Yamaha Wolverine YX70EPNG Manuals

Manuals and User Guides for Yamaha Wolverine YX70EPNG. We have 2 Yamaha Wolverine YX70EPNG manuals available for free PDF download: Service Manual, Owner's Manual

Yamaha Wolverine YX70EPNG Service Manual (503 pages)

Brand: Yamaha | Category: Utility Vehicle | Size: 23.33 MB

Table of Contents

7
- How to Use this Manual
  4
- General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    12
    
    OUTLINE of the EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS Model)
    12
    
    Instrument Functions
    14
  - Important Information
    16
    
    Preparation for Removal and Disassembly
    16
    
    Replacement Parts
    16
    
    Gaskets, Oil Seals and O-Rings
    16
    
    Lock Washers/Plates and Cotter Pins
    16
    
    Bearings and Oil Seals
    17
    
    Circlips
    17
    
    Rubber Parts
    17
  - Basic Service Information
    18
    
    Quick Fasteners
    18
    
    Electrical System
    19
  - Special Tools
    23
Specifications

33
- General Specifications
  34
- Engine Specifications
  35
- Chassis Specifications
  39
- Electrical Specifications
  42
- Tightening Torques
  44
- Lubrication and Sealing Points
  57
  - Engine
    57
- Lubrication System Chart and Diagrams
  58
  - Engine Oil Lubrication Chart
    58
  - Lubrication Diagrams
    60
- Cooling System Diagrams
  66
- Cable Routing
  72
Periodic Checks and Adjustments

105
- General Maintenance and Lubrication Chart
  106
- Introduction
  106
- Periodic Maintenance
  106
- Periodic Maintenance Chart for the Emission Control System
  106
- Adjusting the Valve Clearance
  108
- Checking the Fuel Line
  108
- Checking the Breather Hose
  111
- Checking the Spark Plug
  111
- Adjusting the Exhaust Gas Volume
  112
- Checking the Exhaust System
  112
- Cleaning the Spark Arrester
  112
- Checking the Air Induction System
  113
- Checking the Coolant Level
  113
- Checking the Cooling System
  113
- Changing the Coolant
  114
- Cleaning the Air Filter Element
  116
- Checking the Engine Oil Level
  118
- Changing the Engine Oil
  119
- Measuring the Engine Oil Pressure
  120
- Changing the Final Gear Oil
  121
- Checking the Final Gear Oil Level
  121
- Changing the Differential Gear Oil
  122
- Checking the Differential Gear Oil Level
  122
- Checking the Brake Fluid Level
  123
- Checking the Front Brake Pads
  123
- Checking the Rear Brake Pads
  123
- Bleeding the Hydraulic Brake System
  124
- Checking the Brake Hoses and Brake Pipes
  125
- Adjusting the Brake Pedal
  126
- Adjusting the Parking Brake
  126
- Lubricating the Brake Pedal and Accelerator Pedal
  126
- Adjusting the Accelerator Pedal Free Play
  127
- Checking the V-Belt
  128
- Checking the Wheels
  129
- Replacing the V-Belt
  129
- Checking the Tires
  130
- Adjusting the Front Shock Absorber Assemblies
  131
- Checking the Front Shock Absorber Assemblies
  131
- Adjusting the Rear Shock Absorber Assembly
  134
- Checking the Rear Shock Absorber Assemblies
  134
- Checking the Steering System
  136
- Adjusting the Toe-In
  137
- Checking the Constant Velocity Shaft Assembly Dust Boots
  138
- Checking the Engine Mount
  138
- Checking the Stabilizer Bushing
  138
- Lubricating the Drive Shaft Universal Joints
  138
- Lubricating the Rear Knuckle Pivots
  138
- Checking the Fastener
  139
Chassis

141
- General Chassis (1)
  
  145
  - Installing the Door
    145
- General Chassis (2)
  
  146
  - Removing the Seats
    147
  - Adjusting the Driver Seat Position
    147
  - Installing the Seats
    147
- General Chassis (3)
  
  148
- General Chassis (4)
  
  149
  - Installing the Seat Belts
    151
- General Chassis (5)
  
  152
  - Installing the Enclosure
    154
- General Chassis (6)
  
  155
- General Chassis (7)
  
