Yamaha Wolverine YX70EPNG Service Manual
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Yamaha Wolverine YX70EPNG Service Manual

Yamaha Wolverine YX70EPNG Service Manual

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Table of Contents

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Download this manual See also: Owner's Manual
2016-17
SERVICE MANUAL
YX70EPNG
YXE70WPXG
YXE70WPHG
YXE70WDXG
YXE700E
YXE700SE
2MB-G8198-E0

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Summary of Contents for Yamaha Wolverine YX70EPNG

  • Page 1 2016-17 SERVICE MANUAL YX70EPNG YXE70WPXG YXE70WPHG YXE70WDXG YXE700E YXE700SE 2MB-G8198-E0...
  • Page 2 Brought to you by FordTruckMan & Tinken EBS20002 YX70EPNG/YXE70WPXG/ YXE70WPHG/YXE70WDXG/YXE700E/ YXE700SE SERVICE MANUAL ©2017 by Yamaha Motor Co., Ltd. 2nd edition, May 2017 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 3 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.

  • Page 4: How To Use This Manual

    EBS20004 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 5 EBS20005 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 7: Table Of Contents

    EBS10003 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM DRIVE TRAIN ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-3 OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS model) ..................1-3 INSTRUMENT FUNCTIONS ..............1-5 IMPORTANT INFORMATION ................. 1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-7 REPLACEMENT PARTS................1-7 GASKETS, OIL SEALS AND O-RINGS ............

  • Page 10: Identification

    IDENTIFICATION EBS20009 IDENTIFICATION EBS30003 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the frame. EBS30004 MODEL LABEL The model label “1” is affixed to the frame under the driver seat. This information will be needed to order spare parts.
  • Page 11 IDENTIFICATION...

  • Page 12: Features

    FEATURES EBS20010 FEATURES EBS30007 OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS model)
  • Page 13 FEATURES 1. Speed information from speed sensor b. Twists torsion bar c. Sends the torque sensor signal 2. Engine RPM information from ECU 3. Battery d. EPS control unit calculates assist power 4. EPS control unit e. Electricity output switched by EPS control unit 5.

  • Page 14: Instrument Functions

    FEATURES Pushing the “SELECT” button switches the dis- EBS30008 INSTRUMENT FUNCTIONS play between the odometer mode “ODO” and the tripmeter modes “TRIP A” and “TRIP B” in Multi-function meter unit the following order: ODO → TRIP A → TRIP B → ODO To reset a tripmeter, select it by pushing the “SE- LECT”...
  • Page 15 FEATURES Voltage display mode Refer to “SIGNALING SYSTEM” on page 9-19. Self-diagnosis device This display shows the battery voltage. “ ” appears for 1 second when the voltage display mode is first selected, and then “ ” ap- 1. Fault code display pears and the battery voltage is displayed.

  • Page 16: Important Information

    5. Keep all parts away from any source of fire. EBS30010 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...

  • Page 17: Bearings And Oil Seals

    IMPORTANT INFORMATION EBS30013 EBS30015 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in- manufacturer’s marks or numbers are visible. spection. Some of the rubber parts are sensitive When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc.

  • Page 18: Basic Service Information

    BASIC SERVICE INFORMATION EBS20012 BASIC SERVICE INFORMATION EBS30016 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.

  • Page 19: Electrical System

    BASIC SERVICE INFORMATION ECB01520 EBS30017 NOTICE ELECTRICAL SYSTEM Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- Electrical parts handling tery lead connections could damage the ECB01460 NOTICE electrical components. Never disconnect a battery lead while the en- gine is running;...
  • Page 20 BASIC SERVICE INFORMATION ECB01480 Checking the electrical system NOTICE Handle electrical components with special Before checking the electrical system, make care, and do not subject them to strong shocks. sure that the battery voltage is at least 12 V. ECB01490 ECB01440 NOTICE NOTICE...
  • Page 21 BASIC SERVICE INFORMATION 2. Check: Checking the connections • Lead Check the leads, couplers, and connectors for • Coupler stains, rust, moisture, etc. • Connector 1. Disconnect: Moisture → Dry with an air blower. • Lead Rust/stains → Connect and disconnect sev- •...
  • Page 22 BASIC SERVICE INFORMATION 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 re- sistance 5.40–6.60 kΩ...

  • Page 23: Special Tools

    9-106, 9-108, 9-108, 9-108, 9-109, 9-109, 9-110 Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 Valve lapper 90890-04101 90890-04101 Valve lapping tool YM-A8998 YM-A8998 Yamaha diagnostic tool 3-7, 9-39 90890-03231 Oil filter wrench 3-14 90890-01469 Oil filter wrench YM-01469 66.8 1-14...
  • Page 24 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Pressure gauge 3-15, 7-4 90890-03153 Pressure gauge YU-03153 Oil pressure adapter H 3-15 90890-03139 Ring nut wrench 3-27, 3-29 90890-01268 Spanner wrench YU-01268 Steering nut wrench 3-27, 3-30 90890-01443 Spanner wrench YU-33975 Boots band installation tool 4-50, 8-10, 8-12, 90890-01526...
  • Page 25 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Extension 90890-04136 Compression gauge 90890-03081 90890-03081 Engine compression tester YU-33223 YU-33223 Piston pin puller set 5-20 90890-01304 Piston pin puller YU-01304 YU-01304 Valve spring compressor 5-27, 5-32 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attachment 5-27, 5-32 90890-01243...
  • Page 26 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide remover & installer set (ø5.5) 5-29 90890-04016 Valve guide installer (5.5 mm) YM-04015 Valve guide remover & installer set (ø5.5) 5-29 90890-04016 Valve guide reamer (5.5 mm) YM-01196 Rotor holding tool 5-35, 5-35, 5-36, 90890-04166 5-37, 5-43, 5-44,...
  • Page 27 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Locknut wrench 5-53, 5-57 90890-01348 Locknut wrench YM-01348 Sheave spring compressor 5-53, 5-57 90890-04134 Sheave spring compressor YM-04134 Universal clutch holder 5-62, 5-63 90890-04086 Universal clutch holder YM-91042 Crankcase separating tool 5-68, 5-73, 8-30 90890-01135 Crankcase separator YU-01135-B...
  • Page 28 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Yamaha bond No. 1215 5-69, 8-30 90890-85505 (Three bond No.1215®) Crankshaft installer pot 5-75, 8-28 90890-01274 Installing pot YU-90058 YU-90058/YU-90059 Crankshaft installer bolt 5-75, 8-28 90890-01275 Bolt YU-90060 Adapter (M16) 5-75 90890-04130...
  • Page 29 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Ring nut wrench 5-88, 5-89 90890-01430 Ring nut wrench YM-38404 Final gear backlash band 5-91 90890-01511 Middle drive gear lash tool YM-01230 Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter 90890-01352...
  • Page 30 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Test harness– TPS (3P) 7-13 90890-03204 Test harness– TPS (3P) YU-03204 Universal joint holder 8-12, 8-15 90890-04062 Universal joint holder YM-04062 Ring gear fix bolt (M10) 8-16 90890-01527 Ring gear fix bolt (M10) YM-01527 M10×P1.25 Gear lash measurement tool...
  • Page 31 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Ignition checker 9-101 90890-06754 Oppama pet–4000 spark checker YM-34487 Test harness– lean angle sensor (3P) 9-102 90890-03213 Test harness– lean angle sensor (3P) YU-03213 Test harness– speed sensor (3P) 9-104 90890-03208 Test harness– speed sensor (3P) YU-03208 Test harness S–...
  • Page 32 SPECIAL TOOLS 1-23...

  • Page 33: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-6 ELECTRICAL SPECIFICATIONS ..............2-9 TIGHTENING TORQUES ................2-11 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-11 ENGINE TIGHTENING TORQUES............2-12 CHASSIS TIGHTENING TORQUES............2-17 LUBRICATION AND SEALING POINTS ............2-24 ENGINE....................2-24 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-25 ENGINE OIL LUBRICATION CHART .............2-25 LUBRICATION DIAGRAMS ..............

  • Page 34: General Specifications

    GENERAL SPECIFICATIONS EBS20014 GENERAL SPECIFICATIONS Model Model 2MB2 (YX70EPNG) (for CDN/EPS models) 2MB6 (YX70EPNG) (for CDN/EPS models) 2MB3 (YXE70WPXG) (for Europe/EPS models) 2MB7 (YXE70WPHG) (for Europe/EPS models) B523 (YXE70WDXG) (for Oceania) 2MB4 (YXE70WPXG) (for Oceania/EPS models) 2MB8 (YXE70WPHG) (for Oceania/EPS models) 2MB9 (YXE700E) (for Russia/EPS models) Dimensions...

  • Page 35: Engine Specifications

    ENGINE SPECIFICATIONS EBS20015 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Cylinder arrangement Single cylinder Displacement 708 cm³ Bore × stroke 103.0 × 85.0 mm (4.06 × 3.35 in) Compression ratio 10.1 : 1 Standard compression pressure (at sea level) 650–1000 kPa (6.5–10.0 kgf/cm², 92.4–142.2 psi) Starting system...
  • Page 36 ENGINE SPECIFICATIONS Cooling system Coolant quantity Radiator (including all routes) 2.85 L (3.01 US qt, 2.51 Imp.qt) Coolant reservoir (up to the maximum level mark) 0.20 L (0.21 US qt, 0.18 Imp.qt) Radiator core Width 400.0 mm (15.75 in) Height 253.4 mm (9.98 in) Depth 28.0 mm (1.10 in)
  • Page 37 ENGINE SPECIFICATIONS Valve-stem-to-valve-guide clearance (intake) limit 0.080 mm (0.0031 in) Valve-stem-to-valve-guide clearance (exhaust) limit 0.100 mm (0.0039 in) Valve stem runout 0.040 mm (0.0016 in) Valve spring Installed length (intake) 30.95 mm (1.22 in) Installed length (exhaust) 32.20 mm (1.27 in) Installed compression spring force (intake) 134.00–154.00 N (13.66–15.70 kgf, 30.12–...
  • Page 38 ENGINE SPECIFICATIONS Clutch-stall revolution 3550–3650 r/min V-belt V-belt width limit 32.5 mm (1.28 in) Transmission type V-belt automatic Gear ratio 2.474–0.656 : 1 Low range 31/16 (1.938) High range 30/22 (1.364) 23/14 × 28/23 (2.000) Reverse gear Drive axle runout limit 0.06 mm (0.0024 in) 43/21 ×...

  • Page 39: Chassis Specifications

    CHASSIS SPECIFICATIONS EBS20016 CHASSIS SPECIFICATIONS Chassis Frame type Steel tube frame Caster angle 3.7° Camber angle 0.4° Kingpin angle 12.7° Kingpin offset 7.7 mm (0.30 in) Trail 19.0 mm (0.75 in) Toe-in (with tires touching the ground) 5.0–15.0 mm (0.20–0.59 in) Tread rear (STD) 1304.0 mm (51.34 in) Tread front (STD)
  • Page 40 CHASSIS SPECIFICATIONS Disc outside diameter × thickness 207.0 × 4.0 mm (8.15 × 0.16 in) Brake disc thickness limit 3.5 mm (0.14 in) Brake disc deflection limit 0.10 mm (0.0039 in) Brake pad lining thickness limit 1.0 mm (0.04 in) Master cylinder inside diameter 17.46 mm (0.69 in) 32.03 mm ×...
  • Page 41 CHASSIS SPECIFICATIONS Installed length 378.0 mm (14.88 in) Spring preload adjusting positions Minimum 386.0 mm (15.20 in) Standard 378.0 mm (14.88 in) Maximum 372.0 mm (14.65 in) Rebound damping adjusting positions Minimum 30 click(s) out from the fully turned in position Standard 14 click(s) out from the fully turned in position Maximum...

  • Page 42: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EBS20017 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Engine control unit Model/manufacturer F8T85877/MITSUBISHI Ignition system Ignition system Advancer type Digital Ignition timing (B.T.D.C.) 7.0°/1600 r/min 152.0–228.0 Ω Pickup coil resistance Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω...
  • Page 43 ELECTRICAL SPECIFICATIONS Low-range indicator light Differential gear lock indicator light 14 V, 0.85 W × 2 Helmet/Seat belt indicator light EPS warning light LED (for EPS models) Starter motor Power output 0.80 kW 0.025–0.035 Ω Armature coil resistance Brush overall length limit 5.0 mm (0.20 in) Commutator diameter limit 27.0 mm (1.06 in)

  • Page 44: Tightening Torques

    TIGHTENING TORQUES EBS20018 TIGHTENING TORQUES EBS30018 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

  • Page 45: Engine Tightening Torques

    TIGHTENING TORQUES EBS30019 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size 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) Spark arrester bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Cylinder head cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
  • Page 46 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil pipe bolt (AC magneto cover) 18 Nm (1.8 m·kgf, 13 ft·lbf) Oil pipe bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Oil pump drive sprocket nut 25 Nm (2.5 m·kgf, 18 ft·lbf) Oil pump driven sprocket nut 25 Nm (2.5 m·kgf, 18 ft·lbf) Oil pump bolt...
  • Page 47 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front drive shaft coupling gear nut 190 Nm (19 m·kgf, 137 ft·lbf) (middle gear side) Left-hand threads Middle driven shaft bearing retainer 80 Nm (8.0 m·kgf, 58 ft·lbf) Middle driven pinion gear bearing 25 Nm (2.5 m·kgf, 18 ft·lbf) housing bolt Left-hand...
  • Page 48 TIGHTENING TORQUES Cylinder head bolt and cylinder bolt 1. Temporarily tighten the cylinder head bolts (M6) and cylinder bolts (M6). 2. Tighten the cylinder head bolts (M11) to 30 Nm (3.0 m·kgf, 22 ft·lbf) in the proper tightening se- quence. 3.
  • Page 49 TIGHTENING TORQUES Oil pump bolt Tighten the oil pump bolts to 10 Nm (1.0 m·kgf, 7.2 ft·lbf) in the proper tightening sequence. 2-16...

  • Page 50: Chassis Tightening Torques

    TIGHTENING TORQUES EBS30020 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (front) (M6) 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Engine mounting bolt (front) (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) Engine mounting bolt (rear) (M10) 42 Nm (4.2 m·kgf, 30 ft·lbf)
  • Page 51 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Seat back bolt 6 Nm (0.6 m·kgf, 4.3 ft·lbf) Driver seat frame bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) Passenger seat frame bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) Under-seat compartment panel bolt 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Under-seat storage compartment 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
  • Page 52 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Instrument panel bolt 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Glove compartment latch plate 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf) screw Electrical components tray and 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) frame bolt Cargo bed bolt 9 Nm (0.9 m·kgf, 6.5 ft·lbf) Frame cross member bolt...
  • Page 53 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Steering wheel nut 35 Nm (3.5 m·kgf, 25 ft·lbf) Steering assembly bolt See TIP. Tie-rod 55 Nm (5.5 m·kgf, 40 ft·lbf) Steering joint bolt 33 Nm (3.3 m·kgf, 24 ft·lbf) Rack guide bolt —...
  • Page 54 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Parking brake cable adjusting lock- 16 Nm (1.6 m·kgf, 12 ft·lbf) Differential assembly nut 105 Nm (10.5 m·kgf, 76 ft·lbf) Differential assembly bolt 60 Nm (6.0 m·kgf, 43 ft·lbf) Differential assembly nut 60 Nm (6.0 m·kgf, 43 ft·lbf) Differential gear oil filler bolt 23 Nm (2.3 m·kgf, 17 ft·lbf)
  • Page 55 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Horn switch lead nut (except for — 2.3 Nm (0.23 m·kgf, 1.7 ft·lbf) CDN) Horn bolt (except for CDN) 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Enclosure bolt and nut Tighten the enclosure bolts and nuts to specification in the proper tightening sequence. Enclosure tightening sequence: Steering assembly bolt Tighten the steering assembly bolts to 48 Nm (4.8 m·kgf, 35 ft·lbf) in the proper tightening sequence.
  • Page 56 TIGHTENING TORQUES Fuel pump tightening sequence: Final drive assembly bolt and nut Tighten the final drive assembly bolts and nuts to specification in the proper tightening sequence. Final drive assembly tightening sequence: 2-23...

  • Page 57: Lubrication And Sealing Points

    Shift forks and shift fork guide bar Shift fork and transmission gear contact surface Shift drum stopper ball Shift lever 1 and shift lever 2 Transmission gears Transmission washer and bearing Transmission collars Yamaha bond No.1215 Crankcase mating surface (Three Bond No.1215®) 2-24...

