Yamaha YFM7FGPW Service Manual
  1. Manuals
  2. Brands
  3. Yamaha Manuals
  4. Offroad Vehicle
  5. GRIZZLY 700 FI YFM7FGPW
  6. Service manual
Yamaha YFM7FGPW Service Manual

Yamaha YFM7FGPW Service Manual

Hide thumbs Also See for YFM7FGPW:
1
2
3
4
5
Table Of Contents
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
Table of Contents

Advertisement

Quick Links

See also: Owner's Manual
YFM7FGPW
SERVICE MANUAL
LIT-11616-20-11
3B4-28197-10

Advertisement

Table of Contents
loading

Related Manuals for Yamaha YFM7FGPW

Summary of Contents for Yamaha YFM7FGPW

  • Page 1 YFM7FGPW SERVICE MANUAL LIT-11616-20-11 3B4-28197-10...
  • Page 2 EBS00001 YFM7FGPW SERVICE MANUAL ©2006 by Yamaha Motor Corporation, U.S.A. First Edition, May 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-11616-20-11...
  • 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

    EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section.

  • Page 5: Periodic Checks And Adjustments

    EBS00006 SYMBOLS The following symbols are not relevant to SPEC INFO every vehicle. Symbols 1 to 0 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Fuel injection system COOL 7 Drive train 8 Chassis...

  • Page 6: Table Of Contents

    EBS00008 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM DRIVE TRAIN DRIV CHASSIS CHAS – ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 7 CONTENTS CHAPTER 1 GENERAL INFORMATION VEHICLE IDENTIFICATION................1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM..1-4 EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM ..1-5 INSTRUMENT FUNCTIONS ..............
  • Page 8 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-22 LUBRICATION POINTS AND LUBRICANT TYPES ........2-23 ENGINE....................2-23 COOLANT FLOW DIAGRAMS ..............2-25 OIL FLOW DIAGRAMS ................. 2-26 CABLE ROUTING ..................2-28 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION....................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ......................
  • Page 9 ENGINE ......................3-16 ADJUSTING THE VALVE CLEARANCE ..........3-16 ADJUSTING THE ENGINE IDLING SPEED ...........3-19 ADJUSTING THE THROTTLE LEVER FREE PLAY ......3-20 ADJUSTING THE SPEED LIMITER............3-22 CHECKING THE SPARK PLUG ............. 3-23 CHECKING THE IGNITION TIMING............3-24 MEASURING THE COMPRESSION PRESSURE........3-25 CHECKING THE ENGINE OIL LEVEL............3-28 CHANGING THE ENGINE OIL ...............3-29 CLEANING THE AIR FILTER ELEMENT..........
  • Page 10 ELECTRICAL SYSTEM................. 3-67 CHECKING AND CHARGING THE BATTERY........3-67 CHECKING THE FUSES ................3-73 ADJUSTING THE HEADLIGHT BEAMS..........3-76 REPLACING THE HEADLIGHT BULBS ..........3-76 CHAPTER 4 ENGINE ENGINE REMOVAL ..................4-1 AIR DUCTS, MUFFLER AND EXHAUST PIPE ........4-1 SELECT LEVER UNIT ................4-3 LEADS, CABLES AND HOSES ..............4-4 ENGINE MOUNTING BOLTS ..............4-6 INSTALLING THE ENGINE...............
  • Page 11 AC MAGNETO....................4-42 REMOVING THE AC MAGNETO ROTOR..........4-45 CHECKING THE STATOR COIL AND CRANKSHAFT POSITION SENSOR ....................4-46 CHECKING THE STARTER CLUTCH ............4-46 CHECKING THE TORQUE LIMITER............4-47 INSTALLING THE AC MAGNETO ROTOR ..........4-47 BALANCER GEARS AND OIL PUMP GEARS ..........4-49 REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR ..................
  • Page 12 CRANKSHAFT AND OIL PUMP ..............4-75 OIL PUMP ....................4-76 REMOVING THE CRANKSHAFT ............4-77 CHECKING THE OIL PUMP ..............4-77 CHECKING THE OIL STRAINER ............4-78 CHECKING THE CRANKSHAFT ............4-78 ASSEMBLING THE OIL PUMP...............4-79 INSTALLING THE CRANKSHAFT ............4-79 TRANSMISSION....................
  • Page 13 CHAPTER 6 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM................6-1 CIRCUIT DIAGRAM .................. 6-3 ECU SELF-DIAGNOSTIC FUNCTION............6-5 SELF-DIAGNOSTIC FUNCTION TABLE ..........6-6 TROUBLESHOOTING CHART ..............6-7 DIAGNOSTIC MODE ................6-8 TROUBLESHOOTING DETAILS ............6-12 CHECKING THE INTAKE AIR PRESSURE SENSOR ......6-26 CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....6-26 FUEL TANK....................

  • Page 14: Chassis

    FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR..7-4 REMOVING THE DIFFERENTIAL GEAR ASSEMBLY......7-10 CHECKING THE FRONT CONSTANT VELOCITY JOINTS....7-10 CHECKING THE DIFFERENTIAL GEARS ..........7-11 CHECKING THE DIFFERENTIAL GEAR MOTOR .........7-11 ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS ....7-12 ASSEMBLING THE DIFFERENTIAL GEARS.........7-13 MEASURING THE DIFFERENTIAL GEAR LASH ........7-14 ADJUSTING THE DIFFERENTIAL GEAR LASH........
  • Page 15 FRONT AND REAR BRAKES................. 8-8 FRONT BRAKE PADS ................8-8 REAR BRAKE PADS................. 8-9 REPLACING THE FRONT AND REAR BRAKE PADS......8-10 FRONT BRAKE MASTER CYLINDER............8-12 REAR BRAKE MASTER CYLINDER ............8-15 CHECKING THE MASTER CYLINDERS..........8-18 ASSEMBLING THE FRONT AND REAR BRAKE MASTER CYLINDERS ...................

  • Page 16: Electrical

    REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES ....8-55 CHECKING THE REAR ARMS ...............8-57 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES....8-57 INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES ..................8-58 CHAPTER 9 ELECTRICAL ELECTRICAL COMPONENTS................ 9-1 CHECKING SWITCH CONTINUITY..............9-4 CHECKING THE SWITCHES................9-5 CHECKING THE BULBS AND BULB SOCKETS ..........

  • Page 17: Troubleshooting

    COOLING SYSTEM..................9-45 CIRCUIT DIAGRAM ................9-45 TROUBLESHOOTING ................9-46 FUEL PUMP SYSTEM...................9-50 CIRCUIT DIAGRAM ................9-50 TROUBLESHOOTING ................9-51 2WD/4WD SELECTING SYSTEM..............9-53 CIRCUIT DIAGRAM ................9-53 TROUBLESHOOTING ................9-54 EPS (ELECTRIC POWER STEERING) SYSTEM.........9-58 CIRCUIT DIAGRAM ................9-58 EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION .....9-59 EPS WARNING LIGHT DURING NORMAL OPERATION......9-60 DIAGNOSTIC MODE ................
  • Page 18 FAULTY CLUTCH PERFORMANCE ............10-4 ENGINE OPERATES BUT VEHICLE WILL NOT MOVE ......10-4 CLUTCH SLIPPING ................10-4 POOR STARTING PERFORMANCE............10-4 POOR SPEED PERFORMANCE............10-5 OVERHEATING..................... 10-5 OVERHEATING ..................10-5 OVERCOOLING .................... 10-5 COOLING SYSTEM ................10-5 FAULTY BRAKE ................... 10-5 POOR BRAKING EFFECT..............

  • Page 19: General Information

    VEHICLE IDENTIFICATION INFO EBS00009 GENERAL INFORMATION VEHICLE IDENTIFICATION EBS00010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the front left side of the frame. EBS00011 MODEL LABEL The model label 1 is affixed at the location in the illustration.

  • Page 20: Features

    FEATURES INFO EAS20170 FEATURES OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.

  • Page 21: Fi System

    FEATURES INFO FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm , 46.1 psi). Accord- ingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 22: Outline Of The Eps (Electric Power Steering) System

    FEATURES INFO OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM Speed information from Engine starting RPM speed sensor information from ECU 4. EPS control unit 1. Operates steering Battery calculates assist power 5. Electricity output 3. Sends the torque 2. Twists torsion bar switched by EPS sensor signal control unit...

  • Page 23: Eps (Electric Power Steering) System Block Diagram

    FEATURES INFO EPS (ELECTRIC POWER STEERING) SYSTEM BLOCK DIAGRAM Meter assembly Multifunction display Odometer/Tripmeter A/Tripmeter B/Clock/Fuel meter/Gear position Indicator and warning lights EPS UNIT EPS warning/Engine trouble warning/Coolant temperature warning/Reverse indicator/Neutral indicator/Park indicator/High-range indicator/ Low-range indicator/Differential lock Torque sensor EPS motor •...

  • Page 24: Instrument Functions

    FEATURES INFO INSTRUMENT FUNCTIONS EBU27291 Multifunction display 1 “CLOCK” button 2 “RESET” button 3 “SELECT” button 4 Speedometer 5 Fuel meter 6 Clock/Hour meter 7 Odometer/Tripmeter A/Tripmeter B The multifunction display is equipped with the following: • a speedometer (which shows the riding speed) •...
  • Page 25 FEATURES INFO Clock mode Pushing the “CLOCK” button switches the dis- play between the clock mode “CLOCK” and the hour meter mode “HOUR” in the following order: CLOCK → HOUR → CLOCK To set the clock 1. Set the display to the clock mode. 2.
  • Page 26 FEATURES INFO Self-diagnosis device This model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuits are defective, the multi- function display will indicate a two-digit error code. If the multifunction display indicates such an error code, note the code number, and check the vehicle.

  • Page 27: Important Information

    5. Keep all parts away from any source of fire. EBS00014 REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 28: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION INFO EBS00016 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EBS00017 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu-...

  • Page 29: Checking The Connections

    IMPORTANT INFORMATION INFO EBS00019 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains →...

  • Page 30: Special Tools

    SPECIAL TOOLS INFO EBS00021 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country.
  • Page 31 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Crankshaft installer pot Installing pot Pot installer 90890-01274 YU-90058 YU-90059 YU-90058/YU-90059 This tool is used to install the crankshaft. Crankshaft installer bolt Bolt 90890-01275 YU-90060 This tool is used to install the crankshaft. Piston pin puller set Piston pin puller 90890-01304...
  • Page 32 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Radiator cap tester Radiator pressure tester 90890-01325 YU-24460-01 YU-24460-01 This tool is used to check the cooling sys- tem. Locknut wrench 90890-01348 YM-01348 This tool is needed when removing or installing the secondary sheave spring.
  • Page 33 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Ball joint remover 90890-01474 YM-01474 These tools are used to removing or installing the ball joints. Gear lash measurement tool Middle drive gear lash tool 90890-01475 YM-01475 This tool is used to measure the gear lash.
  • Page 34 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Timing light Inductive clamp timing light 90890-03141 YU-03141 This tool is necessary for checking igni- tion timing. Pressure gauge 90890-03153 YU-03153 This tool is used to measure fuel pres- sure. Belt tension gauge Rear drive belt tension gauge 90890-03170...
  • Page 35 SPECIAL TOOLS INFO Tool No. Tool name/How to use Illustration Valve guide reamer (ø6) Valve guide reamer (6.0 mm) 90890-04066 YM-04066 This tool is needed to rebore the new valve guides. Spacer (crankshaft installer) Pot spacer 90890-04081 YM-91044 YM-91044 This tool is used to install the crankshaft. Extension 90890-04082 This tool is used to measure engine com-...
  • Page 36 This instrument is necessary for checking the ignition system components. Digital tachometer 90890-06760 YU-39951-B This tool is needed for checking engine rpm. Yamaha bond No. 1215 ® (Three bond No.1215 90890-85505 This bond is used on crankcase mating surfaces, etc. 1 - 18...

  • Page 37: Spec

    SPEC GENERAL SPECIFICATIONS EBS01001 SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard 3B41 Model code 3B45 3B48 Dimensions Overall length 2,065 mm (81.3 in) Overall width 1,180 mm (46.5 in) Overall height 1,240 mm (48.8 in) Seat height 905 mm (35.6 in) Wheelbase 1,250 mm (49.2 in) Minimum ground clearance 275 mm (10.8 in)
  • Page 38 SPEC GENERAL SPECIFICATIONS Item Standard Oil quantity Engine oil Periodic oil change 2.00 L (1.76 Imp qt, 2.11 US qt) With oil filter replacement 2.10 L (1.85 Imp qt, 2.22 US qt) Total amount 2.40 L (2.11 Imp qt, 2.54 US qt) Final gear oil Periodic oil change 0.20 L (0.18 Imp qt, 0.21 US qt)
  • Page 39 SPEC GENERAL SPECIFICATIONS Item Standard Tire Type front Tubeless rear Tubeless AT25 × 8-12 Size front AT25 × 10-12 rear Manufacturer/model front DUNLOP/KT421 rear DUNLOP/KT425 Tire pressure (cold tire) Maximum load* 220.0 kg (485 lb) Off-road riding front 32 ~ 38 kPa (0.32 ~ 0.38 kg/cm , 4.6 ~ 5.5 psi) rear 27 ~ 33 kPa (0.27 ~ 0.33 kg/cm...
  • Page 40 SPEC GENERAL SPECIFICATIONS Item Standard Bulb voltage/wattage × quantity 12 V 35.0 W/35.0 W × 2 Headlight 12 V 21.0/5.0 W × 1 Tail/brake light Indicator light Neutral indicator light Reverse indicator light Coolant temperature warning light Engine trouble warning light EPS warning light Park indicator light On-command four-wheel drive/differential...

  • Page 41: Engine Specifications

    SPEC ENGINE SPECIFICATIONS EBS01002 ENGINE SPECIFICATIONS Item Standard Limit Cylinder head Maximum warpage ---- 0.03 mm (0.0012 in) Cylinder Bore 102.000 ~ 102.010 mm 102.080 mm (4.0157 ~ 4.0161 in) (4.0189 in) Measuring point 50.0 mm (1.97 in) ---- Maximum taper 0.05 mm (0.002 in) Out of round...
  • Page 42 SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links 98XRH2010/126 ---- Tensioning system Automatic ---- Rocker arm/rocker arm shaft Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) ---- Shaft outside diameter 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) ---- Arm-to-shaft clearance 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in)
  • Page 43 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve-stem-to-valve-guide clearance Intake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.080 mm (0.0031 in) Exhaust 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) 0.100 mm (0.0039 in) Valve stem runout ---- 0.040 mm (0.0016 in) Valve seat width Intake...
  • Page 44 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston Piston-to-cylinder clearance 0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in) 0.13 mm (0.0051 in) Diameter “D” 101.955 ~ 101.970 mm ---- (4.0140 ~ 4.0146 in) Height “H” 10.0 mm (0.39 in) ---- Offset 0.50 mm (0.0197 in) ---- Offset direction...
  • Page 45 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil ring Dimensions (B × T) 2.50 × 2.80 mm (0.10 × 0.11 in) ---- End gap (installed) 0.20 ~ 0.70 mm (0.008 ~ 0.028 in) ---- Ring side clearance 0.060 ~ 0.150 mm (0.0024 ~ 0.0059 in) ---- Crankshaft Crank width “A”...
  • Page 46 SPEC ENGINE SPECIFICATIONS Item Standard Limit Fuel pump Pump type Electrical ---- Model/manufacturer 3B4/DENSO ---- Oil filter type Cartridge (paper) ---- Oil pump Oil pump type Trochoid ---- Inner-rotor-to-outer-rotor-tip clear- Less than 0.12 mm (0.0047 in) 0.20 mm ance (0.0079 in) Outer-rotor-to-oil-pump-housing 0.090 ~ 0.170 mm (0.0035 ~ 0.0067 in) 0.24 mm...
  • Page 47 SPEC ENGINE SPECIFICATIONS Cylinder head tightening sequence 2 - 11...

  • Page 48: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS EBS01003 CHASSIS SPECIFICATIONS Item Standard Limit Steering system Steering bearing type Ball and race bearing ---- Steering tension 50 N (5.0 kgf) ---- Front suspension Shock absorber travel 90.7 mm (3.57 in) ---- Spring free length 292.0 mm (11.50 in) ---- Installed length 237.0 mm (9.33 in)
  • Page 49 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front disc brake Type Dual ---- Disc outside diameter × thickness 220.0 × 3.5 mm (8.66 × 0.14 in) ---- Brake disc minimum thickness 3.0 mm (0.12 in) ---- Brake disc maximum deflection 0.1 mm (0.004 in) ---- Pad thickness inner 4.4 mm (0.17 in)

  • Page 50: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS EBS01004 ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system Ignition timing (B.T.D.C.) 12°/1,400 r/min ---- Advancer type Digital ---- Transistorized coil ignition 459 ~ 561 Ω at 20 °C (68 °F)/ Crankshaft position sensor resis- ---- tance/color black-green/yellow...
  • Page 51 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Starter relay Model/manufacturer 2768113-A/JIDECO ---- Amperage rating 180.0 A ---- 4.18 ~ 4.62 Ω at 20 °C (68 °F) Coil winding resistance ---- Fuel gauge 19.00 ~ 21.00 Ω Sender unit resistance (full) ---- 139.00 ~ 141.00 Ω...

  • Page 52: Tightening Torques

    SPEC TIGHTENING TORQUES EBS01005 TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Item Part name Q’ty Remarks size Nm m · kg ft · lb Cylinder head (exhaust pipe) Stud bolt Cylinder head Bolt Cylinder head Bolt Cylinder head Bolt Spark plug —...
  • Page 53 SPEC TIGHTENING TORQUES Tightening torque Thread Item Part name Q’ty Remarks size Nm m · kg ft · lb Water pump outlet pipe Bolt Water jacket joint Bolt Timing chain guide Bolt Crankshaft end accessing screw — Timing mark accessing screw —...
  • Page 54 SPEC TIGHTENING TORQUES NOTE: Temporarily tighten the cylinder bolts to 15 Nm (1.5 m · kg, 11 ft · lb) and then tighten them to 50 Nm (5.0 m · kg, 36 ft · lb). 2 - 18...