  155
  - Removing the Steering Wheel
    159
  - Installing the Steering Wheel
    159
- General Chassis (8)
  
  160
- General Chassis (9)
  
  161
  - Installing the Cargo Bed
    163
- General Chassis (10)
  
  164
  - Installing the V-Belt Cooling Ducts
    165
- Front and Rear Wheels
  
  166
  - Removing the Wheels
    167
  - Removing the Wheel Hubs
    167
  - Checking the Wheels
    167
  - Checking the Wheel Hubs
    168
  - Installing the Brake Discs
    168
  - Installing the Wheel Hubs
    168
  - Installing the Wheels
    169
- Front and Rear Brakes
  
  170
  - Introduction
    177
  - Checking the Brake Discs
    177
  - Replacing the Brake Pads
    178
  - Disassembling the Brake Calipers
    179
  - Checking the Brake Calipers
    179
  - Assembling the Brake Calipers
    179
  - Installing the Brake Calipers
    180
  - Checking the Brake Master Cylinder
    181
  - Checking the Brake Pipes
    181
  - Installing the Brake Master Cylinder
    181
- Parking Brake
  
  183
  - Checking the Friction Plates
    185
  - Checking the Parking Brake Plates
    185
  - Checking the Parking Brake Springs
    185
  - Checking the Parking Brake Boss
    185
  - Installing the Parking Brake
    185
  - Installing the Parking Brake Lever
    186
- Pedal Assembly
  
  187
  - Installing the Pedal Assembly
    189
- Steering System
  
  190
  - Removing the Tie-Rod
    192
  - Checking the Steering Joint
    192
  - Checking the Tie-Rod Ends
    192
  - Installing the Steering System
    192
  - Lubricating the Steering Shaft
    194
- Steering Knuckles
  
  195
- Front Arms and Front Shock Absorber Assemblies
  
  198
- Rear Knuckles and Stabilizer
  
  203
Engine

211
- Engine Inspection
  
  214
  - Measuring the Compression Pressure
    214
- Engine Removal (1)
  
  216
  - Installing the Exhaust Pipe and Muffler
    217
- Engine Removal (2)
  
  218
  - Installing the Engine
    222
- Camshafts
  
  223
  - Removing the Camshafts
    225
  - Checking the Camshafts
    226
  - Checking the Camshaft Sprockets
    227
  - Checking the Timing Chain Tensioner
    227
  - Installing the Camshafts
    227
  - Installing the Breather Plate
    229
- Cylinder Head, Cylinder, and Piston
  
  230
  - Removing the Cylinder Head
    233
  - Removing the Piston
    233
  - Checking the Cylinder Head
    234
  - Checking the Cylinder and Piston
    234
  - Checking the Piston Rings
    235
  - Checking the Piston Pin
    236
  - Installing the Piston and Cylinder
    236
  - Installing the Cylinder Head
    237
- Valves and Valve Springs
  
  240
  - Removing the Valves
    240
  - Checking the Valves and Valve Guides
    240
  - Checking the Valve Seats
    242
  - Checking the Valve Springs
    243
  - Checking the Valve Lifters
    244
  - Installing the Valves
    244
  - Engine
    246
- Ac Magneto and Starter Clutch
  
  246
  - Checking the Starter Clutch
    248
  - Removing the Ac Magneto Rotor
    248
  - Removing the Starter Clutch
    248
  - Installing the Ac Magneto Rotor
    249
  - Installing the Starter Clutch
    249
- Electric Starter
  
  251
  - Checking the Starter Motor
    253
  - Assembling the Starter Motor
    254
- Oil Pump Sprockets
  
  255
- Shift Lever
  
  258
  - Checking the Stopper Lever
    260
  - Checking the Shift Levers
    260
  - Installing the Shift Levers
    260
  - Adjusting the Drive Select Lever Shift Rod
    261
- Primary and Secondary Sheaves
  
  263
  - Removing the Primary and Secondary Sheaves
    266
  - Disassembling the Secondary Sheave
    266
  - Checking the V-Belt
    267
  - Checking the Primary Sheave
    267
  - Checking the Primary Sheave Weights
    267
  - Checking the Primary Sheave Sliders
    267
  - Checking the Secondary Sheave
    267
  - Assembling the Primary Sheave
    268
  - Assembling the Secondary Sheave
    269
  - Installing the Primary and Secondary Sheaves
    270
- Clutch
  