  • Page 58: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EBS20020 LUBRICATION SYSTEM CHART AND DIAGRAMS EBS30022 ENGINE OIL LUBRICATION CHART 2-25...
  • Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pan 2. Oil strainer 3. Oil pump 4. Relief valve 5. Oil cooler 6. Oil bypass valve 7. Oil filter cartridge 8. Drive axle 9. Reverse idle gear shaft 10. Oil pipe (crankcase) 11.

  • Page 60: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EBS30023 LUBRICATION DIAGRAMS 2-27...
  • Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil hose (crankcase to cylinder) 2. Oil pipe (crankcase) 3. Oil filter cartridge 4. Oil strainer 5. Oil pump 6. Oil pipe (AC magneto cover) 7. Reverse idle gear shaft 8. Drive axle 9. Relief valve 2-28...
  • Page 62 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 63 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Crankshaft 3. Oil strainer 4. Oil pump 5. Oil pump driven sprocket 2-30...
  • Page 64 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
  • Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil cooler outlet hose 2. Oil cooler inlet hose 3. Oil cooler inlet pipe 4. Oil outlet hose 5. Oil inlet hose 6. Oil cooler outlet pipe 7. Oil outlet pipe 8. Oil inlet pipe 2-32...

  • Page 66: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EBS20021 COOLING SYSTEM DIAGRAMS 2-33...
  • Page 67 COOLING SYSTEM DIAGRAMS 1. Radiator 2. Radiator outlet hose 3. Radiator outlet pipe 4. Radiator inlet pipe 5. Radiator inlet hose 6. Radiator cap 2-34...
  • Page 68 COOLING SYSTEM DIAGRAMS 2-35...
  • Page 69 COOLING SYSTEM DIAGRAMS 1. Radiator outlet pipe 2. Water pump inlet hose 3. Thermostat outlet hose 4. Radiator inlet pipe 2-36...
  • Page 70 COOLING SYSTEM DIAGRAMS 2-37...
  • Page 71 COOLING SYSTEM DIAGRAMS 1. Thermostat outlet hose 2. Water pump inlet hose 3. Water pump 4. Water pump outlet pipe 5. Water pump outlet hose 6. Water jacket joint 2-38...

  • Page 72: Cable Routing

    CABLE ROUTING EBS20022 CABLE ROUTING Frame front (left view) 2-39...
  • Page 73 CABLE ROUTING 1. Horn lead (except for CDN) 2. Headlight lead (left) 3. Throttle cable 4. Brake light switch lead 5. Radiator inlet hose 6. Wire harness 7. EPS torque sensor lead (for EPS models) 8. EPS motor lead (for EPS models) 9.
  • Page 74 CABLE ROUTING Frame center (left view) 2-41...
  • Page 75 CABLE ROUTING 1. Parking brake switch lead 2. Parking brake cable 3. Throttle cable 4. Seat belt switch lead 5. Thermostat outlet hose 6. Wire harness 7. Reverse switch lead 8. Gear position switch lead 9. Coolant temperature sensor lead 10.
  • Page 76 CABLE ROUTING Frame front (right view) 2-43...
  • Page 77 CABLE ROUTING 1. Radiator fan motor breather hose 2. Differential assembly breather hose 3. Coolant reservoir breather hose 4. Headlight lead (right) 5. Horn lead (except for CDN) 6. Radiator outlet hose 7. Differential motor lead 8. Coolant reservoir hose 9.
  • Page 78 CABLE ROUTING Frame center (right view) 2-45...
  • Page 79 CABLE ROUTING 1. Wire harness 2. Seat belt switch lead 3. Parking brake switch lead 4. AC magneto lead 5. Water pump inlet hose 6. Final drive assembly breather hose 7. Fuel injector lead 8. TPS (throttle position sensor) lead 9.
  • Page 80 CABLE ROUTING Electrical components tray (top view) 3 4 5 2-47...
  • Page 81 CABLE ROUTING 1. Wire harness 2. Headlight lead (right) 3. Load control relay 4. Differential motor relay 2 5. Fuel injection system relay 6. Differential motor relay 1 7. Radiator fan motor relay 8. Headlight relay 9. Main fuse lead 10.
  • Page 82 CABLE ROUTING Frame front (top view) 2-49...
  • Page 83 CABLE ROUTING 1. Horn lead (except for CDN) 2. Radiator outlet hose 3. Headlight lead (right) 4. Auxiliary DC jack lead 5. Meter assembly lead 6. Indicator light assembly lead 7. Parking brake switch lead 8. Throttle cable 9. Horn switch lead (except for CDN) 10.
  • Page 84 CABLE ROUTING Frame center (top view) 1 2-51...
  • Page 85 CABLE ROUTING 1. Fuel hose 2. Fuel injector lead 3. Wire harness 4. Coolant temperature sensor lead 5. Spark plug lead 6. Air induction system solenoid lead 7. Ignition coil lead 8. Seat belt switch lead 9. Thermostat outlet hose 10.
  • Page 86 CABLE ROUTING Frame center (top view) 2 2-53...
  • Page 87 CABLE ROUTING 1. Parking brake switch lead 2. Wire harness 3. Ground lead 4. Starter motor lead 5. Fuel pump lead 6. Final drive assembly breather hose 7. Parking brake buzzer lead A. Fasten the parking brake switch lead with the plastic band.
  • Page 88 CABLE ROUTING Fuel tank (top view) 2-55...
  • Page 89 CABLE ROUTING 1. Fuel hose 2. Fuel pump lead 3. Fuel tank breather hose (fuel tank breather hose joint to atmosphere) 4. Fuel tank breather hose (fuel tank to fuel tank breather hose joint) A. Fasten the grommet on the fuel hose with the holder.
  • Page 90 CABLE ROUTING Front brake caliper (left view) 2-57...
  • Page 91 CABLE ROUTING 1. Front brake pipe 2. Rear brake pipe 3. Front brake hose A. Fasten the grommet on the front brake hose with the holder. B. Fasten the front brake hose with the holder. 2-58...
  • Page 92 CABLE ROUTING Rear brake caliper (left view) 2-59...
  • Page 93 CABLE ROUTING 1. Rear brake pipe 2. Rear brake hose A. Fasten the rear brake hose with the holder. B. Fasten the grommet on the rear brake hose with the holder. C. Fasten the rear brake pipe with the holder. D.
  • Page 94 CABLE ROUTING Front brake caliper (top view) 2-61...
  • Page 95 CABLE ROUTING 1. Front brake pipe 2. Rear brake pipe 3. Front brake hose A. Face the paint mark upward. B. Fasten the grommet on the front brake hose with the holder. C. Route the front brake hose under the front upper arm.
  • Page 96 CABLE ROUTING Brake pipe (top and left view) 2-63...
  • Page 97 CABLE ROUTING 1. Rear brake pipe A. Fasten the rear brake pipe with the holder. 2-64...
  • Page 98 CABLE ROUTING Rear brake caliper (top view) 2-65...
  • Page 99 CABLE ROUTING 1. Rear brake pipe 2. Rear brake hose A. Fasten the rear brake pipe with the holder. B. Fasten the rear brake hose with the holder. C. Fasten the grommet on the rear brake hose with the holder. 2-66...
  • Page 100 CABLE ROUTING Parking brake (left view) 2-67...
  • Page 101 CABLE ROUTING 1. Parking brake cable A. Fit the parking brake cable into the holder on the final drive case. B. Fit the parking brake cable into the slit in the parking brake lever. 2-68...
  • Page 102 CABLE ROUTING Final drive assembly (left and right view) 2-69...
  • Page 103 CABLE ROUTING 1. Wire harness 2. Tail/brake light lead (left) 3. Final drive assembly breather hose 4. Tail/brake light lead (right) A. Fasten the wire harness with the holder. B. Place the slack in the tail/brake light lead in the area shown in the illustration.
  • Page 104 CABLE ROUTING 2-71...

  • Page 105: Periodic Checks And Adjustments

    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 ............... 3-6 CHECKING THE BREATHER HOSE............3-6 CHECKING THE EXHAUST SYSTEM............3-7 ADJUSTING THE EXHAUST GAS VOLUME ...........3-7...

  • Page 106: Periodic Maintenance

    However, keep in mind that if the vehicle isn’t used for a long period of time, the month main- tenance 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.
  • Page 107 PERIODIC MAINTENANCE INITIAL EVERY month CHECK OR MAINTENANCE Whichever ITEM 1200 2400 2400 4800 comes first km (mi) (200) (750) (1500) (1500) (3000) hours Final gear oil/Differ- • Check oil level/oil leakage. √ √ ential gear oil • Replace. • Check operation/brake pad wear/fluid leakage. √...

  • Page 108: Checking The Fuel Line

    PERIODIC MAINTENANCE • Cylinder head cover EBS30027 CHECKING THE FUEL LINE Refer to “CAMSHAFTS” on page 5-10. 1. Remove: ECB01270 • Rear panel (right) NOTICE Refer to “GENERAL CHASSIS (1)” on page Before removing the spark plug, blow away 4-1. any dirt accumulated in the spark plug well •...
  • Page 109 PERIODIC MAINTENANCE Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 b. Calculate the difference between the speci- fied valve clearance and the measured valve clearance. Example: Specified valve clearance = 0.10–0.20 mm (0.0039–0.0079 in) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
  • Page 110 PERIODIC MAINTENANCE e. Install the exhaust and intake camshafts, tim- Number “a” Thickness ing chain and camshaft cap. 1.700 mm (0.06693 in) Camshaft cap bolt 1.725 mm (0.06791 in) 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 1.750 mm (0.06890 in) 1.775 mm (0.06988 in) 1.800 mm (0.07087 in) •...

  • Page 111: Checking The Spark Plug

    PERIODIC MAINTENANCE Cylinder head cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Spark plug (new) 11 Nm (1.1 m·kgf, 8.0 ft·lbf) Spark plug (reused) Specified angle 30–45° 10.Connect: • Spark plug cap Refer to “THROTTLE BODY” on page 7-8. 7. Install: •...

  • Page 112: Checking The Exhaust System

    Yamaha diagnostic tool. For more information, refer to the opera- tion 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”...

  • Page 113: Checking The Air Induction System

    PERIODIC MAINTENANCE d. Install a new gasket, and then insert the tail- pipe into the muffler and align the bolt holes. e. Install the bolts “1” and tighten them. Spark arrester bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) ▲ ▲▲▲ ▲...

  • Page 114: Changing The Coolant

    PERIODIC MAINTENANCE 2. Check: • Hood • Coolant level Refer to “GENERAL CHASSIS (6)” on page The coolant level should be between the 4-12. maximum level mark “a” and minimum level 2. Remove: mark “b”. • Coolant reservoir cap “1” Below the minimum level mark →...
  • Page 115 PERIODIC MAINTENANCE ECB01310 NOTICE Place a container under the engine, and then re- • Adding water instead of coolant dilutes the move the coolant drain bolt. antifreeze concentration of the coolant. If water is used instead of coolant; check, and if necessary, correct the antifreeze concentration of the coolant.

  • Page 116: Cleaning The Air Filter Element

    PERIODIC MAINTENANCE 2. Remove: Water pump air bleed bolt • Center storage compartment 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Refer to “GENERAL CHASSIS (3)” on page 4-6. c. Loosen the thermostat cover air bleed bolt “2”, without removing it, to allow all of the air There are check hoses “1”...
  • Page 117 PERIODIC MAINTENANCE ECB01800 NOTICE The engine should never be run without the air filter; excessive piston and/or cylinder wear may result. c. Properly dispose of the used solvent. d. Carefully wash the air filter element in soap water. 6. Check: •...

  • Page 118: Checking The Engine Oil Level

    PERIODIC MAINTENANCE 8. Assemble: • Air filter element frame • Air filter element • Air filter element holder 9. Install: • Air filter element assembly 10.Install: • Air filter case cover 11.Install: • Center storage compartment Refer to “GENERAL CHASSIS (3)” on page Recommended brand 4-6.

  • Page 119: Changing The Engine Oil

    PERIODIC MAINTENANCE EBS30039 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Remove: • Passenger seat cushion Refer to “GENERAL CHASSIS (2)” on page 4-3. • Passenger seat belt buckle rubber cover Refer to “GENERAL CHASSIS (3)”...

  • Page 120: Measuring The Engine Oil Pressure

    PERIODIC MAINTENANCE EWB03620 WARNING The engine, muffler and engine oil are ex- tremely hot. 9. Install: • Dipstick 10.Start the engine, warm it up for several min- utes, and then turn it off. 11.Check: 5. Install: • Engine • Oil pressure gauge “1” (for engine oil leaks) •...

  • Page 121: Checking The Final Gear Oil Level

    PERIODIC MAINTENANCE 7. Install: EBS30041 CHANGING THE FINAL GEAR OIL • Main gallery bolt 1. Place the vehicle on a level surface. • Gasket 2. Place a container under the final drive case. 3. Remove: Main gallery bolt • Final gear oil filler bolt “1” 35 Nm (3.5 m·kgf, 25 ft·lbf) (along with the gasket) LOCTITE®...

  • Page 122: Checking The Differential Gear Oil Level

    PERIODIC MAINTENANCE EBS30042 CHECKING THE DIFFERENTIAL GEAR OIL LEVEL 1. Place the vehicle on a level surface. 2. Remove: • Differential gear oil filler bolt “1” (along with the gasket) 3. Check: • Differential gear oil level The differential gear oil level should be up to the brim “2”...

  • Page 123: Checking The Front Brake Pads

    PERIODIC MAINTENANCE Differential gear oil filler bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) EBS30044 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the front brake pads. 1. Remove: • Front wheels Refer to “FRONT AND REAR WHEELS” on 4.

  • Page 124: Bleeding The Hydraulic Brake System

    PERIODIC MAINTENANCE È In order to ensure a correct reading of the brake fluid level, make sure the top of the brake master cylinder reservoir is horizontal. É EBS30046 BLEEDING THE HYDRAULIC BRAKE SYSTEM EWB02800 WARNING Bleed the hydraulic brake system whenever: A.

  • Page 125: Checking The Brake Hoses And Brake Pipes

    PERIODIC MAINTENANCE 3. Install: • Rear wheels • Front wheels Refer to “FRONT AND REAR WHEELS” on page 4-23. EBS30047 CHECKING THE BRAKE HOSES AND BRAKE PIPES 1. Remove: • Rear panel (left) Refer to “GENERAL CHASSIS (1)” on page 4-1.

  • Page 126: Adjusting The Brake Pedal

    PERIODIC MAINTENANCE 6. Check: • Brake hose holders Loose → Tighten the holder bolts. Damage → Replace. 7. Apply the brake several times. 8. Check: • Brake hoses • Brake pipe Brake fluid leakage → Replace any damaged hose and pipe. Refer to “FRONT AND REAR BRAKES”...

  • Page 127: Adjusting The Accelerator Pedal Free Play

    PERIODIC MAINTENANCE EBS30054 ADJUSTING THE ACCELERATOR PEDAL FREE PLAY 1. Check: • Accelerator pedal free play “a” Out of specification → Adjust. Accelerator pedal free play 12.0–32.0 mm (0.47–1.26 in) 3. Remove: • Center storage compartment Refer to “GENERAL CHASSIS (3)” on page 4-6.

  • Page 128: Checking The V-Belt

    PERIODIC MAINTENANCE h. Install a new gasket and the throttle cable housing cover. If length “c” is 8.5 mm (0.33 in) or more, loosen locknut “5” and turn the adjusting nut “6” in direc- Throttle cable housing cover tion “d” or “e” until the specified accelerator ped- screw al free play is obtained.

  • Page 129: Replacing The V-Belt

    PERIODIC MAINTENANCE 5. Install: b. Remove the V-belt “2” from the primary sheave and secondary sheave. • Drive belt cover Refer to “PRIMARY AND SECONDARY SHEAVES” on page 5-50. 6. Install: • V-belt cooling ducts Refer to “GENERAL CHASSIS (10)” on page 4-21.

  • Page 130: Checking The Tires

    Tire characteristics influence the handling of 75.0 kPa (0.750 kgf/cm², 11 psi) vehicles. The tires listed below have been Rear approved by Yamaha Motor Co., Ltd. for this 75.0 kPa (0.750 kgf/cm², 11 psi) model. If other tire combinations are used, Minimum Vehicle load they can adversely affect your vehicle’s han-...