  • Page 55: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES EBS01006 CHASSIS TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks Nm m · kg ft · lb Engine and front rubber damper Engine and front rubber damper Engine and rear rubber damper Engine and rear rubber damper Rubber damper and frame Differential gear case and frame Differential gear case and frame...
  • Page 56 SPEC TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks Nm m · kg ft · lb Pitman arm nut 21.0 EPS motor cover Pitman arm and tie-rod Steering knuckle and tie-rod Steering knuckle and front lower arm Front arm protector and front lower arm Fuel tank and fuel pump Fuel tank and frame...
  • Page 57 SPEC TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks Nm m · kg ft · lb Rear carrier and rear fender Engine skid plates Trailer hitch and frame Battery holding bracket Battery bracket and fitting screw Fitting screw and frame Electrical components tray and frame Differential gear case filler bolt Differential gear case drain bolt...

  • Page 58: How To Use The Conversion Table

    HOW TO USE THE CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EBS00022 EBS00023 HOW TO USE THE CONVERSION GENERAL TIGHTENING TORQUE TABLE SPECIFICATIONS All specification data in this manual are listed This chart specifies tightening torques for stan- in SI and METRIC UNITS. dard fasteners with a standard ISO thread Use this table to convert METRIC unit data to pitch.

  • Page 59: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EBS00024 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Oil seal lips Bearings O-ring Cylinder head bolts Crankshaft pin Connecting rod big end thrust surface Crankshaft sprocket Inner race (crankshaft) Buffer boss (crankshaft) Crankshaft seal Piston pin Piston and ring groove...
  • Page 60 Shift lever 1 Shift lever 1 gear teeth and shift lever 2 gear teeth Stopper lever stopper Bearing (final drive pinion gear assembly) Bearing (final gear) Yamaha bond No.1215 AC magneto lead grommet ® (Three bond No.1215 Yamaha bond No.1215 Crankcase mating surface ®...

  • Page 61: Coolant Flow Diagrams

    SPEC COOLANT FLOW DIAGRAMS EBS00025 COOLANT FLOW DIAGRAMS 1 Coolant reservoir hose 0 Fast idle plunger inlet hose 2 Radiator inlet hose 3 Fast idle plunger outlet hose 4 Coolant reservoir 5 Water pump 6 Water pump outlet pipe 7 Water pump outlet hose 8 Radiator outlet hose 9 Radiator 2 - 25...

  • Page 62: Oil Flow Diagrams

    SPEC OIL FLOW DIAGRAMS EBS00026 OIL FLOW DIAGRAMS 1 Oil delivery pipe 2 Oil filter cartridge 3 Oil strainer 4 Drive axle 5 Relief valve assembly 6 Reverse idle gear shaft 2 - 26...
  • Page 63 SPEC OIL FLOW DIAGRAMS 1 Camshaft 2 Crankshaft 3 Oil strainer 4 Oil pump rotor 5 Oil pump driven gear 2 - 27...

  • Page 64: Cable Routing

    SPEC CABLE ROUTING EBS00028 CABLE ROUTING 1 Front brake light switch lead 9 Rear brake light switch lead 2 On-command four-wheel-drive motor switch and 0 Radiator fan motor breather hose A Differential gear case breather hose differential gear lock switch lead 3 Front brake hose B EPS motor breather hose 4 Throttle cable...
  • Page 65 SPEC CABLE ROUTING È Pass the front brake hose and throttle cable Ë Pass the rear brake hose and throttle cable through the guide on the handlebar cover. through the guide, making sure to route the É Pass the rear brake cable, shift control cable, cable behind the hose.
  • Page 66 SPEC CABLE ROUTING Ï Route the front brake light switch lead, on-com- Ð Fasten the left handlebar switch lead and rear mand four-wheel-drive motor switch and differ- brake light switch lead with the plastic bands at ential gear lock switch lead, left handlebar the bends in the handlebar, making sure to route switch lead, and rear brake light switch lead over the leads under the handlebar and to face the...
  • Page 67 SPEC CABLE ROUTING Ó Pass the EPS motor breather hose through the × Fasten the front brake light switch lead, on-com- guide on the meter bracket, making sure to face mand four-wheel-drive motor switch and differ- the end of the hose downward. ential gear lock switch lead, left handlebar Ô...
  • Page 68 SPEC CABLE ROUTING Ù Fasten the front brake light switch lead and on- command four-wheel-drive motor switch and dif- ferential gear lock switch lead with the plastic bands at the bends in the handlebar, making sure to route the leads under the handlebar and to face the ends of the bands forward.
  • Page 69 SPEC CABLE ROUTING 1 Coolant reservoir hose B Differential gear motor lead 2 Radiator fan motor breather hose C EPS torque sensor lead 3 Differential gear case breather hose D Fast idle plunger outlet hose 4 EPS motor breather hose E Radiator outlet hose 5 Ground lead F Gear position switch lead...
  • Page 70 SPEC CABLE ROUTING É Route the ground lead, radiator fan motor Í Fasten the radiator outlet hose to the frame with breather hose, differential gear case breather the plastic band, making sure to face the end of hose, and EPS motor breather hose to the inside the band inward.
  • Page 71 SPEC CABLE ROUTING Ñ Fasten the differential gear case breather hose Õ Face the end of the plastic band inward. Ö Route the fuel tank drain hose and position the to the frame with the plastic band, making sure to face the end of the band inward. end of the hose as shown in the illustration.
  • Page 72 SPEC CABLE ROUTING Ú Route the shift control cable under the gear posi- tion switch lead, speed sensor lead, and crank- shaft position sensor lead. Ê Ë È É Ì Ó Ò Ñ Ð Ï Î Í Ô Ö Õ Õ...
  • Page 73 SPEC CABLE ROUTING 1 Wire harness B Differential gear motor lead 2 Fuel injector lead C EPS torque sensor lead 3 Fuel hose D Radiator fan motor lead 4 Intake air temperature sensor lead E Radiator inlet hose 5 Final gear case breather hose F EPS motor breather hose 6 Ground lead G Spark plug lead...
  • Page 74 SPEC CABLE ROUTING M Speed sensor lead Ë Route the radiator fan motor lead between the N Coolant temperature sensor lead electrical components tray and the radiator inlet O EPS motor lead coupler hose. P EPS torque sensor lead coupler Ì...
  • Page 75 SPEC CABLE ROUTING Î Fasten the final gear case breather hose, Ð Face the end of the plastic band inward. Ñ Pass the plastic band through the hole in the ground lead, starter motor lead, fuel injector lead, coolant temperature sensor lead, AC mag- plastic cover, and then fasten the leads and neto lead, and wire harness with the plastic hose with the band, making sure to face the end...
  • Page 76 SPEC CABLE ROUTING 1 Tail/brake light lead È To tail/brake light 2 Rectifier/regulator lead É Fasten the tail/brake light lead to the frame with 3 AC magneto lead a plastic locking tie, making sure to face the end 4 Speed sensor lead of the tie downward.
  • Page 77 SPEC CABLE ROUTING 1 Left headlight lead B Meter lead 2 Negative battery lead C Lean angle sensor lead 3 Right headlight lead D Coolant reservoir breather hose 4 Radiator fan motor lead E Positive battery lead 5 EPS control unit lead F Coolant reservoir hose 6 Auxiliary DC jack lead G EPS motor breather hose...
  • Page 78 SPEC CABLE ROUTING M Joint coupler lead Í To main switch and auxiliary DC jack Î Fasten the left handlebar switch lead, on-com- È To left headlight mand four-wheel-drive motor switch and differ- É Connect the headlight lead coupler, and then ential gear lock switch lead, front brake light fasten the coupler with the holder on the electri- switch lead, and rear brake light switch lead with...
  • Page 79 SPEC CABLE ROUTING Ñ Route the hoses under the positive battery lead, Ö Route the hoses to the inside of the bolt. and then route them upward, to the inside of the coolant reservoir breather hose. Ò Fasten the coolant reservoir breather hose with the holder on the electrical components tray.
  • Page 80 SPEC CABLE ROUTING 1 Throttle cable B Coolant temperature sensor lead 2 Rear brake hose C Rectifier/regulator lead 3 Rear brake cable D AC magneto lead 4 Front brake hose E Fuel hose 5 Negative battery lead F Tail/brake light lead 6 Final gear case breather hose G Fuel pump lead 7 Starter motor lead...
  • Page 81 SPEC CABLE ROUTING É To engine Ï Route the fast idle plunger outlet hose above the Ê To air filter case plastic cover. Ë Route the fuel injector lead and coolant temper- Ð Pass the throttle cable through the guide on the ature sensor lead to the outside of the frame.

  • Page 82: Chk Adj

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

  • Page 83: General Maintenance And Lubrication Chart

    GENERAL MAINTENANCE AND LUBRICATION CHART EBU21863 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL EVERY month Whichever CHECK OR MAINTE- ITEM comes first 1300 2500 2500 5000 NANCE JOB (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or dusty Air filter element •...
  • Page 84 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL EVERY month Whichever CHECK OR MAINTE- ITEM comes first 1300 2500 2500 5000 NANCE JOB (mi) (200) (800) (1600) (1600) (3200) hours Engine oil filter √ √ √ • Replace. cartridge • Change. √ √...

  • Page 85: Engine Skid Plates, Seat, Carriers And Fenders

    ENGINE SKID PLATES, SEAT, CARRIERS AND FENDERS ENGINE SKID PLATES, SEAT, CARRIERS AND FENDERS ENGINE SKID PLATES 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the engine skid plates Remove the parts in the order listed. Front engine skid plate Center engine skid plate Rear engine skid plate...

  • Page 86: Seat And Side Panels

    ENGINE SKID PLATES, SEAT, CARRIERS AND FENDERS SEAT AND SIDE PANELS Order Job/Part Q’ty Remarks Removing the seat and side panels Remove the parts in the order listed. Seat NOTE: Pull up the seat lock lever, then pull up on the rear of the seat.

  • Page 87: Front Carrier And Front Guard

    ENGINE SKID PLATES, SEAT, CARRIERS AND FENDERS EBS00037 FRONT CARRIER AND FRONT GUARD 26 Nm (2.6 m kg, 19 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 26 Nm (2.6 m kg, 19 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 88 ENGINE SKID PLATES, SEAT, CARRIERS AND FENDERS 26 Nm (2.6 m kg, 19 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 26 Nm (2.6 m kg, 19 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 89: Front Fenders And Front Grill

    ENGINE SKID PLATES, SEAT, CARRIERS AND FENDERS FRONT FENDERS AND FRONT GRILL 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks...

  • Page 90: Rear Carrier And Rear Fender

    ENGINE SKID PLATES, SEAT, CARRIERS AND FENDERS EBS00040 REAR CARRIER AND REAR FENDER 34 Nm (3.4 m kg, 24 ft • • 48 Nm (4.8 m kg, 35 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 48 Nm (4.8 m kg, 35 ft •...

  • Page 91: Electrical Components Tray

    ELECTRICAL COMPONENTS TRAY ELECTRICAL COMPONENTS TRAY ELECTRICAL COMPONENTS TRAY 1/2 11 12 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the electrical compo- Remove the parts in the order listed. nents tray Front fender/front grill Refer to “FRONT FENDERS AND FRONT GRILL”.

  • Page 92: Electrical Components Tray 2/2

    ELECTRICAL COMPONENTS TRAY 11 12 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks EPS (electric power steering) control unit Four-wheel-drive motor relay 3 Rear brake relay Four-wheel-drive motor relay 2 Four-wheel-drive motor relay 1 Headlight relay Radiator fan motor coupler Disconnect.
  • Page 93 ELECTRICAL COMPONENTS TRAY ELECTRICAL COMPONENTS TRAY 2/2 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the electrical compo- Remove the parts in the order listed. nents tray Starter relay coupler Disconnect.
  • Page 94 ELECTRICAL COMPONENTS TRAY 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Front brake light switch connector Disconnect. Rear brake light switch connector Disconnect. Meter assembly coupler Disconnect.

  • Page 95: Footrest Boards

    FOOTREST BOARDS EBS00045 FOOTREST BOARDS 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 53 Nm (5.3 m kg, 38 ft • •...

  • Page 96: Air Filter Case

    AIR FILTER CASE AIR FILTER CASE Order Job/Part Q’ty Remarks Removing the air filter case Remove the parts in the order listed. Seat/side panels Refer to “SEAT AND SIDE PANELS”. Air filter case cover Air filter element Air filter element frame Air filter case joint clamp screw Loosen.

  • Page 97: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 98 ADJUSTING THE VALVE CLEARANCE 4. Disconnect: • spark plug cap 1 5. Remove: • spark plug 2 6. Remove: • timing mark accessing screw 1 • crankshaft end accessing screw 2 7. Measure: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0.09 ~ 0.13 mm...
  • Page 99 ADJUSTING THE VALVE CLEARANCE c. Measure the valve clearance with a thick- ness gauge 1. Thickness gauge 90890-03079 Narrow gauge set YM-34483 Out of specification → Adjust. L LLL L LLL L LLL L LLL L LLL 8. Adjust: • valve clearance M MMM M MMM M MMM...

  • Page 100: Adjusting The Engine Idling Speed

    ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE ENGINE IDLING SPEED 12.Install: • O-ring • camshaft sprocket cover 10 Nm (1.0 m · kg, 7.2 ft · lb) • O-ring 1 • intake tappet cover 10 Nm (1.0 m · kg, 7.2 ft · lb) •...

  • Page 101: Adjusting The Throttle Lever Free Play

    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE LEVER FREE PLAY 5. Adjust: • engine idling speed M MMM M MMM M MMM M MMM M MMM a. Turn the idle speed adjusting screw 1 in direction a or b until the specified idling speed is obtained.
  • Page 102 ADJUSTING THE THROTTLE LEVER FREE PLAY 3. Adjust: • throttle lever free play M MMM M MMM M MMM M MMM M MMM First step: a. Slide back the rubber cover 1. b. Loosen the locknut 2 on the throttle body side.

  • Page 103: Adjusting The Speed Limiter

    ADJUSTING THE SPEED LIMITER EBS00053 ADJUSTING THE SPEED LIMITER The speed limiter keeps the throttle from becoming fully-opened even when the throttle lever is applied to the maximum position. Screwing in the adjusting screw stops the engine speed from increasing. 1.

  • Page 104: Checking The Spark Plug

    CHECKING THE SPARK PLUG EBS00057 CHECKING THE SPARK PLUG 1. Remove: • right side panel Refer to “SEAT AND SIDE PANELS”. 2. Disconnect: • spark plug cap 3. Remove: • spark plug 4. Check: • spark plug type Incorrect → Change. Standard spark plug CR8E/NGK 5.

  • Page 105: Checking The Ignition Timing

    CHECKING THE IGNITION TIMING EBS00058 CHECKING THE IGNITION TIMING NOTE: Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing. 1. Remove: • left side panel • right side panel Refer to “SEAT AND SIDE PANELS”. •...

  • Page 106: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE c. Visually check the stationary pointer a to verify it is within the required firing range b indicated on the AC magneto rotor. Incorrect firing range → Check the pulser coil assembly. NOTE: When checking the ignition timing, make sure that the timing light cord does not come in con-...
  • Page 107 MEASURING THE COMPRESSION PRESSURE 4. Disconnect: • spark plug cap 5. Remove: • spark plug CAUTION: Before removing a spark plug, use com- pressed air to blow away any dirt accumu- lated in the spark plug well to prevent it from falling into the cylinder.
  • Page 108 MEASURING THE COMPRESSION PRESSURE b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. WARNING To prevent sparking, ground the spark plug lead before cranking the engine. c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces and piston crown for carbon deposits.

  • Page 109: Checking The Engine Oil Level

    CHECKING THE ENGINE OIL LEVEL EBS00064 CHECKING THE ENGINE OIL LEVEL 1. Place the vehicle on a level surface. 2. Check the engine oil level on a cold engine. NOTE: If the engine was started before checking the oil level, be sure to warm up the engine suffi- ciently, and then wait at least 10 minutes until the oil settles for an accurate reading.

  • Page 110: Changing The Engine Oil

    CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL 6. Install: • dipstick accessing panel Refer to “SEAT AND SIDE PANELS”. EBS00069 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2.
  • Page 111 CHANGING THE ENGINE OIL b. Lubricate the O-ring 3 of the new oil filter cartridge with a thin coat of engine oil. CAUTION: Make sure the O-ring 3 is positioned cor- rectly in the groove of the oil filter car- tridge.

  • Page 112: Cleaning The Air Filter Element

    CHANGING THE ENGINE OIL/ CLEANING THE AIR FILTER ELEMENT 15.Check: • engine oil pressure M MMM M MMM M MMM M MMM M MMM a. Slightly loosen the oil gallery bolt 1. b. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt.
  • Page 113 CAUTION: Do not twist or wring out the element. This could damage the foam material. c. Apply Yamaha foam air filter oil or other quality foam air filter oil to the element. 3 - 32...

  • Page 114: Checking The Throttle Body Joint

    CLEANING THE AIR FILTER ELEMENT/ CHECKING THE THROTTLE BODY JOINT d. Squeeze out the excess oil. NOTE: The element should be wet but not dripping. L LLL L LLL L LLL L LLL L LLL 6. Install: • air filter element frame •...

  • Page 115: Checking The Fuel Hose

    CHECKING THE FUEL HOSE/ CHECKING THE BREATHER HOSES EAS00096 CHECKING THE FUEL HOSE 1. Remove: • seat • right side panel Refer to “SEAT AND SIDE PANELS”. • rear fender Refer to “REAR CARRIER AND REAR FENDER”. • V-belt cooling duct 2 Refer to “ENGINE REMOVAL”...

