Wolverine Yx70epng

2016-17
SERVICE MANUAL
YX70EPNG
YXE70WPXG
YXE70WPHG
YXE70WDXG
YXE700E
YXE700SE
2MB-G8198-E0
Brought to you by
FordTruckMan &
Tinken
EBS20002
YX70EPNG/YXE70WPXG/
YXE70WPHG/YXE70WDXG/YXE700E/
YXE700SE SERVICE MANUAL
©2017 by Yamaha Motor Co., Ltd. 2nd
edition, May 2017
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EBS20003
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-
cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP
Steve loves stinky fish.
EBS30001
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal inju-
ry hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could result

WARNING in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to

NOTICE the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.

EBS20004
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
3
2
7
5
6
EBS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil

G
Filling fluid Molybdenum disulfide oil

M
Lubricant Brake fluid

BF
Special tool B Wheel bearing grease
Tightening torque LS Lithium-soap-based grease

T.
R.
Wear limit, clearance M Molybdenum disulfide grease
Engine speed S Silicone grease
Electrical data Apply locking agent (LOCTITE®).

LT
Engine oil New Replace the part with a new one.

E
EBS10003
TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS
3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL SYSTEM 7
DRIVE TRAIN 8
ELECTRICAL SYSTEM 9
TROUBLESHOOTING 10
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL.......................................................................................... 1-1
FEATURES...................................................................................................... 1-3
1
OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM
(for EPS model) ........................................................................................1-3
INSTRUMENT FUNCTIONS ..................................................................... 1-5
IMPORTANT INFORMATION ......................................................................... 1-7

PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-7
REPLACEMENT PARTS...........................................................................1-7
GASKETS, OIL SEALS AND O-RINGS .................................................... 1-7
LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-7
BEARINGS AND OIL SEALS .................................................................... 1-8
CIRCLIPS ..................................................................................................1-8
RUBBER PARTS.......................................................................................1-8
BASIC SERVICE INFORMATION...................................................................1-9

QUICK FASTENERS................................................................................. 1-9
ELECTRICAL SYSTEM...........................................................................1-10
SPECIAL TOOLS .......................................................................................... 1-14

IDENTIFICATION
EBS20009
IDENTIFICATION
EBS30003
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the frame.
1
EBS30004
MODEL LABEL
The model label “1” is affixed to the frame under
the driver seat. This information will be needed
to order spare parts.
1
1-1
IDENTIFICATION
1-2
FEATURES
EBS20010
FEATURES
EBS30007
OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS model)
1 d 3
e c
f 5 a
b
5
1-3
FEATURES
1. Speed information from speed sensor b. Twists torsion bar

2. Engine RPM information from ECU c. Sends the torque sensor signal
3. Battery d. EPS control unit calculates assist power
4. EPS control unit e. Electricity output switched by EPS control unit
5. EPS unit f. Activates EPS motor
6. EPS motor
7. Torque sensor
a. Operates steering
ECB01790
NOTICE
To prevent accidental damage to the EPS unit, it must not be disassembled.
1-4
FEATURES
EBS30008
Pushing the “SELECT” button switches the dis-
INSTRUMENT FUNCTIONS
play between the odometer mode “ODO” and
the tripmeter modes “TRIP A” and “TRIP B” in
Multi-function meter unit
the following order:
4 5 ODO → TRIP A → TRIP B → ODO
To reset a tripmeter, select it by pushing the “SE-
LECT” button, and then push the “RESET” but-
3 ton for at least three seconds. The tripmeters
2 can be used to estimate the distance that can be
1 traveled with a full tank of fuel. This information
enables you to plan future fuel stops.
TIP
7 6 To switch the display between “mph” and “km/h”,
1. “CLOCK” button turn the main switch to “ ” (off), then push and
2. “RESET” button hold the “SELECT” button while turning the main
3. “SELECT” button switch to “ ” (on).
4. Speedometer
5. Fuel meter Clock, hour meter and voltage display
6. Clock/Hour meter/Voltage display modes
7. Odometer/Tripmeter A/Tripmeter B
The multi-function meter unit is equipped with
the following:
• a speedometer 1
• an odometer 2
• two tripmeters (which show the distance trav- 3
eled since they were last set to zero)
• a clock
• an hour meter (which shows the total time the
4
engine has been running)
• a voltage display (which shows the battery volt- 1. “SELECT” button
age) 2. “RESET” button
• a fuel meter 3. “CLOCK” button
• a self-diagnosis device 4. Clock/Hour meter/Voltage display
Pushing the “CLOCK” button switches the dis-
Odometer and tripmeter modes play between the clock mode “CLOCK”, the hour
meter mode “HOUR”, and the voltage display
mode “ ” in the following order:
CLOCK → HOUR → → CLOCK
1 To set the clock:
2 1. Set the display to the clock mode.
2. Push the “SELECT” button and “RESET” but-
ton together for at least three seconds.
3. When the hour digits start flashing, push the
“RESET” button to set the hours.
3
4. Push the “SELECT” button, and the minute
1. “SELECT” button digits will start flashing.
2. “RESET” button 5. Push the “RESET” button to set the minutes.
3. Odometer/Tripmeter A/Tripmeter B 6. Push the “SELECT” button, and then release
it to start the clock.
1-5
FEATURES
Voltage display mode Refer to “SIGNALING SYSTEM” on page 9-19.
Self-diagnosis device
1 2
This display shows the battery voltage.

“ ” appears for 1 second when the voltage
display mode is first selected, and then “ ” ap-
1. Fault code display
pears and the battery voltage is displayed.
2. Engine trouble warning light “ ”
If the battery voltage is less than 10 volts, “LO” is
displayed, and if the voltage is above 16 volts, This model is equipped with a self-diagnosis de-
“HI” is displayed. vice for various electrical circuits.
ECB02020
If a problem is detected in any of those circuits,
NOTICE
the engine trouble warning light comes on or
If the voltage display indicates “LO” or “HI”, flashes, and the multi-function display indicates
there may be trouble with the battery a fault code.
charging circuit or the battery may be faulty. If the multi-function display indicates a fault
If this occurs, check or repair the vehicle. code, note the code number, and then check the
fuel injection system.
Fuel meter Refer to “FUEL INJECTION SYSTEM” on page
9-33.
1 ECB02030
NOTICE
If the display indicates a fault code, the vehi-
cle should be checked as soon as possible
2 in order to avoid engine damage.
1. Fuel level warning indicator

2. Fuel meter
3. “E” segment
The fuel meter indicates the amount of fuel in the
fuel tank. The display segments of the fuel meter
disappear from “F” (full) towards “E” (empty) as
the fuel level decreases. When the “E” segment
disappears and the fuel level warning indicator
flashes, refuel as soon as possible.
TIP
This fuel meter is equipped with a self-diagnosis
system. If a problem is detected in an electrical
circuit, all the display segments and fuel level
warning indicator start flashing. If this occurs,
check the electrical circuit.
1-6
IMPORTANT INFORMATION
EBS20011
EBS30009
PREPARATION FOR REMOVAL AND

DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
EBS30011
GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
2. Use only the proper tools and cleaning equip- lips with grease.
ment.
Refer to “SPECIAL TOOLS” on page 1-14.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mat-
ed” through normal wear. Mated parts must
always be reused or replaced as an assem-
bly.
1. Oil
2. Lip
3. Spring
4. Grease
EBS30012
LOCK WASHERS/PLATES AND COTTER

PINS
After removal, replace all lock washers/plates
4. During disassembly, clean all of the parts and “1” and cotter pins. After the bolt or nut has been
place them in trays in the order of disassem- tightened to specification, bend the lock tabs
bly. This will speed up assembly and allow for along a flat of the bolt or nut.
the correct installation of all parts.
5. Keep all parts away from any source of fire.
EBS30010
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
1-7
EBS30013 EBS30015
BEARINGS AND OIL SEALS RUBBER PARTS

Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in-
manufacturer’s marks or numbers are visible. spection. Some of the rubber parts are sensitive
When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc. Do not al-
lips with a light coat of lithium-soap-based low any items other than the specified one to
grease. Oil bearings liberally when installing, if contact the parts.
appropriate.
ECB01260
NOTICE
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
EBS30014
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
1-8
BASIC SERVICE INFORMATION
EBS20012

EBS30016
QUICK FASTENERS
Rivet type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, push its pin with a
screwdriver, then pull the fastener out. Screw type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, loosen the screw
with a screwdriver, then pull the fastener out.
2. Install:
• Quick fastener
TIP
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the part to be secured and push 2. Install:
the pin in with a screwdriver. Make sure that the • Quick fastener
pin is flush with the fastener’s head.
TIP
To install the quick fastener, insert the fastener
into the part to be secured and tighten the screw.
1-9
ECB01520
EBS30017
NOTICE
ELECTRICAL SYSTEM
Be sure to connect the battery leads to the
Electrical parts handling correct battery terminals. Reversing the bat-
ECB01460 tery lead connections could damage the
NOTICE electrical components.
Never disconnect a battery lead while the en-
gine is running; otherwise, the electrical
components could be damaged.
ECB01530
NOTICE
When connecting the battery leads to the
ECB01510 battery, be sure to connect the positive bat-
NOTICE tery lead first, then the negative battery lead.
When disconnecting the battery leads from If the negative battery lead is connected first
the battery, be sure to disconnect the nega- and a tool or similar item contacts the vehi-
tive battery lead first, then the positive bat- cle while the positive battery lead is being
tery lead. If the positive battery lead is connected, a spark could be generated,
disconnected first and a tool or similar item which is extremely dangerous.
contacts the vehicle, a spark could be gener-
ated, which is extremely dangerous.
ECB01470
NOTICE
TIP Turn the main switch to “OFF” before dis-

connecting or connecting an electrical com-
If a battery lead is difficult to disconnect due to
ponent.
rust on the battery terminal, remove the rust us-
ing hot water.
1-10
ECB01480
NOTICE Checking the electrical system

Handle electrical components with special TIP
care, and do not subject them to strong Before checking the electrical system, make
shocks. sure that the battery voltage is at least 12 V.
ECB01490 ECB01440
NOTICE NOTICE
Electrical components are very sensitive to Never insert the tester probes into the cou-
and can be damaged by static electricity. pler terminal slots. Always insert the probes
Therefore, never touch the terminals and be from the opposite end “a” of the coupler, tak-
sure to keep the contacts clean. ing care not to loosen or damage the leads.
ECB01500
TIP
NOTICE
When resetting the ECU by turning the main
switch to “OFF”, be sure to wait approximately 5 For waterproof couplers, never insert the
seconds before turning the main switch back to tester probes directly into the coupler. When
“ON”. performing any checks using a waterproof
coupler, use the specified test harness or a
suitable commercially available test har-
ness.
1-11
2. Check:
Checking the connections
• Lead
Check the leads, couplers, and connectors for
• Coupler
stains, rust, moisture, etc.
• Connector
1. Disconnect:
Moisture → Dry with an air blower.
• Lead
Rust/stains → Connect and disconnect sev-
• Coupler
eral times.
• Connector
ECB01540
NOTICE
• When disconnecting a coupler, release the
coupler lock, hold both sections of the cou-
pler securely, and then disconnect the cou-
pler.
• There are many types of coupler locks;
therefore, be sure to check the type of cou-
pler lock before disconnecting the coupler.
3. Connect:
• Lead
• Coupler
• Connector
TIP
• When connecting a coupler or connector, push
both sections of the coupler or connector to-
gether until they are connected securely.
• Make sure all connections are tight.
ECB01550
NOTICE
When disconnecting a connector, do not pull
the leads. Hold both sections of the connec-
tor securely, and then disconnect the con-
nector.
1-12
TIP
The resistance values shown were obtained at
the standard measuring temperature of 20 °C
(68 °F). If the measuring temperature is not 20
°C (68 °F), the specified measuring conditions
will be shown.
Intake air temperature sensor re-

sistance
5.40–6.60 kΩ at 0 °C (32 °F)
4. Check: 290–390 Ω at 80 °C (176 °F)
• Continuity
(with the pocket tester)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
TIP
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
5. Check:
• Resistance
Pocket tester
90890-03112
YU-03112-C
1-13
SPECIAL TOOLS
EBS20013
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
TIP
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, “YS-”, “YK-”, or “ACC-”.
• For others, use part number starting with “90890-”.
Reference
Tool name/Tool No. Illustration
pages
Pocket tester 1-13, 1-13, 9-91,
90890-03112 9-92, 9-92, 9-94,
Analog pocket tester 9-97, 9-100,
YU-03112-C 9-100, 9-101,
9-102, 9-102,
9-103, 9-104,
9-104, 9-106,
9-106, 9-108,
9-108, 9-108,
9-109, 9-109,
9-110
Thickness gauge 3-4
90890-03180
Feeler gauge set
YU-26900-9
Valve lapper 90890-04101

3-4
90890-04101
Valve lapping tool
YM-A8998
YM-A8998
Yamaha diagnostic tool 3-7, 9-39

90890-03231
Oil filter wrench 3-14

90890-01469
Oil filter wrench
YM-01469
66.8
1-14
SPECIAL TOOLS
Reference
pages
Pressure gauge 3-15, 7-4
90890-03153
Pressure gauge
YU-03153
Oil pressure adapter H 3-15

90890-03139
Ring nut wrench 3-27, 3-29

90890-01268
Spanner wrench
YU-01268
Steering nut wrench 3-27, 3-30

90890-01443
Spanner wrench
YU-33975
Boots band installation tool 4-50, 8-10, 8-12,

90890-01526 8-25, 8-27
Boots band installation tool
YM-01526
Ball joint remover 4-54, 4-58

90890-01474
Ball joint remover
YM-01474
Ball joint remover adapter set 4-54, 4-58

90890-01477
Ball joint remover adapter set
YM-01477
Base plate 35mm 45mm ø35 4-54, 4-58

90890-01553
Base plate 35mm
YM-01553 110mm
12mm
Ball joint installer attachment 39mm 4-54, 4-58

90890-01555
Ball joint installer attachment 39mm
YS-01881-A
ø39
1-15
SPECIAL TOOLS
Reference
pages
Extension 5-1
90890-04136
Compression gauge 90890-03081 5-1

90890-03081
Engine compression tester
YU-33223
YU-33223
Piston pin puller set 5-20

90890-01304
Piston pin puller
YU-01304
YU-01304
Valve spring compressor 5-27, 5-32

90890-04019
Valve spring compressor
YM-04019
Valve spring compressor attachment 5-27, 5-32

90890-01243
Valve spring compressor adapter (26 mm)
YM-01253-1
Valve guide remover & installer set (ø5.5) 5-29

90890-04016
Valve guide remover (5.5 mm)
YM-01122
1-16
SPECIAL TOOLS
Reference
pages
90890-04016
Valve guide installer (5.5 mm)
YM-04015

90890-04016
Valve guide reamer (5.5 mm)
YM-01196
Rotor holding tool 5-35, 5-35, 5-36,

90890-04166 5-37, 5-43, 5-44,
YM-04166 5-53, 5-58
Flywheel puller (M38 X P1.5) 5-35

90890-04178
Flywheel puller (M38 X P1.5)
YM-04178
M38×P1.5
Digital circuit tester 5-40, 7-13,

90890-03174 9-103, 9-105,
Model 88 Multimeter with tachometer 9-107
YU-A1927
Sheave fixed block 5-53, 5-57

90890-04135
Sheave fixed bracket
YM-04135
1-17
SPECIAL TOOLS
Reference
pages
Locknut wrench 5-53, 5-57
90890-01348
Locknut wrench
YM-01348
Sheave spring compressor 5-53, 5-57

90890-04134
Sheave spring compressor
YM-04134
Universal clutch holder 5-62, 5-63

90890-04086
Universal clutch holder
YM-91042
Crankcase separating tool 5-68, 5-73, 8-30

90890-01135
Crankcase separator
YU-01135-B
1-18
SPECIAL TOOLS
Reference
pages
Yamaha bond No. 1215 5-69, 8-30
90890-85505
(Three bond No.1215®)
Crankshaft installer pot 5-75, 8-28

90890-01274
Installing pot
YU-90058
YU-90058/YU-90059
Crankshaft installer bolt 5-75, 8-28

90890-01275
Bolt
YU-90060
Adapter (M16) 5-75

90890-04130
Adapter #13
YM-04059
Spacer (crankshaft installer) 5-75

90890-04081
Pot spacer
YM-91044
YM-91044
Coupling gear/middle shaft tool 5-87, 5-87, 5-90,

90890-01229 5-90
Gear holder
YM-01229
Bearing retainer wrench 5-88, 5-89

90890-04128
Middle gear bearing retainer
YM-04128
1-19
SPECIAL TOOLS
Reference
pages
Ring nut wrench 5-88, 5-89
90890-01430
Ring nut wrench
YM-38404
Final gear backlash band 5-91

90890-01511
Middle drive gear lash tool
YM-01230
Radiator cap tester 6-6

90890-01325
Mityvac cooling system tester kit
YU-24460-A
YU-24460-A
Radiator cap tester adapter 6-6

90890-01352
Pressure tester adapter
YU-33984
YU-33984
Mechanical seal installer 6-12

90890-01581
Mechanical seal installer
YM-01581 ø12.5
ø33.8 ø26
Middle driven shaft bearing driver 6-12

90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058
Fuel pressure adapter 7-4

90890-03176
Fuel pressure adapter
YM-03176
1-20
SPECIAL TOOLS
Reference
pages
Test harness– TPS (3P) 7-13
90890-03204
Test harness– TPS (3P)
YU-03204
Universal joint holder 8-12, 8-15

90890-04062
Universal joint holder
YM-04062
Ring gear fix bolt (M10) 8-16

90890-01527
Ring gear fix bolt (M10)
YM-01527
M10×P1.25
Gear lash measurement tool 8-16

90890-01475
YM-01475
Coupling gear holding tool (35) 8-27, 8-31

90890-01571
Coupling gear holding tool (35)
YM-01571
Adapter (M14) 8-28

90890-04059
Adapter #10
YM-90069
Ring gear fix bolt (M10 x 1.5) 8-29

90890-01572
Ring gear fix bolt (M10 x 1.5)
YM-01572
M10×P1.50
Gear lash measurement tool 8-29

90890-01467
Gear lash measurement tool
YM-01467
1-21
SPECIAL TOOLS
Reference
pages
Ignition checker 9-101
90890-06754
Oppama pet–4000 spark checker
YM-34487
Test harness– lean angle sensor (3P) 9-102

90890-03213
Test harness– lean angle sensor (3P)
YU-03213
Test harness– speed sensor (3P) 9-104

90890-03208
Test harness– speed sensor (3P)
YU-03208
Test harness S– pressure sensor 5S7 (3P) 9-107

90890-03211
Test harness S– pressure sensor 5S7 (3P)
YU-03211
1-22
SPECIAL TOOLS
1-23
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................2-2
CHASSIS SPECIFICATIONS ..........................................................................2-6
ELECTRICAL SPECIFICATIONS ...................................................................2-9

2
TIGHTENING TORQUES .............................................................................. 2-11
GENERAL TIGHTENING TORQUE SPECIFICATIONS......................... 2-11
ENGINE TIGHTENING TORQUES......................................................... 2-12
CHASSIS TIGHTENING TORQUES.......................................................2-17
LUBRICATION AND SEALING POINTS ......................................................2-24

ENGINE................................................................................................... 2-24
LUBRICATION SYSTEM CHART AND DIAGRAMS.................................... 2-25

ENGINE OIL LUBRICATION CHART .....................................................2-25
LUBRICATION DIAGRAMS .................................................................... 2-27
COOLING SYSTEM DIAGRAMS .................................................................. 2-33
CABLE ROUTING ......................................................................................... 2-39

GENERAL SPECIFICATIONS
EBS20014
GENERAL SPECIFICATIONS
Model
Model 2MB2 (YX70EPNG) (for CDN/EPS models)
2MB6 (YX70EPNG) (for CDN/EPS models)
2MB3 (YXE70WPXG) (for Europe/EPS models)
2MB7 (YXE70WPHG) (for Europe/EPS models)
B523 (YXE70WDXG) (for Oceania)
2MB4 (YXE70WPXG) (for Oceania/EPS
models)
2MB8 (YXE70WPHG) (for Oceania/EPS
models)
2MB9 (YXE700E) (for Russia/EPS models)
Dimensions
Overall length 2970 mm (116.9 in)
Overall width 1540 mm (60.6 in)
Overall height 1885 mm (74.2 in)
Wheelbase 2065 mm (81.3 in)
Ground clearance 290 mm (11.4 in)
Minimum turning radius 4600 mm (181 in)
Maximum water depth 37 cm (15 in)
Weight
Curb weight 589.0 kg (1299 lb) (YXE70WDXG)
595.0 kg (1312 lb) (YX70EPNG, YXE70WPXG,
YXE70WPHG, YXE700E)
Maximum loading limit 327.0 kg (721 lb)
(Total weight of operator, passenger, cargo,
accessories, and tongue)
Loading
Rear carrier load limit 136.0 kg (300 lb)
Storage compartment load limit 6.4 kg (14 lb)
Trailer hitch pulling load limit 6664 N (680 kgf, 1498 lbf)
Trailer hitch vertical load limit 490 N (50 kgf, 110 lbf)
2-1
ENGINE SPECIFICATIONS
EBS20015
Engine
Engine type Liquid cooled 4-stroke, DOHC
Cylinder arrangement Single cylinder
Displacement 708 cm³
Bore × stroke 103.0 × 85.0 mm (4.06 × 3.35 in)
Compression ratio 10.1 : 1
Standard compression pressure (at sea level) 650–1000 kPa (6.5–10.0 kgf/cm², 92.4–142.2
psi)
Starting system Electric starter
Fuel
Recommended fuel Regular unleaded gasoline only (for Canada
and Oceania)
Regular unleaded gasoline only with a research
octane number of 95 or higher (for Europe)
Unleaded gasoline only. Minimum research
octane number 91 (for Russia)
Fuel tank capacity 37.0 L (9.77 US gal, 8.14 Imp.gal)
Engine oil
Lubrication system Wet sump
Recommended brand YAMALUBE
Type SAE 0W-30, 10W-30, 10W-40, 15W-40, 20W-
40 or 20W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Engine oil quantity
Without oil filter cartridge replacement 2.20 L (2.33 US qt, 1.94 Imp.qt)
With oil filter cartridge replacement 2.30 L (2.43 US qt, 2.02 Imp.qt)
Quantity (disassembled) 3.10 L (3.28 US qt, 2.73 Imp.qt)
Differential gear oil

Type SAE 80 API GL-4 Hypoid gear oil
Quantity 0.18 L (0.19 US qt, 0.16 Imp.qt)
Final gear oil

Type SAE 80 API GL-4 Hypoid gear oil
Quantity 0.64 L (0.68 US qt, 0.56 Imp.qt)
Oil filter
Oil filter type Cartridge
Oil pump
Inner-rotor-to-outer-rotor-tip clearance limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance limit 0.24 mm (0.0094 in)
Oil pressure (hot) 50.0 kPa/1600 r/min (0.50kgf/cm²/1600 r/min,
7.3 psi/1600 r/min)
2-2
Cooling system
Coolant quantity
Radiator (including all routes) 2.85 L (3.01 US qt, 2.51 Imp.qt)
Coolant reservoir (up to the maximum level
mark) 0.20 L (0.21 US qt, 0.18 Imp.qt)
Radiator core
Width 400.0 mm (15.75 in)
Height 253.4 mm (9.98 in)
Depth 28.0 mm (1.10 in)
Radiator capacity 0.925 L (0.98 US qt, 0.81 Imp.qt)
Radiator cap opening pressure 107.9–137.3 kPa (1.1–1.4 kgf/cm², 15.6–19.9
psi)
Thermostat
Valve opening temperature 69–73 °C (156–163 °F)
Valve full open temperature 84 °C (183 °F)
Valve lift (full open) 8.0 mm (0.31 in)
Water pump
Water pump type Single suction centrifugal pump
Impeller shaft tilt limit 0.15 mm (0.006 in)
Spark plug
Manufacturer/model NGK/CPR7EA-9
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)
Cylinder head
Warpage limit 0.03 mm (0.0012 in)
Camshaft
Drive system Chain drive (right)
Camshaft journal diameter 21.946–21.963 mm (0.8640–0.8647 in)
Camshaft-journal-to-camshaft-cap clearance 0.037–0.075 mm (0.0015–0.0030 in)
Camshaft lobe dimensions
Lobe height (Intake) limit 33.8 mm (1.331 in)
Base circle diameter (Intake) limit 24.85 mm (0.978 in)
Lobe height (Exhaust) limit 30.75 mm (1.211 in)
Base circle diameter (Exhaust) limit 22.35 mm (0.880 in)
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.10–0.20 mm (0.0039–0.0079 in)
Exhaust 0.22–0.32 mm (0.0087–0.0126 in)
Valve dimensions
Valve head diameter (intake) 38.90–39.10 mm (1.5315–1.5394 in)
Valve head diameter (exhaust) 31.90–32.10 mm (1.2559–1.2638 in)
Valve seat contact width (intake) 1.34–1.48 mm (0.0528–0.0583 in)
Limit 1.9 mm (0.07 in)
Valve seat contact width (exhaust) 1.34–1.48 mm (0.0528–0.0583 in)
Limit 1.9 mm (0.07 in)
Valve stem diameter (intake) limit 5.420 mm (0.2134 in)
Valve stem diameter (exhaust) limit 5.415 mm (0.1738 in)
Valve guide inside diameter (exhaust) limit 5.550 mm (0.2185 in)
Valve guide inside diameter (exhaust) limit 5.550 mm (0.2185 in)
2-3
Valve-stem-to-valve-guide clearance (intake)

limit 0.080 mm (0.0031 in)
Valve-stem-to-valve-guide clearance
(exhaust) limit 0.100 mm (0.0039 in)
Valve stem runout 0.040 mm (0.0016 in)
Valve spring
Installed length (intake) 30.95 mm (1.22 in)
Installed length (exhaust) 32.20 mm (1.27 in)
Installed compression spring force (intake) 134.00–154.00 N (13.66–15.70 kgf, 30.12–
34.62 lbf)
Installed compression spring force (exhaust) 107.00–123.00 N (10.91–12.54 kgf, 24.05–
27.65 lbf)
Spring tilt (intake) 1.7 mm (0.07 in)
Spring tilt (exhaust) 1.7 mm (0.07 in)
Winding direction (intake) Clockwise
Winding direction (exhaust) Clockwise
Cylinder
Bore 103.000–103.020 mm (4.0551–4.0559 in)
Wear limit 103.080 mm (4.0583 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.050 mm (0.0020 in)
Piston
Piston-to-cylinder clearance 0.040–0.075 mm (0.0016–0.0030 in)
Diameter 102.960–102.975 mm (4.0535–4.0541 in)
Measuring point (from piston skirt bottom) 11.0 mm (0.43 in)
Piston pin bore inside diameter limit 23.035 mm (0.9069 in)
Piston pin outside diameter limit 22.974 mm (0.9045 in)
Piston ring
Top ring
Ring type Barrel
End gap (installed) limit 0.50 mm (0.0197 in)
Ring side clearance limit 0.12 mm (0.0047 in)
2nd ring
Ring type
Ring side clearance limit 0.12 mm (0.0047 in)
Oil ring
Crankshaft
Crank assembly width 65.68–65.76 mm (2.586–2.589 in)
Runout limit 0.030 mm (0.0012 in)
Big end side clearance 0.090–0.500 mm (0.0035–0.0197 in)
Clutch
Clutch type Wet, centrifugal automatic
Clutch shoe thickness limit 1.0 mm (0.04 in)
Clutch housing inside diameter 150.0 mm (5.91 in)
Clutch-in revolution 1950–2050 r/min
2-4
Clutch-stall revolution 3550–3650 r/min
V-belt
V-belt width limit 32.5 mm (1.28 in)
Transmission type V-belt automatic
Gear ratio 2.474–0.656 : 1
Low range 31/16 (1.938)
High range 30/22 (1.364)
Reverse gear 23/14 × 28/23 (2.000)
Drive axle runout limit 0.06 mm (0.0024 in)
Secondary reduction ratio 43/21 × 17/12 × 33/9 (10.636)
Secondary reduction system Shaft drive
Shaft drive
Middle gear backlash 0.10–0.30 mm (0.004–0.012 in)
Final gear backlash 0.13–0.23 mm (0.005–0.009 in)
Differential gear backlash 0.05–0.25 mm (0.002–0.010 in)
Shifting mechanism
Shift fork thickness 5.76–5.89 mm (0.2268–0.2319 in)
Air filter
Air filter element Wet element
Air filter oil grade Foam air-filter oil
Fuel pump
Pump type Electrical
Throttle body
Type/quantity 44EHS/1
ID mark 2MB1 00
Throttle valve size #100
Fuel injector
Model/quantity EAT291/1
Fuel injector resistance 11.5–12.5 Ω
Throttle position sensor

Resistance 2.64–6.16 kΩ
Idling condition
Engine idling speed 1550–1650 r/min
CO% (air induction system ON) 2.5 %
CO% (air induction system OFF) 3.2–4.2 %
Intake vacuum 35.0 kPa (263 mmHg, 10.4 inHg)
Water temperature 75–85 °C (167–185 °F)
Oil temperature 55–65 °C (131–149 °F)
Accelerator pedal free play 12.0–32.0 mm (0.47–1.26 in)
Air induction system

Solenoid resistance 18.0–22.0 Ω
2-5
CHASSIS SPECIFICATIONS
EBS20016
Chassis
Frame type Steel tube frame
Caster angle 3.7°
Camber angle 0.4°
Kingpin angle 12.7°
Kingpin offset 7.7 mm (0.30 in)
Trail 19.0 mm (0.75 in)
Toe-in (with tires touching the ground) 5.0–15.0 mm (0.20–0.59 in)
Tread rear (STD) 1304.0 mm (51.34 in)
Tread front (STD) 1320.0 mm (51.97 in)
Front wheel
Wheel type Panel wheel
Rim size 12 × 6.0AT
Wheel material Steel
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Rear wheel
Wheel type Panel wheel
Rim size 12 × 7.5AT
Wheel material Steel
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Front tire
Type Tubeless
Size 26 × 8–12NHS
Manufacturer/model MAXXIS/MU09
Wear limit (front) 3.0 mm (0.12 in)
Rear tire
Type Tubeless
Size 26 × 10–12NHS
Manufacturer/model MAXXIS/MU10
Wear limit (rear) 3.0 mm (0.12 in)
Tire air pressure (measured on cold tires)

Recommended
Vehicle load 0 kg-maximum (0 lb-maximum)
Front 75.0 kPa (0.750 kgf/cm², 11 psi)
Rear 75.0 kPa (0.750 kgf/cm², 11 psi)
Minimum
Vehicle load 0 kg-maximum (0 lb-maximum)
Front 70.0 kPa (0.700 kgf/cm², 10 psi)
Rear 70.0 kPa (0.700 kgf/cm², 10 psi)
Front brake
Type Disc brake
Operation Unified brake
2-6
Disc outside diameter × thickness 207.0 × 4.0 mm (8.15 × 0.16 in)

Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc deflection limit 0.10 mm (0.0039 in)
Brake pad lining thickness limit 1.0 mm (0.04 in)
Master cylinder inside diameter 17.46 mm (0.69 in)
Caliper cylinder inside diameter 32.03 mm × 2 (1.26 in × 2)
Specified brake fluid DOT 4
Rear brake
Type Disc brake
Operation Unified brake
Disc outside diameter × thickness 207.0 × 4.0 mm (8.15 × 0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc deflection limit 0.10 mm (0.0039 in)
Brake pad lining thickness limit 1.0 mm (0.04 in)
Master cylinder inside diameter 17.46 mm (0.69 in)
Caliper cylinder inside diameter 27.00 mm × 2
Specified brake fluid DOT 4
Brake pedal free play 0 mm (0 in)
Parking brake
Type Mechanical wet multiple disc brake
Friction plate outside diameter × thickness 200.0 × 3.5 mm (7.87 × 0.14 in)
Friction plate thickness limit 3.0 mm (0.12 in)
Front suspension
Type Double wishbone
Spring/shock absorber type Coil spring/gas-oil damper
Shock absorber travel 142.0 mm (5.59 in)
Installed length 329.0 mm (12.95 in)
Wheel travel 246 mm (9.7 in)
Spring preload adjusting positions
Minimum 313.5 mm (12.34 in)
Standard 305.5 mm (12.03 in)
Maximum 298.5 mm (11.75 in)
Rebound damping adjusting positions
Minimum 30 click(s) out from the fully turned in position
Standard 13 click(s) out from the fully turned in position
Maximum 1 click(s) out from the fully turned in position
Compression damping setting (for fast compression damping)
Minimum 2 turn(s) out from the fully turned in position
Standard 1 1/4 turn(s) out from the fully turned in position
Maximum Adjusting bolt fully turned in
Compression damping setting (for slow compression damping)
Rear suspension
Type Double wishbone
Spring/shock absorber type Coil spring/gas-oil damper
Wheel travel 269 mm (10.6 in)
Rear shock absorber assembly travel 180.0 mm (7.09 in)
2-7
Installed length 378.0 mm (14.88 in)

Minimum 386.0 mm (15.20 in)
Standard 378.0 mm (14.88 in)
Maximum 372.0 mm (14.65 in)
Rebound damping adjusting positions
Compression damping setting (for fast compression damping)
Minimum 2 turn(s) out from the fully turned in position
Standard 1 1/4 turn(s) out from the fully turned in position
Maximum Adjusting bolt fully turned in
Compression damping setting (for slow compression damping)
2-8
ELECTRICAL SPECIFICATIONS
EBS20017
Voltage
System voltage 12 V
Engine control unit

Model/manufacturer F8T85877/MITSUBISHI
Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 7.0°/1600 r/min
Pickup coil resistance 152.0–228.0 Ω
Ignition coil
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 2.16–2.64 Ω
Secondary coil resistance 8.64–12.96 kΩ
Spark plug cap

Resistance 10.0 kΩ
Charging system
Charging system AC magneto
Standard output 14.0 V, 35.0 A at 5000 r/min
Stator coil resistance 0.15–0.22 Ω
Rectifier/regulator
Regulator type Semi conductor-short circuit
Regulated voltage (DC) 14.3–14.7 V
Rectifier capacity (DC) 50.0 A
Battery
Model U1-H11L
Voltage, capacity 12 V, 28.0 Ah
Headlight
Bulb type Halogen bulb
Bulb voltage, wattage × quantity

Headlight 12 V, 35.0/35.0 W × 2
Tail/brake light 12 V, 5.0/21.0 W × 2
Indicator and warning lights

Neutral indicator light LED
Reverse indicator light LED
Coolant temperature warning light LED
Parking brake indicator light LED
On-Command four-wheel-drive/differential gear
lock indicator LCD
Engine trouble warning light LED
High-range indicator light LED
2-9
Low-range indicator light LED

Differential gear lock indicator light LED
Helmet/Seat belt indicator light 14 V, 0.85 W × 2
EPS warning light LED (for EPS models)
Starter motor
Power output 0.80 kW
Armature coil resistance 0.025–0.035 Ω
Brush overall length limit 5.0 mm (0.20 in)
Commutator diameter limit 27.0 mm (1.06 in)
Mica undercut (depth) 0.70 mm (0.03 in)
Starter relay
Amperage 180.0 A
Coil resistance 4.18–4.62 Ω
Horn (except for CDN)

Horn type Plane
Quantity 1 pc
Maximum amperage 1.0 A
Fuel sender unit

Sender unit resistance (full) 19.00–21.00 Ω
Sender unit resistance (empty) 139.00–141.00 Ω
EPS torque sensor

Coil resistance 0.875–1.625 kΩ (for EPS models)
Auxiliary DC output
Jack capacity 12 V, 10.0 A (120 W)
Fuel injection sensor

Crankshaft position sensor resistance 152–228 Ω
Intake air pressure sensor output voltage 3.594–3.684 V at 101 kPa (1.01 kgf/cm², 14 psi)
Intake air temperature sensor resistance 5.40–6.60 kΩ at 0 °C (32 °F)
290–390 Ω at 80 °C (176 °F)
Coolant temperature sensor resistance 2.32–2.59 kΩ at 20 °C (68 °F)
310–326 Ω at 80 °C (176 °F)
Fuses
Main fuse 40.0 A
Headlight fuse 15.0 A
Signaling system fuse 10.0 A
Ignition fuse 10.0 A
Radiator fan motor fuse 25.0 A
Auxiliary DC jack fuse 10.0 A
Fuel injection system fuse 10.0 A
Backup fuse 10.0 A
Differential motor fuse 10.0 A
EPS fuse 40.0 A (for EPS models)
Spare fuse 25.0 A
Spare fuse 15.0 A
Spare fuse 10.0 A × 2
2-10
TIGHTENING TORQUES
EBS20018
TIGHTENING TORQUES
EBS30018
GENERAL TIGHTENING TORQUE

SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special com-
ponents or assemblies are provided for each
chapter of this manual. To avoid warpage, tight-
en multi-fastener assemblies in a crisscross pat-
tern and progressive stages until the specified
tightening torque is reached. Unless otherwise
specified, tightening torque specifications re-
quire clean, dry threads. Components should be
at room temperature.
A. Distance between flats

B. Outside thread diameter
General tightening torques

A (nut) B (bolt)
Nm m·kgf ft·lbf
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
2-11
TIGHTENING TORQUES
EBS30019
ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Exhaust pipe nut M8 2 20 Nm (2.0 m·kgf, 14 ft·lbf)
Muffler bolt M8 1 23 Nm (2.3 m·kgf, 17 ft·lbf)
Muffler mount shaft M8 1 17 Nm (1.7 m·kgf, 12 ft·lbf) LT
Spark arrester bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Cylinder head cover bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Breather plate cover bolt M6 4 See TIP.
Camshaft cap bolt M6 8 See TIP.
Cylinder head bolt M11 4 See TIP. E
Cylinder head bolt M6 2 See TIP.

Cylinder bolt M6 2 See TIP.
Cylinder head stud bolt (exhaust
M8 2 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
pipe)
Timing chain tensioner bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing chain tensioner cap bolt M6 1 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Timing chain stopper guide bolt (low-
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
er)
Timing chain guide bolt (intake side) M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Reed valve cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
AC magneto cover bolt M6 11 See TIP.

Crankshaft end accessing screw M32 1 11 Nm (1.1 m·kgf, 8.0 ft·lbf)
Timing mark accessing screw M14 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
AC magneto/crankshaft position
M5 2 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf) LT
sensor lead holder bolt
AC magneto rotor nut M14 1 160 Nm (16 m·kgf, 116 ft·lbf)
Starter clutch bolt M6 8 14 Nm (1.4 m·kgf, 10 ft·lbf)
Thermostat cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Thermostat cover air bleed bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Water pump housing bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant drain bolt M6 1 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Water pump air bleed bolt M6 1 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Left-hand
Impeller M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
threads
Water jacket joint bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Water pump outlet pipe bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil filter cartridge — 1 15 Nm (1.5 m·kgf, 11 ft·lbf)
Oil filter cartridge union bolt M20 1 68 Nm (6.8 m·kgf, 49 ft·lbf) E
Oil cooler bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)

Oil cooler bracket bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Oil cooler pipe holder bolt M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Oil hose bolt (crankcase to cylinder) M12 1 18 Nm (1.8 m·kgf, 13 ft·lbf)
Oil pipe bolt (crankcase) M14 2 35 Nm (3.5 m·kgf, 25 ft·lbf)
2-12
TIGHTENING TORQUES
Thread
size
Oil pipe bolt (AC magneto cover) M8 2 18 Nm (1.8 m·kgf, 13 ft·lbf)
Oil pipe bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pump drive sprocket nut M12 1 25 Nm (2.5 m·kgf, 18 ft·lbf) LT
Oil pump driven sprocket nut M12 1 25 Nm (2.5 m·kgf, 18 ft·lbf) LT
Oil pump bolt M6 3 See TIP.

Oil pump housing cover screw M5 1 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Fuel rail screw M6 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Throttle cable locknut (air intake si-
M7 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
lencer side)
Throttle cable locknut (throttle body
M6 1 0.8 Nm (0.08 m·kgf, 0.58 ft·lbf)
side)
Throttle cable housing cover screw M4 3 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Drive belt cover bolt M6 10 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Drive belt case bolt M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Bearing housing bolt (primary
M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
sheave assembly)
Bearing retainer bolt (bearing hous-
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
ing)
Primary sheave assembly nut M16 1 190 Nm (19 m·kgf, 137 ft·lbf)
Primary sheave cap screw M4 8 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Secondary sheave assembly nut M16 1 100 Nm (10 m·kgf, 72 ft·lbf)
Secondary sheave spring retaining
M36 1 90 Nm (9.0 m·kgf, 65 ft·lbf)
nut
Clutch housing assembly bolt M6 9 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Left-hand
threads
Clutch carrier assembly nut M22 1 190 Nm (19 m·kgf, 137 ft·lbf)
Stake.
E
Crankcase bolt (M8) M8 3 26 Nm (2.6 m·kgf, 19 ft·lbf)

Crankcase bolt (M6) M6 14 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Main gallery bolt M16 1 35 Nm (3.5 m·kgf, 25 ft·lbf) LT
Crankcase plug M16 1 35 Nm (3.5 m·kgf, 25 ft·lbf) LT
Crankcase plug M14 1 18 Nm (1.8 m·kgf, 13 ft·lbf)

Relief plug M14 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Engine oil drain bolt M14 1 22 Nm (2.2 m·kgf, 16 ft·lbf)
Shift drum stopper bolt M14 1 18 Nm (1.8 m·kgf, 13 ft·lbf)
Dipstick guide bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Bearing retainer bolt (crankcase) M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Thermostat outlet hose holder bolt M10 1 48 Nm (4.8 m·kgf, 35 ft·lbf)

Middle drive pinion gear nut M22 1 190 Nm (19 m·kgf, 137 ft·lbf) Stake.
Middle drive shaft bearing housing
M10 4 38 Nm (3.8 m·kgf, 27 ft·lbf) LT
bolt
Middle drive shaft bearing retainer Stake.
M8 4 29 Nm (2.9 m·kgf, 21 ft·lbf)
bolt LT
2-13
TIGHTENING TORQUES
Thread
size
Front drive shaft coupling gear nut
M16 1 190 Nm (19 m·kgf, 137 ft·lbf) LT
(middle gear side)
Left-hand
Middle driven shaft bearing retainer M55 1 80 Nm (8.0 m·kgf, 58 ft·lbf) threads
LT
Middle driven pinion gear bearing

M8 4 25 Nm (2.5 m·kgf, 18 ft·lbf)
housing bolt
Left-hand
Middle driven pinion gear bearing re-
M60 1 130 Nm (13 m·kgf, 94 ft·lbf) threads
tainer
LT
Rear drive shaft coupling gear nut

M16 1 190 Nm (19 m·kgf, 137 ft·lbf) LT
(middle gear side)
Starter motor bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Starter motor cover bolt M5 2 4.9 Nm (0.49 m·kgf, 3.5 ft·lbf)
Brush set bolt M6 1 11 Nm (1.1 m·kgf, 8.0 ft·lbf)
Starter motor lead nut M6 1 4.9 Nm (0.49 m·kgf, 3.5 ft·lbf)
Engine ground lead bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Spark plug M10 1 11 Nm (1.1 m·kgf, 8.0 ft·lbf)
Stator coil assembly bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Throttle position sensor screw M5 2 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)

Intake air pressure sensor screw M5 1 3.6 Nm (0.36 m·kgf, 2.6 ft·lbf)
Crankshaft position sensor bolt M5 2 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf) LT
Coolant temperature sensor M12 1 20 Nm (2.0 m·kgf, 14 ft·lbf)

Gear position switch bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Reverse switch M10 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
Speed sensor bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
TIP
Breather plate cover bolt
Tighten the breather plate cover bolts to 10 Nm (1.0 m·kgf, 7.2 f·lbf) in the proper tightening sequence.
3
1
2 4
TIP
Camshaft cap bolt
Tighten the camshaft cap bolts to 10 Nm (1.0 m·kgf, 7.2 f·lbf) in the proper tightening sequence.
2-14
TIGHTENING TORQUES
6 2
5 1
7 3
4
8
TIP
Cylinder head bolt and cylinder bolt
1. Temporarily tighten the cylinder head bolts (M6) and cylinder bolts (M6).
2. Tighten the cylinder head bolts (M11) to 30 Nm (3.0 m·kgf, 22 ft·lbf) in the proper tightening se-
quence.
quence.
4. Loosen the cylinder head bolts (M11) 360°.
quence.
6. Tighten the cylinder head bolts (M11) to the specified angle 85–90° in the proper tightening se-
quence.
7. Tighten the cylinder head bolts (M11) to the specified angle 85–90° in the proper tightening se-
quence.
8. Tighten the cylinder head bolts (M6) and cylinder bolts (M6) to 10 Nm (1.0 m·kgf, 7.2 ft·lbf) in the
proper tightening sequence.
×4 FWD
×4
4
6
8
5
2
TIP
AC magneto cover bolt
Tighten the AC magneto cover bolts to 10 Nm (1.0 m·kgf, 7.2 ft·lbf) in the proper tightening sequence.
2-15
TIGHTENING TORQUES
10
4
6
8
1
3
2
7
5 9
11
TIP
Oil pump bolt
Tighten the oil pump bolts to 10 Nm (1.0 m·kgf, 7.2 ft·lbf) in the proper tightening sequence.
2-16
TIGHTENING TORQUES
EBS30020
CHASSIS TIGHTENING TORQUES

Thread
size
Engine mounting bolt (front) (M6) M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Engine mounting bolt (front) (M10) M10 2 42 Nm (4.2 m·kgf, 30 ft·lbf)

Engine mounting bolt (rear) (M6) M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Engine mounting bolt (rear) (M10) M10 2 42 Nm (4.2 m·kgf, 30 ft·lbf)

Engine bracket nut (front) M10 4 42 Nm (4.2 m·kgf, 30 ft·lbf)
Engine bracket nut (rear) M10 4 42 Nm (4.2 m·kgf, 30 ft·lbf)
Radiator bracket bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Radiator fan bolt M6 4 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Radiator inlet pipe holder bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Radiator outlet pipe holder bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Coolant reservoir bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Air filter case bolt M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Air filter case joint clamp screw M6 2 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Air intake duct joint clamp screw M6 2 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Air intake silencer joint clamp screw
M5 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
(throttle body side)
Air intake silencer joint clamp screw
M6 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
(air intake silencer side)
Throttle body joint clamp screw
M5 1 2.8 Nm (0.28 m·kgf, 2.0 ft·lbf)
Throttle body joint clamp screw (cyl-
M5 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
inder head side)
Throttle cable locknut (accelerator
M6 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
pedal end)
Fuel tank bolt M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bracket bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank retainer bolt M8 2 16 Nm (1.6 m·kgf, 12 ft·lbf)
Fuel pump nut M6 6 See TIP.
Fuel tank breather hose joint bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Air cut-off valve bracket bolt M6 1 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Drive select lever guide bolt M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Drive select lever shift rod locknut M8 2 15 Nm (1.5 m·kgf, 11 ft·lbf)
Shift arm bolt M6 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf) LT
Shift lever cover bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Shift lever 2 bolt M6 1 14 Nm (1.4 m·kgf, 10 ft·lbf)
Shift drum stopper bolt M14 1 18 Nm (1.8 m·kgf, 13 ft·lbf)
Drive select lever bracket bolt M8 3 17 Nm (1.7 m·kgf, 12 ft·lbf)
Side panel bolt M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Door hinge nut M6 8 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Door hinge bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Door handle latch nut M6 6 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
2-17
TIGHTENING TORQUES
Thread
size
Seat back bolt M6 6 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Driver seat frame bolt M8 4 23 Nm (2.3 m·kgf, 17 ft·lbf)
Passenger seat frame bolt M8 4 23 Nm (2.3 m·kgf, 17 ft·lbf)
Under-seat compartment panel bolt M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Under-seat storage compartment
M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
bolt
Rubber cover bolt M6 2 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Center cover bolt M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Floor board bolt M6 12 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Seat belt guide bolt M11 2 59 Nm (5.9 m·kgf, 43 ft·lbf)
Seat belt bolt (M12 × 20) M12 2 59 Nm (5.9 m·kgf, 43 ft·lbf)
Seat belt bolt (M12 × 18) M12 4 59 Nm (5.9 m·kgf, 43 ft·lbf)
Seat belt buckle bolt M12 2 59 Nm (5.9 m·kgf, 43 ft·lbf)
Seat belt buckle bracket bolt M10 2 59 Nm (5.9 m·kgf, 43 ft·lbf)
Sun top front bracket screw M6 8 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Sun top rear bracket screw M6 8 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Front top frame bolt M10 4 70 Nm (7.0 m·kgf, 51 ft·lbf)
Rear top frame bolt M10 4 70 Nm (7.0 m·kgf, 51 ft·lbf)
Side frame nut (front left) M10 2 70 Nm (7.0 m·kgf, 51 ft·lbf)
Side frame nut (rear left) M10 1 48 Nm (4.8 m·kgf, 35 ft·lbf)
Side frame nut (front right) M10 2 70 Nm (7.0 m·kgf, 51 ft·lbf)
Side frame nut (rear right) M10 1 48 Nm (4.8 m·kgf, 35 ft·lbf)
Rear upper frame bolt M10 4 70 Nm (7.0 m·kgf, 51 ft·lbf)
Rear lower frame bolt M10 4 70 Nm (7.0 m·kgf, 51 ft·lbf)
Rear upper frame and rear lower
M10 2 41 Nm (4.1 m·kgf, 30 ft·lbf)
frame nut
Skid plate bolt M6 6 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Side guard bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Mudguard bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front guard bolt M10 4 48 Nm (4.8 m·kgf, 35 ft·lbf)
Front guard bolt and front grill M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Front grill and front fender bolt M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Front grill and frame bolt M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Front fender and front grill bolt M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Front fender bolt M6 8 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Front over fender and front fender
M6 10 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
bolt (for over fender models)
Front over fender and frame bolt (for
M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
over fender models)
Headlight screw (M5 × 21) M5 4 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Headlight screw (M5 × 44) M5 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Passenger handhold nut M6 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
2-18
TIGHTENING TORQUES
Thread
size
Instrument panel bolt M6 9 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Glove compartment latch plate
M4 2 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
screw
Electrical components tray and
M6 4 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
frame bolt
Cargo bed bolt M6 9 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Frame cross member bolt M8 4 33 Nm (3.3 m·kgf, 24 ft·lbf)
Heat protector bolt M8 2 33 Nm (3.3 m·kgf, 24 ft·lbf)
Latch holder bolt M6 4 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Latch bolt M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Tail/brake light bracket bolt M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Rear over fender bolt (for over fender
M6 12 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
models)
V-belt cooling intake duct joint 1
M6 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
clamp screw (drive belt cover side)
clamp screw (V-belt cooling intake M4 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
duct side)
M4 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
clamp screw
V-belt cooling intake duct bolt M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
V-belt cooling exhaust duct joint
M6 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
clamp screw (drive belt cover side)
V-belt cooling exhaust duct joint
clamp screw (V-belt cooling exhaust M4 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
duct side)
V-belt cooling exhaust duct bolt M6 1 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
V-belt cooling exhaust duct plate bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front wheel nut M12 8 75 Nm (7.5 m·kgf, 54 ft·lbf)
Rear wheel nut M12 8 75 Nm (7.5 m·kgf, 54 ft·lbf)
Front wheel axle nut M24 2 350 Nm (35 m·kgf, 253 ft·lbf) Stake.
Rear wheel axle nut M24 2 350 Nm (35 m·kgf, 253 ft·lbf) Stake.
Steering knuckle nut M12 4 30 Nm (3.0 m·kgf, 22 ft·lbf)
Front shock absorber assembly nut M10 4 55 Nm (5.5 m·kgf, 40 ft·lbf)
Front arm nut M10 8 55 Nm (5.5 m·kgf, 40 ft·lbf) LS
Front arm protector bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)

Rear arm nut M10 8 55 Nm (5.5 m·kgf, 40 ft·lbf)
Rear knuckle nut M12 4 90 Nm (9.0 m·kgf, 65 ft·lbf)
Rear knuckle grease nipple M6 4 2.8 Nm (0.28 m·kgf, 2.0 ft·lbf)
Rear constant velocity shaft dust
M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
boot guard bolt
Stabilizer joint nut M10 4 60 Nm (6.0 m·kgf, 43 ft·lbf)
Stabilizer holder bolt M10 4 85 Nm (8.5 m·kgf, 61 ft·lbf)
Rear shock absorber assembly nut M12 4 82 Nm (8.2 m·kgf, 59 ft·lbf)
2-19
TIGHTENING TORQUES
Thread
size
Steering wheel nut M12 1 35 Nm (3.5 m·kgf, 25 ft·lbf)
Steering assembly bolt M10 4 See TIP.
Tie-rod M28 2 55 Nm (5.5 m·kgf, 40 ft·lbf)
Steering joint bolt M8 2 33 Nm (3.3 m·kgf, 24 ft·lbf)
Rack guide bolt — 1 3.9 Nm (0.39 m·kgf, 2.8 ft·lbf)
Tie-rod end locknut M12 2 40 Nm (4.0 m·kgf, 29 ft·lbf)
Steering knuckle and tie-rod end nut M12 2 39 Nm (3.9 m·kgf, 28 ft·lbf)
Steering column bolt (except for EPS
M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
models)
EPS unit bolt (for EPS models) M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
EPS unit and bracket bolt (for EPS
M8 4 16 Nm (1.6 m·kgf, 12 ft·lbf)
models)
Pedal assembly bolt M8 3 16 Nm (1.6 m·kgf, 12 ft·lbf)
Brake pedal rod locknut M8 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
Brake master cylinder bolt M8 2 16 Nm (1.6 m·kgf, 12 ft·lbf)
Brake master cylinder reservoir
M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
clamp screw
Brake master cylinder reservoir cap — 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Front brake hose joint bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Front brake hose holder bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear brake hose joint bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear brake hose holder bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front brake hose union bolt M10 2 27 Nm (2.7 m·kgf, 20 ft·lbf)
Rear brake hose union bolt M10 2 27 Nm (2.7 m·kgf, 20 ft·lbf)
Brake caliper bleed screw M8 4 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Front brake caliper bolt M10 4 48 Nm (4.8 m·kgf, 35 ft·lbf)
Rear brake caliper bolt M10 4 48 Nm (4.8 m·kgf, 35 ft·lbf)
Front brake pad bolt M10 4 17 Nm (1.7 m·kgf, 12 ft·lbf)
Rear brake pad bolt M10 4 17 Nm (1.7 m·kgf, 12 ft·lbf)
Front brake caliper retaining pin nut M8 2 22 Nm (2.2 m·kgf, 16 ft·lbf) LT
Rear brake caliper retaining pin nut M8 2 22 Nm (2.2 m·kgf, 16 ft·lbf) LT
Front brake caliper guide pin M8 2 17 Nm (1.7 m·kgf, 12 ft·lbf)

Rear brake caliper guide pin M8 2 17 Nm (1.7 m·kgf, 12 ft·lbf)
Brake pipe flare nut M10 4 19 Nm (1.9 m·kgf, 14 ft·lbf)
Brake disc bolt M8 16 30 Nm (3.0 m·kgf, 22 ft·lbf) LT
Front brake disc guard bolt M6 6 9 Nm (0.9 m·kgf, 6.5 ft·lbf)

Rear brake disc guard bolt M6 4 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Rear brake disc cleaning plate bolt M6 4 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Parking brake lever bolt M6 2 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Parking brake arm bolt M8 1 28 Nm (2.8 m·kgf, 20 ft·lbf) LT
Parking brake plate guide pin — 4 28 Nm (2.8 m·kgf, 20 ft·lbf) LT
Parking brake cable locknut M6 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
2-20
TIGHTENING TORQUES
Thread
size
Parking brake cable adjusting lock-
M6 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
nut
Differential assembly nut M12 1 105 Nm (10.5 m·kgf, 76 ft·lbf)
Differential assembly bolt M10 2 60 Nm (6.0 m·kgf, 43 ft·lbf)
Differential assembly nut M10 1 60 Nm (6.0 m·kgf, 43 ft·lbf)
Differential gear oil filler bolt M14 1 23 Nm (2.3 m·kgf, 17 ft·lbf)
Differential gear oil drain bolt M10 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Differential motor bolt M6 3 11 Nm (1.1 m·kgf, 8.0 ft·lbf)
Front drive shaft yoke nut M14 1 62 Nm (6.2 m·kgf, 45 ft·lbf)
Differential case bolt M8 5 24 Nm (2.4 m·kgf, 17 ft·lbf)
Support bearing bracket bolt M8 2 18 Nm (1.8 m·kgf, 13 ft·lbf)
Front drive shaft universal joint yoke
M16 1 150 Nm (15 m·kgf, 108 ft·lbf) LT
nut
Final drive assembly nut (upper side) M12 2 105 Nm (10.5 m·kgf, 76 ft·lbf)
Final drive assembly bracket bolt
M8 4 33 Nm (3.3 m·kgf, 24 ft·lbf)
(upper side)
Final drive assembly nut (lower side) M12 1 105 Nm (10.5 m·kgf, 76 ft·lbf)
M8 2 33 Nm (3.3 m·kgf, 24 ft·lbf)
(lower side)
Final gear oil filler bolt M10 1 23 Nm (2.3 m·kgf, 17 ft·lbf)
Final gear oil drain bolt M10 1 23 Nm (2.3 m·kgf, 17 ft·lbf)
Final drive case cover bolt M8 10 28 Nm (2.8 m·kgf, 20 ft·lbf)
Ring gear bearing housing bolt M10 8 52 Nm (5.2 m·kgf, 38 ft·lbf)
Final drive pinion gear bearing hous-
M8 4 28 Nm (2.8 m·kgf, 20 ft·lbf) LT
ing bolt
Ring gear stopper nut M8 1 16 Nm (1.6 m·kgf, 12 ft·lbf) LT
Rear drive shaft coupling gear nut

M14 1 97 Nm (9.7 m·kgf, 70 ft·lbf) LT
(final drive assembly side)
Main switch nut — 1 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Meter assembly nut M5 3 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Starter relay lead bolt M6 2 3.6 Nm (0.36 m·kgf, 2.6 ft·lbf)
ECU nut M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Lean angle sensor bolt M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Positive battery lead nut M8 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Negative battery lead nut M8 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
EPS control unit bolt (for EPS mod-
M6 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
els)
Intake air temperature sensor screw M5 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Ignition coil bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rectifier/regulator bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Parking brake buzzer bolt M5 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Tail/brake light nut M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
2-21
TIGHTENING TORQUES
Thread
size
Horn switch lead nut (except for
— 2 2.3 Nm (0.23 m·kgf, 1.7 ft·lbf)
CDN)
Horn bolt (except for CDN) M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
TIP
Enclosure bolt and nut
Tighten the enclosure bolts and nuts to specification in the proper tightening sequence.
Enclosure tightening sequence:

4
3
1
6 2
7
5
TIP
Steering assembly bolt
Tighten the steering assembly bolts to 48 Nm (4.8 m·kgf, 35 ft·lbf) in the proper tightening sequence.
Steering assembly tightening sequence:

FWD
4 2
1 3
TIP
Fuel pump nut
Tighten the fuel pump nuts to 7 Nm (0.7 m·kgf, 5.1 ft·lbf) in the proper tightening sequence.
2-22
TIGHTENING TORQUES
Fuel pump tightening sequence:

2 4
5 6
3 1
TIP
Final drive assembly bolt and nut
Tighten the final drive assembly bolts and nuts to specification in the proper tightening sequence.
Final drive assembly tightening sequence:
FWD
89
1 3
4 5
2 17 3
6
2-23
LUBRICATION AND SEALING POINTS
EBS20019
LUBRICATION AND SEALING POINTS

EBS30021
ENGINE
Lubrication point Lubricant/Sealant
Oil seal lips LS
Bearings E
O-rings LS or E
Cylinder head bolt threads and washers E
Crankshaft seals E
Piston pin E
Cylinder inner surface, piston, piston rings and ring grooves E
Valve stems and stem ends (intake and exhaust) E
Valve stem seals (intake and exhaust) E
Valve lifter surfaces E
Camshaft lobes E
Oil pump rotors (inner and outer) E
Oil pump shaft E
Oil filter cartridge union bolt E
Dipstick mating surface E
Starter idler gear inner surface E
Starter idler gear shafts E
Starter wheel gear/Starter clutch E
Clutch housing shaft end LS
Clutch carrier assembly E
One-way clutch bearing E
Reverse idle gear shaft E
Reverse idle gear E
Secondary shaft E
Middle driven pinion gear inner surface M
Middle driven shaft splines M
Shift drum E
Shift forks and shift fork guide bar E
Shift fork and transmission gear contact surface M
Shift drum stopper ball E
Shift lever 1 and shift lever 2 E
Transmission gears E
Transmission washer and bearing LS
Transmission collars M
Yamaha bond No.1215

Crankcase mating surface (Three Bond
No.1215®)
2-24
LUBRICATION SYSTEM CHART AND DIAGRAMS
EBS20020

EBS30022
ENGINE OIL LUBRICATION CHART
11 10
7
5 6
13 12 9 8
4
3
1 2
2-25
1. Oil pan
2. Oil strainer
3. Oil pump
4. Relief valve
5. Oil cooler
6. Oil bypass valve
7. Oil filter cartridge
8. Drive axle
9. Reverse idle gear shaft
10. Oil pipe (crankcase)
11. Oil hose (crankcase to cylinder)
12. Crankshaft
13. Cylinder head
2-26
EBS30023
LUBRICATION DIAGRAMS
5 4
7 8
2-27
1. Oil hose (crankcase to cylinder)

2. Oil pipe (crankcase)
3. Oil filter cartridge
4. Oil strainer
5. Oil pump
6. Oil pipe (AC magneto cover)
7. Reverse idle gear shaft
8. Drive axle
9. Relief valve
2-28
5 4 3
2-29
1. Camshaft
2. Crankshaft
3. Oil strainer
4. Oil pump
5. Oil pump driven sprocket
2-30
1 2
6 3
5
8
2-31
1. Oil cooler outlet hose

