 mm

19 mm 14 mm

55

85

22 mm 16 mm 130

m·kgf

0.6

1.5

3.0

5.5

8.5

13.0

ft·lbf

4.3

11

22

40

61

94

2-14


EAS20340

ENGINE TIGHTENING TORQUES

Item

Exhaust pipe nut

Muffler bolt

Muffler mount shaft

Spark arrester bolt

Intake air pressure sensor screw

Throttle position sensor screw

Injector fuel rail screw

Throttle cable locknut (throttle body end, air intake silencer side)

Throttle cable locknut (throttle body end, throttle body side)

Throttle cable housing cover screw

Cylinder head stud bolt (exhaust pipe)

Reed valve cover bolt

Thread size

Q’ty

M8

M8

M8

M6

M5

M5

M6

1

4

1

2

2

2

1

M7

M6

M4

M8

M6

1

1

3

2

2

Cylinder head bolt M9 4

Tightening torque

20 Nm (2.0 m·kgf, 14 ft·lbf)

23 Nm (2.3 m·kgf, 17 ft·lbf)

17 Nm (1.7 m·kgf, 12 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

3.6 Nm (0.36 m·kgf, 2.6 ft·lbf)

3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)

5 Nm (0.5 m·kgf, 3.6 ft·lbf)

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)

0.8 Nm (0.08 m·kgf, 0.6 ft·lbf)

2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)

15 Nm (1.5 m·kgf, 11 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

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

l = 39 mm

(1.54 in)

E

Cylinder head bolt M9

Cylinder head bolt

Tappet cover bolt

Camshaft sprocket cover bolt

Thermostat cover bolt

Thermostat cover air bleed bolt

Oil check bolt

Camshaft sprocket bolt

Decompression assembly bolt

Valve adjusting screw locknut

Bearing retainer bolt (camshaft)

Cylinder bolt

Cylinder bolt

Timing chain guide (intake side) bolt

Timing chain tensioner cap bolt

M6

M6

M6

M6

M6

M8

M7

M7

M6

M6

M10

M6

M6

M16

2

2

1

2

4

2

1

2

2

1

2

4

2

8

2

2-15

38 Nm (3.8 m·kgf, 27 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

20 Nm (2.0 m·kgf, 14 ft·lbf)

20 Nm (2.0 m·kgf, 14 ft·lbf)

14 Nm (1.4 m·kgf, 10 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

See TIP.

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

20 Nm (2.0 m·kgf, 14 ft·lbf)

LT

E

LT


Item

Thread size

Q’ty

2 Timing chain tensioner bolt

Oil pipe (crankcase to cylinder head) union bolt

Oil pipe (crankcase to cylinder head) union bolt

Oil pipe (crankcase to cylinder head) bolt

Oil pipe union bolt (AC magneto cover)

Thermostat outlet hose guide bolt

Crankcase bolt

Crankcase bolt

Dipstick guide bolt

Engine oil drain bolt

Crankcase plug

Crankcase plug

Oil filter cartridge

M6

M10

M14

M6

M8

M10

Oil filter cartridge union bolt

Timing chain stopper guide (lower) bolt

M6

Bearing retainer bolt (crankcase) M6

Oil pump bolt M6

Oil pump housing cover screw

Water jacket joint bolt

M5

M6

Water pump outlet hose clamp screw

Water pump housing bolt

M5

Coolant drain bolt

Water pump air bleed bolt

M6

Water pump outlet pipe bolt M6

Crankshaft end accessing screw M36

Timing mark accessing screw

Drive select lever shift cable bracket bolt (engine side)

M6

M6

M14

M6

AC magneto cover bolt

AC magneto rotor nut

M6

M16

AC magneto/crankshaft position sensor lead holder bolt

Starter clutch bolt

M20

M5

M8

M8

M6

M6

M14

M16

M14

M20

1

2

1

2

1

2

2

1

11

1

2

3

2

3

1

2

1

1

1

3

1

1

3

13

1

1

1

1

1

1


10 Nm (1.0 m·kgf, 7.2 ft·lbf)

20 Nm (2.0 m·kgf, 14 ft·lbf)

35 Nm (3.5 m·kgf, 25 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

18 Nm (1.8 m·kgf, 13 ft·lbf)

48 Nm (4.8 m·kgf, 35 ft·lbf)

26 Nm (2.6 m·kgf, 19 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

30 Nm (3.0 m·kgf, 22 ft·lbf)

8 Nm (0.8 m·kgf, 5.8 ft·lbf)

18 Nm (1.8 m·kgf, 13 ft·lbf)

17 Nm (1.7 m·kgf, 12 ft·lbf)

30 Nm (3.0 m·kgf, 22 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

5 Nm (0.5 m·kgf, 3.6 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)

1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

60 Nm (6.0 m·kgf, 43 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

30 Nm (3.0 m·kgf, 22 ft·lbf)

Remarks

LS

E

LT

LT

LT

E

LT

2-16


Item

Oil pump driven sprocket nut

Balancer driven gear nut M18 1

Drive belt cover bolt

Bearing housing bolt (primary sheave assembly)

Bearing retainer bolt (bearing housing)

Primary sheave assembly nut

Primary sheave cap screw

M6

M6

M6

M16

M4

Secondary sheave assembly nut M16

Secondary sheave spring retaining nut

M36

Drive belt case bolt

Clutch housing assembly bolt

M6

M6

1

1

8

1

1

8

9

11

4

Clutch carrier assembly nut

Drive select lever unit bolt

Drive select lever shift cable bracket bolt (drive select lever side)

Drive select lever shift cable locknut

Shift arm bolt

Shift lever cover bolt

Shift lever 2 bolt

Shift drum stopper bolt

Middle drive pinion gear nut

Middle drive shaft bearing housing bolt

Middle drive shaft bearing retainer bolt

Front drive shaft yoke nut (middle gear side)

Middle driven shaft bearing retainer

M6

M8

M14

M6

M6

M6

M14

M22

M8

M8

M16

M55 1

5

2

4

1

1

1

4

1

1

1

4

Thread size

Q’ty

M10 1

M22 1


22 Nm (2.2 m·kgf, 16 ft·lbf)

85 Nm (8.5 m·kgf, 61 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

190 Nm (19 m·kgf, 137 ft·lbf)

3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)

100 Nm (10 m·kgf, 72 ft·lbf)

90 Nm (9.0 m·kgf, 65 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Remarks

Use a lock washer.

Use a lock washer.

E

190 Nm (19 m·kgf, 137 ft·lbf)

Left-hand threads

Stake.

M

13 Nm (1.3 m·kgf, 9.4 ft·lbf)

16 Nm (1.6 m·kgf, 12 ft·lbf)

39 Nm (3.9 m·kgf, 28 ft·lbf)

14 Nm (1.4 m·kgf, 10 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

14 Nm (1.4 m·kgf, 10 ft·lbf)

18 Nm (1.8 m·kgf, 13 ft·lbf)

190 Nm (19 m·kgf, 137 ft·lbf)

32 Nm (3.2 m·kgf, 23 ft·lbf)

29 Nm (2.9 m·kgf, 21 ft·lbf)

190 Nm (19 m·kgf, 137 ft·lbf)

80 Nm (8.0 m·kgf, 58 ft·lbf)

Stake.

LT

Stake.

LT

LT

Left-hand threads

LT

2-17


Item

Thread size

Q’ty Tightening torque Remarks

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)

Left-hand threads

LT

Rear drive shaft yoke nut (middle gear side)

Starter motor bolt

Starter motor cover bolt

Brush set bolt

Starter motor lead nut

Negative battery lead bolt

Spark plug

Stator coil assembly bolt

Crankshaft position sensor bolt

Coolant temperature sensor

Gear position switch bolt

Reverse switch

Speed sensor bolt

M16

M6

M5

M6

M6

M6

M10

M6

M5

M12

M6

M10

M6

1

1

1

2

2

1

1

3

2

1

1

2

1

190 Nm (19 m·kgf, 137 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

4.9 Nm (0.49 m·kgf, 3.5 ft·lbf)

11 Nm (1.1 m·kgf, 8.0 ft·lbf)

4.9 Nm (0.49 m·kgf, 3.5 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

13 Nm (1.3 m·kgf, 9.4 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

18 Nm (1.8 m·kgf, 13 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

17 Nm (1.7 m·kgf, 12 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

LT

LT

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

7

1

5

3

6

8

2-18


EAS20350

CHASSIS TIGHTENING TORQUES

Item

Thread size

Q’ty

Engine mounting bolt

Engine mounting bolt

Engine bracket nut

Front fender and front grill bolt

Radiator bracket bolt

Radiator fan bolt

Radiator pipe holder bolt

Front fender and electrical components tray bolt

Front grill and front guard bolt

Front guard bolt

Front guard cover screw

Front grill and frame bolt

Headlight screw

Front fender and frame bolt

Electrical components tray and frame bolt

Muffler heat protector plate bolt

Side panel bolt

ECU nut

Lean angle sensor bolt

Starter relay lead bolt

Positive battery lead nut

Negative battery lead nut

EPS control unit bolt (for EPS models)

V-belt cooling intake duct joint 1 clamp screw (V-belt cooling intake duct side)

V-belt cooling intake duct joint 1 clamp screw (drive belt cover side)

V-belt cooling intake duct joint 2 clamp screw

V-belt cooling exhaust duct joint clamp screw (V-belt cooling exhaust duct side)

V-belt cooling exhaust duct joint clamp screw (drive belt cover side)

Fuel tank retainer bolt

M10

M6

M10

M6

M6

M6

M6

M6

M6

M10

M6

M6

M5

M6

M6

M8

M6

M6

M5

M6

M8

M8

M6

M4

M6

M4

M4

M6

M8

2

6

2

2

4

4

4

6

2

4

4

4

4

4

4

1

1

1

2

1

1

2

2

1

1

1

2

2

6

2-19


42 Nm (4.2 m·kgf, 30 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

42 Nm (4.2 m·kgf, 30 ft·lbf)

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

8 Nm (0.8 m·kgf, 5.8 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)

48 Nm (4.8 m·kgf, 35 ft·lbf)

2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)

1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)

17 Nm (1.7 m·kgf, 12 ft·lbf)

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)

3.6 Nm (0.36 m·kgf, 2.6 ft·lbf)

1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)

1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)

2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)

1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)

2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)

1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)

1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)

2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)

16 Nm (1.6 m·kgf, 12 ft·lbf)

Remarks

LT


Item

Fuel tank bolt

Fuel tank bracket bolt

M6

M6

Fuel tank breather hose joint bolt M6

Fuel pump nut M6

M5 Throttle body joint clamp screw

Air intake silencer joint clamp screw (throttle body side)

M5

Air intake silencer joint clamp screw (air intake silencer side)

Air filter case joint clamp screw

M6

Air intake duct joint clamp screw

Air filter case bolt

Coolant reservoir bolt

Door hinge nut

M6

M6

M6

Door hinge bolt

Door handle latch nut

Front skid plate bolt

Rear skid plate bolt

M6

M6

M6

M6

Lower panel and floor board bolt

Lower panel and frame bolt

Frame cross member bolt

Exhaust pipe heat protector plate bolt

M6

M6

M6

M6

M8

M8

Exhaust pipe heat protector plate bolt

Front wheel axle nut

Front wheel nut

Rear wheel axle nut

Rear wheel nut

Front brake disc guard bolt

Front brake caliper bolt

Front brake disc bolt

M6

M24

M12

M24

M12

M6

M10

M8

Front brake caliper retaining pin nut

Front brake pad bolt

Front brake caliper guide pin

Front brake caliper bleed screw

Rear brake disc guard bolt

Rear brake disc cleaning plate bolt

M8

M10

M8

M8

M6

M6

Thread size

Q’ty

1

6

3

2

2

1

1

2

2

2

4

2

4

4

2

4

8

8

6

2

8

2

4

6

2

8

2

2

3

2

4

4

4

4


7 Nm (0.7 m·kgf, 5.1 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

See TIP.

2.8 Nm (0.28 m·kgf, 2.0 ft·lbf)

3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)

2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)

2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)

2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

17 Nm (1.7 m·kgf, 12 ft·lbf)

17 Nm (1.7 m·kgf, 12 ft·lbf)

8 Nm (0.8 m·kgf, 5.8 ft·lbf)

350 Nm (35 m·kgf, 253 ft·lbf)

75 Nm (7.5 m·kgf, 54 ft·lbf)

350 Nm (35 m·kgf, 253 ft·lbf)

75 Nm (7.5 m·kgf, 54 ft·lbf)

9 Nm (0.9 m·kgf, 6.5 ft·lbf)

48 Nm (4.8 m·kgf, 35 ft·lbf)

30 Nm (3.0 m·kgf, 22 ft·lbf)

22 Nm (2.2 m·kgf, 16 ft·lbf)

17 Nm (1.7 m·kgf, 12 ft·lbf)

17 Nm (1.7 m·kgf, 12 ft·lbf)

5 Nm (0.5 m·kgf, 3.6 ft·lbf)

9 Nm (0.9 m·kgf, 6.5 ft·lbf)

9 Nm (0.9 m·kgf, 6.5 ft·lbf)

Remarks

Stake.

Stake.

LT

LT

2-20


Item

Rear brake disc bolt

Rear brake caliper bolt

Rear brake caliper retaining pin nut

Rear brake pad bolt

Rear brake caliper guide pin

Rear brake caliper bleed screw

Brake pipe flare nut

Front brake hose joint bolt

Rear brake hose joint bolt

Front brake hose holder bolt

Rear brake hose holder bolt

Front brake hose union bolt

Rear brake hose union bolt

Brake master cylinder reservoir cap

Brake master cylinder reservoir clamp screw

Parking brake cable holder bolt

Parking brake caliper guide pin

Parking brake caliper retaining pin nut

Parking brake pad bolt

Parking brake caliper arm nut

Brake master cylinder bolt

Pedal assembly bolt

Brake pedal rod locknut

Throttle cable locknut (accelerator pedal end)

Parking brake lever bolt

Parking brake caliper bolt

Parking brake disc nut

Parking brake cable locknut

Front arm nut

Front shock absorber assembly nut

Steering knuckle nut

Front arm protector bolt

Steering wheel nut

Thread size

Q’ty

M8

M10

8

4

M8 2

M10

M8

M8

M10

M6

M6

M6

M6

M10

M10

—

M6

M6

M8

M10

M12

M6

M12

4

4

4

1

1

2

1

4

2

1

1

2

2

2

4

4

2

1

M6

M6

M10

M6

M6

M10

M8

M8

M8

M8

M8

M8

1

2

2

3

2

8

1

2

1

2

3

1


30 Nm (3.0 m·kgf, 22 ft·lbf)

48 Nm (4.8 m·kgf, 35 ft·lbf)

22 Nm (2.2 m·kgf, 16 ft·lbf)

17 Nm (1.7 m·kgf, 12 ft·lbf)

17 Nm (1.7 m·kgf, 12 ft·lbf)

5 Nm (0.5 m·kgf, 3.6 ft·lbf)

19 Nm (1.9 m·kgf, 14 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

27 Nm (2.7 m·kgf, 20 ft·lbf)

27 Nm (2.7 m·kgf, 20 ft·lbf)

3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)

6 Nm (0.6 m·kgf, 4.3 ft·lbf)

12 Nm (1.2 m·kgf, 8.7 ft·lbf)

17 Nm (1.7 m·kgf, 12 ft·lbf)

22 Nm (2.2 m·kgf, 16 ft·lbf)

17 Nm (1.7 m·kgf, 12 ft·lbf)

17 Nm (1.7 m·kgf, 12 ft·lbf)

16 Nm (1.6 m·kgf, 12 ft·lbf)

16 Nm (1.6 m·kgf, 12 ft·lbf)

17 Nm (1.7 m·kgf, 12 ft·lbf)

2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)

13 Nm (1.3 m·kgf, 9.4 ft·lbf)

40 Nm (4.0 m·kgf, 29 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

16 Nm (1.6 m·kgf, 12 ft·lbf)

45 Nm (4.5 m·kgf, 33 ft·lbf)

45 Nm (4.5 m·kgf, 33 ft·lbf)

30 Nm (3.0 m·kgf, 22 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

35 Nm (3.5 m·kgf, 25 ft·lbf)

Remarks

LT

LT

LT

LS

2-21


Item

Thread size

Q’ty

Steering column bolt (except for

EPS models)

EPS unit bolt (for EPS models)

EPS unit bracket bolt (for EPS models)

Steering joint bolt

Steering assembly bolt

Tie-rod end locknut

Steering knuckle and tie-rod end nut

Rear arm nut

M8

M8

M6

M8

M10

M12

M12

M10

Rear shock absorber assembly nut

Stabilizer joint nut

Stabilizer holder bolt

Rear knuckle nut

Rear arm protector bolt

Rear knuckle grease nipple

Differential gear oil filler bolt

Differential gear oil drain bolt

Differential motor bolt

Front drive shaft yoke nut

Differential case bolt

Front drive shaft universal joint yoke nut

M12

M16

Differential assembly nut

Differential assembly bolt

M12

M10

Differential assembly bracket nut M10

Support bearing bracket bolt M8

Final gear oil filler bolt

Final gear oil drain bolt

M10

M10

Final drive assembly bracket bolt M8

Final drive assembly nut M12

Rear drive shaft yoke nut (final drive assembly side)

Final drive pinion gear bearing housing bolt

M14

M8

M10

M10

M12

M6

M6

M14

M10

M6

M14

M8

Ring gear stopper nut

Final drive case cover bolt

Driver seat frame bolt

M8

M10

M8

4

4

2

2

4

2

2

4

4

1

1

4

1

8

4

6

3

1

1

1

2

1

2

1

1

4

4

4

4

2

3

1

5


21 Nm (2.1 m·kgf, 15 ft·lbf)

21 Nm (2.1 m·kgf, 15 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

27 Nm (2.7 m·kgf, 20 ft·lbf)

See TIP.

40 Nm (4.0 m·kgf, 29 ft·lbf)

39 Nm (3.9 m·kgf, 28 ft·lbf)

45 Nm (4.5 m·kgf, 33 ft·lbf)

82 Nm (8.2 m·kgf, 59 ft·lbf)

60 Nm (6.0 m·kgf, 43 ft·lbf)

85 Nm (8.5 m·kgf, 61 ft·lbf)

85 Nm (8.5 m·kgf, 61 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)

23 Nm (2.3 m·kgf, 17 ft·lbf)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

11 Nm (1.1 m·kgf, 8.0 ft·lbf)

62 Nm (6.2 m·kgf, 45 ft·lbf)

24 Nm (2.4 m·kgf, 17 ft·lbf)

150 Nm (15 m·kgf, 108 ft·lbf)

105 Nm (10.5 m·kgf, 76 ft·lbf)

60 Nm (6.0 m·kgf, 43 ft·lbf)

60 Nm (6.0 m·kgf, 43 ft·lbf)

18 Nm (1.8 m·kgf, 13 ft·lbf)

23 Nm (2.3 m·kgf, 17 ft·lbf)

23 Nm (2.3 m·kgf, 17 ft·lbf)

33 Nm (3.3 m·kgf, 24 ft·lbf)

105 Nm (10.5 m·kgf, 76 ft·lbf)

97 Nm (9.7 m·kgf, 70 ft·lbf)

26 Nm (2.6 m·kgf, 19 ft·lbf)

16 Nm (1.6 m·kgf, 12 ft·lbf)

52 Nm (5.2 m·kgf, 38 ft·lbf)

23 Nm (2.3 m·kgf, 17 ft·lbf)

Remarks

LS

LT

LT

LT

2-22


Item

Center passenger seat frame bolt M8

Outer passenger seat frame bolt M8

Seat back bolt

Headrest bolt

M6

M6

Seat belt bolt

Seat belt buckle bolt

M12

M12

Seat belt guide bolt M11

Passenger handhold bracket bolt M8

Passenger handhold stopper nut

Left floor board and frame bolt

M6

M6

Center floor board and frame bolt M6

Right floor board and frame bolt M6

Center floor board and left floor board bolt

Center floor board and right floor board bolt

Instrument panel bolt

Meter assembly nut

M6

M6

M6

M5

M6 Meter assembly bracket bolt

Glove compartment latch plate screw

Gas spring assembly ball stud nut

Tail/brake light nut

M4

M8

M6

M6 Cargo bed release lever bolt

Cargo bed release lever holder bolt

Cargo hook nut

Tailgate shaft bolt

Tailgate cable bolt

Tailgate cable bracket bolt

Cargo bed heat protector plate bolt

Left side frame nut (front)

M6

M6

Left side frame nut (rear)

Right side frame nut (front)

Right side frame nut (rear)

Front top frame bolt

Rear top frame bolt

Rear center frame bolt

M6

M6

M6

M6

M10

M10

M10

M10

M10

M10

M10

Thread size

Q’ty

3

2

6

3

9

9

4

4

2

6

1

6

4

5

8

3

2

1

2

4

4

4

5

4

4

8

3

4

4

1

4

2

1

2


23 Nm (2.3 m·kgf, 17 ft·lbf)

23 Nm (2.3 m·kgf, 17 ft·lbf)

6 Nm (0.6 m·kgf, 4.3 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

59 Nm (5.9 m·kgf, 43 ft·lbf)

59 Nm (5.9 m·kgf, 43 ft·lbf)

59 Nm (5.9 m·kgf, 43 ft·lbf)

16 Nm (1.6 m·kgf, 12 ft·lbf)

3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)

3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)

16 Nm (1.6 m·kgf, 12 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

9 Nm (0.9 m·kgf, 6.5 ft·lbf)

8 Nm (0.8 m·kgf, 5.8 ft·lbf)

65 Nm (6.5 m·kgf, 47 ft·lbf)

48 Nm (4.8 m·kgf, 35 ft·lbf)

65 Nm (6.5 m·kgf, 47 ft·lbf)

48 Nm (4.8 m·kgf, 35 ft·lbf)

48 Nm (4.8 m·kgf, 35 ft·lbf)

48 Nm (4.8 m·kgf, 35 ft·lbf)

48 Nm (4.8 m·kgf, 35 ft·lbf)

Remarks

2-23


Item

Rear left frame bolt

Rear right frame bolt

Sun top front bracket screw (for sun top models)

Sun top rear bracket screw (for sun top models)

Sun top lower bracket bolt (for sun top models)

Sun top lower bracket nut (for sun top models)

Intake air temperature sensor screw

Rectifier/regulator bolt

Ground lead bolt

Ignition coil bolt

Horn lead nut (for Europe and

Oceania)

Horn nut (for Europe and Oceania)

Thread size

Q’ty

M10

M10

4

4

M6

M6

M6

M6

M5

M6

M6

M6

—

M6

8

8

4

4

1

2

1

2

2

1


48 Nm (4.8 m·kgf, 35 ft·lbf)

48 Nm (4.8 m·kgf, 35 ft·lbf)

3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)

3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

2.3 Nm (023 m·kgf, 1.7 ft·lbf)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

TIP

Enclosure bolt and nut

Tighten the enclosure bolts and nuts to specification in the proper tightening sequence.

Enclosure tightening sequence:

2

2

2

2

1

1

5

3

5

1

1

4

4

3

Remarks

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

Steering assembly tightening sequence:

4

FWD

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

3

1

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

1

2

TIP

Final drive assembly bolt and nut

Tighten the final drive assembly bolts and nuts to specification in the proper tightening sequence.

2-25

Final drive assembly tightening sequence:

6

4

9 8

2

7


1

3

5

FWD

2-26

LUBRICATION AND SEALING POINTS

EAS20360


EAS20370

ENGINE

Lubrication point

Oil seal lips

Bearings

O-rings

Cylinder head bolts

Crankshaft pin

Connecting rod big end thrust surface

Crankshaft sprocket

Inner race (crankshaft)

Buffer boss (crankshaft)

Crankshaft seal

Piston pin

Piston rings and ring grooves

Valve stems and stem ends (intake and exhaust)

Valve stem seals (intake and exhaust)

Rocker arm shafts

Camshaft lobes

Decompressor lever pin

Decompressor lever

Rocker arms (intake and exhaust)

Oil pump shaft

O-ring (oil filter cartridge)

Water pump impeller shaft

Dipstick mating surface

Starter idler gear inner surface

Starter idler gear shaft

Starter wheel gear

Torque limiter

Clutch housing shaft end

Clutch carrier assembly

One-way clutch bearing

Clutch dog

Reverse idle gear shaft

Reverse idle gear

Lubricant/Sealant

LS

LS

M

E

LS

M

E

E

E

E

E

M

LS

E

E

E

E

E

M

M

E

E

E

E

E

M

M

E

E

E

M

E

E

2-27

Lubrication point

Middle driven shaft splines

Shift drum

Shift forks and shift fork guide bar

Shift drum stopper ball

Shift lever 1 and shift lever 2

AC magneto lead grommet

Crankcase mating surface


Lubricant/Sealant

M

E

E

E

E

Yamaha bond

No.1215 (Three bond

No.1215®)

Yamaha bond

No.1215 (Three bond

No.1215®)

2-28

LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS20390


EAS20400

ENGINE OIL LUBRICATION CHART

9

11 10

9

8 7

1

6

5

3

4

2

2-29


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


EAS20410

LUBRICATION DIAGRAMS

6 1

7

5

8

4 3 2

2-31

9

3 2


1. Oil pipe (crankcase to cylinder head)

2. Oil filter cartridge

3. Oil cooler

4. Oil strainer

5. Oil pump

6. Oil pipe (AC magneto cover)

7. Reverse idle gear shaft

8. Drive axle

9. Relief valve assembly

2-32


1

2

2-33

5 4 3


1. Camshaft

2. Crankshaft

3. Oil strainer

4. Oil pump

5. Oil pump driven sprocket

2-34

EAS20420

COOLING SYSTEM DIAGRAMS


1 2 3

1

6 5

2 5

4

4

2-35

1. Radiator

2. Radiator outlet hose

3. Radiator outlet pipe

4. Radiator inlet pipe

5. Radiator inlet hose

6. Radiator cap


2-36

1


2

5

5 4

3

3

6

2 4

2-37

1. Radiator outlet pipe

2. Water pump inlet hose

3. Thermostat outlet hose

4. Oil cooler outlet hose

5. Radiator inlet pipe

6. Thermostat


2-38


1

4

3

5

2

4

9

8

4

7

2-39

6


2. Water pump inlet hose

3. Water pump

4. Water pump outlet pipe

5. Oil cooler inlet hose

6. Oil cooler

7. Oil cooler outlet hose

8. Water pump outlet hose

9. Water jacket joint


2-40

EAS20430

CABLE ROUTING

Radiator view (right side)

1 2 A B 3 4

CABLE ROUTING

13

I

H

G

12

11

10

9

8

5

C

6

D

E

F

2-41

7

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.

CABLE ROUTING

2-42

Radiator view (left side)

B C 10 11 12 13 2 13 D

CABLE ROUTING

2

A

1

2

3

4

5 6

7

8

9

9

4

4

3

5 6

9

3 E

3 F

2-43

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)



9. Radiator inlet hose

10. Differential assembly breather hose

11. Coolant reservoir breather hose

12. Radiator fan motor breather hose


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.

CABLE ROUTING

2-44

CABLE ROUTING

Radiator view (top)

1 2

B

A

M

17

L

K

J

6

5

3

4

7

C

3 D E

4 5 6 7 E

3

4

5

6

N

7

F

12

13

H

11

10 9 G

8

G

16

I

14

15

2-45

1. Right headlight lead


3. Wire harness

4. Negative battery lead

5. Starter motor lead



8. Throttle cable

9. Meter assembly lead

10. Indicator light assembly lead

11. Parking brake switch lead

12. Main switch lead



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

CABLE ROUTING

Engine view (right side)

8

G 1

J

9

H

I

K 2 6

1 A 2 B

C

D

E

B

F

2

6

9 8 7 6 5 4 3

2-47

1. Wire harness

2. Final drive assembly breather hose


4. Intake air temperature sensor lead

5. Speed sensor lead


7. AC magneto lead



A. Route the final drive assembly breather hose through the hole in the frame.

B. Fasten the final drive assembly breather hose with the holder.

C. Fasten the wire harness with the plastic band.

Position the plastic band to the front of the split in the wire harness.

D. Fasten the negative battery lead and starter motor lead with the holder.

E. Fasten the wire harness to the frame with the plastic band. Be sure to position the plastic band above the bracket.

F. 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.

G. Route the wire harness to the inside of the frame.

H. Fasten the negative battery lead and starter motor lead with the plastic band.

I.

10

–

30

°

J. 50

–

60 mm (1.97

–

2.36 in)

K. Align the holder with the white mark on the final drive assembly breather hose.

CABLE ROUTING

2-48

CABLE ROUTING

Engine view (left side)

D

10

B

A

1

C

4

5

6 E

11

2

3

4

5 6 7 8 9

2-49

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.

CABLE ROUTING

2-50

CABLE ROUTING

Engine view (top)

*A *B

9

9

*C

9

*D

10

*E

10

*F

10

9

1 2 3

A

4 B 5 6 C 7 D 8

*B

*C

*D

*A *A

E

*B

*C

*D

*D *D

L 17 16 K J I H G 15 14 13

1 M

13

12

13

11

12 11

*D

*E

*D

*D

*E

*D

*F

F

*F

10

2-51

1. Wire harness



4. Fuel pump lead

5. Fuel hose

6. TPS lead

7. Intake air pressure sensor lead

8. 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)


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

CABLE ROUTING

4 D F

4

2

E D 2

C

1

A 1 A

2

2-53

3

B

1. Wire harness

2. Final drive assembly breather hose


4. Rear brake hose

A. Fasten the wire harness with the holder.

B. Fasten the final drive assembly breather hose with the holder.

C. Insert the projection on the holder into the hole in the cargo bed, and then fasten the wire harness with the holder.

D. Fasten the rear brake hose with the holder.

E. 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.

F. Centerline

CABLE ROUTING

2-54

Fuel tank view

1

2

A

1

3

3

D

D

4

4

C

4

D

2-55

A

1

B 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)

CABLE ROUTING

2-56

CABLE ROUTING

Front brake caliper view (left side)

2 B

1

2

2-57

3

2

A

1. Front brake pipe

2. Front brake hose

3. Rear brake pipe

A. 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.

CABLE ROUTING

2-58

1

B

C

Front brake caliper view (top)

A

2

CABLE ROUTING

3

2-59

1. Front brake hose

2. Front brake pipe

3. Rear brake pipe

A. Face the paint mark upward.

B. Route the front brake hose under the front upper arm.

C. Fasten the front brake hose with the holder.

CABLE ROUTING

2-60

Rear brake caliper view (left side)

B 2 B

CABLE ROUTING

C

1

A

A 1

2

B

2-61

1. Rear brake pipe

2. Rear brake hose

A. Fasten the rear brake pipe with the holder.

B. Fasten the rear brake hose with the holder.

C. Face the paint mark forward.

CABLE ROUTING

2-62

Rear brake caliper view (top)

A 1 A

CABLE ROUTING

B

2

B

C

2

B

2

D

2-63

1. Rear brake pipe

2. Rear brake hose

A. Fasten the rear brake pipe with the holder.

B. Fasten the rear brake hose with the holder.

C. Right side

D. Connect the rear brake hose end that has a projection to the right rear brake caliper.

CABLE ROUTING

2-64

Parking brake view

1

CABLE ROUTING

1

A

1

2-65

B

1


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.

CABLE ROUTING

2-66

CABLE ROUTING

24

23

22

21

20

19

18

17

16

Electrical components tray view

2

A B

3 4 5 6 7 8

1

9

10

11

12

D

15

C

14

13

8

1

9

7

1

17

23

14

E

13

15

2-67

1. Wire harness

2. Right headlight lead

3. Load control relay

4. Differential motor relay 2



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)


14. Left headlight lead


16. Lean angle sensor lead


18. Starter relay lead

19. Positive battery lead

20. EPS fuse (for EPS models)

21. ECU (engine control unit) lead

22. Main fuse


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)

CABLE ROUTING

2-68

2-69

CABLE ROUTING

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


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 EVERY

NO.

ITEM

CHECK OR MAINTENANCE

JOB month

Whichever comes first km (mi)

1

320

(200)

20

1

2

3

4

5

6

*

*

*

*

Fuel line

Valves

Spark plug

Crankcase breather system

Exhaust system

Spark arrester

7

*

Air induction system hours

• Check fuel hose for cracks or damage.

• Replace if necessary.

• Check valve clearance.

• Adjust if necessary.

• Check condition.

• Adjust gap and clean.


• Check breather hose for cracks or damage.


• Check for leakage.

• Tighten if necessary.

• Replace gasket(s) if necessary.

• Clean.

• Check the air cut-off valve, reed valve, and hose for damage.

• Replace any damaged parts if necessary.

√

√

√

3 6 6 12

1200

(750)

2400

(1500)

2400

(1500)

4800

(3000)

75 150

√

150

√

300

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

2

3

4

EVU01650

GENERAL MAINTENANCE AND LUBRICATION CHART

NO.

ITEM


JOB month


1

320

(200)

INITIAL

3

1200

(750)

6 6

EVERY

12

2400

(1500)

2400

(1500)

4800

(3000) hours 20 75 150 150 300

1

*

Cooling system

Air filter element

Engine oil

Engine oil filter cartridge

• Check coolant leakage.

• Repair if necessary.

• Replace coolant every 24 months.

• Clean.


• Replace (warm engine before draining).

• Replace.

√ √ √ √ √

√

Every 20–40 hours

(more often in wet or dusty areas.)

√ √ √

√ √ √

3-1


NO.

ITEM


JOB month


1

320

(200)

INITIAL

3

1200

(750)

6 6

EVERY

12

2400

(1500)

2400

(1500)

4800

(3000) hours

5

6

Final gear oil

Differential gear oil

• Check oil level/oil leakage.

• Replace.

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

Front brake

Rear brake

Parking brake

Brake fluid

Accelerator pedal

V-belt

Wheels

Wheel bearings

Front and rear suspension

Steering system

Stabilizer bushes

Engine mount

Front and rear axle boots

Fittings and fasteners

• Check operation/brake pad wear/fluid leakage.