  • Page 116: Checking The Coolant Level

    CHECKING THE COOLANT LEVEL/ CHANGING THE COOLANT EBS00076 CHECKING THE COOLANT LEVEL 1. Place the vehicle on a level surface. NOTE: The coolant level must be checked on a cold engine since the level varies with engine tem- perature. 2. Check: •...
  • Page 117 CHANGING THE COOLANT 2. Remove: • coolant reservoir cap 1 3. Disconnect: • coolant reservoir hose 2 4. Drain: • coolant (from the coolant reservoir) 5. Connect: • coolant reservoir hose 6. Remove: • radiator cap 1 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot.
  • Page 118 CHANGING THE COOLANT 11.Fill: • cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Total amount 1.99 L (1.75 Imp qt, 2.10 US qt) Coolant reservoir capacity (up to the maximum level mark) 0.17 L...
  • Page 119 CHANGING THE COOLANT 12.Fill: • coolant reservoir (with the recommended coolant to the maxi- mum level mark a) 13.Install: • coolant reservoir cap 1 14.Bleed: • coolant system M MMM M MMM M MMM M MMM M MMM a. Remove the V-belt cooling duct 2 1. b.

  • Page 120: Checking The Cooling System

    CHANGING THE COOLANT/ CHECKING THE COOLING SYSTEM 19.Install: • upper panel • front carrier Refer to “FRONT CARRIER AND FRONT GUARD”. • left side panel • right side panel Refer to “SEAT AND SIDE PANELS”. EAS00104 CHECKING THE COOLING SYSTEM 1.

  • Page 121: Checking The Coolant Temperature Warning Light

    CHECKING THE COOLANT TEMPERATURE WARNING LIGHT EBS00077 CHECKING THE COOLANT TEMPERATURE WARNING LIGHT 1 Coolant temperature warning light Coolant temperature warning light checking method Turn the main switch “ON” and the engine stop switch to “RUN”. Coolant temperature warning Coolant temperature warning light does not come on.

  • Page 122: Checking The V-Belt

    CHECKING THE V-BELT EBS00078 CHECKING THE V-BELT 1. Remove: • drive belt cover Refer to “PRIMARY AND SECONDARY SHEAVES” in chapter 4. 2. Check: • V-belt 1 Cracks/wear/scaling/chipping → Replace. Oil/grease → Check primary sheave and secondary sheave. 3. Measure: •...

  • Page 123: Checking The Exhaust System

    CHECKING THE V-BELT/ CHECKING THE EXHAUST SYSTEM c. Install the V-belt. NOTE: Install the V-belt so that its arrow faces the direction shown in the illustration. d. Remove the bolts. L LLL L LLL L LLL L LLL L LLL EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the...

  • Page 124: Cleaning The Spark Arrester

    CLEANING THE SPARK ARRESTER CLEANING THE SPARK ARRESTER 1. Clean: • spark arrester M MMM M MMM M MMM M MMM M MMM WARNING • Select a well-ventilated area free of com- bustible materials. • Always let the exhaust system cool before performing this operation.

  • Page 125: Chassis

    ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE EBS00080 CHASSIS ADJUSTING THE FRONT BRAKE 1. Measure: • front brake lever free play a Out of specification → Bleed the front brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”. Front brake lever free play (at the end of the brake lever) 0 mm (0 in) EBS00085...
  • Page 126 ADJUSTING THE REAR BRAKE 3. Measure: • brake pedal height c Out of specification → Adjust. Brake pedal height 56.7 mm (2.23 in) d Measuring points 4. Adjust: • brake pedal free play • brake pedal height 5. Remove: • front fender inner panel Refer to “FRONT FENDERS AND FRONT GRILL”.

  • Page 127: Checking The Brake Fluid Level

    ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL g. Adjust the shift control cable. Refer to “ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD”. WARNING After this adjustment is performed, lift the front and rear wheels off the ground by placing a block under the engine, and spin the rear wheels to ensure there is no brake drag.

  • Page 128: Checking The Front Brake Pads

    CHECKING THE BRAKE FLUID LEVEL/ CHECKING THE FRONT BRAKE PADS • 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 129: Checking The Rear Brake Pads

    CHECKING THE REAR BRAKE PADS/ CHECKING THE REAR BRAKE HOSE PROTECTORS EBS00089 CHECKING THE REAR BRAKE PADS 1. Remove: • rear wheels Refer to “FRONT AND REAR WHEELS” in chapter 8. 2. Check: • brake pads Wear indicator groove a almost disap- peared →...

  • Page 130: Checking The Brake Hoses

    CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM EBS00092 CHECKING THE BRAKE HOSES 1. Check: • front brake hoses 1 • rear brake hoses 2 Cracks/wear/damage → Replace. 2. Check: • brake hose holders Loosen → Tighten. 3. Hold the vehicle in an upright position and apply the front or rear brake.
  • Page 131 BLEEDING THE HYDRAULIC BRAKE SYSTEM • When bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake. Ignoring this precaution could allow air to enter the hydraulic brake system, considerably length- ening the bleeding procedure. •...
  • Page 132 BLEEDING THE HYDRAULIC BRAKE SYSTEM/ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD k. Fill the brake master cylinder reservoir to the proper level with the recommended brake fluid. Refer to “CHECKING THE BRAKE FLUID LEVEL”. WARNING After bleeding the hydraulic brake system, check the brake operation.

  • Page 133: Adjusting The Select Lever Control Cable And Shift Rod

    ADJUSTING THE SELECT LEVER CONTROL CABLE AND SHIFT ROD 3. Adjust: • shift control cable • shift rod M MMM M MMM M MMM M MMM M MMM Shift control cable: a. Make sure that the select lever is in NEU- TRAL.

  • Page 134: Checking The Final Gear Oil Level

    CHECKING THE FINAL GEAR OIL LEVEL/ CHANGING THE FINAL GEAR OIL EBS00101 CHECKING THE FINAL GEAR OIL LEVEL 1. Place the vehicle on a level place. 2. Remove: • final gear oil level check bolt 1 3. Check: • oil level Oil level should be up to the bottom brim 2 of the hole.
  • Page 135 CHANGING THE FINAL GEAR OIL 6. Install: • final gear oil drain bolt 23 Nm (2.3 m · kg, 17 ft · lb) NOTE: Check the gasket (drain bolt). If it is damaged, replace it with a new one. 7. Fill: •...

  • Page 136: Checking The Differential Gear Oil Level

    CHECKING THE DIFFERENTIAL GEAR OIL LEVEL/ CHANGING THE DIFFERENTIAL GEAR OIL EBS00103 CHECKING THE DIFFERENTIAL GEAR OIL LEVEL 1. Place the vehicle on a level surface. 2. Remove: • differential gear oil filler bolt 1 3. Check: • oil level Oil level should be up to the brim 2 of hole.

  • Page 137: Checking The Constant Velocity Joint Dust Boots

    CHANGING THE DIFFERENTIAL GEAR OIL/CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS 6. Fill: • differential gear case Periodic oil change 0.215 L (0.19 Imp qt, 0.23 US qt) Total amount 0.23 L (0.20 Imp qt, 0.24 US qt) Recommended oil SAE80 API GL-4 Hypoid gear oil NOTE: If gear oil is filled to the brim of the oil filler...

  • Page 138: Checking The Steering System

    CHECKING THE STEERING SYSTEM EBS00106 CHECKING THE STEERING SYSTEM 1. Place the vehicle on a level surface. 2. Check: • steering assembly bushings Move the handlebar up and down, and/or back and forth. Excessive play → Replace the steering stem bushings. 3.
  • Page 139 CHECKING THE STEERING SYSTEM Belt tension gauge 90890-03170 Rear drive belt tension gauge YM-03170 L LLL L LLL L LLL L LLL L LLL 7. Adjust: • steering tension M MMM M MMM M MMM M MMM M MMM a. Remove the electrical components tray. Refer to “ELECTRICAL COMPONENTS TRAY”.

  • Page 140: Adjusting The Toe-In

    ADJUSTING THE TOE-IN EBS00108 ADJUSTING THE TOE-IN 1. Place the vehicle on a level surface. 2. Measure: • toe-in Out of specification → Adjust. Toe-in 0 ~ 10 mm (0 ~ 0.39 in) (with tires touching the ground) M MMM M MMM M MMM M MMM...

  • Page 141: Checking The Front And Rear Shock Absorbers

    ADJUSTING THE TOE-IN/CHECKING THE FRONT AND REAR SHOCK ABSORBERS b. Loosen the locknuts (tie-rod end) 1 of both tie-rods. c. The same number of turns should be given to both the right and left tie-rods 2 until the specified toe-in is obtained. This is to keep the length of the rods the same.

  • Page 142: Adjusting The Front Shock Absorbers

    CHECKING THE FRONT AND REAR SHOCK ABSORBERS/ ADJUSTING THE FRONT SHOCK ABSORBERS 3. Check: È • operation Pump the shock absorbers up and down for several times. Unsmooth operation → Replace front/rear shock absorber. Refer to “FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES”...

  • Page 143: Adjusting The Rear Shock Absorbers

    • TIRE CHARACTERISTICS 1) Tire characteristics influence the han- dling of ATVs. The tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. If other tire com- binations are used, they can adversely affect your vehicle’s handling character- istics and are therefore not recom- mended.
  • Page 144 CHECKING THE TIRES Manufacturer Size Type AT25 × Front DUNLOP KT421 8-12 AT25 × Rear DUNLOP KT425 10-12 • TIRE PRESSURE 1) Recommended tire pressure Front 35 kPa (0.35 kg/cm , 5.0 psi) Rear 30 kPa (0.30 kg/cm , 4.3 psi) 2) Tire pressure below the minimum speci- fication could cause the tire to dislodge from the rim under severe riding condi-...
  • Page 145 CHECKING THE TIRES 1. Measure: • tire pressure Out of specification → Adjust. NOTE: • The low-pressure tire gauge 1 is included as standard equipment. • If dust or the like is stuck to this gauge, it will not provide the correct readings. Therefore, take two measurements of the tire’s pressure and use the second reading.

  • Page 146: Checking The Wheels

    • cable operation → Unsmooth operation Lubricate replace. Recommended lubricant Yamaha chain and cable lube or engine oil NOTE: Hold the cable end up and apply several drops of lubricant to the cable. 3. Apply: • lithium-soap-based grease (onto end of the cable)

  • Page 147: Lubricating The Levers And Pedals

    LUBRICATING THE LEVERS AND PEDALS EBS00118 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant Lithium-soap-based grease 3 - 66...

  • Page 148: Electrical System

    CHECKING AND CHARGING THE BATTERY EBS00120 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
  • Page 149 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 150 CHECKING AND CHARGING THE BATTERY b. Check the charge of the battery, as shown Relationship between the open-circuit volt- in the charts and the following example. age and the charging time at 20 °C (68 °F) Example c. Open-circuit voltage = 12.0 V d.
  • Page 151 CHECKING AND CHARGING THE BATTERY • If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode! • As shown in the following illustration, the open-circuit voltage of an MF battery sta- bilizes about 30 minutes after charging has been completed.
  • Page 152 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger NOTE: Measure the open-circuit Leave the battery unused for voltage prior to charging. Charger more than 30 minutes before measuring its open-circuit voltage. Ammeter Connect a charger and NOTE: Set the charging voltage to 16 ~ ammeter to the battery and...
  • Page 153 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger NOTE: Measure the open-circuit Leave the battery unused for voltage prior to charging. more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging.

  • Page 154: Checking The Fuses

    CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1, and then the negative battery lead 2. 8. Check: • battery terminals Dirt →...
  • Page 155 CHECKING THE FUSES 2. Check: • fuse M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C...
  • Page 156 CHECKING THE FUSES d. If the fuse immediately blows again, check the electrical circuit. Amperage Items Q’ty rating Main fuse 40 A EPS fuse 40 A Fuel injection 15 A system fuse Ignition fuse 10 A Headlight fuse 15 A Four-wheel- 10 A drive motor fuse...

  • Page 157: Adjusting The Headlight Beams

    ADJUSTING THE HEADLIGHT BEAMS/ REPLACING THE HEADLIGHT BULBS EBS00122 ADJUSTING THE HEADLIGHT BEAMS 1. Adjust: • headlight beam (vertically) M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting screw 1 in direction a or b. Headlight beam is Direction a raised.
  • Page 158 REPLACING THE HEADLIGHT BULBS 4. Remove: • headlight bulb holder 1 • headlight bulb 2 NOTE: Unhook the headlight bulb holder, and then remove the defective bulb. WARNING Keep flammable products and your hands away from the bulb while it is on, as it will be hot.

  • Page 159: Eng

    ENGINE REMOVAL EBS00200 ENGINE ENGINE REMOVAL AIR DUCTS, MUFFLER AND EXHAUST PIPE 7 Nm (0.7 m kg, 5.1 ft • • 20 Nm (2.0 m kg, 14 ft • • 20 Nm (2.0 m kg, 14 ft • • Order Job/Part Q’ty Remarks...
  • Page 160 ENGINE REMOVAL 7 Nm (0.7 m kg, 5.1 ft • • 20 Nm (2.0 m kg, 14 ft • • 20 Nm (2.0 m kg, 14 ft • • Order Job/Part Q’ty Remarks Gasket Muffler bracket Exhaust pipe Gasket For installation, reverse the removal pro- cedure.

  • Page 161: Select Lever Unit

    ENGINE REMOVAL EBS00202 SELECT LEVER UNIT 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 15 Nm (1.5 m kg, 11 ft • • 15 Nm (1.5 m kg, 11 ft •...

  • Page 162: Leads, Cables And Hoses

    ENGINE REMOVAL EBS00204 LEADS, CABLES AND HOSES Order Job/Part Q’ty Remarks Removing the leads, cables and Remove the parts in the order listed. hoses Footrest board Refer to “FOOTREST BOARDS” in chap- ter 3. Air filter case Refer to “AIR FILTER CASE” in chapter Throttle body assembly Refer to “THROTTLE BODY”...
  • Page 163 ENGINE REMOVAL Order Job/Part Q’ty Remarks Starter motor Refer to “STARTER MOTOR” in chapter Drive belt case Refer to “PRIMARY AND SECONDARY SHEAVES”. Cylinder head breather hose Fast idle plunger inlet hose Coolant temperature sensor coupler Disconnect. Spark plug cap Shift control cable Disconnect.

  • Page 164: Engine Mounting Bolts

    ENGINE REMOVAL EBS00205 ENGINE MOUNTING BOLTS 42 Nm (4.2 m kg, 30 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 165 ENGINE REMOVAL 42 Nm (4.2 m kg, 30 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 42 Nm (4.2 m kg, 30 ft •...

  • Page 166: Installing The Engine

    ENGINE REMOVAL EBS00207 INSTALLING THE ENGINE 1. Install: • rubber dampers (front side) 1 • engine mounting bolts (front lower side) 2 • engine mounting bolts (front upper side) 3 • rubber dampers (rear side) 4 • rubber damper nuts (rear side) 5 •...

  • Page 167: Installing The Select Lever Unit

    ENGINE REMOVAL INSTALLING THE SELECT LEVER UNIT 1. Install: • shift arm 1 14 Nm (1.4 m · kg, 10 ft · lb) • select lever unit 2 7 Nm (0.7 m · kg, 5.1 ft · lb) • select lever shift rod 3 15 Nm (1.5 m ·...

  • Page 168: Cylinder Head

    CYLINDER HEAD EBS00218 CYLINDER HEAD 20 Nm (2.0 m kg, 14 ft 20 Nm (2.0 m kg, 14 ft • • • • 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • •...
  • Page 169 CYLINDER HEAD 20 Nm (2.0 m kg, 14 ft 20 Nm (2.0 m kg, 14 ft • • • • 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 13 Nm (1.3 m kg, 9.4 ft •...

  • Page 170: Removing The Cylinder Head

    CYLINDER HEAD EBS00220 REMOVING THE CYLINDER HEAD 1. Align: • “I” mark on the AC magneto rotor (with the stationary pointer on the AC mag- neto cover) M MMM M MMM M MMM M MMM M MMM a. Turn the crankshaft counterclockwise. b.

  • Page 171: Checking The Camshaft Sprocket

    CYLINDER HEAD 5. Remove: • cylinder head NOTE: • Loosen the bolts in the proper sequence as shown. • Loosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them. EBS00224 CHECKING THE CAMSHAFT SPROCKET 1.

  • Page 172: Checking The Cylinder Head

    CYLINDER HEAD EBS00230 CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damag- ing or scratching: • spark plug bore threads • valve seats 2. Check: •...

  • Page 173: Installing The Cylinder Head

    CYLINDER HEAD EBS00232 INSTALLING THE CYLINDER HEAD 1. Install: • dowel pins • cylinder head gasket 2. Install: • cylinder head • cylinder head bolts NOTE: • Lubricate the cylinder head bolt 1 and 2 threads and mating surface with molybde- num disulfide grease.
  • Page 174 CYLINDER HEAD NOTE: When installing the camshaft sprocket, keep the timing chain as tense as possible on the exhaust side. CAUTION: Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. f. Remove the wire from the timing chain. L LLL L LLL L LLL...
  • Page 175 CYLINDER HEAD 7. Check: • “I” mark a NOTE: Check that the “I” mark on the AC magneto rotor is aligned with the stationary pointer b on the AC magneto cover. • “I” mark c NOTE: Check that the “I” mark on the camshaft sprocket is aligned with the stationary pointer d on the cylinder head.

  • Page 176: Rocker Arms And Camshaft

    ROCKER ARMS AND CAMSHAFT EBS00235 ROCKER ARMS AND CAMSHAFT 14 Nm (1.4 m kg, 10 ft • • 14 Nm (1.4 m kg, 10 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the rocker arms and cam- Remove the parts in the order listed.
  • Page 177 ROCKER ARMS AND CAMSHAFT 14 Nm (1.4 m kg, 10 ft • • 14 Nm (1.4 m kg, 10 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Decompressor lever pin Refer to “REMOVING THE ROCKER ARMS AND CAMSHAFT”...