  • Page 131: Checking The Front Shock Absorber Assemblies

    PERIODIC MAINTENANCE EWB03100 WARNING Maximum loading limit 327.0 kg (721 lb) It is dangerous to ride with a worn-out tire. (Total weight of operator, pas- When the tire tread reaches the wear limit, re- senger, cargo, accessories, and place the tire immediately. tongue) Rear carrier load limit 136.0 kg (300 lb)
  • Page 132 PERIODIC MAINTENANCE Ring nut wrench 90890-01268 Spanner wrench YU-01268 ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Elevate the front wheels by placing a suitable stand under the frame. b.
  • Page 133 PERIODIC MAINTENANCE ECB02480 NOTICE Rebound damping adjusting posi- tions Do not force the adjuster past the minimum Minimum or maximum extent of adjustment. The ad- 30 click(s) out from the fully juster may be damaged. turned in position Standard 13 click(s) out from the fully turned in position Maximum 1 click(s) out from the fully...

  • Page 134: Checking The Rear Shock Absorber Assemblies

    PERIODIC MAINTENANCE c. Turn the adjusting ring “2” in direction “a” or “b”. Direction “a” Spring preload is increased (suspen- sion is harder). Direction “b” Spring preload is decreased (suspen- sion is softer). ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
  • Page 135 PERIODIC MAINTENANCE ECB02480 NOTICE Steering nut wrench 90890-01443 Do not force the adjuster past the minimum Spanner wrench or maximum extent of adjustment. The ad- YU-33975 juster may be damaged. Locknut 30 Nm (3.0 m·kgf, 22 ft·lbf) • Set the torque wrench at a right angle to the steering nut wrench.

  • Page 136: Checking The Steering System

    PERIODIC MAINTENANCE EBS30061 CHECKING THE STEERING SYSTEM 1. Place the vehicle on a level surface. 2. Check: • Steering column (except for EPS models) • EPS unit (for EPS models) • Steering wheel nut Move the steering wheel up and down, and back and forth.

  • Page 137: Adjusting The Toe-In

    PERIODIC MAINTENANCE Excessive free play → Replace the front arms (upper and lower) and/or wheel bear- ings. EBS30062 ADJUSTING THE TOE-IN 1. Place the vehicle on a level surface. 2. Measure: • Toe-in Out of specification → Adjust. C. Forward Toe-in (with tires touching the ground) ▲...

  • Page 138: Checking The Stabilizer Bushing

    PERIODIC MAINTENANCE EBS30066 LUBRICATING THE DRIVE SHAFT UNIVERSAL JOINTS 1. Remove: • Center cover Refer to “GENERAL CHASSIS (3)” on page 4-6. 2. Lubricate: • Drive shaft universal joint Recommended lubricant d. Tighten the tie-rod end locknuts to specifica- Lithium-soap-based grease tion.

  • Page 139: Checking The Fastener

    PERIODIC MAINTENANCE TY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT” on page 8-18. A. Front B. Rear EBS30069 CHECKING THE FASTENER 1. Check: • Fasteners Damage/pitting → Replace. Refer to “GENERAL CHASSIS (1)” on page 4-1, “GENERAL CHASSIS (3)” on page 4-6, “GENERAL CHASSIS (6)”...
  • Page 140 PERIODIC MAINTENANCE 3-35...

  • Page 141: Chassis

    CHASSIS GENERAL CHASSIS (1) ................. 4-1 INSTALLING THE DOOR................4-2 GENERAL CHASSIS (2) ................. 4-3 REMOVING THE SEATS ................4-4 ADJUSTING THE DRIVER SEAT POSITION...........4-4 INSTALLING THE SEATS................. 4-4 GENERAL CHASSIS (3) ................. 4-6 GENERAL CHASSIS (4) ................. 4-7 INSTALLING THE SEAT BELTS............... 4-8 GENERAL CHASSIS (5) .................
  • Page 142 FRONT AND REAR BRAKES............... 4-27 INTRODUCTION ..................4-34 CHECKING THE BRAKE DISCS ............4-34 REPLACING THE BRAKE PADS............4-35 DISASSEMBLING THE BRAKE CALIPERS ...........4-36 CHECKING THE BRAKE CALIPERS .............4-36 ASSEMBLING THE BRAKE CALIPERS ..........4-36 INSTALLING THE BRAKE CALIPERS ...........4-37 CHECKING THE BRAKE MASTER CYLINDER ........4-38 CHECKING THE BRAKE PIPES.............
  • Page 143 REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES ....4-63 CHECKING THE REAR ARMS ...............4-65 HANDLING THE REAR SHOCK ABSORBER ASSEMBLIES ....4-65 DISPOSING OF A REAR SHOCK ABSORBER ASSEMBLY ....4-65 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES....4-65 INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES ..................
  • Page 144 GENERAL CHASSIS (1) EBS20024 GENERAL CHASSIS (1) Removing the doors and side panels 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 145: General Chassis (1)

    GENERAL CHASSIS (1) EBS30419 INSTALLING THE DOOR The following procedure applies to both of the doors. 1. Install: • Door hinge “1” Door hinge nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) 2. Install: • Door “1” Fit the tab “a” on the door hinge with the slot “b” in the frame.

  • Page 146: General Chassis (2)

    GENERAL CHASSIS (2) EBS20087 GENERAL CHASSIS (2) Removing the seats 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • ’...

  • Page 147: Removing The Seats

    GENERAL CHASSIS (2) EBS30340 REMOVING THE SEATS The following procedure applies to both of the seats. 1. Remove: • Seat cushion “1” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a.

  • Page 148: General Chassis (3)

    GENERAL CHASSIS (2) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲...

  • Page 149: General Chassis (4)

    GENERAL CHASSIS (3) EBS20088 GENERAL CHASSIS (3) Removing the center cover and floor boards 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...
  • Page 150 GENERAL CHASSIS (4) EBS20089 GENERAL CHASSIS (4) Removing the seat belts 59 Nm (5.9 m kgf, 43 ft Ibf) 59 Nm (5.9 m kgf, 43 ft Ibf) • • • • 59 Nm (5.9 m kgf, 43 ft Ibf) • •...

  • Page 151: Installing The Seat Belts

    GENERAL CHASSIS (4) EBS30343 INSTALLING THE SEAT BELTS 1. Install: • Seat belt buckles Seat belt buckle bolt 59 Nm (5.9 m·kgf, 43 ft·lbf) • Fit the passenger seat belt buckle “1” into the slot “a” in the frame. • Fit the driver seat belt buckle “2” into the slot “b” in the seat belt buckle bracket.

  • Page 152: General Chassis (5)

    GENERAL CHASSIS (5) EBS20090 GENERAL CHASSIS (5) Removing the sun top 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Sun top rear bracket Sun top front bracket Sun top Damper Damper...
  • Page 153 GENERAL CHASSIS (5) Removing the enclosure 70 Nm (7.0 m kgf, 51 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) • • 41 Nm (4.1 m kgf, 30 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) •...

  • Page 154: Installing The Enclosure

    GENERAL CHASSIS (5) EBS30344 INSTALLING THE ENCLOSURE Rear upper frame bolt 1. Install: 70 Nm (7.0 m·kgf, 51 ft·lbf) • Rear lower frame “1” Rear upper frame and rear lower frame nut • Side frame (left) “2” 41 Nm (4.1 m·kgf, 30 ft·lbf) •...

  • Page 155: General Chassis (6)

    GENERAL CHASSIS (6) EBS20091 GENERAL CHASSIS (6) Removing the hood and battery 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...
  • Page 156 GENERAL CHASSIS (7) EBS20092 GENERAL CHASSIS (7) Removing the front fender and instrument panel assembly 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) •...
  • Page 157 GENERAL CHASSIS (7) Removing the front fender and instrument panel assembly 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • •...
  • Page 158 GENERAL CHASSIS (7) Disassembling the instrument panel assembly 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • ’ Order Job/Parts to remove Remarks Meter assembly Indicator light assembly On-Command four-wheel-drive switch Light switch Main switch Auxiliary DC jack Horn switch Except for CDN Instrument panel 4-15...

  • Page 159: Removing The Steering Wheel

    GENERAL CHASSIS (7) EBS30345 REMOVING THE STEERING WHEEL 1. Turn the steering wheel so that it is straight and the front wheels are pointing straight ahead. 2. Remove: • Steering wheel cover “1” While pushing the ends of the projections “a” to- gether, remove the steering wheel cover from the steering wheel.

  • Page 160: General Chassis (8)

    GENERAL CHASSIS (8) EBS20102 GENERAL CHASSIS (8) Removing the electrical components tray 3.6 Nm (0.36 m kgf, 2.6 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) •...

  • Page 161: General Chassis (9)

    GENERAL CHASSIS (8) Removing the electrical components tray 3.6 Nm (0.36 m kgf, 2.6 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 162 GENERAL CHASSIS (9) EBS20103 GENERAL CHASSIS (9) Removing the cargo bed 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 33 Nm (3.3 m kgf, 24 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) • •...

  • Page 163: Installing The Cargo Bed

    GENERAL CHASSIS (9) EBS30420 INSTALLING THE CARGO BED 1. Install: • Cargo bed “1” Cargo bed bolt 9 Nm (0.9 m·kgf, 6.5 ft·lbf) Tighten the bolts “2” and “3” in the order listed, and then tighten the bolts “4”. 4-20...

  • Page 164: General Chassis (10)

    GENERAL CHASSIS (10) EBS20104 GENERAL CHASSIS (10) Removing the V-belt cooling ducts 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...

  • Page 165: Installing The V-Belt Cooling Ducts

    GENERAL CHASSIS (10) EBS30348 INSTALLING THE V-BELT COOLING DUCTS 1. Install: • V-belt cooling intake duct joint 2 “1” • V-belt cooling intake duct joint 1 “2” • V-belt cooling exhaust duct joint “3” • Align the projection “a” on V-belt cooling intake duct joint 2 with the lib on the crankcase.

  • Page 166: Front And Rear Wheels

    FRONT AND REAR WHEELS EBS20025 FRONT AND REAR WHEELS Removing the wheels and brake discs 48 Nm (4.8 m kgf, 35 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 350 Nm (35.0 m kgf, 253 ft lbf) •...

  • Page 167: Removing The Wheels

    FRONT AND REAR WHEELS • Wheel EBS30083 REMOVING THE WHEELS Refer to “CHECKING THE TIRES” on page 1. Place the vehicle on a level surface. 3-25 and “CHECKING THE WHEELS” on 2. Elevate: page 3-24. • Wheels EWB03020 WARNING Place the vehicle on a suitable stand so that the After replacing the tire, ride conservatively to wheels are elevated.

  • Page 168: Checking The Wheel Hubs

    FRONT AND REAR WHEELS Install the brake disc so that the recessed por- tion of the bolt hole faces away from the hub. EBS30088 INSTALLING THE WHEEL HUBS The following procedure applies to all of the wheel hubs. 1. Install: •...

  • Page 169: Installing The Wheels

    FRONT AND REAR WHEELS 3. Check: • Brake disc Refer to “CHECKING THE BRAKE DISCS” on page 4-34. EBS30089 INSTALLING THE WHEELS The following procedure applies to all of the wheels. 1. Tighten: • Wheel nuts “1” Front wheel nut 75 Nm (7.5 m·kgf, 54 ft·lbf) Rear wheel nut 75 Nm (7.5 m·kgf, 54 ft·lbf)

  • Page 170: Front And Rear Brakes

    FRONT AND REAR BRAKES EBS20026 FRONT AND REAR BRAKES Removing the front brake pads 48 Nm (4.8 m kgf, 35 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) •...
  • Page 171 FRONT AND REAR BRAKES Removing the rear brake pads 48 Nm (4.8 m kgf, 35 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • ’ Order Job/Parts to remove Remarks...
  • Page 172 FRONT AND REAR BRAKES Removing the front brake calipers 48 Nm (4.8 m kgf, 35 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • ’ Order Job/Parts to remove Remarks...
  • Page 173 FRONT AND REAR BRAKES Removing the rear brake calipers 48 Nm (4.8 m kgf, 35 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • ’ Order Job/Parts to remove Remarks...
  • Page 174 FRONT AND REAR BRAKES Disassembling the front brake calipers 22 Nm (2.2 m kgf, 16 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) •...
  • Page 175 FRONT AND REAR BRAKES Disassembling the rear brake calipers 22 Nm (2.2 m kgf, 16 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) •...
  • Page 176 FRONT AND REAR BRAKES Removing the brake master cylinder 19 Nm (1.9 m kgf, 14 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) • • ’ Order Job/Parts to remove Remarks...

  • Page 177: Introduction

    FRONT AND REAR BRAKES b. Measure the deflection 3.0 mm (0.12 in) be- EBS30090 INTRODUCTION low the edge of the brake disc. EWB02930 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary.

  • Page 178: Replacing The Brake Pads

    FRONT AND REAR BRAKES • Brake pads 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”.

  • Page 179: Disassembling The Brake Calipers

    FRONT AND REAR BRAKES EBS30093 Recommended brake component replacement DISASSEMBLING THE BRAKE CALIPERS schedule The following procedure applies to all of the brake calipers. Piston seals, piston Every two years dust seals Brake hoses Every four years Before disassembling the brake caliper, drain the brake fluid from the entire brake system.

  • Page 180: Installing The Brake Calipers

    FRONT AND REAR BRAKES Specified brake fluid DOT 4 EBS30096 INSTALLING THE BRAKE CALIPERS The following procedure applies to all of the brake calipers. 1. Install: • Brake caliper “1” (temporarily) • Copper washers • Brake hose “2” • Brake hose union bolt “3” Front brake hose union bolt 27 Nm (2.7 m·kgf, 20 ft·lbf) Rear brake hose union bolt...

  • Page 181: Checking The Brake Master Cylinder

    FRONT AND REAR BRAKES 4. Fill: 2. Check: • Brake master cylinder reservoir • Brake master cylinder reservoir Cracks/damage → Replace the brake master (with the specified amount of the specified brake fluid) cylinder. • Brake master cylinder reservoir diaphragm Specified brake fluid •...
  • Page 182 FRONT AND REAR BRAKES EWB02880 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.

  • Page 183: Parking Brake

    PARKING BRAKE EBS20027 PARKING BRAKE Disassembling the parking brake (10) 28 Nm (2.8 m kgf, 20 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • ’...
  • Page 184 PARKING BRAKE Removing the parking brake lever 16 Nm (1.6 m kgf, 12 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) •...

  • Page 185: Checking The Friction Plates

    PARKING BRAKE EBS30421 CHECKING THE FRICTION PLATES Pitting on the parking brake boss will cause er- The following procedure applies to all of the fric- ratic brake operation. tion plates. 1. Check: • Friction plate Damage/wear → Replace the friction plates as a set.

  • Page 186: Installing The Parking Brake Lever

    PARKING BRAKE EBS30105 INSTALLING THE PARKING BRAKE LEVER 1. Install: • Parking brake lever 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” on page 3-21. 4-43...

  • Page 187: Pedal Assembly

    PEDAL ASSEMBLY EBS20028 PEDAL ASSEMBLY Removing the pedal assembly 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (3)” on page Floor board (left) 4-6.
  • Page 188 PEDAL ASSEMBLY Disassembling the pedal assembly 17 Nm (1.7 m kgf, 12 ft Ibf) • • ’ Order Job/Parts to remove Remarks Brake pedal rod Spring Circlip Washer Brake pedal Spring Circlip Washer Accelerator pedal Pedal assembly bracket 4-45...

  • Page 189: Installing The Pedal Assembly

    PEDAL ASSEMBLY EBS30106 INSTALLING THE PEDAL ASSEMBLY 1. Install: • Throttle cable ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the nut “1” until it stops, and then install the throttle cable to the plate.

  • Page 190: Steering System

    STEERING SYSTEM EBS20029 STEERING SYSTEM Removing the steering assembly 21 Nm (2.1 m kgf, 15 ft Ibf) • • 33 Nm (3.3 m kgf, 24 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 33 Nm (3.3 m kgf, 24 ft Ibf) •...
  • Page 191 STEERING SYSTEM Removing the steering assembly 21 Nm (2.1 m kgf, 15 ft Ibf) • • 33 Nm (3.3 m kgf, 24 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 33 Nm (3.3 m kgf, 24 ft Ibf) •...

  • Page 192: Removing The Tie-Rod

    STEERING SYSTEM EBS30488 REMOVING THE TIE-ROD 1. Straighten the lock washer “a”. 2. Check: • Tie-rod end Bends/damage → Replace. 2. Loosen: Rubber boot damage → Replace the tie-rod • Tie-rod “1” end. EBS30109 INSTALLING THE STEERING SYSTEM 1. Install: •...
  • Page 193 STEERING SYSTEM 3. Bends the lock washer “a”. Tighten the steering assembly bolts in the prop- er tightening sequence as shown. 4. Install: • Dust boots ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...