2. Oil cooler inlet hose
3. Oil cooler inlet pipe
4. Oil outlet hose
5. Oil inlet hose
6. Oil cooler outlet pipe
7. Oil outlet pipe
8. Oil inlet pipe
2-32
COOLING SYSTEM DIAGRAMS
EBS20021
1 2 3
6 5
4
1 6 2 5
2-33
1. Radiator
2. Radiator outlet hose
3. Radiator outlet pipe
4. Radiator inlet pipe
5. Radiator inlet hose
6. Radiator cap
2-34
1 2
4 3
2-35
1. Radiator outlet pipe

2. Water pump inlet hose
3. Thermostat outlet hose
4. Radiator inlet pipe
2-36
4 3 2
2-37

3. Water pump
4. Water pump outlet pipe
5. Water pump outlet hose
6. Water jacket joint
2-38
CABLE ROUTING
EBS20022
CABLE ROUTING
Frame front (left view)
1 B 4
6
7
4 C
4
3
A 3
2
9
1
D
11
5 E
10
F 3
G H 12 9
3 F
2
13
1
5
2-39
CABLE ROUTING
1. Horn lead (except for CDN)

2. Headlight lead (left)
3. Throttle cable
4. Brake light switch lead
6. Wire harness
7. EPS torque sensor lead (for EPS models)
8. EPS motor lead (for EPS models)
9. Radiator fan motor breather hose
10. Radiator fan motor lead
11. Coolant reservoir hose
12. Differential assembly breather hose
13. Coolant reservoir breather hose
A. Fasten the left headlight lead to the frame with the
plastic band.
B. Fasten the right headlight lead and horn lead
(except for CDN) with the holder on the electrical
components tray.
C. Fasten the throttle cable and brake light switch
lead with the holder.
D. Fasten the radiator fan motor lead with the holder
on the radiator fan motor cover.
E. Fasten the coolant reservoir hose with the holder
on the radiator fan cover.
F. Fasten the throttle cable to the radiator inlet hose
with the plastic band. Be sure to route the throttle
cable to the outside of the radiator inlet hose.
G. Route the right headlight lead and horn lead
(except for CDN) through the slot in the electrical
components tray, and then fasten the leads with
the holder on the tray.
H. Route the differential assembly breather hose,
coolant reservoir breather hose, and radiator fan
motor breather hose through the hole in the
electrical components tray. Make sure that the end
of each breather hose protrudes from the electrical
components tray.
2-40
CABLE ROUTING
Frame center (left view)
A
8
9
6 3
B 10
4 5
1
2 3
2-41
CABLE ROUTING
1. Parking brake switch lead

2. Parking brake cable
3. Throttle cable
4. Seat belt switch lead
6. Wire harness
7. Reverse switch lead
8. Gear position switch lead
9. Coolant temperature sensor lead
10. Spark plug lead
A. Fasten the wire harness with the plastic band.
B. Fasten the ignition coil lead and left tail/brake light
2-42
CABLE ROUTING
Frame front (right view)
A B 1
3
C
D H F 4
12
5
11
11
8 9
10
I
6
12
D
E
J
6
9 8 7
G
2
2-43
CABLE ROUTING
1. Radiator fan motor breather hose

2. Differential assembly breather hose
3. Coolant reservoir breather hose
4. Headlight lead (right)
7. Differential motor lead
8. Coolant reservoir hose
9. Wire harness
10. Frame ground lead
11. Starter motor lead
12. Negative battery lead
A. Route the wire harness, starter motor lead,
negative battery lead, and horn lead (except for
CDN) into the electrical components tray.
B. Make sure that there is no slack in the coolant
reservoir breather hose in the area shown in the
illustration.
C. Fasten the right headlight lead and horn lead
(except for CDN) with the plastic band.
D. Fasten the coolant reservoir breather hose to the
radiator outlet hose with the holder at the location
shown in the illustration.
E. Fasten the wire harness, starter motor lead, and
negative battery lead with the plastic band.
F. Fasten the wire harness, starter motor lead, and
Position the plastic band at the section of the wire
harness where the leads branch off from the
harness.
G. Fasten the differential assembly breather hose with
the holder on the radiator fan motor cover.
H. Fasten the radiator outlet hose and radiator fan
motor lead with the plastic band.
I. Fasten the wire harness, starter motor lead, and
J. Fasten the differential motor lead with the holder.
Insert the projection on the holder into the hole in
the frame.
2-44
CABLE ROUTING
Frame center (right view)
A 1 B C 2
B 6 E 5 4 D A 3
2-45
CABLE ROUTING
1. Wire harness
4. AC magneto lead
6. Final drive assembly breather hose
7. Fuel injector lead
8. TPS (throttle position sensor) lead
9. Intake air pressure sensor lead
A. Fasten the wire harness with the holder.
B. Fasten the final drive assembly breather hose with
the holder.
C. Fasten the wire harness with the plastic band.
D. Fasten the water pump inlet hose and AC magneto
E. Fasten the negative battery lead and starter motor
2-46
CABLE ROUTING
Electrical components tray (top view)
2 A B 3 4 5 6 7 8
1 7
8
24 17
23 23
22
21
20 1
19 9
9
18
10
17
16 17
11
12
D
15
C
13
14
14 15
13
E
2-47
CABLE ROUTING
1. Wire harness
3. Load control relay
4. Differential motor relay 2
5. Fuel injection system relay
7. Radiator fan motor relay
8. Headlight relay
9. Main fuse lead
10. Fuel injection system fuse
11. Battery
12. EPS control unit (for EPS models)
15. EPS torque sensor lead (for EPS models)
16. Lean angle sensor lead
17. Negative battery lead
18. Starter relay lead
19. Positive battery lead
20. EPS fuse (for EPS models)
21. ECU lead
22. Main fuse
24. Fuse box
A. Fasten the right headlight lead with the holder on
the electrical components tray.
B. Fasten the wire harness and main fuse lead with
the plastic band, making sure to align the band
with the white tape on the harness.
C. Fasten the left headlight lead, EPS motor lead (for
EPS models), and EPS torque sensor lead (for
EPS models) with the holder on the electrical
components tray.
D. Place the slack in the leads in the electrical
components tray.
E. Connect the EPS motor coupler and EPS torque
sensor coupler, and then insert the projection on
each coupler into the hole in the electrical
components tray. (For EPS models)
2-48
CABLE ROUTING
Frame front (top view)
B C 4 5 6 7
3
2
1
16
15
D
G F 8
14 13
E 10 9
B 12 11
2-49
CABLE ROUTING

4. Auxiliary DC jack lead
5. Meter assembly lead
6. Indicator light assembly lead
8. Throttle cable
9. Horn switch lead (except for CDN)
10. Main switch lead
11. On-Command four-wheel-drive switch lead
12. Light switch lead
13. Brake light switch lead
A. To the electrical components tray
B. Fasten the wire harness with the plastic band.
Position the plastic band at the section of the wire
harness where the leads branch off from the
harness.
C. Fasten the wire harness and horn lead (except for
CDN) at the white mark on the harness with the
plastic band.
D. Fasten the throttle cable with the plastic band.
E. Fasten the wire harness and EPS motor lead (for
EPS models) with the plastic band. Position the
plastic band at the section of the wire harness
before the leads branch off from the harness.
F. Fasten the EPS torque sensor lead (for EPS
models), EPS motor lead (for EPS models), and
brake light switch lead with the holder.
G. Route the EPS torque sensor lead and EPS motor
lead through the hole in the electrical components
tray, and then connect the couplers to the EPS
control unit. (For EPS models)
2-50
CABLE ROUTING
Frame center (top view) 1
1 2 3
FWD
11 10 9 C 8 B 7 A
2-51
CABLE ROUTING
1. Fuel hose
2. Fuel injector lead
3. Wire harness
4. Coolant temperature sensor lead
5. Spark plug lead
6. Air induction system solenoid lead
7. Ignition coil lead
11. Throttle cable
B. Fasten the parking brake cable with the holder.
C. Fasten the thermostat outlet hose and throttle
cable with the plastic band at the location shown in
the illustration.
2-52
CABLE ROUTING
Frame center (top view) 2
B
C
FWD
4 3 D 2 1 D
6 E
F
2
D
5
3
2-53
CABLE ROUTING

2. Wire harness
3. Ground lead
5. Fuel pump lead
7. Parking brake buzzer lead
A. Fasten the parking brake switch lead with the
plastic band.
B. Fasten the parking brake switch lead with the
holder.
C. Fasten the parking brake switch lead and parking
brake buzzer lead with the holder.
D. Fasten the wire harness, ground lead, and starter
motor lead with the plastic band.
E. Fasten the wire harness with the holder.
F. Fasten the fuel pump lead with the holder.
G. Fasten the ground lead and starter motor lead with
the plastic band.
2-54
CABLE ROUTING
Fuel tank (top view)
FWD
1 2
1 A
C
D 3
2 B
D
3
4
2-55
CABLE ROUTING
1. Fuel hose
2. Fuel pump lead
3. Fuel tank breather hose (fuel tank breather hose
joint to atmosphere)
4. Fuel tank breather hose (fuel tank to fuel tank
breather hose joint)
A. Fasten the grommet on the fuel hose with the
holder.
B. Fasten the fuel pump lead with the holder.
C. Insert the end of the fuel tank breather hose (fuel
tank breather hose joint to atmosphere) into the
hole in the frame.
D. 0–3.0 mm (0–0.12 in)
2-56
CABLE ROUTING
Front brake caliper (left view)
B
A
3
2
2-57
CABLE ROUTING
1. Front brake pipe

2. Rear brake pipe
3. Front brake hose
A. Fasten the grommet on the front brake hose with
the holder.
B. Fasten the front brake hose with the holder.
2-58
CABLE ROUTING
Rear brake caliper (left view)
2 A
D
2
C
2
1
A
A B
C
2-59
CABLE ROUTING
1. Rear brake pipe

2. Rear brake hose
A. Fasten the rear brake hose with the holder.
B. Fasten the grommet on the rear brake hose with
the holder.
C. Fasten the rear brake pipe with the holder.
D. Face the paint mark forward.
2-60
CABLE ROUTING
Front brake caliper (top view)
1 A
2-61
CABLE ROUTING
1. Front brake pipe

2. Rear brake pipe
3. Front brake hose
A. Face the paint mark upward.
B. Fasten the grommet on the front brake hose with
the holder.
C. Route the front brake hose under the front upper
arm.
D. Fasten the front brake hose with the holder.
2-62
CABLE ROUTING
Brake pipe (top and left view)
A 1
A 1 A
FWD
FWD
2-63
CABLE ROUTING
1. Rear brake pipe

A. Fasten the rear brake pipe with the holder.
2-64
CABLE ROUTING
Rear brake caliper (top view)
A 1 A
2
C
C
B
2-65
CABLE ROUTING
1. Rear brake pipe

2. Rear brake hose
A. Fasten the rear brake pipe with the holder.
B. Fasten the rear brake hose with the holder.
C. Fasten the grommet on the rear brake hose with
the holder.
2-66
CABLE ROUTING
Parking brake (left view)
2-67
CABLE ROUTING

A. Fit the parking brake cable into the holder on the
final drive case.
B. Fit the parking brake cable into the slit in the
parking brake lever.
2-68
CABLE ROUTING
Final drive assembly (left and right view)
1 4
2
B B
1 A
D 1
4
C
4 3 E
2-69
CABLE ROUTING
1. Wire harness
2. Tail/brake light lead (left)
4. Tail/brake light lead (right)
B. Place the slack in the tail/brake light lead in the
area shown in the illustration.
C. Fasten the tail/brake light lead with the plastic
band.
D. Fasten the tail/brake light lead (right) with the
holder.
E. Fasten the final drive assembly breather hose with
the holder.
2-70
CABLE ROUTING
2-71
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE ............................................................................3-1

INTRODUCTION .......................................................................................3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM ...................................................................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART .......................3-1
CHECKING THE FUEL LINE .................................................................... 3-3
ADJUSTING THE VALVE CLEARANCE .................................................. 3-3
CHECKING THE SPARK PLUG ............................................................... 3-6
CHECKING THE BREATHER HOSE........................................................3-6
CHECKING THE EXHAUST SYSTEM......................................................3-7
ADJUSTING THE EXHAUST GAS VOLUME ...........................................3-7
CLEANING THE SPARK ARRESTER ......................................................3-7
CHECKING THE AIR INDUCTION SYSTEM............................................3-8
CHECKING THE COOLING SYSTEM ......................................................3-8
CHECKING THE COOLANT LEVEL.........................................................3-8
3
CHANGING THE COOLANT..................................................................... 3-9
CLEANING THE AIR FILTER ELEMENT................................................ 3-11
CHECKING THE ENGINE OIL LEVEL....................................................3-13
CHANGING THE ENGINE OIL ...............................................................3-14
MEASURING THE ENGINE OIL PRESSURE ........................................ 3-15
CHECKING THE FINAL GEAR OIL LEVEL ............................................3-16
CHANGING THE FINAL GEAR OIL........................................................ 3-16
CHECKING THE DIFFERENTIAL GEAR OIL LEVEL............................. 3-17
CHANGING THE DIFFERENTIAL GEAR OIL ........................................ 3-17
CHECKING THE FRONT BRAKE PADS ................................................ 3-18
CHECKING THE REAR BRAKE PADS .................................................. 3-18
CHECKING THE BRAKE FLUID LEVEL................................................. 3-18
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-19
CHECKING THE BRAKE HOSES AND BRAKE PIPES ......................... 3-20
ADJUSTING THE BRAKE PEDAL .......................................................... 3-21
LUBRICATING THE BRAKE PEDAL AND ACCELERATOR PEDAL..... 3-21
ADJUSTING THE PARKING BRAKE......................................................3-21
ADJUSTING THE ACCELERATOR PEDAL FREE PLAY ......................3-22
CHECKING THE V-BELT........................................................................3-23
REPLACING THE V-BELT ...................................................................... 3-24
CHECKING THE WHEELS ..................................................................... 3-24
CHECKING THE TIRES..........................................................................3-25
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES ............. 3-26
ADJUSTING THE FRONT SHOCK ABSORBER ASSEMBLIES ............3-26
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................ 3-29
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY.................. 3-29
CHECKING THE STEERING SYSTEM .................................................. 3-31
ADJUSTING THE TOE-IN....................................................................... 3-32
CHECKING THE STABILIZER BUSHING .............................................. 3-33
LUBRICATING THE REAR KNUCKLE PIVOTS ..................................... 3-33
LUBRICATING THE DRIVE SHAFT UNIVERSAL JOINTS ....................3-33
CHECKING THE ENGINE MOUNT ........................................................ 3-33
CHECKING THE CONSTANT VELOCITY SHAFT ASSEMBLY DUST
BOOTS ................................................................................................... 3-33
CHECKING THE FASTENER .................................................................3-34
PERIODIC MAINTENANCE
EBS20023
EBS30024
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EBS30025
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

• For vehicles not equipped with an odometer or hour meter, follow the month maintenance intervals.
• For vehicles equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance
intervals. However, keep in mind that if the vehicle isn’t used for a long period of time, the month main-
tenance intervals should be followed.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
INITIAL EVERY
month 1 3 6 6 12
CHECK OR MAINTENANCE Whichever
NO. ITEM JOB comes first km (mi) 320 1200 2400 2400 4800
(200) (750) (1500) (1500) (3000)
hours 20 75 150 150 300
• Check fuel hose for cracks or damage.

1 * Fuel line • Replace if necessary. √ √ √
2 * Valves • Check valve clearance. √ √ √ √

• Adjust if necessary.
• Check condition.
3 Spark plug • Adjust gap and clean. √ √ √ √ √
• Replace if necessary.
Crankcase breather • Check breather hose for cracks or damage.
4 * √ √ √
system • Replace if necessary.
• Check for leakage.
5 * Exhaust system • Tighten if necessary. √ √ √
• Replace gasket(s) if necessary.
6 Spark arrester • Clean. √ √ √
• Check the air cut-off valve, reed valve, and hose for
7 * Air induction system damage. √ √ √ √ √
• Replace any damaged parts if necessary.
EBS30026
GENERAL MAINTENANCE AND LUBRICATION CHART

INITIAL EVERY
month 1 3 6 6 12
NO. ITEM JOB comes first km (mi) 320 1200 2400 2400 4800
(200) (750) (1500) (1500) (3000)
hours 20 75 150 150 300
• Check coolant leakage.

• Repair if necessary. √ √ √ √ √
1 * Cooling system
• Replace coolant. Every 2 years
• Clean. Every 20–40 hours
2 Air filter element
• Replace if necessary. (more often in wet or dusty areas.)
3 Engine oil • Replace (warm engine before draining). √ √ √ √
Engine oil filter car-
4 • Replace. √ √ √
tridge
3-1
INITIAL EVERY
month 1 3 6 6 12
NO. ITEM
JOB comes first km (mi) 320 1200 2400 2400 4800
(200) (750) (1500) (1500) (3000)
hours 20 75 150 150 300
5 Final gear oil/Differ- • Check oil level/oil leakage. √ √

ential gear oil • Replace.
• Check operation/brake pad wear/fluid leakage.
6 * Front brake • Correct if necessary. Replace pads if worn to the lim- √ √ √ √ √
it.
• Check operation/brake pad wear/fluid leakage.
7 * Rear brake • Correct if necessary. Replace pads if worn to the lim- √ √ √ √ √
it.
8 * Parking brake • Check operation and adjust if necessary. √ √ √ √ √
9 * Brake fluid • Replace. Every 2 years
10 * Accelerator pedal • Check operation and free play. √ √ √ √ √
• Check operation.
11 * V-belt √ √ √
• Check for wear, cracks, or damage.
• Check damage/runout.
12 * Wheels • Repair if necessary. √ √ √ √
13 * Wheel bearings • Check bearing assemblies for looseness/damage. √ √ √ √

• Replace if damaged.
Front and rear sus- • Check operation and for leakage.
14 * √ √
pension • Correct if necessary.
• Check operation and for looseness/Replace if dam-
15 * Steering system aged. √ √ √ √ √
• Check toe-in/Adjust if necessary.
• Check for cracks or other damage, and replace if
16 * Stabilizer bushes necessary. √ √ √
17 * Rear upper and lower • Lubricate with lithium-soap-based grease. √ √ √

knuckle pivots
Drive shaft universal
18 * • Lubricate with lithium-soap-based grease. √ √ √
joint
• Check for cracks or damage.
19 * Engine mount • Check bolt tightness. √ √ √
20 * Front and rear axle • Check for cracks or other damage, and replace if √ √
boots necessary.
Fittings and fasten- • Check all chassis fittings and fasteners.
21 * √ √ √ √ √
ers • Correct if necessary.
TIP
• Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy
or muddy areas, or at full throttle.
• Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake calipers, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-2
EBS30027
• Cylinder head cover
CHECKING THE FUEL LINE
Refer to “CAMSHAFTS” on page 5-10.
1. Remove: ECB01270
• Rear panel (right) NOTICE

Refer to “GENERAL CHASSIS (1)” on page Before removing the spark plug, blow away
4-1. any dirt accumulated in the spark plug well
• Under-seat storage compartment with compressed air to prevent it from falling
Refer to “GENERAL CHASSIS (3)” on page into the cylinder.
4-6.
2. Check: 4. Remove:
• Fuel hose “1” • Crankshaft end accessing screw “1”
Cracks/damage → Replace.
Loose connection → Connect properly.
1
5. Measure:
• Valve clearance
3. Install: Out of specification → Adjust.
• Under-seat storage compartment
Valve clearance (cold)
Refer to “GENERAL CHASSIS (3)” on page
Intake
4-6. 0.10–0.20 mm (0.0039–0.0079 in)
• Rear panel (right) Exhaust
Refer to “GENERAL CHASSIS (1)” on page 0.22–0.32 mm (0.0087–0.0126 in)
4-1.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EBS30028
a. Turn the crankshaft counterclockwise.
ADJUSTING THE VALVE CLEARANCE
b. Position the holes “a” in the intake camshaft
The following procedure applies to all of the
sprocket and exhaust camshaft sprocket
valves.
above the cylinder head mating surface “b”
TIP as shown in the illustration, and align the
• Valve clearance adjustment should be made marks “c”on the sprockets with the cylinder
on a cold engine, at room temperature. head mating surface “b”.
• When the valve clearance is to be measured or
adjusted, the piston must be at top dead center a c c a c
(TDC) on the compression stroke.
c b
1. Remove:
• Frame cross member
4-19.
2. Disconnect:
• Cylinder head breather hose
Refer to “THROTTLE BODY” on page 7-8.
• Spark plug cap c. Measure the valve clearance with a thickness
Refer to “CAMSHAFTS” on page 5-10. gauge “1”.
3. Remove:
• Spark plug
3-3
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
2 1
b. Calculate the difference between the speci-

1 fied valve clearance and the measured valve
clearance.
Example:
Specified valve clearance = 0.10–0.20 mm
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ (0.0039–0.0079 in)
6. Remove: Measured valve clearance = 0.27 mm
• Camshafts (0.0106 in)
Refer to “CAMSHAFTS” on page 5-10. 0.27 mm (0.0106 in)–0.20 mm (0.0079 in) =
7. Adjust: 0.07 mm (0.0028 in)
• Valve clearance c. Check the thickness of the current valve pad,
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
and then calculate the sum of the values ob-
a. Remove the valve lifter “1” and the valve pad tained to determine the required valve pad
“2” with a valve lapper “3”. thickness and the valve pad number.
TIP
Valve lapper • The number “a” marked on the valve pad indi-
90890-04101
cate the valve pad thickness.
Valve lapping tool
YM-A8998 • Refer to the following table for the available
valve pads.
TIP • If there are no available valve pads with the
same thickness as the calculated valve pad
• Cover the timing chain opening with a rag to
thickness, select the next thickest valve pad.
prevent the valve pad from falling into the
crankcase.
• Make a note of the position of each valve lifter a
“1” and valve pad “2” so that they can be in-
177
stalled in the correct place.
Number “a” Thickness

145 1.450 mm (0.05709 in)
150 1.500 mm (0.05906 in)
155 1.550 mm (0.06102 in)
160 1.600 mm (0.06299 in)
162 1.625 mm (0.06398 in)
165 1.650 mm (0.06496 in)
167 1.675 mm (0.06594 in)
3-4
Number “a” Thickness e. Install the exhaust and intake camshafts, tim-
ing chain and camshaft cap.
170 1.700 mm (0.06693 in)
172 1.725 mm (0.06791 in) Camshaft cap bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
175 1.750 mm (0.06890 in)
R.
177 1.775 mm (0.06988 in) TIP
180 1.800 mm (0.07087 in) • Refer to “CAMSHAFTS” on page 5-10.
182 1.825 mm (0.07185 in) • Lubricate the camshaft lobes and camshaft
185 1.850 mm (0.07283 in) journals with engine oil.
• Position the holes “a” in the intake camshaft
187 1.875 mm (0.07382 in)
sprocket and exhaust camshaft sprocket
190 1.900 mm (0.07480 in) above the cylinder head mating surface “b” as
192 1.925 mm (0.07579 in) shown in the illustration, and align the marks
195 1.950 mm (0.07677 in) “c” on the sprockets with the cylinder head mat-
197 1.975 mm (0.07776 in)
ing surface “b”.
• Turn the crankshaft counterclockwise several
200 2.000 mm (0.07874 in) full turns to seat the parts.
202 2.025 mm (0.07972 in)
205 2.050 mm (0.08071 in) a c c a c
207 2.075 mm (0.08169 in)
c b
210 2.100 mm (0.08268 in)
212 2.125 mm (0.08366 in)
215 2.150 mm (0.08465 in)
220 2.200 mm (0.08661 in)
225 2.250 mm (0.08858 in)
230 2.300 mm (0.09055 in)
f. Measure the valve clearance again.
Example: g. If the valve clearance is still out of specifica-
1.775 mm (0.06988 in) + 0.07 mm (0.0028 in) tion, repeat all of the valve clearance adjust-
= 1.845 mm (0.07264 in) ment steps until the specified clearance is
The valve pad number is 185. obtained.
d. Install a new valve pad “1” and the valve lifter ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
“2”.
8. Install:
TIP
• O-ring New
• Lubricate the valve lifter with engine oil. • Crankshaft end accessing screw
• Install the valve lifter and the valve pad in the
correct place. Crankshaft end accessing screw
• The valve lifter must turn smoothly when rotat- 11 Nm (1.1 m·kgf, 8.0 ft·lbf)
T.
R.
ed by hand.
9. Install:
2 • Cylinder head cover gasket New
• Cylinder head cover
• Spark plug
1 TIP
Before installing the spark plug, clean the spark
plug and gasket surface.
3-5
Cylinder head cover bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
Spark plug (new)

11 Nm (1.1 m·kgf, 8.0 ft·lbf)
Spark plug (reused)
Specified angle 30–45°
10.Connect:
• Spark plug cap
Refer to “THROTTLE BODY” on page 7-8.
• Cylinder head breather hose 7. Install:
Refer to “THROTTLE BODY” on page 7-8. • Spark plug
11.Install:
Spark plug (new)
11 Nm (1.1 m·kgf, 8.0 ft·lbf)
T.
R.
Spark plug (reused)
4-19. Specified angle 30–45°
EBS30029
CHECKING THE SPARK PLUG TIP

1. Disconnect: Before installing the spark plug, clean the spark
• Spark plug cap plug and gasket surface.
2. Remove: 8. Connect:
• Spark plug • Spark plug cap
Refer to “CAMSHAFTS” on page 5-10. EBS30030
ECB01270
CHECKING THE BREATHER HOSE
NOTICE 1. Remove:
Before removing the spark plug, blow away • Center storage compartment
any dirt accumulated in the spark plug well Refer to “GENERAL CHASSIS (3)” on page
with compressed air to prevent it from falling 4-6.
into the cylinder. • Rear panel (right)
3. Check: Refer to “GENERAL CHASSIS (1)” on page
• Spark plug type 4-1.
Incorrect → Change. 2. Check:
• Cylinder head breather hose “1”
Manufacturer/model • Throttle body breather hose “2”
NGK/CPR7EA-9 Cracks/damage → Replace.
4. Check: ECB01680
• Electrodes “1” NOTICE

Damage/wear → Replace the spark plug. Make sure the cylinder head breather hose is
• Insulator “2” routed correctly.
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
5. Clean: 2
• Spark plug
(with a spark plug cleaner or wire brush)
6. Measure: 1
• Spark plug gap “a”
(with a wire thickness gauge)
Out of specification → Regap.
Spark plug gap

0.8–0.9 mm (0.031–0.035 in)
3-6
• To adjust the exhaust gas volume, use the CO

adjustment mode of the Yamaha diagnostic
tool. For more information, refer to the opera-
tion manual of the Yamaha diagnostic tool.
1. Connect the Yamaha diagnostic tool to the
coupler. For information about connecting the
1 2 Yamaha diagnostic tool, refer to “YAMAHA
DIAGNOSTIC TOOL” on page 9-39.
Yamaha diagnostic tool

3. Install: 90890-03231
• Rear panel (right)
Refer to “GENERAL CHASSIS (1)” on page EBS30032
4-1. CLEANING THE SPARK ARRESTER

• Center storage compartment 1. Clean:
Refer to “GENERAL CHASSIS (3)” on page • Spark arrester
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
4-6. EWB03080
WARNING
EBS30031
CHECKING THE EXHAUST SYSTEM • Select a well-ventilated area free of com-

1. Check: bustible materials.
• Exhaust pipe “1” • Always let the exhaust system cool before
• Muffler “2” performing this operation.
• Muffler mount “3” • Do not start the engine when removing the
• Springs “4” tailpipe from the muffler.
Cracks/damage → Replace. a. Remove the bolts “1”.
• Gaskets “5” b. Remove the tailpipe “2” by pulling it out of the
Exhaust gas leaks → Replace. muffler and gasket “3”.
2. Check:
• Tightening torque
1
Exhaust pipe nut 2
20 Nm (2.0 m·kgf, 14 ft·lbf)
T.
R.
Muffler bolt
23 Nm (2.3 m·kgf, 17 ft·lbf)
Muffler mount shaft
17 Nm (1.7 m·kgf, 12 ft·lbf)
LOCTITE® 1
5 1 2 3
4
3
4
EBS30574
c. Tap the tailpipe lightly with a soft-face ham-
ADJUSTING THE EXHAUST GAS VOLUME
mer or suitable tool, then use a wire brush to
TIP remove any carbon deposits from the spark
• Be sure to set the CO density level to standard, arrester portion of the tailpipe and the inner
and then adjust the exhaust gas volume. contact surfaces of the muffler.
3-7
d. Install a new gasket, and then insert the tail- 3

pipe into the muffler and align the bolt holes. 6
e. Install the bolts “1” and tighten them. 4
Spark arrester bolt
2
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7
EBS30033
CHECKING THE AIR INDUCTION SYSTEM 5

Refer to “CHECKING THE AIR INDUCTION
SYSTEM” on page 7-17.
EBS30034
CHECKING THE COOLING SYSTEM

1. Remove:
• Rear panels 9
8
4-1.
• Seat frames
4-3.
• Floor boards
Refer to “GENERAL CHASSIS (3)” on page 10
4-6. 14
• Hood 11
13
• Front grill
Refer to “GENERAL CHASSIS (6)” on page 12
4-12.
2. Check:
• Radiator “1”
• Coolant reservoir hose “2”
• Coolant reservoir “3” 3. Install:
• Radiator outlet hose “4” • Front grill
• Radiator inlet hose “5” • Hood
• Radiator outlet pipe “6” Refer to “GENERAL CHASSIS (6)” on page
• Radiator inlet pipe “7” 4-12.
• Thermostat outlet hose “8” • Floor boards
• Thermostat cover “9” Refer to “GENERAL CHASSIS (3)” on page
• Water pump inlet hose “10” 4-6.
• Water pump housing “11” • Seat frames
• Water pump outlet pipe “12” Refer to “GENERAL CHASSIS (2)” on page
• Water pump outlet hose “13” 4-3.
• Water jacket joint “14” • Rear panels
Cracks/damage → Replace. Refer to “GENERAL CHASSIS (1)” on page
Coolant leakage → Replace any damaged 4-1.
hose and pipe EBS30035
Refer to “OIL COOLER” on page 6-1, “RADI- CHECKING THE COOLANT LEVEL
ATOR” on page 6-4, “THERMOSTAT” on 1. Place the vehicle on a level surface.
page 6-8, and “WATER PUMP” on page TIP
6-11. The coolant level must be checked on a cold en-
gine since the level varies with engine tempera-
ture.
3-8
2. Check: • Hood
• Coolant level Refer to “GENERAL CHASSIS (6)” on page
The coolant level should be between the 4-12.
maximum level mark “a” and minimum level 2. Remove:
mark “b”. • Coolant reservoir cap “1”
Below the minimum level mark → Add the 3. Disconnect:
recommended coolant to the proper level. • Coolant reservoir hose “2”
ECB01300
NOTICE
• Adding water instead of coolant lowers the 1
antifreeze content of the coolant. If water is
used instead of coolant check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant. 2
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
4. Drain:
• Coolant
(from the coolant reservoir)
a 5. Connect:
• Coolant reservoir hose
b 6. Remove:
• Radiator cap “1”
EWB02770
WARNING
A hot radiator is under pressure. Therefore,
3. If the coolant is at or below the minimum level do not remove the radiator cap when the en-
mark, remove the reservoir cap “1”, add cool- gine is hot. Scalding hot fluid and steam may
ant or distilled water to the maximum level be blown out, which could cause serious in-
mark “a”, install the reservoir cap. jury. When the engine has cooled, open the
radiator cap as follows:
Coolant reservoir (up to the maxi- Place a thick rag or a towel over the radiator
mum level mark) cap and slowly turn the radiator cap counter-
0.20 L (0.21 US qt, 0.18 Imp.qt) clockwise toward the detent to allow any re-
sidual pressure to escape. When the hissing
sound has stopped, press down on the radi-
ator cap and turn it counterclockwise to re-
1
move.
a
EBS30036
CHANGING THE COOLANT 1