  273
  - Removing the Clutch
    275
  - Checking the Clutch
    275
  - Checking the Clutch Shoe
    275
  - Assembling the Clutch Housing
    276
  - Installing the Clutch
    276
- Crankcase
  
  278
  - Separating the Crankcase
    281
  - Checking the Timing Chain and Timing Chain Guide
    281
  - Checking the Bearings
    281
  - Checking the Crankcase
    282
  - Assembling the Crankcase
    282
- Crankshaft and Oil Pump
  
  284
  - Removing the Crankshaft
    286
  - Checking the Oil Pump
    286
  - Checking the Oil Strainer
    286
  - Checking the Relief Valve
    286
  - Checking the Crankshaft
    287
  - Assembling the Oil Pump
    287
  - Installing the Crankshaft
    287
  - Installing the Oil Pump
    288
- Transmission
  
  293
  - Removing the Transmission
    293
  - Disassembling the Drive Axle
    293
  - Checking the Shift Forks
    293
  - Checking the Shift Drum
    293
  - Checking the Transmission
    294
  - Checking the Secondary Shaft
    294
  - Assembling the Drive Axle
    294
  - Assembling the Shift Fork
    294
  - Installing the Shift Forks and Shift Drum
    295
- Middle Gear
  
  296
  - Removing the Middle Drive Shaft
    300
  - Removing the Middle Driven Shaft
    300
  - Checking the Pinion Gears
    301
  - Installing the Bearing and Oil Seals
    302
  - Installing the Middle Driven Shaft
    302
  - Installing the Middle Drive Shaft
    303
  - Measuring the Middle Gear Backlash
    304
  - Aligning the Middle Gear
    305
Cooling System

309
- Oil Cooler
  
  312
  - Checking the Oil Cooler
    312
  - INSTALLING the HORN (Except for CDN)
    312
- Radiator
  
  313
  - Checking the Radiator
    315
  - Installing the Radiator
    315
- Thermostat
  
  317
  - Checking the Thermostat
    318
  - Installing the Thermostat
    318
- Water Pump
  
  320
  - Disassembling the Water Pump
    321
  - Checking the Water Pump
    321
  - Assembling the Water Pump
    321
  - Installing the Water Jacket Joint
    322
Fuel System

323
- Fuel Tank
  
  324
  - Checking the Fuel Pump Body
    325
  - Checking the Fuel Tank Breather Hose Joint
    325
  - Removing the Fuel Pump
    325
  - Removing the Fuel Tank
    325
  - Installing the Fuel Pump
    326
  - Installing the Fuel Tank
    326
  - Checking the Fuel Pressure
    327
- Air Filter Case
  
  328
  - Installing the Air Filter Case
    330
- Throttle Body
  
  331
  - Removing the Throttle Body
    334
  - Checking the Fuel Injector
    334
  - Checking the Throttle Body
    334
  - Checking the Throttle Body Joint
    334
  - Installing the Throttle Body
    334
  - Adjusting the Throttle Position Sensor
    336
- Air Induction System
  
  337
  - Checking the Air Induction System
    340
  - Installing the Air Induction System
    340
Drive Train

341
Electrical System

373
- Ignition System
  
  376
  - Circuit Diagram
    376
  - Troubleshooting
    378
- Electric Starting System
  
  380
  - Circuit Diagram
    380
  - Starting Circuit Cut-Off System Operation
    382
  - Troubleshooting
    383
- Charging System
  
  386
  - Circuit Diagram
    386
  - Troubleshooting
    388
- Lighting System
  
  390
  - Circuit Diagram
    390
  - Troubleshooting
    392
- Signaling System
  
  394
  - CIRCUIT DIAGRAM (Except for EPS Models)
    394
  - CIRCUIT DIAGRAM (for EPS Models)
    396
  - Troubleshooting
    398
- Cooling System
  
  404
  - Circuit Diagram
    404
  - Troubleshooting
    406
- Fuel Injection System
  
  408
  - CIRCUIT DIAGRAM (Except for EPS Models)
    408
  - CIRCUIT DIAGRAM (for EPS Models)
    410
  - Ecu Self-Diagnostic Function
    412
  - Troubleshooting Method
    413
  - Yamaha Diagnostic Tool
    414
  - Troubleshooting Details (Fuel Injection System)
    416
- Fuel Pump System
  