  • Page 194: Lubricating The Steering Shaft

    STEERING SYSTEM 7. Adjust: • Toe-in Refer to “ADJUSTING THE TOE-IN” on page 3-32. EBS30426 LUBRICATING THE STEERING SHAFT Lubricate the pivoting point and metal-to-metal moving parts of the shaft. Recommended lubricant Lithium-soap-based grease 4-51...

  • Page 195: Steering Knuckles

    STEERING KNUCKLES EBS20030 STEERING KNUCKLES Removing the steering knuckles 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 39 Nm (3.9 m kgf, 28 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...

  • Page 196: Removing The Steering Knuckles

    STEERING KNUCKLES e. Apply lithium-soap-based grease to the spac- EBS30110 REMOVING THE STEERING KNUCKLES er, new bearings and oil seals. The following procedure applies to both of the f. Install the spacer to the steering knuckle. steering knuckles. g. Install the new bearings. 1.
  • Page 197 STEERING KNUCKLES Tool name Tool No. Long bolt 90890-01474 Body YM-01474 Guide bolt 90890-01477 Installer washer YM-01477 90890-01553 Base plate 35 mm YM-01553 Ball joint installer at- 90890-01555 d. Measure the ball joint bore inside diameter tachment 39 mm YS-01881-A “a”.

  • Page 198: Front Arms And Front Shock Absorber Assemblies

    FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES EBS20031 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Removing the front arms and front shock absorber assemblies 55 Nm (5.5 m kgf, 40 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 199 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Removing the front arms and front shock absorber assemblies 55 Nm (5.5 m kgf, 40 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 55 Nm (5.5 m kgf, 40 ft Ibf) •...

  • Page 200: Checking The Front Arms

    FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES damage or personal injury that may result EBS30113 CHECKING THE FRONT ARMS from improper handling of the front shock The following procedure applies to both of the absorber and gas cylinder. front upper arms and front lower arms. •...

  • Page 201: Checking The Front Arm Ball Joints

    FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES • Do not tap or damage the top of the ball joint or EBS30117 CHECKING THE FRONT ARM BALL JOINTS rubber boot. The following procedure applies to both of the front arm ball joints. Ball joint remover 1.

  • Page 202: Installing The Front Arms And Front Shock Absorber Assemblies

    FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES e. Hold the base plate “10” in place while turning in the long bolt “6” to install the new ball joint “5” into the front upper arm “4”. f. Remove the special tools. g.

  • Page 203: Rear Knuckles And Stabilizer

    REAR KNUCKLES AND STABILIZER EBS20032 REAR KNUCKLES AND STABILIZER Removing the rear knuckles and stabilizer 85 Nm (8.5 m kgf, 61 ft Ibf) 60 Nm (6.0 m kgf, 43 ft Ibf) • • • • 60 Nm (6.0 m kgf, 43 ft Ibf) •...
  • Page 204 REAR KNUCKLES AND STABILIZER Removing the rear knuckles and stabilizer 85 Nm (8.5 m kgf, 61 ft Ibf) 60 Nm (6.0 m kgf, 43 ft Ibf) • • • • 60 Nm (6.0 m kgf, 43 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf)

  • Page 205: Checking The Rear Knuckles And Rear Wheel Bearings

    REAR KNUCKLES AND STABILIZER EBS30119 EBS30121 CHECKING THE REAR KNUCKLES AND INSTALLING THE STABILIZER REAR WHEEL BEARINGS 1. Install: The following procedure applies to both of the • Stabilizer “1” rear knuckles and rear wheel bearings. • Bushing “2” 1. Check: •...
  • Page 206 REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES EBS20033 REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES Removing the rear arms and rear shock absorber assemblies 82 Nm (8.2 m kgf, 59 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 207 REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES Removing the rear arms and rear shock absorber assemblies 82 Nm (8.2 m kgf, 59 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 208 REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES property damage or personal injury that may EBS30122 CHECKING THE REAR ARMS result from improper handling of the rear The following procedure applies to both of the shock absorber and gas cylinder. rear upper arms and rear lower arms. •...
  • Page 209 REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES EBS30126 INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES The following procedure applies to both of the rear upper arms, rear lower arms, and rear shock absorber assemblies. 1. Install: • Rear upper arm •...
  • Page 210 REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES 4-67...
  • Page 211 ENGINE ENGINE INSPECTION ..................5-1 MEASURING THE COMPRESSION PRESSURE........5-1 ENGINE REMOVAL (1) ................... 5-3 INSTALLING THE EXHAUST PIPE AND MUFFLER........5-4 ENGINE REMOVAL (2) ................... 5-5 INSTALLING THE ENGINE............... 5-9 CAMSHAFTS....................5-10 REMOVING THE CAMSHAFTS..............5-12 CHECKING THE CAMSHAFTS ..............5-13 CHECKING THE CAMSHAFT SPROCKETS .........5-14 CHECKING THE TIMING CHAIN TENSIONER........
  • Page 212 OIL PUMP SPROCKETS ................5-42 REMOVING THE OIL PUMP DRIVE SPROCKET AND OIL PUMP DRIVEN SPROCKET ............5-43 CHECKING THE OIL PUMP SPROCKETS ..........5-43 INSTALLING THE OIL PUMP DRIVE SPROCKET AND OIL PUMP DRIVEN SPROCKET ............5-43 SHIFT LEVER....................5-45 CHECKING THE STOPPER LEVER ............5-47 CHECKING THE SHIFT LEVERS............
  • Page 213 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............5-81 ASSEMBLING THE SHIFT FORK............5-81 INSTALLING THE SHIFT FORKS AND SHIFT DRUM......

  • Page 214: Engine Inspection

    ENGINE INSPECTION 7. Measure: EBS20105 ENGINE INSPECTION • Compression pressure Out of specification → Refer to steps (b) and EBS30135 (c). MEASURING THE COMPRESSION PRESSURE Standard compression pressure (at sea level) Insufficient compression pressure will result in a 650–1000 kPa (6.5–10.0 kgf/cm², loss of performance.
  • Page 215 ENGINE INSPECTION 10.Install: • Frame cross member Refer to “GENERAL CHASSIS (9)” on page 4-19.

  • Page 216: Engine Removal (1)

    ENGINE REMOVAL (1) EBS20034 ENGINE REMOVAL (1) Removing the muffler and exhaust pipe 20 Nm (2.0 m kgf, 14 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) •...

  • Page 217: Installing The Exhaust Pipe And Muffler

    ENGINE REMOVAL (1) EBS30127 INSTALLING THE EXHAUST PIPE AND MUFFLER 1. Install: • Gasket “1” (muffler side) ECB01640 NOTICE Be careful not to damage the muffler contact surface of the gasket. 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.

  • Page 218: Engine Removal (2)

    ENGINE REMOVAL (2) EBS20093 ENGINE REMOVAL (2) Disconnecting the couplers and leads 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 4.9 Nm (0.49 m kgf, 3.5 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (9)” on page Frame cross member 4-19.
  • Page 219 ENGINE REMOVAL (2) Disconnecting the couplers and leads 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 4.9 Nm (0.49 m kgf, 3.5 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “AIR INDUCTION SYSTEM” on Air cut-off valve page 7-14.
  • Page 220 ENGINE REMOVAL (2) Disconnecting the couplers and leads 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 4.9 Nm (0.49 m kgf, 3.5 ft Ibf) • • ’ Order Job/Parts to remove Remarks Engine ground lead Disconnect. Starter motor lead Disconnect.
  • Page 221 ENGINE REMOVAL (2) Removing the engine 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 42 Nm (4.2 m kgf, 30 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 42 Nm (4.2 m kgf, 30 ft Ibf) •...

  • Page 222: Installing The Engine

    ENGINE REMOVAL (2) EBS30351 INSTALLING THE ENGINE 1. Install: • Engine brackets (rear) “1” (onto the engine) • Engine mounting bolts (rear) (M10) “2” • Engine mounting bolts (rear) (M6) “3” Before installing the engine, tighten the engine mounting bolts (rear) to specification. Engine mounting bolt (rear) (M10) 42 Nm (4.2 m·kgf, 30 ft·lbf) Engine mounting bolt (rear) (M6)

  • Page 223: Camshafts

    CAMSHAFTS EBS20106 CAMSHAFTS Removing the cylinder head cover 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 11 Nm (1.1 m kgf, 8.0 ft Ibf)* • • Specified angle 30–45˚* 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •...
  • Page 224 CAMSHAFTS Removing the camshafts 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) •...

  • Page 225: Removing The Camshafts

    CAMSHAFTS EBS30432 REMOVING THE CAMSHAFTS 1. Remove: • Crankshaft end accessing screw “1” • Timing mark accessing screw “2” ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Remove: • Timing chain tensioner •...

  • Page 226: Checking The Camshafts

    CAMSHAFTS 3. Measure: • Camshaft-journal-to-camshaft-cap clearance Out of specification → Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance 0.037–0.075 mm (0.0015–0.0030 ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the camshafts into the cylinder head EBS30433 CHECKING THE CAMSHAFTS (without the camshaft cap).

  • Page 227: Checking The Camshaft Sprockets

    CAMSHAFTS EBS30435 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • Timing chain tensioner Cracks/damage/rough movement → Re- place. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand.
  • Page 228 CAMSHAFTS 3. Install: • Bearing stoppers • Camshaft cap “1” Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) ECB02450 NOTICE • The camshaft cap bolts must be tightened evenly or damage to the cylinder head, b. Position the mark “a” on the AC magneto ro- camshaft cap, and camshafts will result.

  • Page 229: Installing The Breather Plate

    CAMSHAFTS c. Install a new gasket and the timing chain ten- 7. Measure: sioner cap bolt. • Valve clearance Out of specification → Adjust. Timing chain tensioner cap bolt Refer to “ADJUSTING THE VALVE CLEAR- 5 Nm (0.5 m·kgf, 3.6 ft·lbf) ANCE”...

  • Page 230: Cylinder Head, Cylinder, And Piston

    CYLINDER HEAD, CYLINDER, AND PISTON EBS20107 CYLINDER HEAD, CYLINDER, AND PISTON Removing the cylinder head 30 Nm (3.0 m kgf, 22 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) • • Loosen 360˚ 30 Nm (3.0 m kgf, 22 ft Ibf) •...
  • Page 231 CYLINDER HEAD, CYLINDER, AND PISTON Removing the cylinder head 30 Nm (3.0 m kgf, 22 ft Ibf) • • 70 Nm (7.0 m kgf, 51 ft Ibf) • • Loosen 360˚ 30 Nm (3.0 m kgf, 22 ft Ibf) • •...
  • Page 232 CYLINDER HEAD, CYLINDER, AND PISTON Removing the cylinder and piston ’ Order Job/Parts to remove Remarks Timing chain guide (exhaust side) Cylinder Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Top ring 2nd ring Oil ring 5-19...

  • Page 233: Removing The Cylinder Head

    CYLINDER HEAD, CYLINDER, AND PISTON • Before removing the piston pin, deburr the pis- EBS30438 REMOVING THE CYLINDER HEAD ton pin clip grooves and the piston pin bore ar- 1. Remove: ea. If both areas are deburred and the piston •...

  • Page 234: Checking The Cylinder Head

    CYLINDER HEAD, CYLINDER, AND PISTON EBS30439 CHECKING THE CYLINDER HEAD To ensure an even surface, rotate the cylinder 1. Eliminate: head several times. • Combustion chamber carbon deposits (with a rounded scraper) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...

  • Page 235: Checking The Piston Rings

    CYLINDER HEAD, CYLINDER, AND PISTON b. If out of specification, replace the cylinder, Top ring and replace the piston and piston rings as a Ring side clearance limit set. 0.12 mm (0.0047 in) c. Measure piston skirt diameter “P” with a mi- 2nd ring crometer.

  • Page 236: Checking The Piston Pin

    CYLINDER HEAD, CYLINDER, AND PISTON EBS30150 INSTALLING THE PISTON AND CYLINDER Top ring 1. Install: End gap (installed) limit • Oil ring expander “1” 0.50 mm (0.0197 in) 2nd ring • Lower oil ring rail “2” End gap (installed) limit •...

  • Page 237: Installing The Cylinder Head

    CYLINDER HEAD, CYLINDER, AND PISTON Recommended lubricant Engine oil 5. Install: ×4 • Cylinder “1” • Timing chain guide (exhaust side) ×4 • While compressing the piston rings with one hand, install the cylinder with the other hand. • Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity.
  • Page 238 CYLINDER HEAD, CYLINDER, AND PISTON Oil hose bolt (crankcase to cylin- der) 18 Nm (1.8 m·kgf, 13 ft·lbf) Tighten the clamp screw of each clamp “2” until 6 slots are visible in the area “a” of the clamp as shown in the illustration. 5-25...
  • Page 239 VALVES AND VALVE SPRINGS EBS20037 VALVES AND VALVE SPRINGS Removing the valves and valve springs 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “CYLINDER HEAD, CYLINDER, Cylinder head AND PISTON” on page 5-17. Valve lifter Valve pad Valve cotter...

  • Page 240: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EBS30141 REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “1” and the valve spring compressor attachment “2”.
  • Page 241 VALVES AND VALVE SPRINGS 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) limit b. Install the new valve guide with the valve 0.080 mm (0.0031 in) guide installer “2”...

  • Page 242: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 1. Eliminate: Valve guide remover & installer • Carbon deposits set (ø5.5) (from the valve face and valve seat) 90890-04016 2. Check: Valve guide remover (5.5 mm) • Valve seat YM-01122 Pitting/wear → Replace the cylinder head. Valve guide remover &...

  • Page 243: Checking The Valve Springs

    VALVES AND VALVE SPRINGS After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 244: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 2. Lubricate: b. Installed length • Valve stem “1” 2. Measure: • Valve stem end • Valve spring tilt “a” • Valve stem seal “2” Out of specification → Replace the valve (with the recommended lubricant) spring.
  • Page 245 VALVES AND VALVE SPRINGS 6. Lubricate: b. Smaller pitch • Valve pad 4. Install: • Valve lifter • Valve cotters (with the recommended lubricant) Recommended lubricant Install the valve cotters by compressing the Engine oil valve spring with the valve spring compressor “1”...

  • Page 246: Engine

    AC MAGNETO AND STARTER CLUTCH EBS20039 AC MAGNETO AND STARTER CLUTCH Removing the AC magneto and starter clutch 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) •...
  • Page 247 AC MAGNETO AND STARTER CLUTCH Removing the AC magneto and starter clutch 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) •...

  • Page 248: Removing The Ac Magneto Rotor

    AC MAGNETO AND STARTER CLUTCH • Make sure the flywheel puller is centered over EBS30151 REMOVING THE AC MAGNETO ROTOR the AC magneto rotor. 1. Remove: • AC magneto cover Flywheel puller (M38 X P1.5) 90890-04178 Loosen each bolt 1/4 of a turn at a time, in stag- Flywheel puller (M38 X P1.5) es and in a crisscross pattern.

  • Page 249: Installing The Starter Clutch

    AC MAGNETO AND STARTER CLUTCH 3. Check: Starter clutch bolt • Starter clutch gear contact surfaces 14 Nm (1.4 m·kgf, 10 ft·lbf) Damage/pitting/wear → Replace the defec- tive part(s). 4. Check: While holding the AC magneto rotor “2” with the •...
  • Page 250 AC MAGNETO AND STARTER CLUTCH 2. Tighten: • AC magneto rotor nut “1” AC magneto rotor nut 160 Nm (16 m·kgf, 116 ft·lbf) Hold the AC magneto rotor “2” with the rotor holding tool “3” while tightening the AC magneto rotor nut.

  • Page 251: Electric Starter

    ELECTRIC STARTER EBS20040 ELECTRIC STARTER Removing the starter motor 4.9 Nm (0.49 m kgf, 3.5 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks...
  • Page 252 ELECTRIC STARTER Disassembling the starter motor 4.9 Nm (0.49 m kgf, 3.5 ft Ibf) • • 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • ’ Order Job/Parts to remove Remarks Starter motor front cover Starter motor rear cover Washer kit Armature assembly Brush set...

  • Page 253: Checking The Starter Motor

    ELECTRIC STARTER EBS30157 CHECKING THE STARTER MOTOR Digital circuit tester 1. Check: 90890-03174 • Commutator Model 88 Multimeter with ta- Dirt → Clean with 600-grit sandpaper. chometer YU-A1927 2. Measure: • Commutator diameter “a” Out of specification → Replace the starter Armature coil motor.

  • Page 254: Assembling The Starter Motor

    ELECTRIC STARTER 8. Check: • Bushing Damage/wear → Replace the starter motor rear cover. EBS30158 ASSEMBLING THE STARTER MOTOR 1. Install: • Brush set “1” Align the tab “a” on the brush set with the slot “b” in the starter motor yoke. 2.