1. Remove:
Refer to “GENERAL CHASSIS (1)” on page 7. Remove:
4-1. • Coolant drain bolt “1”
(along with the copper washer)
3-9
ECB01310
TIP
NOTICE
Place a container under the engine, and then re-
• Adding water instead of coolant dilutes the
move the coolant drain bolt.
antifreeze concentration of the coolant. If
water is used instead of coolant; check,
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with wa-
1 ter.
• Do not mix different types of antifreeze.
8. Drain:
11.Install:
• Coolant
• Radiator cap
(from the engine and radiator)
12.Fill:
9. Install:
• Coolant reservoir
• Coolant drain bolt
(with the recommended coolant to the maxi-
(along with the copper washer New ) mum level mark “a”)
13.Install:
Coolant drain bolt
8 Nm (0.8 m·kgf, 5.8 ft·lbf) • Coolant reservoir cap “1”
T.
R.
10.Fill: 1
• Cooling system
(with the specified amount of the recom- a
mended coolant)
Recommended antifreeze
High-quality ethylene glycol an-
tifreeze containing corrosion in-
hibitors for aluminum engines
Mixing ratio 14.Bleed:
1:1 (antifreeze:water) • Cooling system
Radiator (including all routes) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2.85 L (3.01 US qt, 2.51 Imp.qt) a. Loosen the water pump air bleed bolt “1”,
Coolant reservoir (up to the maxi- without removing it, to allow all of the air to es-
mum level mark)
cape from the air bleed bolt hole.
0.20 L (0.21 US qt, 0.18 Imp.qt)
Handling notes for coolant

Coolant is potentially harmful and should be
handled with special care.
EWB02780
WARNING
• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
tor. 1
• If coolant splashes on your clothes, quickly
wash it away with water and then with soap b. When coolant begins to flow out of the bolt
and water. hole, tighten the water pump air bleed bolt to
• If coolant is swallowed, induce vomiting specification.
and get immediate medical attention.
3-10
2. Remove:
Water pump air bleed bolt • Center storage compartment
8 Nm (0.8 m·kgf, 5.8 ft·lbf) Refer to “GENERAL CHASSIS (3)” on page
T.
R.
4-6.
c. Loosen the thermostat cover air bleed bolt
“2”, without removing it, to allow all of the air TIP
to escape from the air bleed bolt hole. There are check hoses “1” at the bottom of the
air filter case and on the air intake duct. If dust
and/or water collects in these hoses, clean the
2 air filter element, filter frame, and air filter case.
A B
d. When coolant begins to flow out of the bolt

hole, tighten the thermostat cover air bleed
bolt to specification.
A. Air filter check hose
Thermostat cover air bleed bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf) B. Air intake duct check hose
T.
R.
3. Remove:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Air filter case cover “1”
15.Start the engine, warm it up for ten minutes,
and then rev the engine five times.
16.Pour the recommended coolant into the radi-
ator until it is full. 1
17.Stop the engine and allow it to cool. If the
coolant level has dropped after the engine
has cooled, add sufficient coolant until it
reaches the top of the radiator, and then in-
stall the radiator cap.
18.Check:
• Coolant level 4. Remove:
Refer to “CHECKING THE COOLANT LEV- • Air filter element assembly “1”
EL” on page 3-9.
19.Start the engine, and then check for coolant
leakage.
20.Install:
• Hood 1
4-12.
4-1.
EBS30037
5. Disassemble:
CLEANING THE AIR FILTER ELEMENT • Air filter element holder “1”
1. Check: • Air filter element “2”
• Check hoses “1” • Air filter element frame “3”
3-11
ECB01800
NOTICE
The engine should never be run without the
air filter; excessive piston and/or cylinder
wear may result.
3
2
1
c. Properly dispose of the used solvent.
d. Carefully wash the air filter element in soap
water.
6. Check:
• Air filter element
• Air filter element frame
• Air filter element holder
Damage → Replace.
7. Clean:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Carefully wash the air filter element in sol- e. Thoroughly rinse the air filter element with
vent. water, and then let it dry.
EWB02760 ECB01290
WARNING NOTICE
Never use low flash point solvents, such as Do not twist the air filter element when
gasoline, to clean the air filter element. Such squeezing it.
solvents may cause a fire or an explosion. f. Pour the recommended oil into a storage bag
large enough for the air filter element.
Air filter oil grade

Foam air-filter oil
g. Place the air filter element into the storage

bag and repeatedly squeeze the element un-
til the air filter element is saturated with oil.
TIP
The air filter element should be wet but not drip-
b. After cleaning, squeeze the air filter element ping.
to remove the excess solvent.
ECB01290
NOTICE
Do not twist the air filter element when
squeezing it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-12
8. Assemble:
• Air filter element frame
• Air filter element holder
9. Install:
• Air filter element assembly
10.Install: c
• Air filter case cover
11.Install:
• Center storage compartment
4-6. Recommended brand
YAMALUBE
EBS30038
Type
CHECKING THE ENGINE OIL LEVEL
SAE 0W-30, 10W-30, 10W-40,
1. Place the vehicle on a level surface. 15W-40, 20W-40 or 20W-50
2. Check the engine oil level on a cold engine. Recommended engine oil grade
TIP API service SG type or higher,
If the engine was started before the oil level was JASO standard MA
checked, be sure to warm up the engine suffi-
ciently, and then wait at least 10 minutes until 0 10 30 50 70 90 110 130 ˚F
the oil settles for an accurate reading.
SAE 0W-30
3. Remove: SAE 10W-30
• Passenger seat cushion SAE 10W-40
Refer to “GENERAL CHASSIS (2)” on page SAE 15W-40
4-3. SAE 20W-40
• Passenger seat belt buckle rubber cover SAE 20W-50
4-6. –20 –10 0 10 20 30 40 50 ˚C
4. Check: ECB01820
• Engine oil level NOTICE

The engine oil level should be between the • Engine oil also lubricates the clutch and the
minimum level mark “a” and maximum level wrong oil types or additives could cause
mark “b”. clutch slippage. Therefore, do not add any
Below the minimum level mark → Add the chemical additives or use engine oils with a
recommended engine oil to the proper level. grade of “CD” or higher and do not use oils
TIP labeled “ENERGY CONSERVING II”.
With the arrow mark “c” pointing in the direction • Do not allow foreign materials to enter the
shown, insert the dipstick completely into the oil crankcase.
filler hole, and then remove it again to check the 5. Check the engine oil level again.
oil level. ECB01830
NOTICE
Be sure the engine oil is at the correct level,
otherwise engine damage may result.
6. Install:
• Passenger seat belt buckle rubber cover
4-6.
b • Passenger seat cushion
a Refer to “GENERAL CHASSIS (2)” on page
4-3.
3-13
EBS30039
CHANGING THE ENGINE OIL

1. Start the engine, warm it up for several min-
utes, and then turn it off. 2 1
2. Remove:
• Passenger seat cushion
4-3.
• Passenger seat belt buckle rubber cover
4-6.
b. Lubricate the O-ring “3” of a new oil filter car-
3. Place a container under the engine oil drain
tridge with a thin coat of engine oil.
bolt. ECB01280
4. Remove: NOTICE
• Dipstick “1” Make sure the O-ring “3” is positioned cor-
• Engine oil drain bolt “2” rectly in the groove of the oil filter cartridge.
(along with the gasket)
1
c. Tighten the new oil filter cartridge to specifi-

cation with the oil filter wrench.
Oil filter cartridge

15 Nm (1.5 m·kgf, 11 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Install:
• Engine oil drain bolt
2
(along with the gasket New )
5. Drain: Engine oil drain bolt
• Engine oil 22 Nm (2.2 m·kgf, 16 ft·lbf)
T.
R.
(completely from the crankcase)

6. If the oil filter cartridge is also to be replaced, 8. Fill:
perform the following procedure. • Crankcase
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ (with the specified amount of the recom-
a. Remove the oil filter cartridge “1” with the oil mended engine oil)
filter wrench “2”.
Engine oil quantity
Oil filter wrench Quantity (disassembled)
90890-01469 3.10 L (3.28 US qt, 2.73 Imp.qt)
Oil filter wrench Without oil filter cartridge re-
YM-01469 placement
2.20 L (2.33 US qt, 1.94 Imp.qt)
With oil filter cartridge replace-
ment
2.30 L (2.43 US qt, 2.02 Imp.qt)
3-14
EWB03620
WARNING
The engine, muffler and engine oil are ex-
tremely hot.
9. Install:
• Dipstick
10.Start the engine, warm it up for several min-
utes, and then turn it off.
11.Check: 5. Install:
• Engine • Oil pressure gauge “1”
(for engine oil leaks) • Adapter “2”
12.Check:
• Engine oil level Pressure gauge
Refer to “CHECKING THE ENGINE OIL 90890-03153
LEVEL” on page 3-13. Pressure gauge
13.Install: YU-03153
• Passenger seat belt buckle rubber cover Oil pressure adapter H
Refer to “GENERAL CHASSIS (3)” on page 90890-03139
4-6.
• Passenger seat cushion
4-3.
2
EBS30458
MEASURING THE ENGINE OIL PRESSURE

1. Check: 1
• Engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-13.
2. Start the engine, warm it up for several min- 6. Measure:
utes, and then turn it off. • Engine oil pressure
ECB02510
(at the following conditions)
NOTICE
When the engine is cold, the engine oil will Oil pressure (hot)
have a higher viscosity, causing the engine 50.0 kPa/1600 r/min
oil pressure to increase. Therefore, be sure (0.50kgf/cm²/1600 r/min, 7.3
to measure the engine oil pressure after psi/1600 r/min)
warming up the engine.
Out of specification → Check.
3. Remove:
• Center cover Engine oil pressure Possible causes
• Under-seat storage compartment • Faulty oil pump
Refer to “GENERAL CHASSIS (3)” on page • Clogged oil strainer
4-6. Below specification • Leaking oil passage
• Broken or damaged
4. Remove: oil seal
• Main gallery bolt “1”
• Leaking oil passage
Above specification • Faulty oil filter
• Oil viscosity too high
3-15
7. Install: EBS30041
CHANGING THE FINAL GEAR OIL

• Main gallery bolt
1. Place the vehicle on a level surface.
• Gasket New 2. Place a container under the final drive case.
3. Remove:
Main gallery bolt
35 Nm (3.5 m·kgf, 25 ft·lbf) • Final gear oil filler bolt “1”
T.

R.
LOCTITE®
• Final gear oil drain bolt “2”
8. Install: (along with the gasket)
• Under-seat storage compartment Completely drain the final drive case of its oil.
• Center cover 1
4-6.
EBS30040
CHECKING THE FINAL GEAR OIL LEVEL

2. Remove:
• Final gear oil filler bolt “1”
(along with the gasket) 2
3. Check:
4. Install:
• Final gear oil level
• Final gear oil drain bolt
The final gear oil level should be up to the
brim “2” of the hole. (along with the gasket New )
Below the brim → Add the recommended fi-
Final gear oil drain bolt
nal gear oil to the proper level.
23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
Type
SAE 80 API GL-4 Hypoid gear 5. Fill:
oil • Final drive case
(with the specified amount of the recom-
ECB01690 mended final gear oil)
NOTICE
Take care not to allow foreign material to en- Type
ter the final drive case. SAE 80 API GL-4 Hypoid gear
oil
Quantity (disassembled)
0.72 L (0.76 US qt, 0.63 Imp.qt)
Quantity
0.64 L (0.68 US qt, 0.56 Imp.qt)
ECB01690
1 NOTICE
Take care not to allow foreign material to en-
ter the final drive case.
2
6. Check:
4. Install: • Oil level
• Final gear oil filler bolt Refer to “CHECKING THE FINAL GEAR OIL
(along with the gasket New ) LEVEL” on page 3-16.
7. Install:
Final gear oil filler bolt • Final gear oil filler bolt
23 Nm (2.3 m·kgf, 17 ft·lbf) (along with the gasket New )
T.
R.
Final gear oil filler bolt

23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
3-16
EBS30042
CHECKING THE DIFFERENTIAL GEAR OIL

LEVEL
2. Remove:
• Differential gear oil filler bolt “1”
3. Check:
• Differential gear oil level 1
The differential gear oil level should be up to
the brim “2” of the hole.
Below the brim → Add the recommended dif-
ferential gear oil to the proper level.
Type
SAE 80 API GL-4 Hypoid gear
oil
ECB01600
NOTICE 2
Take care not to allow foreign material to en-
ter the differential case. 4. Install:
• Differential gear oil drain bolt
1
Differential gear oil drain bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
2
5. Fill:
• Differential case
mended differential gear oil)
4. Install:
Type
• Differential gear oil filler bolt SAE 80 API GL-4 Hypoid gear
(along with the gasket New ) oil
Quantity (disassembled)
Differential gear oil filler bolt 0.20 L (0.21 US qt, 0.18 Imp.qt)
23 Nm (2.3 m·kgf, 17 ft·lbf) Quantity
T.
R.
0.18 L (0.19 US qt, 0.16 Imp.qt)

EBS30043
CHANGING THE DIFFERENTIAL GEAR OIL ECB01600
1. Place the vehicle on a level surface. NOTICE

2. Place a container under the differential case. Take care not to allow foreign material to en-
3. Remove: ter the differential case.
• Differential gear oil filler bolt “1”
6. Check:
• Oil level
• Differential gear oil drain bolt “2”
Refer to “CHECKING THE DIFFERENTIAL
GEAR OIL LEVEL” on page 3-17.
Completely drain the differential case of its
7. Install:
oil.
• Differential gear oil filler bolt
3-17
Differential gear oil filler bolt a

23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
EBS30044
CHECKING THE FRONT BRAKE PADS

The following procedure applies to all of the front
brake pads.
1. Remove:
• Front wheels
Refer to “FRONT AND REAR WHEELS” on
page 4-23. 4. Install:
2. Operate the brake. • Rear wheels
3. Check: Refer to “FRONT AND REAR WHEELS” on
• Front brake pads page 4-23.
Wear indicator grooves “a” have almost dis- EBS30045
appeared → Replace the brake pads and CHECKING THE BRAKE FLUID LEVEL
brake pad spring as a set. 1. Place the vehicle on a level surface.
Refer to “FRONT AND REAR BRAKES” on TIP
page 4-27. When checking the brake fluid level, make sure
that the top of the brake master cylinder reser-
a voir is horizontal.
2. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the
specified brake fluid to the proper level.
Specified brake fluid

DOT 4
4. Install: EWB02880
• Front wheels WARNING

Refer to “FRONT AND REAR WHEELS” on • Use only the designated brake fluid. Other
page 4-23. brake fluids may cause the rubber seals to
EBS30050
deteriorate, causing leakage and poor
CHECKING THE REAR BRAKE PADS brake performance.
The following procedure applies to all of the rear • Refill with the same type of brake fluid that
brake pads. is already in the system. Mixing brake fluids
1. Remove: may result in a harmful chemical reaction,
• Rear wheels leading to poor brake performance.
Refer to “FRONT AND REAR WHEELS” on • When refilling, be careful that water does
page 4-23. not enter the brake master cylinder reser-
2. Operate the brake. voir. Water will significantly lower the boil-
3. Check: ing point of the brake fluid and could cause
• Rear brake pads vapor lock.
Wear indicator grooves “a” have almost dis- ECB01320
appeared → Replace the brake pads and NOTICE

brake pad spring as a set. Brake fluid may damage painted surfaces
Refer to “FRONT AND REAR BRAKES” on and plastic parts. Therefore, always clean up
page 4-27. any spilt brake fluid immediately.
3-18
TIP È
In order to ensure a correct reading of the brake
2
fluid level, make sure the top of the brake master
cylinder reservoir is horizontal. 1
É
2
a
1
EBS30046
BLEEDING THE HYDRAULIC BRAKE

SYSTEM
EWB02800
WARNING
Bleed the hydraulic brake system whenever:
• the system is disassembled. A. Front brake
• a brake hose is loosened, disconnected or B. Rear brake
replaced. d. Place the other end of the hose into a con-
• the brake fluid level is very low. tainer.
• brake operation is faulty. e. Slowly apply the brake several times.
TIP f. Fully depress the brake pedal and hold it in
position.
• Be careful not to spill any brake fluid or allow
g. Loosen the bleed screw.
the brake master cylinder reservoir to overflow.
• When bleeding the hydraulic brake system, TIP
make sure there is always enough brake fluid Loosening the bleed screw will release the pres-
before applying the brake. Ignoring this pre- sure and cause the brake pedal to fully extend.
caution could allow air to enter the hydraulic h. Tighten the bleed screw, and then release
brake system, considerably lengthening the the brake pedal.
bleeding procedure. i. Repeat steps (e) to (h) until all of the air bub-
• If bleeding is difficult, it may be necessary to let bles have disappeared from the brake fluid in
the brake fluid settle for a few hours. Repeat the plastic hose.
the bleeding procedure when the tiny bubbles j. Tighten the bleed screw to specification.
in the hose have disappeared.
1. Remove: Brake caliper bleed screw
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
T.
• Front wheels
R.
• Rear wheels k. Fill the brake master cylinder reservoir to the

Refer to “FRONT AND REAR WHEELS” on proper level with the specified brake fluid.
page 4-23. Refer to “CHECKING THE BRAKE FLUID
2. Bleed: LEVEL” on page 3-19.
• Hydraulic brake system EWB02810
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ WARNING
a. Fill the brake master cylinder reservoir to the
After bleeding the hydraulic brake system,
proper level with the specified brake fluid.
check the brake operation.
b. Install the diaphragm (brake master cylinder
reservoir). ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Connect a clear plastic hose “1” tightly to the
bleed screw “2”.
3-19
3. Install:
• Rear wheels
• Front wheels
page 4-23. 3
EBS30047
CHECKING THE BRAKE HOSES AND

BRAKE PIPES
2
1. Remove:
• Rear panel (left)
4-1.
4-6.
2. Check:
• Front brake hoses “1”
Cracks/damage/wear → Replace.
3. Check:
• Front brake pipe “2”
4. Check:
• Rear brake pipe “3”
5. Check:
• Rear brake hoses “4”
3
1 1
4
4
1 1
3
4 4
3-20
6. Check:
• Brake hose holders
Loose → Tighten the holder bolts.
Damage → Replace. b
7. Apply the brake several times. 1
8. Check:
• Brake hoses
• Brake pipe a
Brake fluid leakage → Replace any damaged
2
hose and pipe.
Refer to “FRONT AND REAR BRAKES” on c. Tighten the locknut to specification.
page 4-27.
9. Install: Brake pedal rod locknut
• Center storage compartment 17 Nm (1.7 m·kgf, 12 ft·lbf)
T.
R.
Refer to “GENERAL CHASSIS (3)” on page EWB03090
4-6. WARNING
• Rear panel (left) After this adjustment is performed, lift the
Refer to “GENERAL CHASSIS (1)” on page front and rear wheels off the ground by plac-
4-1. ing a block under the frame, and spin the
EBS30048 front and rear wheels to ensure there is no
ADJUSTING THE BRAKE PEDAL brake drag. If any brake drag is noticed per-
1. Check: form the above steps again.
• Brake pedal free play “a”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Out of specification → Adjust.
EBS30049
Brake pedal free play LUBRICATING THE BRAKE PEDAL AND

0 mm (0 in) ACCELERATOR PEDAL
Lubricate the pivoting point and metal-to-metal
moving parts of the pedal.
a Recommended lubricant
Lithium-soap-based grease
2. Adjust:
• Brake pedal free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1”.
b. Turn the brake pedal rod “2” in direction “a” or
“b” until the correct free play is obtained. EBS30478
ADJUSTING THE PARKING BRAKE

Direction “a” 1. Place the vehicle on a level surface.
Brake pedal free play is increased. 2. Check:
Direction “b” • Parking brake lever free play “a”
Brake pedal free play is decreased. Out of specification → Adjust.
Parking brake lever free play

0 mm (0 in)
3-21
EBS30054
ADJUSTING THE ACCELERATOR PEDAL

a FREE PLAY
1. Check:
• Accelerator pedal free play “a”
Accelerator pedal free play

12.0–32.0 mm (0.47–1.26 in)
3. Remove:
4-6.
4. Adjust:
• Parking brake lever free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Release the parking brake lever.
b. Slide back the rubber cover “1”. a
c. Loosen the locknut “2”. 2. Remove:
d. Turn the adjusting nut “3” in direction “a” or “b” • Side cover (left)
until the correct free play is obtained. • Rear panel (left)
TIP Refer to “GENERAL CHASSIS (1)” on page
If there is any brake drag of the parking brake, 4-1.
turn the adjusting nut in direction “a”. If there is • Center storage compartment
free play, turn the adjusting nut in direction “b”. Refer to “GENERAL CHASSIS (3)” on page
4-6.
3. Adjust:
• Accelerator pedal free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3 a. Remove the throttle cable housing cover “1”.
a 1
1
b
2
e. Tighten the locknut to specification.
Parking brake cable locknut

16 Nm (1.6 m·kgf, 12 ft·lbf)
T.
R.
f. Slide the rubber cover to its original position. b. Slide back the rubber cover “2”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Loosen the locknut “3”.
d. Turn the adjusting nut “4” in direction “a” or “b”
5. Install:
until the specified accelerator pedal free play
is obtained.
4-6. Direction “a”
Accelerator pedal free play is in-
creased.
Direction “b”
Accelerator pedal free play is de-
creased.
3-22
f
7
2 b 4 8
a
3
TIP h. Install a new gasket and the throttle cable

If length “c” is 8.5 mm (0.33 in) or more, loosen housing cover.
locknut “5” and turn the adjusting nut “6” in direc-
Throttle cable housing cover
tion “d” or “e” until the specified accelerator ped- screw
T.
al free play is obtained.
R.
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Direction “d” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

Accelerator pedal free play is in- 4. Install:
creased. • Rear panel (left)
Direction “e” • Side panel (left)
Accelerator pedal free play is de- Refer to “GENERAL CHASSIS (1)” on page
creased.
4-1.
EBS30055
CHECKING THE V-BELT

6 5 1. Remove:
e • Frame cross member
4-19.
c • V-belt cooling ducts
d Refer to “GENERAL CHASSIS (10)” on page
4-21.
2. Remove:
e. Tighten the locknuts to specification. • Drive belt cover
Refer to “PRIMARY AND SECONDARY
Throttle cable locknut (air intake SHEAVES” on page 5-50.
silencer side) 3. Check:
T.
R.
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) • V-belt “1”

Throttle cable locknut (throttle Cracks/damage/wear → Replace.
body side) Grease/oil → Clean the primary and second-
0.8 Nm (0.08 m·kgf, 0.58 ft·lbf) ary sheaves.
Refer to “REPLACING THE V-BELT” on
f. Slide the rubber cover to its original position.
page 3-25.
g. Check the throttle valve pulley stopper gap.
4. Measure:
TIP • V-belt width “a”
When the accelerator pedal is fully depressed Out of specification → Replace.
(throttle valve fully open), the gap “f” between Refer to “REPLACING THE V-BELT” on
the throttle valve pulley “7” and the pulley stop- page 3-25.
per “8” should be 1 mm (0.04 in) or less.
V-belt width limit
32.5 mm (1.28 in)
3-23
5. Install: b. Remove the V-belt “2” from the primary

• Drive belt cover sheave and secondary sheave.
SHEAVES” on page 5-50.
6. Install:
• V-belt cooling ducts
4-21.
4-19.
EBS30056
REPLACING THE V-BELT c. Install a new V-belt.

1. Remove: TIP
• Frame cross member Install the new V-belt so that its arrow faces the
Refer to “GENERAL CHASSIS (9)” on page direction shown in the illustration.
4-19.
• V-belt cooling ducts
4-21.
2. Remove:
• Bearing housing
SHEAVES” on page 5-50.
3. Replace:
• V-belt
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the bolts “1” (90101-06016) into the d. Remove the bolts.
secondary fixed sheave holes. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP EBS30057
CHECKING THE WHEELS

Tightening the bolts “1” will push the secondary
sliding sheave away, causing the gap between
wheels.
the secondary fixed and sliding sheaves to wid-
1. Check:
en.
• Wheel “1”
Damage/bends → Replace.
EWB03010
WARNING
• Never attempt even small repairs to the
wheel.
• Ride conservatively after installing a tire to
allow it to seat itself properly on the rim.
3-24
Front tire
1
Type
Tubeless
Size
26 × 8–12NHS
Manufacturer/model
MAXXIS/MU09
Rear tire
Type
Tubeless
2. Measure: Size
• Radial wheel runout 26 × 10–12NHS
• Lateral wheel runout Manufacturer/model
Refer to “CHECKING THE WHEELS” on MAXXIS/MU10
page 4-24.
3. Check: Tire pressure
• Wheel bearings EWB02980
Refer to “CHECKING THE STEERING WARNING

KNUCKLES AND FRONT WHEEL BEAR- • Tire pressure below the minimum specifi-
INGS” on page 4-53 and “CHECKING THE cation could cause the tire to dislodge from
REAR KNUCKLES AND REAR WHEEL the rim under severe riding conditions.
BEARINGS” on page 4-62. • Use no more than the following pressures
when seating the tire beads.
EBS30058
CHECKING THE TIRES Front

The following procedure applies to all of the 250 kPa (2.5 kgf/cm²) (36 psi)
tires. Rear
EWB02960 250 kPa (2.5 kgf/cm²) (36 psi)
WARNING Higher pressures and fast inflation may
This model is equipped with low-pressure cause a tire to burst. Inflate the tires very
tires. It is important that they be inflated cor- slowly and carefully.
rectly and maintained at the proper pres-
sures. Tire air pressure (measured on
cold tires)
Recommended
Tire characteristics Vehicle load
EWB02970
WARNING 0 kg-maximum (0 lb-maximum)

Front
Tire characteristics influence the handling of 75.0 kPa (0.750 kgf/cm², 11 psi)
vehicles. The tires listed below have been Rear
approved by Yamaha Motor Co., Ltd. for this 75.0 kPa (0.750 kgf/cm², 11 psi)
model. If other tire combinations are used, Minimum
they can adversely affect your vehicle’s han- Vehicle load
dling characteristics and are therefore not 0 kg-maximum (0 lb-maximum)
recommended. Front
70.0 kPa (0.700 kgf/cm², 10 psi)
Rear
70.0 kPa (0.700 kgf/cm², 10 psi)
Maximum loading limit

EWB02990
WARNING
Be extra careful of the vehicle balance and
stability when towing a trailer.
3-25
EWB03100
Maximum loading limit WARNING

327.0 kg (721 lb) It is dangerous to ride with a worn-out tire.
(Total weight of operator, pas- When the tire tread reaches the wear limit, re-
senger, cargo, accessories, and place the tire immediately.
tongue)
Rear carrier load limit
136.0 kg (300 lb)
Storage compartment load limit
6.4 kg (14 lb)
Trailer hitch pulling load limit
6664 N (680 kgf, 1498 lbf)
Trailer hitch vertical load limit
490 N (50 kgf, 110 lbf)
1. Measure:
• Tire pressure
Out of specification → Adjust. a. Wear limit
EWB03000
EBS30059
WARNING CHECKING THE FRONT SHOCK ABSORBER
Uneven or improper tire pressure may ad- ASSEMBLIES
versely affect the handling of this vehicle The following procedure applies to both of the
and may cause loss of control. front shock absorber assemblies.
• Maintain proper tire pressures. 1. Place the vehicle on a level place.
• Set tire pressures when the tires are cold. 2. Check:
• Tire pressures must be equal in both front • Front shock absorber assembly
tires and equal in both rear tires. Refer to “CHECKING THE FRONT SHOCK
TIP
ABSORBER ASSEMBLIES” on page 4-57.
3. Check:
• The tire pressure gauge “1” is included as stan-
• Operation
dard equipment.
Pump the front shock absorber assembly up
• In order to insure an accurate reading, make
and down several times.
sure that the gauge is clean before use.
Unsmooth operation → Replace front shock
absorber assembly.
Refer to “FRONT ARMS AND FRONT
SHOCK ABSORBER ASSEMBLIES” on
page 4-55.
EBS30430
ADJUSTING THE FRONT SHOCK

ABSORBER ASSEMBLIES
1 The following procedure applies to both of the
front shock absorber assemblies.
EWB03600
2. Check: WARNING
• Tire surfaces Always adjust the spring preload, rebound
Wear/damage → Replace. damping force and compression damping
force of both front shock absorbers to the
Wear limit (front) same setting. Uneven adjustment can result
3.0 mm (0.12 in)
in poor handling and loss of stability.
Wear limit (rear)
3.0 mm (0.12 in) 1. Adjust:
• Spring preload
3-26
Ring nut wrench

90890-01268
Spanner wrench
YU-01268
c
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Elevate the front wheels by placing a suitable
stand under the frame.
b. Loosen the locknut “1”.
c. Turn the adjusting ring “2” in direction “a” or
“b”. c. Spring preload adjusting positions
Direction “a” d. Tighten the locknut “1” with a steering nut

Spring preload is increased (suspen- wrench “3”.
sion is harder).
Direction “b” Steering nut wrench
Spring preload is decreased (suspen- 90890-01443
sion is softer). Spanner wrench
YU-33975

Minimum Locknut
313.5 mm (12.34 in) 30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.
Standard
305.5 mm (12.03 in) TIP
Maximum • Set the torque wrench at a right angle to the
298.5 mm (11.75 in) steering nut wrench.
ECB02470
• Always tighten the locknut against the adjust-
NOTICE ing ring, then torque it to specification.
Never attempt to turn the adjusting ring be-
yond the maximum or minimum setting.
TIP 3
• Be sure to remove all dirt and mud from around
the locknut and adjusting ring before adjust-
ment.
1
• The length of the spring (installed) changes 1.5
mm (0.06 in) per turn of the adjusting ring.
1 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2 2. Adjust:
• Rebound damping force
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw “1” in direction “a” or
“b”.
a
b Direction “a”
Rebound damping force is increased
(suspension is harder).
Direction “b”
Rebound damping force is decreased
(suspension is softer).
3-27
ECB02480
Rebound damping adjusting posi- NOTICE

tions Do not force the adjuster past the minimum
Minimum or maximum extent of adjustment. The ad-
30 click(s) out from the fully juster may be damaged.
turned in position
Standard
13 click(s) out from the fully a
turned in position
Maximum 1
1 click(s) out from the fully b
turned in position 1
ECB02480
NOTICE
Do not force the adjuster past the minimum
or maximum extent of adjustment. The ad-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
juster may be damaged.
4. Adjust:
• Compression damping force (slow compres-
sion damping)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b a. Turn the adjusting screw “1” in direction “a” or
“b”.
a
Direction “a”
Compression damping force is in-
creased (suspension is harder).
1 Direction “b”
Compression damping force is de-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
creased (suspension is softer).
3. Adjust:
• Compression damping force (fast compres-
sion damping) Compression damping setting (for
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ slow compression damping)
a. Turn the adjusting bolt “1” in direction “a” or Minimum
“b”. 18 click(s) out from the fully
turned in position
Direction “a” Standard
Compression damping force is in- 12 click(s) out from the fully
creased (suspension is harder). turned in position
Direction “b” Maximum
Compression damping force is de- 1 click(s) out from the fully
creased (suspension is softer). turned in position
ECB02480
Compression damping setting (for NOTICE

fast compression damping) Do not force the adjuster past the minimum
Minimum or maximum extent of adjustment. The ad-
2 turn(s) out from the fully juster may be damaged.
turned in position
Standard
1 1/4 turn(s) out from the fully
turned in position
Maximum
Adjusting bolt fully turned in
3-28
c. Turn the adjusting ring “2” in direction “a” or

a “b”.
Direction “a”
b Spring preload is increased (suspen-
1 sion is harder).
Direction “b”
1
Spring preload is decreased (suspen-
sion is softer).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Spring preload adjusting positions