  • Page 178: Removing The Rocker Arms And Camshaft

    ROCKER ARMS AND CAMSHAFT EBS00237 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Loosen: • locknuts • valve adjusting screws 2. Remove: • intake rocker arm shaft • exhaust rocker arm shaft • intake rocker arm • exhaust rocker arm NOTE: Remove the rocker arm shafts with the slide hammer bolt 1 and weight 2.

  • Page 179: Checking The Decompression System

    ROCKER ARMS AND CAMSHAFT 3. Measure: • camshaft runout Out of specification → Replace. Camshaft runout limit 0.015 mm (0.0006 in) EBS00225 CHECKING THE DECOMPRESSION SYSTEM 1. Check: • decompression system M MMM M MMM M MMM M MMM M MMM a.

  • Page 180: Installing The Camshaft And Rocker Arms

    ROCKER ARMS AND CAMSHAFT 4. Measure: • rocker arm shaft outside diameter Out of specification → Replace. Rocker arm shaft outside diame- 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) 5. Calculate: • rocker-arm-to-rocker-arm-shaft clearance NOTE: Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter.
  • Page 181 ROCKER ARMS AND CAMSHAFT 2. Lubricate: • camshaft • decompressor lever pin • decompressor lever Recommended lubricant Engine oil 3. Install: • decompressor lever pin 1 • decompressor lever 2 NOTE: Install the decompressor lever pin 1 and decompressor lever 2 in the camshaft 3 as shown in the illustration.
  • Page 182 ROCKER ARMS AND CAMSHAFT 6. Install: • exhaust rocker arm 1 • exhaust rocker arm shaft 2 • intake rocker arm • intake rocker arm shaft NOTE: • Use a slide hammer bolt 3 to install the rocker arm shaft. •...

  • Page 183: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EBS00234 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Cylinder head Refer to “CYLINDER HEAD”. Rocker arms/rocker arm shafts/cam- Refer to “ROCKER ARMS AND CAM- shaft SHAFT”.

  • Page 184: Removing The Valves And Valve Springs

    VALVES AND VALVE SPRINGS EBS00238 REMOVING THE VALVES AND VALVE SPRINGS The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.

  • Page 185: Checking The Valves And Valve Springs

    VALVES AND VALVE SPRINGS 3. Remove: • valve spring retainer 1 • valve spring 2 • valve 3 • valve stem seal 4 • valve spring seat 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. EBS00240 CHECKING THE VALVES AND VALVE SPRINGS...
  • Page 186 VALVES AND VALVE SPRINGS 2. Replace: • valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. M MMM M MMM M MMM M MMM M MMM a.
  • Page 187 VALVES AND VALVE SPRINGS 4. Measure: • margin thickness a Out of specification → Replace. Margin thickness 0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in) 5. Measure: • valve stem runout Out of specification → Replace. Runout limit 0.040 mm (0.0016 in) NOTE: •...
  • Page 188 VALVES AND VALVE SPRINGS e. If the valve seat is too wide, too narrow, or the seat is not centered, the valve seat must be refaced. L LLL L LLL L LLL L LLL L LLL 9. Lap: • valve face •...

  • Page 189: Installing The Valves And Valve Springs

    VALVES AND VALVE SPRINGS h. Press the valve through the valve guide and onto the valve seat to make a clear pattern. i. Measure the valve seat width again. If the valve seat width is out of specification, reface and relap the valve seat. L LLL L LLL L LLL...
  • Page 190 VALVES AND VALVE SPRINGS 2. Lubricate: • valve stem 1 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. Install: • valve spring seats 1 • valve stem seals 2 • valves 3 • valve springs 4 • valve spring retainers 5 NOTE: Install the valve springs with the larger pitch a facing upwards.
  • Page 191 VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood. CAUTION: Hitting the valve tip with excessive force could damage the valve. 4 - 33...

  • Page 192: Cylinder And Piston

    CYLINDER AND PISTON EBS00245 CYLINDER AND PISTON 1st 15 Nm (1.5 m kg, 11 ft • • 2nd 50 Nm (5.0m kg, 36 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the cylinder and piston Remove the parts in the order listed.

  • Page 193: Removing The Piston

    CYLINDER AND PISTON EBS00247 REMOVING THE PISTON 1. Remove: • piston pin clips 1 • piston pin 2 • piston 3 NOTE: • Before removing the piston pin clips, cover the crankcase opening with a clean rag to prevent the piston pin clips from falling into the crankcase.
  • Page 194 CYLINDER AND PISTON 2. Measure: • piston-to-cylinder clearance M MMM M MMM M MMM M MMM M MMM a. Measure the cylinder bore “C” with a cylin- der bore gauge. NOTE: Measure the cylinder bore “C” in parallel to and at right angles to the crankshaft.

  • Page 195: Checking The Piston Rings

    CYLINDER AND PISTON f. If out of specification, replace the cylinder, and the piston and piston rings as a set. L LLL L LLL L LLL L LLL L LLL EBS00250 CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specification →...

  • Page 196: Checking The Piston Pin

    CYLINDER AND PISTON Piston ring end gap Top ring 0.20 ~ 0.35 mm (0.008 ~ 0.014 in) <Limit>: 0.60 mm (0.024 in) 2nd ring 0.75 ~ 0.90 mm (0.030 ~ 0.035 in) <Limit>: 1.25 mm (0.049 in) Oil ring 0.20 ~ 0.70 mm (0.008 ~ 0.028 in) EBS00251 CHECKING THE PISTON PIN...

  • Page 197: Installing The Piston And Cylinder

    CYLINDER AND PISTON 4. Calculate: • piston-pin-to-piston-pin-bore clearance Out of specification → Replace the piston pin and piston as a set. Piston-pin-to-piston-pin-bore clearance = Piston pin bore diameter b – Piston pin outside diameter a Piston-pin-to-piston clearance 0.004 ~ 0.024 mm (0.0002 ~ 0.0009 in) <Limit>: 0.074 mm (0.0029 in) EBS00252...
  • Page 198 CYLINDER AND PISTON 2. Install: • piston 1 • piston pin 2 • piston pin clips 3 NOTE: • Apply engine oil to the piston pin. • Make sure the punch mark a on the piston points towards the exhaust side of the cylin- der.
  • Page 199 CYLINDER AND PISTON 7. Install: • cylinder bolts NOTE: Lubricate the cylinder bolt 1 threads and mat- ing surface with engine oil. 8. Tighten: • cylinder bolts 1 (1st) 15 Nm (1.5 m · kg, 11 ft · lb) • cylinder bolts 1 (2nd) 50 Nm (5.0 m ·...

  • Page 200: Ac Magneto

    AC MAGNETO EBS00256 AC MAGNETO 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • •...
  • Page 201 AC MAGNETO 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 70 Nm (7.0 m kg, 50 ft •...
  • Page 202 AC MAGNETO 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 70 Nm (7.0 m kg, 50 ft •...

  • Page 203: Removing The Ac Magneto Rotor

    AC MAGNETO EBS00259 REMOVING THE AC MAGNETO ROTOR 1. Remove: • lead holder 1 • AC magneto cover NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.

  • Page 204: Checking The Stator Coil And Crankshaft Position Sensor

    AC MAGNETO Flywheel puller 90890-01362 Heavy duty puller YU-33270-B EBS00262 CHECKING THE STATOR COIL AND CRANKSHAFT POSITION SENSOR 1. Check: • stator coil 1 • crankshaft position sensor 2 Damage → Replace the crankshaft position sensor/stator assembly. EBS00263 CHECKING THE STARTER CLUTCH 1.

  • Page 205: Checking The Torque Limiter

    7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: Align the projection a on the stator coil with the slot b in the AC magneto cover. 2. Apply: • Sealant 1 (into the slit) Yamaha bond No. 1215 90890-85505 ® (Three bond No.1215 4 - 47...
  • Page 206 AC MAGNETO 3. Install: • woodruff key • AC magneto rotor NOTE: • Before installing the rotor, clean the outside of the crankshaft and the inside of the rotor. • After installing the rotor, check that the rotor rotates smoothly. If not, reinstall the key and rotor.

  • Page 207: Balancer Gears And Oil Pump Gears

    BALANCER GEARS AND OIL PUMP GEARS BALANCER GEARS AND OIL PUMP GEARS Order Job/Part Q’ty Remarks Removing the balancer gears and oil Remove the parts in the order listed. pump gears Starter wheel gear Refer to “AC MAGNETO”. Lock washer Refer to “REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP Balancer driven gear...
  • Page 208 BALANCER GEARS AND OIL PUMP GEARS Order Job/Part Q’ty Remarks Lock washer Refer to “REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR” and “INSTALLING THE BAL- ANCER DRIVE GEAR, BALANCER DRIVEN GEAR, AND OIL PUMP DRIVEN GEAR”. Oil pump driven gear Plate Spring Refer to “REMOVING THE BALANCER...

  • Page 209: Removing The Balancer Driven Gear And Oil Pump Driven Gear

    BALANCER GEARS AND OIL PUMP GEARS REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP DRIVEN GEAR 1. Straighten the lock washer tabs. 2. Loosen: • balancer driven gear nut 1 • oil pump driven gear nut 2 NOTE: Place an aluminum plate 3 between the teeth of the balancer drive gear 4 and balancer driven gear 5, then loosen the nuts.

  • Page 210: Installing The Balancer Drive Gear, Balancer Driven Gear, And Oil Pump Driven Gear

    BALANCER GEARS AND OIL PUMP GEARS INSTALLING THE BALANCER DRIVE GEAR, BALANCER DRIVEN GEAR, AND OIL PUMP DRIVEN GEAR 1. Install: • pin • spring • balancer drive gear (onto the buffer boss) NOTE: Align the punch mark a on the balancer drive gear with the hole b to the buffer boss.

  • Page 211: Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES EBS00269 PRIMARY AND SECONDARY SHEAVES 10 Nm (1.0 m kg, 7.2 ft • • (11) 10 Nm (1.0 m kg, 7.2 ft • • 140 Nm (14.0 m kg, 100 ft • • 100 Nm (10.0 m kg, 72 ft •...
  • Page 212 PRIMARY AND SECONDARY SHEAVES 10 Nm (1.0 m kg, 7.2 ft • • (11) 10 Nm (1.0 m kg, 7.2 ft • • 140 Nm (14.0 m kg, 100 ft • • 100 Nm (10.0 m kg, 72 ft • •...

  • Page 213: Primary Sheave

    PRIMARY AND SECONDARY SHEAVES EBS00270 PRIMARY SHEAVE Order Job/Part Q’ty Remarks Disassembling the primary sheave Remove the parts in the order listed. Primary pulley sheave cap Primary pulley slider Primary pulley cam Primary pulley weight Refer to “ASSEMBLING THE PRIMARY SHEAVE”.

  • Page 214: Secondary Sheave

    PRIMARY AND SECONDARY SHEAVES EBS00271 SECONDARY SHEAVE Order Job/Part Q’ty Remarks Disassembling the secondary Remove the parts in the order listed. sheave Spring seat Compression spring Refer to “DISASSEMBLING THE SEC- Spring seat ONDARY SHEAVE” and “ASSEMBLING Guide pin THE SECONDARY SHEAVE”. Secondary sliding sheave O-ring Secondary fixed sheave...

  • Page 215: Removing The Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES EBS00272 REMOVING THE PRIMARY AND SECONDARY SHEAVES 1. Loosen: • secondary sheave nut 1 • primary sheave nut 2 NOTE: • Use the sheave holder 3 to hold the primary sheave. • First, loosen the secondary sheave nut 2, then loosen the primary sheave nut 1.

  • Page 216: Checking The Primary Sheave

    PRIMARY AND SECONDARY SHEAVES EBS00274 CHECKING THE PRIMARY SHEAVE 1. Check: • weight outside diameter a Out of specification → Replace the weight. Weight outside diameter 30 mm (1.18 in) <Limit>: 29.5 mm (1.16 in) 2. Check: • primary pulley slider •...

  • Page 217: Assembling The Primary Sheave

    Remove any excess grease. 2. Install: • weights 1 NOTE: • Apply Yamaha Grizzly grease (90 g) to the whole outer surface of the weights and install. • Apply Yamaha Grizzly grease (2.5 g) to the inner surface of the collar.

  • Page 218: Assembling The Secondary Sheave

    PRIMARY AND SECONDARY SHEAVES 3. Install: • slider 1 • cam 2 • primary sliding sheave cap 3 Nm (0.3 m · kg, 2.2 ft · lb) EBS00277 ASSEMBLING THE SECONDARY SHEAVE 1. Apply: ® • BEL-RAY assembly lube (to the secondary sliding sheave 1 inner surface and oil seals) ®...
  • Page 219 PRIMARY AND SECONDARY SHEAVES 4. Install: • spring seat • compression spring • spring seat • nut M MMM M MMM M MMM M MMM M MMM a. Attach the sheave fixed block, locknut wrench and sheave spring compressor to the secondary sheave.

  • Page 220: Installing The Primary And Secondary Sheaves

    PRIMARY AND SECONDARY SHEAVES EBS00279 INSTALLING THE PRIMARY AND SECONDARY SHEAVES 1. Install: • secondary sheave • V-belt • primary sheave NOTE: • Tightening the bolts 1 will push the second- ary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen.

  • Page 221: Clutch

    CLUTCH EBS00291 CLUTCH Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Primary sheave/secondary sheave Refer to “PRIMARY AND SECONDARY SHEAVES”. Clutch housing assembly Gasket Dowel pin Refer to “REMOVING THE CLUTCH” and “INSTALLING THE CLUTCH”. One-way clutch bearing Clutch carrier assembly For installation, reverse the removal pro-...
  • Page 222 CLUTCH EBS00292 Order Job/Part Q’ty Remarks Disassembling the clutch housing Remove the parts in the order listed. assembly Oil seal Circlip Bearing housing Circlip Bearing Circlip Bearing Clutch housing For assembly, reverse the disassembly procedure. 4 - 64...

  • Page 223: Removing The Clutch

    CLUTCH EBS00296 REMOVING THE CLUTCH 1. Remove: • clutch housing assembly • gasket • dowel pins NOTE: Working in crisscross pattern, loosen each bolt 1/4 of a turn. Remove them after all of them are loosened. 2. Straighten: • punched portion of the nut 1 3.

  • Page 224: Checking The Clutch

    CLUTCH EBS00299 CHECKING THE CLUTCH 1. Check: • clutch housing Heat damage/wear/damage → Replace. • one-way clutch bearing Chafing/wear/damage → Replace. NOTE: • Replace the one-way clutch assembly and clutch housing as a set. • The one-way clutch bearing must be installed with the flange side facing in.

  • Page 225: Installing The Clutch

    CLUTCH EBS00309 INSTALLING THE CLUTCH 1. Install: • clutch carrier assembly • nut 1 190 Nm (19.0 m · kg, 140 ft · lb) CAUTION: The clutch carrier assembly nut has left- handed threads. To tighten the clutch car- rier assembly nut turn it counterclockwise. NOTE: Use a clutch holding tool 2 to hold the clutch carrier assembly.

  • Page 226: Crankcase

    CRANKCASE EBS00319 CRANKCASE TIMING CHAIN AND OIL FILTER 7 Nm (0.7 m kg, 5.1 ft • • 17 Nm (1.7 m kg, 12 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 68 Nm (6.8 m kg, 49 ft •...

  • Page 227: Crankcase

    CRANKCASE 7 Nm (0.7 m kg, 5.1 ft • • 17 Nm (1.7 m kg, 12 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 68 Nm (6.8 m kg, 49 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 228 CRANKCASE EBS00320 CRANKCASE 10 Nm (1.0 m kg, 7.2 ft 18 Nm (1.8 m kg, 13 ft • • • • 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 229: Crankcase Bearings

    CRANKCASE EBS00321 CRANKCASE BEARINGS 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the crankcase bearings Remove the parts in the order listed. Crankshaft/oil pump Refer to “CRANKSHAFT AND OIL PUMP”. Transmission Refer to “TRANSMISSION”. Middle drive shaft/middle driven shaft Refer to “MIDDLE GEAR”.

  • Page 230: Separating The Crankcase

    CRANKCASE EBS00332 SEPARATING THE CRANKCASE 1. Separate: • right crankcase • left crankcase M MMM M MMM M MMM M MMM M MMM a. Remove the lead holders and crankcase bolts. NOTE: • Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove È...

  • Page 231: Checking The Bearings

    Clogged → Blow out with compressed air. EBS00342 ASSEMBLING THE CRANKCASE 1. Apply: • sealant 1 (to the mating surfaces of both case halves) Yamaha bond No. 1215 90890-85505 ® (Three bond No.1215 NOTE: Apply two coats of sealant to the area a shown in the illustration.

  • Page 232: Installing The Shift Lever

    CRANKCASE 3. Fit the right crankcase onto the left crank- case. Tap lightly on the case with a soft hammer. CAUTION: Before installing and torquing the crank- case holding bolts, be sure to check whether the transmission is functioning properly by manually rotating the shift drum in both directions.

  • Page 233: Crankshaft And Oil Pump

    CRANKSHAFT AND OIL PUMP EBS00326 CRANKSHAFT AND OIL PUMP 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the crankshaft and oil Remove the parts in the order listed. pump Crankcase Separate.

  • Page 234: Oil Pump

    CRANKSHAFT AND OIL PUMP EBS00327 OIL PUMP 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Part Q’ty Remarks Disassembling the oil pump Remove the parts in the order listed. Oil pump housing cover Oil pump shaft Oil pump inner rotor Oil pump outer rotor Oil pump housing For assembly, reverse the disassembly...

  • Page 235: Removing The Crankshaft

    CRANKSHAFT AND OIL PUMP EBS00336 REMOVING THE CRANKSHAFT 1. Remove: • crankshaft 1 Use a crankcase separating tool 2. Crankcase separating tool 90890-01135 Crankcase separator YU-01135-B EBS00331 CHECKING THE OIL PUMP 1. Check: • oil pump housing • oil pump housing cover Cracks/wear/damage →...