  • Page 255: Oil Pump Sprockets

    OIL PUMP SPROCKETS EBS20114 OIL PUMP SPROCKETS Removing the oil pump sprockets 25 Nm (2.5 m kgf, 18 ft Ibf) • • 25 Nm (2.5 m kgf, 18 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 256: Removing The Oil Pump Drive Sprocket And Oil Pump Driven Sprocket

    OIL PUMP SPROCKETS EBS30524 REMOVING THE OIL PUMP DRIVE Install the oil pump drive sprocket so that the SPROCKET AND OIL PUMP DRIVEN protruding portion “a” of the sprocket is facing to- SPROCKET ward the crankcase. 1. Loosen: • Oil pump driven sprocket nut “1” •...
  • Page 257 OIL PUMP SPROCKETS Oil pump drive sprocket nut 25 Nm (2.5 m·kgf, 18 ft·lbf) LOCTITE® Oil pump driven sprocket nut 25 Nm (2.5 m·kgf, 18 ft·lbf) LOCTITE® ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 258: Shift Lever

    SHIFT LEVER EBS20042 SHIFT LEVER Removing the drive select lever shift rod and drive select lever 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 15 Nm (1.5 m kgf, 11 ft Ibf) • • 15 Nm (1.5 m kgf, 11 ft Ibf) •...
  • Page 259 SHIFT LEVER Removing the shift levers and stopper lever 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 260: Checking The Stopper Lever

    SHIFT LEVER EBS30163 CHECKING THE STOPPER LEVER 1. Check: • Stopper lever Damage/wear → Replace. • Stopper lever spring Damage/wear → Replace. EBS30164 CHECKING THE SHIFT LEVERS 1. Check: • Shift lever 1 3. Install: • Shift lever 2 • Shift lever 2 assembly “1” Damage/wear →...

  • Page 261: Adjusting The Drive Select Lever Shift Rod

    SHIFT LEVER EBS30444 ADJUSTING THE DRIVE SELECT LEVER Press the spacer into the shift lever cover, mak- SHIFT ROD ing sure that the slit “a” in the spacer is facing up- EWB03060 NOTICE ward as shown in the illustration. Before moving the drive select lever, bring the vehicle to a complete stop and take your foot off the accelerator pedal.
  • Page 262 SHIFT LEVER Drive select lever shift rod lock- 15 Nm (1.5 m·kgf, 11 ft·lbf) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5-49...

  • Page 263: Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES EBS20043 PRIMARY AND SECONDARY SHEAVES Removing the primary and secondary sheaves 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 100 Nm (10.0 m kgf, 72 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 264 PRIMARY AND SECONDARY SHEAVES Disassembling the primary sheave * Apply Yamaha Grizzly grease or Yamaha grease F. ’ Order Job/Parts to remove Remarks Primary sheave cap Primary sheave slider Primary sheave cam Primary sheave weight Spacer Oil seal Hunterworks.com click to save...
  • Page 265 PRIMARY AND SECONDARY SHEAVES Disassembling the secondary sheave ® * Apply Yamaha grease H or POLYREX EM ’ Order Job/Parts to remove Remarks Secondary sheave spring retaining nut Upper spring seat Compression spring Lower spring seat Guide pin Secondary sliding sheave...

  • Page 266: Removing The Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES EBS30167 REMOVING THE PRIMARY AND Sheave fixed block SECONDARY SHEAVES 90890-04135 1. Loosen: Sheave fixed bracket YM-04135 • Primary sheave assembly nut “1” Locknut wrench 90890-01348 Use the rotor holding tool “2” to hold the primary Locknut wrench sheave.

  • Page 267: Checking The V-Belt

    PRIMARY AND SECONDARY SHEAVES 2. Check: • Primary sliding sheave • Primary fixed sheave Cracks/damage → Replace. EBS30171 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the pri- mary sheave weights. 1. Check: • Primary sheave weight ▲...

  • Page 268: Assembling The Primary Sheave

    • Spacer inner surface • Primary sliding sheave inner surface Recommended lubricant Yamaha Grizzly grease or Yamaha grease F • Apply Yamaha Grizzly grease or Yamaha grease F (2.5 g) to the inner surface of the EBS30174 ASSEMBLING THE PRIMARY SHEAVE spacer.

  • Page 269: Assembling The Secondary Sheave

    • Guide pin grooves “1” (with the recommended lubricant) Recommended lubricant Yamaha grease H or POLYREX EM® Apply Yamaha grease H or POLYREX EM® (5.0 g) to the guide pin grooves. 2. Lubricate: • Secondary sliding sheave “1” • Secondary fixed sheave “2”...

  • Page 270: Installing The Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Attach the sheave fixed block “5”, locknut wrench “6” and sheave spring compressor “7” to the secondary sheave. Sheave fixed block 90890-04135 Sheave fixed bracket...
  • Page 271 PRIMARY AND SECONDARY SHEAVES A. Correct position B. Incorrect position 3. Tighten: • Primary sheave assembly nut “1” Primary sheave assembly nut 190 Nm (19 m·kgf, 137 ft·lbf) Use the rotor holding tool “2” to hold the primary sheave. 2. Check: •...
  • Page 272 PRIMARY AND SECONDARY SHEAVES Shift the transmission into “L” (low) or “H” (high), set the parking brake, and then tighten the sec- ondary sheave assembly nut. 5. Lubricate: • Bearing housing bearing inner surface and ball (with the recommended lubricant) Recommended lubricant Shell Sunlight Grease 3®...

  • Page 273: Clutch

    CLUTCH EBS20044 CLUTCH Removing the clutch 190 Nm (19 m kgf, 137 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “PRIMARY AND SECONDARY Drive belt case SHEAVES”...
  • Page 274 CLUTCH Disassembling the clutch housing assembly ’ Order Job/Parts to remove Remarks Oil seal Circlip Bearing housing Circlip Bearing Seal ring One-way clutch bearing Bearing Clutch housing 5-61...

  • Page 275: Removing The Clutch

    CLUTCH • One-way clutch bearing EBS30177 REMOVING THE CLUTCH Chafing/wear/damage → Replace. 1. Remove: • Clutch housing assembly • Replace the one-way clutch bearing and clutch housing as a set. Working in crisscross pattern, loosen each bolt • The one-way clutch bearing must be installed 1/4 of a turn.

  • Page 276: Assembling The Clutch Housing

    CLUTCH a. Clutch shoe wear limit EBS30181 INSTALLING THE CLUTCH EBS30180 1. Install: ASSEMBLING THE CLUTCH HOUSING • Clutch carrier assembly 1. Install: • Clutch carrier assembly nut “1” • Bearing “1” (into the clutch housing “2”) Clutch carrier assembly nut 190 Nm (19 m·kgf, 137 ft·lbf) Installed depth “a”...
  • Page 277 CLUTCH • Tighten the bolts in stages, using a crisscross pattern. • After tightening the bolts, check that the clutch housing assembly rotates smoothly. 5-64...

  • Page 278: Crankcase

    CRANKCASE EBS20045 CRANKCASE Separating the crankcase 7 Nm (0.7 m kgf, 5.1 ft Ibf) 17 Nm (1.7 m kgf, 12 ft Ibf) 18 Nm (1.8 m kgf, 13 ft Ibf) • • • • • • 35 Nm (3.5 m kgf, 25 ft Ibf) 10 Nm (1.0 m...
  • Page 279 CRANKCASE Separating the crankcase 7 Nm (0.7 m kgf, 5.1 ft Ibf) 17 Nm (1.7 m kgf, 12 ft Ibf) 18 Nm (1.8 m kgf, 13 ft Ibf) • • • • • • 35 Nm (3.5 m kgf, 25 ft Ibf) •...
  • Page 280 CRANKCASE Removing the crankcase bearings 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “CRANKSHAFT AND OIL PUMP” Crankshaft/Oil pump on page 5-71. Middle drive shaft/Middle driven shaft Refer to “MIDDLE GEAR” on page 5-83. Transmission Refer to “TRANSMISSION”...

  • Page 281: Separating The Crankcase

    CRANKCASE EBS30182 SEPARATING THE CRANKCASE 1. Remove: • Crankcase bolts Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. EBS30183 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1.

  • Page 282: Checking The Crankcase

    2. Thoroughly clean the crankcase mating sur- faces. 3. Apply: • Sealant “1” (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) Do not allow any sealant to come into contact with the oil gallery. 5-69...
  • Page 283 CRANKCASE • Adapter “2” • Oil filter cartridge union bolt Oil filter cartridge union bolt 68 Nm (6.8 m·kgf, 49 ft·lbf) ×3 ×2 ×1 Align the pin “a” in the adapter with the hole “b” in the crankcase. ×3 ×2 ×6 A.

  • Page 284: Crankshaft And Oil Pump

    CRANKSHAFT AND OIL PUMP EBS20046 CRANKSHAFT AND OIL PUMP Removing the crankshaft and oil pump 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Separate.
  • Page 285 CRANKSHAFT AND OIL PUMP Disassembling the oil pump 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • ’ Order Job/Parts to remove Remarks Oil pump housing cover Oil pump shaft Oil pump inner rotor Oil pump outer rotor Oil pump housing 5-72...

  • Page 286: Removing The Crankshaft

    CRANKSHAFT AND OIL PUMP EBS30188 REMOVING THE CRANKSHAFT 1. Remove: • Crankshaft “1” • Balancer “2” • Remove the crankshaft with the crankcase separating tool “3”. • Make sure the crankcase separating tool is centered over the crankshaft. • Remove the crankshaft “1” and balancer “2” at 1.

  • Page 287: Checking The Crankshaft

    CRANKSHAFT AND OIL PUMP EBS30191 CHECKING THE CRANKSHAFT Recommended lubricant 1. Measure: Engine oil • Crankshaft width “a” Out of specification → Replace the crank- 2. Install: shaft. • Oil pump housing “1” • Oil pump outer rotor “2” Crank assembly width •...

  • Page 288: Installing The Oil Pump

    CRANKSHAFT AND OIL PUMP 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 EBS30445 INSTALLING THE OIL PUMP 1. Install: • Oil pump Oil pump bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tighten the bolts to specification in the proper...
  • Page 289 TRANSMISSION EBS20047 TRANSMISSION Removing the transmission, shift drum and shift forks 18 Nm (1.8 m kgf, 13 ft Ibf) • • ’ Order Job/Parts to remove Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-65. Middle driven gear Refer to “MIDDLE GEAR” on page 5-83. Shift drum stopper bolt Spring Ball...
  • Page 290 TRANSMISSION Removing the transmission, shift drum and shift forks 18 Nm (1.8 m kgf, 13 ft Ibf) • • ’ Order Job/Parts to remove Remarks Drive axle assembly Collar Reverse idle gear Bearing Reverse idle gear shaft 5-77...
  • Page 291 TRANSMISSION Disassembling the drive axle assembly ’ Order Job/Parts to remove Remarks Washer Collar High wheel gear Washer Clutch dog Circlip Washer Collar Low wheel gear 5-78...
  • Page 292 TRANSMISSION Disassembling the drive axle assembly ’ Order Job/Parts to remove Remarks Washer Circlip Middle drive gear Circlip Washer Bearing Reverse wheel gear Collar Drive axle 5-79...

  • Page 293: Transmission

    TRANSMISSION EBS30194 REMOVING THE TRANSMISSION 1. Remove: • Shift drum “1” • Shift fork assembly “2” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Pull out the guide bar from the right crank- case, and then remove the shift fork cam fol- lowers.

  • Page 294: Checking The Transmission

    TRANSMISSION EBS30199 CHECKING THE SECONDARY SHAFT 1. Check: • Gear teeth Blue discoloration/pitting/wear → Replace. EBS30200 ASSEMBLING THE DRIVE AXLE 1. Install: • Washer “1” • Circlip “2” EBS30198 CHECKING THE TRANSMISSION 1. Measure: • Be sure the circlip sharp-edged corner “a” is •...

  • Page 295: Installing The Shift Forks And Shift Drum

    TRANSMISSION EBS30202 INSTALLING THE SHIFT FORKS AND SHIFT DRUM 1. Install: • Reverse idle gear “1” • Drive axle assembly “2” • Secondary shaft “3” • Shift fork assembly “4” • Shift drum “5” Install the shift fork assembly “4” with the “L” mark “a”...

  • Page 296: Middle Gear

    MIDDLE GEAR EBS20048 MIDDLE GEAR Removing the middle drive shaft 190 Nm (19 m kgf, 137 ft lbf) • • 38 Nm (3.8 m kgf, 27 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • ’...
  • Page 297 MIDDLE GEAR Removing the middle drive shaft 190 Nm (19 m kgf, 137 ft lbf) • • 38 Nm (3.8 m kgf, 27 ft Ibf) • • 29 Nm (2.9 m kgf, 21 ft Ibf) • • ’ Order Job/Parts to remove Remarks Bearing retainer Bearing...
  • Page 298 MIDDLE GEAR Removing the middle driven shaft 190 Nm (19 m kgf, 137 ft lbf) • • 25 Nm (2.5 m kgf, 18 ft Ibf) • • 80 Nm (8.0 m kgf, 58 ft Ibf) • • 130 Nm (13 m kgf, 94 ft lbf) •...
  • Page 299 MIDDLE GEAR Removing the middle driven shaft 190 Nm (19 m kgf, 137 ft lbf) • • 25 Nm (2.5 m kgf, 18 ft Ibf) • • 80 Nm (8.0 m kgf, 58 ft Ibf) • • 130 Nm (13 m kgf, 94 ft lbf) •...

  • Page 300: Removing The Middle Drive Shaft

    MIDDLE GEAR EBS30203 REMOVING THE MIDDLE DRIVE SHAFT Coupling gear/middle shaft tool 1. Straighten: 90890-01229 • Punched portion of the middle drive pinion Gear holder YM-01229 gear nut 2. Loosen: • Middle drive pinion gear nut “1” Wrap the middle drive shaft in a folded rag, and then secure it in a vise.

  • Page 301: Checking The Pinion Gears

    MIDDLE GEAR • Install a suitable socket “2” on the middle Ring nut wrench driven pinion gear end to protect the thread 90890-01430 from damage. Ring nut wrench c. Press the middle driven pinion gear end and YM-38404 remove the bearing housing. ECB01750 NOTICE The middle driven shaft bearing retainer has...

  • Page 302: Installing The Bearing And Oil Seals

    MIDDLE GEAR EBS30206 INSTALLING THE BEARING AND OIL SEALS Ring nut wrench 1. Install: 90890-01430 • Bearing “1” Ring nut wrench YM-38404 • Oil seal “2” (into the bearing housing “3”) ECB01760 NOTICE Installed depth “a” of bearing The middle driven shaft bearing retainer has 0.9–1.4 mm (0.035–0.055 in) left-hand threads.

  • Page 303: Installing The Middle Drive Shaft

    MIDDLE GEAR ECB01770 NOTICE The middle driven pinion gear bearing retain- er has left-hand threads. To tighten the re- tainer turn it counterclockwise. 5. Install: • Rear drive shaft coupling gear “1” • Washer • Rear drive shaft coupling gear nut “2” Rear drive shaft coupling gear ▲...

  • Page 304: Measuring The Middle Gear Backlash

    MIDDLE GEAR • Wrap the middle drive shaft in a folded rag, and then secure it in a vise. • Lock the threads with a drift punch. 2. Install: • Washer “1” • Bearing “2” • Bearing retainers “3” • Bearing retainer bolts “4” EBS30209 MEASURING THE MIDDLE GEAR Middle drive shaft bearing retain-...

  • Page 305: Aligning The Middle Gear

    MIDDLE GEAR a. 39.3 mm (1.55 in) b. 25.3 mm (1.00 in) d. Measure the gear lash while rotating the mid- dle driven shaft back and forth. Measure the gear lash at 4 positions. Rotate the middle driven gear 90° each time. e.
  • Page 306 MIDDLE GEAR 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 thick- ness “B”, use the following formula. Middle driven pinion gear shim thickness “B” = “f” - “g” + “h” - “i” - “j” “f”...
  • Page 307 MIDDLE GEAR If the driven pinion gear is marked “+02”, Therefore, “B” is 0.81. “g” is 61.02 “B” = 89.53 - 61.02 + 80.40 - 99.98 - 8.12 = 0.81 Round off hundredth digit and select appro- priate shim(s). In the above example, the calculated shim thickness is 0.81 mm.
  • Page 308 MIDDLE GEAR 5-95...