EBS30060 Minimum
CHECKING THE REAR SHOCK ABSORBER 386.0 mm (15.20 in)
ASSEMBLIES Standard
The following procedure applies to both of the 378.0 mm (14.88 in)
rear shock absorber assemblies. Maximum
1. Place the vehicle on a level place. 372.0 mm (14.65 in)
2. Check: ECB02470
• Rear shock absorber assembly NOTICE
Refer to “CHECKING THE REAR SHOCK
Never attempt to turn the adjusting ring be-
yond the maximum or minimum setting.
3. Check:
• Operation TIP
Pump the rear shock absorber assembly up • Be sure to remove all dirt and mud from around
and down several times. the locknut and adjusting ring before adjust-
Unsmooth operation → Replace rear shock ment.
absorber assembly. • The length of the spring (installed) changes 1.5
Refer to “REAR ARMS AND REAR SHOCK mm (0.06 in) per turn of the adjusting ring.
EBS30431
ADJUSTING THE REAR SHOCK ABSORBER

ASSEMBLY 1
The following procedure applies to both of the
rear shock absorber assemblies.
EWB03610 2
WARNING
Always adjust the spring preload, rebound a
b
damping force and compression damping
force of both rear shock absorbers to the
same setting. Uneven adjustment can result
in poor handling and loss of stability.
1. Adjust:
• Spring preload
c
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ c. Spring preload adjusting positions

a. Elevate the rear wheels by placing a suitable
stand under the frame. d. Tighten the locknut “1” with a steering nut
b. Loosen the locknut “1”. wrench “3”.
3-29
ECB02480
Steering nut wrench NOTICE

90890-01443 Do not force the adjuster past the minimum
Spanner wrench or maximum extent of adjustment. The ad-
YU-33975 juster may be damaged.
Locknut
30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.
TIP
b
• Set the torque wrench at a right angle to the a
steering nut wrench. 1
• Always tighten the locknut against the adjust-
ing ring, then torque it to specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
3 • Compression damping force (fast compres-
sion damping)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting bolt “1” in direction “a” or
1 “b”.
Direction “a”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ creased (suspension is harder).
2. Adjust: Direction “b”
• Rebound damping force Compression damping force is de-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ creased (suspension is softer).
“b”.
Compression damping setting (for
Direction “a” fast compression damping)
Rebound damping force is increased Minimum
(suspension is harder). 2 turn(s) out from the fully
Direction “b” turned in position
Rebound damping force is decreased Standard
(suspension is softer). 1 1/4 turn(s) out from the fully
turned in position
Maximum
Rebound damping adjusting posi- Adjusting bolt fully turned in
tions
ECB02480
Minimum
NOTICE
30 click(s) out from the fully
turned in position Do not force the adjuster past the minimum
Standard or maximum extent of adjustment. The ad-
14 click(s) out from the fully juster may be damaged.
turned in position
Maximum
turned in position
3-30
EBS30061
CHECKING THE STEERING SYSTEM

2. Check:
b a • Steering column (except for EPS models)
• EPS unit (for EPS models)
• Steering wheel nut
Move the steering wheel up and down, and
1 1 back and forth.
Excessive play → Check that the steering
column bolts, EPS unit bolts, or steering
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
wheel nut are tightened to specification.
4. Adjust: Refer to “STEERING SYSTEM” on page
• Compression damping force (slow compres- 4-47.
sion damping)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
“b”.
Direction “a”
creased (suspension is harder).
Direction “b”
Compression damping force is de-
creased (suspension is softer).
3. Check:
• Tie-rod ends
Compression damping setting (for Free play → Replace the tie-rod end.
slow compression damping) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Minimum a. Turn the steering wheel left until it stops.
18 click(s) out from the fully b. Move the steering wheel slightly to the right
turned in position and left.
Standard
c. Check for play in the tie-rod ends.
turned in position d. Turn the steering wheel right until it stops.
Maximum e. Move the steering wheel slightly to the left
1 click(s) out from the fully and right.
turned in position f. Check for play in the tie-rod ends.
ECB02480
NOTICE
Do not force the adjuster past the minimum
or maximum extent of adjustment. The ad-
juster may be damaged.
b
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Raise the front end of the vehicle so that
1 1 there is no weight on the front wheels.
5. Check:
• Ball joints and wheel bearings
Move the wheels laterally back and forth.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-31
Excessive free play → Replace the front

arms (upper and lower) and/or wheel bear-
ings.
EBS30062
ADJUSTING THE TOE-IN

2. Measure:
• Toe-in
Toe-in (with tires touching the C. Forward

ground)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5.0–15.0 mm (0.20–0.59 in)
3. Adjust:
TIP • Toe-in
EWB03110
Before measuring the toe-in, make sure that the WARNING
tire pressure is correct. • Be sure that both tie-rods are turned the
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ same amount. If not, the vehicle will drift
a. Mark both front tire tread centers. right or left even though the steering wheel
b. Face the steering wheel straight ahead. is straight. This may lead to mishandling
c. Measure the width “A” between the marks. and an accident.
d. Rotate the front tires 180° until the marks are • After setting the toe-in to specification, run
exactly opposite one another. the vehicle slowly for some distance with
e. Measure the width “B” between the marks. both hands lightly holding the steering
f. Calculate the toe-in using the formula given wheel and check that the steering wheel re-
below. sponds correctly. If not, turn either the right
or left tie-rod within the toe-in specification.
Toe-in = “B” – “A”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Mark both tie-rods ends.
g. If the toe-in is incorrect, adjust it.
This reference point will be needed during
adjustment.
b. Loosen the tie-rod end locknuts “1” of both
tie-rods.
c. The same number of turns should be given to
both the right and left tie-rods “2” until the
specified toe-in is obtained. This is to keep
the length of the tie-rods the same.
3-32
EBS30066
1 2 2 1 LUBRICATING THE DRIVE SHAFT

UNIVERSAL JOINTS
1. Remove:
• Center cover
4-6.
2. Lubricate:
• Drive shaft universal joint
Recommended lubricant
d. Tighten the tie-rod end locknuts to specifica- Lithium-soap-based grease
tion.
Tie-rod end locknut

40 Nm (4.0 m·kgf, 29 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Steering wheel
TIP
After adjusting the toe-in, the steering wheel
should be centered.
Refer to “INSTALLING THE STEERING
WHEEL” on page 4-16.
EBS30064
CHECKING THE STABILIZER BUSHING

1. Check:
• Stabilizer bushings
Damage/wear → Replace.
Refer to “REAR KNUCKLES AND STABILIZ-
ER” on page 4-60.
EBS30065 EBS30067
LUBRICATING THE REAR KNUCKLE CHECKING THE ENGINE MOUNT

PIVOTS 1. Check:
1. Remove: • Engine brackets
• Rear arm protectors Cracks/damage → Replace.
2. Lubricate: • Engine mounting bolts
• Rear knuckle pivots • Engine bracket nuts
Loosen → Tighten.
Recommended lubricant Refer to “ENGINE REMOVAL (2)” on page
Lithium-soap-based grease 5-5.
EBS30068
CHECKING THE CONSTANT VELOCITY

SHAFT ASSEMBLY DUST BOOTS
1. Check:
• Dust boots “1”
Damage → Replace.
Refer to “FRONT CONSTANT VELOCITY
SHAFT ASSEMBLIES, DIFFERENTIAL AS-
SEMBLY AND FRONT DRIVE SHAFTS” on
page 8-4 and “REAR CONSTANT VELOCI-
3-33
TY SHAFT ASSEMBLIES, FINAL DRIVE

ASSEMBLY AND REAR DRIVE SHAFT” on
page 8-18.
A
1 1
1 1
A. Front
B. Rear
EBS30069
CHECKING THE FASTENER

1. Check:
• Fasteners
Damage/pitting → Replace.
4-1, “GENERAL CHASSIS (3)” on page 4-6,
“GENERAL CHASSIS (6)” on page 4-12,
“GENERAL CHASSIS (7)” on page 4-13, and
“GENERAL CHASSIS (9)” on page 4-19.
3-34
3-35
CHASSIS
GENERAL CHASSIS (1) ................................................................................. 4-1

INSTALLING THE DOOR..........................................................................4-2
GENERAL CHASSIS (2) ................................................................................. 4-3

REMOVING THE SEATS ..........................................................................4-4
ADJUSTING THE DRIVER SEAT POSITION...........................................4-4
INSTALLING THE SEATS......................................................................... 4-4
GENERAL CHASSIS (3) ................................................................................. 4-6
GENERAL CHASSIS (4) ................................................................................. 4-7

INSTALLING THE SEAT BELTS............................................................... 4-8
GENERAL CHASSIS (5) ................................................................................. 4-9

INSTALLING THE ENCLOSURE ............................................................ 4-11
GENERAL CHASSIS (6) ............................................................................... 4-12

4
GENERAL CHASSIS (7) ............................................................................... 4-13
REMOVING THE STEERING WHEEL....................................................4-16
INSTALLING THE STEERING WHEEL .................................................. 4-16
GENERAL CHASSIS (8) ............................................................................... 4-17
GENERAL CHASSIS (9) ............................................................................... 4-19

INSTALLING THE CARGO BED............................................................. 4-20
GENERAL CHASSIS (10) ............................................................................. 4-21

INSTALLING THE V-BELT COOLING DUCTS....................................... 4-22
FRONT AND REAR WHEELS ...................................................................... 4-23

REMOVING THE WHEELS..................................................................... 4-24
REMOVING THE WHEEL HUBS ............................................................ 4-24
CHECKING THE WHEELS ..................................................................... 4-24
CHECKING THE WHEEL HUBS............................................................. 4-25
INSTALLING THE BRAKE DISCS .......................................................... 4-25
INSTALLING THE WHEEL HUBS........................................................... 4-25
INSTALLING THE WHEELS ................................................................... 4-26
FRONT AND REAR BRAKES....................................................................... 4-27
INTRODUCTION .....................................................................................4-34
CHECKING THE BRAKE DISCS ............................................................ 4-34
REPLACING THE BRAKE PADS............................................................ 4-35
DISASSEMBLING THE BRAKE CALIPERS ...........................................4-36
CHECKING THE BRAKE CALIPERS .....................................................4-36
ASSEMBLING THE BRAKE CALIPERS ................................................. 4-36
INSTALLING THE BRAKE CALIPERS ...................................................4-37
CHECKING THE BRAKE MASTER CYLINDER ..................................... 4-38
CHECKING THE BRAKE PIPES............................................................. 4-38
INSTALLING THE BRAKE MASTER CYLINDER ................................... 4-38
PARKING BRAKE......................................................................................... 4-40

CHECKING THE FRICTION PLATES.....................................................4-42
CHECKING THE PARKING BRAKE PLATES ........................................ 4-42
CHECKING THE PARKING BRAKE SPRINGS...................................... 4-42
CHECKING THE PARKING BRAKE BOSS ............................................4-42
INSTALLING THE PARKING BRAKE .....................................................4-42
INSTALLING THE PARKING BRAKE LEVER ........................................ 4-43
PEDAL ASSEMBLY ......................................................................................4-44

INSTALLING THE PEDAL ASSEMBLY .................................................. 4-46
STEERING SYSTEM .....................................................................................4-47

REMOVING THE TIE-ROD ..................................................................... 4-49
CHECKING THE STEERING JOINT.......................................................4-49
CHECKING THE TIE-ROD ENDS........................................................... 4-49
INSTALLING THE STEERING SYSTEM ................................................ 4-49
LUBRICATING THE STEERING SHAFT ................................................ 4-51
STEERING KNUCKLES................................................................................ 4-52

REMOVING THE STEERING KNUCKLES ............................................. 4-53
CHECKING THE STEERING KNUCKLES AND
FRONT WHEEL BEARINGS .................................................................. 4-53
CHECKING THE STEERING KNUCKLE BALL JOINTS ........................ 4-53
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES ............. 4-55

CHECKING THE FRONT ARMS............................................................. 4-57
HANDLING THE FRONT SHOCK ABSORBER ASSEMBLIES.............. 4-57
DISPOSING OF A FRONT SHOCK ABSORBER ASSEMBLY............... 4-57
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES ............. 4-57
CHECKING THE FRONT ARM BALL JOINTS ....................................... 4-58
INSTALLING THE FRONT ARMS AND
FRONT SHOCK ABSORBER ASSEMBLIES.........................................4-59
REAR KNUCKLES AND STABILIZER ......................................................... 4-60

CHECKING THE REAR KNUCKLES AND REAR WHEEL BEARINGS .4-62
CHECKING THE STABILIZER................................................................4-62
INSTALLING THE STABILIZER..............................................................4-62
REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES ................. 4-63
CHECKING THE REAR ARMS ...............................................................4-65
HANDLING THE REAR SHOCK ABSORBER ASSEMBLIES ................ 4-65
DISPOSING OF A REAR SHOCK ABSORBER ASSEMBLY ................. 4-65
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................ 4-65
INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER
ASSEMBLIES ......................................................................................... 4-66
GENERAL CHASSIS (1)
EBS20024
GENERAL CHASSIS (1)

Removing the doors and side panels
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

T.R
.
7 7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
5 4
6 (4)
3
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
(4)
2
1
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
Order Job/Parts to remove Q’ty Remarks

The following procedure applies to both of
the doors.
1 Door hinge 1
2 Door 1
3 Door handle latch 1
4 Rubber damper 1
5 Fuel tank cap 1 Right side only.
6 Side panel 1
7 Rear panel 1
4-1
GENERAL CHASSIS (1)
EBS30419
INSTALLING THE DOOR

The following procedure applies to both of the 2 1
doors.
1. Install:
• Door hinge “1”
Door hinge nut

7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.
2. Install:
• Door “1”
TIP
Fit the tab “a” on the door hinge with the slot “b”
in the frame.
Door hinge bolt

7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.
a b
3. Install:
• Door handle latch “1”
TIP
Adjust the position of the door handle latch so
that it fully engages the bar “2” on the frame
when the door is closed.
Door handle latch nut

7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.
4-2
GENERAL CHASSIS (2)
EBS20087
GENERAL CHASSIS (2)

Removing the seats
6 Nm (0.6 m•kgf, 4.3 ft•Ibf)

T.R
.
5
1
(3)
(3) New
(3)
23 Nm (2.3 m•kgf, 17 ft•Ibf)
(4)
T.R
.
(3)
(4)
New 5
2
23 Nm (2.3 m•kgf, 17 ft•Ibf)

T.R
.

1 Seat cushion 2
2 Driver seat frame 1
3 Passenger seat frame 1
4 Seat back 2
5 Shoulder holster 2
4-3
GENERAL CHASSIS (2)
EBS30340
REMOVING THE SEATS

seats. 2
1. Remove: b
c
• Seat cushion “1” d
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Lift the front of the seat cushion.
b. Pull the cushion off. a
1 b. Forward position
c. Center position
d. Rear position
c. Install the driver seat frame bolts, and then
tighten the bolts to specification.
Driver seat frame bolt

23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30341
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ADJUSTING THE DRIVER SEAT POSITION 3. Install:
The driver seat can be adjusted to one of three • Driver seat cushion
positions to suit the driver’s preference. Refer to “INSTALLING THE SEATS” on page
1. Remove: 4-4.
• Driver seat cushion
EBS30342
Refer to “REMOVING THE SEATS” on page INSTALLING THE SEATS
4-4. The following procedure applies to both of the
2. Adjust: seats.
• Driver seat position 1. Install:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Seat cushion “1”
a. Remove the driver seat frame bolts “1”. EWB03120
WARNING
1 A loose seat could cause the operator to lose
control, or cause the operator or passengers
to fall.
1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Insert the projections “a” on the rear of the
seat cushion under the seat frame.
b. Insert the projection “b” on the front of the
cushion into the grommet while pushing the
b. Move the driver seat frame “2” to the desired cushion downward.
position and align the bolt holes in the seat TIP
frame with the bolt holes “a” in the vehicle Make sure the seats are properly secured before
frame. riding.
4-4
GENERAL CHASSIS (2)
a
1
b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-5
GENERAL CHASSIS (3)
EBS20088
GENERAL CHASSIS (3)

Removing the center cover and floor boards
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf) 9 Nm (0.9 m•kgf, 6.5 ft•Ibf)
T.R
.
T.R
.
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

7
T.R
.
1
6 (6)
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf) 9
T.R
.
4 (6)
2
5
10
(6) 3
8
(8)
(4)
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

T.R
.
(4)
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

T.R
.
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

T.R
.

Seat backs 4-3.
1 Center storage compartment 1
2 Driver seat belt buckle rubber cover 1
3 Passenger seat belt buckle rubber cover 1
4 Center cover 1
5 Under-seat storage compartment 1
6 Rubber cover 1
7 Under-seat compartment panel 1
8 Floor board (right) 1
9 Pedal assembly rubber cover 1
10 Floor board (left) 1
4-6
GENERAL CHASSIS (4)
EBS20089
GENERAL CHASSIS (4)

Removing the seat belts
59 Nm (5.9 m•kgf, 43 ft•Ibf) 59 Nm (5.9 m•kgf, 43 ft•Ibf)

T.R
T.R
.
.
1
3 6
8 5
59 Nm (5.9 m•kgf, 43 ft•Ibf) 4

T.R
.

Side panels/Rear panels 4-1.
Under-seat storage compartment 4-6.
1 Driver seat belt 1
2 Seat belt rubber cover (left) 1
3 Passenger seat belt 1
4 Seat belt rubber cover (right) 1
5 Seat belt switch coupler 1 Disconnect.
6 Driver seat belt buckle 1
7 Seat belt buckle bracket 1
8 Passenger seat belt buckle 1
4-7
GENERAL CHASSIS (4)
EBS30343
INSTALLING THE SEAT BELTS

1. Install:
• Seat belt buckles 1
Seat belt buckle bolt a
59 Nm (5.9 m·kgf, 43 ft·lbf)
T.
R.
TIP
• Fit the passenger seat belt buckle “1” into the
slot “a” in the frame.
• Fit the driver seat belt buckle “2” into the slot “b”
in the seat belt buckle bracket. 2
1 c
1 b
2
b
2
2. Install:
• Seat belts
Seat belt bolt (M12 × 20)

59 Nm (5.9 m·kgf, 43 ft·lbf)
T.
R.
Seat belt bolt (M12 × 18)

59 Nm (5.9 m·kgf, 43 ft·lbf)
Seat belt guide bolt
59 Nm (5.9 m·kgf, 43 ft·lbf)
TIP
• Install the seat belt anchor plates “1” so that
they contact the stoppers “a”.
• Fit the projection “b” on each seat belt “2” into
the holes “c” in the frame.
4-8
GENERAL CHASSIS (5)
EBS20090
GENERAL CHASSIS (5)

Removing the sun top
4
(4)
1 New 5
(4)
(4) 2
(8)
(4)
(8)
3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)

T.R
.

1 Sun top rear bracket 4
2 Sun top front bracket 4
3 Sun top 1
4 Damper 4
5 Damper 4
4-9
GENERAL CHASSIS (5)
Removing the enclosure

70 Nm (7.0 m•kgf, 51 ft•Ibf)
70 Nm (7.0 m•kgf, 51 ft•Ibf)
T.R
.
T.R
.
4
3
41 Nm (4.1 m•kgf, 30 ft•Ibf)
T.R
.
70 Nm (7.0 m•kgf, 51 ft•Ibf)
T.R
.
5 7
8
6
(4)
2 48 Nm (4.8 m•kgf, 35 ft•Ibf)

T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf) 70 Nm (7.0 m•kgf, 51 ft•Ibf)

T.R
.
T.R
.

Seat backs 4-3.
Seat belts 4-7.
1 Rear lower frame rubber cover (right) 1
2 Rear lower frame rubber cover (left) 1
3 Front top frame 1
4 Rear top frame 1
5 Rear upper frame 1
6 Side frame (right) 1
7 Side frame (left) 1
8 Rear lower frame 1
4-10
GENERAL CHASSIS (5)
EBS30344
INSTALLING THE ENCLOSURE Rear upper frame bolt

1. Install: 70 Nm (7.0 m·kgf, 51 ft·lbf)
T.
R.
• Rear lower frame “1” Rear upper frame and rear lower
• Side frame (left) “2” frame nut
• Side frame (right) “3” 41 Nm (4.1 m·kgf, 30 ft·lbf)
• Rear upper frame “4” Front top frame bolt
• Rear top frame “5” 70 Nm (7.0 m·kgf, 51 ft·lbf)
• Front top frame “6” Rear top frame bolt
70 Nm (7.0 m·kgf, 51 ft·lbf)
TIP Side frame nut (front right)
Do not fully tighten the bolts and nuts. 70 Nm (7.0 m·kgf, 51 ft·lbf)
Side frame nut (front left)
70 Nm (7.0 m·kgf, 51 ft·lbf)
Side frame nut (rear right)
FWD 48 Nm (4.8 m·kgf, 35 ft·lbf)
Side frame nut (rear left)
6 48 Nm (4.8 m·kgf, 35 ft·lbf)
Rear lower frame bolt
70 Nm (7.0 m·kgf, 51 ft·lbf)
5
4
3
5 1
3 6
4 2
6 2
7
5
1
2. Tighten:
• Rear upper frame bolts
• Rear upper frame and rear lower frame nuts
• Front top frame bolts
• Rear top frame bolts
• Side frame nuts (front right)
• Side frame nuts (front left)
• Side frame nut (rear right)
• Side frame nut (rear left)
• Rear lower frame bolts
TIP
Tighten the bolts and nuts in the proper tighten-
ing sequence as shown ( 1, 2, and so on).
4-11
GENERAL CHASSIS (6)
EBS20091
GENERAL CHASSIS (6)

Removing the hood and battery
5
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf) 4
T.R
.
8 4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

T.R
.
6
2
9 7
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.
11 12
10
3 1
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf)

T.R
.
(6)
48 Nm (4.8 m•kgf, 35 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
T.R
.

1 Skid plate 1
2 Side guard 2
3 Mudguard 2
4 Hood 1
5 Air intake duct cover 1
6 Negative battery lead 1 Disconnect.
7 Positive battery lead 1 Disconnect.
8 Battery band 2
9 Battery 1
10 Front guard 1
11 Headlight coupler 2 Disconnect.
12 Front grill 1
4-12
GENERAL CHASSIS (7)
EBS20092
GENERAL CHASSIS (7)

Removing the front fender and instrument panel assembly
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf) 1 7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
T.R
.
(8)
(2)
(5)
(5)
1 4
5
35 Nm (3.5 m•kgf, 25 ft•Ibf)
T.R
(5) 2
.
(5) 3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
2.3 Nm (0.23 m•kgf, 1.7 ft•Ibf)

T.R
.
(9) 3
(5)
6
7
89 4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.

Center cover/Pedal assembly rubber cover 4-6.
Side frames 4-9.
Hood/Side guards 4-12.
1 Front over fender 2 For over fender models
2 Front fender 1
3 Passenger handhold 1
4 Steering wheel cover 1
5 Steering wheel 1
6 Meter assembly coupler 1 Disconnect.
7 Indicator light assembly coupler 1 Disconnect.
8 On-Command four-wheel-drive switch coupler 1 Disconnect.
9 Light switch coupler 1 Disconnect.
4-13
GENERAL CHASSIS (7)
Removing the front fender and instrument panel assembly

T.R
.
T.R
.
(8)
(2)
(5)
(5)
35 Nm (3.5 m•kgf, 25 ft•Ibf)
T.R
(5)
.
(5) 3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
2.3 Nm (0.23 m•kgf, 1.7 ft•Ibf) 12

T.R
.
13 (9)
(5)
10
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.
11

10 Main switch coupler 1 Disconnect.
11 Auxiliary DC jack coupler 1 Disconnect.
Disconnect.
12 Horn switch lead 2 Except for CDN
13 Instrument panel assembly 1
4-14
GENERAL CHASSIS (7)
Disassembling the instrument panel assembly
3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf)
T.R
1
.
2
8
(3)
6
5
7
4

1 Meter assembly 1
2 Indicator light assembly 1
3 On-Command four-wheel-drive switch 1
4 Light switch 1
5 Main switch 1
6 Auxiliary DC jack 1
7 Horn switch 1 Except for CDN
8 Instrument panel 1
4-15
GENERAL CHASSIS (7)
EBS30345
REMOVING THE STEERING WHEEL

1. Turn the steering wheel so that it is straight 1
and the front wheels are pointing straight
ahead.
2. Remove:
• Steering wheel cover “1”
TIP
While pushing the ends of the projections “a” to-
gether, remove the steering wheel cover from
the steering wheel. 2. Operate the vehicle at low speeds and make
sure that the steering wheel is straight when
a the vehicle is advancing straight ahead.
3. Remove:
• Steering wheel “1”
TIP
Use a general puller “2” to separate the steering
wheel and steering column.
EBS30347
INSTALLING THE STEERING WHEEL

1. Install:
• Steering wheel “1”
Steering wheel nut

35 Nm (3.5 m·kgf, 25 ft·lbf)
T.
R.
TIP
Install the steering wheel onto the steering col-
umn so that it is centered as shown in the illus-
tration.
4-16
GENERAL CHASSIS (8)
EBS20102
GENERAL CHASSIS (8)

Removing the electrical components tray
5 3.6 Nm (0.36 m•kgf, 2.6 ft•Ibf)

9
T.R
.
4 4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.
2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)
T.R
.
7
8
3
6
(4)
2
1 1
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf)

T.R
.
FW
D

Instrument panel assembly 4-13.
1 Headlight coupler 2 Disconnect.
2 Lean angle sensor 1
3 Starter relay 1
4 Main fuse 1
5 EPS fuse 1 For EPS models
6 ECU (Engine Control Unit) 1
7 EPS control unit 1 For EPS models
8 Fuse box 1
9 Differential motor relay 2 1
4-17
GENERAL CHASSIS (8)
Removing the electrical components tray

11 10 3.6 Nm (0.36 m•kgf, 2.6 ft•Ibf)
T.R
.
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.
14 13
12 2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)
T.R
.
(4)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
15 3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf)

T.R
.
FW
D

10 Differential motor relay 1 1
11 Headlight relay 1
12 Load control relay 1
13 Fuel injection system relay 1
14 Radiator fan motor relay 1
15 Electrical components tray 1
4-18
GENERAL CHASSIS (9)
EBS20103
GENERAL CHASSIS (9)

Removing the cargo bed
T.R
.
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
2
2
1
33 Nm (3.3 m•kgf, 24 ft•Ibf)

T.R
.
9 Nm (0.9 m•kgf, 6.5 ft•Ibf)

9
T.R
.
33 Nm (3.3 m•kgf, 24 ft•Ibf)

T.R
.
5 5 (6)
5
5
10 9
(4)
(6) 73
4 8
11
(6) (6) 6
9 Nm (0.9 m•kgf, 6.5 ft•Ibf)
T.R
.
8
3
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.

Under-seat compartment panel 4-6.
1 Tailgate 1
2 Latch 2
3 Tail/brake light connector 6 Disconnect.
4 Cargo bed 1
5 Latch holder 4
6 Tail/brake light bracket (left) 1
7 Tail/brake light bracket (right) 1
8 Tail/brake light 2
9 Rear over fender 2 For over fender models
10 Heat protector 1
11 Frame cross member 1
4-19
GENERAL CHASSIS (9)
EBS30420
INSTALLING THE CARGO BED

1. Install:
• Cargo bed “1”
Cargo bed bolt

9 Nm (0.9 m·kgf, 6.5 ft·lbf)
T.
R.
TIP
Tighten the bolts “2” and “3” in the order listed,
and then tighten the bolts “4”.
FWD
4 2 4
4-20
GENERAL CHASSIS (10)
EBS20104

Removing the V-belt cooling ducts
FW
D
T.R
T.R
.
.
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
T.R
.
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
T.R
.
4 6
2
1
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

T.R
.
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf) 2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
T.R
T.R
.