• Correct if necessary. Replace pads if worn to the limit.

• Check operation/brake pad wear/fluid leakage.


• Check operation and free play/brake pad wear.


• Replace.

• Check operation and free play.

• Check operation.

• Check for wear, cracks, or damage.

• Check balance/damage/runout.

• Repair if necessary.

• Check bearing assemblies for looseness/damage.

• Replace if damaged.

• Check operation and for leakage.

• Correct if necessary.

• Check operation and for looseness/Replace if damaged.

• Check toe-in/Adjust if necessary.

• Check for cracks or other damage, and replace if necessary.

Rear upper and lower knuckle pivots

Drive shaft universal joint

• Lubricate with lithium-soap-based grease.

• Lubricate with lithium-soap-based grease.

• Check for cracks or damage.

• Check bolt tightness.

• Check for cracks or other damage, and replace if necessary.

• Check all chassis fittings and fasteners.

• Correct if necessary.

20

√

√

√

√

√

√

√

√

√

√

√

75

√

√

√

√

√

√

150

√

√

√

Every 2 years

√

√

√

√

√

√

√

√

√

√

150

√

√

√

√

√

√

√

√

√

√

√

√

√

300

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

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


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.

1

4. Install:

• Right passenger compartment panel

• Outer passenger seat frame


5. Lower the cargo bed.

EAS20520

ADJUSTING THE VALVE CLEARANCE

The following procedure applies to all of the valves.

TIP

• Valve clearance adjustment should be made on a cold engine, at room temperature.

• When the valve clearance is to be measured or adjusted, the piston must be at top dead center

(TDC) on the compression stroke.


2. Remove:

• Frame cross member

• Right rear panel


• 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”

3

2

4

1

5. Disconnect:

• Spark plug cap

6. Remove:

• Spark plug

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”

2

1

8. Measure:

• Valve clearance


→

Adjust.

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 b a

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 c

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

Direction “a”

Valve clearance is increased.

Direction “b”

Valve clearance is decreased.

b a

4

3

2

1

c. Measure the valve clearance with the thickness gauge “1”.


→

Adjust.

Thickness gauge

90890-03079

Narrow gauge set

YM-34483

1

▲ ▲▲▲ ▲ ▲▲▲ ▲

9. Adjust:

• Valve clearance

▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ a. Loosen the locknut “1”.

▼ ▼▼▼ ▼▼▼ b. Insert the thickness gauge “2” between the end of the adjusting screw and the valve tip.

• Hold the adjusting screw to prevent it from moving and tighten the locknut to specification.

.

T

R

.

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

.

T

R

.

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

3-4


TIP

Before installing the spark plug, clean the spark plug and gasket surface.

.

T

R

.

Spark plug

13 Nm (1.3 m·kgf, 9.4 ft·lbf)

12.Connect:

• Spark plug cap

13.Install:

• O-ring New

• Camshaft sprocket cover

• 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)

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.

4. Check:

• Spark plug type

Incorrect

→

Change.

Manufacturer/model

NGK/CPR7EA-9

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)


→

Regap.

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





16.Lower the cargo bed.

EAS20690

CHECKING THE SPARK PLUG


2. Disconnect:

• Spark plug cap

3. Remove:

• Spark plug

8. Install:

• Spark plug

.

T

R

.

Spark plug

13 Nm (1.3 m·kgf, 9.4 ft·lbf)

TIP


9. Connect:

• Spark plug cap

3-5



EAS1XD1057

CHECKING THE BREATHER HOSES


2. Remove:



3. Check:

• Cylinder head breather hose “1”

• Throttle body breather hose “2”

Cracks/damage

→

Replace.

Loose connection

→

Connect properly.

ECA1XD1016

NOTICE

Make sure the cylinder head breather hose and throttle body breather hose are routed correctly.

1

2

4. Install:




EAS21080

CHECKING THE EXHAUST SYSTEM


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

.

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

5

4

5

1

2


EAS1XD2005

ADJUSTING THE EXHAUST GAS VOLUME

(for Europe and Oceania)

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. 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

EAS1XD2001

CLEANING THE SPARK ARRESTER

1. Clean:

• Spark arrester

▼ ▼▼▼ ▼ ▼▼▼ ▼

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”.

3-6


2

1

2

1

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.

.

T

R

.

Spark arrester bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

EAS1XD1013

CHECKING THE AIR INDUCTION SYSTEM

Refer to “CHECKING THE AIR INDUCTION

SYSTEM” on page 7-19.

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


• Air filter case

Refer to “AIR FILTER CASE” on page 7-5.


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, “RADI-

ATOR” on page 6-4, “THERMOSTAT” on

page 6-8 and “WATER PUMP” on page 6-11.

7

5

6

4

8

3

1

9

2

3-7


17

14

13

12

10 a b

16

15

11


5. Install:

• Air filter case



• Center passenger compartment panel



• Front fender

• Hood

• Side frames



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.

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.

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.

Coolant reservoir capacity (up to the maximum level mark)

0.28 L (0.30 US qt, 0.25 Imp.qt)

1 a

EAS21130

CHANGING THE COOLANT

1. Remove the hood.


3. Remove:



4. Remove:

• Coolant reservoir cap “1”

5. Disconnect:

• Coolant reservoir hose “2”

1

2

3-8

6. Drain:

• Coolant

(from the coolant reservoir)


7. Connect:

• Coolant reservoir hose

8. Remove:

• Radiator cap “1”

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.

1

9. Remove:

• Coolant drain bolt “1”

(along with the copper washer)

TIP

Place a container under the engine, and then remove the coolant drain bolt.

10.Drain:

• Coolant

(from the engine and radiator)

11.Install:

• Coolant drain bolt

1

(along with the copper washer

New

)

.

T

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)

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)

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.

ECA13480

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.

13.Install:

• Radiator cap

3-9


14.Fill:

• Coolant reservoir

(with the recommended coolant to the maximum level mark “a”)

15.Install:

• Coolant reservoir cap “1”

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

b. When coolant begins to flow out of the bolt hole, tighten the water pump air bleed bolt to specification.

.

T

R

.

Water pump air bleed bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

c. Loosen the thermostat cover air bleed bolt

“2”, without removing it, to allow all of the air to escape from the air bleed bolt hole.

d. When coolant begins to flow out of the bolt hole, tighten the thermostat cover air bleed bolt to specification.

.

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 LEV-

EL” on page 3-8.

21.Start the engine, and then check for coolant leakage.

22.Install:




24.Install the hood.

EAS20951

CLEANING THE AIR FILTER ELEMENT

1. Check:

• Check hoses “1”

2. Remove:

• Center passenger seat cushion


TIP

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.

È

1

2

3-10

É

1


3

2

1

A. Air filter case check hose

B. Air intake duct check hose

3. Remove:

• Air filter case cover “1”

1

6. Check:

• Air filter element

• Air filter element frame

• Air filter element holder

Damage

→

Replace.

7. Clean:


▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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

5. Disassemble:

• Air filter element holder “1”

• Air filter element “2”

• Air filter element frame “3”

ECA1XD1028

NOTICE

The engine should never be run without the air filter; excessive piston and/or cylinder wear may result.

b. After cleaning, squeeze the air filter element to remove the excess solvent.

ECA13430

NOTICE

Do not twist the air filter element when squeezing it.

3-11

c. Properly dispose of the used solvent.


d. Carefully wash the air filter element in soap water.

e. Thoroughly rinse the air filter element with water, and then let it dry.

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.

TIP

The air filter element should be wet but not dripping.

11.Install:

• Center passenger seat cushion


EAS28910

CHECKING THE ENGINE OIL LEVEL


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.


4. Check:

• Engine oil level

The engine oil level should be between the minimum level mark “a” and maximum level mark “b”.


→

Add the recommended engine oil to the proper level.

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.

▲ ▲▲▲ ▲ ▲▲▲ ▲

8. Assemble:

▲ ▲▲▲ ▲

• Air filter element frame


• Air filter element holder

9. Install:

• Air filter element assembly

10.Install:

• Air filter case cover

▲ ▲▲▲ ▲▲▲

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

3-12


0 10 30 50 70 90 110 130 ˚F

SAE 5W-30

SAE 10W-30

SAE 10W-40

SAE 15W-40

SAE 20W-40

SAE 20W-50

–20 –10 0

10 20 30 40 50 ˚C

ECA1XD1031

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.

5. Check the engine oil level again.

ECA1XD1032

NOTICE

Be sure the engine oil is at the correct level, otherwise engine damage may result.


EAS20780

CHANGING THE ENGINE OIL

1. Start the engine, warm it up for several minutes, and then turn it off.


3. Remove:



4. Place a container under the engine oil drain bolt.

5. Remove:

• Dipstick “1”

• Engine oil drain bolt “2”

(along with the gasket)

2

1

2

6. Drain:

• Engine oil

(completely from the crankcase)

7. If the oil filter cartridge is also to be replaced, perform the following procedure.

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the oil filter cartridge “1” with the oil filter wrench “2”.

Oil filter wrench

90890-01426

YU-38411

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

3-13

c. Tighten the new oil filter cartridge to specification with the oil filter wrench.


.

T

R

.

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)

9. Fill:

• Crankcase

(with the specified amount of the recommended engine oil)

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)

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

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Slightly loosen the oil check bolt “1”.

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.

.

T

R

.

Oil check bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

▲ ▲▲▲ ▲ ▲▲▲ ▲

15.Install:


▲ ▲▲▲ ▲ ▲▲▲



EAS21460

CHECKING THE FINAL GEAR OIL LEVEL


2. Remove:

• Final gear oil filter bolt “1”


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.

Type

SAE 80 API GL-4 Hypoid gear oil

ECA1XD1017

NOTICE

Do not allow foreign material to enter the final drive case.

1

2

1

3-14


4. Check:

• Final gear oil filler bolt gasket

Damage

→

Replace.

5. Install:

• Final gear oil filler bolt


.

T

R

.

Final gear oil filler bolt

23 Nm (2.3 m·kgf, 17 ft·lbf)

EAS21470

CHANGING THE FINAL GEAR OIL


2. Place a container under the final drive case.

3. Remove:

• Final gear oil level check bolt “1”


• Final gear oil drain bolt “2”


Completely drain the final drive case of its oil.

1

6. Check:

• Oil level

Refer to “CHECKING THE FINAL GEAR OIL


7. Install:

• Final gear oil filler bolt


.

T

R

.

Final gear oil filler bolt

23 Nm (2.3 m·kgf, 17 ft·lbf)

EAS1XD1014

CHECKING THE DIFFERENTIAL GEAR OIL

LEVEL


2. Remove:

• Differential gear oil filler bolt “1”


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.

Type


ECA1XD1007

NOTICE

Do not allow foreign material to enter the differential case.

1

2

4. Install:

• Final gear oil drain bolt

(along with the gasket New )

.

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)

Type


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)

ECA1XD1017

NOTICE

Do not allow foreign material to enter the final drive case.

4. Check:

• Differential gear oil filler bolt gasket

Damage

→

Replace.

5. Install:

• Differential gear oil filler bolt


T

.

R

.

Differential gear oil filler bolt

23 Nm (2.3 m·kgf, 17 ft·lbf)

2

3-15


EAS1XD1015

CHANGING THE DIFFERENTIAL GEAR OIL


2. Place a container under the differential case.

3. Remove:

• Differential gear oil filler bolt “1”


• Differential gear oil drain bolt “2”


Completely drain the differential case of its oil.

1

ECA1XD1007

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


.

T

R

.

Differential gear oil filler bolt

23 Nm (2.3 m·kgf, 17 ft·lbf)

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.

a

2

4. Install:

• Differential gear oil drain bolt

(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


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

TIP


EAS21240

CHECKING THE BRAKE FLUID LEVEL


When checking the brake fluid level, make sure that the top of the brake master cylinder reservoir is horizontal.

3-16


2. Check:

• Brake fluid level

Below the minimum level mark “a”

→

Add the specified brake fluid to the proper level.

Specified brake fluid

DOT 4 a

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.

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.

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.

3-17

• 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.

1. Remove:

• Front wheels

• Rear wheels


2. Bleed:

• Hydraulic brake system

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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

É

1

A. Front brake

B. Rear brake

2


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.

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.

.

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


EWA13110

WARNING

After bleeding the hydraulic brake system, check the brake operation.

▲ ▲▲▲ ▲ ▲▲▲ ▲

3. Install:

• Rear wheels

▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

• Front wheels


EAS1XD1048

CHECKING THE BRAKE HOSES AND

BRAKE PIPES

1. Remove:


• Side frames

• Hood

• Front fender




• Left rear panel


• Air filter case


2. Check:

• Front brake hoses “1”

Cracks/damage/wear

→

Replace.

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.

3

1

3

3

1

2

3-18

PERIODIC MAINTENANCE a

4 4

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.


9. Install:

• Air filter case


• Left rear panel




• Front fender

• Hood

• Side frames



EAS29190

ADJUSTING THE BRAKE PEDAL

1. Check:

• Brake pedal free play “a”


→

Adjust.

TIP

The end of the brake pedal rod “1” should lightly contact the brake master cylinder “2”.

Brake pedal free play

0 mm (0 in)

2 1

2. Adjust:

• Brake pedal free play

▼ ▼▼▼ ▼ ▼▼▼ ▼ a. Loosen the locknut “1”.

▼ ▼▼▼ ▼ ▼▼▼ b. Turn the brake pedal rod “2” in direction “a” or

“b” until the correct free play is obtained.


Brake pedal free play is increased.


Brake pedal free play is decreased.

b

1

3-19 a

2

c. Tighten the locknut to specification.

.

T

R

.

Brake pedal rod locknut

17 Nm (1.7 m·kgf, 12 ft·lbf)

EWA1XD1005

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.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

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

PERIODIC MAINTENANCE a

EAS21260

CHECKING THE REAR BRAKE PADS

The following procedure applies to all of the rear brake pads.

1. Remove:

• Rear wheels



3. Check:

• Rear brake pads

Wear indicator grooves “a” have almost disappeared

→



a

EAS29210

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

4. Install:

• Rear wheels


EAS1XD1059

CHECKING THE PARKING BRAKE PADS


2. Check:

• Parking brake pads

A wear indicator groove “a” has almost appeared

→


Refer to “PARKING BRAKE” on page 4-42.

3. Adjust:

• Parking brake lever free play

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ a. Release the parking brake lever.

▼▼▼ b. Slide back the rubber cover “1”.

c. Loosen the locknut “2”.

d. Turn the adjusting nut “3” in direction “a” or “b” until the correct free play is obtained.


Parking brake cable free play is increased.


Parking brake cable free play is decreased.

2

1 a

3 b

3-20


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.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

EAS21690

CHECKING AND LUBRICATING THE

CABLES

The following procedure applies to all of the inner and outer cables.

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.

1. Check:

• Outer cable

Damage

→

Replace.

2. Check:

• Cable operation

Rough movement

→

Lubricate.


Engine oil or a suitable cable lubricant

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)

EAS20660

ADJUSTING THE ACCELERATOR PEDAL

FREE PLAY

1. Check:

• Accelerator pedal free play “a”


→

Adjust.

Accelerator pedal free play

12.0–32.0 mm (0.47–1.26 in) a


3. Remove:



4. Adjust:

• Accelerator pedal free play

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the throttle cable housing cover “1”.

2 a b

4

3

1

b. Slide back the rubber cover “2”.


d. Turn the adjusting nut “4” in direction “a” or “b” until the specified accelerator pedal free play is obtained.


Accelerator pedal free play is increased.


Accelerator pedal free play is decreased.

3-21


TIP

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.

Direction “d”

Accelerator pedal free play is increased.

Direction “e”

Accelerator pedal free play is decreased.

c

6 d e

5

e. Tighten the locknuts to specification.

T

.

R

.

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)

f. Slide the rubber cover to its original position.

g. Check the throttle valve pulley stopper gap.

TIP

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

.

T

R

.

Throttle cable housing cover screw

2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)

▲ ▲▲▲ ▲ ▲▲▲ ▲

5. Install:

▲ ▲▲▲ ▲ ▲▲▲




EAS1XD1060

CHECKING THE V-BELT


2. Remove:


• Left rear panel

• V-belt cooling ducts


3. Remove:

• Drive belt cover



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”


→

Replace.

Refer to “REPLACING THE V-BELT” on page 3-23.

V-belt width

33.0–33.6 mm (1.30–1.32 in)

Limit

32.5 mm (1.28 in)

7

h. Install the throttle cable housing cover.

3-22

6. Install:

• Drive belt cover




7. Install:


• Left rear panel




EAS1XD1061

REPLACING THE V-BELT


2. Remove:


• Left rear panel



3. Remove:

• Bearing housing



4. Replace:

• V-belt

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Install the bolts “1” (90101-06016) into the secondary fixed sheave holes.

TIP

Tightening the bolts “1” will push the secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen.

TIP

Install the new V-belt so that its arrow faces the direction shown in the illustration.

d. Remove the bolts.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲

1

▲▲▲

EAS29350

CHECKING THE WHEELS

The following procedure applies to all of the wheels.

1. Check:

• Wheel “1”

Damage/bends

→

Replace.

EWA14990

WARNING

• Never attempt even small repairs to the wheel.

• Ride conservatively after installing a tire to allow it to seat itself properly on the rim.

1

b. Remove the V-belt “2” from the primary sheave and secondary sheave.

c. Install a new V-belt.

3-23

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 BEAR-

INGS” on page 4-57 and “CHECKING THE

REAR KNUCKLES AND REAR WHEEL

BEARINGS” on page 4-66.


EAS29340

CHECKING THE TIRES

The following procedure applies to all of the tires.

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


MAXXIS/MU09

Rear tire

Type

Tubeless

Size

25

×

10–12NHS


MAXXIS/MU10

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.

3-24


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)

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)

1. Measure:

• Tire pressure


→

Adjust.



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)

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.

EWA14980

WARNING

Uneven or improper tire pressure may adversely affect the handling of this vehicle and may cause loss of control.

• Maintain proper tire pressures.

• Set tire pressures when the tires are cold.

• Tire pressures must be equal in both front tires and equal in both rear tires.

2. Check:

• Tire surfaces

Wear/damage

→

Replace.

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.

EAS29320

CHECKING THE REAR SHOCK ABSORBER

ASSEMBLIES

The following procedure applies to both of the rear shock absorber assemblies.

3-25


1. Place the vehicle on a level place.

2. Check:

• Rear shock absorber assembly

Refer to “CHECKING THE REAR SHOCK


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


EAS29280

CHECKING THE STEERING SYSTEM


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.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

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.

3. Check:

• Tie-rod ends

Free play

→

Replace the tie-rod end.

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ 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.

EAS29290

ADJUSTING THE TOE-IN


2. Measure:

• Toe-in


→

Adjust.

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. Mark both front tire tread centers.

b. Face the steering wheel straight ahead.

▼▼▼ c. Measure the width “A” between the marks.

d. 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

Toe-in = “B” – “A”

g. If the toe-in is incorrect, adjust it.


1

2 2

1

C. Forward

▲ ▲▲▲ ▲ ▲▲▲ ▲

3. Adjust:

• Toe-in

EWA1XD1007

WARNING

▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

• 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.

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ 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.

d. Tighten the tie-rod end locknuts to specification.

.

T

R

.

Tie-rod end locknut

40 Nm (4.0 m·kgf, 29 ft·lbf)

▲ ▲▲▲ ▲ ▲▲▲ ▲

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.

EAS1XD1062

LUBRICATING THE STEERING SHAFT

Lubricate the pivoting point and metal-to-metal moving parts of the shaft.



EAS1XD1063

CHECKING THE STABILIZER BUSHINGS

1. Check:

• Stabilizer bushings

Damage/wear

→

Replace.

Refer to “REAR KNUCKLES AND STABILIZ-

ER” on page 4-64.

3-27


EAS1XD1064

LUBRICATING THE REAR KNUCKLE

PIVOTS

1. Remove:

• Rear arm protectors

2. Lubricate:

• Rear knuckle pivots



EAS1XD1016

LUBRICATING THE DRIVE SHAFT

UNIVERSAL JOINTS

1. Remove:



• Air filter case


2. Lubricate:

• Drive shaft universal joint



EAS1XD1065

CHECKING THE ENGINE MOUNT

1. Check:

• Engine brackets

Cracks/damage

→

Replace.

• Engine mounting bolts

• Engine bracket nuts

Loosen

→

Tighten.


EAS29270

CHECKING THE CONSTANT VELOCITY

SHAFT ASSEMBLY DUST BOOTS

1. Check:

• Dust boots “1”

Damage

→

Replace.

Refer to “FRONT CONSTANT VELOCITY

SHAFT ASSEMBLIES, DIFFERENTIAL AS-

SEMBLY AND FRONT DRIVE SHAFT” on

page 8-3 and “REAR CONSTANT VELOCI-

TY SHAFT ASSEMBLIES, FINAL DRIVE

ASSEMBLY AND REAR DRIVE SHAFT” on page 8-17.

A

1 1

3-28

B

1 1

A. Front

B. Rear

EAS1XD1066

CHECKING THE FASTENERS

1. Check:

• Fasteners

Damage/pitting

→

Replace.



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

EAS21830

GENERAL CHASSIS

Removing the skid plates

GENERAL CHASSIS

1

2

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

Order

1

2

Job/Parts to remove

Front skid plate

Rear skid plate

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

Q’ty

1

1

Remarks


4-1

Removing the doors and side panels

T.R.

4.0 Nm (0.40 m

•

kgf, 2.9 ft

•

Ibf)

GENERAL CHASSIS

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)

5

4

3

6

(4)

(4)

1

2

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)


4

5

6

1

2

3

Door hinge

Door

Door handle latch

Rubber damper

Fuel tank cap

Side panel

Q’ty Remarks

The following procedure applies to both of the doors.

1

1

1

1

1

1

Right side only.

Lift the cargo bed.


4-2

EAS1XD1019

INSTALLING THE DOOR

The following procedure applies to both of the doors.

1. Install:

• Door hinge “1”

T

.

R

.

Door hinge nut

1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)

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

2

1

GENERAL CHASSIS

1

GENERAL CHASSIS

Removing the seats

T.R.

6 Nm (0.6 m

•

kgf, 4.3 ft

•

Ibf)

T.R.

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

7

5

(3)

(3)

(3)

(3)

New

(3)

6

1

6

(3)

(3)

(3)

(4)

(4)

(4)

4

3

2

T.R

23 Nm (2.3 m

•

kgf, 17 ft

•

Ibf)

New

Order

6

7

4

5

1

2

3


Seat cushion

Center passenger seat frame

Driver seat frame

Outer passenger seat frame

Seat back

Shoulder holster

Headrest

Q’ty

2

3

1

3

3

1

1

Remarks


4-4

GENERAL CHASSIS

EAS1XD1017

REMOVING THE SEATS

The following procedure applies to all of the seats.

1. Remove:

• Seat cushion “1”

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ a. Lift the front of the seat cushion.

b. Pull the cushion off.

▼ ▼▼▼ ▼▼▼

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

EAS1XD1049

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

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Remove the driver seat frame bolts “1”.

1

1

1

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.

2 d c b a

b.

c.

d.

Forward position

Center position

Rear position c. Install the driver seat frame bolts, and then tighten the bolts to specification.

.

T

R

.

Driver seat frame bolt

23 Nm (2.3 m·kgf, 17 ft·lbf)

▲ ▲▲▲ ▲ ▲▲▲ ▲

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”

EWA1XD1008

WARNING

A loose seat could cause the operator to lose control, or cause the operator or passengers to fall.

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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.

TIP

Make sure the seats are properly secured before riding.

4-5

b

1 a a

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

GENERAL CHASSIS

4-6

Removing the seat belts

T.R.

59 Nm (5.9 m

•

kgf, 43 ft

•

Ibf)

GENERAL CHASSIS

4

2

6

7

3

5

6

7

4

5

1

2

3

T.R

59 Nm (5.9 m

•

kgf, 43 ft

•

Ibf)


Side panels

Set belt switch coupler

Driver seat belt

Driver seat belt buckle

Center passenger seat belt

Center passenger seat belt buckle

Outer passenger seat belt

Outer passenger seat belt buckle

1

T.R

59 Nm (5.9 m

•

kgf, 43 ft

•

Ibf)

1

1

1

1

1

1

1

Q’ty Remarks

Refer to “Removing the doors and side panels”.

Disconnect.


4-7

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

GENERAL CHASSIS

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

1

New

2

1

6

3

(4)

(4)

(4)

(4)

(4)

(4)

7

(4)

New

(4)

4

1

2

New

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

1

2

New

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

T.R

3.0 Nm (0.30 m

•

kgf, 2.2 ft

•

Ibf)

Order

6

7

4

5

1

2

3


Sun top lower bracket

Damper

Sun top rear bracket

Sun top front bracket

Sun top

Damper

Damper

Q’ty

4

4

4

1

2

4

4

Remarks


4-9

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)

3

5

7

1

GENERAL CHASSIS

T.R

48 Nm (4.8 m

•

kgf, 35 ft

•

Ibf)

4

2

6

T.R

48 Nm (4.8 m

•

kgf, 35 ft

•

Ibf)

5

6

7

3

4

1

2

T.R

48 Nm (4.8 m

•

kgf, 35 ft

•

Ibf)


Headrests

Seat belts

Sun top

Rear top frame

Front top frame

Rear right frame

Rear left frame

Right side frame

Left side frame

Rear center frame

T.R

65 Nm (6.5 m

•

kgf, 47 ft

•

Ibf)

1

1

1

1

1

1

1

Q’ty Remarks

Refer to “Removing the seats”.

Refer to “Removing the seat belts”.

For sun top models

Refer to “Removing the sun top (for sun top models)”.


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”

TIP

Do not fully tighten the bolts and nuts.

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ a. Install the rear center frame “1”.

▼ ▼▼▼ ▼▼▼

1

b. Install the right side frame “2” and left side frame “3”.

2 3

c. Install the rear right frame “4” and rear left frame “5”.

5

4

d. Install the front top frame “6” and rear top frame “7”.

7

6

4-11

▲ ▲▲▲ ▲ ▲▲▲ ▲

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)

TIP

Tighten the bolts and nuts in the proper sequence as shown ( 1, 2, and so on).

▲▲▲

.

T

R

.

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)

2

2

2

2

1

1

5

3

5

1

1

4

4

3

GENERAL CHASSIS

Removing the hood and battery

T.R.

4.0 Nm (0.40 m

•

kgf, 2.9 ft

•

Ibf)

T.R.

1.5 Nm (0.15 m

•

kgf, 1.1 ft

•

Ibf)

2

5

4

6

3

9

1

T.R.

4.0 Nm (0.40 m

•

kgf, 2.9 ft

•

Ibf)

9

10

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)

T.R

48 Nm (4.8 m

•

kgf, 35 ft

•

Ibf)

Order

1

2


Front skid plate

Hood

Air intake duct cover

3 Negative battery lead

7

8

9

10

4

5

6

Positive battery lead

Battery band

Battery

Front guard

Front guard cover

Headlight coupler

Front grill

4-12

7

8

2

1

1

2

1

2

1

Q’ty Remarks

Refer to “Removing the skid plates”.

1

1

1

Disconnect.

ECA1XD1033

NOTICE

First disconnect the negative battery lead, then disconnect the positive lead.

Disconnect.

Disconnect.


GENERAL CHASSIS

Removing the front fender and instrument panel

T.R

35 Nm (3.5 m

•

kgf, 25 ft

•

Ibf)

T.R.

3.8 Nm (0.38 m

•

kgf, 2.8 ft

•

Ibf)

4

T.R.

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

T.R

4.0 Nm (0.40 m

•

kgf, 2.9 ft

•

Ibf)

8

1

(6)

9

6

(6)

10

T.R.

4.0 Nm (0.40 m

•

kgf, 2.9 ft

•

Ibf)

3

5

7

11

12

(7)

2

(4)

(4)

T.R

3.0 Nm (0.30 m

•

kgf, 2.2 ft

•

Ibf)

T.R

16 Nm (1.6 m

•

kgf, 12 ft

•

Ibf)

T.R

2.3 Nm (0.23 m

•

kgf, 1.7 ft

•

Ibf)

7

8

5

6

3

4

1

2

9

10

11

12

T.R

4.0 Nm (0.40 m

•

kgf, 2.9 ft

•

Ibf)


Sun top

Side frames

Hood

Front fender

Passenger handhold

Steering wheel cover

Steering wheel

Meter assembly

Meter assembly bracket

Parking brake lever rubber cover

On-Command four-wheel-drive switch

Light switch

Main switch

Indicator light assembly

Auxiliary DC jack

1

1

1

1

1

1

1

1

1

1

1

1

Q’ty Remarks

For sun top models


Refer to “Removing the enclosure”.

Refer to “Removing the hood and battery”.

4-13

GENERAL CHASSIS

Removing the front fender and instrument panel

T.R

35 Nm (3.5 m

•

kgf, 25 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)

T.R

4.0 Nm (0.40 m

•

kgf, 2.9 ft

•

Ibf)

14

T.R.

4.0 Nm (0.40 m

•

kgf, 2.9 ft

•

Ibf)

(7)

(6)

(6)

13

(4)

(4)

T.R

3.0 Nm (0.30 m

•

kgf, 2.2 ft

•

Ibf)

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

13

14

Horn switch


Instrument panel

Q’ty

1

1

Remarks

For Europe and Oceania


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”

TIP

While pushing the ends of the projections “a” together, remove the steering wheel cover from the steering wheel.

a

1

2. Operate the vehicle at low speeds and make sure that the steering wheel is straight when the vehicle is advancing straight ahead.

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

Removing the floor boards and panels

3

T.R.

4.0 Nm (0.40 m

•

kgf, 2.9 ft

•

Ibf)

(2)

2

(2)

(9)

1

(4)

(7)

(7)

T.R

4.0 Nm (0.40 m

•

kgf, 2.9 ft

•

Ibf)

GENERAL CHASSIS

4

6

5

(5)

3

4

1

2

5

6

Order

(4)

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

Seat frames

Side panels

Seat belts


Sun top

Side frames

Hood

Instrument panel

Rubber cover

Center floor board

Left floor board

Right floor board

Left lower panel

Right lower panel

1

1

1

1

1

1

Q’ty Remarks

Refer to “Removing the seats”.

Refer to “Removing the doors and side panels”.

Refer to “Removing the seat belts”.

For sun top models




Refer to “Removing the front fender and instrument panel”.

4-16

Removing the floor boards and panels

T.R.

4.0 Nm (0.40 m

•

kgf, 2.9 ft

•

Ibf)

(2)

(2)

(9)

(4)

(7)

(7)

T.R

4.0 Nm (0.40 m

•

kgf, 2.9 ft

•

Ibf)

GENERAL CHASSIS

8

7

9

(5)

Order

7

8

9

10

11

11

(4)

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)


Center passenger compartment panel

Left passenger compartment panel

Right passenger compartment panel

Left rear panel

Right rear panel

Q’ty

1

1

1

1

1

10

Remarks


4-17

GENERAL CHASSIS

Removing the electrical components tray

1

9

8

3

T.R.

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

6

(4)

2

1

7

8

5

6

9

3

4

1

2


Sun top

Side frames

Hood

Instrument panel

Headlight coupler

Lean angle sensor

Starter relay

Main fuse

EPS fuse

ECU (engine control unit)

EPS (electronic power steering) control unit

Fuse box

Differential motor relay 2

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)

FWD

D

1

1

1

1

1

1

1

2

1

Q’ty Remarks

For sun top models




Refer to “Removing the front fender and instrument panel”.

Disconnect.

For EPS models

For EPS models

4-18

Removing the electrical components tray

11

10

14

13

12

GENERAL CHASSIS

T.R.

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)

(4)

1

Order

13

14

15

10

11

12


Differential motor relay 1

Headlight relay

Load control relay

Fuel injection system relay

Radiator fan motor relay

Electrical components tray

15

Q’ty

1

1

1

1

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)

FWD

D

Remarks


4-19

GENERAL CHASSIS

Removing the V-belt cooling ducts

T.R.

1.5 Nm (0.15 m

•

kgf, 1.1 ft

•

Ibf)

T.R

59 Nm (5.9 m

•

kgf, 43 ft

•

Ibf)

3

4

6

1

5

T.R

2.0 Nm (0.20 m

•

kgf, 1.4 ft

•

Ibf)

2

T.R

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

2.0 Nm (0.20 m

•

kgf, 1.4 ft

•

Ibf)

3

4

1

2

5

6


Frame cross member

V-belt cooling exhaust duct

V-belt cooling exhaust duct joint

Outer passenger seat belt bolt

V-belt cooling intake duct

V-belt cooling intake duct joint 1

V-belt cooling intake duct joint 2

Q’ty Remarks

Refer to “Removing the cargo bed”.

1

1

1

1

1

1


4-20

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

2

3

1 b

2

3 c

4-21

GENERAL CHASSIS

GENERAL CHASSIS

Removing the cargo bed

T.R.

16 Nm (1.6 m

•

kgf, 12 ft

•

Ibf)

T.R.

17 Nm (1.7 m

•

kgf, 12 ft

•

Ibf)

(4)

1

5

3

2

4

Order

1

2

2

T.R

16 Nm (1.6 m

•

kgf, 12 ft

•

Ibf)


Frame cross member

Tail/brake light connector

3 Gas spring assembly

4

5

Pin

Cargo bed assembly

Q’ty

1

6

1

Lift the cargo bed.

Disconnect.

Remarks

TIP

Install the gas spring assembly so that the cylinder end is pointing upward.

2

1


4-22

GENERAL CHASSIS

Disassembling the cargo bed

T.R.