  • Page 309: Cooling System

    COOLING SYSTEM OIL COOLER....................6-1 CHECKING THE OIL COOLER ..............6-3 INSTALLING THE HORN (except for CDN)..........6-3 RADIATOR ...................... 6-4 CHECKING THE RADIATOR..............6-6 INSTALLING THE RADIATOR..............6-6 THERMOSTAT ....................6-8 CHECKING THE THERMOSTAT.............. 6-9 INSTALLING THE THERMOSTAT............6-9 WATER PUMP....................6-11 DISASSEMBLING THE WATER PUMP..........6-12 CHECKING THE WATER PUMP ............
  • Page 310 OIL COOLER EBS20050 OIL COOLER Removing the oil cooler 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
  • Page 311 OIL COOLER Removing the oil cooler 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 312: Oil Cooler

    OIL COOLER EBS30211 CHECKING THE OIL COOLER 1. Check: • Oil cooler fins Obstruction → Clean. Apply compressed air to the rear of the oil cooler. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. 2.

  • Page 313: Radiator

    RADIATOR EBS20051 RADIATOR Removing the radiator 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...
  • Page 314 RADIATOR Removing the radiator 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) •...

  • Page 315: Checking The Radiator

    RADIATOR EBS30213 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.
  • Page 316 RADIATOR Refer to “CHANGING THE COOLANT” on page 3-9. 3. Check: • Cooling system Leaks → Repair or replace any faulty part. 4. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-6.

  • Page 317: Thermostat

    THERMOSTAT EBS20052 THERMOSTAT Removing the thermostat 20 Nm (2.0 m kgf, 14 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-9.

  • Page 318: Checking The Thermostat

    THERMOSTAT • Thermostat housing (cylinder head) EBS30215 CHECKING THE THERMOSTAT • Thermostat outlet hose 1. Check: Cracks/damage → Replace. • Thermostat Does not open at 69–73 °C (156–163°F) → EBS30216 INSTALLING THE THERMOSTAT Replace. 1. Install: • Copper washer • Coolant temperature sensor ECB01910 NOTICE Use extreme care when handling the coolant...
  • Page 319 THERMOSTAT Refer to “CHECKING THE RADIATOR” on page 6-6. 6-10...

  • Page 320: Water Pump

    WATER PUMP EBS20053 WATER PUMP Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 321: Disassembling The Water Pump

    WATER PUMP EBS30217 DISASSEMBLING THE WATER PUMP Install the oil seal with a socket that matches its 1. Remove: outside diameter. • Mechanical seal “1” Installed depth of oil seal “a” Remove the mechanical seal from the inside of 0 mm (0 in) the AC magneto cover.

  • Page 322: Installing The Water Jacket Joint

    WATER PUMP 3. Install: • Impeller “1” Impeller 10 Nm (1.0 m·kgf, 7.2 ft·lbf) After installation, check that the impeller shaft ro- tates smoothly. 4. Install: • AC magneto cover Refer to “AC MAGNETO AND STARTER CLUTCH” on page 5-33. EBS30471 INSTALLING THE WATER JACKET JOINT 1.

  • Page 323: Fuel System

    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 ..................

  • Page 324: Fuel Tank

    FUEL TANK EBS20054 FUEL TANK Removing the fuel tank 16 Nm (1.6 m kgf, 12 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...

  • Page 325: Removing The Fuel Tank

    FUEL TANK EBS30221 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel hose connector holder • Fuel hose EWB03050 WARNING Cover fuel hose connections with a cloth when disconnecting them.

  • Page 326: Installing The Fuel Pump

    FUEL TANK È É a. upward EBS30226 INSTALLING THE FUEL TANK 1. Install: EBS30225 INSTALLING THE FUEL PUMP • Dampers “1” 1. Install: • Fuel pump gasket “1” Fit the projection “a” on the dampers into the hole “b” in the frame. •...

  • Page 327: Checking The Fuel Pressure

    FUEL TANK Refer to “GENERAL CHASSIS (9)” on page Fuel tank bracket bolt 4-19. 7 Nm (0.7 m·kgf, 5.1 ft·lbf) b. Disconnect the fuel hose “1” from the fuel rail. Fuel tank bolt Refer to “REMOVING THE THROTTLE 7 Nm (0.7 m·kgf, 5.1 ft·lbf) BODY”...

  • Page 328: Air Filter Case

    AIR FILTER CASE EBS20055 AIR FILTER CASE Removing the air filter case and air intake duct 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) •...
  • Page 329 AIR FILTER CASE Removing the air filter case and air intake duct 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) •...

  • Page 330: Installing The Air Filter Case

    AIR FILTER CASE EBS30228 INSTALLING THE AIR FILTER CASE 1. Install: • Air intake duct joint “1” (to the air filter case “2”) Align the projection “a” on the air intake duct joint between the projections “b” on the air filter case. 2.

  • Page 331: Throttle Body

    THROTTLE BODY EBS20056 THROTTLE BODY Removing the throttle body assembly 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 2.8 Nm (0.28 m kgf, 2.0 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf)
  • Page 332 THROTTLE BODY Removing the throttle body 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 2.8 Nm (0.28 m kgf, 2.0 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) •...
  • Page 333 THROTTLE BODY Disassembling the throttle body assembly 3.6 Nm (0.36 m kgf, 2.6 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • ’ Order Job/Parts to remove Remarks Intake air pressure sensor Intake air pressure sensor hose...

  • Page 334: Removing The Throttle Body

    THROTTLE BODY EBS30229 EBS30231 REMOVING THE THROTTLE BODY CHECKING THE THROTTLE BODY 1. Disconnect: 1. Check: • Fuel hose • Throttle body Cracks/damage → Replace the throttle body. EWB03050 WARNING 2. Check: Cover fuel hose connections with a cloth • Fuel passages Obstructions →...
  • Page 335 THROTTLE BODY Air intake silencer joint clamp screw (air intake silencer side) 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) Air intake silencer joint clamp screw (throttle body side) 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) • Align the projection “a” on the throttle body as- sembly between the tabs “b”...

  • Page 336: Adjusting The Throttle Position Sensor

    THROTTLE BODY Throttle position sensor output voltage 0.63–0.73 V f. After adjusting the throttle position sensor an- gle, tighten the throttle position sensor screws “2”. Throttle position sensor screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) EBS30234 ADJUSTING THE THROTTLE POSITION SENSOR EWB03070 WARNING...

  • Page 337: Air Induction System

    AIR INDUCTION SYSTEM EBS20057 AIR INDUCTION SYSTEM 1. Air intake silencer 2. Air induction system hose (air intake silencer to air cut-off valve) 3. Air cut-off valve 4. Air induction system hose (air cut-off valve to reed valve cover) 5. Reed valve 7-14...
  • Page 338 AIR INDUCTION SYSTEM Removing the air cut-off valve 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (9)” on page Cargo bed 4-19. Air induction system solenoid coupler Disconnect. Air induction system hose (air cut-off valve to reed valve cover) Air induction system hose (air intake silencer to...
  • Page 339 AIR INDUCTION SYSTEM Removing the reed valve 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • ’ Order Job/Parts to remove Remarks Reed valve cover Reed valve assembly Reed valve plate 7-16...

  • Page 340: Checking The Air Induction System

    AIR INDUCTION SYSTEM 2. Check: EBS30235 CHECKING THE AIR INDUCTION SYSTEM • Reed valve • Reed valve stopper Air injection • Reed valve seat The air induction system burns unburned ex- Cracks/damage → Replace the reed valve haust gases by injecting fresh air (secondary air) assembly.

  • Page 341: Drive Train

    DRIVE TRAIN TROUBLESHOOTING..................8-1 CHECKING NOISES ................. 8-2 TROUBLESHOOTING CHART ..............8-3 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFTS........... 8-4 DISASSEMBLING THE UNIVERSAL JOINTS........8-10 DISASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES ..................8-10 CHECKING THE FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES ..................

  • Page 342: Troubleshooting

    TROUBLESHOOTING EBS20058 TROUBLESHOOTING The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1. A pronounced hesitation or “jerky” movement A. Bearing damage. during acceleration, deceleration, or sustained B. Improper gear backlash. speed. (This must not be confused with engine C.

  • Page 343: Checking Noises

    TROUBLESHOOTING ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ EBS30237 CHECKING NOISES a. Clean the entire vehicle thoroughly, then dry 1. Investigate any unusual noises. b. Apply a leak detection compound or dry pow- ▼...

  • Page 344: Troubleshooting Chart

    TROUBLESHOOTING EBS30238 TROUBLESHOOTING CHART When basic conditions (a) and (b) described in “CHECKING NOISES” exist, check the following points: YES → Replace the wheel bearing. (Refer to 1. Elevate and spin both wheels. Feel “STEERING KNUCKLES” on page 4-52 for wheel bearing damage. and “REAR KNUCKLES AND STABILIZ- ER”...

  • Page 345: Front Constant Velocity Shaft Assemblies, Differential Assembly And Front Drive Shafts

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFTS EBS20059 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFTS Removing the front constant velocity shaft assemblies, differential assembly, and front drive shafts 18 Nm (1.8 m kgf, 13 ft Ibf) •...
  • Page 346 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFTS Removing the front constant velocity shaft assemblies, differential assembly, and front drive shafts 18 Nm (1.8 m kgf, 13 ft Ibf) • • 60 Nm (6.0 m kgf, 43 ft Ibf) •...
  • Page 347 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFTS Disassembling the front constant velocity shaft assemblies A: Wheel side B: Differential side ’ Order Job/Parts to remove Remarks The following procedure applies to both of the front constant velocity shaft assemblies. Boot band Boot band Dust boot...
  • Page 348 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFTS Disassembling the front constant velocity shaft assemblies A: Wheel side B: Differential side ’ Order Job/Parts to remove Remarks Dust boot Constant velocity joint Clip Constant velocity shaft...
  • Page 349 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFTS Disassembling the differential assembly 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • 62 Nm (6.2 m kgf, 45 ft Ibf) • • 24 Nm (2.4 m kgf, 17 ft Ibf) •...
  • Page 350 FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFTS Disassembling the differential assembly 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • 62 Nm (6.2 m kgf, 45 ft Ibf) • • 24 Nm (2.4 m kgf, 17 ft Ibf) •...

  • Page 351: Disassembling The Universal Joints

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFTS EBS30239 DISASSEMBLING THE UNIVERSAL JOINTS 1. Remove: • Universal joint ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a.

  • Page 352: Checking The Front Constant Velocity Shaft Assemblies

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFTS B. Wheel side EBS30241 CHECKING THE FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES The following procedure applies to both of the front constant velocity shaft assemblies. 1. Check: • Double offset joint splines •...

  • Page 353: Removing The Front Drive Shaft Yoke

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFTS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the dust boots. b. Install the boot bands “4” and “5”. Use the boot band installation tool “6”.

  • Page 354: Removing The Differential Gear Assembly

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFTS • Differential case cover Cracks/damage → Replace. When the differential case and/or the differential case cover are replaced, be sure to adjust the shim of the differential gear assembly. 2.

  • Page 355: Assembling The Front Drive Shaft

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFTS Installed depth of oil seal “a” -0.5–0.5 mm (-0.020–0.020 in) A. Check that the differential motor pinion gear “2” turns counterclockwise. B. Check that the differential motor pinion gear “2”...

  • Page 356: Assembling The Universal Joint

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFTS “a” on the differential motor pinion gear is aligned with the mark “b” on the differential motor case. ECB01650 NOTICE Do not use a 12 V battery to operate the dif- ferential motor pinion gear.

  • Page 357: Measuring The Differential Gear Backlash

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFTS EBS30251 MEASURING THE DIFFERENTIAL GEAR BACKLASH 1. Secure the differential case in a vise or anoth- er supporting device. 2. Remove: • Drain bolt • Gasket 3. Install: •...

  • Page 358: Adjusting The Differential Gear Backlash

    FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN- TIAL ASSEMBLY AND FRONT DRIVE SHAFTS EBS30252 ADJUSTING THE DIFFERENTIAL GEAR BACKLASH 1. Remove: • Differential gear assembly shim(s) “1” • Differential gear assembly “2” 2. Adjust: • Gear backlash ▼ ▼▼▼ ▼ ▼▼▼ ▼...

  • Page 359: Rear Constant Velocity Shaft Assemblies, Final Drive Assembly And Rear Drive Shaft

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT EBS20060 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Removing the rear constant velocity shaft assemblies, final drive assembly, and rear drive shaft 33 Nm (3.3 m kgf, 24 ft Ibf) •...
  • Page 360 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 33 Nm (3.3 m kgf, 24 ft Ibf) • • 33 Nm (3.3 m kgf, 24 ft Ibf) 105 Nm (10.5 m...
  • Page 361 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Disassembling the rear constant velocity shaft assemblies A: Wheel side B: Final drive side ’ Order Job/Parts to remove Remarks The following procedure applies to both of the rear constant velocity shaft assemblies. Boot band Boot band Clip...
  • Page 362 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Disassembling the rear constant velocity shaft assemblies A: Wheel side B: Final drive side ’ Order Job/Parts to remove Remarks Dust boot Constant velocity joint Clip Constant velocity shaft 8-21...
  • Page 363 Ibf) • • 52 Nm (5.2 m kgf, 38 ft Ibf) • • * Apply Yamaha bond No. 1215 (90890-85505). ’ Order Job/Parts to remove Remarks Ring gear stopper Ring gear bearing housing Ring gear bearing housing gasket Dowel pin...
  • Page 364 Ibf) • • 52 Nm (5.2 m kgf, 38 ft Ibf) • • * Apply Yamaha bond No. 1215 (90890-85505). ’ Order Job/Parts to remove Remarks Oil seal Rear drive shaft coupling gear nut (final drive assembly side) Rear drive shaft coupling gear (final drive as-...
  • Page 365 17 ft Ibf) • • 52 Nm (5.2 m kgf, 38 ft Ibf) • • * Apply Yamaha bond No. 1215 (90890-85505). ’ Order Job/Parts to remove Remarks Circlip Final drive pinion gear bearing housing Final drive pinion gear Bearing...

  • Page 366: Disassembling The Rear Constant Velocity Shaft Assemblies

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT 3. Remove: EBS30253 DISASSEMBLING THE REAR CONSTANT • Dust boot VELOCITY SHAFT ASSEMBLIES • Constant velocity joint The following procedure applies to both of the • Clip rear constant velocity shaft assemblies. 1.
  • Page 367 REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT b. Install the constant velocity joint. • 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 con- stant velocity joint using a soft-face hammer.

  • Page 368: Disassembling The Final Drive Assembly

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Install the dust boots. b. Install the boot bands “2” and “3”. Use the boot band installation tool “4”.

  • Page 369: Checking The Rear Drive Shaft

    1. Install: pinion gear. • Ring gear stopper “1” • Ring gear stopper nut “2” • Apply Yamaha bond No.1215 to the ring gear stopper threads. • Apply LOCTITE® to the nut threads. 2. Adjust: • Ring gear stopper clearance ▼...

  • Page 370: Measuring The Final Gear Backlash

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT b. Turn the ring gear stopper 120° counterclock- 3. Attach: wise. • Gear lash measurement tool “1” • Dial gauge “2” Gear lash measurement tool 90890-01467 Gear lash measurement tool YM-01467 c.

  • Page 371: Assembling The Final Drive Assembly

    (onto the washer contact surface and splines and final drive ring gear shim (final drive case of the final drive pinion gear) side) “4” to obtain the shim thickness. Yamaha bond No. 1215 Final drive ring gear shims (final 90890-85505 drive case side) “4”...

  • Page 372: Installing The Final Drive Assembly

    REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE ASSEMBLY AND REAR DRIVE SHAFT Final drive assembly bracket bolt (upper side) 33 Nm (3.3 m·kgf, 24 ft·lbf) Final drive assembly nut (upper side) 105 Nm (10.5 m·kgf, 76 ft·lbf) Final drive assembly nut (lower side) 105 Nm (10.5 m·kgf, 76 ft·lbf) Final drive assembly bracket bolt...

  • Page 373: Electrical System

    FUEL INJECTION SYSTEM................9-33 CIRCUIT DIAGRAM (except for EPS models) ........9-33 CIRCUIT DIAGRAM (for EPS models)............9-35 ECU SELF-DIAGNOSTIC FUNCTION............9-37 TROUBLESHOOTING METHOD............9-38 YAMAHA DIAGNOSTIC TOOL ...............9-39 TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM) ....9-41 FUEL PUMP SYSTEM...................9-65 CIRCUIT DIAGRAM ................9-65 TROUBLESHOOTING ................9-67 2WD/4WD SELECTING SYSTEM..............9-69...
  • Page 374 EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)...9-73 CIRCUIT DIAGRAM ................9-73 EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION .....9-75 EPS WARNING LIGHT DURING NORMAL OPERATION......9-75 DIAGNOSTIC MODE ................9-76 SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)......9-78 TROUBLESHOOTING DETAILS (EPS SYSTEM) ........9-79 ELECTRICAL COMPONENTS..............9-83 CHECKING THE SWITCHES ..............9-89 CHECKING THE BULBS AND BULB SOCKETS ........