Frame cross member 4-19.
1 V-belt cooling exhaust duct 1
2 V-belt cooling exhaust duct plate 1
3 V-belt cooling exhaust duct joint 1
4 V-belt cooling intake duct 1
5 V-belt cooling intake duct joint 1 1
6 V-belt cooling intake duct joint 2 1
4-21
EBS30348
INSTALLING THE V-BELT COOLING DUCTS

1. Install:
• V-belt cooling intake duct joint 2 “1”
• V-belt cooling intake duct joint 1 “2”
• V-belt cooling exhaust duct joint “3”
TIP
• Align the projection “a” on V-belt cooling intake
duct joint 2 with the lib on the crankcase.
• Fit the projection “b” on the V-belt cooling in-
take duct joints and V-belt cooling exhaust duct
joint between the projections on the V-belt
cooling intake duct and V-belt cooling exhaust
duct.
• Align the slit “c” in V-belt cooling intake duct
joint 1 and V-belt cooling exhaust duct joint
with the projection on the drive belt cover.
a 1 b
b
2
c b
4-22
FRONT AND REAR WHEELS
EBS20025

Removing the wheels and brake discs
48 Nm (4.8 m•kgf, 35 ft•Ibf)
T.R
.
4
30 Nm (3.0 m•kgf, 22 ft•Ibf) 6

T.R
.
5
LT
New 3
2
350 Nm (35.0 m•kgf, 253 ft•lbf)
T.R
.
1
D
FW
75 Nm (7.5 m•kgf, 54 ft•Ibf)
T.R
.

wheels.
1 Wheel 1
2 Wheel cap 1
3 Wheel axle nut 1
TIP
4 Brake caliper 1 Do not apply the brake pedal when the
brake caliper is off of the brake disc as the
brake pads will be forced shut.
5 Wheel hub 1
6 Brake disc 1
4-23
EBS30083
• Wheel
REMOVING THE WHEELS
Refer to “CHECKING THE TIRES” on page
3-25 and “CHECKING THE WHEELS” on
2. Elevate:
page 3-24.
• Wheels EWB03020
TIP WARNING
Place the vehicle on a suitable stand so that the After replacing the tire, ride conservatively to
wheels are elevated. allow the tire to be properly seated in the rim.
Failure to do so may cause an accident re-
EBS30084 sulting in vehicle damage and possible inju-
REMOVING THE WHEEL HUBS ry.
wheel hubs.
1. Straighten the wheel axle nut rib “a”.
2. Measure:
• Radial wheel runout “1”
2. Remove: • Lateral wheel runout “2”
• Wheel axle nut Over the specified limit → Replace the wheel
3. Remove: or check the wheel bearing play.
• Brake caliper Refer to “CHECKING THE STEERING
KNUCKLES AND FRONT WHEEL BEAR-
TIP
INGS” on page 4-53 and “CHECKING THE
Do not apply the brake pedal when removing the REAR KNUCKLES AND REAR WHEEL
brake caliper. BEARINGS” on page 4-62.
4. Remove:
• Wheel hub “1” Front wheel
Radial wheel runout limit
TIP 2.0 mm (0.08 in)
Use a general puller “2” to separate the wheel Lateral wheel runout limit
hub and constant velocity shaft. 2.0 mm (0.08 in)
Rear wheel
Radial wheel runout limit
2.0 mm (0.08 in)
Lateral wheel runout limit
2 2.0 mm (0.08 in)
EBS30085
CHECKING THE WHEELS

wheels.
1. Check:
• Tire
4-24
TIP
Install the brake disc so that the recessed por-
tion of the bolt hole faces away from the hub.
EBS30088
INSTALLING THE WHEEL HUBS

wheel hubs.
1. Install:
• Wheel hub “1”
TIP
EBS30086 Tap lightly on the wheel hub with a soft-face
CHECKING THE WHEEL HUBS hammer until five threads on the end of the con-
The following procedure applies to all of the stant velocity shaft will be exposed when the
wheel hubs. washer is installed.
1. Check:
• Wheel hub “1”
• Splines (wheel hub) “2”
Wear/damage → Replace the wheel hub.
1
2 2. Install:
• Wheel axle nut New
Front wheel axle nut

350 Nm (35 m·kgf, 253 ft·lbf)
T.
R.
EBS30087
INSTALLING THE BRAKE DISCS Rear wheel axle nut

350 Nm (35 m·kgf, 253 ft·lbf)
brake discs.
TIP
1. Install:
• Brake disc • Do not apply oil to the threads of the nut.
• After tightening the nut, stake the collar of the
Brake disc bolt nut into the notch of the shaft.
30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.
LOCTITE®
4-25
3. Check:
• Brake disc
Refer to “CHECKING THE BRAKE DISCS”
on page 4-34.
EBS30089
INSTALLING THE WHEELS

wheels.
1. Tighten:
• Wheel nuts “1”
Front wheel nut

75 Nm (7.5 m·kgf, 54 ft·lbf)
T.
R.
Rear wheel nut

75 Nm (7.5 m·kgf, 54 ft·lbf)
EWB03130
WARNING
Tapered wheel nuts are used for both the
front and rear wheels. Install each nut with
its tapered side towards the wheel.
4-26
FRONT AND REAR BRAKES
EBS20026

Removing the front brake pads
FW
D
48 Nm (4.8 m•kgf, 35 ft•Ibf)
T.R
1
.
1
3 5 Nm (0.5 m•kgf, 3.6 ft•Ibf)

T.R
.
17 Nm (1.7 m•kgf, 12 ft•Ibf)

T.R
.

the front brake calipers.
Front wheel page 4-23.
1 Brake caliper bolt 2
2 Brake pad bolt 2
3 Brake pad 2
4 Brake pad spring 1
4-27
Removing the rear brake pads
FW 48 Nm (4.8 m•kgf, 35 ft•Ibf)
T.R
.
D
5 Nm (0.5 m•kgf, 3.6 ft•Ibf)

T.R
.
3
1
17 Nm (1.7 m•kgf, 12 ft•Ibf)

4
T.R
.

the rear brake calipers.
Rear wheel page 4-23.
2 Brake pad bolt 2
3 Brake pad 2
4-28
Removing the front brake calipers

48 Nm (4.8 m•kgf, 35 ft•Ibf)
FW
T.R
.
D
17 Nm (1.7 m•kgf, 12 ft•Ibf)

T.R
.
3
4
New 2
2 New
1 27 Nm (2.7 m•kgf, 20 ft•Ibf)
T.R
.

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-19.
1 Brake hose union bolt 1
2 Copper washer 2
3 Brake hose 1 Disconnect.
4 Brake pad bolt 2 Loosen.
6 Brake caliper 1
4-29
Removing the rear brake calipers

48 Nm (4.8 m•kgf, 35 ft•Ibf)
FW
T.R
.
D
17 Nm (1.7 m•kgf, 12 ft•Ibf)

T.R
.
3
27 Nm (2.7 m•kgf, 20 ft•Ibf)
T.R
.
6 2 New 1

Drain.
1 Brake hose union bolt 1
2 Copper washer 2
3 Brake hose 1 Disconnect.
4 Brake pad bolt 2 Loosen.
6 Brake caliper 1
4-30
Disassembling the front brake calipers

22 Nm (2.2 m•kgf, 16 ft•Ibf)
T.R
.
17 Nm (1.7 m•kgf, 12 ft•Ibf)
T.R
.
4
S
5
6
LT 7
S
8 New
2
9 New
BF
3
10
1
5 Nm (0.5 m•kgf, 3.6 ft•Ibf)
T.R
.
17 Nm (1.7 m•kgf, 12 ft•Ibf)

T.R
.

1 Brake pad bolt 2
2 Brake pad 2
4 Brake caliper bracket 1
5 Brake caliper guide pin 1
6 Brake caliper retaining pin 1
7 Brake caliper piston 2
8 Brake caliper piston dust seal 2
9 Brake caliper piston seal 2
10 Bleed screw 1
4-31
Disassembling the rear brake calipers

22 Nm (2.2 m•kgf, 16 ft•Ibf)
T.R
.
17 Nm (1.7 m•kgf, 12 ft•Ibf)
T.R
.
4
S
5
6
LT 7 2
S
8 New
9 New
3
BF
10
1
5 Nm (0.5 m•kgf, 3.6 ft•Ibf)
T.R
.
17 Nm (1.7 m•kgf, 12 ft•Ibf)

T.R
.

1 Brake pad bolt 2
2 Brake pad 2
4 Brake caliper bracket 1
5 Brake caliper guide pin 1
6 Brake caliper retaining pin 1
7 Brake caliper piston 2
8 Brake caliper piston dust seal 2
9 Brake caliper piston seal 2
10 Bleed screw 1
4-32
Removing the brake master cylinder
19 Nm (1.9 m•kgf, 14 ft•Ibf)
T.R
.
3.5 Nm (0.35 m•kgf, 2.5 ft•Ibf)
T.R
.
4
2
16 Nm (1.6 m•kgf, 12 ft•Ibf)

T.R
.
D
FW

Drain.
1 Brake master cylinder reservoir cap 1
2 Brake master cylinder reservoir diaphragm 1
Brake master cylinder reservoir diaphragm hold-
3 1
er
4 Rear brake pipe 1 Disconnect.
5 Front brake pipe 1 Disconnect.
6 Brake master cylinder 1
4-33
EBS30090
b. Measure the deflection 3.0 mm (0.12 in) be-
INTRODUCTION
EWB02930
low the edge of the brake disc.
WARNING
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
• Never disassemble brake components un-
less absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Never use solvents on internal brake com- 4. Measure:

ponents. • Brake disc thickness “a”
• Use only clean or new brake fluid for clean- Measure the brake disc thickness at a few dif-
ing brake components. ferent locations.
• Brake fluid may damage painted surfaces Out of specification → Replace.
and plastic parts. Therefore, always clean
Front brake
up any spilt brake fluid immediately.
Brake disc thickness limit
• Avoid brake fluid coming into contact with 3.5 mm (0.14 in)
the eyes as it can cause serious injury. Rear brake
FIRST AID FOR BRAKE FLUID ENTERING Brake disc thickness limit
THE EYES: 3.5 mm (0.14 in)
• Flush with water for 15 minutes and get im-
mediate medical attention.
EBS30091
CHECKING THE BRAKE DISCS

brake discs.
1. Remove:
• Wheels
page 4-23.
2. Check: 5. Adjust:
• Brake disc • Brake disc deflection
Damage/galling → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3. Measure: a. Remove the brake disc.
• Brake disc deflection b. Rotate the brake disc by one bolt hole.
Out of specification → Correct the brake disc c. Install the brake disc.
deflection or replace the brake disc.
Brake disc bolt
Front brake 30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.
Brake disc deflection limit LOCTITE®

0.10 mm (0.0039 in)
Rear brake TIP
Brake disc deflection limit Install the brake disc so that the recessed por-
0.10 mm (0.0039 in)
tion of the bolt hole faces away from the hub.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the dial gauge at a right angle against
the brake disc surface.
4-34
• Brake pads
TIP
Always install new brake pads and brake pad
spring as a set.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose “1” tightly to the
bleed screw “2”. Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with your
d. Measure the brake disc deflection.
finger.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within 1
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2
6. Install:
• Wheels
page 4-23.
EBS30092 c. Tighten the bleed screw.
REPLACING THE BRAKE PADS
The following procedure applies to all of the Brake caliper bleed screw
brake calipers. 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
T.
R.
TIP
d. Install the brake pad spring and brake pads.
When replacing the brake pads, it is not neces- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
sary to disconnect the brake hose or disassem-
3. Install:
ble the brake caliper.
• Brake pad bolts
1. Measure: • Brake caliper
• Brake pad wear limit “a”
Out of specification → Replace the brake Front brake pad bolt
pads as a set. 17 Nm (1.7 m·kgf, 12 ft·lbf)
T.
R.
Rear brake pad bolt

Front brake 17 Nm (1.7 m·kgf, 12 ft·lbf)
Brake pad lining thickness limit Front brake caliper bolt
1.0 mm (0.04 in) 48 Nm (4.8 m·kgf, 35 ft·lbf)
Rear brake Rear brake caliper bolt
Brake pad lining thickness limit 48 Nm (4.8 m·kgf, 35 ft·lbf)
1.0 mm (0.04 in)
4. Check:
Below the minimum level mark → Add the
Refer to “CHECKING THE BRAKE FLUID
a 5. Check:
• Brake pedal operation
Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC
2. Install: BRAKE SYSTEM” on page 3-19.
• Brake pad spring
4-35
EBS30093
DISASSEMBLING THE BRAKE CALIPERS Recommended brake component replacement

The following procedure applies to all of the schedule
brake calipers. Piston seals, piston
Every two years
TIP dust seals
Before disassembling the brake caliper, drain Brake hoses Every four years
the brake fluid from the entire brake system. Every two years and
Brake fluid whenever the brake is
1. Remove: disassembled
• Brake caliper pistons “1”
• Brake caliper piston dust seals “2” 1. Check:
• Brake caliper piston seals “3” • Brake caliper pistons “1”
Rust/scratches/wear → Replace the brake
caliper pistons.
3 • Brake caliper cylinders “2”
2 Scratches/wear → Replace the brake caliper.
• Brake caliper body “3”
Cracks/damage → Replace the brake cali-
per.
3 • Brake fluid delivery passages
1 (brake caliper body)
2
Obstruction → Blow out with compressed air.
EWB03140
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose joint WARNING
opening “a” to force out the pistons from the Whenever a brake caliper is disassembled,
brake caliper. replace the brake caliper piston dust seals
EWB02890 and brake caliper piston seals.
WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis- 2
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
3
1
2
EBS30095
ASSEMBLING THE BRAKE CALIPERS

a brake calipers.
EWB03150
WARNING
b. Remove the brake caliper piston dust seals • Before installation, all internal brake com-
and piston seals. ponents should be cleaned and lubricated
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
with clean or new brake fluid.
• Never use solvents on internal brake com-
EBS30094
CHECKING THE BRAKE CALIPERS ponents as they will cause the brake caliper
The following procedure applies to all of the piston dust seals and brake caliper piston
brake calipers. seals to swell and distort.
• Whenever a brake caliper is disassembled,
Recommended brake component replacement
replace the brake caliper piston dust seals
schedule
and brake caliper piston seals.
Brake pads If necessary
4-36
Specified brake fluid B

DOT 4
EBS30096
INSTALLING THE BRAKE CALIPERS 2

The following procedure applies to all of the b
brake calipers.
1. Install: 3
• Brake caliper “1” 1
(temporarily)
• Copper washers New C
• Brake hose “2”
• Brake hose union bolt “3”
Front brake hose union bolt 2

27 Nm (2.7 m·kgf, 20 ft·lbf) c
T.
R.
Rear brake hose union bolt

27 Nm (2.7 m·kgf, 20 ft·lbf) 3
EWB02870
1
WARNING
Proper brake hose routing is essential to in- D
sure safe vehicle operation.
ECB01610
2
NOTICE
• When installing the front brake hose (left) d
onto the front brake caliper (left), fit the pro-
jection “a” on the brake hose into the slot in 3
the brake caliper.
• When installing the front brake hose (right) 1
onto the front brake caliper (right), make
sure that the pipe section “b” on the end of A. Front brake (left)
the brake hose contacts the rib on the B. Front brake (right)
brake caliper. C. Rear brake (left)
• When installing the rear brake hose (left) D. Rear brake (right)
onto the rear brake caliper (left), fit the pipe 2. Remove:
section “c” on the end of the brake hose • Brake caliper
into the slot in the brake caliper. 3. Install:
• When installing the rear brake hose (right) • Brake pad spring
onto the rear brake caliper (right), make • Brake pads
sure that the projection “d” on the brake • Brake pad bolts
hose contacts the rib on the brake caliper. • Brake caliper
Refer to “REPLACING THE BRAKE PADS”
È on page 4-35.
Front brake pad bolt

17 Nm (1.7 m·kgf, 12 ft·lbf)
T.
R.
2 Rear brake pad bolt

17 Nm (1.7 m·kgf, 12 ft·lbf)
Front brake caliper bolt
3 48 Nm (4.8 m·kgf, 35 ft·lbf)
a Rear brake caliper bolt
1 48 Nm (4.8 m·kgf, 35 ft·lbf)
4-37
4. Fill: 2. Check:
• Brake master cylinder reservoir • Brake master cylinder reservoir
(with the specified amount of the specified Cracks/damage → Replace the brake master
brake fluid) cylinder.
• Brake master cylinder reservoir diaphragm
Specified brake fluid • Brake master cylinder reservoir diaphragm
DOT 4 holder
EWB02880
WARNING 3. Check:
• Use only the designated brake fluid. Other • Brake pipes
brake fluids may cause the rubber seals to Cracks/damage → Replace.
deteriorate, causing leakage and poor EBS30098
brake performance. CHECKING THE BRAKE PIPES

• Refill with the same type of brake fluid that The following procedure applies to both of the
is already in the system. Mixing brake fluids brake pipes.
may result in a harmful chemical reaction, 1. Check:
leading to poor brake performance. • Brake pipe end (flare nut)
• When refilling, be careful that water does Damage → Replace the brake master cylin-
not enter the brake master cylinder reser- der, brake pipes, and related parts as a set.
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
ECB01320
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
5. Bleed:
• Brake system EBS30099
Refer to “BLEEDING THE HYDRAULIC INSTALLING THE BRAKE MASTER
BRAKE SYSTEM” on page 3-19. CYLINDER
6. Check: 1. Install:
• Brake fluid level • Brake master cylinder
Below the minimum level mark → Add the • Brake pipes
Refer to “CHECKING THE BRAKE FLUID Brake master cylinder bolt
LEVEL” on page 3-18. 16 Nm (1.6 m·kgf, 12 ft·lbf)
T.
R.
7. Check: Brake pipe flare nut

• Brake pedal operation 19 Nm (1.9 m·kgf, 14 ft·lbf)
Soft or spongy feeling → Bleed the brake sys- EWB03160
tem. WARNING
Refer to “BLEEDING THE HYDRAULIC Proper brake pipe routing is essential to in-
BRAKE SYSTEM” on page 3-19. sure safe vehicle operation.
EBS30097
2. Fill:
CHECKING THE BRAKE MASTER
• Brake master cylinder reservoir
CYLINDER
(with the specified amount of the specified
1. Check:
brake fluid)
• Brake master cylinder
Damage/scratches/wear → Replace. Specified brake fluid
• Brake fluid delivery passages DOT 4
(brake master cylinder body)
Obstruction → Blow out with compressed air.
4-38
EWB02880
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
ECB01320
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
3. Bleed:
• Brake system
4. Check:
Below the minimum level mark → Add the
Refer to “CHECKING THE BRAKE FLUID
5. Check:
• Brake pedal operation
Soft or spongy feeling → Bleed the brake sys-
tem.
4-39
PARKING BRAKE
EBS20027
PARKING BRAKE
Disassembling the parking brake
(10)
28 Nm (2.8 m•kgf, 20 ft•Ibf) LT

LT
T.R
6
.
(6) New
(4) 10
4
8 LS
2
5
7
1 11
23 9 LT
LT
1
3
1 9
3
1 New
9 3 1
LT 9
28 Nm (2.8 m•kgf, 20 ft•Ibf) New
T.R
.
28 Nm (2.8 m•kgf, 20 ft•Ibf)

T.R
.
(8)

Refer to “REAR CONSTANT VELOCITY
SHAFT ASSEMBLIES, FINAL DRIVE AS-
Final drive case cover assembly SEMBLY AND REAR DRIVE SHAFT” on
page 8-18.
1 Parking brake plate 5
2 Parking brake spring 2
3 Friction plate 4
4 Parking brake cam plate 1
5 Parking brake cam plate spring 1
6 Ball 6
7 Parking brake boss 1
8 Bearing 1
9 Parking brake plate guide pin 4
10 Parking brake arm 1
11 Parking brake camshaft 1
4-40
PARKING BRAKE
Removing the parking brake lever
16 Nm (1.6 m•kgf, 12 ft•Ibf)
T.R
.
4
1
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

T.R
.
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
13 Nm (1.3 m•kgf, 9.4 ft•Ibf)

T.R
.

Center cover 4-6.
1 Parking brake switch 1
2 Parking brake buzzer 1
3 Parking brake lever 1
4 Parking brake cable 1 Disconnect.
4-41
PARKING BRAKE
EBS30421
CHECKING THE FRICTION PLATES TIP

The following procedure applies to all of the fric- Pitting on the parking brake boss will cause er-
tion plates. ratic brake operation.
1. Check:
• Friction plate
Damage/wear → Replace the friction plates
as a set.
2. Measure:
• Friction plate thickness
Out of specification → Replace the friction
plates as a set.
TIP
Measure the friction plate at four places.
EBS30425
Friction plate thickness limit INSTALLING THE PARKING BRAKE

3.0 mm (0.12 in) 1. Install:
• Parking brake plates
• Friction plates
• Parking brake springs
• Circlips New
TIP
Install the outer parking brake plates “a” and in-
ner parking brake plates “b” so that they are po-
sitioned as shown in the illustration.
EBS30422
CHECKING THE PARKING BRAKE PLATES

parking brake plates.
1. Check: b
• Parking brake plate
Damage → Replace the parking brake plates a
as a set.
2. Install:
EBS30423
CHECKING THE PARKING BRAKE SPRINGS • Parking brake arm “1”

The following procedure applies to both of the TIP
parking brake springs. Align the wide groove “a” in the parking brake
1. Check: arm with the alignment mark “b” in the parking
• Parking brake spring brake camshaft “2”.
Damage → Replace the parking brake
springs as a set. a b 1
EBS30424
2
CHECKING THE PARKING BRAKE BOSS
1. Check:
• Parking brake boss splines
Damage/pitting/wear → Replace the parking
brake boss.
4-42
PARKING BRAKE
EBS30105
INSTALLING THE PARKING BRAKE LEVER

1. Install:
• Parking brake lever
Parking brake lever bolt

13 Nm (1.3 m·kgf, 9.4 ft·lbf)
T.
R.
2. Adjust:
• Parking brake lever free play
Refer to “ADJUSTING THE PARKING
BRAKE” on page 3-21.
4-43
PEDAL ASSEMBLY
EBS20028
PEDAL ASSEMBLY
Removing the pedal assembly
FW
D
2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)
T.R
.
2
3
16 Nm (1.6 m•kgf, 12 ft•Ibf)

T.R
.

Floor board (left) 4-6.
Drain.
Refer to “FRONT AND REAR BRAKES” on
Brake master cylinder page 4-27.
1 Brake light switch 1
2 Throttle cable 1 Disconnect.
3 Pedal assembly 1
4-44
PEDAL ASSEMBLY
Disassembling the pedal assembly
11
LS New 8
3
LS 10
9
9
2
New LS 7
5
New 4
5
6
17 Nm (1.7 m•kgf, 12 ft•Ibf)
T.R
.

1 Pin 1
2 Brake pedal rod 1
3 Spring 1
4 Circlip 1
5 Washer 2
6 Brake pedal 1
7 Spring 1
8 Circlip 1
9 Washer 2
10 Accelerator pedal 1
11 Pedal assembly bracket 1
4-45
PEDAL ASSEMBLY
EBS30106
INSTALLING THE PEDAL ASSEMBLY

1. Install: 1 2
b
• Throttle cable
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the nut “1” until it stops, and then install a
the throttle cable to the plate.
b. Tighten the locknut “2” to specification.
Throttle cable locknut (accelera-

tor pedal end)
T.
R.
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• Accelerator pedal free play
Refer to “ADJUSTING THE ACCELERATOR
PEDAL FREE PLAY” on page 3-22.
3. Adjust:
• Brake pedal free play
Refer to “ADJUSTING THE BRAKE PEDAL”
on page 3-21.
4. Adjust:
• Brake light operation timing
TIP
Adjustment is correct when the brake light
comes on by depressing the brake pedal less
than 5.0–10.0 mm (0.20–0.39 in).
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the main body “1” of the brake light
switch so that it does not rotate and turn the
adjusting nut “2” in direction “a” or “b” until the
brake light comes on at the proper time.
Direction “a”
Brake light comes on sooner.
Direction “b”
Brake light comes on later.
4-46
STEERING SYSTEM
EBS20029
STEERING SYSTEM
Removing the steering assembly
21 Nm (2.1 m•kgf, 15 ft•Ibf)
T.R
.
33 Nm (3.3 m•kgf, 24 ft•Ibf)
T.R
.
4 (4) 3
40 Nm (4.0 m•kgf, 29 ft•Ibf)
T.R
.
5
1
New
6
(4) New
* (4) 1
LS * 33 Nm (3.3 m•kgf, 24 ft•Ibf)
T.R
.
40 Nm (4.0 m•kgf, 29 ft•Ibf)

T.R
.
New
New
55 Nm (5.5 m•kgf, 40 ft•Ibf)
New
T.R
.
LS
48 Nm (4.8 m•kgf, 35 ft•Ibf)
T.R
.
55 Nm (5.5 m•kgf, 40 ft•Ibf)

T.R
.
39 Nm (3.9 m•kgf, 28 ft•Ibf)

T.R
.
* Apply MOLYKOTE® EM-30L GREASE

1 Steering joint bolt 2
2 Steering column 1 Except for EPS models
Disconnect.
3 EPS motor coupler 1 For EPS models
Disconnect.
4 EPS torque sensor coupler 1 For EPS models
5 EPS unit 1 For EPS models
6 Steering joint 1
4-47
STEERING SYSTEM
Removing the steering assembly

21 Nm (2.1 m•kgf, 15 ft•Ibf)
T.R
.
33 Nm (3.3 m•kgf, 24 ft•Ibf)
T.R
.
40 Nm (4.0 m•kgf, 29 ft•Ibf) (4)
T.R
.
9
7
New
(4) New
10
* 11
(4)
LS * 33 Nm (3.3 m•kgf, 24 ft•Ibf)
T.R
11
.
40 Nm (4.0 m•kgf, 29 ft•Ibf)

T.R
.
New 8 New
55 Nm (5.5 m•kgf, 40 ft•Ibf)
New
T.R
.
LS
48 Nm (4.8 m•kgf, 35 ft•Ibf)
7
T.R
.
55 Nm (5.5 m•kgf, 40 ft•Ibf) 9

T.R
.
39 Nm (3.9 m•kgf, 28 ft•Ibf) 10

T.R
.
* Apply MOLYKOTE® EM-30L GREASE

7 Tie-rod end locknut 2
8 Steering assembly 1
9 Tie-rod end 2
10 Dust boot 2
TIP
11 Tie-rod set 2 Replace the tie-rod and lock washer as a
set.
4-48
STEERING SYSTEM
EBS30488
REMOVING THE TIE-ROD

1. Straighten the lock washer “a”.
2. Check:
• Tie-rod end
Bends/damage → Replace.
2. Loosen:
Rubber boot damage → Replace the tie-rod
• Tie-rod “1”
end.
EBS30109
INSTALLING THE STEERING SYSTEM

1. Install:
• Lock washer “1” New
TIP
1
Align the tabs “a” on the lock washer with the
groove “b” in the steering assembly.
EBS30107
CHECKING THE STEERING JOINT

1. Check: a
• Steering joint b
Rough movement → Replace.
New 1
2. Tighten:
• Tie-rod “1”
Tie-rod
55 Nm (5.5 m·kgf, 40 ft·lbf)
T.
R.
EBS30108
CHECKING THE TIE-ROD ENDS

tie-rod ends.
1. Check:
• Tie-rod end free play and movement 1
Rough movement → Replace the tie-rod end.
4-49
STEERING SYSTEM
3. Bends the lock washer “a”. TIP

Tighten the steering assembly bolts in the prop-
er tightening sequence as shown.
FWD
a 4 2
1
4. Install:
• Dust boots 1 3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the tabs “a” into the holes “b” in the boot 6. Install:
band “1”. • Steering joint “1”
• Steering column “2” (except for EPS models)
a • EPS unit “2” (for EPS models)
Steering column bolt (except for

EPS models)
T.
1
R.
21 Nm (2.1 m·kgf, 15 ft·lbf)

EPS unit bolt (for EPS models)
b 21 Nm (2.1 m·kgf, 15 ft·lbf)
Steering joint bolt
33 Nm (3.3 m·kgf, 24 ft·lbf)
b. Crimp the portion “c” of the boot band with the TIP
boots band installation tool “2”.
• Align the alignment mark “a” on the steering
Boots band installation tool assembly shaft and the slit “b” in the steering
90890-01526 joint with the alignment mark “c” on the steering
Boots band installation tool assembly housing.
YM-01526 • Fit the steering joint onto the steering column
shaft or EPS unit shaft so that the bolt hole “d”
in the joint is aligned with the area “e” on the
2 shaft that does not have splines.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install: c a b
• Steering assembly “1”
Steering assembly bolt

48 Nm (4.8 m·kgf, 35 ft·lbf)
T.
R.
4-50
STEERING SYSTEM
1
d
e
7. Adjust:
• Toe-in
Refer to “ADJUSTING THE TOE-IN” on page
3-32.
EBS30426
LUBRICATING THE STEERING SHAFT

Lubricate the pivoting point and metal-to-metal
moving parts of the shaft.
Lithium-soap-based grease
4-51
STEERING KNUCKLES
EBS20030
STEERING KNUCKLES
Removing the steering knuckles
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
2
39 Nm (3.9 m•kgf, 28 ft•Ibf)
T.R
.
3
New
7
8 New
9
1
New
30 Nm (3.0 m•kgf, 22 ft•Ibf) LS
T.R
.
New
4
New 5
8 New
New LS
30 Nm (3.0 m•kgf, 22 ft•Ibf)

T.R
.
6 New 7 New
9 Nm (0.9 m•kgf, 6.5 ft•Ibf)

T.R
.

the steering knuckles.
Front wheel hub page 4-23.
1 Brake disc guard 1
2 Tie-rod end 1 Disconnect.
3 Front brake hose holder 1
4 Steering knuckle 1
5 Circlip 1
6 Ball joint 1
7 Oil seal 2
8 Bearing 2
9 Spacer 1
4-52
STEERING KNUCKLES
EBS30110
e. Apply lithium-soap-based grease to the spac-
REMOVING THE STEERING KNUCKLES
er, new bearings and oil seals.
f. Install the spacer to the steering knuckle.
steering knuckles.
g. Install the new bearings.
1. Remove:
• Steering knuckle “1” TIP
TIP
Install the wheel side bearing first.
ECB01620
Use a general puller to separate the ball joints
NOTICE
“2” from the steering knuckle “1” or the front low-
er arm “3”. Do not strike the inner race or balls of the
bearing. Contact should be made only with
the outer race.
h. Install the new oil seals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30112
CHECKING THE STEERING KNUCKLE BALL

JOINTS
steering knuckle ball joints.
1. Check:
EBS30111
• Ball joint (steering knuckle)
CHECKING THE STEERING KNUCKLES Damage/pitting → Replace the ball joint.
AND FRONT WHEEL BEARINGS Rubber boot damage → Replace the ball
The following procedure applies to both of the joint.
steering knuckles and front wheel bearings. Rough movement → Replace the ball joint.
1. Check:
• Steering knuckle
Damage/pitting → Replace.
2. Check:
• Front wheel bearings “1”
Rough movement/excessive free play → Re-
place.
• Oil seals “2”
Damage → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the surface of the steering knuckle. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b. Remove the oil seals. a. Clean the surface of the steering knuckle.
c. Drive out the bearings. b. Remove the circlip “1”.
EWB03030
WARNING
Eye protection is recommended when using
striking tools.
d. Remove the spacer “3”.
3 1
2 2
c. Remove the ball joint “2”.
TIP
Use a suitable socket “3” to separate the ball
joint “2” from the steering knuckle “4”.
1
4-53
STEERING KNUCKLES
No. Tool name Tool No.

6 Long bolt
90890-01474
4 7 Body
YM-01474
8 Guide bolt
3 90890-01477
9 Installer washer
YM-01477
90890-01553
10 Base plate 35 mm
2 YM-01553
Ball joint installer at- 90890-01555
d. Measure the ball joint bore inside diameter 11
tachment 39 mm YS-01881-A
“a”.
Out of specification → Replace the steering
knuckle. 8 11
7
9
Ball joint bore inside diameter
32.90–32.95 mm (1.295–1.297 in) 6
10
8
6 7 9 8 11 5 10
a
e. Attach the special tools and a new ball joint
“5” to the steering knuckle “4”.
TIP
• Always use a new ball joint. 8 4
• Do not tap or damage the top of the ball joint or f. Hold the base plate “10” in place while turning
rubber boot. in the long bolt “6” to install the new ball joint
“5” into the steering knuckle “4”.
Ball joint remover g. Remove the special tools.
90890-01474 h. Install a new circlip.
Ball joint remover ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
YM-01474
90890-01477
YM-01477
Base plate 35mm
90890-01553
Base plate 35mm
YM-01553
Ball joint installer attachment
39mm
90890-01555
39mm
YS-01881-A
4-54
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES
EBS20031

Removing the front arms and front shock absorber assemblies
LS 5 55 Nm (5.5 m•kgf, 40 ft•Ibf)
T.R
5 7
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
7
T.R
.
LS
2
7
LS 55 Nm (5.5 m•kgf, 40 ft•Ibf)
T.R
.
9 9
6
LS
8 New
5
4
New
5 30 Nm (3.0 m•kgf, 22 ft•Ibf)
3
T.R
.
T.R
55 Nm (5.5 m•kgf, 40 ft•Ibf)
.
30 Nm (3.0 m•kgf, 22 ft•Ibf)

T.R
.
1
New
D
FW 4 7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.

the front upper arms, front lower arms, and
front shock absorber assemblies.
1 Front arm protector 1
4 Nut 2
5 Nut/Bolt (front shock absorber assembly) 2/2
6 Front shock absorber assembly 1
7 Nut/Bolt (front upper arm) 2/2
8 Front upper arm 1
9 Dust cover 2
4-55
Removing the front arms and front shock absorber assemblies

T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
LS
T.R
.
15 10 10 10
15
10
LS
New
12
12 15 13 New
30 Nm (3.0 m•kgf, 22 ft•Ibf)
T.R
14
.
15 55 Nm (5.5 m•kgf, 40 ft•Ibf)
T.R
.
11
30 Nm (3.0 m•kgf, 22 ft•Ibf)
T.R
.
New
D
FW 7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.