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

8

3

3

(7)

3

(7)

3

2

5

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

4

1

5

6

7

4

Order

6

7

4

5

8

9

1

2

3

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

(5)

T.R

9 Nm (0.9 m

•

kgf, 6.5 ft

•

Ibf)

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

9

T.R

8 Nm (0.8 m

•

kgf, 5.8 ft

•

Ibf)


Cargo bed left panel

Cargo bed right panel

Cargo hook

Tail/brake light

Tailgate cable

Tailgate

Tailgate shaft

Cargo bed release lever

Cargo bed heat protector plate

Q’ty

1

1

2

2

1

1

1

1

4

Remarks

For assembly, reverse the disassembly procedure.

4-23

GENERAL CHASSIS

EAS1XD1021

DISASSEMBLING THE CARGO BED

1. Remove:

• Tailgate “1”

TIP

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.

25˚ a

1 b

EAS1XD1022

ASSEMBLING THE CARGO BED

1. Install:

• Tailgate shaft “1”

.

T

R

.

Tailgate shaft bolt

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

TIP

Install the tailgate shaft so that the end with the slot “a” is pointing to the left.

b

25˚

1 c a

▲ ▲▲▲ ▲ ▲▲▲ ▲

3. Install:

• Tailgate cables “1”

▲ ▲▲▲ ▲ ▲▲▲

.

T

R

.

Tailgate cable bolt

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

TIP

Connect the straight end “a” of each tailgate cable to the tailgate “2”, and the offset end “b” to the cargo bed “3”.

3

1 b a

2

1 a

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

FRONT AND REAR WHEELS

EAS21870


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

T.R

350 Nm (35.0 m

•

kgf, 253 ft

•

lbf)

2

Order

D

FWD


1

2

3

4

5

6

Wheel

Wheel cap

Wheel axle nut

Brake caliper

Wheel hub

Brake disc

1

T.R

75 Nm (7.5 m

•

kgf, 54 ft

•

Ibf)

Q’ty Remarks


1

1

1

1

TIP

Do not apply the brake pedal when the brake caliper is off of the brake disc as the brake pads will be forced shut.

1

1


4-25


EAS21890

REMOVING THE WHEELS


2. Elevate:

• Wheels

TIP

Place the vehicle on a suitable stand so that the wheels are elevated.

EAS1XD1023

REMOVING THE WHEEL HUBS

The following procedure applies to all of the wheel hubs.

1. Straighten the wheel axle nut rib “a”.

• Wheel

Refer to “CHECKING THE TIRES” on page

3-24 and “CHECKING THE WHEELS” on page 3-23.

EWA15000

WARNING

After replacing the tire, ride conservatively to allow the tire to be properly seated in the rim.

Failure to do so may cause an accident resulting in vehicle damage and possible injury.

a

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”

TIP

Use a general puller “2” to separate the wheel hub and constant velocity shaft.

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 BEAR-

INGS” on page 4-57 and “CHECKING THE

REAR KNUCKLES AND REAR WHEEL

BEARINGS” on page 4-66.

Radial wheel runout limit

2.0 mm (0.08 in)

Lateral wheel runout limit

2.0 mm (0.08 in)

2

1

EAS29380

CHECKING THE WHEELS


1. Check:

• Tire

4-26


TIP

Install the brake disc so that the recessed portion of the bolt hole faces away from the hub.

EAS29390

CHECKING THE WHEEL HUBS


1. Check:


Cracks/damage

→

Replace.

• Splines (wheel hub) “2”

Wear/damage

→

Replace the wheel hub.

1

2

EAS1XD1071

INSTALLING THE BRAKE DISCS

The following procedure applies to all of the brake discs.

1. Install:

• Brake disc

.

T

R

.

Brake disc bolt

30 Nm (3.0 m·kgf, 22 ft·lbf)

LOCTITE®

EAS29410

INSTALLING THE WHEEL HUBS


1. Install:


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.

1

2. Install:

• Wheel axle nut New

.

T

R

.

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.

4-27

3. Check:

• Brake disc

Refer to “CHECKING THE BRAKE DISCS” on page 4-36.

EAS29420

INSTALLING 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


Removing the front brake pads

FWD

D

1

T.R

48 Nm (4.8 m

•

kgf, 35 ft

•

Ibf)

1

3

T.R

17 Nm (1.7 m

•

kgf, 12 ft

•

Ibf)

2

4


1

2

3

4

Front wheel

Brake caliper bolt

Brake pad bolt

Brake pad

Brake pad spring

2

2

2

1

Q’ty Remarks

The following procedure applies to both of the front brake calipers.



4-29

Removing the rear brake pads

FWD

D


T.R

48 Nm (4.8 m

•

kgf, 35 ft

•

Ibf)

1

3

1

2

4


1

2

3

4

Rear wheel

Brake caliper bolt

Brake pad bolt

Brake pad

Brake pad spring

T.R

17 Nm (1.7 m

•

kgf, 12 ft

•

Ibf)

2

2

2

1

Q’ty Remarks

The following procedure applies to both of the rear brake calipers.



4-30

Removing the front brake calipers

FWD

D


T.R

48 Nm (4.8 m

•

kgf, 35 ft

•

Ibf)

5

5

6

4

New

2

T.R

17 Nm (1.7 m

•

kgf, 12 ft

•

Ibf)

3

2

New

1

T.R

27 Nm (2.7 m

•

kgf, 20 ft

•

Ibf)


3

4

1

2

5

6

Front wheel

Brake fluid

Union bolt

Copper washer

Brake hose

Brake pad bolt

Brake caliper bolt

Brake caliper

1

2

1

2

2

1

Q’ty Remarks



Drain.

Refer to “BLEEDING THE HYDRAULIC

BRAKE SYSTEM” on page 3-17.

Disconnect.

Loosen.


4-31

Removing the rear brake calipers

FWD

D


T.R

48 Nm (4.8 m

•

kgf, 35 ft

•

Ibf)

5

T.R

17 Nm (1.7 m

•

kgf, 12 ft

•

Ibf)

5

4

3

T.R

27 Nm (2.7 m

•

kgf, 20 ft

•

Ibf)

3

4

1

2

5

6

Order

Rear wheel

Brake fluid

Union bolt

Copper washer

Brake hose

Brake pad bolt

Brake caliper bolt

Brake caliper

6


2

New

1

1

2

1

2

2

1

Q’ty Remarks



Drain.



Disconnect.

Loosen.


4-32


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

LT

6

S

7

8

New

9

New

2

S

BF

3

10

T.R

5 Nm (0.5 m

•

kgf, 3.6 ft

•

Ibf)


6

7

4

5

1

2

3

8

9

10

Brake pad bolt

Brake pad

Brake pad spring

Brake caliper bracket

Brake caliper guide pin

Brake caliper retaining pin

Brake caliper piston

Brake caliper piston dust seal

Brake caliper piston seal

Bleed screw

1

T.R

17 Nm (1.7 m

•

kgf, 12 ft

•

Ibf)

Q’ty Remarks


1

2

1

1

2

2

1

2

2

1


4-33


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

LT

6

S

7

8

New

9

New

2

S

3

BF

10

T.R

5 Nm (0.5 m

•

kgf, 3.6 ft

•

Ibf)


6

7

4

5

1

2

3

8

9

10

Brake pad bolt

Brake pad

Brake pad spring


Brake caliper guide pin

Brake caliper retaining pin


Brake caliper piston dust seal


Bleed screw

1

T.R

17 Nm (1.7 m

•

kgf, 12 ft

•

Ibf)

Q’ty Remarks


1

2

1

1

2

2

1

2

2

1


4-34

Removing the brake master cylinder

T.R.

3.5 Nm (0.35 m

•

kgf, 2.5 ft

•

Ibf)

1

3

2

4

7

5


T.R

19 Nm (1.9 m

•

kgf, 14 ft

•

Ibf)

6

T.R

16 Nm (1.6 m

•

kgf, 12 ft

•

Ibf)

D

FWD

1

2

3

6

7

4

5


Brake fluid

Brake master cylinder reservoir cap

Brake master cylinder reservoir diaphragm

Brake master cylinder reservoir diaphragm holder

Brake master cylinder reservoir float

Rear brake pipe

Front brake pipe

Brake master cylinder

1

1

1

1

1

1

1

Q’ty Remarks

Drain.



Disconnect.

Disconnect.


4-35


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.

EAS22240

CHECKING THE BRAKE DISCS

The following procedure applies to all of the brake discs.

1. Remove:

• Wheels


2. Check:

• Brake disc

Damage/galling

→

Replace.

3. Measure:

• Brake disc deflection


→

Correct the brake disc deflection or replace the brake disc.

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. Measure:

▲ ▲▲▲ ▲ ▲▲▲

• Brake disc thickness “a”

Measure the brake disc thickness at a few different locations.


→

Replace.

Brake disc thickness limit

3.5 mm (0.14 in)

5. Adjust:


▼ ▼▼▼ ▼ ▼▼▼ ▼ a. Remove the brake disc.

▼ ▼▼▼ ▼ b. Rotate the brake disc by one bolt hole.

c. Install the brake disc.

▼▼▼

.

T

R

.

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.

4-36


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.

▲ ▲▲▲ ▲ ▲▲▲ ▲

6. Install:

• Wheels

▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲


EAS22250

REPLACING THE BRAKE PADS

The following procedure applies to all of the brake calipers.

TIP

When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.

1. Measure:

• Brake pad wear limit “a”


→

Replace the brake pads as a set.

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) a

2. Install:

• Brake pad spring

• Brake pads

TIP

Always install new brake pads and brake pad spring as a set.

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container.

b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger.

1

2

4-37

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:



→





5. Check:

• Brake pedal operation

Soft or spongy feeling

→

Bleed the brake system.



EAS22350

DISASSEMBLING 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”

3

2

3

1

2

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Blow compressed air into the brake hose joint opening “a” to force out the pistons from the brake caliper.

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.

b. Remove the brake caliper piston dust seals and piston seals.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

EAS22390

CHECKING THE BRAKE CALIPERS


Recommended brake component replacement schedule

Brake pads

Piston seals, piston dust seals

Brake hoses

If necessary

Every two years

Brake fluid

Every four years

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.

EWA1XD1010

WARNING

Whenever a brake caliper is disassembled, replace the brake caliper piston seals and brake caliper piston dust seals.

2 a

3

1

2

EAS22410

ASSEMBLING THE BRAKE CALIPERS


4-38


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.


DOT 4

EAS22440

INSTALLING THE BRAKE CALIPERS


1. Install:

• Brake caliper “1”

(temporarily)

• Copper washers

• Brake hose “2”

New

• Brake hose union bolt “3”

.

T

R

.

Brake hose union bolt

27 Nm (2.7 m·kgf, 20 ft·lbf)

EWA1XD1022

WARNING

Proper brake hose routing is essential to in-

sure safe vehicle operation. Refer to “CABLE

ROUTING” on page 2-41.

ECA1XD1008

NOTICE

• 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.

• 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.

È

É

Ê

Ë

2

3

1

2 c

3

1

A. Left front brake

B. Right front brake

C. Left rear brake

D. Right rear brake

2. Remove:

• Brake caliper

a b

1

2

2 d

3

3

1

4-39


3. Install:

• Brake pads


• Brake pad bolts

• Brake caliper

Refer to “REPLACING THE BRAKE PADS” on page 4-37.

.

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. Fill:

• Brake master cylinder reservoir

(with the specified amount of the specified brake fluid)


DOT 4

EWA1XD1021

WARNING




ECA13540

NOTICE


5. Bleed:

• Brake system



6. Check:



→




7. Check:



→




EAS1XD1072

CHECKING THE BRAKE MASTER

CYLINDER

1. Check:

• Brake master cylinder

Damage/scratches/wear

→

Replace.

• Brake fluid delivery passages

(brake master cylinder body)

Obstruction

→


2. Check:


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.

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.

EAS1XD1073

INSTALLING THE BRAKE MASTER

CYLINDER

1. Install:

• Brake master cylinder

• Brake pipes

4-40


.

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 in-

sure safe vehicle operation. Refer to “CABLE

ROUTING” on page 2-41.

2. Fill:


(with the specified amount of the specified brake fluid)


DOT 4

EWA13540

WARNING




ECA13540

NOTICE


3. Bleed:

• Brake system



4. Check:



→




5. Check:



→


4-41



PARKING BRAKE

EAS1XD1074

PARKING BRAKE

Removing the parking brake pads

D

FWD

1

6

7

5

8

9

T.R

40 Nm (4.0 m

•

kgf, 29 ft

•

Ibf)

T.R

17 Nm (1.7 m

•

kgf, 12 ft

•

Ibf)

4

2

5

3

T.R

17 Nm (1.7 m

•

kgf, 12 ft

•

Ibf)

6

7

4

5

8

9

1

2

3


Rear skid plate


Parking brake caliper

Parking brake cable (parking brake caliper end)

Spring


Parking brake pad

Brake pad spring


Parking brake caliper arm

Q’ty Remarks

Refer to “GENERAL CHASSIS” on page

4-1.

2

1

1

2

1

1

2

1

1 Disconnect.


4-42

Removing the parking brake caliper

PARKING BRAKE

D

FWD

2

1

1

3

T.R

40 Nm (4.0 m

•

kgf, 29 ft

•

Ibf)

Order

1

2

3


Rear skid plate



Parking brake cable (parking brake caliper end)

Q’ty Remarks


4-1.

2

1

1 Disconnect.


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

New

7

8

10

11

S

14

New

2

LT

T.R.

22 Nm (2.2 m

•

kgf, 16 ft

•

Ibf)

S

12

13

4

3

New

Order

12

13

14

8

9

10

11

6

7

4

5

1

2

3


Spring


Parking brake pad

Brake pad spring


Parking brake caliper arm


Push rod

Parking brake caliper arm shaft


Parking brake caliper guide pin

Parking brake caliper retaining pin

Parking brake cable holder


T.R

12 Nm (1.2 m

•

kgf, 8.7 ft

•

Ibf)

S

9

6

5

T.R

17 Nm (1.7 m

•

kgf, 12 ft

•

Ibf)

1

Q’ty

1

1

1

1

1

1

1

1

1

1

1

1

2

2

Left-hand threads

Remarks


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

16 Nm (1.6 m

•

kgf, 12 ft

•

Ibf)

Order

1

2

3


Sun top/Side frames/Hood/Front fender/Instrument panel

Parking brake switch

Parking brake lever

Parking brake cable (parking brake lever end)

Q’ty Remarks


4-1.

1

1

1 Disconnect.


4-45

Removing the parking brake disc

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

1

PARKING BRAKE

Order

1


Final drive assembly

Parking brake disc

Q’ty Remarks

Refer to “REAR CONSTANT VELOCITY

SHAFT ASSEMBLIES, FINAL DRIVE AS-

SEMBLY AND REAR DRIVE SHAFT” on page 8-17.

1


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.

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.

EAS1XD1077

CHECKING THE PARKING BRAKE DISC

1. Check:

• Brake disc

Galling/damage

→

Replace.

2. Measure:


• Brake disc thickness “a”


→

Replace.

Brake disc deflection limit

0.10 mm (0.004 in)

Brake disc thickness limit

3.0 mm (0.12 in)

TIP

Measure the deflection 3.0 mm (0.12 in) below the edge of the brake disc.

a

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) a

2. Install:


• Parking brake pads

• Parking brake pad bolts

.

T

R

.

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.

3. Adjust:

• Brake pad clearance

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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”


→


4-47

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”.

2 a

c. Install the parking brake caliper arm nut “3”, and then temporarily tighten it.

3

PARKING BRAKE

2. Adjust:

• Parking brake cable free play

Refer to “ADJUSTING THE PARKING

BRAKE LEVER” on page 3-20.

EAS1XD1051

INSTALLING THE PARKING BRAKE LEVER

1. Install:

• Parking brake lever

.

T

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.

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

EAS1XD1080

PEDAL ASSEMBLY

Removing the pedal assembly

FWD

D

PEDAL ASSEMBLY

T.R

2.5 Nm (0.25 m

•

kgf, 1.8 ft

•

Ibf)

1

2

3

T.R

16 Nm (1.6 m

•

kgf, 12 ft

•

Ibf)

Order

1

2

3



Brake fluid

Brake master cylinder

Steering joint

Brake light switch

Throttle cable

Pedal assembly

1

1

1

Q’ty Remarks


4-1.

Drain.




Refer to “STEERING SYSTEM” on page

4-52.

Disconnect.


4-49

PEDAL ASSEMBLY

Disassembling the pedal assembly

2

LS

3

New

New

4

T.R

17 Nm (1.7 m

•

kgf, 12 ft

•

Ibf)

5

1

5

6

LS

11

LS

9

10

New

8

9

7

Order

6

7

4

5

1

2

3

8

9

10

11


Pin

Brake pedal rod

Spring

Circlip

Washer

Brake pedal

Spring

Circlip

Washer

Accelerator pedal

Pedal assembly bracket

Q’ty

1

1

1

2

1

1

1

1

1

1

2

Remarks


4-50

PEDAL ASSEMBLY

EAS1XD1052

INSTALLING THE PEDAL ASSEMBLY

1. Adjust:

• Throttle cable length “a”

Throttle cable length

5.5–6.5 mm (0.22–0.26 in)

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ 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

▲ ▲▲▲ ▲ ▲▲▲ ▲

1 2 b a

▲ ▲▲▲ ▲ ▲▲▲

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲

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.


Brake light comes on sooner.


Brake light comes on later.

4-51

STEERING SYSTEM

EAS1XD1081

STEERING SYSTEM

Removing the steering assembly

T.R.

40 Nm (4.0 m

•

kgf, 29 ft

•

Ibf)

T.R.

21 Nm (2.1 m

•

kgf, 15 ft

•

Ibf)

T.R.

27 Nm (2.7 m

•

kgf, 20 ft

•

Ibf)

3

(4)

2

4

5

6

1

1

New

(4)

New

T.R

27 Nm (2.7 m

•

kgf, 20 ft

•

Ibf)

New

T.R

40 Nm (4.0 m

•

kgf, 29 ft

•

Ibf)

1

2

3

4

Order

T.R

48 Nm (4.8 m

•

kgf, 35 ft

•

Ibf)

T.R

39 Nm (3.9 m

•

kgf, 28 ft

•

Ibf)

T.R

39 Nm (3.9 m

•

kgf, 28 ft

•

Ibf)



Steering joint bolt

Steering column

EPS motor coupler

EPS torque sensor coupler

5

6

EPS unit

Steering joint

Q’ty Remarks


4-1.

2

1

1

1

1

Except for EPS models

Disconnect.

For EPS models

Disconnect.

For EPS models

For EPS models

ECA1XD1009

NOTICE

The EPS unit should not be disassembled.

1

4-52

STEERING SYSTEM

Removing the steering assembly

T.R.

40 Nm (4.0 m

•

kgf, 29 ft

•

Ibf)

9

7

T.R.

21 Nm (2.1 m

•

kgf, 15 ft

•

Ibf)

T.R

27 Nm (2.7 m

•

kgf, 20 ft

•

Ibf)

(4)

7

9

New

10

New

(4)

8

T.R

27 Nm (2.7 m

•

kgf, 20 ft

•

Ibf)

New

T.R

40 Nm (4.0 m

•

kgf, 29 ft

•

Ibf)

Order

7

8

9

10

T.R

48 Nm (4.8 m

•

kgf, 35 ft

•

Ibf)

T.R

39 Nm (3.9 m

•

kgf, 28 ft

•

Ibf)

T.R

39 Nm (3.9 m

•

kgf, 28 ft

•

Ibf)

10


Tie-rod end locknut

Steering assembly

Tie-rod end

Dust boot

Q’ty

2

1

2

2

Remarks


4-53

EAS1XD1082

CHECKING THE STEERING JOINT

1. Check:

• Steering joint

Rough movement

→

Replace.

STEERING SYSTEM

b. Crimp the portion “c” of the boot band with the boots band installation tool “2”.

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

→


▲ ▲▲▲ ▲ ▲▲▲ ▲

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

1

2. Check:

• Tie-rod end

Bends/damage

→

Replace.

Rubber boot damage

→


EAS29650

INSTALLING THE STEERING SYSTEM

1. Install:

• Dust boots

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Fit the tabs “a” into the holes “b” in the boot band “1”.

a

1

3

3. Install:

• Steering joint “1”

• Steering column “2” (except for EPS models)

• EPS unit “2” (for EPS models)

.

T

R

.

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)

1 b

4-54

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.

STEERING SYSTEM

4-55

STEERING KNUCKLES

EAS1XD1084


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

8

9

New

1

T.R

30 Nm (3.0 m

•

kgf, 22 ft

•

Ibf)

New

New

5

New

LS

Order

T.R

30 Nm (3.0 m

•

kgf, 22 ft

•

Ibf)


6

7

4

5

8

9

1

2

3

Front wheel hub

Brake disc guard

Tie-rod end

Front brake hose holder

Steering knuckle

Circlip

Ball joint

Oil seal

Bearing

Spacer

New

4

8

LS

6

New

7

New

T.R

9 Nm (0.9 m

•

kgf, 6.5 ft

•

Ibf)

1

2

1

1

2

1

1

1

1

Q’ty Remarks

The following procedure applies to both of the steering knuckles.


Disconnect.


4-56


EAS29670

REMOVING THE STEERING KNUCKLES

The following procedure applies to both of the steering knuckles.

1. Remove:

• Steering knuckle “1”

TIP

Use a general puller to separate the ball joints

“2” from the steering knuckle “1” or the front lower arm “3”.

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.

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.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

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

→


Rough movement

→


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.

EWA15040

WARNING

Eye protection is recommended when using striking tools.

d. Remove the spacer “3”.

3

2 2

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Clean the surface of the steering knuckle.

b. Remove the circlip “1”.

1

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

4

3

2

d. Measure the ball joint bore inside diameter

“a”.


→

Replace the steering knuckle.

Ball joint bore inside diameter

32.90–32.95 mm (1.295–1.297 in)


No.

Tool name

6 Long bolt

7 Body

8 Guide bolt

9 Installer washer

Tool No.

90890-01474

YM-01474

10 Base plate 35 mm

11

Ball joint installer attachment 39 mm

90890-01477

YM-01477

90890-01553

YM-01553

90890-01555

YS-01881-A

7

8

11

9

6

8

6 7 9 8 11 5 10

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.

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

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.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

4-58

FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES

EAS29710


Removing the front arms and front shock absorber assemblies

5

LS

7

5

7

T.R

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

5

New

4

5

3

T.R

30 Nm (3.0 m

•

kgf, 22 ft

•

Ibf)

T.R

45 Nm (4.5 m

•

kgf, 33 ft

•

Ibf)

1

7

8

5

6

9

3

4

1

2

D

FWD

Order

T.R

30 Nm (3.0 m

•

kgf, 22 ft

•

Ibf)

New

4

T.R

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.


Front wheel

Front arm protector



Nut

Nut/Bolt (front shock absorber assembly)

Front shock absorber assembly

Nut/Bolt (front upper arm)

Front upper arm

Dust cover

2/2

1

2/2

1

2

1

2

1

1

4-59


Removing the front arms and front shock absorber assemblies

LS

LS

LS

13

13

10

10

LS

14

New

New

10

16

11

12

16

12

15

New

T.R

45 Nm (4.5 m

•

kgf, 33 ft

•

Ibf)

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

T.R

30 Nm (3.0 m

•

kgf, 22 ft

•

Ibf)

T.R

45 Nm (4.5 m

•

kgf, 33 ft

•

Ibf)

Order

13

14

15

16

10

11

12

New

T.R

30 Nm (3.0 m

•

kgf, 22 ft

•

Ibf)

D

FWD

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)


Nut/Bolt (front lower arm)

Front lower arm

Dust cover

Bushing

Circlip

Ball joint

Bushing

Q’ty

1

2

2

1

2/2

1

2

Remarks


4-60


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.

B

A

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.

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.

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.

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.

▲ ▲▲▲ ▲ ▲▲▲ ▲

2. Check:

▲ ▲▲▲ ▲

• Front upper arm

• Front lower arm

Bends/damage

→

Replace.

3. Check:

• Bushings

Wear/damage

→

Replace.

B

▲ ▲▲▲ ▲▲▲

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

EAS29760

CHECKING THE FRONT SHOCK ABSORBER

ASSEMBLIES

The following procedure applies to both of the front shock absorber assemblies.

1. Check:


Oil leaks/gas leaks

→

Replace the front shock absorber assembly.

• Front shock absorber rod

Bends/damage

→


• Spring

Move the spring up and down.


Fatigue

→


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

→


Rubber boot damage

→


Rough movement

→


▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Clean the surface of the front upper arm.

b. Remove the circlip “1”.

TIP

• Always use a new ball joint.

• Do not tap or damage the top of the ball joint or rubber boot.

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

No.

Tool name

6 Long bolt

7 Body

8 Guide bolt

9 Installer washer

Tool No.

90890-01474

YM-01474

10 Base plate 35 mm

11

Ball joint installer attachment 39 mm

90890-01477

YM-01477

90890-01553

YM-01553

90890-01555

YS-01881-A

1

11

7

8

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”.

10

8

3

4

2

d. Attach the special tools and a new ball joint

“5” to the front upper arm “4”.

4

8

5

6

7

8

9

11

10

4-62


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.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

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


▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Install the front upper arm “1” and front lower arm “2”.

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)

3,4

6,7

2

▲ ▲▲▲ ▲ ▲▲▲ ▲

1

5

6,7

8

▲ ▲▲▲ ▲

8

▲▲▲

4-63

REAR KNUCKLES AND STABILIZER

EAS29800


Removing the rear knuckles and stabilizer

FWD

D

T.R.

85 Nm (8.5 m

•

kgf, 61 ft

•

Ibf)

9

9

T.

R

60 Nm (6.0 m

•

kgf, 43 ft

•

Ibf)

LS

New

6

T.R.

9 Nm (0.9 m

•

kgf, 6.5 ft

•

Ibf)

New

6

4

7

3

8

7

4

5

4

5

4

1

2

LS

T.R.

85 Nm (8.5 m

•

kgf, 61 ft

•

Ibf)


6

7

4

5

8

9

1

2

3

Rear wheel hub

Rear brake disc cleaning plate

Brake disc guard

Rear knuckle

Spacer cover

Spacer

Oil seal

Bearing

Spacer

Stabilizer joint

2

2

4

2

1

2

1

1

1

Q’ty Remarks

The following procedure applies to both of the rear knuckles.


4-64


Removing the rear knuckles and stabilizer

FWD

D

T.R.

85 Nm (8.5 m

•

kgf, 61 ft

•

Ibf)

10

11

12

10

11

T.

R

60 Nm (6.0 m

•

kgf, 43 ft

•

Ibf)

LS

T.R.

9 Nm (0.9 m

•

kgf, 6.5 ft

•

Ibf)

Order

10

11

12


Stabilizer holder

Bushing

Stabilizer

LS

T.R.

85 Nm (8.5 m

•

kgf, 61 ft

•

Ibf)

Q’ty

2

2

1

Remarks


4-65


EAS1XD1089

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.


Damage

→

Replace.

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Clean the surface of the rear knuckle.

b. Remove the oil seals.

c. Drive out the bearings.

EWA15040

WARNING

Eye protection is recommended when using striking tools.

d. Remove the spacer “3”.

1

2 2

EAS29830

INSTALLING THE STABILIZER

1. Install:

• Stabilizer “1”

• Bushing “2”

• Stabilizer holder “3”

.

T

R

.

Stabilizer holder bolt

85 Nm (8.5 m·kgf, 61 ft·lbf)

TIP

Install the bushing with its slit “a” facing downward.

3

2 a

1

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


Removing the rear arms and rear shock absorber assemblies

3

FWD

D

T.R.

82 Nm (8.2 m

•

kgf, 59 ft

•

Ibf)

3

LS

8

5

7

8

6

LS

6

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.

45 Nm (4.5 m

•

kgf, 33 ft

•

Ibf)

T.R.

82 Nm (8.2 m

•

kgf, 59 ft

•

Ibf)

T.R

85 Nm (8.5 m

•

kgf, 61 ft

•

Ibf)

4

3

1

3

4

1

2

5

6

7

8

Order

Rear wheel

T.R.

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)


Stabilizer joint

Rear arm protector

Rear brake hose holder

Nut/Bolt (rear shock absorber)

Rear shock absorber

Nut/Bolt (rear upper arm

–

rear knuckle)

Nut/Bolt (rear upper arm

–

frame)

Rear upper arm

Dust cover

1

1

2/2

1

1/1

2/2

1

2

Q’ty Remarks

The following procedure applies to both of the rear upper arms, rear lower arms, and rear shock absorber assemblies.


Refer to “REAR KNUCKLES AND STABI-

LIZER” on page 4-64.

4-67


Removing the rear arms and rear shock absorber assemblies

FWD

D

LS

13

13

LS

10

T.R.

82 Nm (8.2 m

•

kgf, 59 ft

•

Ibf)

LS

10

10

T.R.

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

T.R

85 Nm (8.5 m

•

kgf, 61 ft

•

Ibf)

12

13

13

12

9

11

9

T.R.

45 Nm (4.5 m

•

kgf, 33 ft

•

Ibf)

T.R.

82 Nm (8.2 m

•

kgf, 59 ft

•

Ibf)

T.R

85 Nm (8.5 m

•

kgf, 61 ft

•

Ibf)

10

Order

9

10

11

12

13


Nut/Bolt (rear lower arm

–

rear knuckle)

Nut/Bolt (rear lower arm

–

frame)

Rear lower arm

Dust cover

Bushing

T.R.

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

Q’ty

1/1

2/2

1

2

4

Remarks


4-68


EAS29850

CHECKING THE REAR ARMS

The following procedure applies to both of the rear upper arms and rear lower arms.

1. Check:

• Rear arm free play

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Check the rear arm side play “A” by moving it from side to side.

If side play is noticeable, check the bushings.

B

A

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.

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.

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.

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

▲ ▲▲▲ ▲ ▲▲▲ ▲

2. Check:

• Rear upper arm

▲ ▲▲▲ ▲

• Rear lower arm

Bends/damage

→

Replace.

3. Check:

• Bushings

Wear/damage

→

Replace.

▲ ▲▲▲ ▲▲▲

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

EAS29860

CHECKING THE REAR SHOCK ABSORBER

ASSEMBLIES

The following procedure applies to both of the rear shock absorber assemblies.

1. Check:


Oil leaks/gas leaks

→

Replace the rear shock absorber assembly.

• Rear shock absorber rod

Bends/damage

→


• Spring

Move the spring up and down.


Fatigue

→


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


▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Install the rear upper arm “1” and rear lower arm “2”.

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”.

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)

3,4

3,4

▲ ▲▲▲ ▲ ▲▲▲ ▲

2

6,7

5

1

6,7

8,9

▲ ▲▲▲ ▲

8,9

▲▲▲

4-70


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

EAS23711

ENGINE REMOVAL

Removing the muffler and exhaust pipe

T.R.

17 Nm (1.7 m

•

kgf, 12 ft

•

Ibf)

2

ENGINE REMOVAL

T.R

8 Nm (0.8 m

•

kgf, 5.8 ft

•

Ibf)

1

T.R

20 Nm (2.0 m

•

kgf, 14 ft

•

Ibf)

6

T.R

17 Nm (1.7 m

•

kgf, 12 ft

•

Ibf)

Order

6

7

4

5

8

1

2

3

T.R

23 Nm (2.3 m

•

kgf, 17 ft

•

Ibf)


Exhaust pipe heat protector plate

Muffler heat protector plate

Spring

Muffler

Gasket

Muffler mount

Exhaust pipe

Gasket

4

LT

5

New

3

8

7

Q’ty

1

1

1

1

1

1

1

2

Lift the cargo bed.

Remarks


5-1

EAS1XD1025

INSTALLING THE EXHAUST PIPE AND

MUFFLER

1. Install:

• Gasket “1” New

(muffler side)

ECA1XD1012

NOTICE

Be careful not to damage the muffler contact surface of the gasket.

TIP

Install the gasket completely onto the exhaust pipe “2” by pushing the side “a” of the gasket. If 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) a

1

1

ENGINE REMOVAL

1

3. Install:

• Springs “1”

TIP

Install the springs so that the spring ends are pointing inward as shown in the illustration.

5-2

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)

ENGINE REMOVAL


Cargo bed/Frame cross member/Seat frames/Rear panels/Center passenger compartment panel/V-belt cooling ducts

Drive select lever shift cable

Coolant

Thermostat outlet hose

Water pump inlet hose

Oil cooler outlet hose

Air induction system hose (air cut-off valve to reed valve cover)

Q’ty Remarks


4-1.

Disconnect.

Refer to “SHIFT LEVER” on page 5-45.

Drain.

Refer to “CHANGING THE COOLANT” on page 3-8.

Disconnect.

Refer to “THERMOSTAT” on page 6-8.

Disconnect.

Refer to “WATER PUMP” on page 6-11.

Disconnect.

Refer to “OIL COOLER” on page 6-1.

Disconnect.

Refer to “AIR INDUCTION SYSTEM” on page 7-15.

5-3

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

5

3

ENGINE REMOVAL

4

6

8

7

7

8

5

6

9

3

4

1

2


Air intake silencer

Rear drive shaft

Spark plug cap

Coolant temperature sensor coupler

Reverse switch coupler

Gear position switch coupler

Engine ground lead

Starter motor lead

Speed sensor coupler

Crankshaft position sensor coupler

AC magneto coupler

9

1

1

1

1

2

1

1

1

1

Q’ty Remarks

Refer to “THROTTLE BODY” on page 7-8.

Refer to “REAR CONSTANT VELOCITY

SHAFT ASSEMBLIES, FINAL DRIVE AS-

SEMBLY AND REAR DRIVE SHAFT” on page 8-17.

Disconnect.

Disconnect.

Disconnect.

Disconnect.

Disconnect.

Disconnect.

Disconnect.

Disconnect.

Disconnect.