  • Page 376: Ignition System

    IGNITION SYSTEM EBS20074 IGNITION SYSTEM EBS30264 CIRCUIT DIAGRAM...
  • Page 377 IGNITION SYSTEM 1. Crankshaft position sensor 5. Frame ground 6. Main switch 7. Engine ground 8. Battery 9. Main fuse 21.ECU (Engine Control Unit) 22.Ignition coil 23.Spark plug 30.Lean angle sensor 34.Joint coupler 60.Ignition fuse B. Wire harness C. Negative battery sub-wire harness...

  • Page 378: Troubleshooting

    IGNITION SYSTEM EBS30265 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Hood 2. Cargo bed 3. Passenger seat frame 4. Passenger seat belt buckle rubber cover NG → 1.
  • Page 379 IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 9-89. OK ↓ NG → 9. Check the lean angle sensor. Refer to “CHECKING THE LEAN Replace the lean angle sensor. ANGLE SENSOR”...

  • Page 380: Electric Starting System

    ELECTRIC STARTING SYSTEM EBS20075 ELECTRIC STARTING SYSTEM EBS30266 CIRCUIT DIAGRAM...
  • Page 381 ELECTRIC STARTING SYSTEM 4. Load control relay 5. Frame ground 6. Main switch 7. Engine ground 8. Battery 9. Main fuse 11.Starter relay 12.Starter motor 17.Gear position switch 21.ECU (Engine Control Unit) 34.Joint coupler 56.Brake light switch 60.Ignition fuse 62.Signaling system fuse B.

  • Page 382: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EBS30267 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to “ ” (start), the starter motor can only operate if at least one of the following conditions is met: • The transmission is in neutral (the neutral circuit of the gear position switch is closed). •...

  • Page 383: Troubleshooting

    ELECTRIC STARTING SYSTEM EBS30268 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Hood 2. Cargo bed NG → 1. Check the fuses. (Main, ignition, and signaling sys- tem) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 384 ELECTRIC STARTING SYSTEM NG → 9. Check the gear position switch. Refer to “CHECKING THE Replace the gear position switch. SWITCHES” on page 9-89. OK ↓ NG → 10.Check the entire starting system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM”...
  • Page 385 ELECTRIC STARTING SYSTEM 9-10...

  • Page 386: Charging System

    CHARGING SYSTEM EBS20076 CHARGING SYSTEM EBS30269 CIRCUIT DIAGRAM 9-11...
  • Page 387 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 5. Frame ground 8. Battery 9. Main fuse B. Wire harness C. Negative battery sub-wire harness 9-12...

  • Page 388: Troubleshooting

    CHARGING SYSTEM EBS30270 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Hood 2. Passenger seat frame 3. Passenger seat belt buckle rubber cover NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”...
  • Page 389 CHARGING SYSTEM 9-14...

  • Page 390: Lighting System

    LIGHTING SYSTEM EBS20077 LIGHTING SYSTEM EBS30271 CIRCUIT DIAGRAM 9-15...
  • Page 391 LIGHTING SYSTEM 4. Load control relay 5. Frame ground 6. Main switch 8. Battery 9. Main fuse 52.Light switch 53.Headlight relay 54.Headlight 57.Tail/brake light 60.Ignition fuse 63.Headlight fuse B. Wire harness C. Negative battery sub-wire harness 9-16...

  • Page 392: Troubleshooting

    LIGHTING SYSTEM EBS30272 TROUBLESHOOTING Any of the following fail to light: headlight or taillight. • Before troubleshooting, remove the following part(s): 1. Hood NG → 1. Check the condition of each bulb and bulb socket. Refer to “CHECKING THE BULBS Replace the bulb(s) and bulb socket(s).
  • Page 393 LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 9-15. OK ↓ The lighting system circuit is OK. 9-18...

  • Page 394: Signaling System

    SIGNALING SYSTEM EBS20078 SIGNALING SYSTEM EBS30273 CIRCUIT DIAGRAM (except for EPS models) 9-19...
  • Page 395 SIGNALING SYSTEM 4. Load control relay 5. Frame ground 6. Main switch 7. Engine ground 8. Battery 9. Main fuse 17.Gear position switch 21.ECU (Engine Control Unit) 26.Coolant temperature sensor 27.Speed sensor 31.Parking brake switch 32.Parking brake buzzer 33.Reverse switch 34.Joint coupler 35.Seat belt switch 36.Indicator light assembly...

  • Page 396: Circuit Diagram (For Eps Models)

    SIGNALING SYSTEM EBS30352 CIRCUIT DIAGRAM (for EPS models) 9-21...
  • Page 397 SIGNALING SYSTEM 4. Load control relay 5. Frame ground 6. Main switch 7. Engine ground 8. Battery 9. Main fuse 18.Gear position switch 22.ECU (Engine Control Unit) 27.Coolant temperature sensor 28.Speed sensor 32.Parking brake switch 33.Parking brake buzzer 34.Reverse switch 35.Joint coupler 41.Seat belt switch 42.Indicator light assembly...

  • Page 398: Troubleshooting

    SIGNALING SYSTEM EBS30274 TROUBLESHOOTING • Any of the following fail to light: warning light, brake light or an indicator light. • The fuel meter fails to come on. • The speedometer fails to operate. • The parking brake buzzer fails to sound. •...
  • Page 399 SIGNALING SYSTEM Checking the signaling system The tail/brake lights fail to come on. NG → 1. Check the tail/brake light bulbs and sockets. Replace the tail/brake light bulb, socket or Refer to “CHECKING THE BULBS both. AND BULB SOCKETS” on page 9-92.
  • Page 400 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM (ex- Properly connect or replace the wire har- cept for EPS models)” on page 9-19 ness. and “CIRCUIT DIAGRAM (for EPS models)” on page 9-21. OK ↓...
  • Page 401 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM (ex- Properly connect or replace the wire har- cept for EPS models)” on page 9-19 ness. and “CIRCUIT DIAGRAM (for EPS models)” on page 9-21. OK ↓...
  • Page 402 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM (ex- Properly connect or replace the wire har- cept for EPS models)” on page 9-19 ness. and “CIRCUIT DIAGRAM (for EPS models)” on page 9-21. OK ↓...
  • Page 403 SIGNALING SYSTEM 9-28...

  • Page 404: Cooling System

    COOLING SYSTEM EBS20079 COOLING SYSTEM EBS30275 CIRCUIT DIAGRAM 9-29...
  • Page 405 COOLING SYSTEM 5. Frame ground 6. Main switch 8. Battery 9. Main fuse 21.ECU (Engine Control Unit) 26.Coolant temperature sensor 34.Joint coupler 58.Radiator fan motor fuse 60.Ignition fuse 65.Radiator fan motor 66.Radiator fan motor circuit breaker 67.Radiator fan motor relay B.

  • Page 406: Troubleshooting

    COOLING SYSTEM EBS30276 TROUBLESHOOTING The radiator fan motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Hood 2. Heat protector NG → 1. Check the fuses. (Main, radiator fan motor, and igni- tion) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 407 COOLING SYSTEM NG → 8. Check the entire cooling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 9-29. OK ↓ Replace the ECU. 9-32...

  • Page 408: Fuel Injection System

    FUEL INJECTION SYSTEM EBS20080 FUEL INJECTION SYSTEM EBS30277 CIRCUIT DIAGRAM (except for EPS models) 9-33...
  • Page 409 8. Battery 9. Main fuse 10.Fuel injection system fuse 13.Fuel injection system relay 14.Air induction system solenoid 17.Gear position switch 19.Yamaha diagnostic tool coupler 20.ISC (Idle Speed Control) unit 21.ECU (Engine Control Unit) 22.Ignition coil 23.Spark plug 24.Fuel injector 25.Intake air temperature sensor 26.Coolant temperature sensor...

  • Page 410: Circuit Diagram (For Eps Models)

    FUEL INJECTION SYSTEM EBS30353 CIRCUIT DIAGRAM (for EPS models) 9-35...
  • Page 411 8. Battery 9. Main fuse 11.Fuel injection system fuse 14.Fuel injection system relay 15.Air induction system solenoid 18.Gear position switch 20.Yamaha diagnostic tool coupler 21.ISC (Idle Speed Control) unit 22.ECU (Engine Control Unit) 23.Ignition coil 24.Spark plug 25.Fuel injector 26.Intake air temperature sensor 27.Coolant temperature sensor...

  • Page 412: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EBS30278 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 413: Troubleshooting Method

    FUEL INJECTION SYSTEM The engine operation is not normal, but the EBS30279 TROUBLESHOOTING METHOD engine trouble warning light does not come The engine operation is not normal and the 1. Check the operation of the following sensors engine trouble warning light comes on. and actuators in the diagnostic mode.

  • Page 414: Yamaha Diagnostic Tool

    FUEL INJECTION SYSTEM EBS30280 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool 90890-03231...
  • Page 415 FUEL INJECTION SYSTEM Operation of the Yamaha diagnostic tool (Malfunction mode) Malfunction results are displayed in the top part of the window area. 1. Recovered The item list of the malfunction detected in the past (already recovered) are displayed. 2. Detected The item list of the malfunction currently occurred are displayed.

  • Page 416: Troubleshooting Details (Fuel Injection System)

    FUEL INJECTION SYSTEM 5. Item The item names of the detected malfunction are displayed. 6. Condition The current conditions are displayed. (Detected/Recovered) 7. Symptom The symptoms of the detected malfunction are displayed. 8. Diagnosis code The diagnosis codes related to the detected malfunction are displayed. 9.
  • Page 417 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received from the Item crankshaft position sensor. Improperly connected → Con- Connection of ECU coupler. Crank the engine. Check the locking condition of nect the coupler securely or re- Fault code number is not dis- played →...
  • Page 418 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Improperly connected → Con- Connection of intake air pres- Turn the main switch to “ ” sure sensor coupler. nect the coupler securely or re- (on).
  • Page 419 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Defective intake air pressure Execute the diagnostic mode. Turn the main switch to “ ” sensor. (Code No. 03) (on). When engine is stopped: Fault code number is not dis- played →...
  • Page 420 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged or de- Item tached hose). Defective intake air pressure Execute the diagnostic mode. sensor. (Code No. 03) When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is indicated.
  • Page 421 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Improperly connected → Con- Connection of ECU coupler. Turn the main switch to “ ” Check the locking condition of nect the coupler securely or re- (on).
  • Page 422 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: stuck throttle position sensor is detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Throttle position sensor signal Indicated • 14–20 (fully closed position) Procedure Check with throttle valve fully closed.
  • Page 423 FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Improperly connected → Con- Connection of coolant tempera- Turn the main switch to “ ” ture sensor coupler. nect the coupler securely or re- (on). Check the locking condition of place the wire harness.
  • Page 424 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Indicated Displays the intake air temperature. Compare the actually measured intake air temperature with the indicated Procedure value.
  • Page 425 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Defective intake air temperature Execute the diagnostic mode. Turn the main switch to “ ” sensor. (Code No. 05) (on). When engine is cold: Fault code number is not dis- played →...
  • Page 426 Actuates the ignition coil five times at one-second intervals. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on each time the ignition coil is actuated. Check that a spark is generated five times. Procedure •...
  • Page 427 Fully closes the ISC valve, and then opens the valve. This operation takes approximately 3 seconds. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on during the operation. Procedure The operating sound can be heard when ISC valve operates.
  • Page 428 Fully closes the ISC valve, and then opens the valve. This operation takes approximately 3 seconds. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on during the operation. Procedure The operating sound can be heard when ISC valve operates.
  • Page 429 Actuates fuel injector five times at one-second intervals. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on each time the fuel injector is actuated. Disconnect the fuel pump coupler, and then check that fuel injector is ac- Procedure tuated five times by listening for the operating sound.
  • Page 430 FUEL INJECTION SYSTEM Fault code No. Item Fuel injector: open or short circuit detected. Improperly connected → Con- Connection of fuel injector cou- Execute the diagnostic mode. pler. nect the coupler securely or re- (Code No. 36) Operating sound → Go to item Check the locking condition of place the wire harness.
  • Page 431 FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Improperly connected → Con- Connection of lean angle sen- Turn the main switch to “ ” sor coupler. nect the coupler securely or re- (on), then to “ ”...
  • Page 432 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sen- Item sor. Check that the number increases when the rear wheels are rotated. The Procedure number is cumulative and does not reset each time the wheel is stopped. Probable cause of malfunc- Confirmation of service com- Item...
  • Page 433 ” on the Yamaha di- agnostic 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 listen- Procedure ing for the operating sound.
  • Page 434 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel injector Item and fuel pump. Open or short circuit → Replace Wire harness continuity. Start the engine and let it idle the wire harness. for approximately 5 seconds. Between fuel injection system Fault code number is not dis- played →...
  • Page 435 FUEL INJECTION SYSTEM Fault code No. EEPROM fault code number: an error is detected while reading or Item writing on EEPROM. “01” is indicated in diagnostic Change the CO concentration, Turn the main switch to “ ” mode (code No. 60). EEPROM and rewrite in EEPROM.
  • Page 436 FUEL INJECTION SYSTEM Fault code No. Faulty ECU (Engine Control Unit) memory. (When this malfunction is Item detected in the ECU, the fault code number might not appear.) Malfunction in ECU. Replace the ECU. Turn the main switch to “ ”...
  • Page 437 FUEL INJECTION SYSTEM Fault code No. Er-2 Fault code No. Er-2 ECU (Engine Control Unit) internal malfunction (output signal error): Item no signals are received from the ECU within the specified duration. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 438 FUEL INJECTION SYSTEM Fault code No. Er-3 ECU (Engine Control Unit) internal malfunction (output signal error): Item data from the ECU cannot be received correctly. Improperly connected → Con- Connection of meter assembly Turn the main switch to “ ” coupler.
  • Page 439 FUEL INJECTION SYSTEM Fault code No. Er-4 ECU (Engine Control Unit) internal malfunction (input signal error): Item non-registered data has been received from the meter assembly. Improperly connected → Con- Connection of ECU coupler. Turn the main switch to “ ”...

  • Page 440: Fuel Pump System

    FUEL PUMP SYSTEM EBS20081 FUEL PUMP SYSTEM EBS30282 CIRCUIT DIAGRAM 9-65...
  • Page 441 FUEL PUMP SYSTEM 5. Frame ground 6. Main switch 8. Battery 9. Main fuse 10.Fuel injection system fuse 13.Fuel injection system relay 21.ECU (Engine Control Unit) 34.Joint coupler 50.Fuel pump 60.Ignition fuse B. Wire harness C. Negative battery sub-wire harness 9-66...

  • Page 442: Troubleshooting

    FUEL PUMP SYSTEM EBS30283 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Hood 2. Rear panel (right) 3. Under-seat storage compartment NG → 1. Check the fuses. (Main, fuel injection system, and ig- nition) Replace the fuse(s).
  • Page 443 FUEL PUMP SYSTEM 9-68...

  • Page 444: 2Wd/4Wd Selecting System

    2WD/4WD SELECTING SYSTEM EBS20082 2WD/4WD SELECTING SYSTEM EBS30284 CIRCUIT DIAGRAM 9-69...
  • Page 445 2WD/4WD SELECTING SYSTEM 4. Load control relay 5. Frame ground 6. Main switch 8. Battery 9. Main fuse 15.Differential motor relay 1 16.Differential motor 18.On-Command four-wheel-drive switch 21.ECU (Engine Control Unit) 34.Joint coupler 39.Meter assembly 40.Multi-function meter 48.On-Command differential gear lock indicator light 51.Differential motor relay 2 59.Differential motor fuse...

  • Page 446: Troubleshooting

    2WD/4WD SELECTING SYSTEM EBS30285 TROUBLESHOOTING • The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential gear lock indicator fails to come on. • The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential gear lock indicator flashes. • Before troubleshooting, remove the following part(s): 1.
  • Page 447 2WD/4WD SELECTING SYSTEM NG → 8. Check the differential motor opera- tion. Refer to “CHECKING THE DIF- Replace the differential motor. FERENTIAL MOTOR OPERATION” on page 8-13. OK ↓ NG → 9. Check the entire 2WD/4WD select- ing system wiring. Properly connect or replace the 2WD/4WD Refer to “CIRCUIT DIAGRAM”...