10 Nut/Bolt (front lower arm) 2/2
11 Front lower arm 1
12 Dust cover 2
13 Circlip 1
14 Ball joint 1
15 Bushing 4
4-56
EBS30113
damage or personal injury that may result
CHECKING THE FRONT ARMS
from improper handling of the front shock
absorber and gas cylinder.
front upper arms and front lower arms.
• Do not tamper or attempt to open the front
1. Check:
shock absorber or gas cylinder.
• Front arm free play
• Do not subject the front shock absorber or
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the front arm side play “A” by moving gas cylinder to an open flame or any other
it from side to side. source of high heat. High heat can cause an
If side play is noticeable, check the bushings. explosion due to excessive gas pressure.
• Do not deform or damage the front shock
absorber or gas cylinder in any way. If the
front shock absorber, gas cylinder or both
are damaged, damping performance will
A suffer.
EBS30115
DISPOSING OF A FRONT SHOCK

ABSORBER ASSEMBLY
A Gas pressure must be released before dispos-
ing of a front shock absorber assembly. To re-
b. Check the front arm vertical movement “B” by lease the gas pressure, drill a 2–3 mm (0.08–
moving it up and down. 0.12 in) hole through the front shock absorber as
If the vertical movement is tight or rough, or if shown.
there is binding, check the bushings. EWB03180
WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
B
B
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Front upper arm
• Front lower arm
EBS30116
CHECKING THE FRONT SHOCK ABSORBER

3. Check: ASSEMBLIES
• Bushings The following procedure applies to both of the
Wear/damage → Replace. front shock absorber assemblies.
EBS30114 1. Check:
HANDLING THE FRONT SHOCK ABSORBER • Front shock absorber assembly
ASSEMBLIES Gas leaks → Replace the front shock absorb-
EWB03170
er assembly.
WARNING
• Front shock absorber rod
Shock absorbers and gas cylinders contain Bends/damage → Replace the front shock
highly compressed nitrogen gas. Before absorber assembly.
handling the front shock absorber or gas cyl- • Spring
inder, read and make sure you understand Move the spring up and down.
the following information. The manufacturer Fatigue → Replace the front shock absorber
cannot be held responsible for property assembly.
4-57
EBS30117
• Do not tap or damage the top of the ball joint or
CHECKING THE FRONT ARM BALL JOINTS
rubber boot.
front arm ball joints.
1. Check: Ball joint remover
• Ball joint (front upper arm) 90890-01474
Ball joint remover
Damage/pitting → Replace the ball joint.
YM-01474
Rubber boot damage → Replace the ball Ball joint remover adapter set
joint. 90890-01477
Rough movement → Replace the ball joint. Ball joint remover adapter set
YM-01477
Base plate 35mm
90890-01553
Base plate 35mm
YM-01553
39mm
90890-01555
39mm
YS-01881-A
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the surface of the front upper arm.
b. Remove the circlip “1”. No. Tool name Tool No.
6 Long bolt
90890-01474
7 Body
YM-01474
8 Guide bolt
90890-01477
9 Installer washer
YM-01477
1
90890-01553
10 Base plate 35 mm
YM-01553
Ball joint installer at- 90890-01555
11
tachment 39 mm YS-01881-A
c. Remove the ball joint “2”.
TIP 11
8
Use a suitable socket “3” to separate the ball 7 9
joint “2” from the front upper arm “4”.
6
3
10
8
4
6
2 7
8
d. Attach the special tools and a new ball joint 9
“5” to the front upper arm “4”. 11
TIP 10
• Always use a new ball joint. 8
4
5
4-58
e. Hold the base plate “10” in place while turning

in the long bolt “6” to install the new ball joint
“5” into the front upper arm “4”.
f. Remove the special tools.
g. Install a new circlip.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6,7
EBS30118
INSTALLING THE FRONT ARMS AND

FRONT SHOCK ABSORBER ASSEMBLIES 5
The following procedure applies to both of the 1
front upper arms, front lower arms, and front
shock absorber assemblies.
1. Install: 6,7
3,4
• Front upper arm 8
• Front lower arm
• Front shock absorber assembly
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the front upper arm “1” and front lower 2
arm “2”.
TIP 8
• Lubricate the front upper and lower arm bolts
“3” with lithium-soap-based grease. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Be sure to position the front upper and lower
arm bolts “3” so that the bolt heads face for-
ward.
• Temporarily tighten the front upper and lower
arm nuts “4”.
b. Install the front shock absorber assembly “5”,
bolts “6”, and nuts “7”.
Front shock absorber assembly

nut
T.
R.
55 Nm (5.5 m·kgf, 40 ft·lbf)
TIP
• Install the front shock absorber assembly so
that the gas cylinder is facing rearward.
• Be sure to position the front shock absorber
bolts “6” so that the bolt heads face forward.
c. Install the steering knuckle and nuts “8”.
Steering knuckle nut

30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.
d. Install new cotter pins.

e. Tighten the front upper and lower arm nuts
“4” to specification.
Front arm nut

55 Nm (5.5 m·kgf, 40 ft·lbf)
T.
R.
4-59
REAR KNUCKLES AND STABILIZER
EBS20032

Removing the rear knuckles and stabilizer
FW
D 85 Nm (8.5 m•kgf, 61 ft •Ibf) 60 Nm (6.0 m•kgf, 43 ft •Ibf)
T.
T.
R.
R.
9
60 Nm (6.0 m•kgf, 43 ft •Ibf)

T.
R.
New 6
LS
9 Nm (0.9 m•kgf, 6.5 ft •Ibf)
T.
R.
7 New
New 6 4
3 5
4
8
7 New
4 5
4
1 90 Nm (9.0 m•kgf, 65 ft •Ibf)

2
T.
R.
LS

the rear knuckles.
Rear wheel hub page 4-23.
1 Rear brake disc cleaning plate 1
2 Brake disc guard 1
3 Rear knuckle 1
4 Spacer cover 4
5 Spacer 2
6 Oil seal 2
7 Bearing 2
8 Spacer 1
9 Stabilizer joint 2
4-60
Removing the rear knuckles and stabilizer
FW
D 85 Nm (8.5 m•kgf, 61 ft •Ibf) 60 Nm (6.0 m•kgf, 43 ft •Ibf)
10
T.
T.
R.
R.
11
12
10
11
60 Nm (6.0 m•kgf, 43 ft •Ibf)

T.
R.
New
LS
9 Nm (0.9 m•kgf, 6.5 ft •Ibf)
T.
R.
New
New
New
90 Nm (9.0 m•kgf, 65 ft •Ibf)

T.
R.
LS

10 Stabilizer holder 2
11 Bushing 2
12 Stabilizer 1
4-61
EBS30119 EBS30121
CHECKING THE REAR KNUCKLES AND INSTALLING THE STABILIZER

REAR WHEEL BEARINGS 1. Install:
The following procedure applies to both of the • Stabilizer “1”
rear knuckles and rear wheel bearings. • Bushing “2”
1. Check: • Stabilizer holder “3”
• Rear knuckle
Damage/pitting → Replace. Stabilizer holder bolt
2. Check: 85 Nm (8.5 m·kgf, 61 ft·lbf)
T.
R.
• Rear wheel bearings “1”
Rough movement/excessive free play → Re- TIP
place. Install the bushing with its slit “a” facing down-
• Oil seals “2” ward.
Damage → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the surface of the rear knuckle.
2
b. Remove the oil seals.
c. Drive out the bearings. 3
EWB03030 1
WARNING
Eye protection is recommended when using a
striking tools.
d. Remove the spacer “3”.
1
2 2
e. Apply lithium-soap-based grease to the spac-

er, new bearings and oil seals.
f. Install the spacer to the rear knuckle.
g. Install the new bearings.
TIP
Install the wheel side bearing first.
ECB01620
NOTICE
Do not strike the inner race or balls of the
bearing. Contact should be made only with
the outer race.
h. Install the new oil seals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30120
CHECKING THE STABILIZER

1. Check:
• Stabilizer
Bends/cracks/damage → Replace.
4-62
REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES
EBS20033

Removing the rear arms and rear shock absorber assemblies
FW 7 Nm (0.7 m•kgf, 5.1 ft •Ibf) 3 82 Nm (8.2 m•kgf, 59 ft •Ibf)
T.
R.
D
T.
R.
8 3
LS
8
6
7
6 LS
5 LS
6
2
6
5 2
7 Nm (0.7 m•kgf, 5.1 ft •Ibf)
T.
R.
90 Nm (9.0 m•kgf, 65 ft•Ibf)

T.R
.
55 Nm (5.5 m•kgf, 40 ft •Ibf)

4
T.
R.
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

3
T.R
.
3
82 Nm (8.2 m•kgf, 59 ft •Ibf)
T.
R.
90 Nm (9.0 m•kgf, 65 ft•Ibf)

T.R
.

the rear upper arms, rear lower arms, and
rear shock absorber assemblies.
Refer to “REAR KNUCKLES AND STABI-
Stabilizer joint LIZER” on page 4-60.
1 Rear constant velocity shaft dust boot guard 1
2 Rear brake hose holder 2
3 Nut/Bolt (rear shock absorber) 2/2
4 Rear shock absorber assembly 1
5 Nut/Bolt (rear upper arm–rear knuckle) 1/1
6 Nut/Bolt (rear upper arm–frame) 2/2
7 Rear upper arm 1
8 Dust cover 2
4-63
Removing the rear arms and rear shock absorber assemblies
FW 7 Nm (0.7 m•kgf, 5.1 ft •Ibf)

82 Nm (8.2 m•kgf, 59 ft •Ibf)
T.
R.
D
T.
R.
13
LS
13
LS
LS
10
10 10
7 Nm (0.7 m•kgf, 5.1 ft •Ibf)
10
T.
R.
90 Nm (9.0 m•kgf, 65 ft•Ibf)

T.R
.
12
13
12 55 Nm (5.5 m•kgf, 40 ft •Ibf)
T.
R.
13
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.
11 82 Nm (8.2 m•kgf, 59 ft •Ibf)

T.
R.
9 90 Nm (9.0 m•kgf, 65 ft•Ibf)

T.R
.
9 Nut/Bolt (rear lower arm–rear knuckle) 1/1

10 Nut/Bolt (rear lower arm–frame) 2/2
11 Rear lower arm 1
12 Dust cover 2
13 Bushing 4
4-64
EBS30122
property damage or personal injury that may
CHECKING THE REAR ARMS
result from improper handling of the rear
shock absorber and gas cylinder.
rear upper arms and rear lower arms.
• Do not tamper or attempt to open the rear
1. Check:
shock absorber or gas cylinder.
• Rear arm free play
• Do not subject the rear shock absorber or
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the rear arm side play “A” by moving it gas cylinder to an open flame or any other
from side to side. source of high heat. High heat can cause an
If side play is noticeable, check the bushings. explosion due to excessive gas pressure.
• Do not deform or damage the rear shock
absorber or gas cylinder in any way. If the
rear shock absorber, gas cylinder or both
are damaged, damping performance will
A
suffer.
EBS30124
DISPOSING OF A REAR SHOCK ABSORBER

ASSEMBLY
A Gas pressure must be released before dispos-
ing of a rear shock absorber assembly. To re-
b. Check the rear arm vertical movement “B” by lease the gas pressure, drill a 2–3 mm (0.08–
moving it up and down. 0.12 in) hole through the rear shock absorber as
If the vertical movement is tight or rough, or if shown.
there is binding, check the bushings. EWB03180
WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
B
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Rear upper arm
• Rear lower arm
EBS30125
CHECKING THE REAR SHOCK ABSORBER

3. Check: ASSEMBLIES
• Bushings The following procedure applies to both of the
Wear/damage → Replace. rear shock absorber assemblies.
EBS30123 1. Check:
HANDLING THE REAR SHOCK ABSORBER • Rear shock absorber assembly
ASSEMBLIES Gas leaks → Replace the rear shock absorb-
EWB03190
er assembly.
WARNING
• Rear shock absorber rod
This rear shock absorber and gas cylinder Bends/damage → Replace the rear shock
contain highly compressed nitrogen gas. Be- absorber assembly.
fore handling the rear shock absorber or gas • Spring
cylinder, read and make sure you under- Move the spring up and down.
stand the following information. The manu- Fatigue → Replace the rear shock absorber
facturer cannot be held responsible for assembly.
4-65
EBS30126
INSTALLING THE REAR ARMS AND REAR

SHOCK ABSORBER ASSEMBLIES 6,7
rear upper arms, rear lower arms, and rear
shock absorber assemblies. 5
1. Install:
• Rear upper arm
• Rear lower arm
• Rear shock absorber assembly 3,4
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the rear upper arm “1” and rear lower 3,4
arm “2”. 1
TIP 8,9
• Lubricate the rear upper and lower arm bolts
“3” with lithium-soap-based grease.
• Be sure to position the rear upper and lower 6,7
arm bolts “3” so that the bolt heads face for-
ward. 8,9
• Temporarily tighten the rear upper and lower
2
arm nuts “4”.
b. Install the rear shock absorber assembly “5”, ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
bolts “6”, and nuts “7”.
Rear shock absorber assembly

nut
T.
R.
82 Nm (8.2 m·kgf, 59 ft·lbf)
TIP
• Install the rear shock absorber assembly so
that the gas cylinder is facing forward.
• Be sure to position the rear shock absorber
bolts “6” so that the bolt heads face forward.
c. Install the rear knuckle bolts “8”, and nuts “9”.
Rear knuckle nut

90 Nm (9.0 m·kgf, 65 ft·lbf)
T.
R.
d. Tighten the rear upper and lower arm nuts “4”

to specification.
Rear arm nut

55 Nm (5.5 m·kgf, 40 ft·lbf)
T.
R.
4-66
4-67
ENGINE
ENGINE INSPECTION .................................................................................... 5-1

MEASURING THE COMPRESSION PRESSURE....................................5-1
ENGINE REMOVAL (1) ................................................................................... 5-3

INSTALLING THE EXHAUST PIPE AND MUFFLER................................5-4
ENGINE REMOVAL (2) ................................................................................... 5-5

INSTALLING THE ENGINE....................................................................... 5-9
CAMSHAFTS.................................................................................................5-10
REMOVING THE CAMSHAFTS..............................................................5-12
CHECKING THE CAMSHAFTS ..............................................................5-13
CHECKING THE CAMSHAFT SPROCKETS .........................................5-14
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-14
INSTALLING THE CAMSHAFTS ............................................................ 5-14
INSTALLING THE BREATHER PLATE .................................................. 5-16
CYLINDER HEAD, CYLINDER, AND PISTON ............................................. 5-17

REMOVING THE CYLINDER HEAD.......................................................5-20
REMOVING THE PISTON ...................................................................... 5-20
CHECKING THE CYLINDER HEAD .......................................................5-21
CHECKING THE CYLINDER AND PISTON ...........................................5-21
5
CHECKING THE PISTON RINGS........................................................... 5-22
CHECKING THE PISTON PIN ................................................................5-23
INSTALLING THE PISTON AND CYLINDER .........................................5-23
INSTALLING THE CYLINDER HEAD .....................................................5-24
VALVES AND VALVE SPRINGS.................................................................. 5-26

REMOVING THE VALVES...................................................................... 5-27
CHECKING THE VALVES AND VALVE GUIDES ..................................5-27
CHECKING THE VALVE SEATS ............................................................ 5-29
CHECKING THE VALVE SPRINGS........................................................ 5-30
CHECKING THE VALVE LIFTERS ......................................................... 5-31
INSTALLING THE VALVES .................................................................... 5-31
AC MAGNETO AND STARTER CLUTCH ....................................................5-33

REMOVING THE AC MAGNETO ROTOR.............................................. 5-35
REMOVING THE STARTER CLUTCH ...................................................5-35
CHECKING THE STARTER CLUTCH ....................................................5-35
INSTALLING THE STARTER CLUTCH .................................................. 5-36
INSTALLING THE AC MAGNETO ROTOR ............................................5-36
ELECTRIC STARTER ...................................................................................5-38

CHECKING THE STARTER MOTOR .....................................................5-40
ASSEMBLING THE STARTER MOTOR................................................. 5-41
OIL PUMP SPROCKETS .............................................................................. 5-42
REMOVING THE OIL PUMP DRIVE SPROCKET AND
OIL PUMP DRIVEN SPROCKET ........................................................... 5-43
CHECKING THE OIL PUMP SPROCKETS ............................................5-43
INSTALLING THE OIL PUMP DRIVE SPROCKET AND
OIL PUMP DRIVEN SPROCKET ........................................................... 5-43
SHIFT LEVER................................................................................................5-45
CHECKING THE STOPPER LEVER ......................................................5-47
CHECKING THE SHIFT LEVERS........................................................... 5-47
INSTALLING THE SHIFT LEVERS......................................................... 5-47
ADJUSTING THE DRIVE SELECT LEVER SHIFT ROD........................ 5-48
PRIMARY AND SECONDARY SHEAVES....................................................5-50

REMOVING THE PRIMARY AND SECONDARY SHEAVES ................. 5-53
DISASSEMBLING THE SECONDARY SHEAVE.................................... 5-53
CHECKING THE V-BELT........................................................................5-54
CHECKING THE PRIMARY SHEAVE ....................................................5-54
CHECKING THE PRIMARY SHEAVE WEIGHTS................................... 5-54
CHECKING THE PRIMARY SHEAVE SLIDERS .................................... 5-54
CHECKING THE SECONDARY SHEAVE .............................................. 5-54
ASSEMBLING THE PRIMARY SHEAVE ................................................ 5-55
ASSEMBLING THE SECONDARY SHEAVE..........................................5-56
INSTALLING THE PRIMARY AND SECONDARY SHEAVES................ 5-57
CLUTCH ........................................................................................................5-60
REMOVING THE CLUTCH ..................................................................... 5-62
CHECKING THE CLUTCH...................................................................... 5-62
CHECKING THE CLUTCH SHOE........................................................... 5-62
ASSEMBLING THE CLUTCH HOUSING................................................ 5-63
INSTALLING THE CLUTCH.................................................................... 5-63
CRANKCASE ................................................................................................5-65
SEPARATING THE CRANKCASE.......................................................... 5-68
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE............. 5-68
CHECKING THE BEARINGS.................................................................. 5-68
CHECKING THE CRANKCASE ..............................................................5-69
ASSEMBLING THE CRANKCASE.......................................................... 5-69
CRANKSHAFT AND OIL PUMP ................................................................... 5-71

REMOVING THE CRANKSHAFT ........................................................... 5-73
CHECKING THE OIL PUMP ................................................................... 5-73
CHECKING THE OIL STRAINER ........................................................... 5-73
CHECKING THE RELIEF VALVE ........................................................... 5-73
CHECKING THE CRANKSHAFT ............................................................ 5-74
ASSEMBLING THE OIL PUMP...............................................................5-74
INSTALLING THE CRANKSHAFT .......................................................... 5-74
INSTALLING THE OIL PUMP .................................................................5-75
TRANSMISSION............................................................................................ 5-76
REMOVING THE TRANSMISSION ........................................................ 5-80
DISASSEMBLING THE DRIVE AXLE.....................................................5-80
CHECKING THE SHIFT FORKS............................................................. 5-80
CHECKING THE SHIFT DRUM ..............................................................5-80
CHECKING THE TRANSMISSION ......................................................... 5-81
CHECKING THE SECONDARY SHAFT................................................. 5-81
ASSEMBLING THE DRIVE AXLE........................................................... 5-81
ASSEMBLING THE SHIFT FORK........................................................... 5-81
INSTALLING THE SHIFT FORKS AND SHIFT DRUM........................... 5-82
MIDDLE GEAR ..............................................................................................5-83

REMOVING THE MIDDLE DRIVE SHAFT ............................................. 5-87
REMOVING THE MIDDLE DRIVEN SHAFT...........................................5-87
CHECKING THE PINION GEARS .......................................................... 5-88
INSTALLING THE BEARING AND OIL SEALS ...................................... 5-89
INSTALLING THE MIDDLE DRIVEN SHAFT .........................................5-89
INSTALLING THE MIDDLE DRIVE SHAFT ............................................5-90
MEASURING THE MIDDLE GEAR BACKLASH..................................... 5-91
ALIGNING THE MIDDLE GEAR ............................................................. 5-92
ENGINE INSPECTION
EBS20105
7. Measure:
ENGINE INSPECTION • Compression pressure
EBS30135
Out of specification → Refer to steps (b) and
MEASURING THE COMPRESSION (c).
PRESSURE
Standard compression pressure
TIP (at sea level)
Insufficient compression pressure will result in a 650–1000 kPa (6.5–10.0 kgf/cm²,
loss of performance. 92.4–142.2 psi)
1. Measure:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Valve clearance a. With the throttle wide open, crank the engine
Out of specification → Adjust. by turning the main switch to “ ” (start) until
Refer to “ADJUSTING THE VALVE CLEAR- the reading on the compression gauge stabi-
ANCE” on page 3-3. lizes.
2. Start the engine, warm it up for several min- EWB03200
utes, and then turn it off. WARNING

3. Remove: To prevent sparking, ground the spark plug
• Frame cross member lead before cranking the engine.
b. If the compression pressure is above the
4-19.
maximum specification, check the cylinder
4. Disconnect:
head, valve surfaces and piston crown for
• Spark plug cap
carbon deposits.
5. Remove:
Carbon deposits → Eliminate.
• Spark plug
ECB01870
c. If the compression pressure is below the min-
NOTICE imum specification, pour a teaspoonful of en-
Before removing the spark plug, use com- gine oil into the spark plug bore and measure
pressed air to blow away any dirt accumulat- again.
ed in the spark plug well to prevent it from Refer to the following table.
falling into the cylinder. Compression pressure (with oil applied into the
cylinder)
6. Install:
Reading Diagnosis
• Extension “1”
• Compression gauge “2” Piston ring(s) wear or
Higher than without oil
damage → Repair.
Extension Piston, valves, cylinder
90890-04136 head gasket, or piston
Same as without oil
Compression gauge ring(s) possibly defec-
90890-03081 tive → Repair.
Engine compression tester
YU-33223 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Install:
• Spark plug
2
1
Spark plug
Specified angle 30°–45°
T.
R.
TIP
Before installing the spark plug, clean the spark
plug and gasket surface.
9. Connect:
• Spark plug cap
5-1
ENGINE INSPECTION
10.Install:
4-19.
5-2
ENGINE REMOVAL (1)
EBS20034
ENGINE REMOVAL (1)

Removing the muffler and exhaust pipe
20 Nm (2.0 m•kgf, 14 ft•Ibf)
T.R
.
7 New
New 4
1
LT 2
3 23 Nm (2.3 m•kgf, 17 ft•Ibf)

T.R
.
5 17 Nm (1.7 m•kgf, 12 ft•Ibf)

T.R
.

1 Spring 2
2 Muffler 1
3 Muffler heat protector plate 1
4 Gasket 1
5 Muffler mount 1
6 Exhaust pipe 1
7 Gasket 1
5-3
ENGINE REMOVAL (1)
EBS30127
INSTALLING THE EXHAUST PIPE AND 1

MUFFLER
1. Install:
• Gasket “1” New
(muffler side)
ECB01640
NOTICE
Be careful not to damage the muffler contact
surface of the gasket. 1
TIP
Install the gasket completely onto the exhaust
pipe “2” by pushing the side “a” of the gasket. If
the gasket is difficult to install, tap lightly on the
gasket with a soft-face hammer.
New 1 2
2. Install:
• Muffler mount “1”
Installed length “a”

28 mm (1.10 in)
a
1
3. Install:
• Springs “1”
TIP
Install the springs so that the spring ends are
pointing inward as shown in the illustration.
5-4
ENGINE REMOVAL (2)
EBS20093
ENGINE REMOVAL (2)

Disconnecting the couplers and leads
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
4.9 Nm (0.49 m•kgf, 3.5 ft•Ibf)
T.R
.
FW
D

Frame cross member 4-19.
Refer to “GENERAL CHASSIS (10)” on
V-belt cooling ducts page 4-21.
Disconnect.
Drive select lever shift rod Refer to “SHIFT LEVER” on page 5-45.
Drive belt case SHEAVES” on page 5-50.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-14.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-9.
Oil inlet pipe/Oil outlet pipe Refer to “OIL COOLER” on page 6-1.
Water pump inlet hose Refer to “RADIATOR” on page 6-4.
Thermostat Refer to “THERMOSTAT” on page 6-8.
Water pump outlet pipe Refer to “WATER PUMP” on page 6-11.
5-5
ENGINE REMOVAL (2)

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
4.9 Nm (0.49 m•kgf, 3.5 ft•Ibf)
3
T.R
.
1
2
FW
D

Refer to “AIR INDUCTION SYSTEM” on
Air cut-off valve page 7-14.
Throttle body Refer to “THROTTLE BODY” on page 7-8.
Refer to “FRONT CONSTANT VELOCITY
SHAFT ASSEMBLIES, DIFFERENTIAL AS-
Front drive shaft (middle gear side) SEMBLY AND FRONT DRIVE SHAFTS” on
page 8-4.
Refer to “REAR CONSTANT VELOCITY
SHAFT ASSEMBLIES, FINAL DRIVE AS-
Rear drive shaft SEMBLY AND REAR DRIVE SHAFT” on
page 8-18.
1 Spark plug cap 1 Disconnect.
2 Coolant temperature sensor coupler 1 Disconnect.
3 Ignition coil connector 2 Disconnect.
4 Reverse switch coupler 1 Disconnect.
5 Gear position switch coupler 1 Disconnect.
5-6
ENGINE REMOVAL (2)

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
4.9 Nm (0.49 m•kgf, 3.5 ft•Ibf)
T.R
.
6
7
9 8
10
FW
D

6 Engine ground lead 1 Disconnect.
7 Starter motor lead 1 Disconnect.
8 Speed sensor coupler 1 Disconnect.
9 Crankshaft position sensor coupler 1 Disconnect.
10 AC magneto lead coupler 2 Disconnect.
5-7
ENGINE REMOVAL (2)
Removing the engine
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
42 Nm (4.2 m•kgf, 30 ft•Ibf)
7
T.
R.
9
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
8
T.R
.
2
9 6 1
LT
LT
LT
7 2
8 6
1
FW
3 LT D
42 Nm (4.2 m•kgf, 30 ft•Ibf) 5
T.
R.

1 Engine mounting bolt (front) 2
2 Engine mounting bolt (front) 2
3 Engine bracket nut (rear) 2
TIP
4 Engine 1 Remove the engine from the top of the vehi-
cle.
5 Engine bracket nut (front) 2

6 Engine bracket (front) 2
7 Engine mounting bolt (rear) 2
8 Engine mounting bolt (rear) 2
9 Engine bracket (rear) 2
5-8
ENGINE REMOVAL (2)
EBS30351
INSTALLING THE ENGINE

1. Install:
• Engine brackets (rear) “1”
(onto the engine)
• Engine mounting bolts (rear) (M10) “2” 6
• Engine mounting bolts (rear) (M6) “3”
TIP
Before installing the engine, tighten the engine
mounting bolts (rear) to specification.
Engine mounting bolt (rear) (M10) 1 3

42 Nm (4.2 m·kgf, 30 ft·lbf) 2 8
T.
R.
Engine mounting bolt (rear) (M6) 1 4 9

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
3 8 4
2
2. Install:
• Engine brackets (front) “4”
9
(onto the frame) 5
7
• Engine bracket nuts (front) “5”
• Engine “6”
• Engine bracket nuts (rear) “7”
• Engine mounting bolts (front) (M10) “8”
ECB01630
NOTICE
Make sure that the engine does not strike the
brake pipe when installing it.
TIP
Do not fully tighten the bolts and nuts.
3. Tighten:
• Engine bracket nuts (front) “5”
• Engine bracket nuts (rear) “7”
Engine bracket nut (front)

42 Nm (4.2 m·kgf, 30 ft·lbf)
T.
R.
Engine bracket nut (rear)

42 Nm (4.2 m·kgf, 30 ft·lbf)
Engine mounting bolt (front)
(M10)
42 Nm (4.2 m·kgf, 30 ft·lbf)
Engine mounting bolt (front) (M6)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
5-9
CAMSHAFTS
EBS20106
CAMSHAFTS
Removing the cylinder head cover
D
3
1 FW
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
4 11 Nm (1.1 m•kgf, 8.0 ft•Ibf)*

(4)
T.R
Specified angle 30–45˚*
.
5 2
4
New
6
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) New

T.R
.
(4) 8
7
New
* When installing a new spark plug, tighten the spark plug to 11 Nm (1.1 m·kgf, 8.0 ft·lbf).
* When reusing a spark plug, tighten the spark plug to 30°–45°.

Heat protector/Frame cross member 4-19.
Fuel tank Refer to “FUEL TANK” on page 7-1.
1 Spark plug cap 1 Disconnect.
2 Spark plug 1
3 Breather plate cover 1
4 Breather plate cover gasket 2
5 Breather plate 1
6 Cylinder head cover 1
7 Cylinder head cover gasket 1
8 Timing chain guide (upper side) 1
5-10
CAMSHAFTS
Removing the camshafts

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
. 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
5
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
6
.
E 5 Nm (0.5 m•kgf, 3.6 ft•Ibf)
T.R
.
(8) E
6
7 New
New D
8 FW
E
3
4
E
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.
E
New
2
New
E 1
11 Nm (1.1 m•kgf, 8.0 ft•Ibf)
T.R
.