5-4

Removing the engine

ENGINE REMOVAL

4

LT

1

2

5

3

T.R

42 Nm (4.2 m

•

kgf, 30 ft

•

Ibf)

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

1

LT

7

6

LT

2

7

LT

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

T.R

42 Nm (4.2 m

•

kgf, 30 ft

•

Ibf)

Order

1

2

3


Engine mounting bolt (front)

Engine mounting bolt (front)

Engine bracket nut (rear)

4

5

6

7

Engine

Engine bracket nut (front)

Engine bracket (front)

Engine mounting bolt (rear)

2

2

2

Q’ty

2

2

2

Remarks

1

ECA1XD1034

NOTICE

Make sure that the engine does not strike the brake pipe when removing it.

TIP

Remove the engine from the top of the vehicle.

5-5

ENGINE REMOVAL

Removing the engine

8

LT

9

LT

T.R

42 Nm (4.2 m

•

kgf, 30 ft

•

Ibf)

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

LT

8

LT

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

T.R

42 Nm (4.2 m

•

kgf, 30 ft

•

Ibf)

Order

8

9


Engine mounting bolt (rear)

Engine bracket (rear)

Q’ty

2

2

Remarks


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”

TIP

Before installing the engine, tighten the engine mounting bolts (rear) to specification.

.

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®

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”


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”



.

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

6

7 9

8

4

2

3

9

8

2

3

1

5-7

CYLINDER HEAD

EAS24100

CYLINDER HEAD

Removing the cylinder head

1

2

T.R.

13 Nm (1.3 m

•

kgf, 9.4 ft

•

Ibf)

T.R

35 Nm (3.5 m

•

kgf, 25 ft

•

Ibf)

M

(4)

New

LS

T.R

20 Nm (2.0 m

•

kgf, 14 ft

•

Ibf)

T.R.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

T.R.

20 Nm (2.0 m

•

kgf, 14 ft

•

Ibf)

3

LS

New

New

(4)

LS

T.R.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

New

E

T.R

1.5 Nm (0.15 m

•

kgf, 1.1 ft

•

Ibf)

LS

New

Order

1

2

3

Right rear panel/Frame cross member

Exhaust pipe

Engine oil


Oil pipe (crankcase to cylinder head)

Coolant

E

T.R.

38 Nm (3.8 m

•

kgf, 27 ft

•

Ibf)

Thermostat/Coolant temperature sensor

Throttle body assembly

Reed valve assembly

Spark plug cap

Spark plug

Cylinder head breather hose

1

1

1

T.R

2.0 Nm (0.20 m

•

kgf, 1.4 ft

•

Ibf)

Q’ty Remarks


4-1.


Disconnect.

Refer to “CHANGING THE ENGINE OIL” on page 3-13.


Drain.


Refer to “THERMOSTAT” on page 6-8.


Refer to “AIR INDUCTION SYSTEM” on page 7-15.

Disconnect.

Disconnect.

5-8

CYLINDER HEAD

Removing the cylinder head

T.R.

13 Nm (1.3 m

•

kgf, 9.4 ft

•

Ibf)

T.R.

35 Nm (3.5 m

•

kgf, 25 ft

•

Ibf)

M

(4)

5

6

New

LS

11

10

T.R

20 Nm (2.0 m

•

kgf, 14 ft

•

Ibf)

T.R.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

T.R.

20 Nm (2.0 m

•

kgf, 14 ft

•

Ibf)

LS

New

7

New

14

9

4

8

(4)

5

LS

12

New

T.R.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

13

New

E

T.R

1.5 Nm (0.15 m

•

kgf, 1.1 ft

•

Ibf)

LS

New

Order

7

8

9

10

4

5

6

11

12

13

14


Camshaft sprocket cover

Tappet cover

Oil check bolt

Timing chain tensioner cap bolt

Timing chain tensioner

Timing chain tensioner gasket

Camshaft sprocket

Decompressor assembly

Cylinder head

Cylinder head gasket

Dowel pin

E

T.R.

38 Nm (3.8 m

•

kgf, 27 ft

•

Ibf)

Q’ty

1

1

1

1

1

2

1

1

2

1

1

T.R

2.0 Nm (0.20 m

•

kgf, 1.4 ft

•

Ibf)

Remarks


5-9

CYLINDER HEAD

EAS24130

REMOVING THE CYLINDER HEAD

1. Align:

• “I” mark “a” on the AC magneto rotor

(with the stationary pointer “b” on the AC magneto cover)

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Turn the crankshaft counterclockwise.

b a

4. Remove:

• Timing chain tensioner


• Camshaft sprocket

• Timing chain

TIP

To prevent the timing chain from falling into the crankcase, fasten it with a wire.

5. Remove:

• Cylinder head

TIP

• Loosen the bolts in the proper sequence as shown.

• Loosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them.

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.

d c

1 2 3 4

×2 ×2 ×2 ×2

4

▲ ▲▲▲ ▲ ▲▲▲ ▲

2. Loosen:

▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

• Camshaft sprocket bolts “1”

• Decompressor assembly bolts “2”

TIP

While holding the AC magneto rotor nut with a wrench, loosen the camshaft sprocket bolts and decompressor assembly bolts.

3. Loosen:

1

• Timing chain tensioner cap bolt

2

2

1

7

5

3

6

8

Cylinder head bolts “1”

Length: 135 mm (5.31 in)







EAS24160

CHECKING THE CYLINDER HEAD

1. Eliminate:

• Combustion chamber carbon deposits

(with a rounded scraper)

5-10

CYLINDER HEAD

ECA1XD1035

NOTICE

Do not use a sharp instrument; otherwise, the following may be damaged or scratched:

• Spark plug bore threads

• Valve seats

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.

TIP

To ensure an even surface, rotate the cylinder head several times.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

EAS1XD1092

CHECKING THE CAMSHAFT SPROCKET

1. Check:


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


→

Resurface the cylinder head.

Warpage limit

0.03 mm (0.0012 in)

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Place a straightedge “1” and a thickness gauge “2” across the cylinder head.

1

b. Measure the warpage.

2

5-11

a. 1/4 tooth b. Correct

1. Timing chain roller

2. 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:


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.

CYLINDER HEAD

• Spring

• One-way cam

• Timing chain tensioner rod

Damage/wear

→

Replace the timing chain tensioner.

1 2 3 4

EAS24230

INSTALLING THE CYLINDER HEAD

1. Install:

• Dowel pins

• Cylinder head gasket New

2. Install:

• Cylinder head

• Cylinder head bolts

.

T

R

.

Cylinder head bolt “1”

35 Nm (3.5 m·kgf, 25 ft·lbf)


35 Nm (3.5 m·kgf, 25 ft·lbf)


38 Nm (3.8 m·kgf, 27 ft·lbf)


10 Nm (1.0 m·kgf, 7.2 ft·lbf)









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.

×2 ×2 ×2 ×2

4 2 3 1

5

7

2

3

8

4

6

1

4 2 3 1

3. Install:

• Decompressor assembly


(onto the camshaft)

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the decompressor assembly onto the camshaft, and then finger tighten the decompressor assembly bolts “1”.

b. Turn the crankshaft counterclockwise.

c. Align the “I” mark “a” on the AC magneto rotor with the stationary pointer “b” on the AC magneto cover.

d. 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”.

b a

5-12

CYLINDER HEAD

2

4 c d

4

1

d. Install the spring “5”, a new copper washer

“6”, and the timing chain tensioner cap bolt

“7”.

T

.

R

.

Timing chain tensioner cap bolt

20 Nm (2.0 m·kgf, 14 ft·lbf)

6

New

5

7

4

New

3

3

TIP

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.

f. Remove the wire from the timing chain.

▲ ▲▲▲ ▲ ▲▲▲ ▲

4. Install:

▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲


▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ 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.

▲ ▲▲▲ ▲ ▲▲▲ ▲

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.

1 a b

2

c. Install the timing chain tensioner housing “3” and a new gasket “4” onto the cylinder.

.

T

R

.

Timing chain tensioner bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

TIP

Install the gasket with its beaded side facing the timing chain tensioner.

c d

5-13

CYLINDER HEAD

7. Tighten:

• Camshaft sprocket bolts “1”

• Decompressor assembly bolts “2”

.

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)

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.

1

2

EAS20710

MEASURING THE COMPRESSION

PRESSURE

TIP

Insufficient compression pressure will result in a loss of performance.

1. Measure:

• Valve clearance


→

Adjust.

Refer to “ADJUSTING THE VALVE CLEAR-

ANCE” on page 3-3.

2. Start the engine, warm it up for several minutes, and then turn it off.


4. Disconnect:

• Spark plug cap

5. Remove:

• Spark plug

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.

6. Attach:

• Compression gauge “1”

Compression gauge

90890-03081

Engine compression tester

YU-33223

1

8. Measure:

• Valve clearance


→

Adjust.

Refer to “ADJUSTING THE VALVE CLEAR-

ANCE” on page 3-3.

7. Measure:

• Compression pressure


→

Refer to steps (b) and

(c).

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

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ 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

Same as without oil

Piston ring(s) wear or damage

→

Repair.

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


9. Connect:

• Spark plug cap


5-15

CYLINDER HEAD

ROCKER ARMS AND CAMSHAFT

EAS1XD1093


Removing the rocker arms and camshaft

5

6

T.R.

14 Nm (1.4 m

•

kgf, 10 ft

•

Ibf)

3

6

5

6

5

T.R.

14 Nm (1.4 m

•

kgf, 10 ft

•

Ibf)

2

M

E

5

6

4

M

E

7

8

9

10

3

4

1

2

5

6


Cylinder head

Bearing retainer

Rocker arm shaft

Intake rocker arm

Exhaust rocker arm

Locknut

Valve adjusting screw

Camshaft

Decompressor lever

Decompressor lever pin

Bearing

E

2

9

E

10

M

T.R.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

7

E

1

8

E

LT

1

1

1

Q’ty Remarks

Refer to “CYLINDER HEAD” on page 5-8.

1

1

1

2

4

4

1

ECA1XD1038

NOTICE

Do not disassemble the camshaft assembly.


5-16

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

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


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)

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”


→


3. Measure:

• Camshaft runout


→


Camshaft runout limit

0.015 mm (0.0006 in)

5-17


Rocker arm inside diameter

12.000–12.018 mm (0.4724–

0.4731 in)

EAS1XD1094

CHECKING THE DECOMPRESSION SYSTEM

1. Check:

• Decompression system

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ 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.

4. Measure:

• Rocker arm shaft outside diameter


→

Replace.

Rocker arm shaft outside diameter

11.981–11.991 mm (0.4717–

0.4721 in)

1

2

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

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


→

Replace.

5. Calculate:

• Rocker-arm-to-rocker-arm-shaft clearance


→

Replace the defective part(s).

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.

5-18

EAS24040

INSTALLING THE CAMSHAFT AND ROCKER

ARMS

1. Install:

• Bearing “1”

(into the cylinder head “2”)


TIP

• Apply engine oil to the bearing.

• Install the bearing so that the seal “a” is facing the camshaft.

Installed depth

0 mm (0 in)

TIP

Install the camshaft so that the pins “a” become horizontal.

1

2

2

1 a b

b. Installed depth

2. Lubricate:

• Camshaft

• Decompressor lever pin

• Decompressor lever


Camshaft

Molybdenum disulfide oil

Camshaft bearing, decompressor lever pin, decompressor lever

Engine oil

3. Install:

• Decompressor lever pin “1”

• Decompressor lever “2”

TIP

Install the decompressor lever pin and decompressor lever into the camshaft “3” as shown in the illustration.

3 a

5. Lubricate:

• Rocker arms

• Rocker arm shafts


Rocker arm inner surface

Molybdenum disulfide grease

Rocker arm shaft

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.

Slide hammer bolt

90890-01083

Slide hammer bolt 6 mm

YU-01083-1

1

2

3

1

4. Install:

• Camshaft “1”

5-19

VALVES AND VALVE SPRINGS

EAS24270


Removing the valves and valve springs

1

2

2

3

3

M

6

New

7

6

M

New

7

M

New

7

6

3

2

3

1

7

6

New

M

2

8

8

5

7

8

5

6

3

4

1

2


Cylinder head

Camshaft

Valve cotter

Valve spring retainer

Valve spring

Exhaust valve

Intake valve

Valve stem seal

Valve spring seat

Valve guide

4

5

M

4

4

4

2

4

4

2

8

4

Q’ty Remarks


Refer to “ROCKER ARMS AND CAM-

SHAFT” on page 5-16.


5-20


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.

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Pour a clean solvent “a” into the intake and exhaust ports.

b. Check that the valves properly seal.

TIP

There should be no leakage at the valve seat “1”.

3. Remove:

• Valve spring retainer “1”

• Valve spring “2”

• Valve “3”

• Valve stem seal “4”

• Valve spring seat “5”

TIP

Identify the position of each part very carefully so that it can be reinstalled in its original place.

▲ ▲▲▲ ▲ ▲▲▲ ▲

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

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


→

Replace the valve guide.

• Valve-stem-to-valve-guide clearance =

Valve guide inside diameter “a” -

Valve stem diameter “b”

5-21

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)


b. Install a new valve guide with the valve guide installer “2” and valve guide remover “1”.

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

2. Replace:

• Valve guide

TIP

To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °C (212 °F) in an oven.

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Remove the valve guide with the valve guide remover “1”.

TIP

After replacing the valve guide, reface the valve seat.

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

▲▲▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲

3. Eliminate:

• Carbon deposits

(from the valve face and valve seat)

5-22


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”


→

Replace the valve.

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)

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”


→

Replace the cylinder head.

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


→

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.

Valve stem runout

0.040 mm (0.0016 in)

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Apply blue layout fluid “b” onto the valve face.

b. Install the valve into the cylinder head.

c. Press the valve through the valve guide and onto the valve seat to make a clear impression.

d. Measure the valve seat width.

5-23


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

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.

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.

b. Apply molybdenum disulfide oil onto the valve stem.

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.

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.

TIP

For the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

EAS24310

CHECKING THE VALVE SPRINGS

The following procedure applies to all of the valve springs.

1. Measure:

• Valve spring free length “a”


→

Replace the valve spring.

5-24

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

2. Measure:

• Compressed valve spring force “a”


→


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)

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. Lubricate:

• Valve stem “1”

• Valve stem seal “2” New

(with the recommended lubricant)


Molybdenum disulfide oil

b. Installed length

3. Measure:

• Valve spring tilt “a”


→


5-25

3. Install:

• Valve spring seat “1”

• Valve stem seal “2” New


• 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


Removing the cylinder and piston

E

E

1

8

9

10

E

T.R.

1st 15 Nm (1.5 m

•

kgf, 11 ft

•

lbf)

2nd 50 Nm (5.0 m

•

kgf, 36 ft

•

lbf)

T.R.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

2

E

7

3

New

4

New

5

E

6

New

5

4

6

7

4

5

1

2

3

8

9

10


Cylinder head

Water jacket joint

Timing chain guide (exhaust side)

Cylinder

Cylinder gasket

Dowel pin

Piston pin clip

Piston pin

Piston

Top ring

2nd ring

Oil ring

1

1

2

2

1

1

1

1

1

1

Q’ty Remarks




5-27


EAS24380

REMOVING THE PISTON

1. Remove:

• Piston pin clips “1”

• Piston pin “2”

• Piston “3”

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”.

Piston pin puller set

90890-01304

Piston pin puller

YU-01304

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.

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

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure the cylinder bore with the cylinder bore gauge.

2

1

3

2. Remove:

• Top ring

• 2nd ring

• Oil ring

5-28

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)


Cylinder bore = maximum of D

1

–D

6

Taper limit = maximum of D

1

or D

2

- maximum of D

5

or D

6

Out of round limit = maximum of D

1

, D

3

or D

5

- minimum of D

2

, D

4

or D

6 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)

TIP

Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.

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. 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

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.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

EAS24430

CHECKING THE PISTON RINGS

1. Measure:

• Piston ring side clearance


→

Replace the piston and piston rings as a set.

2. Install:

• Piston ring

(into the cylinder)

TIP

Level the piston ring into the cylinder with the piston crown.

a. 50 mm (1.97 in)

3. Measure:

• Piston ring end gap


→

Replace the piston ring.

5-29


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


0.75–0.90 mm (0.03–0.04 in)

Limit

1.25 mm (0.049 in)

Oil ring


0.20–0.70 mm (0.01–0.03 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”


→

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)

4. Calculate:

• Piston-pin-to-piston-pin-bore clearance


→

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)

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”


→

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)

5-30

2. Install:

• Piston “1”

• Piston pin “2”

• Piston pin clips “3”

New

TIP

• Apply engine oil to the piston pin.


• Make sure the punch mark “a” on the piston points towards the exhaust side of the cylinder.

• Before installing the piston pin clips, cover the crankcase opening with a clean rag to prevent the clips from falling into the crankcase.

• Pass the timing chain and timing chain guide

(exhaust side) through the timing chain cavity.

1

1 a

2

3

New

3. Install:

• Cylinder gasket

• Dowel pins

4. Lubricate:

• Piston

New

• Piston rings

• Cylinder



Engine oil

5. Offset:

• Piston ring end gaps

a

135˚

45˚

e b

45˚ 45˚

45˚ 45˚

d c

A a. Upper oil ring rail b. Top ring c. Oil ring expander d. Lower oil ring rail e. 2nd ring

A. 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.

7. Install:

• Cylinder bolts “1”

• Cylinder bolts (timing chain side) “2”

TIP

• 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

R

.

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)

2

E

1

2

1

E

5-31

AC MAGNETO AND STARTER CLUTCH

EAS1XD1095


Removing the AC magneto and starter clutch

7

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

T.R

18 Nm (1.8 m

•

kgf, 13 ft

•

Ibf)

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

1

4

2

LT

(3)

LT

New

New

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

LT

(11)

New

6

E

5

6

7

3

4

1

2

6

Order

E


Right rear panel

Engine oil

E

Coolant

Water pump housing

Stator coil coupler


AC magneto cover

Oil pipe (AC magneto cover)

AC magneto cover gasket

Dowel pin

Lead holder

E

5

New

3

LS

T.R

2.0 Nm (0.20 m

•

kgf, 1.4 ft

•

Ibf)

T.R

1.5 Nm (0.15 m

•

kgf, 1.1 ft

•

Ibf)

(3)

LT

T.R

30 Nm (3.0 m

•

kgf, 22 ft

•

Ibf)

1

2

1

1

1

2

1

Q’ty

T.R.

60 Nm (6.0 m

•

kgf, 43 ft

•

Ibf)

Remarks


4-1.

Drain.


Drain.



Disconnect.

Disconnect.

5-32


Removing the AC magneto and starter clutch

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

T.R

18 Nm (1.8 m

•

kgf, 13 ft

•

Ibf)

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

LT

(3)

LT

New

8

New

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

LT

9

(11)

New

E

18

New

10

12

Order

11

12

13

14

8

9

10

15

16

17

18

E

17

15

16

E


Crankshaft position sensor

Stator coil

Torque limiter

Starter idle gear

Starter idle gear shaft

AC magneto rotor

Starter clutch

Woodruff key

Starter wheel gear

Washer

Bushing

11

E

14

18

New

13

(3)

LT

T.R

30 Nm (3.0 m

•

kgf, 22 ft

•

Ibf)

T.R.

60 Nm (6.0 m

•

kgf, 43 ft

•

Ibf)

Remarks Q’ty

1

1

1

1

1

1

1

1

2

1

1

LS

T.R

2.0 Nm (0.20 m

•

kgf, 1.4 ft

•

Ibf)

T.R

1.5 Nm (0.15 m

•

kgf, 1.1 ft

•

Ibf)


5-33


EAS24490

REMOVING THE AC MAGNETO ROTOR

1. Remove:

• AC magneto cover

TIP

Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

ECA13880

NOTICE

To protect the end of the crankshaft, place an appropriate sized socket between the flywheel puller set center bolt and the crankshaft.

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

2. Remove:

• AC magneto rotor nut “1”

• Washer

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

3

1

1

2

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.

Sheave holder

90890-01701


YS-01880-A

2

3. Remove:

• AC magneto rotor “1”

(with the starter clutch)

• Woodruff key

1

3

2

5-34


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

→


3. Check:

• Starter clutch gear contact surfaces

Damage/pitting/wear

→


4. Check:

• Starter clutch operation

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ 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.

B

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.


Sheave holder

90890-01701


YS-01880-A

3

2 a

1

A

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

EAS1XD1096

CHECKING THE TORQUE LIMITER

1. Check:

• Torque limiter

Damage/wear

→

Replace.

TIP

Do not disassemble the torque limiter.

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

EAS1XD1097

INSTALLING THE AC MAGNETO ROTOR

1. Install:

• Woodruff key

• AC magneto rotor

• Washer

• AC magneto rotor nut

TIP

• 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.


• After installing the AC magneto rotor, check that the AC magneto rotor rotates smoothly. If not, reinstall the woodruff key and AC magneto rotor.

2. Tighten:

• AC magneto rotor nut “1”

.

T

R

.

AC magneto rotor nut

60 Nm (6.0 m·kgf, 43 ft·lbf)

TIP

• Hold the AC magneto rotor “2” with the sheave holder “3” while tightening the AC magneto rotor nut.


Sheave holder

90890-01701


YS-01880-A

3

.

T

R

.

AC magneto cover bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

TIP

• 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.

2 b a

1

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:


5-36

ELECTRIC STARTER

EAS24780


Removing the starter motor

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

1

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)

2

Order

1

2

3


Frame cross member

Air intake silencer

Negative battery lead

Starter motor lead

Starter motor

3

FWD

D

1

1

1

Q’ty Remarks


4-1.


Disconnect.

Disconnect.


5-37


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

1

Order

4

5

6

1

2

3


Starter motor front cover

Starter motor rear cover

Washer kit

Armature assembly

Brush set

Starter motor yoke

Q’ty

1

1

1

1

1

1

Remarks


5-38

EAS24790

CHECKING THE STARTER MOTOR

1. Check:

• Commutator

Dirt

→

Clean with 600-grit sandpaper.

2. Measure:

• Commutator diameter “a”


→

Replace the starter motor.

Commutator diameter

28.0 mm (1.10 in)

Limit

27.0 mm (1.06 in) a


▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure the armature assembly resistances with the digital circuit tester.

Digital circuit tester

90890-03174

Model 88 Multimeter with tachometer

YU-A1927

Armature coil

Commutator resistance “1”

0.0250–0.0350

Ω

Insulation resistance “2”

Above 1 M

Ω b. If any resistance is out of specification, replace the starter motor.

3. Measure:

• Mica undercut “a”


→

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)

TIP

The mica of the commutator must be undercut to ensure proper operation of the commutator.

▲ ▲▲▲ ▲ ▲▲▲ ▲

5. Measure:

▲ ▲▲▲ ▲ ▲▲▲

• Brush length “a”


→

Replace the brush set.

Brush overall length

12.5 mm (0.49 in)

Limit

5.00 mm (0.20 in)

4. Measure:

• Armature assembly resistances (commutator and insulation)


→


6. Measure:

• Brush spring force


→

Replace the brush set.

5-39

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.

b a b

2

1

3

7. Check:

• Gear teeth

Damage/wear

→

Replace the armature assembly.

8. Check:

• Bushing

• Bearing

• Oil seal

Damage/wear

→


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

BALANCER GEARS AND OIL PUMP GEARS

EAS1XD1098


Removing the balancer gears and oil pump gears

E

T.R

85 Nm (8.5 m

•

kgf, 61 ft

•

Ibf)

4

2

5

3

New

1

New

E

3

4

1

2

5


Right rear panel

Engine oil

Coolant

Water pump housing

Starter wheel gear

Lock washer

Balancer driven gear

Lock washer

Oil pump drive gear

Oil pump driven sprocket

New

T.R

22 Nm (2.2 m

•

kgf, 16 ft

•

Ibf)

1

1

1

1

1

Q’ty Remarks


4-1.

Drain.


Drain.



Refer to “AC MAGNETO AND STARTER

CLUTCH” on page 5-32.

5-41


Removing the balancer gears and oil pump gears

7

E

8

6

T.R

85 Nm (8.5 m

•

kgf, 61 ft

•

Ibf)

Order

9

10

11

12

6

7

8


Chain

Straight key

Spacer

Plate

Balancer drive gear

Spring

Pin

E

10

11 12

9

New

T.R

22 Nm (2.2 m

•

kgf, 16 ft

•

Ibf)

Q’ty

8

4

1

1

1

1

1

Remarks


5-42


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.

1

3

4

5

2

2. Install:

• Spacer

• Oil pump drive gear

• Oil pump driven sprocket “1”

• Chain “2”

TIP

Install the oil pump driven sprocket with the

“3B4” mark “a” facing out.

EAS1XD1053

CHECKING THE OIL PUMP GEARS

1. Check:

• Oil pump drive gear

• Oil pump driven sprocket

Cracks/wear/damage

→

Replace.

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.

EAS1XD1028

INSTALLING THE BALANCER DRIVE GEAR,

BALANCER DRIVEN GEAR, AND OIL PUMP

DRIVEN SPROCKET

1. Install:

• Balancer drive gear

(onto the buffer boss)

• Pins

• Springs

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.

2

4. Install:

2 a

• Oil pump driven sprocket nut “1”

• Balancer driven gear nut “2”

• Lock washers New

1

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

1 a

5-43


.

T

R

.

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)

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

2

T.R

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

3

T.R

16 Nm (1.6 m

•

kgf, 12 ft

•

Ibf)

FWD

D

Order

1

2

3




Drive select lever unit

Drive select lever shift cable bracket

1

1

1

Q’ty Remarks


4-1.

Disconnect.


5-45

SHIFT LEVER

Disassembling the drive select lever unit

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

1

2

3

4

5

6

LS

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

LS

Order

6

7

4

5

1

2

3


Drive select lever knob

Drive select lever guide

Dust cover

Drive select lever

Spring

Shift arm

Drive select lever unit housing

7

Q’ty

1

1

1

1

1

1

1

Remarks


5-46

SHIFT LEVER

Removing the shift levers and stopper lever

7

E

5

New

4

New

T.R

14 Nm (1.4 m

•

kgf, 10 ft

•

Ibf)

LS

1

6

2

3

E

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

LS

6

7

4

5

1

2

3

8

9

10


Right rear panel


Shift arm


Shift lever cover

Shift lever cover gasket

Dowel pin

Shift lever 1

Stopper lever spring

Shift lever 2

Stopper lever

10

E

9

8

T.R

14 Nm (1.4 m

•

kgf, 10 ft

•

Ibf)

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

1

1

1

1

1

1

1

1

1

1

Q’ty Remarks


4-1.

Disconnect.


5-47

SHIFT LEVER

EAS25430

CHECKING THE STOPPER LEVER

1. Check:

• Stopper lever

Damage/wear

→

Replace.

• Stopper lever spring

Damage/wear

→

Replace.

EAS25440

CHECKING THE SHIFT LEVERS

1. Check:

• Shift lever 1

• Shift lever 2

Damage/wear

→

Replace.

EAS1XD1030

INSTALLING THE SHIFT LEVERS

1. Install:

• Shift lever 2 assembly “1”

.

T

R

.

Shift lever 2 bolt

14 Nm (1.4 m·kgf, 10 ft·lbf)

TIP

Align the projection “a” on the shift drum with the slit “b” in the stopper lever.

3. Install:

• Oil seal “1” New

(into the shift lever cover “2”)

Installed depth “a”

1.0–1.5 mm (0.04–0.06 in)

New

1 a

2

4. Install:

• Shift arm “1”

TIP

Align the slit “a” in the shift arm with the projection “b” on shift lever 1.

b

1 a

1 b

2. Install:

• Shift lever 1 “1”

TIP

When installing shift lever 1, align the alignment mark “a” on shift lever 1 with the punch marks “b” on shift lever 2 “2”.

b a

1 a

EAS1XD1031

ADJUSTING THE DRIVE SELECT LEVER

SHIFT CABLE

EWA1XD1002

WARNING

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.

1. Check:

• Drive select lever free play “a”


→

Adjust the drive select lever shift cable.

Drive select lever free play

Less than 4 mm (0.16 in)

2

5-48

SHIFT LEVER a a

5 a

4 b

L

H

N

R

R

N

2

H

L

1

2. Check:

• Drive select lever shift cable length “a”


→

Adjust.

Drive select lever shift cable length

165 mm (6.50 in)

TIP

When checking the drive select lever shift cable length, shift the drive select lever into “N” (neutral).

3 a

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.


d. Turn the adjusting nut “5” in direction “a” or “b” until the specified cable length is obtained.


Shift cable length is increased.


Shift cable length is decreased.

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.

.

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.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

5-49

PRIMARY AND SECONDARY SHEAVES

EAS1XD1099


Removing the primary and secondary sheaves

New

10

T.R.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

New

11

9

T.R.

100 Nm (10.0 m

•

kgf, 72 ft

•

Ibf)

6

8

(8)

7

E

T.R.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

New

LS

4

3

4

5

(11)

T.R

190 Nm (19 m

•

kgf, 137 ft

•

lbf)

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

1

6

7

4

5

1

2

3

8

9

10

11


Frame cross member/Left rear panel/V-belt cooling ducts

Drive belt cover

Rubber gasket

Bearing housing

Dowel pin

Primary sheave assembly

V-belt

Primary fixed sheave

Secondary sheave assembly

Drive belt case

Rubber gasket

Rubber gasket

1

1

2

1

1

1

1

1

1

1

1

Q’ty

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

New

2

Remarks


4-1.


5-50

Disassembling the primary sheave


Order

6

7

4

5

8

1

2

3


Primary sheave cap

Primary sheave slider

Primary sheave cam

Primary sheave weight

Spacer

Oil seal

Primary sliding sheave

O-ring

* Apply Yamaha Grizzly grease or Yamaha grease F.

Q’ty

2

1

8

1

1

1

4

1

Remarks


5-51

Disassembling the secondary sheave


Order

6

7

4

5

8

9

1

2

3


Secondary sheave spring retaining nut

Upper spring seat

Compression spring

Lower spring seat

Guide pin

Secondary sliding sheave

O-ring

Secondary fixed sheave

Oil seal

* Apply Yamaha grease H or POLYREX EM®

Q’ty

1

2

1

4

1

2

1

1

1

Remarks


5-52

2

1


EAS1XD1100

REMOVING THE PRIMARY AND

SECONDARY SHEAVES

1. Loosen:

• Primary sheave assembly nut “1”

TIP

Use the sheave holder “2” to hold the primary sheave.

Sheave holder

90890-01701


YS-01880-A

Sheave fixed block

90890-04135

Sheave fixed bracket

YM-04135

Locknut wrench

90890-01348

YM-01348

Sheave spring compressor

90890-04134

YM-04134

b. Place the sheave fixed block in a vise and secure it.

c. Tighten the sheave spring compressor nut “5” and compress the spring.

d. Loosen the 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.

4

5

2. Loosen:

• Secondary sheave assembly nut “1”

TIP

Shift the transmission into “R” (reverse), set the parking brake, and then loosen the secondary sheave assembly nut.

1

3

1

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

▲ ▲▲▲ ▲ ▲▲▲ ▲

2

▲ ▲▲▲ ▲ ▲▲▲


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”


→

Replace.

V-belt width

33.0–33.6 mm (1.30–1.32 in)

Limit

32.5 mm (1.28 in)

1. Check:

• Primary sheave weight

Cracks/damage/wear

→

Replace.

2. Measure:

• Primary sheave weight outside diameter “a”


→

Replace.

Primary sheave weight outside diameter

30 mm (1.18 in)

Limit

29.5 mm (1.16 in)

EAS24680

CHECKING THE PRIMARY SHEAVE

1. Check:

• Primary sliding sheave splines

Wear/cracks/damage

→

Replace.

• Primary sheave cam

Cracks/damage

→

Replace.

2. Check:

• Primary sliding sheave

• Primary fixed sheave

Cracks/damage

→

Replace.

EAS24690


WEIGHTS

The following procedure applies to all of the primary sheave weights.

EAS24700


SLIDERS

The following procedure applies to all of the primary sheave sliders.

1. Check:

• Primary sheave slider

Cracks/damage/wear

→

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

→


3. Check:

• Guide pins “2”

Damage/wear

→


5-54

4. Check:

• Secondary sheave spring

Damage

→

Replace.

5. Measure:

• Secondary sheave spring free length “a”


→

Replace the secondary sheave spring.

Free length

130.6 mm (5.14 in)

Limit

128.0 mm (5.04 in)


2. Install:

• Oil seals “1” New

(into the primary sliding sheaver “2”)


0 mm (0 in)

New

1 a a

2

3. Lubricate:

• Spacer inner surface

• Primary sliding sheave inner surface

1

New


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


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”)


0 mm (0 in)

2

1

New

a a

New

1

2. Lubricate:

• Secondary sliding sheave “1”

• Secondary fixed sheave “2”



Yamaha grease H or POLYREX

EM®

TIP

Apply Yamaha grease H or POLYREX EM® (15 g) to the inner surfaces of the secondary sheaves.

5. Lubricate:

• Guide pin grooves “1”



Yamaha grease H or POLYREX

EM®

TIP

Apply Yamaha grease H or POLYREX EM® (5.0 g) to the guide pin grooves.

6. Install:

• Lower spring seat “1”

• Compression spring “2”

• Upper spring seat “3”

• Secondary sheave spring retaining nut “4”

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Attach the sheave fixed block “5”, locknut wrench “6” and sheave spring compressor “7” to the secondary sheave.

5-56


Sheave fixed block

90890-04135

Sheave fixed bracket

YM-04135

Locknut wrench

90890-01348

YM-01348

Sheave spring compressor

90890-04134

YM-04134

b. Place the sheave fixed block in a vise and secure it.

c. Tighten the sheave spring compressor nut “8” and compress the spring.

d. Install the secondary sheave spring retaining nut “4” and tighten it to specification using the locknut wrench.

.

T

R

.

Secondary sheave spring retaining nut

90 Nm (9.0 m·kgf, 65 ft·lbf)

TIP

Install the secondary sheave spring retaining nut

“4” with its tapered side “a” facing the secondary sheaves.