  440
  - Circuit Diagram
    440
  - Troubleshooting
    442
- 2Wd/4Wd Selecting System
  
  444
  - Circuit Diagram
    444
  - Troubleshooting
    446
- EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS Models)
  
  448
- Electrical Components
  
  458
  - Checking the Switches
    464
  - Checking the Bulbs and Bulb Sockets
    467
  - Replacing the Headlight Bulbs
    468
  - Adjusting the Headlight Beams
    469
  - Checking the Fuses
    469
  - Checking and Charging the Battery
    470
  - Checking the Relays
    472
  - Checking the Spark Plug Cap
    475
  - Checking the Ignition Coil
    475
  - Checking the Ignition Spark Gap
    476
  - Checking the Crankshaft Position Sensor
    476
  - Checking the Lean Angle Sensor
    477
  - Checking the Starter Motor Operation
    477
  - Checking the Stator Coil
    478
  - Checking the Rectifier/Regulator
    478
  - Checking the Fuel Sender
    478
  - Checking the Fuel Meter/Fuel Level Warning Light
    479
  - Checking the Speed Sensor
    479
  - Checking the Parking Brake Buzzer
    480
  - Checking the Radiator Fan Motor
    480
  - Checking the Radiator Fan Motor Circuit Breaker
    480
  - Checking the Coolant Temperature Sensor
    481
  - Checking the Throttle Position Sensor
    481
  - Checking the Intake Air Pressure Sensor
    482
  - Checking the Intake Air Temperature Sensor
    482
  - Checking the Fuel Injector
    483
  - Checking the Air Induction System Solenoid
    483
  - Checking the Differential Motor Position Switch
    484
  - CHECKING the EPS MOTOR (for EPS Models)
    484
  - CHECKING the EPS TORQUE SENSOR (for EPS Models)
    485
Troubleshooting

487
- General Information
  487
- Troubleshooting
  
  488
  - General Information
    488
  - Starting Failures
    488
  - Incorrect Engine Idling Speed
    488
  - Poor Medium-And-High-Speed Performance
    489
  - Faulty Drive Train
    490
  - Faulty Gear Shifting
    491
  - Shift Lever Does Not Move
    491
  - Jumps out of Gear
    491
  - Faulty Clutch Performance
    491
  - Overheating
    491
  - Overcooling
    492
  - Poor Braking Performance
    492
  - Faulty Shock Absorber Assembly
    492
  - Unstable Handling
    492
  - Faulty Lighting or Signaling System
    492
- Self-Diagnostic Function and Diagnostic Code Table
  
  494
  - Self-Diagnostic Function Table
    494
  - Communication Error with the Meter
    494
  - Diagnostic Code: Sensor Operation Table
    495
  - Diagnostic Code: Actuator Operation Table
    496
  - Wiring Diagram
    498

Yamaha Wolverine YX70EPNG Owner's Manual (182 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 3.88 MB