  • Page 236: Checking The Oil Strainer

    CRANKSHAFT AND OIL PUMP CHECKING THE OIL STRAINER 1. Check: • oil strainer Damage → Replace. Contaminants → Clean with engine oil. EBS00360 CHECKING THE CRANKSHAFT 1. Measure: • crank width a Out of specification → Replace the crank- shaft. Crank width 74.95 ~ 75.00 mm (2.951 ~ 2.953 in)

  • Page 237: Assembling The Oil Pump

    CRANKSHAFT AND OIL PUMP EBS00318 ASSEMBLING THE OIL PUMP 1. Install: • oil pump housing 1 • oil pump outer rotor 2 • oil pump inner rotor 3 • oil pump shaft 4 • pin 5 NOTE: When installing the oil pump shaft 4 align the pin 5 with the groove a in the inner rotor 3.
  • Page 238 CRANKSHAFT AND OIL PUMP NOTE: Hold the connecting rod at the Top Dead Cen- ter (TDC) with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against the bearing. CAUTION: Apply engine oil to each bearing to protect the crankshaft against scratches and to...

  • Page 239: Transmission

    TRANSMISSION EBS00345 TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. Middle driven gear Refer to “MIDDLE GEAR”. Shift drum Shift fork assembly Shift fork “R” Spring Refer to “ASSEM- Refer to “REMOV- BLING THE ING THE TRANS-...
  • Page 240 TRANSMISSION Order Job/Part Q’ty Remarks Stopper lever Refer to “REMOVING THE TRANSMIS- SION” and “INSTALLING THE TRANS- Stopper lever shaft MISSION”. For installation, reverse the removal pro- cedure. 4 - 82...

  • Page 241: Drive Axle

    TRANSMISSION EBS00348 DRIVE AXLE Order Job/Part Q’ty Remarks Disassembling the drive axle Remove the parts in the order listed. assembly Washer Collar High wheel gear Washer Clutch dog Circlip Washer Collar Low wheel gear Washer Circlip Middle drive gear Circlip 4 - 83...
  • Page 242 TRANSMISSION Order Job/Part Q’ty Remarks Washer Bearing Reverse wheel gear Stopper wheel Drive axle For assembly, reverse the disassembly procedure. 4 - 84...

  • Page 243: Removing The Transmission

    TRANSMISSION REMOVING THE TRANSMISSION 1. Remove: • shift drum 1 • shift fork assembly 2 M MMM M MMM M MMM M MMM M MMM a. Pull out the guide bar from the left crank- case. b. Push down on the drive shaft, and then slide the shift fork assembly to remove the shift fork cam followers.

  • Page 244: Checking The Shift Drum

    TRANSMISSION EBS00351 CHECKING THE SHIFT DRUM 1. Check: • shift drum grooves Scratches/wear/damage → Replace. EBS00354 CHECKING THE TRANSMISSION 1. Measure: • drive axle runout (with a centering device and dial gauge 1) Out of specification → Replace the drive axle.

  • Page 245: Checking The Secondary Shaft

    TRANSMISSION CHECKING THE SECONDARY SHAFT 1. Check: • gear teeth Blue discoloration/pitting/wear → Replace. CHECKING THE STOPPER LEVER AND STOPPER WHEEL 1. Check: • stopper lever pawl 1 Bends/damage/wear → Replace the stop- per lever and stopper wheel as a set. •...

  • Page 246: Installing The Transmission

    TRANSMISSION EBS00356 INSTALLING THE TRANSMISSION 1. Install: • stopper lever shaft • stopper lever • reverse idle gear 1 • drive axle assembly 2 • secondary shaft 3 • shift fork assembly 4 • shift drum 5 NOTE: Install the shift forks 6 with the “L” mark a and “R”...

  • Page 247: Middle Gear

    MIDDLE GEAR EBS00363 MIDDLE GEAR MIDDLE DRIVE SHAFT Order Job/Part Q’ty Remarks Removing the middle drive shaft Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. Bearing housing Middle drive pinion gear nut Middle drive pinion gear Middle drive gear shim Refer to “REMOVING THE MIDDLE Middle drive shaft...

  • Page 248: Middle Driven Shaft

    MIDDLE GEAR EBS00364 MIDDLE DRIVEN SHAFT Order Job/Part Q’ty Remarks Removing the middle driven shaft Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. Front drive shaft coupling gear nut (middle gear side) Front drive shaft coupling gear (middle gear side) Middle driven pinion gear assembly Rear drive shaft coupling gear nut...
  • Page 249 MIDDLE GEAR Order Job/Part Q’ty Remarks Bearing Middle driven pinion gear bearing retainer Refer to “REMOVING THE MIDDLE Bearing DRIVEN SHAFT” and “INSTALLING THE MIDDLE DRIVEN SHAFT”. Middle driven shaft bearing retainer Bearing Middle driven shaft For installation, reverse the removal pro- cedure.

  • Page 250: Removing The Middle Drive Shaft

    MIDDLE GEAR EBS00365 REMOVING THE MIDDLE DRIVE SHAFT 1. Straighten: • punched portion of the middle drive pinion gear nut 2. Loosen: • middle drive pinion gear nut 1 NOTE: Secure the middle drive shaft in the vise with a clean rag.

  • Page 251: Removing The Middle Driven Shaft

    MIDDLE GEAR EBS01020 REMOVING THE MIDDLE DRIVEN SHAFT 1. Remove: • front drive shaft coupling gear nut (middle gear side) 1 • washer • front drive shaft coupling gear (middle gear side) 2 NOTE: Use the coupling gear/middle shaft tool 3 to hold the coupling gear.
  • Page 252 MIDDLE GEAR CAUTION: • Never directly press the middle driven pinion gear end with a hydraulic press, this will result in damage to the middle driven pinion gear thread. • Install a suitable socket 2 on the middle driven pinion gear end to protect the thread from damage.

  • Page 253: Checking The Pinion Gears

    MIDDLE GEAR 5. Remove: • oil seal 1 • middle driven shaft bearing retainer 2 NOTE: Attach the ring nut wrench 3. Ring nut wrench 90890-01430, YM-38404 CAUTION: The middle driven shaft bearing retainer has left-handed threads. To loosen the retainer turn it clockwise.

  • Page 254: Selecting Middle Drive And Driven Gear Shims

    MIDDLE GEAR EBS00370 SELECTING MIDDLE DRIVE AND DRIVEN GEAR SHIMS When the drive and driven gear, bearing hous- ing assembly and/or crankcase replaced, be sure to adjust the gear shim 1, 2. 1. Select: • middle drive gear shim 1 •...
  • Page 255 MIDDLE GEAR e = a numeral (usually a decimal number) on the left crankcase specifies a thickness of “9.0” Example: 1) If the bearing housing is marked “–02”, ..a is 0.58 2) b is 17.0 3) c is 55.0 4) If the right crankcase is marked “64.97”, ..
  • Page 256 MIDDLE GEAR c. To find shim thickness “B” use the following formula: Middle driven pinion gear shim thickness “B” = f – g + h – i – j – 0.05 Where: f = a numeral (usually a decimal number) on the bearing housing is either added to or subtracted from “77.5”...

  • Page 257: Installing The Bearing And Oil Seals

    MIDDLE GEAR 7) Round off hundredth digit and select appro- priate shim(s). In the example above, the calculated shim thickness is 0.72 mm. The chart instructs you, however, to round off 2 to 0. Hundredths Round value 0, 1, 2 3, 4, 5, 6, 7 8, 9 Shims are supplied in the following thickness.

  • Page 258: Installing The Middle Driven Shaft

    MIDDLE GEAR EBS00373 INSTALLING THE MIDDLE DRIVEN SHAFT 1. Install: • middle driven shaft bearing retainer 1 80 Nm (8.0 m · kg, 58 ft · lb) NOTE: Attach the ring nut wrench 2. Ring nut wrench 90890-01430, YM-38404 CAUTION: The middle driven shaft bearing retainer has left-handed threads.
  • Page 259 MIDDLE GEAR 3. Install: • middle driven gear shim(s) 1 • bearing housing NOTE: Install the shim(s) so that the tabs are posi- tioned as shown in the illustration. 4. Install: • rear drive shaft coupling gear (middle gear side) 1 •...

  • Page 260: Installing The Middle Drive Shaft

    MIDDLE GEAR INSTALLING THE MIDDLE DRIVE SHAFT 1. Install: • circlip • middle driven gear 1 (to the middle drive shaft 2) Installed depth of middle driven gear a 24.7 ~ 24.9 mm (0.97 ~ 0.98 in) 2. Tighten: • middle drive pinion gear nut 1 180 Nm (18.0 m ·...
  • Page 261 MIDDLE GEAR e. If the gear lash is incorrect, adjust the gear lash by middle driven pinion gear shims and/or middle drive pinion gear shim(s). L LLL L LLL L LLL L LLL L LLL 4 - 103...

  • Page 262: Cool

    COOL RADIATOR EBS00125 COOLING SYSTEM RADIATOR 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft • • • • Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Front fenders Refer to “FRONT FENDERS AND FRONT GRILL”...
  • Page 263 COOL RADIATOR 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft • • • • Order Job/Part Q’ty Remarks Coolant reservoir cap Coolant reservoir Fast idle plunger outlet hose Radiator outlet hose Radiator inlet hose Radiator bracket Radiator Radiator fan...

  • Page 264: Checking The Radiator

    COOL RADIATOR EBS00127 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction → Clean. Apply compressed air to the rear of the radi- ator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. 2.

  • Page 265: Installing The Radiator

    COOL RADIATOR EBS00128 INSTALLING THE RADIATOR 1. Fill: • cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: • cooling system Leaks → Repair or replace any faulty part. 3.

  • Page 266: Thermostat

    COOL THERMOSTAT EBS00129 THERMOSTAT 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the thermostat Remove the parts in the order listed. Air filter case Refer to “AIR FILTER CASE”...

  • Page 267: Checking The Thermostat

    COOL THERMOSTAT EBS00132 CHECKING THE THERMOSTAT 1. Check: • thermostat 1 Does not open at 50 ~ 54 °C (122 ~ 129.2 °F) → Replace. M MMM M MMM M MMM M MMM M MMM a. Suspend the thermostat in a container filled with water.

  • Page 268: Water Pump

    COOL WATER PUMP EBS00134 WATER PUMP 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • Order Job/Part Q’ty Remarks Removing the water pump Remove the parts in the order listed.
  • Page 269 COOL WATER PUMP 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • Order Job/Part Q’ty Remarks Gasket Circlip Impeller shaft Water pump seal Bearing Oil seal For installation, reverse the removal pro-...

  • Page 270: Disassembling The Water Pump

    COOL WATER PUMP EBS00138 DISASSEMBLING THE WATER PUMP 1. Remove: • water pump seal 1 NOTE: Tap out the water pump seal from the inside of the AC magneto cover 2. 2. Remove: • bearing 1 • oil seal 2 NOTE: Tap out the bearing and oil seal from the out- side of the AC magneto cover 3.

  • Page 271: Assembling The Water Pump

    COOL WATER PUMP EBS00140 ASSEMBLING THE WATER PUMP 1. Install: • oil seal 1 (into the AC magneto cover 2) NOTE: • Before installing the oil seal, apply tap water or coolant onto its out surface. • Install the oil seal with a socket 3 that matches its outside diameter.
  • Page 272 COOL WATER PUMP 3. Measure: • impeller shaft tilt Out of specification → Replace. CAUTION: Make sure the rubber damper and rubber damper holder are flush with the impeller. Impeller shaft tilt limit 0.15 mm (0.006 in) 1 Straightedge 2 Impeller shaft 5 - 11...

  • Page 273: Fuel Injection System

    FUEL INJECTION SYSTEM EAS00894 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 ECU (engine control unit) 8 Fuel injector 2 Lean angle sensor 9 Fuel pump 3 Fuel injection system relay 0 Speed sensor 4 Engine trouble warning light A Crankshaft position sensor 5 Intake air pressure sensor B Coolant temperature sensor 6 TPS (throttle position sensor)
  • Page 274 FUEL INJECTION SYSTEM 6 - 2...

  • Page 275: Circuit Diagram

    FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 6 - 3...
  • Page 276 FUEL INJECTION SYSTEM 1 Crankshaft position sensor 4 Main switch 6 Main fuse 8 Battery 9 Fuel injection system fuse H Fuel injection system relay K ECU (engine control unit) L Ignition coil M Spark plug N Fuel injector O Intake air temperature sensor P Coolant temperature sensor Q Speed sensor R TPS (throttle position sensor)

  • Page 277: Ecu Self-Diagnostic Function

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

  • Page 278: Self-Diagnostic Function Table

    FUEL INJECTION SYSTEM EAS27380 SELF-DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for the type of malfunction.

  • Page 279: Troubleshooting Chart

    FUEL INJECTION SYSTEM EAS00904 TROUBLESHOOTING CHART Engine operation is not normal or the engine trouble warning light is on. * Engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light comes on. The engine trouble warning light does not come on.

  • Page 280: Diagnostic Mode

    FUEL INJECTION SYSTEM EAS00905 DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators without connecting the measurement equipment by simply switching the meter indication from the normal mode to the diagnostic monitoring mode.
  • Page 281 FUEL INJECTION SYSTEM 6. Verify the operation of the sensor or actua- tor. • Sensor operation The data representing the operating condi- tions of the sensor appears on the LCD meter. • Actuator operation Set the engine stop switch to “ON” to oper- ate the actuator.
  • Page 282 FUEL INJECTION SYSTEM Diagnostic code table Fault Symptom Probable cause of malfunction Diagnostic code No. code No. • Open or short circuit in wire harness. • Defective crankshaft position sensor. No normal signals are received from • Malfunction in pickup rotor. —...
  • Page 283 FUEL INJECTION SYSTEM Sensor operation table Diagnos- tic code Item Meter display Checking method Throttle angle • Fully closed position 15 ~ 20 Check with throttle fully closed. • Fully opened position 95 ~ 100 Check with throttle fully open. Pressure difference Displays the intake air pressure.

  • Page 284: Troubleshooting Details

    FUEL INJECTION SYSTEM Actuator operation table • Actuator operation Set the engine stop switch to “OFF” and then to “RUN”. Diagnos- tic code Item Actuation Checking method Actuates the ignition coil five times in one-second intervals. Check the spark five times. Ignition coil The engine trouble warning light also flashes five •...
  • Page 285 FUEL INJECTION SYSTEM Fault code No. 12 Symptom No normal signals are received from the crankshaft posi- tion sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of crankshaft Check for looseness or pinching. Cranking the position sensor.
  • Page 286 FUEL INJECTION SYSTEM Fault code No. 13 Symptom Intake air pressure sensor: open or short circuit detected. Diagnostic code No. D03 Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 287 FUEL INJECTION SYSTEM Fault code No. 14 Symptom Intake air pressure sensor: hose system malfunction (clogged or detached hose). Diagnostic code No. D03 Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Intake air pressure sensor hose •...
  • Page 288 FUEL INJECTION SYSTEM Fault code No. 15 Symptom Throttle position sensor: open or short circuit detected. Diagnostic code No. D01 Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle posi- • Check for looseness or pinching. Turning the tion sensor.
  • Page 289 FUEL INJECTION SYSTEM Fault code No. 16 Symptom Stuck throttle position sensor detected. Diagnostic code No. D01 Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle posi- • Check the installed area for Reinstated by tion sensor.
  • Page 290 FUEL INJECTION SYSTEM Fault code No. 22 Symptom Intake air temperature sensor: open or short circuit detected. Diagnostic code No. D05 Intake air temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of air tempera- Check for looseness or pinching.
  • Page 291 FUEL INJECTION SYSTEM Fault code No. 30 Symptom The vehicle has overturned. Diagnostic code No. D08 Lean angle sensor Order Item/components and probable Check or maintenance job Reinstatement cause method The vehicle has overturned. Raise the vehicle upright. Turning the main switch to Installed condition of the lean Check for looseness or pinching.
  • Page 292 FUEL INJECTION SYSTEM Fault code No. 33 Symptom Malfunction detected in the primary lead of the ignition coil. Diagnostic code No. D30 Ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the connector and cou- Starting the •...
  • Page 293 FUEL INJECTION SYSTEM Fault code No. 39 Symptom Open circuit detected in a injector. Diagnostic code No. D36 Injector Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the couplers for any pins Cranking the •...
  • Page 294 FUEL INJECTION SYSTEM Fault code No. 41 Symptom Lean angle sensor: open or short circuit detected. Diagnostic code No. D08 Lean angle sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 295 FUEL INJECTION SYSTEM Fault code No. 42 Symptom No normal signals are received from the speed sensor. Diagnostic code No. D07 Speed sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the •...
  • Page 296 FUEL INJECTION SYSTEM Fault code No. 43 Symptom Power supply to the injector and fuel pump is not normal. Diagnostic code No. D09 Fuel system voltage Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the •...
  • Page 297 FUEL INJECTION SYSTEM Fault code No. 46 Symptom Power supply is not normal. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the • Main wire harness-ECU coupler that may be pulled out.

  • Page 298: Checking The Intake Air Pressure Sensor

    FUEL INJECTION SYSTEM EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR 1. Check: • intake air pressure sensor output voltage Out of specification → Replace. Intake air pressure sensor output voltage 3.00 ~ 4.00 V M MMM M MMM M MMM M MMM M MMM a.
  • Page 299 FUEL INJECTION SYSTEM M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 100) to the intake air temperature sensor terminal as shown. Br/W B/L Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe → brown/white 1 Negative tester probe →...

  • Page 300: Fuel Tank

    FUEL TANK FUEL TANK 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Rear fender Refer to “ENGINE SKID PLATES, SEAT, CARRIERS AND FENDERS”...
  • Page 301 FUEL TANK 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Fuel tank shield Damper For installation, reverse the removal pro- cedure. 6 - 29...

  • Page 302: Removing The Fuel Tank

    FUEL TANK REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel hose connector holder • fuel hose CAUTION: • Be sure to disconnect the fuel hose by hand.

  • Page 303: Checking The Fuel Pump Body

    FUEL TANK CAUTION: • Do not drop the fuel pump or give it a strong shock. • Do not touch the base section of the fuel sender. CHECKING THE FUEL PUMP BODY 1. Check: • fuel pump body Obstruction → Clean. Cracks/damage →...