7

8

4

6

3

2

1 a

4

e. Remove the sheave spring compressor, locknut wrench, and sheave fixed block.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

EAS1XD1101

INSTALLING THE PRIMARY AND

SECONDARY SHEAVES

1. Install:

• Secondary sheave

• V-belt

• Primary fixed sheave

• Primary sheave

TIP

• Be sure to push in the primary sheave cam “1” when installing the primary sheave so that the primary sheave weights “2” will be properly 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.

1

2 a

5

3

5-57


Sheave holder

90890-01701


YS-01880-A

2. Check:

• Primary sheave weights position


→

Repeat step (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.

A

2

2

1

4. Tighten:

• Secondary sheave assembly nut “1”

.

T

R

.

Secondary sheave assembly nut

100 Nm (10.0 m·kgf, 72 ft·lbf)

TIP

Shift the transmission into “L” (low) or “H” (high), set the parking brake, and then tighten the secondary sheave assembly nut.

4

B

2

3

1

4 3

1

A. Correct position

B. Incorrect position

3. Tighten:

• Primary sheave assembly nut “1”

.

T

R

.

Primary sheave assembly nut

190 Nm (19 m·kgf, 137 ft·lbf)

TIP

Use the sheave holder “2” to hold the primary sheave.

1

5. Lubricate:

• Bearing housing oil seal inner surface




TIP

Apply 2.3 g or more of lithium-soap-based grease to the groove in the oil seal as shown in the illustration.

5-58

LS


5-59

CLUTCH

EAS25061

CLUTCH

Removing the clutch

T.R.

190 Nm (19 m

•

kgf, 137 ft

•

lbf)

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

2

New

1

4

3

3

(7)

5

M

E

E

LS

1

2

3

4

5


Drive belt case

Clutch housing assembly

Clutch housing assembly gasket

Dowel pin

Clutch carrier assembly nut


Q’ty Remarks



1

1

2

1

1

Left-hand threads


5-60

Disassembling the clutch housing assembly

CLUTCH

9

8

7

6

New

E

Order

6

7

4

5

8

9

1

2

3


Oil seal

Circlip

Bearing housing

Circlip

Bearing

Seal ring

One-way clutch bearing

Bearing

Clutch housing

Q’ty

1

1

1

1

1

1

1

1

1

Remarks


5-61

CLUTCH

EAS25070

REMOVING THE CLUTCH

1. Remove:


TIP

Working in crisscross pattern, loosen each bolt

1/4 of a turn. Remove them after all of them are loosened.


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.

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.


90890-04086

YM-91042 a

1

EAS1XD1102

CHECKING THE CLUTCH

1. Check:

• Clutch housing

Damage/wear

→

Replace.

2

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

EAS28990

CHECKING THE CLUTCH SHOE

1. Check:

• Clutch shoe

Damage/wear

→

Replace.

Glazed areas

→

Sand with coarse sandpaper.

TIP

After sanding the glazed areas, clean the clutch with a cloth.

2. Measure:

• Clutch shoe thickness


→

Replace.

Clutch shoe thickness

1.5 mm (0.06 in)

Limit

1.0 mm (0.04 in)

5-62

CLUTCH a

1

New a. Clutch shoe wear limit

EAS1XD1103

ASSEMBLING THE CLUTCH HOUSING

1. Install:

• Bearing “1”

(into the clutch housing “2”

)


2.5–2.7 mm (0.10–0.11 in) a

2

1

2. Install:


TIP

The one-way clutch bearing should be installed in the clutch housing with the “OUT SIDE” mark

“a” facing the clutch housing.

2

EAS1XD1104

INSTALLING THE CLUTCH

1. Install:

• Clutch carrier assembly

• Clutch carrier assembly nut “1” New

.

T

R

.

ECA1XD1020

NOTICE

Clutch carrier assembly nut

190 Nm (19 m·kgf, 137 ft·lbf)

The clutch carrier assembly nut has lefthand threads. To tighten the clutch carrier assembly nut, turn it counterclockwise.

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.


90890-04086

YM-91042

2. Lock the threads with a drift punch.

2

3. Install:


(into the bearing housing “2”

)


0 mm (0 in)

5-63

1

New

3. Install:

• Dowel pins

• Gasket New


.

T

R

.

Clutch housing assembly bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

TIP

• Tighten the bolts in stages, using a crisscross pattern.

• After tightening the bolts, check that the clutch housing assembly rotates smoothly.

CLUTCH

5-64

CRANKCASE

EAS25540

CRANKCASE

Separating the crankcase

T.R.

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

LT

LS

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)

T.R.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

Order

1

2

T.R.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

T.R

42 Nm (4.2 m

•

kgf, 30 ft

•

Ibf)


Engine

Oil cooler

Cylinder head

Piston

Starter wheel gear

Starter motor

Balancer gears/Oil pump gears

Shift levers

Drive belt case


Timing chain guide (intake side)

Timing chain stopper guide (lower)

T.R

18 Nm (1.8 m

•

kgf, 13 ft

•

Ibf)

T.R.

17 Nm (1.7 m

•

kgf, 12 ft

•

Ibf)

New

New

LS

E

T.R.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

T.R.

26 Nm (2.6 m

•

kgf, 19 ft

•

Ibf)

T.R.

8 Nm (0.8 m

•

kgf, 5.8 ft

•

Ibf)

T.R

48 Nm (4.8 m

•

kgf, 35 ft

•

Ibf)

LS

New

LT

(3)

New

1

LS

New

2

Q’ty

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

Remarks




Refer to “CYLINDER AND PISTON” on page

5-27.

Refer to “AC MAGNETO AND STARTER

CLUTCH” on page 5-32.

Refer to “ELECTRIC STARTER” on page

5-37.

Refer to “BALANCER GEARS AND OIL

PUMP GEARS” on page 5-41.

Refer to “SHIFT LEVER” on page 5-45.



Refer to “CLUTCH” on page 5-60.

1

1

5-65

CRANKCASE

Separating the crankcase

T.R.

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

8

7

LS

11

LT

12

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

Order

8

9

6

7

3

4

5

10

11

12

13

T.R.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

10

T.R.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

T.R

42 Nm (4.2 m

•

kgf, 30 ft

•

Ibf)


Timing chain

Speed sensor

Dipstick

Relief valve assembly

Reverse switch

Gear position switch

Thermostat outlet hose guide

Engine bracket

Left crankcase

Dowel pin

Right crankcase

T.R

18 Nm (1.8 m

•

kgf, 13 ft

•

Ibf)

T.R.

17 Nm (1.7 m

•

kgf, 12 ft

•

Ibf)

9

New

New

LS

5

E

T.R.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

T.R.

26 Nm (2.6 m

•

kgf, 19 ft

•

Ibf)

T.R.

8 Nm (0.8 m

•

kgf, 5.8 ft

•

Ibf)

T.R

48 Nm (4.8 m

•

kgf, 35 ft

•

Ibf)

12

4

LS

New

LT

(3)

Q’ty

1

1

1

1

1

1

1

2

1

2

1

New

LS

New

6

3

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

Remarks


5-66

CRANKCASE

Removing the crankcase bearings

New

LS

LS

1

2

New

3

6

5

7

7

LT

7

4

E

T.R.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

E

7

7

E

E

E

6

7

4

5

1

2

3


Crankshaft/Oil pump

Transmission

Middle drive shaft/Middle driven shaft

Collar

O-ring

Oil seal

Bearing retainer

Spacer

Crankshaft seal

Bearing

7

7

7

E

E

2

9

1

1

1

1

1

Q’ty Remarks

Refer to “CRANKSHAFT AND OIL PUMP” on page 5-71.

Refer to “TRANSMISSION” on page 5-76.

Refer to “MIDDLE GEAR” on page 5-83.


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

B

A. Right crankcase

B. Left crankcase

2. Remove:

• Left crankcase

• Dowel pins

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.

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

→


4

3

2

1

EAS1XD1106

CHECKING THE BEARINGS

1. Check:

• Bearings

Clean and lubricate, then rotate the inner race with a finger.

Roughness

→

Replace.

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

→


EAS25700

ASSEMBLING THE CRANKCASE

1. Install:


(into the left crankcase “2”

)


1.0–1.5 mm (0.04–0.06 in)

1

New

a

2

2 a

5. Fit the left crankcase onto the right crankcase. Tap lightly on the crankcase with a soft hammer.

ECA1XD1021

NOTICE

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.

6. Install:

• Crankcase bolts

7. Tighten:

• Crankcase bolts

.

T

R

.

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.

2. Thoroughly clean the crankcase mating surfaces.

3. Apply:

• Sealant “1”

(onto the crankcase mating surfaces)


90890-85505


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”

2

1

5-69

A

3

2 3

×2 ×3

2

3

B

1 2 3

×3 ×2 ×6

3

3

2

3

2

3

1

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

CRANKCASE

EAS1XD1107

CRANKSHAFT AND OIL PUMP

Removing the crankshaft and oil pump


3

4

T.R.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

1

2

3

4


Crankcase

Oil pump

Oil pump gasket

Balancer

Crankshaft

1

2

New

T.R.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

Q’ty Remarks

Separate.

Refer to “CRANKCASE” on page 5-65.

1

1

1

1


5-71


Disassembling the oil pump

6

4

5

2

3

1

E

E

T.R.

5 Nm (0.5 m

•

kgf, 3.6 ft

•

Ibf)

Order

4

5

6

1

2

3


Oil pump housing cover

Pin

Oil pump shaft

Oil pump inner rotor

Oil pump outer rotor

Oil pump housing

Q’ty

1

1

1

1

1

1

Remarks


5-72

EAS1XD1108

REMOVING THE CRANKSHAFT

1. Remove:

• Crankshaft “1”

TIP

• Remove the crankshaft with the crankcase separating tool “2”.

• Make sure the crankcase separating tool is centered over the crankshaft.

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


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)

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”


→


1. Inner rotor

2. Outer rotor

3. Oil pump housing

3. Check:

• Oil pump operation

Rough movement

→


5-73

CRANKSHAFT AND OIL PUMP c b b

EAS24990

CHECKING THE OIL STRAINER

1. Check:

• Oil strainer

Damage

→


Contaminants

→

Clean with solvent.

EAS1XD1109

CHECKING THE CRANKSHAFT

1. Measure:

• Crankshaft width A “a”


→

Replace the crankshaft.

Width A

74.92–75.00 mm (2.950–2.953 in)

2. Measure:

• Crankshaft runout C “b”


→


Runout limit C

0.030 mm (0.0012 in)

3. Measure:

• Big end side clearance D “c”


→


Big end side clearance D

0.350–0.650 mm (0.0138–0.0256 in) a

4. Check:

• Crankshaft sprocket

Damage/wear

→


• Bearing

Cracks/damage/wear

→


5. Check:

• Crankshaft journal

Scratches/wear

→


• Crankshaft journal oil passage

Obstruction

→


EAS25010

ASSEMBLING THE OIL PUMP

1. Lubricate:

• Inner rotor

• Outer rotor

• Oil pump shaft



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 a

1

2

3 a

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

ECA1XD1040

NOTICE

Apply engine oil to each bearing to protect the crankshaft against scratches and to make installation easier.

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.

TRANSMISSION

EAS26241

TRANSMISSION

Removing the transmission, shift drum and shift forks

3

2

1

4

E

10

E

T.R

18 Nm (1.8 m

•

kgf, 13 ft

•

Ibf)

New

E

E

7

8

5

6

3

4

1

2

9

10


Crankcase

Middle driven gear

Bolt

Spring

Ball

Shift drum

Shift fork assembly

Shift fork “R”

Spring

Shift fork “L”

Shift fork guide bar

Secondary shaft

5

9

New

8

7

E

New

6

E

E

1

1

1

1

1

1

1

1

1

1

Q’ty Remarks

Separate.


Refer to “MIDDLE GEAR” on page 5-83.

5-76

Removing the transmission, shift drum and shift forks

E

E

TRANSMISSION

T.R

18 Nm (1.8 m

•

kgf, 13 ft

•

Ibf)

New

E

12

14

13

15

E

11

New

Order

11

12

13

14

15


Drive axle assembly

Collar

Reverse idle gear

Bearing

Reverse idle gear shaft

E

New

E

E

Q’ty

1

1

1

1

1

Remarks


5-77

TRANSMISSION

Disassembling the drive axle assembly

1

2

3

4

New

6

7

5

8

9

M

M

M

M

M

M

M

12

10

11

New

14

13

New

15

16

Order

12

13

14

15

16

8

9

10

11

6

7

4

5

1

2

3


Washer

Collar

High wheel gear

Washer

Clutch dog

Circlip

Washer

Collar

Low wheel gear

Washer

Circlip

Middle drive gear

Circlip

Washer

Bearing

Reverse wheel gear

Q’ty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

5-78

Remarks

TRANSMISSION

Disassembling the drive axle assembly

M

M

M

M

M

M

M

18

17

Order

17

18

Collar

Drive axle

Job/Parts to remove Q’ty

1

1

Remarks


5-79

TRANSMISSION

EAS26250

REMOVING THE TRANSMISSION

1. Remove:

• Shift drum “1”

• Shift fork assembly “2”

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ 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.

1

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.

1

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.

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

EAS26300

CHECKING THE TRANSMISSION

1. Measure:

• Drive axle runout

(with a centering device and dial gauge “1”)


→

Replace the drive axle.

Drive axle runout limit

0.06 mm (0.0024 in)

4. Check:

• Transmission gear movement

Rough movement

→


5. Check:

• Circlips

Bends/damage/looseness

→

Replace.

EAS1XD1112

CHECKING THE SECONDARY SHAFT

1. Check:

• Gear teeth

Blue discoloration/pitting/wear

→

Replace.

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”.

New

2 b

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

New

5

3

1

2 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.

2

4

3

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

TRANSMISSION

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

New

9

10

11

E

New

T.R

29 Nm (2.9 m

•

kgf, 21 ft

•

Ibf)

12

10

8 7

6

5

1

1

2

3

4

9

10

11

12

7

8

5

6


Crankcase

Middle drive shaft/bearing housing assembly

Middle drive pinion gear nut

Middle drive pinion gear

Middle drive pinion gear shim

Middle drive shaft assembly

Middle driven gear

Circlip

Middle drive shaft

Middle drive shaft bearing housing assembly

Bearing retainer

Bearing

Washer

1

1

1

2

1

1

1

1

Q’ty Remarks

Separate.


1

1

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

New

E

New

T.R

29 Nm (2.9 m

•

kgf, 21 ft

•

Ibf)

13

Order

13


Bearing housing

Q’ty

1

Remarks


5-84

MIDDLE GEAR

Removing the middle driven shaft

T.R.

190 Nm (19 m

•

kgf, 137 ft

•

lbf)

LT

T.R

80 Nm (8.0 m

•

kgf, 58 ft

•

Ibf)

T.R

130 Nm (13 m

•

kgf, 94 ft

•

lbf)

T.R

25 Nm (2.5 m

•

kgf, 18 ft

•

Ibf)

5

6

9

4

4

8

10

11

12

7

1

2

3

4

9

10

11

12

7

8

5

6


Crankcase

Rear drive shaft yoke nut (middle gear side)

Rear drive shaft yoke (middle gear side)

Middle driven pinion gear assembly

Middle driven pinion gear shim

Front drive shaft yoke nut (middle gear side)

Front drive shaft yoke (middle gear side)

Middle driven pinion gear

Bearing

Oil seal

Middle driven pinion gear bearing retainer

Bearing

O-ring

T.R

190 Nm (19 m

•

kgf, 137 ft

•

lbf)

1

1

1

1

1

1

1

1

Q’ty Remarks

Separate.


1

1

1


Left-hand threads

5-85

MIDDLE GEAR

Removing the middle driven shaft

T.R.

190 Nm (19 m

•

kgf, 137 ft

•

lbf)

LT

15

T.R

14

80 Nm (8.0 m

•

kgf, 58 ft

•

Ibf)

T.R

130 Nm (13 m

•

kgf, 94 ft

•

lbf)

16

17

T.R

25 Nm (2.5 m

•

kgf, 18 ft

•

Ibf)

13

T.R

190 Nm (19 m

•

kgf, 137 ft

•

lbf)

Order

13

14

15

16

17


Bearing housing

Oil seal

Middle driven shaft bearing retainer

Bearing

Middle driven shaft

Q’ty

1

1

1

1

1

Left-hand threads

Remarks


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”

TIP

Wrap the middle drive shaft in a folded rag, and then secure it in a vise.

Coupling gear/middle shaft tool

90890-01229

Gear holder

YM-01229

2

3. Remove:

• Middle drive pinion gear nut

• Middle drive pinion gear

• Shim(s)

4. Remove:

• Middle driven gear “1”

• Circlip

• Middle drive shaft “2”

TIP

Press the middle drive shaft end and remove the middle driven gear.

1

3

2. Remove:

• Front drive shaft yoke nut “1”

• Washer

• Front drive shaft yoke “2”

TIP

Use the coupling gear/middle shaft tool “3” to hold the front drive shaft coupling sleeve.


90890-01229

Gear holder

YM-01229

2

1

2

EAS1XD1117

REMOVING THE MIDDLE DRIVEN SHAFT

1. Remove:

• Rear drive shaft yoke nut “1”

• Washer

• Rear drive shaft yoke “2”

TIP

Use the coupling gear/middle shaft tool “3” to hold the rear drive shaft coupling sleeve.

1

3

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.

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.

5-87

MIDDLE GEAR

• Install a suitable socket “2” on the middle driven pinion gear end to protect the thread from damage.

c. Press the middle driven pinion gear end and remove the bearing housing.

Ring nut wrench

90890-01430

YM-38404

ECA1XD1023

NOTICE

The middle driven shaft bearing retainer has left-hand threads. To loosen the retainer turn it clockwise.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

4. Remove:

• Middle driven pinion gear bearing retainer

• Bearing

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ 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

ECA1XD1022

NOTICE

The middle driven pinion gear bearing retainer has left-hand threads. To loosen the retainer, turn it clockwise.

1

2

3

6. Remove:

• Middle driven shaft “1”

(with bearing)

1

2

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

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.

1

MIDDLE GEAR

• Bearings

Pitting/damage

→

Replace.

EAS1XD1119

INSTALLING THE BEARING AND OIL SEALS

1. Install:

• Bearing “1”


(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

3

Ring nut wrench

90890-01430

YM-38404

ECA1XD1024

NOTICE

The middle driven shaft bearing retainer has left-hand threads. To tighten the retainer turn it counterclockwise.

1

2

New

b

2. Install:


(into the crankcase “2”

)

Installed depth “a” of oil seal

1.0–1.5 mm (0.039–0.059 in) a

1

New

2

EAS1XD1120

INSTALLING THE MIDDLE DRIVEN SHAFT

1. Install:

• Middle driven shaft bearing retainer “1”

.

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

2

2. Install:

• Middle driven pinion gear bearing retainer “1”

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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”.

Bearing retainer wrench

90890-04128

Middle gear bearing retainer

YM-04128

c. Tighten the bearing retainer.

.

T

R

.

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

1

2

▲ ▲▲▲ ▲ ▲▲▲ ▲

3. Install:

▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

• Middle driven pinion gear shim(s) “1”

• Bearing housing

TIP

Install the shim(s) so that the tabs are positioned as shown in the illustration.

1

2

3

5. Install:


• Washer

• Rear drive shaft yoke nut “2”

.

T

R

.

Rear drive shaft yoke nut (middle gear side)

190 Nm (19 m·kgf, 137 ft·lbf)

LOCTITE®

TIP

Use the coupling gear/middle shaft tool “3” to hold the rear drive shaft yoke.


90890-01229

Gear holder

YM-01229

1

4. Install:

• Front drive shaft yoke “1”

• Washer

• Front drive shaft yoke nut “2”

.

T

R

.

Front drive shaft yoke nut (middle gear side)

190 Nm (19 m·kgf, 137 ft·lbf)

LOCTITE®

TIP

Use the coupling gear/middle shaft tool “3” to hold the front drive shaft yoke.


90890-01229

Gear holder

YM-01229

1

2

3

EAS1XD1121

INSTALLING THE MIDDLE DRIVE SHAFT

1. Install:

• Circlip

• Middle driven gear “1”

(onto the middle drive shaft “2”)

Installed depth “a” of middle driven gear

24.7–24.9 mm (0.972–0.980 in)

5-90

MIDDLE GEAR a

1

2

2. Tighten:

• Bearing retainer bolts “1” New

.

T

R

.

Middle drive shaft bearing retainer bolt

29 Nm (2.9 m·kgf, 21 ft·lbf)

LOCTITE®

TIP

Stake the bearing retainer bolts at the cutouts “a” in the bearing retainers “2”.

a

New

1

2 a

2

New

1

1

New

a

3. Tighten:

• Middle drive pinion gear nut “1” New

.

T

R

.

Middle drive pinion gear nut

190 Nm (19 m·kgf, 137 ft·lbf)

TIP

• Wrap the middle drive shaft in a folded rag, and then secure it in a vise.

• Lock the threads with a drift punch.

EAS25890

MEASURING THE MIDDLE GEAR

BACKLASH

1. Measure:

• Middle gear backlash


→

Adjust.


Middle gear backlash

0.10–0.30 mm (0.004–0.012 in)

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ 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.

c. Attach the final gear backlash band “3” and dial gauge “4”.

Final gear backlash band

90890-01511

Middle drive gear lash tool

YM-01230

3

4 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).

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

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

1. Select:

• Middle drive pinion gear shim(s) “1”

• Middle driven pinion gear shim(s) “2”

2 a k e b d

A c

1 i g h f

5-92 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”

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

a

“b” is 17.0

“c” is 55.0

If the left crankcase is marked “64.96”,

“d” is 64.96

d

Hundredth

0, 1, 2

3, 4, 5, 6, 7

8, 9

Rounded value

0

5

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”

“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.

If the right crankcase is marked “9.01”,

“e” is 9.01

f 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

“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

MIDDLE GEAR f j

If the driven pinion gear is marked “+02”,

“g” is 61.02

If the driven pinion gear is marked “+02”,

“h” is 80.52

g

If the right crankcase is marked “99.98”,

“i” is 99.98

h

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.

Hundredth Rounded value

0, 1, 2

3, 4, 5, 6, 7

8, 9

0

5

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

• 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.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

i

If the left crankcase is marked “8.12”,

“j” is 8.12

5-94

5-95

MIDDLE GEAR

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)

New

T.R

18 Nm (1.8 m

•

kgf, 13 ft

•

Ibf)

New

New

T.R

35 Nm (3.5 m

•

kgf, 25 ft

•

Ibf)

New

4

1

2

New

New

LS

T.R

18 Nm (1.8 m

•

kgf, 13 ft

•

Ibf)

E

3

1

2

3

4

T.R

17 Nm (1.7 m

Order

•

kgf, 12 ft

Engine oil

Coolant

•

Ibf)

LS

T.R

30 Nm (3.0 m

•

kgf, 22 ft

•

Ibf)

Q’ty Job/Parts to remove

Rear skid plate/Right rear panel/Center passenger compartment panel

Air filter case

Remarks


4-1.


Drain.


Drain.



Water pump outlet pipe/Oil cooler inlet hose

Oil filter cartridge

Oil filter cartridge union bolt

Oil cooler

Oil cooler outlet hose

1

1

1

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)

New

5

T.R

18 Nm (1.8 m

•

kgf, 13 ft

•

Ibf)

New

6

New

T.R

35 Nm (3.5 m

•

kgf, 25 ft

•

Ibf)

New

T.R

17 Nm (1.7 m

•

kgf, 12 ft

•

Ibf)

Order

5

6

LS


Oil pipe (crankcase to cylinder head)

Oil pipe (AC magneto cover)

New

New

LS

T.R

18 Nm (1.8 m

•

kgf, 13 ft

•

Ibf)

E

T.R

30 Nm (3.0 m

•

kgf, 22 ft

•

Ibf)

Q’ty

1

1

Remarks


6-2

OIL COOLER

EAS26420

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.

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.

1 a

.

T

R

.

Oil filter cartridge union bolt

30 Nm (3.0 m·kgf, 22 ft·lbf)

4. Fill:

• Cooling system



• Crankcase

(with the specified amount of the recommended engine oil)


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.

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.

b a b

1

2

6-3

RADIATOR

EAS26380

RADIATOR

Removing the radiator

T.R.

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

6

7

8

5

4

1

(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)

6

7

4

5

8

1

2

3


Side frames/Front fender/Instrument panel/Center passenger compartment panel/Center floor board/Left floor board/Right floor board/Electrical components tray

Air filter case

Coolant

Radiator cap

Coolant reservoir hose

Coolant reservoir breather hose

Coolant reservoir cap

Coolant reservoir

Radiator inlet hose

Radiator inlet pipe

Radiator outlet hose

Q’ty

1

1

1

1

1

1

1

1

Remarks


4-1.


Drain.


6-4

Removing the radiator

T.R.

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

RADIATOR

12

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

11

10

9

15

14

(4)

T.R

8 Nm (0.8 m

•

kgf, 5.8 ft

•

Ibf)

13

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

Order

12

13

14

15

9

10

11


Radiator outlet pipe

Radiator fan motor coupler

Horn

Radiator bracket

Radiator

Radiator fan

Radiator fan motor breather hose

Q’ty

1

1

1

1

1

1

1

Remarks

Disconnect.

For Europe and Oceania


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.

2. Check:

• Radiator hoses

• Radiator pipes

Cracks/damage/wear

→

Replace.

3. Measure:



→


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”.

Radiator cap tester

90890-01325

Mityvac cooling system tester kit

YU-24460-A

Radiator cap tester adapter

90890-01352

Pressure tester adapter

YU-33984

b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.

▲ ▲▲▲ ▲ ▲▲▲ ▲

4. Check:

▲ ▲▲▲ ▲ ▲▲▲

• Radiator fan

Damage

→

Replace.

Malfunction

→

Check and repair.

Refer to “COOLING SYSTEM” on page 9-29.

EAS26400

INSTALLING THE RADIATOR

1. Fill:

• Cooling system



2. Check:

• Cooling system

Leaks

→


3. Measure:



→



EAS1XD2002

INSTALLING THE HORN (for Europe and

Oceania)

1. Install:

• Horn “1”

.

T

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

b a

1

RADIATOR

6-7

THERMOSTAT

EAS26440

THERMOSTAT

Removing the thermostat

T.R.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

2

LS

New

1

New

4

5

New

3

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

T.R

18 Nm (1.8 m

•

kgf, 13 ft

•

Ibf)

3

4

1

2

5


Coolant

Thermostat outlet hose

Thermostat cover

Thermostat

Coolant temperature sensor coupler

Coolant temperature sensor

1

1

1

1

1

Q’ty Remarks

Drain.


Disconnect.


6-8

THERMOSTAT

EAS26450

CHECKING THE THERMOSTAT

1. Check:

• Thermostat

Does not open at 69–73 °C (156–163°F)

→

Replace.

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Suspend the thermostat “1” in a container “2” filled with water.

b. Slowly heat the water “3”.

c. Place a thermometer “4” in the water.

d. While stirring the water, observe the thermostat and thermometer indicated temperature.

• Thermostat housing (cylinder head)

• Thermostat outlet hose

Cracks/damage

→

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.

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

3

1

7 mm

(0.28 in )

71±2 ° C 85 ° C

(159±3 ° F) (185 ° F)

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

LS

3. Fill:

• Cooling system



4. Check:

• Cooling system

Leak

→


5. Measure:



→



THERMOSTAT

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

7

8

5

6

3

4

1

2

2

3

T.R

1.5 Nm (0.15 m

•

kgf, 1.1 ft

•

Ibf)

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)


Center compartment panel/Right side cover/Right rear cover/Rear skid plate

Air filter case

Engine oil

Coolant

Water pump inlet hose

Water jacket joint

Water pump outlet hose

Water pump outlet pipe

Oil cooler inlet hose

Water pump breather hose

Water pump housing

Gasket

5

E

New

4

(11)

M

6

New

8

New

7

New

New

LS

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

1

1

1

1

1

1

1

1

Q’ty Remarks


4-1.


Drain.


Drain.


6-11

Removing the water pump

LS

WATER PUMP

15

14

New

10

T.R.

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

16

20

LS

21

New

13

11

15

E

New

(11)

M

18

19

12

New

17

9

New

T.R

1.5 Nm (0.15 m

•

kgf, 1.1 ft

•

Ibf)

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

Order

16

17

18

19

20

21

12

13

14

15

9

10

11


Dowel pin


AC magneto coupler


AC magneto cover

AC magneto cover gasket

Dowel pin

Circlip

Impeller shaft

Mechanical seal (impeller side)

Mechanical seal (housing side)

Bearing

Oil seal

New

New

LS

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

Q’ty

1

1

1

1

1

1

1

2

1

1

2

1

2 Disconnect.

Disconnect.

Remarks


6-12

EAS26510

DISASSEMBLING THE WATER PUMP

1. Remove:

• Mechanical seal (impeller side) “1”

(from the impeller, with a thin, flat-head screwdriver)

TIP

Do not scratch the impeller shaft.

2. Remove:

• Mechanical seal (housing side) “1”

TIP

Remove the mechanical seal (housing side) from the inside of the AC magneto cover.

WATER PUMP

EAS26540

CHECKING THE WATER PUMP

1. Check:

• Water pump housing 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.

EAS26560

ASSEMBLING THE WATER PUMP

1. Install:


(into the AC magneto cover)

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.

Installed depth of oil seal “a”

8.1–8.7 mm (0.32–0.34 in)

1

New

1

3. Remove:

• Bearing “1”


TIP

Remove the bearing and oil seal from the inside of the AC magneto cover.

2

1 a

2. Install:

• Mechanical seal (housing side) “1”

ECA1XD1056

New

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.

6-13

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

3

2

1

New

WATER PUMP

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)

A. Push down

2. Mechanical seal installer

3. Middle driven shaft bearing driver

3. Install:

• Mechanical seal (impeller side) “1”

New

TIP

Before installing the mechanical seal (impeller side), apply tap water or coolant onto its outer surface.

1. Straightedge

2. Impeller

5. Install:

• Impeller “1”

• Circlip New

TIP

After installation, check that the impeller shaft rotates smoothly.

4. Measure:

• Impeller shaft tilt


→

Repeat steps (3) and

(4).

ECA1XD1057

NOTICE

Make sure the mechanical seal (impeller side) is flush with the impeller.

1

EAS1XD1008

INSTALLING THE AC MAGNETO COVER

1. Install:


• AC magneto cover gasket “2”

• AC magneto cover “3”

New

TIP

Align the slit “a” on the impeller shaft with the projection “b” on the oil pump driven sprocket.

6-14

b a

1

3

2

New

2. Install:


• 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



4. Check:

• Cooling system

Leaks

→


5. Measure:



→



6-15

WATER PUMP

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.

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

5

4

(6)

1

2

6

1

7

7

9

11

3

New

6

7

4

5

1

2

3

8

9

10

11

Order

8

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)


Outer passenger seat frame/Right side panel/Right rear cover

Fuel tank breather hose

Fuel tank breather hose joint

Fuel pump coupler

Fuel hose connector holder

Fuel hose

Fuel tank retainer

Damper

Fuel tank bracket

Fuel tank

Damper

Fuel pump

10

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

Q’ty Remarks


4-1.

1

2

1

1

2

1

1

2

1

1

1

Disconnect.


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.

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.

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.

EAS26640

REMOVING THE FUEL PUMP

1. Remove:

• Fuel pump bracket

• Fuel pump

• Fuel pump gasket

ECA14720

NOTICE

• Do not drop the fuel pump or give it a strong shock.

• Do not touch the base section of the fuel sender.

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

a. upward

EAS26700

INSTALLING THE FUEL PUMP

1. Install:

• Fuel pump gasket “1” New

TIP

• Always use a new fuel pump gasket.

• Install the fuel pump gasket with the lip side “a” facing upward.

New

1 a

1 a

2 4

5

6 a

3 b

1

EAS1XD1006

INSTALLING THE FUEL TANK

1. Install:

• Dampers “1”

TIP

Fit the projections “a” on the dampers into the holes “b” in the frame.

a

1 b

1

2. Install:

• Fuel pump

• Fuel pump bracket

.

T

R

.

Fuel pump nut

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

TIP

• 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.

2. Install:

• Fuel tank “1”

• Fuel tank bolts “2”

• Fuel tank retainer “3”

• Fuel tank retainer bolts “4”

TIP

Finger tighten the fuel tank bolts and fuel tank retainer bolts.

3

4 4

1

2

2

3. Tighten:

• Fuel tank bolts “1”–“3”

• Fuel tank retainer bolts “4”, “5”

2

7-3

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

1 2

4. Install:

• Fuel hose

• Fuel hose connector holder “1”

• Fuel pump coupler

ECA1XD1053

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.

EAS1XD1123

CHECKING THE FUEL PRESSURE

1. Check:

• Fuel pressure

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ a. Remove the frame cross member.

▼▼▼


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.

Pressure gauge

90890-03153

YU-03153

Fuel pressure adapter

90890-03176

YM-03176

3

1

d. Start the engine.

e. Measure the fuel pressure.


→

Replace the fuel pump.

2

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

2

1

New

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)

6

7

6

T.R

2.0 Nm (0.20 m

•

kgf, 1.4 ft

•

Ibf)

New

5

8

9

8

3

4

T.R

1.5 Nm (0.15 m

•

kgf, 1.1 ft

•

Ibf)

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

7

8

5

6

9

3

4

1

2


Side frames/Front fender/Instrument panel/Side panels/Center passenger compartment panel/Floor boards

Air filter case cover

Air filter element holder

Air filter element

Air filter element frame

Intake air temperature sensor coupler


Air filter case joint

Air intake duct joint clamp screw

Air intake duct joint

1

2

1

2

1

1

1

1

1

Q’ty Remarks


4-1.

Disconnect.

Loosen.

Loosen.