Table of Contents
6
Location of the Warning and Specification Labels
9
Safety Information
22
Description
29
- Left View
  29
- Right View
  30
- Controls and Instruments
  31
Instrument and Control Functions
32
- Main Switch
  32
- Indicator Lights and Warning Lights
  33
- Multi-Function Meter Unit
  37
- Light Switch
  41
- On-Command Drive Knob "2WD/4WD/DIFF LOCK
  42
- Accelerator Pedal
  43
- Brake Pedal
  43
- Parking Brake Lever
  44
Drive Select Lever
44
Fuel Tank Cap
45
Doors
45
Seats
46
Adjusting the Driver Seat Position
47
Seat Belts
48
Glove Compartment
48
Storage Compartments
49
Cup Holders
50
Cargo Bed
51
Adjusting the Front Shock Absorber Assemblies
53
Adjusting the Rear Shock Absorber Assemblies
58
Trailer Hitch Bracket and Receiver
63
Auxiliary DC Jack
63
For Your Safety - Pre-Operation Checks
65
Front and Rear Brakes
67
Fuel
67
Engine Oil
69
Final Gear Oil
70
Coolant
70
Differential Gear Oil
71
Accelerator Pedal
71
Seat Belts
71
Passenger Handhold
72
Steering
72
Fittings and Fasteners
72
Instruments, Lights and Switches
72
Control Cables
72
Tires
72
Operation
75
Engine Break-In
75
Starting the Engine
76
Drive Select Lever Operation and Reverse Driving
77
On-Command Drive Knob
79
Parking
81
Loading
81
Basic Guide for Safe Use
84
Know Your Vehicle
84
Learning to Operate Your Vehicle
95
Periodic Maintenance and Adjustment
105
Owner's Manual and Tool Kit
106
Periodic Maintenance Chart for the Emission Control System
108
General Maintenance and Lubrication Chart
110
Hood
114
Panels
115
Engine Oil and Oil Filter Cartridge
118
Final Gear Oil
124
Differential Gear Oil
126
Coolant
128
Axle Boots
133
Spark Plug Inspection
134
Cleaning the Air Filter Element
136
Cleaning the Air Filter Case/Air Duct Check Hose
139
V-Belt Case Drain Plug
140
Cleaning the Spark Arrester
140
Valve Clearance
142
Brakes
142
Checking the Front and Rear Brake Pads
142
Checking the Brake Fluid Level
143
Brake Fluid Replacement
144
Checking the Brake Pedal
144
Parking Brake
145
Brake Light Switch Adjustment
145
Cable Inspection and Lubrication
146
Brake Pedal and Accelerator Pedal Lubrication
146
Checking the Stabilizer Bushes
147
Rear Knuckle Upper and Lower Pivot Lubrication (Left and Right)
147
Steering Shaft Lubrication
148
Wheel Removal
148
Tire Replacement
149
Wheel Installation
150
Battery
150
Jump-Starting
154
Fuse Replacement
155
Replacing a Headlight Bulb
158
- Headlight Beam Adjustment
  160
- Tail/Brake Light Bulb Replacement
  161
- Troubleshooting
  161
- Troubleshooting Charts
  163
Cleaning and Storage
165
- Cleaning
  165
- Storage
  166
Specifications
168
Consumer Information
173
- Identification Number Records
  173
- Yamaha Side by Side Off-Road Vehicle Warranty Policy
  176
Index
178

Yamaha Categories

Motorcycle Musical Instrument Electronic Keyboard Receiver Amplifier

More Yamaha Manuals

Yamaha Wolverine YX70EPNG Manuals

Yamaha Wolverine YX70EPNG Service Manual (503 pages)

Table of Contents

Table of Contents

Specifications

Periodic Checks and Adjustments

Chassis

General Chassis (1)

General Chassis (2)

General Chassis (3)

General Chassis (4)

General Chassis (5)

General Chassis (6)

General Chassis (7)

General Chassis (8)

General Chassis (9)

General Chassis (10)

Front and Rear Wheels

Front and Rear Brakes

Parking Brake

Pedal Assembly

Steering System

Steering Knuckles

Front Arms and Front Shock Absorber Assemblies

Rear Knuckles and Stabilizer

Engine

Engine Inspection

Engine Removal (1)

Engine Removal (2)

Camshafts

Cylinder Head, Cylinder, and Piston

Valves and Valve Springs

Ac Magneto and Starter Clutch

Electric Starter

Oil Pump Sprockets

Shift Lever

Primary and Secondary Sheaves

Clutch

Crankcase

Crankshaft and Oil Pump

Transmission

Middle Gear

Cooling System

Oil Cooler

Radiator

Thermostat

Water Pump

Fuel System

Fuel Tank

Air Filter Case

Throttle Body

Air Induction System

Drive Train

Troubleshooting

Front Constant Velocity Shaft Assemblies, Differential Assembly and Front Drive Shafts

Rear Constant Velocity Shaft Assemblies, Final Drive Assembly and Rear Drive Shaft

Electrical System

Ignition System

Electric Starting System

Charging System

Lighting System

Signaling System

Cooling System

Fuel Injection System

Fuel Pump System

2Wd/4Wd Selecting System

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

Electrical Components

Troubleshooting

Troubleshooting

Self-Diagnostic Function and Diagnostic Code Table

Yamaha Wolverine YX70EPNG Owner's Manual (182 pages)

Table of Contents

Related Products

Yamaha Categories