  • Page 304: Installing The Fuel Hose

    FUEL TANK INSTALLING THE FUEL HOSE 1. Install: • fuel hose • fuel hose connector holder 1 • fuel pump coupler CAUTION: When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holder is in the correct position, otherwise the fuel hose will not be properly installed.

  • Page 305: Throttle Body

    THROTTLE BODY EAS00909 THROTTLE BODY 3 Nm (0.3 m kg, 2.2 ft • • Order Job/Part Q’ty Remarks Removing the throttle body Remove the parts in the order listed. Air filter case Refer to “AIR FILTER CASE” in chapter Coolant Drain.
  • Page 306 THROTTLE BODY 3 Nm (0.3 m kg, 2.2 ft • • Order Job/Part Q’ty Remarks Throttle body joint clamp screw Loosen. Refer to “INSTALLING THE THROTTLE BODY ASSEM- Throttle body assembly BLY”. Fuel hose Disconnect. Refer to “REMOVING THE THROTTLE BODY ASSEMBLY”...
  • Page 307 THROTTLE BODY Order Job/Part Q’ty Remarks Disassembling the throttle body Remove the parts in the order listed. assembly Intake air pressure sensor Intake air pressure sensor hose Throttle position sensor Injector fuel rail Fuel injector Fast idle plunger unit Throttle body CAUTION: The throttle body should not be disas- sembled.

  • Page 308: Removing The Throttle Body Assembly

    THROTTLE BODY REMOVING THE THROTTLE BODY ASSEMBLY 1. Disconnect: • fuel hose CAUTION: • Be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools. • Although the fuel has been removed from the fuel tank be careful when disconnect- ing the fuel hose, since there may be fuel remaining in it.

  • Page 309: Installing The Throttle Body Assembly

    THROTTLE BODY M MMM M MMM M MMM M MMM M MMM a. Wash the throttle body in a petroleum- based solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages with com- pressed air. L LLL L LLL L LLL...

  • Page 310: Checking The Fuel Pump And Pressure Regulator Operation

    THROTTLE BODY 4. Install: • throttle cable 5. Check: • throttle position sensor Refer to “CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR”. 6. Adjust: • throttle lever free play Refer to “ADJUSTING THE THROTTLE LEVER FREE PLAY” in chapter 3. 7.

  • Page 311: Checking And Adjusting The Throttle Position Sensor

    THROTTLE BODY e. Start the engine. f. Measure the fuel pressure. Fuel pressure 324 kPa (3.24 kg/cm , 46.1 psi) Out of specification → Replace the fuel pump. L LLL L LLL L LLL L LLL L LLL EAS00916 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 1.
  • Page 312 THROTTLE BODY b. Connect the digital circuit tester to the throt- tle position sensor coupler. Positive digital circuit tester probe → yellow 1 Negative digital circuit tester probe → black/blue 2 Digital circuit tester 90890-03174 Model 88 Multimeter with tachom- eter YU-A1927 c.

  • Page 313: Driv

    DRIV TROUBLESHOOTING EBS00155 DRIVE TRAIN TROUBLESHOOTING The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1. A pronounced hesitation or “jerky” move- A. Bearing damage. ment during acceleration, deceleration or B. Improper gear lash. sustained speed. (This must not be con- C.
  • Page 314 DRIV TROUBLESHOOTING c. A slight “thunk” evident at low speed opera- tion. This noise must be distinguished from normal vehicle operation. Diagnosis: Possible broken gear teeth. WARNING Stop riding immediately if broken gear teeth are suspected. This condition could result in the shaft drive assembly locking up, causing loss of control of the vehicle and possible injury to the rider.

  • Page 315: Troubleshooting Chart

    DRIV TROUBLESHOOTING EBS00157 TROUBLESHOOTING CHART When basic condition “a” and “b” exist, check the following points: YES Replace the wheel bearing. Elevate and spin both wheels. Feel for wheel bearing damage. (Refer to “STEERING SYSTEM” and “REAR KNUCKLES AND STABILIZER” in chapter Check the wheel nuts and hub nuts for tight- Torque to specification.

  • Page 316: Front Constant Velocity Joints And Differential Gear

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR EBS00158 FRONT CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR 55 Nm (5.5 m kg, 40 ft • • 55 Nm (5.5 m kg, 40 ft • • Order Job/Part Q’ty Remarks Removing the front constant veloc- Remove the parts in the order listed.
  • Page 317 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR 55 Nm (5.5 m kg, 40 ft • • 55 Nm (5.5 m kg, 40 ft • • Order Job/Part Q’ty Remarks Differential gear case assembly Front drive shaft Spring Damper Coupling gear Dust seal Dust seal For installation, reverse the removal pro-...
  • Page 318 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR EBS00159 Order Job/Part Q’ty Remarks Disassembling the front constant Remove the parts in the order listed. velocity joints The following procedure applies to both of the front constant velocity joints. Clip Boot band Boot band Dust boot Clip...
  • Page 319 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR Order Job/Part Q’ty Remarks Clip Refer to “ASSEMBLING THE FRONT CONSTANT VELOCITY JOINTS”. Joint shaft For assembly, reverse the disassembly procedure. 7 - 7...
  • Page 320 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR EBS00160 24 Nm (2.4 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • 62 Nm (6.2 m kg, 45 ft • • 11 Nm (1.1 m kg, 8.0 ft •...
  • Page 321 FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR 24 Nm (2.4 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • 62 Nm (6.2 m kg, 45 ft • • 11 Nm (1.1 m kg, 8.0 ft •...

  • Page 322: Removing The Differential Gear Assembly

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR EBS00163 REMOVING THE DIFFERENTIAL GEAR ASSEMBLY 1. Remove: • differential gear assembly 1 NOTE: The ring gear and the differential gear should be fastened together. Do not disassemble the differential gear. CAUTION: The differential gear are assembled into a proper unit at the factory by means of spe- cialized equipment.

  • Page 323: Checking The Differential Gears

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR EBS00166 CHECKING THE DIFFERENTIAL GEARS 1. Check: • gear teeth Pitting/galling/wear → Replace. • bearing Pitting/damage → Replace. • oil seal • O-ring Damage → Replace. 2. Check: • front drive shaft splines •...

  • Page 324: Assembling The Front Constant Velocity Joints

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR É Check that the pinion gear 2 turns clockwise. É NOTE: Be sure not to disassemble the gear motor and remove the pinion gear. L LLL L LLL L LLL L LLL L LLL EBS00167 ASSEMBLING THE FRONT CONSTANT...

  • Page 325: Assembling The Differential Gears

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR EBS01009 ASSEMBLING THE DIFFERENTIAL GEARS 1. Measure: • gear lash Refer to “MEASURING THE DIFFEREN- TIAL GEAR LASH”. 2. Install: • differential gear motor M MMM M MMM M MMM M MMM M MMM a.

  • Page 326: Measuring The Differential Gear Lash

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR 3. Check: • differential gear operation Unsmooth operation → Replace the differ- ential gear assembly. Insert the double off-set joint into the differ- ential gear, and turn the gear back and forth. EBS00174 MEASURING THE DIFFERENTIAL GEAR LASH...

  • Page 327: Adjusting The Differential Gear Lash

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR 5. Measure: • gear lash Gently rotate the coupling gear from engagement to engagement. Differential gear lash 0.05 ~ 0.25 mm (0.0020 ~ 0.0098 in) NOTE: Measure the gear lash at four positions. Rotate the shaft 90°...

  • Page 328: Checking The Differential Gear Operation

    FRONT CONSTANT VELOCITY JOINTS AND DRIV DIFFERENTIAL GEAR EBS00177 CHECKING THE DIFFERENTIAL GEAR OPERATION 1. Block the rear wheels, and elevate the front wheels by placing a suitable stand under the frame. 2. Remove the wheel cap from the axle nut (right or left).

  • Page 329: Rear Constant Velocity Joints And Final Drive Gear

    REAR CONSTANT VELOCITY JOINTS AND FINAL DRIV DRIVE GEAR EBS00178 REAR CONSTANT VELOCITY JOINTS AND FINAL DRIVE GEAR 55 Nm (5.5 m kg, 40 ft • • 55 Nm (5.5 m kg, 40 ft • • Order Job/Part Q’ty Remarks Removing the rear constant velocity Remove the parts in the order listed.
  • Page 330 REAR CONSTANT VELOCITY JOINTS AND FINAL DRIV DRIVE GEAR 55 Nm (5.5 m kg, 40 ft • • 55 Nm (5.5 m kg, 40 ft • • Order Job/Part Q’ty Remarks Spring Damper Coupling gear Dust seal Dust seal For installation, reverse the removal pro- cedure.
  • Page 331 REAR CONSTANT VELOCITY JOINTS AND FINAL DRIV DRIVE GEAR EBS01011 Order Job/Part Q’ty Remarks Disassembling the rear constant Remove the parts in the order listed. velocity joints The following procedure applies to both of the rear constant velocity joints. Clip Boot band Boot band Dust boot...
  • Page 332 REAR CONSTANT VELOCITY JOINTS AND FINAL DRIV DRIVE GEAR Order Job/Part Q’ty Remarks Clip Refer to “ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS”. Joint shaft For assembly, reverse the disassembly procedure. 7 - 20...
  • Page 333 REAR CONSTANT VELOCITY JOINTS AND FINAL DRIV DRIVE GEAR EBS00179 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft •...
  • Page 334 REAR CONSTANT VELOCITY JOINTS AND FINAL DRIV DRIVE GEAR 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft •...
  • Page 335 REAR CONSTANT VELOCITY JOINTS AND FINAL DRIV DRIVE GEAR 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft •...

  • Page 336: Assembling The Rear Constant Velocity Joints

    REAR CONSTANT VELOCITY JOINTS AND FINAL DRIV DRIVE GEAR EBS00167 ASSEMBLING THE REAR CONSTANT VELOCITY JOINTS 1. Apply: • molybdenum disulfide grease (into the ball joint assembly) NOTE: Molybdenum disulfide grease is included in the repair kit. 2. Install: • dust boots 1 •...

  • Page 337: Disassembling The Final Drive Pinion Gear Assembly

    REAR CONSTANT VELOCITY JOINTS AND FINAL DRIV DRIVE GEAR DISASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY 1. Loosen: • rear drive shaft coupling gear (final gear side) nut 1 NOTE: Secure the final drive pinion gear teeth in the vise with a clean rag. EBS00184 POSITIONING THE FINAL DRIVE PINION GEAR AND RING GEAR...
  • Page 338 REAR CONSTANT VELOCITY JOINTS AND FINAL DRIV DRIVE GEAR 3) If “–05” is stamped on the final drive pinion gear bearing housing, c = 67.8 – 0.05 = 67.75 NOTE: After replacing any part in the final drive pinion gear assembly, the overall length of the assembly will change.

  • Page 339: Adjusting The Final Driven Pinion Gear Backlash

    REAR CONSTANT VELOCITY JOINTS AND FINAL DRIV DRIVE GEAR EBS00186 ADJUSTING THE FINAL DRIVEN PINION GEAR BACKLASH 1. Select: • final driven pinion gear shim(s) 1, 2 M MMM M MMM M MMM M MMM M MMM a. To find the final driven pinion gear shim thickness “B”, use the following formula.
  • Page 340 REAR CONSTANT VELOCITY JOINTS AND FINAL DRIV DRIVE GEAR 6) Round off the hundredth digit and select the appropriate shim(s). In the example above, the calculated number is 5.16. The chart instructs you to round off 6 to 5 at the hun- dredth place.

  • Page 341: Measuring The Final Driven Pinion Gear Thrust Washer Clearance

    REAR CONSTANT VELOCITY JOINTS AND FINAL DRIV DRIVE GEAR EBS00187 MEASURING THE FINAL DRIVEN PINION GEAR THRUST WASHER CLEARANCE 1. Measure: “C” • final driven pinion gear thrust washer clear- ance “C” M MMM M MMM M MMM M MMM M MMM ®...

  • Page 342: Measuring The Wheel Gear Thrust Clearance

    REAR CONSTANT VELOCITY JOINTS AND FINAL DRIV DRIVE GEAR EBS00187 MEASURING THE WHEEL GEAR THRUST CLEARANCE 1. Measure: • wheel gear thrust clearance “D” M MMM M MMM M MMM M MMM M MMM ® a. Place four pieces of Plastigauge between the originally fitted wheel gear shim(s) and the wheel gear.

  • Page 343: Checking The Rear Drive Shaft

    • bearings Damage → Replace. NOTE: • Reusing roller bearings is acceptable, but Yamaha recommends installing new ones. Do not reuse the oil seal. • When the final drive pinion gear, final driven pinion gear and/or wheel gear are replaced,...

  • Page 344: Measurement The Final Gear Lash

    REAR CONSTANT VELOCITY JOINTS AND FINAL DRIV DRIVE GEAR EBS00193 MEASUREMENT THE FINAL GEAR LASH 1. Secure the gear case in a vise or another supporting device. 2. Remove: • drain plug • gasket 3. Install: • a bolt of the specified size 1 (into the drain plug hole) CAUTION: Finger tighten the bolt until it holds the ring...

  • Page 345: Adjusting The Final Gear Lash

    REAR CONSTANT VELOCITY JOINTS AND FINAL DRIV DRIVE GEAR EBS00194 ADJUSTING THE FINAL GEAR LASH 1. Remove: • final driven pinion gear assembly 1 • final driven pinion gear shim 2 • final driven pinion gear shim 3 • thrust washer 4 2.

  • Page 346: Assembling The Final Drive Pinion Gear Assembly

    REAR CONSTANT VELOCITY JOINTS AND FINAL DRIV DRIVE GEAR Thrust washer 0.25 0.30 0.35 Thickness (mm) 0.40 0.45 0.50 L LLL L LLL L LLL L LLL L LLL ASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY 1. Tighten: • rear drive shaft coupling gear nut (final gear side) 1 NOTE: Secure the final drive pinion gear teeth in the...

  • Page 347: Assembling The Final Gear Case

    REAR CONSTANT VELOCITY JOINTS AND FINAL DRIV DRIVE GEAR ASSEMBLING THE FINAL GEAR CASE 1. Install: • oil seals 1 Installed depth of oil seal a 5.5 mm (0.22 in) 7 - 35...

  • Page 348: Chas

    CHAS FRONT AND REAR WHEELS EBS00378 CHASSIS FRONT AND REAR WHEELS FRONT WHEELS 30 Nm (3.0 m kg, 22 ft • • 260 Nm (26.0 m kg, 190 ft • • 30 Nm (3.0 m kg, 22 ft • • 55 Nm (5.5 m kg, 40 ft •...
  • Page 349 CHAS FRONT AND REAR WHEELS 30 Nm (3.0 m kg, 22 ft • • 260 Nm (26.0 m kg, 190 ft • • 30 Nm (3.0 m kg, 22 ft • • 55 Nm (5.5 m kg, 40 ft • •...

  • Page 350: Rear Wheels

    CHAS FRONT AND REAR WHEELS EBS00379 REAR WHEELS 30 Nm (3.0 m kg, 22 ft • • 260 Nm (26.0 m kg, 190 ft • • 30 Nm (3.0 m kg, 22 ft • • 55 Nm (5.5 m kg, 40 ft •...
  • Page 351 CHAS FRONT AND REAR WHEELS 30 Nm (3.0 m kg, 22 ft • • 260 Nm (26.0 m kg, 190 ft • • 30 Nm (3.0 m kg, 22 ft • • 55 Nm (5.5 m kg, 40 ft • •...

  • Page 352: Checking The Wheels

    CHAS FRONT AND REAR WHEELS EBS00383 CHECKING THE WHEELS 1. Check: • wheels 2. Measure: • wheel runout Over the specified limit → Replace the wheel or check the wheel bearing play 1. Wheel runout limit Front Radial 2: 2.0 mm (0.08 in) Lateral 3: 2.0 mm (0.08 in) Rear Radial 2: 2.0 mm (0.08 in)

  • Page 353: Checking The Brake Discs

    CHAS FRONT AND REAR WHEELS EBS00389 CHECKING THE BRAKE DISCS 1. Check: • brake discs Galling/damage → Replace. 2. Measure: • brake disc deflection Out of specification → Check the wheel runout. Brake disc maximum deflection Front: 0.1 mm (0.004 in) Rear: 0.1 mm (0.004 in) •...

  • Page 354: Installing The Wheels

    CHAS FRONT AND REAR WHEELS EBS00392 INSTALLING THE WHEELS 1. Install: • wheels NOTE: The arrow mark 1 on the tire must point in the direction of rotation È of the wheel. 2. Tighten: • wheel nuts 1 55 Nm (5.5 m · kg, 40 ft · lb) WARNING Tapered wheel nuts 1 are used for both the front and rear wheels.

  • Page 355: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES EBS00400 FRONT AND REAR BRAKES FRONT BRAKE PADS 5 Nm (0.5 m kg, 3.6 ft • • 17 Nm (1.7 m kg, 12 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty...

  • Page 356: Rear Brake Pads

    CHAS FRONT AND REAR BRAKES EBS00401 REAR BRAKE PADS 5 Nm (0.5 m kg, 3.6 ft • • 30 Nm (3.0 m kg, 22 ft • • 17 Nm (1.7 m kg, 12 ft • • Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed.

  • Page 357: Replacing The Front And Rear Brake Pads

    CHAS FRONT AND REAR BRAKES EBS00402 CAUTION: Disc brake components rarely require dis- assembly. DO NOT: • disassemble components unless abso- lutely necessary; • use solvents on internal brake compo- nents; • use spent brake fluid for cleaning; (use only clean brake fluid) •...
  • Page 358 CHAS FRONT AND REAR BRAKES 2. Install: • brake pad spring • brake pads NOTE: Always install new brake pads and brake pad spring as a set. M MMM M MMM M MMM M MMM M MMM a. Connect a suitable hose 1 tightly to the brake caliper bleed screw 2.