7-5

AIR FILTER CASE

Removing the air filter case and air intake duct

12

New

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)

T.R

2.0 Nm (0.20 m

•

kgf, 1.4 ft

•

Ibf)

New

10

11

T.R

1.5 Nm (0.15 m

•

kgf, 1.1 ft

•

Ibf)

T.R

7 Nm (0.7 m

•

kgf, 5.1 ft

•

Ibf)

Order

10

11

12


Intake air temperature sensor

Air filter case

Air intake duct

Q’ty

1

1

1

Remarks


7-6

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

AIR FILTER CASE

7-7

THROTTLE BODY

EAS26970

THROTTLE BODY

Removing the throttle body

11

T.R

3.5 Nm (0.35 m

•

kgf, 2.5 ft

•

Ibf)

1

10

10

2

T.R

2.0 Nm (0.20 m

•

kgf, 1.4 ft

•

Ibf)

7

LS

8

3

5

9

4

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)

6

New

T.R

2.0 Nm (0.20 m

•

kgf, 1.4 ft

•

Ibf)

6

7

4

5

1

2

3

8

9

10

11

T.R

2.0 Nm (0.20 m

•

kgf, 1.4 ft

•

Ibf)


Frame cross member

Intake air pressure sensor coupler

Throttle position sensor coupler

Throttle body breather hose

Fuel injector coupler

ISC unit coupler

Throttle cable housing cover

Throttle cable

Fuel hose

Cylinder head breather hose

Air intake silencer joint clamp screw

Air intake silencer joint

1

1

1

1

1

1

1

2

1

1

1

Q’ty Remarks


4-1.

Disconnect.

Disconnect.

Disconnect.

Disconnect.

Disconnect.

Disconnect.

Loosen.

7-8

THROTTLE BODY

Removing the throttle body

T.R

3.5 Nm (0.35 m

•

kgf, 2.5 ft

•

Ibf)

13

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)

14

12

New

12

T.R

2.0 Nm (0.20 m

•

kgf, 1.4 ft

•

Ibf)

LS

17

16 15

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

12

13

14

15

16

17


Throttle body joint clamp screw

Throttle body assembly

Throttle body joint

Air induction system solenoid hose (air intake silencer to air induction system solenoid)


Air intake silencer

Q’ty

2

1

1

1

1

1

Loosen.

Disconnect.

Loosen.

Remarks


7-9

THROTTLE BODY

Disassembling the throttle body assembly

T.R.

3.6 Nm (0.36 m

•

kgf, 2.6 ft

•

Ibf)

T.R

3.5 Nm (0.35 m

•

kgf, 2.5 ft

•

Ibf)

3

2

LS

New

6

Order

1

2

3

4

5


Intake air pressure sensor

Intake air pressure sensor hose

Throttle position sensor

Injector fuel rail

Fuel injector

6 Throttle body

1

T.R

5 Nm (0.5 m

•

kgf, 3.6 ft

•

Ibf)

4

5

New

New

Q’ty

1

1

1

1

1

Remarks

1

ECA1XD1043

NOTICE

The throttle body should not be disassembled.


7-10

THROTTLE BODY

EAS1XD1125

REMOVING THE THROTTLE BODY

ASSEMBLY

1. Disconnect:

• 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.

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.

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.

EAS26990

CHECKING THE THROTTLE BODY

1. Check:

• Throttle body

Cracks/damage

→

Replace the throttle body.

2. Check:

• Fuel passages

Obstructions

→

Clean.

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

EAS21020

CHECKING THE THROTTLE BODY JOINT

1. Check:

• Throttle body joint “1”

Cracks/damage

→

Replace.

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.

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 INJEC-

TOR” on page 9-106.

7-11 b

2. Install:

• Throttle body joint clamps “1”

1 a

THROTTLE BODY

TIP

Align the projections on the throttle body joint with the gap in each throttle body joint clamp.

1

3. Install:

• Throttle body assembly “1”

TIP

Align the projection “a” on the throttle body assembly between the tabs “b” on the throttle body joint.

1 b a b

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.

b

1 a

2

4. Connect:

• Fuel hose

ECA1XD1044

NOTICE

When connecting the fuel hose, make sure that it is securely connected, and that the fuel hose connector cover is in the correct position, otherwise the fuel hose will not be properly connected.

TIP

• 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.

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.

1 b b a a

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

1. Check:

• Throttle position sensor

Refer to “CHECKING THE THROTTLE PO-

SITION 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


90890-03174


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

THROTTLE BODY

EAS27040

AIR INDUCTION SYSTEM


2 3 4

1

5

7-15

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


Removing the air cut-off valve

1

2

4

3

Order

1

2

3

4


Air induction system solenoid coupler

Air induction system hose (air cut-off valve joint to reed valve cover)

Air induction system hose (air intake silencer to air cut-off valve)

Air cut-off valve

Q’ty

1

1

Disconnect.

1

1

Remarks


7-17


Removing the reed valve

3

2

LT

1

LT

Order

1

2

3

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)


Air induction system hose (air cut-off valve to reed valve cover)

Reed valve cover

Reed valve assembly

Reed valve plate

Q’ty Remarks

Disconnect.

Refer to “Removing the air cut-off valve”.

1

1

1


7-18


EAS27060


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.

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.

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

1

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

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.

EAS29900

CHECKING NOISES

1. Investigate any unusual noises.

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼

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 “MEA-

SURING THE FINAL GEAR BACKLASH” on page 8-26.

EWA13780

WARNING

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.

c. A slight “thunk” evident at low speed operation. This noise must be distinguished from normal vehicle operation.

Diagnosis: Possible broken gear teeth.

EWA13790

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

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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.

8-1

TROUBLESHOOTING

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.

• Always clean the vehicle and recheck the suspected location of an apparent leakage.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

EAS29910

TROUBLESHOOTING CHART

When basic conditions (a) and (b) described in “CHECKING NOISES” exist, check the following points:

YES

→

1. Elevate and spin both wheels. Feel for wheel bearing damage.

Replace the wheel bearing. (Refer to

“STEERING KNUCKLES” on page 4-56

and “REAR KNUCKLES AND STABILIZ-

ER” on page 4-64.)

NO

↓

2. Check the wheel nuts and axle nuts

→ for tightness.

YES

↓

3. Check the front constant velocity

→ shaft assemblies. Feel for bearing damage.

Torque to specification. (Refer to “FRONT

AND REAR WHEELS” on page 4-25.

Constant velocity shaft bearings and differential bearings are probably not damaged.

Repeat the test or remove the individual components.

YES

↓

4. Check the parking brake adjust-

→ ment.

Adjust per instructions. (Refer to “AD-

JUSTING THE PARKING BRAKE LEVER” on page 3-20.)

YES

↓

5. Check the rear constant velocity

→ shaft assemblies. Feel for bearing damage.

Constant velocity shaft bearings and final gear bearings are probably not damaged.

Repeat the test or remove the individual components.

YES

↓

Remove the shaft drive components.

8-2

FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN-

TIAL 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.

18 Nm (1.8 m

•

kgf, 13 ft

•

Ibf)

T.R.

150 Nm (15 m

•

kgf, 108 ft

•

lbf)

T.R

60 Nm (6.0 m

•

kgf, 43 ft

•

Ibf)

T.R.

105 Nm (10.5 m

•

kgf, 76 ft

•

lbf)

LS

New

New

2

LS

1

New

LT

New

LS

LS

New

LS

1

New

LS

New

4

LS

3

4

1

2

Order

LS

3

T.R

60 Nm (6.0 m

•

kgf, 43 ft

•

Ibf)


Sun top/Side frames/Front fender/Front guard/Instrument panel/Center passenger compartment panel/Center floor board/Front skid plate

Air filter case

Steering knuckles

Differential gear oil

Front constant velocity shaft assembly

Differential motor coupler

Differential assembly breather hose

Differential assembly

1

1

2

1

Q’ty Remarks


4-1.


Refer to “STEERING KNUCKLES” on page

4-56.

Drain.

Refer to “CHANGING THE DIFFERENTIAL

GEAR OIL” on page 3-16.

Disconnect.

Disconnect.

8-3



Removing the front constant velocity shaft assemblies, differential assembly, and front drive shaft

T.R.

18 Nm (1.8 m

•

kgf, 13 ft

•

Ibf)

T.R.

150 Nm (15 m

•

kgf, 108 ft

•

lbf)

T.R.

60 Nm (6.0 m

•

kgf, 43 ft

•

Ibf)

T.R.

105 Nm (10.5 m

•

kgf, 76 ft

•

lbf)

LS

Order

8

9

10

11

5

6

7

12

13

14

15

9

New

New

LS

5

8

LS

LT

New

6

LS

LS

7

9

8

10

LS

New

13

12

11

New

15

LS

14

New

New

LS

New

New

New

T.R

60 Nm (6.0 m

•

kgf, 43 ft

•

Ibf)


Support bearing bracket

Front drive shaft (differential side)

Dust seal

Universal joint

Universal joint yoke

Front drive shaft (middle gear side)

Support bearing housing

Support bearing rubber

Oil seal

Oil seal

Bearing

Q’ty

1

1

2

2

1

1

1

1

1

1

1

Remarks


8-4



Disassembling the front constant velocity shaft assemblies

5

6

New

7

4

New

New

2

3

New

1


6

7

4

5

8

9

1

2

3

Boot band

Boot band

Dust boot

Clip

Double offset joint

Circlip

Ball bearing

Boot band

Boot band

New

8

New

9

Q’ty Remarks

The following procedure applies to both of the front constant velocity shaft assemblies.

1

1

1

1

1

1

1

1

1

8-5



Disassembling the front constant velocity shaft assemblies

13

Order

10

11

12

13


Dust boot

Constant velocity joint

Clip

Constant velocity shaft

A: Wheel side

B: Differential side

10

12

New

11

Q’ty

1

1

1

1

Remarks


8-6



Disassembling the differential assembly

1

New

LS

T.R

11 Nm (1.1 m

•

kgf, 8.0 ft

•

Ibf)

T.R

62 Nm (6.2 m

•

kgf, 45 ft

•

Ibf)

New

LS

5

3

2

LS

New

10

4

5

2

3

6

7

8

9

10

Order

1

*

7

8

6

9

(3)

T.R

LS

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

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)

4


Differential motor

Front drive shaft yoke nut (differential case side)

Front drive shaft yoke (differential case side)

Bracket

Differential case cover

Differential gear assembly

Differential gear assembly shim

Bearing

Bearing

Oil seal

T.R

24 Nm (2.4 m

•

kgf, 17 ft

•

Ibf)

1

1

1

1

1

1

1

1

Q’ty

1

Remarks

ECA1XD1002

NOTICE

Do not disassemble the differential motor or remove the differential motor pinion gear.

Refer to “ADJUSTING THE DIFFEREN-

TIAL GEAR BACKLASH” on page 8-16.

8-7



Disassembling the differential assembly

T.R

11 Nm (1.1 m

•

kgf, 8.0 ft

•

Ibf)

New

15 LS

T.R

62 Nm (6.2 m

•

kgf, 45 ft

•

Ibf)

New

LS

LS

New

16

*

13

11

12

14

T.R

LS

New

*

24 Nm (2.4 m

•

kgf, 17 ft

•

Ibf)

15

(3)

LS

New

T.R

23 Nm (2.3 m

•

kgf, 17 ft

•

Ibf)

Order

14

15

16

11

12

13

New

T.R

10 Nm (1.0 m

•

kgf, 7.2 ft

•

Ibf)


Clip

Differential pinion gear

Bearing

Bearing

Oil seal

Differential case

T.R

24 Nm (2.4 m

•

kgf, 17 ft

•

Ibf)

Remarks Q’ty

1

2

1

1

1

1


* SAE 80 API GL-4 Hypoid gear oil

8-8



EAS1XD1036

DISASSEMBLING THE UNIVERSAL JOINTS

1. Remove:

• Universal joint

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ a. Remove the circlips “1”

▼ ▼▼▼ ▼▼▼ b. Place the universal joint in a press.

c. With a suitable diameter pipe “2” beneath the universal joint yoke “3”, press the bearing “4” into the pipe as shown.

TIP

It may be necessary to lightly tap the universal joint yoke with a punch.

A

A

5

4

1

2

3

A. Differential side

2. Remove:

• Boot band “1”

TIP

Use the boot band installation tool “2”.


90890-01526

YM-01526

B d. Repeat the steps for the opposite bearing.

e. Remove the universal joint.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

EAS29930

DISASSEMBLING THE FRONT CONSTANT

VELOCITY SHAFT ASSEMBLIES


1. Remove:

• Boot bands

• Clip “1”

• Double offset joint “2”

• Circlip “3”

• Ball bearing “4”

• Dust boot “5”

TIP

Before removing the clip, slide the dust boot away from the double offset joint.

2

1

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.

8-9



B

A

New

1

3

B. Wheel side

EAS29960

CHECKING THE FRONT CONSTANT



1. Check:

• Double offset joint splines

• Constant velocity joint splines

• Constant velocity shaft splines

Wear/damage

→

Replace.

2. Check:

• Dust boots

Cracks/damage

→

Replace.

ECA1XD1006

NOTICE

Always use new boot bands.

3. Check:

• Balls and ball races

• Inner surface of double offset joint

Pitting/wear/damage

→

Replace.

EAS29990

ASSEMBLING THE FRONT CONSTANT



1. Install:

• Clip “1” New

• Constant velocity joint “2”

• Constant velocity shaft “3”

• Dust boot

▼ ▼▼▼ ▼ ▼▼▼ ▼ 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.

A

A

New

1

3

2

A. Wheel side

▲ ▲▲▲ ▲ ▲▲▲ ▲

2. Install:

• Dust boot




▲ ▲▲▲ ▲ ▲▲▲

• 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.

8-10



▼▼▼

B

1

2

New

▼ ▼▼▼ ▼ ▼▼▼ ▼ a. Install the dust boots.

▼ ▼▼▼ ▼ b. Install the dust boot bands “4” and “5”.

TIP



90890-01526

YM-01526

B

6

3

4

New

4

B. Differential side

3. Apply:

• Molybdenum disulfide grease

(into the double offset joint, constant velocity joint, and dust boots)


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:


• 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.

▲ ▲▲▲ ▲ ▲▲▲ ▲

5. Check:

▲ ▲▲▲ ▲ ▲▲▲

• Thrust movement free play

Excessive play

→

Replace the constant velocity shaft assembly.

EAS1XD1035

REMOVING THE FRONT DRIVE SHAFT

YOKE

1. Remove:

• Front drive shaft yoke

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



1

EAS1XD1046

REMOVING THE DIFFERENTIAL GEAR

ASSEMBLY

1. Remove:

• Differential gear assembly “1”

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.

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.

2. Check:

• Gear teeth


→

Replace.

TIP

When the differential pinion gear and/or the differential assembly are replaced, be sure to adjust the shim of the differential gear assembly.

3. Check:

• Bearings

Damage

→

Replace.

1

EAS1XD1127

CHECKING THE FRONT DRIVE SHAFT

1. Check:

• Drive shaft splines

• Coupling sleeve splines

Wear/damage

→

Replace.

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.

EAS1XD1038

CHECKING THE DIFFERENTIAL MOTOR

OPERATION

1. Check:

• Differential motor operation

Does not operate

→

Replace.

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).

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.

8-12



A

3V

3

1 a

2

2

B

3V

2

1

A. Check that the differential motor pinion gear

“2” turns counterclockwise.

B. Check that the differential motor pinion gear

“2” turns clockwise.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

EAS1XD1039

ASSEMBLING THE DIFFERENTIAL

ASSEMBLY

1. Install:



Installed depth of oil seal “a”

-0.5–0.5 mm (-0.020–0.020 in)

3 a a

4

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

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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.

1

1 1

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.

ECA1XD1013

NOTICE

Do not use a 12 V battery to operate the differential motor pinion gear.

8-13



2 b a

3

3V 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

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.

4

4

5

4

7

6

5. Install:

• Front drive shaft yoke

• Washer

• Front drive shaft yoke nut

.

T

R

.

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.

Universal joint holder

90890-04062

YM-04062

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)

▲ ▲▲▲ ▲ ▲▲▲ ▲

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.

1

EAS1XD1010

ASSEMBLING THE UNIVERSAL JOINT

1. Install:

• Universal joint

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the universal joint into the front drive shaft yoke.

8-14



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.

ECA1XD1015

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.

Ring gear fix bolt (M10)

90890-01527

YM-01527

ECA16250

NOTICE

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.

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.

e. Install new circlips “2” into the groove of each bearing.

2

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

a

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



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.

Thinner shim

Differential gear backlash is 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

T.R

33 Nm (3.3 m

•

kgf, 24 ft

•

Ibf)

1

(4)

5

New

2

LS

LS

3

T.R

33 Nm (3.3 m

•

kgf, 24 ft

•

Ibf)

LS

New

4

T.R

105 Nm (10.5 m

•

kgf, 76 ft

•

lbf)

3

4

1

2

5


Rear skid plate

Rear knuckles


Muffler

Final gear oil

Rear constant velocity shaft assembly

Final drive assembly breather hose

Final drive assembly bracket (upper side)

Final drive assembly

Spring

1

1

2

1

1

Q’ty Remarks

Refer to“GENERAL CHASSIS” on page 4-1.

Refer to “REAR KNUCKLES AND STABI-

LIZER” on page 4-64.


Refer to“ENGINE REMOVAL” on page 5-1.

Drain.

Refer to “CHANGING THE FINAL GEAR

OIL” on page 3-15.

Disconnect.

8-17



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

T.R

33 Nm (3.3 m

•

kgf, 24 ft

•

Ibf)

(4)

6

10

9

LS

LS

8

7

New

T.R

33 Nm (3.3 m

•

kgf, 24 ft

•

Ibf)

LS

New

11

T.R

105 Nm (10.5 m

•

kgf, 76 ft

•

lbf)

Order

9

10

11

6

7

8


Rear drive shaft

Damper

Rear drive shaft coupling sleeve

Dust seal

Dust seal

Final drive assembly bracket (lower side)

Q’ty

1

1

1

1

1

1

Remarks


8-18



Disassembling the rear constant velocity shaft assemblies

5

6

New

7

4

New

New

2

3

New

1


6

7

4

5

1

2

3

8

9

10

11

12

Boot band

Boot band

Dust boot

Clip

Double offset joint

Circlip

Ball bearing

Boot band

Boot band

Dust boot

Constant velocity joint

Clip

New

8

10

New

9

12

New

11

Q’ty Remarks

The following procedure applies to both of the rear constant velocity shaft assemblies.

1

1

1

1

1

1

1

1

1

1

1

1

8-19



Disassembling the rear constant velocity shaft assemblies

13

Order

13


Constant velocity shaft

A: Wheel side

B: Final drive side

Q’ty

1

Remarks


8-20



Disassembling the final drive assembly

T.R.

23 Nm (2.3 m

•

kgf, 17 ft

•

Ibf)

New

7

8

5

6

3

4

1

2

9

10

11

12

13

1

LS

*

New

Order

*

13

3

5

LT

LS

11

New

10

New

12

LS

New

8

New

6

2

(4)

7

4

New

9

(8)

*

T.R

52 Nm (5.2 m

•

kgf, 38 ft

•

Ibf)

T.R

16 Nm (1.6 m

•

kgf, 12 ft

•

Ibf)

LT

LS

T.R

26 Nm (2.6 m

•

kgf, 19 ft

•

Ibf)

T.R

97 Nm (9.7 m

•

kgf, 70 ft

•

Ibf)


Parking brake disc

Final drive pinion gear assembly

Rear drive shaft yoke (final drive assembly side)

Final drive pinion gear

Final drive pinion gear shim

Collar

Oil seal

Bearing

Final drive pinion gear bearing housing

Ring gear stopper

Final drive case cover

Final drive case cover gasket

Oil seal

Final drive ring gear

Q’ty Remarks


1

1

1

1

1

1

1

1

1

1

1

1

8-21



Disassembling the final drive assembly

T.R.

23 Nm (2.3 m

•

kgf, 17 ft

•

Ibf)

New

New

21

LS

*

New

18

20

19

15

17

*

16

14

19

LS

New

LS

Order

14

18

19

20

21

15

16

17

LT

(4)

(8)

New

*

T.R

52 Nm (5.2 m

•

kgf, 38 ft

•

Ibf)

T.R

16 Nm (1.6 m

•

kgf, 12 ft

•

Ibf)

LT

LS

T.R

26 Nm (2.6 m

•

kgf, 19 ft

•

Ibf)

T.R

97 Nm (9.7 m

•

kgf, 70 ft

•

Ibf)

Remarks Job/Parts to remove

Final drive ring gear shim (final drive case cover side)

Final drive ring gear shim (final drive case side)

Bearing

Bearing

Bearing

Dowel pin

Final drive case

Oil seal

Q’ty

1

2

1

1

1

1


* SAE 80 API GL-4 Hypoid gear oil

8-22

A

5



EAS30060

DISASSEMBLING THE REAR CONSTANT



1. Remove:

• Boot bands

• Clip “1”


• Circlip “3”


• Dust boot “5”

TIP

Before removing the clip, slide the dust boot away from the double offset joint.

B

2

B. Wheel side

1

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.

2

B

1

A

4

3

A. Final drive side

2. Remove:

• Boot bands “1”



90890-01526

YM-01526

B. Wheel side

EAS30330

CHECKING THE REAR CONSTANT



1. Check:

• Double offset joint splines

• Constant velocity joint splines

• Constant velocity shaft splines

Wear/damage

→

Replace.

2. Check:

• Dust boots

Cracks/damage

→

Replace.

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



EAS30070

ASSEMBLING THE REAR CONSTANT



1. Install:

• Clip “1” New

• Constant velocity joint “2”

• Constant velocity shaft “3”

• Dust boot

▼ ▼▼▼ ▼ ▼▼▼ ▼ a. Install the 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.




• 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.

B

1

2

New

A

New

1

B

3

3

4

New

A

A

New

1

3

2

A. Wheel side

▲ ▲▲▲ ▲ ▲▲▲ ▲

2. Install:

• Dust boot

▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

8-24

B. Final drive side

3. Apply:

• Molybdenum disulfide grease

(into the double offset joint, constant velocity joint, and dust boots)


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)

TIP

Molybdenum disulfide grease is included in the repair kit.

4. Install:


• 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.

• Washer


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”.



90890-01526

YM-01526

6

4

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

5. Check:

• Thrust movement free play

Excessive play

→

Replace the constant velocity shaft assembly.

2

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.

ECA1XD1005

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.

c. Press the gear end and remove the final drive pinion gear.

2

1

EAS1XD1043

DISASSEMBLING THE FINAL DRIVE PINION

GEAR ASSEMBLY

1. Remove:

• Rear drive shaft yoke nut

8-25

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲

EAS30150

CHECKING THE REAR DRIVE SHAFT

1. Check:

• Drive shaft splines

• Coupling sleeve splines

Wear/damage

→

Replace.

▲▲▲



EWA15060

WARNING

Do not attempt to straighten a bent shaft; this may dangerously weaken it.

b. Turn the ring gear stopper 120° counterclockwise.

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.

2. Check:

• Gear teeth


→

Replace the final drive pinion gear and ring gear as a set.

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.

EAS1XD1011

ADJUSTING THE RING GEAR STOPPER

1. Install:

• Ring gear stopper “1”

• Nut

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”.

c. Tighten the ring gear stopper nut “3”.

.

T

R

.

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)

Ring gear fix bolt (M10 x 1.5)

90890-01572

YM-01572

EAS1XD1012

NOTICE

Finger tighten the bolt until if holds the ring gear. Otherwise, the ring gear will be damaged.

2

1

1

3. Attach:

• Gear lash measurement tool “1”

• Dial gauge “2”

Gear lash measurement tool

90890-01467

YM-01467

3

8-26

1



2 a

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.

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 drive ring gear shims (final drive case cover side) “3”

Thickness (mm)

0.2 0.3

Final gear backlash

0.13–0.23 mm (0.005–0.009 in)

TIP

Measure the gear backlash at four positions. Rotate the final drive pinion gear 90° each time.

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.

EAS30180

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

2

1

2

3

Final drive ring gear shims (final drive case side) “4”

Thickness (mm)

0.2 0.3

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

EAS1XD1130

ASSEMBLING THE FINAL DRIVE PINION

GEAR ASSEMBLY

1. Apply:

• Sealant

(onto the washer contact surface and splines of the final drive pinion gear)


90890-85505


2. Adjust:

• Gear backlash

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Select a suitable shim(s) using the following chart.

Thinner shim

Final gear backlash is increased.

Thicker shim

Final gear backlash is decreased.

b. If increased by more than 0.2 mm (0.008 in):

8-27



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

4

3 1 3

5

9 8 7

FWD

TIP

• Secure the rear differential assembly in a vise.

• Use the coupling gear holding tool (35) “2” to hold the rear drive shaft yoke.

2

2

1

Coupling gear holding tool (35)

90890-01571

YM-01571

2

.

T

R

.

1

EAS1XD1045

INSTALLING THE FINAL DRIVE ASSEMBLY

1. Install

• Final drive assembly bracket (upper side) “1”

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



8-29


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


SIGNALING SYSTEM ................................................................................... 9-19

CIRCUIT DIAGRAM (for CDN) ................................................................ 9-19

CIRCUIT DIAGRAM (for Europe and Oceania)....................................... 9-21


COOLING SYSTEM....................................................................................... 9-29

CIRCUIT DIAGRAM ................................................................................ 9-29


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


2WD/4WD SELECTING SYSTEM................................................................. 9-67

CIRCUIT DIAGRAM ................................................................................ 9-67


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

EAS27090

IGNITION SYSTEM

EAS27100

CIRCUIT DIAGRAM

Y Y

/W R/

IGNITION SYSTEM

9-1


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

IGNITION SYSTEM

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 FUS-

ES” on page 9-92.

OK

↓

2. Check the battery.

→

Refer to “CHECKING AND

CHARGING THE BATTERY” on page 9-93.

OK

↓

3. Check the spark plug.

→

Refer to “CHECKING THE SPARK

PLUG” on page 3-5.

OK

↓

4. Check the ignition spark gap.

→

Refer to “CHECKING THE IGNI-

TION SPARK GAP” on page 9-99.

NG

↓

5. Check the spark plug cap.

→

Refer to “CHECKING THE SPARK

PLUG CAP” on page 9-98.

OK

↓

6. Check the ignition coil.

→

Refer to “CHECKING THE IGNI-

TION COIL” on page 9-98.

OK

↓

7. Check the crankshaft position sen-

→ sor.

Refer to “CHECKING THE CRANK-

SHAFT POSITION SENSOR” on page 9-99.

OK

↓

8. Check the main switch.

→

Refer to “CHECKING THE

SWITCHES” on page 9-87.

OK

↓

Replace the fuse(s).

• Clean the battery terminals.

• Recharge or replace the battery.

Re-gap or replace the spark plug.

Ignition system is OK.

Replace the spark plug cap.

Replace the ignition coil.

Replace the crankshaft position sensor/stator assembly.

Replace the main switch.

9-3

IGNITION SYSTEM

9. Check the lean angle sensor.

→

Refer to “CHECKING THE LEAN

ANGLE SENSOR” on page 9-100.

OK

↓

10.Check the entire ignition system

→ wiring.

Refer to “CIRCUIT DIAGRAM” on page 9-1.

OK

↓

Replace the ECU.

Replace the lean angle sensor.

Properly connect or replace the wire harness.

9-4

EAS27160

ELECTRIC STARTING SYSTEM

EAS27170

CIRCUIT DIAGRAM


Y Y

/W R/

9-5


5. Frame ground

6. Main switch

7. Engine ground

8. Battery

9. Main fuse

11.Starter relay

12.Starter motor

17.Gear position switch


33.Joint coupler

55.Brake light switch

59.Ignition fuse

61.Signaling system fuse

B. Wire harness



9-6


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

1

10

2

5

6

7

3

4

8

9

9-7

1. Battery

2. Main fuse

3. Ignition fuse

4. Main switch


6. Signaling system fuse

7. Brake light switch


9. Gear position switch

10.Starter relay

11.Starter motor


9-8


EAS27190

TROUBLESHOOTING

The starter motor fails to turn.

TIP


1. Hood


1. Check the fuses.

→

(Main, ignition, and signaling system)


ES” on page 9-92.

OK

↓


→



OK

↓

3. Check the starter motor operation.

→

Refer to “CHECKING THE START-

ER MOTOR OPERATION” on page

9-100.

NG

↓

4. Check the starter motor.

→

Refer to “CHECKING THE START-

ER MOTOR” on page 5-39.

OK

↓

5. Check the starter relay.

→

Refer to “CHECKING THE RE-

LAYS” on page 9-95.

OK

↓

6. Check the load control relay.

→



OK

↓


→



OK

↓

8. Check the brake light switch.

→



OK

↓




Starter motor is OK. Perform the electric starting system troubleshooting, starting with step 5.

Repair or replace the starter motor.

Replace the starter relay.

Replace the load control relay.


Replace the brake light switch.

9-9


9. Check the gear position switch.

→



OK

↓

10.Check the entire starting system

→ wiring.


OK

↓

Replace the ECU.

Replace the gear position switch.


9-10

EAS27200

CHARGING SYSTEM

EAS27210

CIRCUIT DIAGRAM

CHARGING SYSTEM

Y Y

/W R/

9-11

2. AC magneto

3. Rectifier/regulator

5. Frame ground

8. Battery

9. Main fuse

B. Wire harness


CHARGING SYSTEM

9-12

CHARGING SYSTEM

EAS27230

TROUBLESHOOTING

The battery is not being charged.

TIP


1. Hood

2. Right side panel

3. Right rear panel

1. Check the fuse.

→

(Main)


ES” on page 9-92.

OK

↓


→



OK

↓

3. Check the stator coil.

→

Refer to “CHECKING THE STATOR

COIL” on page 9-101.

OK

↓

4. Check the rectifier/regulator.

→

Refer to “CHECKING THE RECTI-

FIER/REGULATOR” on page

9-101.

OK

↓

5. Check the entire charging system

→ wiring.


OK

↓

The charging system circuit is OK.

Replace the fuse.




Replace the rectifier/regulator.


9-13

9-14

CHARGING SYSTEM

EAS27240

LIGHTING SYSTEM

EAS27250

CIRCUIT DIAGRAM

Y Y

/W R/

LIGHTING SYSTEM

9-15


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


LIGHTING SYSTEM

9-16

LIGHTING SYSTEM

EAS27260

TROUBLESHOOTING

Any of the following fail to light: headlight or taillight.

TIP


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.

OK

↓

2. Check the fuses.

→

(Main, ignition, and headlight)


ES” on page 9-92.

OK

↓


→



OK

↓


→



OK

↓

5. Check the light switch.

→



OK

↓

6. Check the headlight relay.

→



OK

↓


→



OK

↓

Replace the bulb(s) and bulb socket(s).





Replace the light switch.

Replace the headlight relay.


9-17

LIGHTING SYSTEM

8. Check the entire lighting system

→ wiring.


OK

↓

The lighting system circuit is OK.


9-18

EAS27270

SIGNALING SYSTEM

EAS1XD2004

CIRCUIT DIAGRAM (for CDN)


Y Y

/W R/

9-19


5. Frame ground

6. Main switch

7. Engine ground

8. Battery

9. Main fuse



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


56.Tail/brake light

59.Ignition fuse

60.Backup fuse


67.Backup light

68.Backup light relay

A. Optional

B. Wire harness



9-20

EAS1XD2003

CIRCUIT DIAGRAM (for Europe and Oceania)


Y Y

/W R/

9-21


5. Frame ground

6. Main switch

7. Engine ground

8. Battery

9. Main fuse




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


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


56.Tail/brake light

59.Ignition fuse

60.Backup fuse


67.Horn switch

68.Horn

69.Backup light

70.Backup light relay

A. Optional

B. Wire harness



9-22


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


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


10.Sun top

11.Side frames

12.Front fender

1. Check the fuses.

→

(Main, ignition, signaling system, and backup)


ES” on page 9-92.

OK

↓


→



OK

↓


→



OK

↓


→



OK

↓






9-23


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.

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.

OK

↓

2. Check the brake light switch.

→



OK

↓


→ wiring.




OK

↓

This circuit is OK.

Replace the tail/brake light bulb, socket or both.

Replace the brake light switch.


The neutral, high-range, and/or low-range indicator light fails to come on.

1. Check the gear position switch.

→



Replace the gear position switch.

OK

↓

9-24



→ wiring.




OK

↓

Replace the meter assembly or ECU.

The reverse indicator light fails to come on.

1. Check the reverse switch.

→



OK

↓


→ wiring.




OK

↓


The park indicator light fails to come on.

1. Check the parking brake switch.

→



OK

↓


→ wiring.




OK

↓



Replace the reverse switch.


Replace the parking brake switch.


The coolant temperature warning light fails to come on.

1. Check the coolant temperature sen-

→ sor.

Refer to “CHECKING THE COOL-

ANT TEMPERATURE SENSOR” on page 9-103.

OK

↓

Replace the coolant temperature sensor.

9-25



→ wiring.




OK

↓


The fuel meter fails to come on.

1. Check the fuel sender.

→

Refer to “CHECKING THE FUEL

SENDER” on page 9-101.

OK

↓


→ wiring.




OK

↓

Replace the meter assembly.

The speedometer fails to come on.

1. Check the speed sensor.

→

Refer to “ELECTRICAL COMPO-

NENTS” on page 9-81.

OK

↓


→ wiring.




OK

↓


The helmet/seat belt indicator light fails to come on.

1. Check the seat belt switch.

→



OK

↓


Replace the fuel pump assembly.


Replace the speed sensor.


Replace the driver seat belt buckle.

9-26



→ wiring.




OK

↓

Replace the indicator light assembly or

ECU.

The horn fails to sound (for Europe and Oceania).

1. Check the horn switch.

→



OK

↓


→ wiring.


Europe and Oceania)” on page

9-21.

OK

↓

Replace the horn.


Replace the horn switch.


9-27

9-28


EAS27300

COOLING SYSTEM

EAS27310

CIRCUIT DIAGRAM

Y Y

/W R/

COOLING SYSTEM

9-29

5. Frame ground

6. Main switch

8. Battery

9. Main fuse



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


COOLING SYSTEM

9-30

COOLING SYSTEM

EAS27320

TROUBLESHOOTING

The radiator fan motor fails to turn.