  • Page 448: Eps (Electric Power Steering) System (For Eps Models)

    EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) EBS20083 EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) EBS30286 CIRCUIT DIAGRAM 9-73...
  • Page 449 EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) 4. Load control relay 5. Frame ground 6. Main switch 8. Battery 9. Main fuse 10.EPS fuse 22.ECU (Engine Control Unit) 28.Speed sensor 35.Joint coupler 36.EPS unit 37.EPS motor 38.EPS torque sensor 39.EPS self-diagnosis signal connector 40.EPS control unit 45.Meter assembly...

  • Page 450: Eps Control Unit's Self-Diagnostic Function

    EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) EBS30287 EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION The EPS control unit is equipped with a self-diagnostic function. If this function detects a malfunction in the EPS system, it lights the EPS warning light to alert the rider that a malfunction has occurred in the system.

  • Page 451: Diagnostic Mode

    EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) EBS30289 DIAGNOSTIC MODE Setting the diagnostic mode (present and past malfunctions) 1. Disconnect the EPS self-diagnosis signal connector “1”. 2. Turn the main switch to “ ” (on). 3. Select the signaling mode by grounding the EPS self-diagnosis signal connector (male side) to the EPS control unit “2”...
  • Page 452 EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) Signaling method Example 1: Fault code No. 23 0.5 × 3 0.5 × 5 a. EPS self-diagnosis signal connector B. Display of the present malfunctions stops when the past malfunction display mode is b.

  • Page 453: Self-Diagnostic Function Table (Eps System)

    EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) After the mode selection judgment is completed (present display or past malfunction mode), the current fault code signaling stops immediately, and then the EPS warning light starts flashing at 1.5-second in- tervals. 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.

  • Page 454: Troubleshooting Details (Eps System)

    EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) Fault code Probable cause of mal- Item Symptom function • Faulty battery. • Malfunction in the charging system. EPS control unit Battery voltage has dropped. Refer to “CHARGING SYSTEM” on page 9-11. •...
  • Page 455 EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) Fault code No. 21 Fault code No. Symptom Speed sensor: no normal signals are received from the speed sensor. Order Item/components and probable cause Check or maintenance job Reinstatement method Connections • Check the locking condition of the Starting the en- •...
  • Page 456 EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) Fault code No. 41, 42, 43, 45 Fault code No. 41, 42, Symptom EPS motor: no normal signals are received from the EPS motor. 43, 45 Order Item/components and probable cause Check or maintenance job Reinstatement method Connections...
  • Page 457 EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models) Fault code No. 54 Fault code No. Symptom Relay contacts in the EPS control unit are welded together. Order Item/components and probable cause Check or maintenance job Reinstatement method Malfunction in EPS control unit. Replace the EPS control unit.

  • Page 458: Electrical Components

    ELECTRICAL COMPONENTS EBS20084 ELECTRICAL COMPONENTS 9-83...
  • Page 459 ELECTRICAL COMPONENTS 1. Radiator fan motor 2. Lean angle sensor 3. Brake light switch 4. Parking brake buzzer 5. Parking brake switch 6. Seat belt switch 7. Gear position switch 8. Reverse switch 9. Intake air pressure sensor 10. TPS (throttle position sensor) 11.
  • Page 460 ELECTRICAL COMPONENTS 9-85...
  • Page 461 ELECTRICAL COMPONENTS 1. Auxiliary DC jack 2. Meter assembly 3. Indicator light assembly 4. Main switch 5. On-Command four-wheel-drive switch 6. Light switch 7. EPS torque sensor (for EPS models) 8. EPS motor (for EPS models) 9. EPS control unit (for EPS models) 10.
  • Page 462 ELECTRICAL COMPONENTS 19 18 17 16 15 14 9-87...
  • Page 463 ELECTRICAL COMPONENTS 1. Load control relay 2. Fuel injection system relay 3. Radiator fan motor relay 4. Headlight relay 5. Differential motor relay 1 6. Differential motor relay 2 7. Fuel injection system fuse 8. Spare fuse 9. Starter relay 10.

  • Page 464: Checking The Switches

    ELECTRICAL COMPONENTS EBS30292 CHECKING THE SWITCHES L/W B G/R DIFF LOCK Br/R Br/R (off) Br P L/W G/R (on) (start) (off) 9-89...
  • Page 465 ELECTRICAL COMPONENTS 1. Horn switch (except for CDN) 2. Main switch 3. On-Command four-wheel-drive switch 4. Gear position switch 5. Reverse switch 6. Seat belt switch 7. Light switch 8. Parking brake switch 9. Brake light switch 9-90...
  • Page 466 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECB01430 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.

  • Page 467: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS • Avoid touching the glass part of a headlight EBS30293 CHECKING THE BULBS AND BULB bulb to keep it free from oil, otherwise the SOCKETS transparency of the glass, the life of the bulb, and the luminous flux will be adverse- Do not check any of the lights that use LEDs.

  • Page 468: Replacing The Headlight Bulbs

    ELECTRICAL COMPONENTS 4. Remove: • Headlight bulb holder “1” Check each bulb socket for continuity in the • Headlight bulb “2” same manner as described in the bulb section; EWB02860 however, note the following. WARNING ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼...

  • Page 469: Adjusting The Headlight Beams

    ELECTRICAL COMPONENTS Amperage Fuses Q’ty rating EPS (for EPS models) 40.0 A Main 40.0 A Radiator fan motor 25.0 A Headlight 15.0 A Backup 10.0 A Fuel injection system 10.0 A 9. Install: Ignition 10.0 A • Headlight rear cover Differential motor 10.0 A Signaling system...

  • Page 470: Checking And Charging The Battery

    ELECTRICAL COMPONENTS d. If the fuse immediately blows again, check ECB01990 NOTICE the electrical circuit. • This is a VRLA (Valve Regulated Lead Acid) EWB02850 WARNING battery. Never remove the sealing caps be- Never use a fuse with an amperage rating cause the balance between cells will not be other than that specified.
  • Page 471 ELECTRICAL COMPONENTS 5. Charge: • Positive tester probe → • Battery positive battery terminal • Negative tester probe → (refer to the appropriate charging method) negative battery terminal EWB02840 WARNING Do not quick charge a battery. • The charge state of a VRLA (Valve Regulated ECB02000 Lead Acid) battery can be checked by measur- NOTICE...

  • Page 472: Checking The Relays

    ELECTRICAL COMPONENTS 7. Connect: • Battery leads (to the battery terminals) ECB01330 NOTICE First, connect the positive battery lead “1”, and then the negative battery lead “2”. A. Open-circuit voltage (V) B. Time (minutes) C. Charging D. Ambient temperature 20 °C (68 °F) E.
  • Page 473 ELECTRICAL COMPONENTS Starter relay Headlight relay First step: Br/B R/Y L/Y 1. Positive battery terminal 2. Negative battery terminal 1. Positive tester probe 3. Positive tester probe 2. Negative tester probe 4. Negative tester probe 3. Negative tester probe Result Result Continuity Continuity...
  • Page 474 ELECTRICAL COMPONENTS Radiator fan motor relay Differential motor relay 1 First step: Br/R Br/R Br/R 1. Positive battery terminal 2. Negative battery terminal 1. Positive tester probe 3. Positive tester probe 2. Negative tester probe 4. Negative tester probe 3. Negative tester probe Result Result Continuity...

  • Page 475: Checking The Spark Plug Cap

    ELECTRICAL COMPONENTS Differential motor relay 2 ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the spark plug cap from the spark First step: plug lead. b. Connect the pocket tester (Ω × 1k) to the spark plug cap as shown.

  • Page 476: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS Minimum ignition spark gap 6.0 mm (0.24 in) If the ignition spark gap is within specification, the ignition system circuit is operating normally. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 477: Checking The Lean Angle Sensor

    ELECTRICAL COMPONENTS • Positive tester probe → Pocket tester yellow/green (wire harness color) 90890-03112 • Negative tester probe → Analog pocket tester black/blue (wire harness color) YU-03112-C • Positive tester probe → gray “1” • Negative tester probe → 65˚ 65˚...

  • Page 478: Checking The Stator Coil

    ELECTRICAL COMPONENTS EBS30305 CHECKING THE STATOR COIL Charging voltage 1. Disconnect: above 14 V at 5000 r/min • Stator coil couplers (from the wire harness) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...

  • Page 479: Checking The Fuel Meter/Fuel Level Warning Light

    ELECTRICAL COMPONENTS Warning light comes on for a few seconds, Pocket tester then goes off → Warning light is OK. 90890-03112 Warning light does not come on → Replace Analog pocket tester the meter assembly. YU-03112-C Warning light flashes eight times, then goes off for 3 seconds in a repeated cycle (mal- •...

  • Page 480: Checking The Parking Brake Buzzer

    ELECTRICAL COMPONENTS b. Connect the battery to the radiator fan motor coupler as shown. • Positive battery terminal → blue “1” • Negative battery terminal → black “2” c. Turn the main switch to “ ” (on). d. Elevate the rear wheels and slowly rotate them.

  • Page 481: Checking The Coolant Temperature Sensor

    ELECTRICAL COMPONENTS b. Measure the radiator fan motor circuit break- d. Heat the coolant or let it cool down to the er resistance. specified temperatures. e. Measure the coolant temperature sensor re- ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...

  • Page 482: Checking The Intake Air Pressure Sensor

    ELECTRICAL COMPONENTS Test harness S– pressure sensor 5S7 (3P) 90890-03211 Test harness S– pressure sensor 5S7 (3P) YU-03211 Digital circuit tester 90890-03174 Model 88 Multimeter with ta- chometer b. Measure the throttle position sensor maxi- YU-A1927 mum resistance. • Positive tester probe → ▲...

  • Page 483: Checking The Fuel Injector

    ELECTRICAL COMPONENTS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ • Positive tester probe a. Connect the pocket tester (Ω × 1k or Ω × 100) Fuel injector terminal “1” to the intake air temperature sensor terminals •...

  • Page 484: Checking The Differential Motor Position Switch

    ELECTRICAL COMPONENTS g. Check the differential motor position switch EBS30318 CHECKING THE DIFFERENTIAL MOTOR no continuity. POSITION SWITCH ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 1. Check: • Differential motor position switch EBS30319 CHECKING THE EPS MOTOR (for EPS Out of specification →...

  • Page 485: Checking The Eps Torque Sensor (For Eps Models)

    ELECTRICAL COMPONENTS EBS30320 CHECKING THE EPS TORQUE SENSOR (for EPS models) 1. Remove: • EPS unit ECB01660 NOTICE Make sure do not remove the torque sensor and its protector from the EPS unit. 2. Check: • EPS torque sensor resistance Out of specification →...
  • Page 486 ELECTRICAL COMPONENTS 9-111...

  • Page 487: Troubleshooting

    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 ................10-3 FAULTY GEAR SHIFTING..............10-4 SHIFT LEVER DOES NOT MOVE ............10-4 JUMPS OUT OF GEAR................10-4 FAULTY CLUTCH PERFORMANCE ............10-4 OVERHEATING ..................10-4 OVERCOOLING..................10-5 POOR BRAKING PERFORMANCE............

  • Page 488: Troubleshooting

    TROUBLESHOOTING Electrical system EBS20085 TROUBLESHOOTING 1. Battery • Discharged battery EBS30321 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • Blown, damaged or incorrect fuse The following guide for troubleshooting does not • Improperly installed fuse cover all the possible causes of trouble. It should 3.

  • Page 489: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING Electrical system 1. Battery • Discharged battery • Faulty battery 2. Spark plug • Incorrect spark plug gap • Incorrect spark plug heat range • Fouled spark plug • Worn or damaged electrode • Worn or damaged insulator • Faulty spark plug cap 3.

  • Page 490: Faulty Drive Train

    TROUBLESHOOTING EBS30325 FAULTY DRIVE TRAIN The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1. A pronounced hesitation or “jerky” movement A. Bearing damage. during acceleration, deceleration, or sustained B. Improper gear backlash. speed. (This must not be confused with engine C.

  • Page 491: Faulty Gear Shifting

    TROUBLESHOOTING Poor starting performance EBS30326 FAULTY GEAR SHIFTING 1. V-belt • V-belt slips Shifting is difficult • Oil or grease on the V-belt Refer to “FAULTY CLUTCH PERFORMANCE” 2. Primary and secondary sheaves on page 10-4. • Faulty operation • Worn pin groove EBS30327 SHIFT LEVER DOES NOT MOVE •...

  • Page 492: Overcooling

    TROUBLESHOOTING • Damaged pipe • Bent or damaged damper rod • Improperly connected pipe EBS30334 UNSTABLE HANDLING Fuel system 1. Steering wheel 1. Throttle body • Bent or improperly installed steering wheel • Faulty throttle body 2. Steering components • Damaged or loose throttle body joint •...
  • Page 493 TROUBLESHOOTING Tail/brake light bulb burnt out • Wrong tail/brake light bulb • Faulty battery • Faulty brake light switch • Tail/brake light bulb life expired • Faulty rectifier/regulator • Improperly grounded circuit 10-6...

  • Page 494: Self-Diagnostic Function And Diagnostic Code Table

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EBS20086 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EBS30336 SELF-DIAGNOSTIC FUNCTION TABLE For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 9-38. Fault code Item Crankshaft position sensor: no normal signals are received from the crankshaft position sen- sor.

  • Page 495: Diagnostic Code: Sensor Operation Table

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EBS30338 DIAGNOSTIC CODE: SENSOR OPERATION TABLE The diagnostic code numbers cannot be displayed on the multi-function meter. To display the diagnos- tic code numbers, use the Yamaha diagnostic tool. Diagnostic Item Display Procedure code No.

  • Page 496: Diagnostic Code: Actuator Operation Table

    • Connect an ignition check- The “CHECK” indicator and “ ” on the Yamaha diag- nostic tool screen come on each time the ignition coil is actuated. Fuel injector Actuates the fuel injector five...
  • Page 497 The “CHECK” indicator and operating sound. “ ” on the Yamaha diag- nostic tool screen come on each time the relay is actuat- (When the relay is on, the “CHECK” indicator and “...

  • Page 498: Wiring Diagram

    19. On-Command four-wheel-drive 18. On-Command four-wheel-drive ness switch switch 20. Yamaha diagnostic tool coupler 19. Yamaha diagnostic tool coupler 21. ISC (Idle Speed Control) unit 20. ISC (Idle Speed Control) unit 22. ECU (Engine Control Unit) 21. ECU (Engine Control Unit) 23.
  • Page 499 55. EPS warning light EBS30002 COLOR CODE 56. Fuel sender Black 57. Fuel pump Brown 58. Differential motor relay 2 Green 59. Light switch Gray 60. Headlight relay Blue 61. Headlight Light green 62. Auxiliary DC jack Orange 63. Brake light switch Pink 64.
  • Page 500 YXE70WDXG 2016 WIRING DIAGRAM YXE70WDXG 2016 SCHÉMA DE CÂBLAGE Br/Y Br/Y Br/Y Br/Y R/W L/B R/G G/R W/G Y/B L/B Br/L Br/Y Br/Y Br/R Br/Y (Gy) Gy B Br/W W Gy P Y/G P/W O/L Y/W B/G Gy/G W/B B/W G/R Br/R Br/R (Gy) Br/Y R/W...
  • Page 501 YXE70WDXG 2016 WIRING DIAGRAM YXE70WDXG 2016 SCHÉMA DE CÂBLAGE (Gy) (Gy) (Gy) (Gy) (Gy) (Gy) (Gy) (Gy) (Gy) (off) (on) (start) DIFF LOCK (Gy) (off) (Gy)
  • Page 502 YX70EPNG/YXE70WPXG/YXE70WPHG/YXE700E 2016 WIRING DIAGRAM YX70EPNG/YXE70WPXG/YXE70WPHG/YXE700E 2016 SCHÉMA DE CÂBLAGE Br/Y Br/Y Br/Y Br/Y L/B R/G G/R W/G Y/B L/B Br/L Br/Y Br/Y Br/R Br/Y (Gy) Gy B Br/W W Gy P Y/G P/W O/L Y/W B/G Gy/G W/B B/W G/R Br/R Br/R (Gy) Br/Y R/W...
  • Page 503 YX70EPNG/YXE70WPXG/YXE70WPHG/YXE700E 2016 WIRING DIAGRAM YX70EPNG/YXE70WPXG/YXE70WPHG/YXE700E 2016 SCHÉMA DE CÂBLAGE (Gy) (Gy) (Gy) (Gy) (Gy) (Gy) (Gy) (Gy) (Gy) (off) (on) (start) DIFF LOCK (Gy) (Gy) (Gy) (Gy) (Gy) (Gy) (Gy) (off) ( B ) (Gy)

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