  • Page 359: Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EBS00407 FRONT BRAKE MASTER CYLINDER 7 Nm (0.7 m kg, 5.1 ft • • 6 Nm (0.6 m kg, 4.3 ft • • ∗ 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft •...
  • Page 360 CHAS FRONT AND REAR BRAKES 7 Nm (0.7 m kg, 5.1 ft • • 6 Nm (0.6 m kg, 4.3 ft • • ∗ 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft •...
  • Page 361 CHAS FRONT AND REAR BRAKES EBS00409 Order Job/Part Q’ty Remarks Disassembling the front brake mas- Remove the parts in the order listed. ter cylinder Dust boot Refer to “ASSEMBLING THE FRONT Circlip AND REAR BRAKE MASTER CYLIN- DERS”. Brake master cylinder kit For assembly, reverse the disassembly procedure.

  • Page 362: Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EBS00410 REAR BRAKE MASTER CYLINDER 7 Nm (0.7 m kg, 5.1 ft • • 6 Nm (0.6 m kg, 4.3 ft • • ∗ ∗ 6 Nm (0.6 m kg, 4.3 ft • • Apply silicone grease. 27 Nm (2.7 m kg, 19 ft •...
  • Page 363 CHAS FRONT AND REAR BRAKES 7 Nm (0.7 m kg, 5.1 ft • • 6 Nm (0.6 m kg, 4.3 ft • • ∗ ∗ 6 Nm (0.6 m kg, 4.3 ft • • Apply silicone grease. 27 Nm (2.7 m kg, 19 ft •...
  • Page 364 CHAS FRONT AND REAR BRAKES EBS00411 Order Job/Part Q’ty Remarks Disassembling the rear brake mas- Remove the parts in the order listed. ter cylinder Dust boot Refer to “ASSEMBLING THE FRONT Circlip AND REAR BRAKE MASTER CYLIN- DERS”. Brake master cylinder kit For assembly, reverse the disassembly procedure.

  • Page 365: Checking The Master Cylinders

    CHAS FRONT AND REAR BRAKES EBS00413 CHECKING THE MASTER CYLINDERS 1. Check: • brake master cylinder Wear/scratches → Replace the brake mas- ter cylinder assembly. • brake master cylinder body Cracks/damage → Replace. • brake fluid delivery passage (brake master cylinder body) Blockage →...

  • Page 366: Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EBS00418 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • brake master cylinder 1 • brake master cylinder holder 2 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: • Align the end of the brake master cylinder holder with the punch mark a on the handle- bar.
  • Page 367 CHAS FRONT AND REAR BRAKES 3. Fill: • brake fluid reservoir Recommended brake fluid DOT 4 CAUTION: Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. WARNING • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance.

  • Page 368: Installing The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EBS00418 INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • brake master cylinder 1 • brake master cylinder holder 2 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: • Align the end of the brake master cylinder holder with the punch mark a on the handle- bar.
  • Page 369 CHAS FRONT AND REAR BRAKES 3. Fill: • brake fluid reservoir Recommended brake fluid DOT 4 CAUTION: Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. WARNING • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance.

  • Page 370: Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EBS00421 FRONT BRAKE CALIPERS 17 Nm (1.7 m kg, 12 ft • • 27 Nm (2.7 m kg, 19 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed.
  • Page 371 CHAS FRONT AND REAR BRAKES EBS00423 5 Nm (0.5 m kg, 3.6 ft • • ∗ 17 Nm (1.7 m kg, 12 ft • • ∗ Apply silicone grease. Order Job/Part Q’ty Remarks Disassembling the front brake cali- Remove the parts in the order listed. pers The following procedure applies to both of the front brake calipers.

  • Page 372: Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES EBS00424 REAR BRAKE CALIPERS 17 Nm (1.7 m kg, 12 ft • • 30 Nm (3.0 m kg, 22 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Part Q’ty Remarks Removing the rear brake calipers Remove the parts in the order listed.
  • Page 373 CHAS FRONT AND REAR BRAKES EBS00425 5 Nm (0.5 m kg, 3.6 ft • • 17 Nm (1.7 m kg, 12 ft • • ∗ ∗ Apply silicone grease. Order Job/Part Q’ty Remarks Disassembling the rear brake cali- Remove the parts in the order listed. pers The following procedure applies to both of the rear brake calipers.

  • Page 374: Disassembling The Front And Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES EBS00427 È DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERS 1. Remove: • brake caliper piston 1 • dust seal 2 • caliper piston seal 3 È Front É Rear M MMM M MMM M MMM M MMM M MMM a.

  • Page 375: Assembling The Front And Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES WARNING All internal brake components should be cleaned in new brake fluid only. Do not use solvents as they will cause seals to swell and distort. 1. Check: È • brake caliper piston 1 Scratches/rust/wear → Replace the brake caliper assembly.

  • Page 376: Installing The Front And Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES 2. Install: • brake caliper piston 1 EBS00434 È INSTALLING THE FRONT AND REAR BRAKE CALIPERS 1. Install: • brake caliper assembly • brake caliper bolts 1 30 Nm (3.0 m · kg, 22 ft · lb) •...
  • Page 377 CHAS FRONT AND REAR BRAKES WARNING • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. • Refill with the same type of brake fluid: mixing brake fluids may result in a harm- ful chemical reaction and lead to poor brake performance.

  • Page 378: Steering System

    CHAS STEERING SYSTEM EBS00444 STEERING SYSTEM HANDLEBAR 20 Nm (2.0 m kg, 14 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Handlebar cover Plastic band On-command four-wheel-drive motor switch and differential gear lock switch...
  • Page 379 CHAS STEERING SYSTEM 20 Nm (2.0 m kg, 14 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Rear brake master cylinder holder Rear brake master cylinder Refer to “INSTALLING THE REAR BRAKE MASTER CYLINDER”. Spacer Left handlebar switch Handlebar grip...

  • Page 380: Removing The Handlebar Grips

    CHAS STEERING SYSTEM EBS00447 REMOVING THE HANDLEBAR GRIPS 1. Remove: • handlebar grips 1 NOTE: Blow compressed air between the handlebar and handlebar grip, and gradually push the grip off the handlebar. EBS00448 CHECKING THE HANDLEBAR 1. Check: • handlebar Bends/cracks/damage →...

  • Page 381: Installing The Handlebar Grips

    CHAS STEERING SYSTEM EBS00450 INSTALLING THE HANDLEBAR GRIPS 1. Install: • handlebar grip 1 NOTE: • Before applying adhesive, wipe off grease or oil on the handlebar surface a with a lacquer thinner. • Install the handlebar grips to the handlebar so that arrow mark L faces up on the left han- dlebar grip and the arrow mark R faces up on the right handlebar.

  • Page 382: Installing The Front Brake Master Cylinder

    CHAS STEERING SYSTEM EBS00453 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • front brake master cylinder 1 • front brake master cylinder holder 2 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: • Align the end of the brake master cylinder holder with the punch mark a on the handle- bar.

  • Page 383: Steering Stem

    CHAS STEERING SYSTEM EBS00454 STEERING STEM 50 Nm (5.0 m kg, 36 ft • • 23 Nm (2.3 m kg, 17 ft • • 50 Nm (5.0 m kg, 36 ft • • 125 Nm (12.5 m kg, 90 ft •...
  • Page 384 CHAS STEERING SYSTEM 50 Nm (5.0 m kg, 36 ft • • 23 Nm (2.3 m kg, 17 ft • • 50 Nm (5.0 m kg, 36 ft • • 125 Nm (12.5 m kg, 90 ft • • 30 Nm (3.0 m kg, 22 ft •...

  • Page 385: Checking The Steering Stem

    CHAS STEERING SYSTEM EBS00456 CHECKING THE STEERING STEM 1. Check: • steering stem Bends → Replace. WARNING Do not attempt to straighten a bent stem; this may dangerously weaken the stem. 2. Check: • oil seals • steering stem bushings Wear/damage →...
  • Page 386 CHAS STEERING SYSTEM 4. Install: • collar D • steering stem joint E • steering stem joint bolts F (temporarily tighten) NOTE: ® • Apply LOCTITE to the steering stem joint bolts. • Align the spline a on the steering stem with the groove b in the steering stem joint.

  • Page 387: Installing The Pitman Arm

    CHAS STEERING SYSTEM INSTALLING THE PITMAN ARM 1. Install: • pitman arm 1 • washer • pitman arm nut 210 Nm (21.0 m · kg, 150 ft · lb) • clip NOTE: Align the punch mark b on the EPS unit with the groove a in the pitman arm.

  • Page 388: Tie-Rods And Steering Knuckles

    CHAS STEERING SYSTEM EBS00460 TIE-RODS AND STEERING KNUCKLES 25 Nm (2.5 m kg, 18 ft • • 25 Nm (2.5 m kg, 18 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft •...
  • Page 389 CHAS STEERING SYSTEM 25 Nm (2.5 m kg, 18 ft • • 25 Nm (2.5 m kg, 18 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 25 Nm (2.5 m kg, 18 ft •...

  • Page 390: Removing The Steering Knuckles

    CHAS STEERING SYSTEM EBS00461 REMOVING THE STEERING KNUCKLES 1. Remove: • steering knuckle 1 NOTE: Use a general puller to separate the ball joint 2 from the steering knuckle 1 or the front lower arm 3. EBS00462 CHECKING THE TIE-RODS 1.
  • Page 391 CHAS STEERING SYSTEM c. Remove the ball joint. NOTE: Use a remover attachment 3 to separate the ball joint 1 from the steering knuckle 2. d. Measure the ball joint bore inside diameter Out of specification → Replace the steering knuckle.
  • Page 392 CHAS STEERING SYSTEM f. Attach the ball joint remover/installer, new 2 1 3 4 ball joint (with rubber boot and retaining ring) 1, installer spacer 6 and installer washer 2 to the steering knuckle 3. NOTE: Do not tap or damage the top of the ball joint. g.

  • Page 393: Installing The Tie-Rods

    CHAS STEERING SYSTEM EBS00465 INSTALLING THE TIE-RODS 1. Install: • tie-rods (left and right) 25 Nm (2.5 m · kg, 18 ft · lb) NOTE: The tie-rod side which must be installed on the out side has grooves 1. 2. Adjust: •...

  • Page 394: Front Arms And Front Shock Absorber Assemblies

    FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES EBS00468 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 45 Nm (4.5 m kg, 32 ft 45 Nm (4.5 m kg, 32 ft • • • • 25 Nm (2.5 m kg, 18 ft •...
  • Page 395 FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES 45 Nm (4.5 m kg, 32 ft 45 Nm (4.5 m kg, 32 ft • • • • 25 Nm (2.5 m kg, 18 ft • • 45 Nm (4.5 m kg, 32 ft •...

  • Page 396: Removing The Front Arms

    FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES EBS00469 REMOVING THE FRONT ARMS 1. Check: • front arm free play M MMM M MMM M MMM M MMM M MMM a. Check the front arm side play È by moving È...

  • Page 397: Front Arms And Front Shock Absorber

    FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES Ball joint remover 90890-01474, YM-01474 Ball joint remover attachment set 90890-01480 Ball joint adapter set YM-01480 Body 90890-01474 YM-01474 Long bolt 90890-01480 Base YM-01480 Remover 90890-01474 attachment YM-01474 90890-01480 Installer spacer YM-01480 90890-01474 Installer washer YM-01474...

  • Page 398: Checking The Front Shock Absorbers

    FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES EBS00471 CHECKING THE FRONT SHOCK ABSORBERS 1. Check: • shock absorber assembly Oil leaks → Replace the shock absorber assembly. • spring Fatigue → Replace the shock absorber assembly. Move the spring up and down. EBS00475 INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBERS...

  • Page 399: Rear Knuckles And Stabilizer

    CHAS REAR KNUCKLES AND STABILIZER EBS01023 REAR KNUCKLES AND STABILIZER 50 Nm (5.0 m kg, 36 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 400 CHAS REAR KNUCKLES AND STABILIZER 50 Nm (5.0 m kg, 36 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • •...

  • Page 401: Checking The Rear Knuckles

    CHAS REAR KNUCKLES AND STABILIZER EBS01024 CHECKING THE REAR KNUCKLES 1. Check: • rear knuckle Damage/pitting → Replace. 2. Check: • rear wheel bearing 1 Bearing allow play in the wheel hub or the wheel turns roughly → Replace. M MMM M MMM M MMM M MMM...

  • Page 402: Rear Arms And Rear Shock Absorber Assemblies

    REAR ARMS AND REAR SHOCK ABSORBER CHAS ASSEMBLIES EBS00476 REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES 45 Nm (4.5 m kg, 32 ft • • 45 Nm (4.5 m kg, 32 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 403: Rear Arms And Rear Shock Absorber

    REAR ARMS AND REAR SHOCK ABSORBER CHAS ASSEMBLIES 45 Nm (4.5 m kg, 32 ft • • 45 Nm (4.5 m kg, 32 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 45 Nm (4.5 m kg, 32 ft •...

  • Page 404: Checking The Rear Arms

    REAR ARMS AND REAR SHOCK ABSORBER CHAS ASSEMBLIES CHECKING THE REAR ARMS 1. Check: • rear arms Bends/damage → Replace. 2. Check: • bushings Wear/damage → Replace. EBS00478 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES 1. Check: • shock absorber assemblies Oil leaks →...

  • Page 405: Installing The Rear Arms And Rear Shock Absorber Assemblies

    REAR ARMS AND REAR SHOCK ABSORBER CHAS ASSEMBLIES EBS01027 INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES 1. Install: • rear arms • rear shock absorber assemblies M MMM M MMM M MMM M MMM M MMM a. Install the rear upper arm 1 and rear lower arm 2.

  • Page 406: Elec

    – ELEC ELECTRICAL COMPONENTS EBS00500 ELECTRICAL ELECTRICAL COMPONENTS 1 Four-wheel-drive motor relay 3 8 EPS fuse 2 Rear brake relay 9 Main fuse 3 Four-wheel-drive motor relay 2 0 Fuse box (ignition, headlights, four-wheel-drive 4 Four-wheel-drive motor relay 1 motor, radiator fan motor, signaling system, aux- 5 Headlight relay iliary DC jack) 6 Fuel injection system fuse...
  • Page 407 – ELEC ELECTRICAL COMPONENTS C Reverse switch D Gear position switch E Auxiliary DC jack F Main switch G Differential gear motor H EPS motor I EPS torque sensor J Radiator fan motor 9 - 2...
  • Page 408 – ELEC ELECTRICAL COMPONENTS 1 Lean angle sensor B Crankshaft position sensor 2 Radiator fan motor relay C Coolant temperature sensor 3 Fuel injection system relay D Ignition coil 4 Starting circuit cut-off relay E Battery 5 Front brake light switch F ECU (engine control unit) 6 Rear brake light switch G EPS (electric power steering) control unit...

  • Page 409: Checking Switch Continuity

    – ELEC CHECKING SWITCH CONTINUITY EBS01028 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. CAUTION: Never insert the tester probes into the cou- pler terminal slots 1.

  • Page 410: Checking The Switches

    – ELEC CHECKING THE SWITCHES EBS01029 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading →...
  • Page 411 – ELEC CHECKING THE SWITCHES 1 Main switch 2 Light switch 3 Engine stop switch 4 Start switch 5 Override switch 6 On-command four-wheel-drive motor switch and differential gear lock switch 7 Four-wheel-drive motor switch 8 Gear position switch 9 Reverse switch 0 Rear brake light switch A Front brake light switch 9 - 6...

  • Page 412: Checking The Bulbs And Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS EBS01030 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.

  • Page 413: Checking The Condition Of The Bulbs

    – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: • bulb WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

  • Page 414: Checking The Condition Of The Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS M MMM M MMM M MMM M MMM M MMM a. Connect the positive tester probe to termi- nal 1 and the negative tester probe to ter- minal 2, and check the continuity. b.

  • Page 415: Ignition System

    – ELEC IGNITION SYSTEM EBS00503 IGNITION SYSTEM CIRCUIT DIAGRAM 9 - 10...

  • Page 416: Troubleshooting

    – ELEC IGNITION SYSTEM EBS01045 EBS01043 TROUBLESHOOTING 1. Main and ignition fuses The ignition system fails to operate (no • Check the main and ignition fuses for con- spark or intermittent spark). tinuity. Refer to “CHECKING THE FUSES” in Check: chapter 3.
  • Page 417 – ELEC IGNITION SYSTEM EBS01032 EBS01034 3. Spark plug 4. Ignition spark gap • Check the condition of the spark plug. • Disconnect the spark plug cap from the • Check the spark plug type. spark plug. • Connect the ignition checker 1 as shown. •...
  • Page 418 – ELEC IGNITION SYSTEM EBS01036 EBS01038 5. Spark plug cap resistance 6. Ignition coil resistance • Remove the spark plug cap from the spark • Disconnect the ignition coil connectors plug lead. from the ignition coil terminals. • Connect the pocket tester (Ω × 1k) to the •...
  • Page 419 – ELEC IGNITION SYSTEM EBS01041 EBS01040 7. Main switch 9. Crankshaft position sensor resistance • Check the main switch for continuity. • Disconnect the crankshaft position sensor Refer to “CHECKING THE SWITCHES”. coupler from the wire harness. • Connect the pocket tester (Ω × 100) to the •...
  • Page 420 – ELEC IGNITION SYSTEM EBS01047 10.Lean angle sensor 11.Wiring • Remove the lean angle sensor. • Check the entire ignition system’s wiring. • Connect the pocket tester (DC 20 V) to the Refer to “CIRCUIT DIAGRAM”. lean angle sensor coupler as shown. •...

  • Page 421: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM EBS00506 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 9 - 16...

  • Page 422: Starting Circuit Operation

    – ELEC ELECTRIC STARTING SYSTEM EBS00507 STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, starting circuit cut-off relay, rear brake light switch, rear brake relay and gear position switch. If the main switch is on and the engine stop switch is in the RUN position, the starter motor can be operated only if:...