TIP


1. Hood

2. Front skid plate

3. Frame cross member

1. Check the fuses.

→

(Main, ignition, and radiator fan motor)


ES” on page 9-92.

OK

↓


→



OK

↓


→



OK

↓

4. Check the radiator fan motor.

→

Refer to “CHECKING THE RADIA-

TOR FAN MOTOR” on page 9-103.

OK

↓

5. Check the radiator fan motor relay.

→



OK

↓

6. Check the radiator fan motor circuit

→ breaker.

Refer to “CHECKING THE RADIA-

TOR FAN MOTOR CIRCUIT

BREAKER” on page 9-103.

OK

↓

7. Check the coolant temperature sen-

→ sor.

Refer to “CHECKING THE COOL-

ANT TEMPERATURE SENSOR” on page 9-103.

OK

↓





Replace the radiator fan motor.

Replace the radiator fan motor relay.

Replace the radiator fan motor circuit breaker.

Replace the coolant temperature sensor.

9-31

COOLING SYSTEM

8. Check the entire cooling system

→ wiring.


OK

↓

Replace the ECU.


9-32

EAS27330

FUEL INJECTION SYSTEM

EAS27340

CIRCUIT DIAGRAM


Y Y

/W R/

9-33



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


19.Yamaha diagnostic tool coupler

20.ISC (idle speed control) unit


22.Ignition coil

23.Spark plug

24.Fuel injector

25.Intake air temperature sensor


27.Speed sensor

28.TPS (throttle position sensor)

29.Intake air pressure sensor

30.Lean angle sensor

33.Joint coupler


40.Engine trouble warning light

49.Fuel pump

59.Ignition fuse

60.Backup fuse


66.Radiator fan motor relay

B. Wire harness



9-34


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

ECU operation

Fuel injection operation

Vehicle operation

Flashing*

Warning provided when unable to start engine

Operation stopped Cannot be operated

Remains on 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)”:

12: Crankshaft position sensor 39:

Fuel injector

(open or short-circuit)

30:

33:

Lean angle sensor

(latch up detected)

Faulty ignition

41:

50:

Lean angle sensor

(open or short-circuit)

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


EAS27400

TROUBLESHOOTING METHOD

The engine operation is not normal and the engine trouble warning light comes on.

1. Check:

• Fault code number

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Check the fault code number displayed on the multi-function meter.

b. Identify the faulty system with the fault code.

c. Identify the probable cause of the malfunction.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

2. Check and repair the probable cause of malfunction.

Fault code No.

No fault code No.

Check and repair.

Refer to “TROUBLE-

SHOOTING DETAILS

(FUEL INJECTION

SYSTEM)” on page

9-38.

Monitor the operation of the sensors and actuators in the diagnostic mode.

Refer to “TROUBLE-

SHOOTING DETAILS

(FUEL INJECTION

SYSTEM)” on page

9-38 and “SELF-DI-

AGNOSTIC FUNC-

TION AND

DIAGNOSTIC CODE

TABLE” on page

10-5.

Check and repair.

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.

5. Erase the malfunction history in the diagnos-

tic mode (code No. 62). Refer to “SELF-DI-

AGNOSTIC FUNCTION AND DIAGNOSTIC

CODE TABLE” on page 10-5.

TIP

Turning the main switch to “ ” (off) will not erase the malfunction history.

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

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.

9-36


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:

Monitoring mode:

Logging mode:

View log:

ECU rewrite:

Determine whether each sensor or actuator is functioning properly.

Displays a graph of sensor output values for actual operating conditions.

Records and saves the sensor output value in actual driving conditions.

Displays the logging data.

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


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-DIAGNOS-

TIC 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

1

—

—

Probable cause of malfunction and check

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.

Maintenance job

2

3

Connection of ECU coupler.



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.


Confirmation of service completion

Crank the engine.

Fault code number is not displayed

→

Service is finished.

Fault code number is displayed

→

Go to item 2.

Crank the engine.


→



→

Go to item 3.

Crank the engine.


→



→

Go to item 4.

9-38


Fault code No.

Item

4

5

6

12

shaft position sensor.

Check for looseness or pinching.

Malfunction in ECU.

Crankshaft position sensor: no normal signals are received from the crankshaft position sensor.

Installed condition of crank-

Defective crankshaft position sensor.

Improperly installed sensor

→

Reinstall or replace the sensor.

Check the crankshaft position sensor.


CRANKSHAFT POSITION

SENSOR” on page 9-99.

Replace if defective.

Replace the ECU.

Crank the engine.


→



→

Go to item 5.

Crank the engine.


→



→

Go to item 6.

Fault code No.

13

Item Intake air pressure sensor: open or short circuit detected.



Indicated

Able to start engine

Able to drive vehicle

03

Displays the intake air pressure.

Procedure

Item

Turn and hold the main switch in the “ ” (start) position, then press the accelerator pedal. (If the display value changes, the performance is OK.)


Maintenance job


1 Connection of intake air pressure sensor coupler.




→


Turn the main switch to “

(on).


→

Go to item 2.

”


→


2 Connection of ECU coupler.




→



(on).


→

Go to item 3.

”


→


9-39


Fault code No.

Item

3

4

5

6

13


Intake air pressure sensor: open or short circuit detected.


→


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


ECU coupler.



(on).

”


→



→

Go to item 4.

Installed condition of intake air pressure sensor.


Defective intake air pressure sensor.


→



(on).


→



→

Go to item 5.

”

Turn the main switch to “ ”

(on).


→



→

Go to item 6.

Malfunction in ECU.

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)



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.



INTAKE AIR PRESSURE


Replace the ECU.

9-40


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).




03


Indicated

Procedure

Item

1




Condition of intake air pressure sensor hose.

Check the intake air pressure sensor hose condition.

→

Maintenance job

Clogged or detached hose

Repair or replace the sensor hose.


Start the engine and let it idle for approximately 5 seconds.


→



→

Go to item 2.

2 Defective intake air pressure sensor.


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)




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.



INTAKE AIR PRESSURE


9-41


TIP


“13” first.

Fault code No.

15

Item Throttle position sensor: open or short circuit detected.





01

Indicated

Procedure

Item

1

Throttle position sensor signal

• 14–20 (fully closed position)

Check with throttle valve fully closed.


Connection of throttle position sensor coupler.




→


Maintenance job



(on).


→



→

Go to item 2.

2

3






→



(on).


→

Go to item 3.

”


→


4 Installed condition of throttle position sensor.



→


Between throttle position sensor coupler and ECU coupler.

yellow–yellow

Between throttle position sensor coupler and joint coupler.



ECU coupler.



→

Reinstall or adjust the sensor.

Refer to “ADJUSTING THE

THROTTLE POSITION



(on).


→



→

Go to item 4.


(on).

”


→



→

Go to item 5.

9-42


Fault code No.

Item

5

6

7

15

Defective throttle position sensor.

Malfunction in ECU.

Throttle position sensor: open or short circuit detected.

Throttle position sensor resistance.

Measure the throttle position sensor resistance.


THROTTLE POSITION


Check throttle position sensor signal.


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.

Replace the ECU.


(on).


→



→

Go to item 6.


(on).


→



→

Go to item 7.

TIP


“15” first.

Fault code No.

16

Item

Throttle position sensor: stuck throttle position sensor is detected.



Indicated



01


• 14–20 (fully closed position)

Procedure

Item



Maintenance job

1 Installed condition of throttle position sensor.



→

Reinstall or adjust the sensor.


THROTTLE POSITION




(on), then press the accelerator pedal.


→



→

Go to item 2.

9-43


Fault code No.

Item

2

3

16

Malfunction in ECU.

Throttle position sensor: stuck throttle position sensor is detected.

Defective throttle position sensor.

Check throttle position sensor signal.


When the throttle valve is fully closed:

A value of 14–20 is indicated.


→


Replace the ECU.


(on), then operate the throttle.


→



→

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.


“16” first.

Fault code No.

21

Item Coolant temperature sensor: open or short circuit detected.




06


Indicated

Procedure

Item

1


Connection of coolant temperature sensor coupler.



Displays the coolant temperature.

Compare the actually measured coolant temperature with the meter display value.


→


Maintenance job



(on).


→



→

Go to item 2.





→



(on).


→

Go to item 3.

”


→


9-44


Fault code No.

Item

3

4

5

6

21


Coolant temperature sensor: open or short circuit detected.


→


Between coolant temperature sensor coupler and ECU coupler.

green/yellow–green/yellow

Between coolant temperature sensor coupler and joint coupler.



ECU coupler.



(on).

”


→



→

Go to item 4.

Installed condition of coolant temperature sensor.


Defective coolant temperature sensor.

Malfunction in ECU.


→



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.



COOLANT TEMPERATURE


Replace the ECU.


(on).


→



→

Go to item 5.

”


(on).


→



→

Go to item 6.

TIP


“21” first.

Fault code No.

22

Item Intake air temperature sensor: open or short circuit detected.




05


Indicated

Procedure

Item

Displays the intake air temperature.

Compare the actually measured intake air temperature with the indicated value.


Maintenance job


9-45


Fault code No.

Item

1

2

3

4

5

6

22

Connection of intake air temperature sensor coupler.



Intake air temperature sensor: open or short circuit detected.


→



(on).


→

Go to item 2.

”


→






→



(on).


→

Go to item 3.

”


→




→


Between intake air temperature sensor coupler and ECU coupler.

brown/white–brown/white

Between intake air temperature sensor coupler and joint coupler.



ECU coupler.



(on).

”


→



→

Go to item 4.

Installed condition of intake air temperature sensor.


Defective intake air temperature sensor.

Malfunction in ECU.


→



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.



INTAKE AIR TEMPERA-

TURE SENSOR” on page

9-105.

Replace the ECU.


(on).


→



→

Go to item 5.

”


(on).


→



→

Go to item 6.

9-46


TIP


“22” first.

Fault code No.

30

Item Latch up detected.





08

Indicated

Procedure

Item

1

2

3

4 angle sensor.

Lean angle sensor output voltage

• 3.6–4.4 (upright)

• 0.7–1.3 (overturned)

Remove the lean angle sensor and incline it more than 65 degrees.


Maintenance job

The vehicle has overturned.

Raise the vehicle upright.

Installed condition of lean

Defective lean angle sensor.

Malfunction in ECU.

Check the installed direction and condition of the sensor.



→

Check the lean angle sensor.



LEAN ANGLE SENSOR” on page 9-100.

Replace the ECU.



(on), then to “ ” (off), and then back to “ ” (on).


→



→

Go to item 2.




→



→

Go to item 3.


(on) then to “ ” (off), and then back to “ ” (on).


→



→

Go to item 4.

Fault code No.

Item



33

Ignition coil: open or short circuit detected in the primary lead of the ignition coil.



30

9-47


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

Item

Check that a spark is generated five times.

• Connect an ignition checker.


Maintenance job


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).


→

Connect the connector securely or replace the wire harness.



→



→

Go to item 2.





→




→



→

Go to item 3.

3 Wire harness continuity.


→


Between ignition coil connector and ECU coupler.

orange–orange

4

5

Installed condition of ignition coil.


Defective ignition coil.

Improperly installed ignition coil

→

Measure the primary coil resistance of the ignition coil.

Replace if out of specification.


IGNITION COIL” on page

9-98.

Reinstall or replace the ignition coil.



→



→

Go to item 4.



→



→

Go to item 5.



→



→

Go to item 6.

6 Malfunction in ECU.


No spark

→

Replace the

ECU.

9-48


Fault code No.

37

A

Component other than ISC (idle speed control) unit is defective (ISC operating sound is heard).

Item

B

Defective ISC (idle speed control) unit (ISC operating sound is not heard).



Actuation



54

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

Item

The operating sound can be heard when ISC valve operates.


Maintenance job


1

2

3

4

Locate the malfunction.

Incorrect speed sensor signal.

Throttle valve does not fully close.

ISC valve is not moving correctly.


Fully closes the ISC (idle speed control) valve, and then fully opens the valve.

Check the speed sensor.


Rotate the rear wheel by hand and check that the indicated value increases.

Value does not increase

→

Go to fault code No. 42.

Check the throttle body.


Check the throttle cable.


ACCELERATOR PEDAL

FREE PLAY” on page 3-21.

Replace the throttle body assembly.

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.



→



→

Go to item 3.



→



→

Go to item 4.



→



→

Go to item 5.


Replace the ECU.

9-49


TIP

• Do not remove the ISC (idle speed control) valve.


“21” first.


“22” first.


“46” first.


“42” first.

Fault code No.

37

A

Component other than ISC (idle speed control) unit is defective

(ISC operating sound is heard).

Item

B

Defective ISC (idle speed control) unit (ISC operating sound is not heard).





54

Actuation

Procedure

Item

1



2

3

Connection of ISC (idle

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.



speed control) unit coupler.






Maintenance job


Fully closes the ISC (idle speed control) valve, and then fully opens the valve.



Improperly connected ness.

→

→

Connect the coupler securely or replace the wire har-



→

Go to item 2 in section A for the component other than

ISC (idle speed control) unit is defective.


→

Go to item 2.



→

Go to item 8.


→

Go to item 3.



→

Go to item 8.


→

Go to item 4.

9-50


7

8

Fault code No.

Item

4

5

6

37

A

Component other than ISC (idle speed control) unit is defective

(ISC operating sound is heard).


Installed condition of ISC

(idle speed control) unit.


B

ISC valve is not moving correctly.

Defective ISC (idle speed control) unit (ISC operating sound is not heard).


→


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



→

Go to item 8.


→

Go to item 5.

Improperly installed ISC (idle speed control) unit

→

Reinstall the ISC (idle speed control) unit.

Replace the throttle body assembly.



→

Go to item 8.


→

Go to item 6.



→

Go to item 8.


→

Go to item 7.

Malfunction in ECU.

Replace the ECU.

Delete the fault code.


Check that the fault code number is not displayed.

TIP

• Do not remove the ISC (idle speed control) valve.


“21” first.


“22” first.


“46” first.


“42” first.

9-51


Fault code No.

39

Item Injector: open or short circuit detected.

5

6



Actuation

Procedure

Item

1


Connection of injector coupler.



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.

Check that injector is actuated five times by listening for the operating sound.


→


Maintenance job



Operating sound

→

Go to item 6.

No operating sound

→

Go to item 2.

2

3

4

Defective injector.







36

Measure the injector resistance.

Replace if out of specification.


FUEL INJECTOR” on page

9-106.


→



Operating sound

→

Go to item 6.

No operating sound

→

Go to item 3.


Operating sound

→

Go to item 6.

No operating sound

→

Go to item 4.

Malfunction in ECU.



→


Between injector coupler and

ECU coupler.

red–red

Between injector coupler and joint coupler.

red/blue–red/blue

Replace the ECU.


Operating sound

→

Go to item 6.

No operating sound

→

Go to item 5.



9-52


Fault code No.

41

Item Lean angle sensor: open or short circuit detected.



5



08

Indicated

Procedure

Item

1


Connection of lean angle sensor coupler.




• 3.6–4.4 (upright)

• 0.7–1.3 (overturned)


Maintenance job


→





”


→



→

Go to item 2.

2

3






→


Open or short circuit place 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

→

Reblack/blue–black/blue


ECU coupler.





→



→

Go to item 3.




→



→

Go to item 4.

4 Defective lean angle sensor.



→

Check the lean angle sensor.



LEAN ANGLE SENSOR” on page 9-100.

Malfunction in ECU.

Replace the ECU.




→



→

Go to item 5.

9-53


Fault code No.

42

Item

Speed sensor: no normal signals are received from the speed sensor.





07

Indicated

Procedure

Item

1


Connection of speed sensor coupler.



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.


→


Maintenance job



(on), and then rotate the rear wheel by hand.


→

Go to item 6.


→

Go to item 2.

2

3






→





→

Go to item 6.


→

Go to item 3.




→

Go to item 6.


→

Go to item 4.

4 Defective speed sensor.


→


Between speed sensor coupler and ECU coupler.

white–white

Between speed sensor coupler and joint coupler.



ECU coupler.



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.




→

Go to item 6.


→

Go to item 5.

9-54


Fault code No.

Item

5

6

Malfunction in ECU.


42

Speed sensor: no normal signals are received from the speed sensor.

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).


TIP


“42” first.

Fault code No.

43

Item

Fuel system voltage: incorrect voltage supplied to the fuel injector and fuel pump.



09

50

Item

1



09, 50

Indicated

Procedure

Actuation

Procedure


Connection of fuel injection system relay coupler.



Fuel system voltage (battery voltage)

Approximately 12.0

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.)

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 is actuated five times by listening for the operating sound.


→


Maintenance job




→



→

Go to item 2.

9-55


Fault code No.

Item

2

3

4

5

6

43




Fuel system voltage: incorrect voltage supplied to the fuel injector and fuel pump.


→




→



→

Go to item 3.



→


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


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



→



→

Go to item 4.

Defective fuel injection system relay.

Defective fuel injection system relay.


No operating sound

→

Replace the fuel injection system relay.


Fuel system voltage is below 3 V

→




→



→

Go to item 5.



→



→

Go to item 6.

Malfunction in ECU.

Replace the ECU.

Fault code No.

Item



44

EEPROM fault code number: an error is detected while reading or writing on EEPROM.



60

9-56


Fault code No.

44

Item

EEPROM fault code number: an error is detected while reading or writing on EEPROM.

Indicated

Procedure

Item

—


1

2


The fault code No. 44 detected EEPROM errors are indicated.

00 indication: Normal status

“01” is indicated in diagnostic mode (code No. 60). EE-

PROM data error for adjustment of CO concentration.

Maintenance job


01 indication: Go to item 2

Change the CO concentration, and rewrite in EE-

PROM.


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).

—



(on).

”


→



→

Repeat item 1. If the same number is indicated, go to item 3.


Replace the ECU.

Fault code No.

46

Item Charging voltage is abnormal.



Indicated

Procedure

Item

—


1 Malfunction in charging system.



—

—

Maintenance job

Check the charging system.

Refer to “CHARGING SYS-

TEM” on page 9-11.

Defective rectifier/regulator or AC magneto

→

Replace.

Defective connection in the charging system circuit

→





→



→

Repeat the maintenance job.

TIP


“46” first.

9-57


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.)



Indicated

Procedure

Item

1

—

—


Malfunction in ECU.



—

Maintenance job

Replace the ECU.



(on).


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.



Indicated

Able to start engine (unable when ECU is malfunctioning)

Able to drive vehicle (unable when ECU is malfunctioning)

—

—

Procedure

Item

—


1 Connection of meter assembly coupler.



Maintenance job


→




(on).


→



→

Go to item 2.

2

3






→



(on).


→

Go to item 3.

”


→



→


Between meter assembly coupler and ECU coupler.

yellow/blue–yellow/blue


(on).


→



→

Go to item 4.

9-58


Fault code No.

Item

4

5

Er-1

ECU (engine control unit) internal malfunction (output signal error): signals cannot be transmitted between the ECU and the multi-function meter.

Defective meter assembly.

Malfunction in ECU.

Replace the meter assembly. Turn the main switch to “ ”

(on).


→



→

Go to item 5.

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.




—


Indicated

Procedure

Item

1

—

—


Connection of meter assembly coupler.




→


Maintenance job

2

3






→


4 Defective meter assembly.



(on).


→



→

Go to item 2.


(on).

”


→



→

Go to item 3.


→ place the wire harness.

Re-




(on).


→



→

Go to item 4.

Replace the meter assembly. Turn the main switch to “

”

(on).


→



→

Go to item 5.

9-59


Fault code No.

Item

Er-2

ECU (engine control unit) internal malfunction (output signal error): no signals are received from the ECU within the specified duration.

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.



Indicated

Procedure

Item

—


1

2



—

—









→


→


Maintenance job

3

4

5



Malfunction in ECU.



(on).


→



→

Go to item 2.


(on).

”


→



→

Go to item 3.



Re-




(on).


→



→

Go to item 4.


(on).


→



→

Go to item 5.

Replace the ECU.

9-60


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.




—


Indicated

Procedure

Item

1

—

—






→


Maintenance job

2

3






→


4

5


Malfunction in ECU.



(on).


→



→

Go to item 2.


(on).

”


→



→

Go to item 3.



Re-




(on).


→



→

Go to item 4.


(on).


→



→

Go to item 5.

Replace the ECU.

9-61

9-62


EAS27550

FUEL PUMP SYSTEM

EAS27560

CIRCUIT DIAGRAM


Y Y

/W R/

9-63

5. Frame ground

6. Main switch

8. Battery

9. Main fuse

10.Fuel injection system fuse

13.Fuel injection system relay


33.Joint coupler

49.Fuel pump

59.Ignition fuse

B. Wire harness



9-64


EAS27570

TROUBLESHOOTING

If the fuel pump fails to operate.

TIP


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)


ES” on page 9-92.

OK

↓


→



OK

↓


→



OK

↓

4. Check the fuel injection system re-

→ lay.



OK

↓

5. Check the fuel pump.

→

Refer to “CHECKING THE FUEL

PUMP BODY” on page 7-2.

OK

↓

6. Check the entire fuel pump system

→ wiring.


OK

↓

Replace the ECU.








9-65

9-66


EAS30200

2WD/4WD SELECTING SYSTEM

EAS30210

CIRCUIT DIAGRAM


Y Y

/W R/

9-67


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


33.Joint coupler


50.Differential motor relay 2

58.Differential motor fuse

59.Ignition fuse


B. Wire harness



9-68


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


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)


ES” on page 9-92.


OK

↓


→



OK

↓


→






OK

↓

4. Check the On-Command four-

→ wheel-drive switch.

Refer to“CHECKING THE


OK

↓

5. Check the differential motor relay 1.

→



OK

↓

6. Check the differential motor relay 2.

→



OK

↓


→



OK

↓

Replace the On-Command four-wheeldrive switch.

Replace the differential motor relay 1.

Replace the differential motor relay 2.


9-69


8. Check the differential motor opera-

→ tion.

Refer to “CHECKING THE DIF-

FERENTIAL MOTOR OPERATION” on page 8-12.

OK

↓

9. Check the entire 2WD/4WD select-

→ ing system wiring.


OK

↓


Replace the differential motor.

Properly connect or replace the 2WD/4WD selecting system wiring.

The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential gear lock indicator flashes.

1. Check the differential motor posi-

→ tion switch.

Refer to “CHECKING THE DIF-

FERENTIAL MOTOR POSITION

SWITCH” on page 9-106.

Replace the differential motor.

OK

↓

2. Check the entire 2WD/4WD select-

→ ing system wiring.


OK

↓

Properly connect or replace the 2WD/4WD selecting system wiring.

Replace the ECU.

9-70

EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)

EAS30230


EAS30240

CIRCUIT DIAGRAM

( B

( B

Y Y

/W R/

9-71



5. Frame ground

6. Main switch

8. Battery

9. Main fuse

10.EPS fuse


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


B. Wire harness


D. EPS (electric power steering) control unit

9-72


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) e a d g b f g c f

a. Main switch b. EPS warning light (no malfunction detected) c. EPS warning light (malfunction detected) d.

“ ” (off) e. “

”

(on)

h i

f.

Off g. Comes on.

h. Initial lighting: 2 seconds i.

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


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 b h g j d

5

i g k c f e

A

B i

5 2

0.5

×

3

1

0.5

×

5

3 2 a. EPS self-diagnosis signal connector b. Diagnostic mode c. EPS warning light d. Disconnected e. On f.

Off g. Grounded h. Normal mode (diagnostic mode not activated) i.

Mode selection judgment j.

Present malfunction signaling mode k. Past malfunction signaling mode

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 d b e

A f

5

g

1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5

a. EPS self-diagnosis signal connector b. EPS warning light c. Disconnected d. Comes on e. Goes off f.

Grounded g. Mode selection judgment

A. The EPS warning light comes on for 5 seconds during the diagnostic mode selection judgment.

9-75


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.

a b c

T1 T1 T1 T1 T1 T2

a. EPS self-diagnosis signal connector b. Disconnected 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

41

42

43

45

52

Item

EPS torque sensor

Speed sensor

Engine speed signal

EPS motor

EPS control unit

Symptom

No normal signals are received from the torque sensor.

No normal signals are received from the speed sensor.

No normal signals are received from the ECU.

No normal signals are received from the EPS motor.

Relay contacts in the EPS control unit are welded together.

Probable cause of malfunction

• Open or short circuit in wire harness.

• Malfunction in torque sensor.

• Malfunction in EPS control unit.


• Malfunction in speed sensor.



• Malfunction in ECU.



• Malfunction in EPS motor.


Malfunction in EPS control unit.

9-76


Fault code No.

53

54

55

Item

EPS control unit

EPS control unit

EPS control unit

Symptom

Battery voltage has dropped.

Relay contacts in the EPS control unit are welded together.

Battery voltage has increased.

Abnormality exists between the

EPS and the ECU.

Probable cause of malfunction

• Faulty battery.

• Malfunction in the charging system.

Refer to “CHARGING

SYSTEM” on page

9-11.



• Malfunction in the charging system.

Refer to “CHARGING

SYSTEM” on page

9-11.


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 “DIAG-

NOSTIC MODE” on page 9-74.

Fault code No. 11,

13,

15, 16

Symptom EPS torque sensor: open or short circuit detected.

Order Item/components and probable cause

1 Connections

• EPS torque sensor coupler

2

3

Defective EPS torque sensor.

Open or short circuit in EPS torque sensor lead.

Check or maintenance job Reinstatement method

• Check the coupler for any pins that may have pulled out.

• Check the locking condition of the coupler.

• If there is a malfunction, repair it and connect the coupler securely.

• Replace if defective.

Refer to “CHECKING THE EPS

TORQUE SENSOR (for EPS models)” on page 9-107.

• 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

Turning the main switch to

“ ” (off).

9-77


Fault code No. 21 Symptom Speed sensor: open or short circuit detected.


1

2

3


Connections

• Speed sensor coupler

• EPS control unit coupler at the wire harness




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

Defective speed sensor.

• Replace if defective.


SPEED SENSOR” on page

9-102.

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 “DIAG-

NOSTIC

MODE” on page 9-74.

Fault code No. 22 Symptom No normal signals are received from the ECU.


1

2

3


Connections

• EPS control unit coupler at the wire harness

• ECU coupler at the wire harness




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

Malfunction in ECU.

Replace the ECU.


“ ” (off).

9-78


Fault code No. 41,

42,

43, 45

Symptom EPS motor: open or short circuit detected.


1 Connections

• EPS motor coupler

2

3

Open or short circuit in EPS motor lead.

Defective EPS motor.





• Replace if there is an open or short circuit.

• Between EPS motor and EPS control unit coupler.

red–red black–black


Refer to “CHECKING THE EPS

MOTOR (for EPS models)” on page 9-107.


“ ” (off).

Fault code No. 52 Symptom Relay contacts in the EPS control unit are welded together.

Check or maintenance job Order Item/components and probable cause

1 Malfunction in EPS control unit.

Replace the EPS control unit.

Reinstatement method


“ ” (off).

Fault code No. 53 Symptom Power supply to the EPS control unit is not normal (low battery voltage).


1 Faulty battery.

2

3

Malfunction in rectifier/regulator or charging system.


Check or maintenance job

Replace or charge the battery.




Refer to “CHECKING THE REC-

TIFIER/REGULATOR” on page

9-101.




“ ” (off).

9-79


Fault code No. 54 Symptom Relay contacts in the EPS control unit are welded together.

Check or maintenance job Order Item/components and probable cause

1 Malfunction in EPS control unit.




“ ” (off).

Fault code No. 55 Symptom Power supply to the EPS control unit is not normal (high battery voltage).

Malfunction in control unit.


1 Faulty battery.

2

3

Malfunction in rectifier/regulator.


Check or maintenance job

Replace the battery.




Refer to “CHECKING THE REC-

TIFIER/REGULATOR” on page

9-101.




“ ” (off).

9-80

ELECTRICAL COMPONENTS

EAS27972


4

5

6

7

8

3

9

2

10

11

12

1

13

20

14

19

18

17

16

15

9-81

1. Radiator fan motor


3. Parking brake switch

4. Ignition coil


6. TPS (throttle position sensor)

7. Fuel injector

8. ISC (idle speed control)

9. Air induction system solenoid


11. Reverse switch


13. Speed sensor



16. Fuel sender

17. Fuel pump

18. Seat belt switch


20. Differential motor


9-82


3

2

4

5

6

7

1

14

13

12

11

10

9

8

9-83

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)




9-84

1

2

3

6

5

4


8

19 18

17

16

15

14

12

13

12

11

10

8

9

7

9-85




4. Headlight relay




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


16. Auxiliary DC jack fuse

17. Differential motor fuse

18. Ignition fuse

19. Backup fuse


9-86


EAS27980

CHECKING THE SWITCHES

1

Br Y

(B)

2

L/R B

3

(off)

(on)

(start)

Br/R R/B L/Y Br/R

4

2WD

4WD

DIFF LOCK

L/W B G/R

L/W G/R

B

5

G/W

9

OFF

ON

Br P

8

(off)

Br L Y

7

L B

6

L W

Gy

(B)

9-87



3. Main switch


5. Reverse switch


7. Seat belt switch

8. Light switch

9. Horn switch (for Europe and Oceania)


9-88


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


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

“

“ ” (on).

”. There is continuity between the brown/red and red/black leads when the switch is set to

b

Br/R R/B L/Y Br/R

a

(off)

(on)

(start)

Br/R R/B

L/Y Br/R

9-89


EAS27990

CHECKING THE BULBS AND BULB

SOCKETS

TIP

Do not check any of the lights that use LEDs.

Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals.

Damage/wear

→

Repair or replace the bulb, bulb socket or both.


→

Properly connect.

No continuity

→

Repair or replace the bulb, bulb socket or both.

Types of bulbs

The bulbs used on this vehicle are shown in the illustration.

• 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.

EWA1XD1018

WARNING

Since headlight bulbs get extremely hot, keep flammable products and your hands away from them until they have cooled down.

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.

2. Check:

• Bulb (for continuity)


No continuity

→

Replace.

Pocket tester

90890-03112


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


Checking the condition of the bulb sockets

The following procedure applies to all of the bulb sockets.

1. Check:

• Bulb socket (for continuity)


No continuity

→

Replace.

Pocket tester

90890-03112


YU-03112-C

TIP

Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following.

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Install a good bulb into the bulb socket.

b. Connect the pocket tester probes to the 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.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

EAS21790

REPLACING THE HEADLIGHT BULBS

The following procedure applies to both of the headlight bulbs.

1. Remove:

• Headlight rear cover “1”

1

3. Disconnect:

• Headlight coupler “1”

1

2

1

4. Remove:

• Headlight bulb holder “1”

• Headlight bulb “2”

EWA13320

WARNING

Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

TIP

Unhook the headlight bulb holder, and then remove the defective bulb.

2. Remove:

• Headlight bulb holder cover “1”

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.

6. Install:

• Headlight bulb holder

7. Connect:

• Headlight coupler

9-91


8. Install:

• Headlight bulb holder cover

ECA1XD1049

NOTICE

Make sure the headlight bulb holder cover is securely fitted over the bulb holder and seated properly.

TIP

Pass the headlight lead “1” through the slot “a” in the headlight unit as shown, and then reinstall the bulb holder cover.

1

9. Install:

• Headlight rear cover

a

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”.


Headlight beam is raised.


Headlight beam is lowered.

EAS28000

CHECKING THE FUSES

The following procedure applies to all of the fuses.

ECA1XD1050

NOTICE

To avoid a short circuit, always turn the main switch to “ ” (off) when checking or replacing a fuse.

1. Remove:

• Hood


2. Check:

• Fuse

No.

Fuses

Amperage rating

Q’ty

12

13

14

8

9

10

11

1 EPS (for EPS models) 40.0 A

2

3

Main

Radiator fan motor

40.0 A

25.0 A

4

5

Headlight

Backup

6 Fuel injection system

7 Ignition

15.0 A

10.0 A

10.0 A

10.0 A

Differential motor

Signaling system

Auxiliary DC jack

Spare

Spare

10.0 A

10.0 A

10.0 A

25.0 A

15.0 A

Spare 10.0 A

1

1

1

1

1

1

1

1

1

1

1

1

2

2 1

6 a b

▲ ▲▲▲ ▲ ▲▲▲ ▲

1

▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

11 13 3

12

14

5 7 8 10 9 4

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester to the fuse and check the continuity.

TIP

Set the pocket tester selector to “

Ω ×

1”.

9-92


Pocket tester

90890-03112


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.

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

▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲


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.

• 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.

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.

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.

1. Remove:

• Hood


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

2


D. These values vary with the temperature, the condition of the battery plates, and the electrolyte level.

1

3. Remove:

• Battery

4. Check:

• Battery charge

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Connect a pocket tester to the battery terminals.

• Positive tester probe

→ positive battery terminal

• Negative tester probe

→ negative battery terminal

TIP

• 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.

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)


B. Charging condition of the battery (%)

C. Ambient temperature 20 °C (68 °F)

▲ ▲▲▲ ▲ ▲▲▲ ▲

5. Charge:

• Battery

▲ ▲▲▲ ▲ ▲▲▲

(refer to the appropriate charging method)

EWA13300

WARNING

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.

9-94


• 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


B. Time (minutes)

C. Charging

D. Ambient temperature 20 °C (68 °F)

E. Check the open-circuit voltage.

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼

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.

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.

TIP

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.

d. Charge the battery until the battery’s charging voltage is 15 V.

2

9-95

8. Check:

• Battery terminals

Dirt

→

Clean with a wire brush.

Loose connection

→

Connect properly.

9. Install:

• Hood


EAS28040

CHECKING THE RELAYS

Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, replace the relay.

Pocket tester

90890-03112


YU-03112-C

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.


→

Replace.

Starter relay

3

R

Br/B

R/Y L/Y

B

2 1

4

1. Positive battery terminal

2. Negative battery terminal

3. Positive tester probe

4. Negative tester probe

Result

Continuity

(between “3” and “4”)

Load control relay

3

4

2

B

Br/L

R

Br/R

1

+





Result

Continuity



Headlight relay

First step:

1

3

2

B G

Y

L

Y




Second step:

3

5

4

2

Result

Continuity


No continuity


1

+

B G

Y

L

Y






Result

No continuity


Continuity


9-96

Radiator fan motor relay

R/L

R

Br/R





Result

Continuity


Fuel injection system relay

3

4

2

Br/R

1





Result

Continuity



Differential motor relay 1

First step:

1

3

2

Y/B B Br/R

Br/R

B/Y




Result

Continuity


No continuity


Second step:

3

5

4

2

Y/B B Br/R

Br/R

B/Y

1

+






Result

No continuity


Continuity


9-97

Differential motor relay 2

First step:

1

3

2

G/R B Br/R

Br/R

Br/B




Result

Continuity


No continuity


Second step:

3

5

4

2

G/R B Br/R

Br/R

Br/B

1

+






Result

No continuity


Continuity


EAS28060

CHECKING THE SPARK PLUG CAP

1. Check:

• Spark plug cap resistance


→

Replace.

Resistance

7.5–12.5 k

Ω

9-98


▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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.

Pocket tester

90890-03112


YU-03112-C

c. Measure the spark plug cap resistance.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

EAS28090

CHECKING THE IGNITION COIL

1. Check:

• Primary coil resistance


→

Replace.

Primary coil resistance

2.16–2.64

Ω

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the ignition coil connectors from the ignition coil terminals.


Ω ×

1) to the ignition coil as shown.

Pocket tester

90890-03112


YU-03112-C


→ brown/red “1”


→ orange “2”


c. Measure the primary coil resistance.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲

2. Check:

• Secondary coil resistance


→

Replace.

▲ ▲▲▲ ▲▲▲

Secondary coil resistance

8.64–12.96 k

Ω

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Disconnect the spark plug cap from the ignition coil.


Ω ×

1k) to the ignition coil as shown.

Pocket tester

90890-03112


YU-03112-C


→ brown/red “1”


→

Spark plug lead “2”

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.

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the spark plug cap from the spark plug.

b. Connect the ignition checker “1” as shown.

Ignition checker

90890-06754

Oppama pet–4000 spark checker

YM-34487

c. Measure the secondary coil resistance.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

EAS28930

CHECKING THE IGNITION SPARK GAP

1. Check:

• Ignition spark gap


→

Perform the ignition system troubleshooting, starting with step 5.

2. Spark plug cap 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


→


Crankshaft position sensor resistance

408.0–612.0

Ω

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ a. Connect the pocket tester (

Ω ×

▼▼▼

100) to the crankshaft position sensor coupler as shown.

9-99

Pocket tester

90890-03112


YU-03112-C


→ gray “1”


→ black “2”



→ yellow/green (wire harness color)


→ black/blue (wire harness color)

1

65˚ 65˚

Gy

B

1 2

b. Measure the crankshaft position sensor resistance.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

EAS28130

CHECKING THE LEAN ANGLE SENSOR

1. Remove:

• Lean angle sensor

2. Check:

• Lean angle sensor output voltage


→

Replace.

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).

Test harness-lean angle sensor

(3P)

90890-03213

YU-03213

Pocket tester

90890-03112


YU-03112-C

c. Turn the main switch to “ ” (on).

d. Turn the lean angle sensor to 65°.

e. Measure the lean angle sensor output voltage.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

EAS28940

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.

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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.

9-100


b. Check the starter motor operation.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

EAS28150

CHECKING THE STATOR COIL

1. Disconnect:

• Stator coil couplers


2. Check:

• Stator coil resistance


→


Stator coil resistance

0.09–0.13

Ω

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Connect the digital circuit tester to the stator coil coupler as shown.


90890-03174


YU-A1927


→ white “1”


→ white “2”


→ white “1”


→ white “3”


→ white “2”


→ white “3”

W W W

3 2 1

b. Measure the stator coil resistance.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

EAS28170

CHECKING THE RECTIFIER/REGULATOR

1. Check:

• Charging voltage


→

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.

Pocket tester

90890-03112


YU-03112-C


→ positive battery terminal “1”


→ negative battery terminal “2”

1

2

c. Start the engine and let it run at approximately 5000 r/min.

d. Measure the charging voltage.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

EAS28230

CHECKING THE FUEL SENDER

1. Disconnect:

• Fuel pump coupler


2. Remove:

• Fuel pump assembly

(from the fuel tank)

3. Check:

• Fuel sender resistance


→


9-101


Sender unit resistance (full)

19.0–21.0

Ω

Sender unit resistance (empty)

139.0–141.0

Ω


Ω ×

▼ ▼▼▼ ▼▼▼

10 or

Ω ×

100) to the fuel sender terminals as shown.

Pocket tester

90890-03112


YU-03112-C


→ orange/black “1”


→ black/white “2” c. Measure the fuel sender resistance.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

EAS29040

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)

→


1

R/L B B/W O/B

1 2

b. Move the fuel sender float to minimum “3” and maximum “4” level positions.

4

3

EAS28240

CHECKING THE SPEED SENSOR

1. Check:

• Speed sensor output voltage


→

Replace.

Output voltage reading cycle

0.6 V–4.8 V–0.6 V–4.8 V–0.6 V

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 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


YU-03112-C

9-102


→ white (wire harness color)



1


EAS1XD1128

CHECKING THE RADIATOR FAN MOTOR

CIRCUIT BREAKER

1. Remove:

• Radiator fan motor circuit breaker

(from the wire harness) 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.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

EAS28250

CHECKING THE RADIATOR FAN MOTOR

1. Check:

• Radiator fan motor

Faulty/rough movement

→

Replace.

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ 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”

2. Check:

• Radiator fan motor circuit breaker resistance


→

Replace the radiator fan motor circuit breaker.

Radiator fan motor circuit breaker resistance

0–0.05

Ω

at 25 °C (77 °F)

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the digital circuit tester to the radiator fan motor circuit breaker as shown.


90890-03174


YU-A1927

c. Check the radiator fan motor movement.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲ b. Measure the radiator fan motor circuit breaker resistance.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

EAS28260

CHECKING THE COOLANT TEMPERATURE

SENSOR

1. Remove:


9-103


EWA14130

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


→

Replace.

Coolant temperature sensor resistance

2.32–2.59 k

Ω

at 20 °C (68 °F)

310–326

Ω

at 80 °C (176 °F)


Ω ×

▼ ▼▼▼ ▼▼▼

1k or

Ω ×

100) to the coolant temperature sensor terminals as shown.

Pocket tester

90890-03112


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.

c. Place a thermometer “3” in the coolant.

3

EAS28300

CHECKING THE THROTTLE POSITION

SENSOR

1. Remove:


(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.

2. Check:

• Throttle position sensor maximum resistance


→


Resistance

2.64–6.16 k

Ω


Ω ×

▼▼▼

1k) to the throttle position sensor terminals as shown.

Pocket tester

90890-03112


YU-03112-C


→ blue “1”


→ black/blue “2”

1

2

d. Heat the coolant or let it cool down to the specified temperatures.

e. Measure the coolant temperature sensor resistance.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲

3. Install:


▲ ▲▲▲ ▲▲▲

.

T

R

.

Coolant temperature sensor

18 Nm (1.8 m·kgf, 13 ft·lbf)

b. Measure the throttle position sensor maximum resistance.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲

3. Install:


9-104


TIP

When installing the throttle position sensor, ad-

just its angle properly. Refer to “ADJUSTING

THE THROTTLE POSITION SENSOR” on page

7-12.

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


→

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


YU-03112-C


→ pink (wire harness color)



1

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


→

Replace.

Intake air temperature sensor resistance

5.40–6.60 k

Ω

at 0 °C (32 °F)

290–390

Ω

at 80 °C (176 °F)


Ω ×

1k or

Ω ×

▼▼▼

100) to the intake air temperature sensor terminals as shown.

Pocket tester

90890-03112


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


3

1

1

2

d. Heat the water or let it cool down to the specified temperatures.

e. Measure the intake air temperature sensor resistance.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

EAS1XD1004

CHECKING THE FUEL INJECTOR

1. Check:

• Fuel injector resistance


→

Replace the fuel injector.

Fuel injector resistance

11.5–12.5

Ω

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼▼▼ a. Disconnect the fuel injector coupler from wire harness.


Ω ×

1) to the fuel injector terminals as shown.

Pocket tester

90890-03112


YU-03112-C


Injector terminal “1”


Injector terminal “2”

2

EAS28370


SOLENOID

1. Check:

• Air induction system solenoid resistance


→

Replace.

Solenoid resistance

20–24

Ω

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the air induction system solenoid coupler from the wire harness.


Ω ×

1) to the air induction system solenoid terminals as shown.

Pocket tester

90890-03112


YU-03112-C


→

Air induction system solenoid terminal “1”


→

Air induction system solenoid terminal “2”

2

1

c. Measure the air induction system solenoid resistance.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲

EAS1XD1037

CHECKING THE DIFFERENTIAL MOTOR

POSITION SWITCH

1. Check:

• Differential motor position switch


→

Replace.

Pocket tester

90890-03112


YU-03112-C

c. Measure the fuel injector resistance.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲

9-106


TIP

Check the differential motor position switch for continuity between the terminals “1” and “3” and between the terminals “2” and “3” when the On-

Command four-wheel-drive switch is set to the

“2WD”, “4WD”, and “DIFF LOCK” positions.

2WD position

No continuity



4WD position

Continuity


No continuity


DIFF LOCK position

Continuity


No continuity


TIP

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


→

red “1”


→

EPS motor body “3”

No continuity


→

black

“2”


→

EPS motor body “3”

2

1

3

B R

1 2 3

▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ 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


→

Replace the EPS unit.

9-107


Ω ×

▼▼▼

1) to the EPS motor coupler terminal and EPS motor body.

Pocket tester

90890-03112


YU-03112-C

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


→

Replace the steering column.

EPS torque sensor

Coil resistance

0.875–1.625 k

Ω

(for EPS models)


Ω ×

▼ ▼▼▼ ▼▼▼

1k) to the EPS torque sensor coupler terminals as shown.

Pocket tester

90890-03112


YU-03112-C


→ red “1”


→ black “2”

2

G R

B W

1

b. Measure the EPS torque sensor resistance.

▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲▲▲


9-108

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

EAS28451

TROUBLESHOOTING

EAS28460


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

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

10-1

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

EAS28490

INCORRECT ENGINE IDLING SPEED

Engine

1. Cylinder and cylinder head

• Incorrect valve clearance

• Damaged valve train components

2. Air filter


Fuel system

1. Throttle body

• Damaged or loose throttle body joint

• Improper throttle cable free play

• Flooded throttle body

• Faulty air induction system


1. Battery

• Discharged battery

TROUBLESHOOTING

• Faulty battery

2. Spark plug



• 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


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

FAULTY GEAR SHIFTING

Shifting is difficult

Refer to “FAULTY CLUTCH” on page 10-3.

EAS1XD1001

SHIFT LEVER DOES NOT MOVE

Shift drum and shift forks

• Foreign object in a shift drum groove

• Seized shift fork

• Bent shift fork guide bar

Transmission

• Seized transmission gear

• Foreign object between transmission gears

• Improperly assembled transmission

EAS28550

JUMPS OUT OF GEAR

Shift forks

• Worn shift fork

Shift drum

• Incorrect axial play

• Worn shift drum groove

Transmission

• Worn gear dog

10-2

EAS28580

FAULTY CLUTCH

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

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


• Faulty operation

• Worn pin groove

• Worn pin

3. Clutch shoe

• Bent, damaged or worn clutch shoe

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


• Worn primary sliding sheave

5. Secondary fixed sheave

• Worn secondary fixed sheave

6. Secondary sliding sheave

• Worn secondary sliding sheave

TROUBLESHOOTING

EAS28600

OVERHEATING

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

Fuel system

1. Throttle body

• Faulty throttle body

• Damaged or loose throttle body joint

2. Air filter


Chassis

1. Brake(s)

• Dragging brake


1. Spark plug



2. Ignition system

• Faulty ECU

3. Radiator fan

• Faulty fan motor

• Disconnected circuit breaker terminal

• Faulty coolant temperature sensor

10-3

TROUBLESHOOTING

EAS28610

OVERCOOLING

Cooling system

1. Thermostat

• Thermostat stays open

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

EAS1XD1129

FAULTY SHOCK ABSORBER ASSEMBLY

Leaking oil

• Bent, damaged or rusty damper rod

• Cracked or damaged shock absorber

• Damaged oil seal lip

Malfunction

• Fatigued or damaged shock absorber spring

• Bent or damaged damper rod

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

6. Frame

• Bent frame

• Damaged frame

EAS28710

FAULTY LIGHTING OR SIGNALING SYSTEM

Headlight does not come on

• Wrong headlight bulb

• Too many electrical accessories

• Hard charging

• Incorrect connection


• Poor contacts (main or light switch)

• Burnt-out headlight bulb

Headlight bulb burnt out

• Wrong headlight bulb

• Faulty battery

• Faulty rectifier/regulator


• Faulty main switch

• Faulty light switch

• Headlight bulb life expired

Tail/brake light does not come on

• Wrong tail/brake light bulb

• Too many electrical accessories

• Incorrect connection

• Burnt-out tail/brake light bulb

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


SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS1XD1002


Self-diagnostic function table

Fault code No.

Item

Reference pages

12

13

14

33

37

39

41

42

15

16

21

22

30

43

44

46

50

Crankshaft position sensor: no normal signals are received from the crankshaft position sensor.

Intake air pressure sensor: open or short circuit detected.

Intake air pressure sensor: hose system malfunction (clogged or detached hose).

Throttle position sensor: open or short circuit detected.

Throttle position sensor: stuck throttle position sensor is detected.

Coolant temperature sensor: open or short circuit detected.

Intake air temperature sensor: open or short circuit detected.

Latch up detected.

Ignition coil: open or short circuit detected in the primary lead of the ignition coil.

Component other than ISC (idle speed control) unit is defective (ISC operating sound is heard).

Defective ISC (idle speed control) unit (ISC operating sound is not heard).

Injector: open or short circuit detected.

Lean angle sensor: open or short circuit detected.

Speed sensor: no normal signals are received from the speed sensor.

Fuel system voltage: incorrect voltage supplied to the fuel injector and fuel pump.

EEPROM fault code number: an error is detected while reading or writing on EEPROM.

Charging voltage is abnormal.

Faulty ECU (engine control unit) memory. (When this malfunction is detected in the ECU, the fault code number might not appear.)

9-38

9-39

9-41

9-42

9-43

9-44

9-45

9-47

9-47

9-49

9-50

9-52

9-53

9-54

9-55

9-56

9-57

9-58

10-5


Communication error with the meter

Fault code No.

Er-1

Er-2

Er-3

Er-4

Item

ECU (engine control unit) internal malfunction (output signal error): signals cannot be transmitted between the ECU and the multi-function meter.

ECU (engine control unit) internal malfunction (output signal error): no signals are received from the ECU within the specified duration.

ECU (engine control unit) internal malfunction (output signal error): data from the ECU cannot be received correctly.

ECU (engine control unit) internal malfunction (input signal error): non-registered data has been received from the meter.

Reference pages

9-58

9-59

9-60

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.


01

Item


• Fully closed position

Display Procedure

03

05

06

07

Intake air pressure

Intake air temperature

Coolant temperature

Vehicle speed pulse

14–20


When engine is cold: Displays temperature closer to ambient temperature.

When engine is hot: Displays ambient temperature

20 °C (68 °F).

When engine is cold: Displays temperature closer to ambient temperature.

When engine is hot: Displays current coolant temperature.

0–999



Compare the actually measured intake air temperature with the display value.

Compare the actually measured coolant temperature with the display value.

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



08

09

21

60

61

Item Display Procedure

Lean angle sensor

• Upright

• Overturned

Fuel system voltage (battery voltage)


3.6–4.4

0.7–1.3

Approximately 12.0


Gear position switch

• Transmission is in neutral

ON

• Transmission is in gear OFF

EEPROM fault code display

• No history

• History exists

00

• No malfunctions detected (If the fault code 44 is indicated, the ECU is defective.)

01 (Cylinder fault code)

Malfunction history code display

• No history

• History exists

00

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.)

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.

—

—

—

10-7



62

Item

Malfunction history code erasure

• No history

• History exists

Display Procedure

00

• 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.)

0–254 [-]

—

Save the malfunction history to the computer, and then delete the fault codes.

— 70 Control number

Diagnostic code: actuator operation table


Item

30

36

48

Ignition coil

Injector

Air induction system solenoid

Actuation Procedure

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.

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 a spark is generated five times.

• Connect an ignition checker.

Check that the injector is actuated five times by listening for the operating sound.

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



50

51

54

Item Actuation Procedure

Fuel injection system relay Actuates the fuel injection system relay five times at one-second intervals.


(When the relay is on, the

“CHECK” indicator and

“ ” on the Yamaha diagnostic tool screen go off.

When the relay is off, the


“ ” on the Yamaha diagnostic tool screen come on.)

Radiator fan motor relay Actuates the radiator fan motor relay five times at five-second intervals. (2 seconds on, 3 seconds off)


(When the relay is on, the


“ ” on the Yamaha diagnostic tool screen go off.

When the relay is off, the


“ ” on the Yamaha diagnostic tool screen come on.)

ISC valve Actuates and fully closes the ISC valve, then opens it to the stand-by opening position when the engine is started.

This operation takes approximately 3 seconds until it is completed.


Check that the fuel injection system relay unit is actuated five times by listening for the operating sound.

Check that the radiator fan motor relay is actuated five times by listening for the operating sound.


10-9

EAS28740

WIRING DIAGRAM

YX70ME/YX70MHE/YX70MNE/

YXM700DE 2014


2. AC magneto



5. Frame ground

6. Main switch

7. Engine ground

8. Battery

9. Main fuse


11. Starter relay

12. Starter motor







19. Yamaha diagnostic tool coupler



22. Ignition coil

23. Spark plug

24. Fuel injector



27. Speed sensor





32. Reverse switch

33. Joint coupler



36. Helmet indicator light

37. Seat belt indicator light

38. Meter assembly

39. Multi-function meter


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


51. Light switch

52. Headlight relay

53. Headlight



56. Tail/brake light



59. Ignition fuse

60. Backup fuse


62. Headlight fuse





67. Horn switch (for Europe and

Oceania)


69. Backup light

70. Backup light relay

A. Optional

B. Wire harness


EAS28750

COLOR CODE

G/Y

Gy/G

L/B

L/R

L/W

L/Y

O/B

O/L

B/Y

Br/B

Br/L

Br/R

Br/W

Br/Y

G/R

G/W

R

Sb

W

Y

B/G

B/L

B/R

B/W

L

Lg

O

P

B

Br

G

Gy

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


2. AC magneto



5. Frame ground

6. Main switch

7. Engine ground

8. Battery

9. Main fuse

10. EPS fuse


12. Starter relay

13. Starter motor







20. Yamaha diagnostic tool coupler



23. Ignition coil

24. Spark plug

25. Fuel injector



28. Speed sensor





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



42. Helmet indicator light

43. Seat belt indicator light

44. Meter assembly

45. Multi-function meter


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


58. Light switch

59. Headlight relay

60. Headlight



63. Tail/brake light



66. Ignition fuse

67. Backup fuse


69. Headlight fuse





74. Horn switch (for Europe and

Oceania)


76. Backup light

77. Backup light relay

A. Optional

B. Wire harness


D. EPS (electric power steering) control unit

EAS1XD1042

COLOR CODE

G/Y

Gy/G

L/B

L/R

L/W

L/Y

O/B

O/L

B/Y

Br/B

Br/L

Br/R

Br/W

Br/Y

G/R

G/W

R

Sb

W

Y

B/G

B/L

B/R

B/W

L

Lg

O

P

B

Br

G

Gy

W/B

W/G

W/R

Y/B

Y/G

Y/L

Y/R

Y/W

O/W

P/L

P/W

R/B

R/G

R/L

R/W

R/Y

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


YXM700DE 2014 WIRING DIAGRAM

YX70ME/YX70MHE/

YX70MNE/YXM700DE 2014

SCHÉMA DE CÂBLAGE

L B

B R/W

B

R/W

R/W

L

64

B Br

67

OFF

ON

Br

P

Br/Y B

Br/Y

B

68

A

L Br/Y

(B)

69

W B

(B)

B

W

L

Br/Y

L

B

Br/Y

G/W

70

Br/Y L

B

G/W

W W

(Gy)

W

(Gy)

B/L

Gy

Gy B

1

W W

(Gy)

W

(Gy)

Gy B/L

2

B

W W

W W

W W

W W W

(Gy)

3

B

(B)

R

R

B

Br/Y

14

Br/Y R/W

(B)

R/W

R

Br/R

66

Br/R

R

R/L

Y/R

R/L

Y/R

R/L

4

R

Br/R

Br/R

R

Br/L

B

Br/L

B

5

B B B

B

R/B Br/R

6

(off)

(on)

(start)

Br/R R/B

L/Y

Br/R

(B)

Br/R L/Y

R

R

R

9

R

R

8

R

B A B

B

R

Br/B

10

11

L/Y

R/Y

B

12

Br/B

R/Y L/Y

(B)

7

13

Br/B

Br/R

Br/R

Br/B

R/L

L/R

R/L

R/L

L/R

R/Y

Y/R

R/W L/B R/G G/R W/G Y/B

B P/L L/B Br/L

R

O

(B)

Lg

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

G/Y R/L G/W Y L/Y Y/L Y W/R B/R L B/L L/W R/W

(B)

R/W

R/W

B/W R/W

Y/W

W/G R/W

Br/L R/W

R/G

P/L

(B)

20

R/G

P/L

W/G

Br/L

R/W

19

Y/W

B/W

15

Br/R

Br/R

B/Y

P/W B/G

O/L B/Y

16

W/B

Br/B B/R

Gy/G

Sb W/R

17 L Gy W

B/Y

Br/R

Br/R B Y/B

Y/B

B

B/G P/W W/B B/R B O/L Br/B B/Y

(B)

(Gy)

B

L W

Gy

(B)

W/R Sb

Gy/G

(B)

L/W

G/R

L/W G/R

B

(W)

18

2WD

4WD

DIFF LOCK

G/R L/W

B/W

B

B/W

Y/W

R/L

R/W

R/Y

Y/R

Y/B

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

G/W

Gy

Br/R

R/W

R/G

P/L

W/G

Br/L

21

B/W

B

31

P

B/L

Lg

L/B

Y/G

L/B

L/B

L/R

L/R B

B L/B

B

O

Br/R

O

R

Br/W

G/Y

W

L

Y

R

Br/W

24

25

G/Y

26

22

23

R/L

R/L R

(Gy)

B/L

B/L

Br/W B/L

(B)

G/Y B/L

(B)

L

W

B/L

L/Y

27

B/L

Y

L

28

W L/Y

B/L

L W

B/L

B/L Y L

(B)

L

P

B/L

29

B/L P L

(B)

L

Y/G

B/L

30

L

Y/G B/L

(Gy)

65

Br/L

R/B

Br/R

R

W/B

63

62

61

60

Br

Br/Y

Br/Y

R/W

R

59

58

57

Br/L

R

B

W/B

Y Br/Y

(B)

Br/Y

Br

(B)

Y

55

Br

54

G W/B G

Y

W/B B

B

51

(off)

Br

L Y

Y

Y

Y

Y

L

Y

G B

(B)

52

B

G

G

Y Br

L

L

L

Y L

56

Y L L

Y

56

Y G

G Y

B

Y G

B

B

53

Y G

53

G Y

B

B

Y G

B

B

50

Br/R

Br/R

Br/R

Br/B

Br/R

B G/R

G/R

B

(B)

Br/B

38

R/L O/B

49

48

B B/W

R/L B B/W O/B

(Dg)

R/W

Br/Y

O/B

40

41

42

43

44

45

46

47

39

Y/L

B/W

O/B R/W

Y/L Br/Y B/W

(B)

35

Br/Y

Br

B Br/Y

L/B

(B)

Br B

L

B

36 37

L

L/B

Lg

Lg B

34

B Lg

B

G/W

32

R/W R/W R/W R/W R/W R/W

B/L B/L B/L B/L B/L B/L

L

B/L B/L

L L L L

(B)

33

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

L

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

G/W G/W G/W Y Y 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

(B)

33

G/W

G/W

G/W

Y

Y

Y

Br/Y

Br/Y

Br/Y

Br/Y

Br/Y

Br/Y

B

B

A

B

C


YXM700DE 2014 WIRING DIAGRAM

YX70ME/YX70MHE/

YX70MNE/YXM700DE 2014


67

OFF

ON

68

A

(B)

69

(B)

70

(Gy)

1

(Gy)

2

(Gy)

(Gy)

(Gy)

3

(B)

14

(B)

66

64

65

4

(B)

(B)

(B)

20

19

5

6

(off)

(on)

(start)

(B)

A

8

9

7

10

11

12

(B)

13

63

62

61

60

59

58

57

(B)

(B)

55

54

51

(off)

(B)

52

56 56

53 53

50

(B)

15

(B)

(Gy)

16

17

(B)

(B)

(W)

18

2WD

4WD

DIFF LOCK

49

48

(Dg)

38

40

41

42

43

44

45

46

47

39

(B)

21

31

(B)

35

36 37

22

23

24

25

26

(Gy)

(B)

27

(B)

28

29

(B)

(B)

30

(Gy)

34

32

(B)

33

33

(B)

A

B C

YX70MPE/YX70MPHE/YX70MPNE/

YXM700PE/YXM700PHE

2014 WIRING DIAGRAM


YXM700PE/YXM700PHE 2014


R

Br/R

73

Br/R

R

R/L

Y/R

R/L

Y/R

R/L

L B

B R/W

B

R/W

R/W

L

71

72

4

R

Br/R

Br/R

R

Br/L

B

Br/L

B

Br/L

R/B

Br/R

R

B Br

74

OFF

ON

Br

P

Br/Y B

Br/Y

B

75

W W

(Gy)

W

(Gy)

B/L

Gy

Gy B

1

W W

(Gy)

W

(Gy)

Gy B/L

2

B

W W

W W

W W

W W W

(Gy)

3

B

(B)

R

R

B

5

B B B

B

R/B Br/R

6

(off)

(on)

(start)

Br/R R/B

L/Y

Br/R

(B)

Br/R L/Y

A

L Br/Y

(B)

76

W B

(B)

B

W

L

Br/Y

L

B

Br/Y

G/W

77

Br/Y L

B

G/W

R

R

R

8

9

B A B

B

R

R

R R

10

R

R

Br/B

11

12

L/Y

R/Y

R/B

R

R/B

B

13

Br/B

R/Y L/Y

(B)

7

14

Br/Y

R/L

R/L

L/R

Br/Y R/W

(B)

15

Br/B

Br/R

Br/R

Br/B

R/L

L/R

R/W

W/B

70

69

68

67

Br

Br/Y

Br/Y

R/W

R

66

65

64

Br/L

R

B

W/B

Y Br/Y

(B)

Br/Y

Br

(B)

Y

62

Br

61

G W/B G

Y

W/B B

B

58

(off)

Br

L Y

Y

Y

Y

Y

L

Y

G B

(B)

59

B

G

G

Y Br

L

L

L

Y L

63

Y L L

Y

63

Y G

G Y

B

Y G

B

B

60

Y G

60

G Y

B

B

Y G

B

B

R/Y O/W R/W L/B R/G G/R W/G Y/B

Y/R B P/L L/B Br/L

R

O

(B)

Lg

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

G/Y R/L G/W Y L/Y Y/L Y W/R B/R L B/L L/W R/W

(B)

R/W

R/W

R/W

B/W R/W

Y/W

20

Y/W

B/W

W/G R/W

Br/L R/W

R/G

P/L

(B)

21

R/G

P/L

W/G

Br/L

16

Br/R

Br/R

B/Y

P/W B/G

O/L B/Y

17

W/B

Br/B B/R

Gy/G

Sb W/R

18 L Gy W

B/Y

Br/R

Br/R B Y/B

Y/B

B

B/G P/W W/B B/R B O/L Br/B B/Y

(B)

(Gy)

B

L W

Gy

(B)

W/R Sb

Gy/G

(B)

L/W G/R

B

(W)

19

2WD

4WD

DIFF LOCK

L/W G/R

B

B/W

G/R L/W

B/W

G/W

Gy

Br/R

R/W

O/W

R/G

P/L

W/G

Br/L

Y/W

R/L

R/W

R/Y

Y/R

Y/B

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

22

B/W

B

32

P

B/L

Lg

L/B

Y/G

L/B

L/B

L/R

L/R B

B L/B

B

O

Br/R

O

R

Br/W

G/Y

W

L

Y

R

Br/W

25

26

G/Y

27

23

24

R/L

R/L R

(Gy)

B/L

B/L

Br/W B/L

(B)

G/Y B/L

(B)

L

W

B/L

L/Y

28

B/L

Y

L

29

W L/Y

B/L

L W

B/L

B/L Y L

(B)

L

P

B/L

30

B/L P L

(B)

L

Y/G

B/L

31

L

Y/G B/L

(Gy)

57

Br/R

Br/R

Br/R

Br/B

Br/R

B G/R

G/R

B

(B)

Br/B

G/W

33

R/W R/W R/W R/W R/W R/W

B/L B/L B/L B/L B/L B/L B/L

L L L L

B/L W W W

L

W

W

W

B/L

B/L

B/L

B/L

B/L

B/L

B/L

B/L

(B)

34

R/W

R/W

R/W

R/W

R/W

R/W

L

L

L

L

L

35

G R

B W

(Gy)

37

G R B W

36

R B

B R

(Gy)

44

R/L O/B

56

55

B B/W

R/L B B/W O/B

(Dg)

R/W

Br/Y

O/B

46

50

51

52

47

48

49

53

54

45

Y/L

B/W

O/B G/R R/W

Y/L Br/Y B/W

(B)

G/R

R G

W B

R/B

R

B

B

G

Br

R/B

(Gy)

G

(Gy)

G R B W R

B

R B

39

O

L/B Br

G W

(B)

O

G/R

W

G/R

O/W

L/B

O/W R

G/R W

L/B

(B)

W/B

L/B

38

41

Br/Y

Br

B Br/Y

L/B

(B)

Br B

L

B

42 43

L

L/B

Lg

Lg B

40

B Lg

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 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

(B)

34

G/W

G/W

G/W

Y

Y

Y

Br/Y

Br/Y

Br/Y

Br/Y

Br/Y

Br/Y

B

(B)

D

A

B

B

B

B

C

B

(B)

C


YXM700PE/YXM700PHE

2014 WIRING DIAGRAM


YXM700PE/YXM700PHE 2014


74

OFF

ON

75

A

(B)

76

(B)

77

(Gy)

1

(Gy)

2

(Gy)

(Gy)

(Gy)

3

(B)

73

71

72

4

5

6

(off)

(on)

(start)

(B)

A

8

9

7

10

11

12

13

(B)

14

15

(B)

70

69

68

67

66

65

64

(B)

(B)

62

61

58

(off)

(B)

59

63 63

60 60

57

(B)

20

(B)

(B)

(B)

21

16

(B)

(Gy)

17

18

(B)

(B)

(W)

19

2WD

4WD

DIFF LOCK

56

55

(Dg)

44

45

46

50

51

52

47

48

49

53

54

(B)

22

32

B

(Gy)

(Gy)

39

(B)

(B)

(B)

41

25

26

27

23

24

28

(B)

(Gy)

(B)

29

30

(B)

(B)

31

42 43

(Gy)

38

40

35

(Gy)

33

(B)

34

37 36

(Gy)

34

(B)

A

B

B

C

(B)

D

(B)

C

YX70 MPNE | YX70 MPHE | YX70 MPE | YX70 MNE | YX70 MHE | YXM700 DE | YXM700 PHE | Yamaha YX70 ME, MHE, MNE, MPE, MPHE, MPNE, YXM700 PE, PHE, DE ATV Service manual 500 Pages

YX70 MPNE | YX70 MPHE | YX70 MPE | YX70 MNE | YX70 MHE | YXM700 DE | YXM700 PHE | Yamaha YX70 ME, MHE, MNE, MPE, MPHE, MPNE, YXM700 PE, PHE, DE ATV Service manual

SERVICE MANUAL

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND

ADJUSTMENTS

CHASSIS

ENGINE

COOLING SYSTEM

FUEL SYSTEM

DRIVE TRAIN

ELECTRICAL SYSTEM

TROUBLESHOOTING

(off)

(on)

(start)

(off)

(on)

(start)

Key Features

Frequently Answers and Questions

What kind of engine does the Yamaha Viking have?

What type of transmission does the Yamaha Viking have?

What is the fuel capacity of the Yamaha Viking?

What type of engine oil does the Yamaha Viking use?

Related manuals

Table of contents

YX70 MPNE | YX70 MPHE | YX70 MPE | YX70 MNE | YX70 MHE | YXM700 DE | YXM700 PHE | Yamaha YX70 ME, MHE, MNE, MPE, MPHE, MPNE, YXM700 PE, PHE, DE ATV Service manual 500 Pages

YX70 MPNE | YX70 MPHE | YX70 MPE | YX70 MNE | YX70 MHE | YXM700 DE | YXM700 PHE | Yamaha YX70 ME, MHE, MNE, MPE, MPHE, MPNE, YXM700 PE, PHE, DE ATV Service manual

SERVICE MANUAL

TABLE OF CONTENTS

(off)

(on)

(start)

(off)

(on)

(start)

Key Features

Frequently Answers and Questions

What kind of engine does the Yamaha Viking have?

What type of transmission does the Yamaha Viking have?

What is the fuel capacity of the Yamaha Viking?

What type of engine oil does the Yamaha Viking use?

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Table of contents