  • Page 423: Troubleshooting

    – ELEC ELECTRIC STARTING SYSTEM EBS01048 EBS01044 TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main, ignition and signaling system fuses 2.
  • Page 424 – ELEC ELECTRIC STARTING SYSTEM EBS01052 EBS01054 4. Starting circuit cut-off relay 5. Starter relay • Remove the starting circuit cut-off relay • Remove the starter relay from the wire from the wire harness. harness. • Connect the pocket tester (Ω × 1) and bat- •...
  • Page 425 – ELEC ELECTRIC STARTING SYSTEM EBS01054 EBS01053 6. Rear brake relay 7. Diode 2 • Remove the rear brake relay from the wire • Remove the diode 2 from the wire har- harness. ness. • Connect the pocket tester (Ω × 1) and bat- •...
  • Page 426 – ELEC ELECTRIC STARTING SYSTEM EBS01041 11.Rear brake light switch 8. Main switch • Check the rear brake light switch for conti- • Check the main switch for continuity. nuity. Refer to “CHECKING THE SWITCHES”. Refer to “CHECKING THE SWITCHES”. •...

  • Page 427: Starter Motor

    – ELEC STARTER MOTOR EBS01061 STARTER MOTOR Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Muffler Refer to “ENGINE REMOVAL” in chapter Starter motor lead Disconnect. Ground lead Disconnect. Starter motor For installation, reverse the removal pro- cedure.
  • Page 428 – ELEC STARTER MOTOR Order Job/Part Q’ty Remarks Bushing Shim Refer to “ASSEMBLING THE STARTER Brush holder set MOTOR”. Armature assembly Starter motor yoke For assembly, reverse the disassembly procedure. 9 - 23...

  • Page 429: Checking The Starter Motor

    – ELEC STARTER MOTOR EBS01064 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600-grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 27 mm (1.06 in) 3.
  • Page 430 – ELEC STARTER MOTOR M MMM M MMM M MMM M MMM M MMM a. Measure the armature assembly resis- tances with the pocket tester. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Armature coil Commutator resistance 1 0.0250 ~ 0.0350 Ω at 20 °C (68 °F) Insulation resistance 2 Above 1 MΩ...

  • Page 431: Assembling The Starter Motor

    – ELEC STARTER MOTOR EBS00515 ASSEMBLING THE STARTER MOTOR 1. Install: • brush holder set 1 NOTE: Align the projection a on the brush holder set with the slot b in the starter motor yoke. 2. Install: • starter motor yoke 1 •...

  • Page 432: Charging System

    – ELEC CHARGING SYSTEM EBS00516 CHARGING SYSTEM CIRCUIT DIAGRAM B/L Gy G/Y B (BLACK) (GRAY) Br/B Br/B Br/L (BLACK) (GRAY) Br/L Br/L R (BLACK) Br/L Br/L Br/Y Br/L 2 AC magneto 3 Rectifier/regulator 6 Main fuse 8 Battery 9 - 27...

  • Page 433: Troubleshooting

    – ELEC CHARGING SYSTEM EBS01065 EBS01044 TROUBLESHOOTING 2. Battery The battery is not being charged. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main fuse 2. battery Minimum open-circuit voltage 3.
  • Page 434 – ELEC CHARGING SYSTEM EBS01066 EBS01100 3. Charging voltage 4. Stator coil resistance • Connect the engine tachometer to the • Disconnect the AC magneto coupler from spark plug lead. the wire harness. • Connect the pocket tester (Ω × 1) to the •...

  • Page 435: Lighting System

    – ELEC LIGHTING SYSTEM EBS00518 LIGHTING SYSTEM CIRCUIT DIAGRAM 4 Main switch 6 Main fuse 8 Battery m Light switch W R G B q Headlight relay W R G B r Headlight B/L Gy u Headlight fuse G/Y B x Tail/brake light (BLACK) (BLACK)

  • Page 436: Troubleshooting

    – ELEC LIGHTING SYSTEM EBS01067 EBS01044 TROUBLESHOOTING 2. Battery Any of the following fail to light: head- • Check the condition of the battery. light, tail/brake light. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main and headlight fuses Minimum open-circuit voltage 2.

  • Page 437: Checking The Lighting System

    – ELEC LIGHTING SYSTEM EBS01069 2. Headlight relay 5. Wiring • Remove the headlight relay. • Connect the pocket tester (Ω × 1) and bat- • Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM”. tery (12 V) to the headlight relay as shown. •...
  • Page 438 – ELEC LIGHTING SYSTEM 3. Voltage 2. Voltage • Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the headlight couplers as shown. tail/brake light connectors as shown. È When the light switch is set to “LO” Tail/brake light connectors (wire harness É...

  • Page 439: Signaling System

    – ELEC SIGNALING SYSTEM EBS00521 SIGNALING SYSTEM CIRCUIT DIAGRAM 9 - 34...
  • Page 440 – ELEC SIGNALING SYSTEM 4 Main switch 6 Main fuse 8 Battery J Reverse switch K ECU (engine control unit) P Coolant temperature sensor Q Speed sensor U Gear position switch W Multifunction meter Y Coolant temperature warning light Z Park indicator light [ Reverse indicator light \ Neutral indicator light ] High-range indicator light...

  • Page 441: Troubleshooting

    – ELEC SIGNALING SYSTEM EBS01073 EBS01044 TROUBLESHOOTING 2. Battery Any of the following fail to light: warning • Check the condition of the battery. light, brake light or an indicator light. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1.

  • Page 442: Checking The Signaling System

    – ELEC SIGNALING SYSTEM EBS01075 EBS01053 CHECKING THE SIGNALING SYSTEM 3. Diode 3 EBS01076 1. The brake light fails to come on. • Remove the diode 3 from the wire har- ness. 1. Brake light bulb and bulb socket • Connect the pocket tester (Ω × 1) to the •...
  • Page 443 – ELEC SIGNALING SYSTEM EBS01078 4. Voltage 2. The neutral, park, high-range, and/or low- range indicator light fails to come on. • Connect the pocket tester (DC 20 V) to the tail/brake light connectors (wire harness 1. Gear position switch side) as shown.
  • Page 444 – ELEC SIGNALING SYSTEM EBS01079 EBS01081 3. The reverse indicator light fails to come on. 4. The differential gear lock indicator light and/ or four-wheel-drive motor indicator light fails 1. Reverse switch to come on. • Check the reverse switch for continuity. 1.
  • Page 445 – ELEC SIGNALING SYSTEM 5. While the override switch is pushed, the 2. Voltage segments of the speedometer digits will not • Connect the pocket tester (DC 20 V) to the appear as shown in the illustration. meter assembly coupler as shown. Positive tester probe →...
  • Page 446 – ELEC SIGNALING SYSTEM EBS01083 6. The coolant temperature warning light does not come on when the main switch is set to “ON”, or if the coolant temperature warning light does not come on when the tempera- ture is high (more than 112 °C (233.6 °F)). EBS00812 1.
  • Page 447 – ELEC SIGNALING SYSTEM 7. The fuel level indicator light fails to come 2. Voltage • Connect the pocket tester (DC 20 V) to the 1. Fuel sender meter assembly coupler as shown. Positive tester probe → brown 1 • Drain the fuel from the fuel tank and then Negative tester probe →...
  • Page 448 – ELEC SIGNALING SYSTEM 8. The speedometer fails to come on. 2. Voltage 1. Speed sensor • Connect the pocket tester (DC 20 V) to the meter assembly coupler as shown. • Connect the pocket tester (DC 20 V) to the Positive tester probe →...
  • Page 449 – ELEC SIGNALING SYSTEM 2. Voltage • Connect the pocket tester (DC 20 V) to the meter assembly coupler as shown. Positive tester probe → brown 1 Negative tester probe → black/white 2 Br/B • Set the main switch to “ON”. •...

  • Page 450: Cooling System

    – ELEC COOLING SYSTEM EBS00532 COOLING SYSTEM CIRCUIT DIAGRAM 9 - 45...

  • Page 451: Troubleshooting

    – ELEC COOLING SYSTEM EBS01085 EBS01044 TROUBLESHOOTING 2. Battery The radiator fan motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main, ignition, and radiator fan motor fuses 2.
  • Page 452 – ELEC COOLING SYSTEM EBS01086 5. Radiator fan motor relay 4. Radiator fan motor • Remove the radiator fan motor relay from • Disconnect the radiator fan motor coupler the wire harness. • Connect the pocket tester (Ω × 1) and bat- from the wire harness.
  • Page 453 – ELEC COOLING SYSTEM 6. Radiator fan motor circuit breaker • Remove the radiator fan motor circuit breaker from the wire harness. NOTE: The radiator fan motor circuit breaker 1 is attached to the wire harness with black tape near the tail/brake light connectors 2. •...
  • Page 454 – ELEC COOLING SYSTEM EBS00812 7. Coolant temperature sensor • Remove the coolant temperature sensor from the cylinder head. • Connect the pocket tester (Ω × 100) to the coolant temperature sensor 1 as shown. • Immerse the coolant temperature sensor in a container filled with coolant 2.

  • Page 455: Fuel Pump System

    – ELEC FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM 9 - 50...

  • Page 456: Troubleshooting

    – ELEC FUEL PUMP SYSTEM TROUBLESHOOTING EBS01044 2. Battery The fuel pump fails to operate. • Check the condition of the battery. Check: Refer to “CHECKING AND CHARGING 1. main, ignition, and fuel injection system THE BATTERY” in chapter 3. fuses Minimum open-circuit voltage 2.
  • Page 457 – ELEC FUEL PUMP SYSTEM 5. Fuel injection system relay 6. Fuel pump • Remove the fuel injection system relay • Check the condition of the fuel pump. from the wire harness. Refer to “CHECKING THE FUEL PUMP • Connect the pocket tester (Ω × 1) and bat- BODY”...

  • Page 458: 2Wd/4Wd Selecting System

    – ELEC 2WD/4WD SELECTING SYSTEM EBS00535 2WD/4WD SELECTING SYSTEM CIRCUIT DIAGRAM 9 - 53...

  • Page 459: Troubleshooting

    – ELEC 2WD/4WD SELECTING SYSTEM EBS01095 EBS01043 TROUBLESHOOTING 1. Main and four-wheel-drive motor fuses The four-wheel-drive motor indicator • Check the main and four-wheel-drive light fails to come on. motor fuses for continuity. Refer to “CHECKING THE FUSES” in Check: chapter 3.
  • Page 460 – ELEC 2WD/4WD SELECTING SYSTEM EBS01096 EBS01097 4. Four-wheel-drive motor relay 1 5. Four-wheel-drive motor relay 2 • Remove the four-wheel-drive motor relay • Remove the four-wheel-drive motor relay 1 from the wire harness. 2 from the wire harness. • Connect the pocket tester (Ω × 1) and the •...
  • Page 461 – ELEC 2WD/4WD SELECTING SYSTEM EBS01098 EBS01092 6. Four-wheel-drive motor relay 3 7. On-command four-wheel-drive motor switch and differential gear lock switch • Remove the four-wheel-drive motor relay 3 from the wire harness. • Check the on-command four-wheel-drive • Connect the pocket tester (Ω × 1) and the motor switch and differential gear lock battery (12 V) to the four-wheel-drive switch for continuity.
  • Page 462 – ELEC 2WD/4WD SELECTING SYSTEM EBS01094 8. Differential gear motor 9. Wiring connection • Disconnect the differential gear motor cou- • Check the connections of the entire 2WD/ pler. 4WD selecting system. • Remove the differential gear motor from Refer to “CIRCUIT DIAGRAM”. the differential gear case.

  • Page 463: Eps (Electric Power Steering) System

    – ELEC EPS (ELECTRIC POWER STEERING) SYSTEM EBS00532 EPS (ELECTRIC POWER STEERING) SYSTEM CIRCUIT DIAGRAM 9 - 58...

  • Page 464: Eps Control Unit's Self-Diagnostic Function

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

  • Page 465: Eps Warning Light During Normal Operation

    – ELEC EPS (ELECTRIC POWER STEERING) SYSTEM EPS WARNING LIGHT DURING NORMAL OPERATION The EPS warning light comes on initially for 2 seconds after the main switch is turned to “ON”. How- ever, the warning light remains on until the engine is started. In addition, if a malfunction is detected while the warning light comes on initially, the warning light remains on.

  • Page 466: Diagnostic Mode

    – ELEC EPS (ELECTRIC POWER STEERING) SYSTEM DIAGNOSTIC MODE Setting the diagnostic mode (present and past malfunctions) 1. Turn the main switch to “ON”. 2. Disconnect the EPS self-diagnosis signal connector 1. NOTE: Do not disconnect the EPS self-diagnosis sig- nal connector before turning the main switch to “ON”.
  • Page 467 – ELEC EPS (ELECTRIC POWER STEERING) SYSTEM Identifying fault codes When the diagnostic mode is activated, the fault codes determined by the fail-safe specifications are signaled by the EPS warning light as follows. • Present malfunction signaling mode: Currently detected fault codes are signaled. •...
  • Page 468 – ELEC EPS (ELECTRIC POWER STEERING) SYSTEM Deleting fault codes To delete fault codes, ground the EPS self-diagnosis signal connector 3 or more times within 5 sec- onds while the present or past malfunction mode is activated. The currently selected mode remains active after the fault codes of that mode are deleted.

  • Page 469: Self-Diagnostic Function Table (Eps System)

    – ELEC EPS (ELECTRIC POWER STEERING) SYSTEM SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM) Fault Item Symptom Probable cause of malfunction code No. • Open or short circuit in wire harness. No normal signals are received from the EPS torque sensor • Malfunction in torque sensor. torque sensor.

  • Page 470: Troubleshooting Details (Eps System)

    – ELEC EPS (ELECTRIC POWER STEERING) SYSTEM TROUBLESHOOTING DETAILS (EPS SYSTEM) NOTE: The malfunction history is stored even if the main switch is turned to “OFF”, therefore, be sure to erase the history (present and past malfunction signaling modes) after repairing the cause of the EPS system malfunction.
  • Page 471 – ELEC EPS (ELECTRIC POWER STEERING) SYSTEM Fault code No. 21 Symptom Speed sensor: open or short circuit detected. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the •...
  • Page 472 – ELEC EPS (ELECTRIC POWER STEERING) SYSTEM Fault code 41, 42, Symptom EPS motor: open or short circuit detected. 43, 45 Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 473 – ELEC EPS (ELECTRIC POWER STEERING) SYSTEM Fault code No. 54 Symptom Relay contacts in the EPS control unit are welded together. Order Item/components and probable Check or maintenance job Reinstatement cause method Malfunction in EPS control unit. Replace the EPS control unit. Turning the main switch to “OFF”.

  • Page 474: Checking The Eps Motor

    – ELEC EPS (ELECTRIC POWER STEERING) SYSTEM CHECKING THE EPS MOTOR 1. Remove: • EPS unit 2. Check: • EPS motor Out of specification → Replace. NOTE: The pocket tester and the analog pocket tester readings are shown in the following table. Continuity Positive tester probe →...
  • Page 475 – ELEC EPS (ELECTRIC POWER STEERING) SYSTEM M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 1k) to the EPS torque sensor coupler terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Positive tester probe →...

  • Page 476: Trbl Shtg

    TRBL STARTING FAILURE/HARD STARTING SHTG EBS00537 TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for check, adjustment and replacement of parts.

  • Page 477: Compression System

    TRBL STARTING FAILURE/HARD STARTING/POOR IDLE SPEED PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE SHTG COMPRESSION SYSTEM Cylinder and cylinder head Piston and piston rings • Loose spark plug • Improperly installed piston ring • Loose cylinder head or cylinder • Worn, fatigued or broken piston ring •...

  • Page 478: Faulty Drive Train

    TRBL FAULTY DRIVE TRAIN SHTG EBS00540 FAULTY DRIVE TRAIN The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1. A pronounced hesitation or “jerky” move- A. Bearing damage. ment during acceleration, deceleration, or B. Improper gear lash. sustained speed.

  • Page 479: Faulty Gear Shifting

    FAULTY GEAR SHIFTING/ TRBL FAULTY CLUTCH PERFORMANCE SHTG EBS00542 FAULTY GEAR SHIFTING HARD SHIFTING Refer to “FAULTY CLUTCH PERFORMANCE”. SHIFT LEVER DOES NOT MOVE Shift drum, shift forks Transmission • Groove jammed with impurities • Seized transmission gear • Seized shift fork •...

  • Page 480: Poor Speed Performance

    FAULTY CLUTCH PERFORMANCE/ TRBL OVERHEATING/OVERCOOLING/FAULTY BRAKE SHTG POOR SPEED PERFORMANCE V-belt Primary sliding sheave • Oil or grease on the V-belt • Worn primary sliding sheave Primary pulley weight Secondary fixed sheave • Faulty operation • Worn secondary fixed sheave •...

  • Page 481: Shock Absorber Malfunction

    SHOCK ABSORBER MALFUNCTION/ TRBL UNSTABLE HANDLING/LIGHTING SYSTEM SHTG EBS00551 SHOCK ABSORBER MALFUNCTION MALFUNCTION • Bent or damaged damper rod • Damaged oil seal lip • Fatigued shock absorber spring EBS00552 UNSTABLE HANDLING UNSTABLE HANDLING Handlebar Wheels • Improperly installed or bent •...
  • Page 482 TRBL SHTG 10 - 7...
  • Page 483 YFM7FGPW 2007 WIRING DIAGRAM 1 Crankshaft position sensor l Left handlebar switch COLOR CODE 2 AC magneto m Light switch B.... Black 3 Rectifier/regulator n Engine stop switch Br ..Brown 4 Main switch o Start switch G ... Green...
  • Page 484 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
  • Page 485 YFM7FGPW 2007 WIRING DIAGRAM P Y/G G/Y Br/W L Sb Gy Y/W B/L R/B O W/B B/R Gy/G W/R G/W G/R R/L Y/W B/W L/B B W R G B R W R G B R B/L Gy G/Y B...

This manual is also suitable for:

Yfm7fgpw 2007

Table of Contents