1 Crankshaft end accessing screw 1
2 Timing mark accessing screw 1
3 Timing chain tensioner 1
4 Timing chain tensioner gasket 1
5 Camshaft cap 1
6 Bearing stopper 2
7 Intake camshaft 1
8 Exhaust camshaft 1
5-11
CAMSHAFTS
EBS30432
REMOVING THE CAMSHAFTS c e f c f

1. Remove:
• Crankshaft end accessing screw “1” e d
• Timing mark accessing screw “2”
2 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1 3. Remove:
• Timing chain tensioner
• Timing chain tensioner gasket
2. Align: 4. Remove:
• Mark “a” on the AC magneto rotor • Camshaft cap “1”
(with the mark “b” in the AC magneto cover) • Bearing stoppers “2”
ECB02430
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
NOTICE
• To prevent damage to the cylinder head,
camshafts or camshaft cap, loosen the
camshaft cap bolts in stages and in a criss-
cross pattern, working from the outside in.
• Be sure not to let the bearing stoppers fall
into the crankcase when removing it.
b. Position the mark “a” on the AC magneto ro-

tor with the mark “b” in the AC magneto cov-
er.
a
1
b
2
TIP
When the holes “c” in the intake camshaft
sprocket and exhaust camshaft sprocket are po-
sitioned above the cylinder head mating surface 5. Remove:
“d” as shown in the illustration, and the marks “e” • Intake camshaft “1”
and “f” on the sprockets are aligned with the cyl- • Exhaust camshaft “2”
inder head mating surface “d”, the piston is at TIP
TDC.
To prevent the timing chain from coming off the
crankshaft sprocket, fasten it with a wire “3”.
5-12
CAMSHAFTS
1 3. Measure:
• Camshaft-journal-to-camshaft-cap clearance
Out of specification → Measure the camshaft
3 journal diameter.
Camshaft-journal-to-camshaft-
cap clearance
0.037–0.075 mm (0.0015–0.0030
in)
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EBS30433 a. Install the camshafts into the cylinder head
CHECKING THE CAMSHAFTS (without the camshaft cap).
1. Check: b. Position a strip of Plastigauge® “1” onto the
• Camshaft lobes camshaft journal as shown.
Blue discoloration/pitting/scratches → Re-
place the camshaft. 1
2. Measure:
• Camshaft lobe dimensions “a” and “b”
Out of specification → Replace the camshaft.
Camshaft lobe dimensions

Lobe height (Intake) limit
33.8 mm (1.331 in)
Base circle diameter (Intake) limit
24.85 mm (0.978 in)
Lobe height (Exhaust) limit c. Install the camshaft cap.
30.75 mm (1.211 in) TIP
Base circle diameter (Exhaust) • Tighten the camshaft cap bolts in the tighten-
limit ing sequence as shown.
22.35 mm (0.880 in)
• Do not turn the camshaft when measuring the
camshaft journal-to-camshaft cap clearance
with the Plastigauge®.
Camshaft cap bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
6 2
5 1
7 3
4
8
d. Remove the camshaft cap, and then mea-
sure the width of the Plastigauge® “1”.
5-13
CAMSHAFTS
EBS30435
1 CHECKING THE TIMING CHAIN TENSIONER

1. Check:
• Timing chain tensioner
Cracks/damage/rough movement → Re-
place.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Lightly press the timing chain tensioner rod
into the timing chain tensioner housing by
hand.
TIP
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
While pressing the timing chain tensioner rod,
4. Measure: wind it clockwise with a flat-head screwdriver un-
• Camshaft journal diameter “a” til it stops.
Out of specification → Replace the camshaft.
Within specification → Replace the cylinder
head and camshaft cap as a set.
Camshaft journal diameter

21.946–21.963 mm (0.8640–
0.8647 in)
b. Make sure that the timing chain tensioner rod

moves in and out of the timing chain tension-
er housing smoothly. If there is rough move-
ment, replace the timing chain tensioner.
EBS30434
CHECKING THE CAMSHAFT SPROCKETS

1. Check:
• Camshaft sprocket
More than 1/4 tooth wear “a” → Replace the
camshaft sprockets and timing chain as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30436
INSTALLING THE CAMSHAFTS

1. Align:
• Mark “a” on the AC magneto rotor
(with the mark “b” in the AC magneto cover)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. 1/4 tooth
b. Correct
1. Timing chain
2. Camshaft sprocket
5-14
CAMSHAFTS
3. Install:
• Bearing stoppers
• Camshaft cap “1”
Camshaft cap bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
ECB02450
NOTICE
• The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
b. Position the mark “a” on the AC magneto ro- camshaft cap, and camshafts will result.
tor with the mark “b” in the AC magneto cov- • Do not turn the crankshaft when installing
er. the camshaft cap to avoid damage or im-
a proper valve timing.
TIP
Tighten the camshaft cap bolts in the tightening
sequence as shown.
b
6 2
1
5 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7 3
2. Install:
• Timing chain “1”
(onto the camshaft sprockets “2”) 4
• Exhaust camshaft 8
• Intake camshaft 4. Install:
ECB02440
NOTICE • Timing chain tensioner gasket New

Do not turn the crankshaft when installing • Timing chain tensioner
the timing chain to avoid damage or improp- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the timing chain tensioner cap bolt
er valve timing.
and gasket.
TIP b. Install a new gasket and the timing chain ten-
When installing the timing chain “1”, make sure sioner “1” onto the cylinder.
that the holes “a” in the camshaft sprockets “2”
Timing chain tensioner bolt
are positioned above the cylinder head mating
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
surface “b” as shown in the illustration, and the

R.
marks “c” and “d” on the sprockets are aligned

TIP
with the cylinder head mating surface “b”.
Turn the timing chain tensioner rod fully clock-
c d wise with a flat-head screwdriver, and then, with
a a
2 2 the tensioner rod turned all the way into the tim-
1 d ing chain tensioner housing (with the thin screw-
c b driver still installed), install the timing chain
tensioner “1” onto the cylinder.
5-15
CAMSHAFTS
1 c c c
c d
c. Install a new gasket and the timing chain ten- 7. Measure:

sioner cap bolt. • Valve clearance
Timing chain tensioner cap bolt
Refer to “ADJUSTING THE VALVE CLEAR-
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
T.
ANCE” on page 3-3.

R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EBS30437
5. Turn: INSTALLING THE BREATHER PLATE

• Crankshaft 1. Install:
(several turns counterclockwise) • Breather plate cover gaskets New
6. Check: • Breather plate
• Mark “a” • Breather plate cover
Make sure the mark “a” on the AC magneto
rotor is aligned with the mark “b” in the AC Breather plate cover bolt
magneto cover. 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
• Camshaft sprocket mark “c”

Make sure the marks “c” on the camshaft TIP
sprockets are aligned with the cylinder head Tighten the breather plate cover bolts in the
mating surface “d”. proper tightening sequence as shown.
Out of alignment → Adjust.
Refer to the installation steps above.
• Timing chain guide 3
Make sure that the timing chain guide and 1
timing chain are positioned correctly.
a 2 4
5-16
CYLINDER HEAD, CYLINDER, AND PISTON
EBS20107

Removing the cylinder head
1st 30 Nm (3.0 m•kgf, 22 ft•Ibf)

(4) D
2nd 70 Nm (7.0 m•kgf, 51 ft•Ibf) FW
3rd Loosen 360˚
New
T.R
4th 30 Nm (3.0 m•kgf, 22 ft•Ibf)
.
5th Specified angle 85–90˚
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
E
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
2

T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
New
18 Nm (1.8 m•kgf, 13 ft•Ibf)

T.R
.

Drain.
page 3-9.
Drain.
page 3-14.
Refer to “ENGINE REMOVAL (1)” on page
Exhaust pipe 5-3.
Cylinder head cover/Intake camshaft/Exhaust Refer to “CAMSHAFTS” on page 5-10.
camshaft
Thermostat/Coolant temperature sensor Refer to “THERMOSTAT” on page 6-8.
Water jacket joint Refer to “WATER PUMP” on page 6-11.
Throttle body assembly Refer to “THROTTLE BODY” on page 7-8.
Refer to “AIR INDUCTION SYSTEM” on
Reed valve assembly page 7-14.
1 Oil hose (crankcase to cylinder) 1
2 Cylinder bolt 2
5-17
Removing the cylinder head
1st 30 Nm (3.0 m•kgf, 22 ft•Ibf)

(4) D
2nd 70 Nm (7.0 m•kgf, 51 ft•Ibf) FW
New 4 3rd Loosen 360˚
3
T.R
4th 30 Nm (3.0 m•kgf, 22 ft•Ibf)
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
E
5
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
7
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) New 6

T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
New
18 Nm (1.8 m•kgf, 13 ft•Ibf)

T.R
.

3 Cylinder head bolt 2 M6
4 Cylinder head bolt 4 M11
5 Cylinder head 1
6 Cylinder head gasket 1
7 Dowel pin 2
5-18
Removing the cylinder and piston
D
FW
1
E
8
9
10 E
New 5 3 New
7 4
E
6
New 5 4
E

1 Timing chain guide (exhaust side) 1
2 Cylinder 1
3 Cylinder gasket 1
4 Dowel pin 2
5 Piston pin clip 2
6 Piston pin 1
7 Piston 1
8 Top ring 1
9 2nd ring 1
10 Oil ring 1
5-19
EBS30438
• Before removing the piston pin, deburr the pis-
REMOVING THE CYLINDER HEAD
ton pin clip grooves and the piston pin bore ar-
1. Remove:
ea. If both areas are deburred and the piston
• Cylinder bolt (M6) (×2)
pin is still difficult to remove, remove it with the
• Cylinder head bolt (M6) (×2)
piston pin puller set “4”.
• Cylinder head bolt (M11) (×4)
• Remove the piston pin from the side of the pis-
• Cylinder head
ton that has the manufacturer’s mark “a”.
TIP
• Loosen the bolts in the proper sequence as Piston pin puller set
shown. 90890-01304
• Loosen each bolt 1/2 of a turn at a time. After Piston pin puller
all of the bolts are fully loosened, remove them. YU-01304
• M6 × 25 mm: “1”–“4”
• M11 × 208 mm: “5”–“8” 1
a 2
×4 FWD
×4
3
8
5
3
1
4
7
6
2. Remove:
• Top ring
EBS30146
• 2nd ring
REMOVING THE PISTON • Oil ring
1. Remove: TIP
• Piston pin clips “1” When removing a piston ring, open the end gap
• Piston pin “2” with your fingers and lift the other side of the ring
• Piston “3” over the piston crown.
ECB01380
NOTICE
Do not use a hammer to drive the piston pin
out.
TIP
• Before removing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
the piston pin clips from falling into the crank-
case.
5-20
EBS30439
CHECKING THE CYLINDER HEAD TIP

1. Eliminate: To ensure an even surface, rotate the cylinder
• Combustion chamber carbon deposits head several times.
(with a rounded scraper) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ECB01851
NOTICE EBS30147
CHECKING THE CYLINDER AND PISTON

Do not use a sharp instrument; otherwise,
1. Check:
the following may be damaged or scratched:
• Piston wall
• Spark plug bore threads
• Cylinder wall
• Valve seats
Vertical scratches → Replace the cylinder,
2. Check: and replace the piston and piston rings as a
• Cylinder head set.
Damage/scratches → Replace. 2. Measure:
• Cylinder head water jacket • Piston-to-cylinder clearance
Mineral deposits/rust → Eliminate. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3. Measure: a. Measure the cylinder bore “C” with the cylin-
• Cylinder head warpage der bore gauge.
Out of specification → Resurface the cylinder TIP
head. Measure the cylinder bore “C” by taking side-to-
side and front-to-back measurements of the cyl-
Warpage limit inder.
0.03 mm (0.0012 in)
Bore
103.000–103.020 mm (4.0551–
4.0559 in)
Wear limit
103.080 mm (4.0583 in)
Taper limit
0.050 mm (0.0020 in)
Out of round limit
0.050 mm (0.0020 in)
“C” = maximum of D1, D2, D3, D4, D5, D6

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge “1” and a thickness Taper (front-to-back) = maximum difference be-
gauge “2” across the cylinder head. tween D1, D3, D5
Taper (side-to-side) = maximum difference be-
tween D2, D4, D6
1
Out of round (top) = difference between D1, D2
Out of round (middle) = difference between D3,
2
D4
Out of round (bottom) = difference between D5,
D6
b. Measure the warpage.

c. If the limit is exceeded, resurface the cylinder
head as follows.
d. Place a 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder head
using a figure-eight sanding pattern.
5-21
b. If out of specification, replace the cylinder,

and replace the piston and piston rings as a Top ring
set. Ring side clearance limit
c. Measure piston skirt diameter “P” with a mi- 0.12 mm (0.0047 in)
2nd ring
crometer.
Ring side clearance limit
Diameter 0.12 mm (0.0047 in)
102.960–102.975 mm (4.0535–
4.0541 in)
2. Install:
• Piston ring
a. 11.0 mm (0.43 in) from the bottom edge of the (into the cylinder)
piston TIP
d. If out of specification, replace the piston and Use the piston crown to level the piston ring near
piston rings as a set. bottom of cylinder “a”, where cylinder wear is
e. Calculate the piston-to-cylinder clearance lowest.
with the following formula.
• Piston-to-cylinder clearance = a
Cylinder bore “C” -
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.040–0.075 mm (0.0016–0.0030
in)
f. If out of specification, replace the cylinder, b

and replace the piston and piston rings as a b. Upper of cylinder
set.
3. Measure:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Piston ring end gap
Out of specification → Replace the piston
EBS30148
CHECKING THE PISTON RINGS

1. Measure: ring.
• Piston ring side clearance TIP
Out of specification → Replace the piston The oil ring expander end gap cannot be mea-
and piston rings as a set. sured. If the oil ring rail gap is excessive, replace
TIP all three piston rings.
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
ring grooves and piston rings.
5-22
EBS30150
Top ring INSTALLING THE PISTON AND CYLINDER

End gap (installed) limit 1. Install:
0.50 mm (0.0197 in) • Oil ring expander “1”
2nd ring • Lower oil ring rail “2”
End gap (installed) limit • Upper oil ring rail “3”
0.70 mm (0.0276 in) • 2nd ring “4”
Oil ring • Top ring “5”
End gap (installed) limit
TIP
1.0 mm (0.039 in)
Be sure to install the piston rings so that the
EBS30149 manufacturer’s marks or numbers face up.
CHECKING THE PISTON PIN
1. Check:
• Piston pin
Blue discoloration/grooves → Replace the
piston pin, and then check the lubrication sys-
tem.
2. Measure:
• Piston pin outside diameter “a” 1
Out of specification → Replace the piston pin. 2
Piston pin outside diameter limit
22.974 mm (0.9045 in) 2. Install:
• Piston “1”
• Piston pin “2”
• Piston pin clips “3” New
TIP
• Apply engine oil to the piston pin.
• Make sure the manufacturer’s mark “a” on the
piston points towards the AC magneto side.
• Install the piston pin from the side of the piston
that has the manufacturer’s mark “a”.
• Before installing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
3. Measure:
the clips from falling into the crankcase.
• Piston pin bore diameter “b”
Out of specification → Replace the piston.
a
1
Piston pin bore inside diameter
limit
23.035 mm (0.9069 in)
3 New
2
3. Install:
• Cylinder gasket New
• Dowel pins
b 4. Lubricate:
• Piston
• Piston rings
• Cylinder
(with the recommended lubricant)
5-23
Engine oil
5. Install:
• Cylinder “1” ×4 FWD
• Timing chain guide (exhaust side) ×4
TIP
• While compressing the piston rings with one 1
hand, install the cylinder with the other hand.
• Pass the timing chain and timing chain guide 4
(exhaust side) through the timing chain cavity. 6
8
1
7
5
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Temporarily tighten the cylinder head bolts
EBS30440
(M6) and cylinder bolts (M6).
INSTALLING THE CYLINDER HEAD b. Tighten the cylinder head bolts (M11) to 30
1. Install: Nm (3.0 m·kgf, 22 ft·lbf) in the proper tighten-
• Cylinder head ing sequence.
• Cylinder head bolt (M11) (×4) New c. Tighten the cylinder head bolts (M11) to 70
• Cylinder head bolt (M6) (×2) Nm (7.0 m·kgf, 51 ft·lbf) in the proper tighten-
• Cylinder bolt (M6) (×2) ing sequence.
TIP d. Loosen the cylinder head bolts (M11) 360°.
• Pass the timing chain through the timing chain e. Tighten the cylinder head bolts (M11) to 30
cavity. Nm (3.0 m·kgf, 22 ft·lbf) in the proper tighten-
• Lubricate the cylinder head bolt (M11) threads ing sequence.
and mating surface with engine oil. f. Tighten the cylinder head bolts (M11) to the
specified angle 85–90° in the proper tighten-
2. Tighten: ing sequence.
• Cylinder head bolts (M11) “1”–“4” g. Tighten the cylinder head bolts (M11) to the
• Cylinder head bolts (M6) “5”, “6” specified angle 85–90° in the proper tighten-
• Cylinder bolts (M6) “7”, “8” ing sequence.
Cylinder head bolt (M11) h. Tighten the cylinder head bolts (M6) and cyl-
1st: 30 Nm (3.0 m·kgf, 22 ft·lbf) inder bolts (M6) to 10 Nm (1.0 m·kgf, 7.2
T.
R.
2nd: 70 Nm (7.0 m·kgf, 51 ft·lbf) ft·lbf) in the proper tightening sequence.

3rd: Loosen 360° ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4th: 30 Nm (3.0 m·kgf, 22 ft·lbf) 3. Install:
5th: Specified angle 85–90° • Oil hose (crankcase to cylinder) “1”
6th: Specified angle 85–90° • Clamps “2”
Cylinder head bolt (M6) • Oil hose joint “3”
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder bolt (M6) • Gaskets New
10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Oil hose bolt (crankcase to cylinder) “4”
5-24
Oil hose bolt (crankcase to cylin-

der)
T.
R.
18 Nm (1.8 m·kgf, 13 ft·lbf)
TIP
Tighten the clamp screw of each clamp “2” until
6 slots are visible in the area “a” of the clamp as
3
2 4
a
1
5-25
VALVES AND VALVE SPRINGS
EBS20037

Removing the valves and valve springs
1
E
2 E
3
1 E 4
2 New 8 5 8 New
3
4 5 9 New
10
10 11 New E
11 New
E
E
New
New 9
E
E New
E
7
E
E
13 Nm (1.3 m•kgf, 9.4 ft•Ibf)
6
T.R
.

Refer to “CYLINDER HEAD, CYLINDER,
Cylinder head AND PISTON” on page 5-17.
1 Valve lifter 4
2 Valve pad 4
3 Valve cotter 8
4 Valve spring retainer 4
5 Valve spring 4
6 Intake valve 2
7 Exhaust valve 2
8 Valve stem seal (intake) 2 Gray
9 Valve stem seal (exhaust) 2 Light green
10 Valve spring seat 4
11 Valve guide 4
5-26
EBS30141
REMOVING THE VALVES TIP

The following procedure applies to all of the Remove the valve cotters by compressing the
valves and related components. valve spring with the valve spring compressor
TIP
“1” and the valve spring compressor attachment
“2”.
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal. Valve spring compressor
90890-04019
1. Remove: Valve spring compressor
• Valve lifter “1” YM-04019
• Valve pad “2” Valve spring compressor attach-
TIP ment
90890-01243
Make a note of the position of each valve lifter Valve spring compressor adapt-
and valve pad so that they can be reinstalled in er (26 mm)
their original place. YM-01253-1
2 1
2. Check:
• Valve sealing 4. Remove:
Leakage at the valve seat → Check the valve • Valve spring retainer “1”
face, valve seat, and valve seat width. • Valve spring “2”
Refer to “CHECKING THE VALVE SEATS” • Valve “3”
on page 5-29. • Valve stem seal “4”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Valve spring seat “5”
a. Pour a clean solvent “a” into the intake and TIP
exhaust ports. Identify the position of each part very carefully so
b. Check that the valves properly seal. that it can be reinstalled in its original place.
TIP
There should be no leakage at the valve seat “1”. 1
4
3 5
EBS30142
CHECKING THE VALVES AND VALVE

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
GUIDES
3. Remove:
valves and valve guides.
• Valve cotters
5-27
1. Measure:
• Valve-stem-to-valve-guide clearance
Out of specification → Replace the valve
guide.
• Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” -
Valve stem diameter “b”
Valve-stem-to-valve-guide clear-
ance (intake) limit
0.080 mm (0.0031 in) b. Install the new valve guide with the valve
Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remover
ance (exhaust) limit “1”.
0.100 mm (0.0039 in)
c. After installing the valve guide, bore the valve

guide with the valve guide reamer “3” to ob-
tain the proper valve-stem-to-valve-guide
clearance.
2. Replace:
• Valve guide
TIP TIP
To ease valve guide removal and installation, After replacing the valve guide, reface the valve
and to maintain the correct fit, heat the cylinder seat.
head to 100 °C (212 °F) in an oven.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide with the valve guide
remover “1”.
5-28
1. Eliminate:
Valve guide remover & installer • Carbon deposits
set (ø5.5) (from the valve face and valve seat)
90890-04016 2. Check:
Valve guide remover (5.5 mm)
• Valve seat
YM-01122
Valve guide remover & installer Pitting/wear → Replace the cylinder head.
set (ø5.5) 3. Measure:
90890-04016 • Valve seat width “a”
Valve guide installer (5.5 mm) Out of specification → Replace the cylinder
YM-04015 head.
Valve guide remover & installer
set (ø5.5) Valve seat contact width (intake)
90890-04016 1.34–1.48 mm (0.0528–0.0583 in)
Valve guide reamer (5.5 mm) Valve seat contact width (ex-
YM-01196 haust)
1.34–1.48 mm (0.0528–0.0583 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
4. Check:
• Valve face
Pitting/wear → Grind the valve face.
• Valve stem end
Mushroom shape or diameter larger than the
body of the valve stem → Replace the valve.
5. Measure:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Valve stem runout a. Apply blue layout fluid “b” onto the valve face.
Out of specification → Replace the valve.
TIP
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always re-
place the valve stem seal.
Valve stem runout

0.040 mm (0.0016 in)
b. Install the valve into the cylinder head.

c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width.
TIP
Where the valve seat and valve face contacted
one another, the blueing will have been re-
moved.
EBS30143 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE VALVE SEATS 4. Lap:
The following procedure applies to all of the • Valve face
valves and valve seats. • Valve seat
5-29
TIP
After replacing the cylinder head or replacing the
valve and valve guide, the valve seat and valve
face should be lapped.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound “a” to the
valve face.
ECB01360
NOTICE
Do not let the lapping compound enter the
h. Install the valve into the cylinder head.
gap between the valve stem and the valve
i. Press the valve through the valve guide and
guide.
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width “c” again. If the
valve seat width is out of specification, reface
and lap the valve seat.
b. Apply engine oil onto the valve stem.

c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
the lapping compound. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP EBS30144
For the best lapping results, lightly tap the valve CHECKING THE VALVE SPRINGS
seat while rotating the valve back and forth be- The following procedure applies to all of the
tween your hands. valve springs.
1. Measure:
• Compressed valve spring force “a”
Out of specification → Replace the valve
spring.
Installed compression spring

force (intake)
134.00–154.00 N (13.66–15.70
kgf, 30.12–34.62 lbf)
Installed compression spring
force (exhaust)
e. Apply a fine lapping compound to the valve 107.00–123.00 N (10.91–12.54
face and repeat the above steps. kgf, 24.05–27.65 lbf)
f. After every lapping procedure, be sure to Installed length (intake)
30.95 mm (1.22 in)
clean off all of the lapping compound from the
Installed length (exhaust)
valve face and valve seat. 32.20 mm (1.27 in)
g. Apply blue layout fluid “b” onto the valve face.
5-30
b. Installed length 2. Lubricate:

• Valve stem “1”
2. Measure: • Valve stem end
• Valve spring tilt “a” • Valve stem seal “2”
Out of specification → Replace the valve (with the recommended lubricant)
spring.
Spring tilt (intake) Engine oil
1.7 mm (0.07 in)
Spring tilt (exhaust)
1.7 mm (0.07 in) 2
1
E
3. Install:
• Valve spring seat “1”
(into the cylinder head)
EBS30441
CHECKING THE VALVE LIFTERS • Valve stem seal “2” New

The following procedure applies to all of the • Valve “3”
valve lifters. • Valve spring “4”
1. Check: • Valve spring retainer “5”
• Valve lifter TIP
Damage/scratches → Replace the valve lift- • Make sure each valve is installed in its original
ers and cylinder head. place.
EBS30145
• Install the valve springs with the larger pitch “a”
INSTALLING THE VALVES facing up.
valves and related components. 5
1. Deburr: 2 New
• Valve stem end
(with an oil stone)
4
3 1
5-31
b. Smaller pitch 6. Lubricate:

• Valve pad
4. Install: • Valve lifter
• Valve cotters (with the recommended lubricant)
TIP
Install the valve cotters by compressing the Recommended lubricant
Engine oil
valve spring with the valve spring compressor
“1” and the valve spring compressor attachment 7. Install:
“2”. • Valve pad
• Valve lifter
Valve spring compressor TIP
90890-04019
Valve spring compressor • The valve lifter must move smoothly when ro-
YM-04019 tated with a finger.
Valve spring compressor attach- • Each valve lifter and valve pad must be rein-
ment stalled in their original position.
90890-01243
Valve spring compressor adapt-
er (26 mm)
YM-01253-1
5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
ECB01370
NOTICE
Hitting the valve tip with excessive force
could damage the valve.
5-32
AC MAGNETO AND STARTER CLUTCH
EBS20039

Removing the AC magneto and starter clutch
3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)
T.R
18 Nm (1.8 m•kgf, 13 ft•Ibf)

.
LT
LT D
T.R
FW
.
18 Nm (1.8 m•kgf, 13 ft•Ibf)
T.R
.
6
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
1
5
New New
(3) 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
2
LT 7
New 4
E
E New
E
3
(8)
New
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
New 11 Nm (1.1 m•kgf, 8.0 ft•Ibf)

T.R
.
E 4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

T.R
.
(8) E
E
160 Nm (16 m•kgf, 116 ft•lbf)
T.R
14 Nm (1.4 m•kgf, 10 ft•Ibf)

.
T.R
.

Engine 5-5.
Water pump housing Refer to “WATER PUMP” on page 6-11.
1 Oil pipe (AC magneto cover) 1
2 Oil pipe holder 1
3 AC magneto cover 1
4 AC magneto cover gasket 1
AC magneto/Crankshaft position sensor lead
5 1
holder
6 Crankshaft position sensor 1
7 Stator coil 1
5-33
Removing the AC magneto and starter clutch

3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)
T.R
18 Nm (1.8 m•kgf, 13 ft•Ibf)

.
LT
LT D
T.R
FW
.
18 Nm (1.8 m•kgf, 13 ft•Ibf)
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
New New
(3) 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
LT
New
E
E New
9 E
8
13
11 (8)
New
10 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
15 New 11 Nm (1.1 m•kgf, 8.0 ft•Ibf)

T.R
.
E T.R
.
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
14 12
(8) E
E
160 Nm (16 m•kgf, 116 ft•lbf)
T.R
14 Nm (1.4 m•kgf, 10 ft•Ibf)

.
16
T.R
.

8 Starter idle gear 1 1
9 Starter idle gear shaft 1 1
10 Starter idle gear 2 1
11 Starter idle gear shaft 2 1
12 AC magneto rotor 1
13 Woodruff key 1
14 Starter wheel gear 1
15 Bushing 1
16 Starter clutch 1
5-34
EBS30151
• Make sure the flywheel puller is centered over
REMOVING THE AC MAGNETO ROTOR
the AC magneto rotor.
1. Remove:
• AC magneto cover
Flywheel puller (M38 X P1.5)
TIP
90890-04178
Loosen each bolt 1/4 of a turn at a time, in stag- Flywheel puller (M38 X P1.5)
es and in a crisscross pattern. After all of the YM-04178
bolts are fully loosened, remove them.
1 2
EBS30152
2. Remove:
REMOVING THE STARTER CLUTCH
• AC magneto rotor nut “1”
1. Remove:
• Washer
• Starter clutch bolts “1”
TIP
TIP
Hold the AC magneto rotor “2” with the rotor
Hold the AC magneto rotor “2” with the rotor
holding tool “3” while loosening the AC magneto
holding tool “3” while removing the starter clutch
rotor nut.
bolts.
Rotor holding tool

Rotor holding tool
90890-04166
90890-04166
YM-04166
YM-04166
1
3
2
3
1 2
3. Remove:
EBS30153
• AC magneto rotor “1” CHECKING THE STARTER CLUTCH
(with the starter clutch) 1. Check:
• Woodruff key • Starter clutch rollers
ECB01390
NOTICE Damage/wear → Replace.

2. Check:
To protect the end of the crankshaft, place an
• Starter idle gear
appropriate sized socket between the fly-
• Starter wheel gear
wheel puller set center bolt and the crank-
Burrs/chips/roughness/wear → Replace the
shaft.
defective part(s).
TIP
• Use the flywheel puller “2”.
5-35
3. Check:
• Starter clutch gear contact surfaces Starter clutch bolt
Damage/pitting/wear → Replace the defec- 14 Nm (1.4 m·kgf, 10 ft·lbf)
T.
R.
tive part(s).
4. Check: TIP
• Starter clutch operation While holding the AC magneto rotor “2” with the
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ rotor holding tool “3”, tighten the starter clutch
a. Install the starter clutch and stater wheel gear bolts.
“1” onto the AC magneto rotor “2”, and hold
the AC magneto rotor. Rotor holding tool
b. When turning the starter wheel gear clock- 90890-04166
wise “A”, the starter clutch and the starter YM-04166
wheel gear should engage; otherwise, the
starter clutch is faulty and must be replaced.
3 1
c. When turning the starter wheel gear counter-
clockwise “B”, it should turn freely; otherwise,
the starter clutch is faulty and must be re-
placed.
1 1
A
1 2
EBS30156
INSTALLING THE AC MAGNETO ROTOR

1. Install:
B • Woodruff key
2 • AC magneto rotor “1”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Washer “2”
EBS30155
• AC magneto rotor nut “3”
INSTALLING THE STARTER CLUTCH TIP
1. Install: • Clean the tapered portion of the crankshaft and
• Bushing “1” the AC magneto rotor hub.
(into the starter wheel gear “2”) • When installing the AC magneto rotor, make
sure the woodruff key is properly seated in the
Installed depth keyway of the crankshaft.
0.7 mm (0.03 in)
• Lubricate the threads of the crankshaft and
washer mating surfaces with engine oil.
• Install the washer “2” with its rounded side “a”,
2 facing away from the AC magneto rotor.
• After installing the AC magneto rotor, check
1
that the AC magneto rotor rotates smoothly. If
not, reinstall the woodruff key and AC magneto
rotor.
a a
a. Installed depth
2. Install:
• Starter clutch
• Starter clutch bolts “1”
5-36
b
2
a
3
a
2 3 1
1
2. Tighten:
• AC magneto rotor nut “1” 10
4
AC magneto rotor nut 6
8
160 Nm (16 m·kgf, 116 ft·lbf) 1
T.
R.
3
TIP
2
Hold the AC magneto rotor “2” with the rotor 7
holding tool “3” while tightening the AC magneto 5 9
rotor nut. 11
Rotor holding tool

90890-04166
YM-04166
3. Install:
• AC magneto cover “1”
AC magneto cover bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
TIP
• Align the slot “a” in the impeller shaft “2” with
the projection “b” on the oil pump shaft “3”.
• Tighten the AC magneto cover bolts in the
proper tightening sequence as shown.
5-37
ELECTRIC STARTER
EBS20040
ELECTRIC STARTER
Removing the starter motor
2 4.9 Nm (0.49 m•kgf, 3.5 ft•Ibf)
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
3
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
D
FW

Center cover 4-6.
Air intake silencer Refer to “THROTTLE BODY” on page 7-8.
1 Engine ground lead 1 Disconnect.
2 Starter motor lead 1 Disconnect.
3 Starter motor 1
5-38
ELECTRIC STARTER
Disassembling the starter motor
4.9 Nm (0.49 m•kgf, 3.5 ft•Ibf)

T.R
.
New
New
4 11 Nm (1.1 m•kgf, 8.0 ft•Ibf)

T.R
.
3
E
New
New
1 New

1 Starter motor front cover 1
2 Starter motor rear cover 1
3 Washer kit 1
4 Armature assembly 1
5 Brush set 1
6 Starter motor yoke 1
5-39
ELECTRIC STARTER
EBS30157
CHECKING THE STARTER MOTOR Digital circuit tester

1. Check: 90890-03174
• Commutator Model 88 Multimeter with ta-
Dirt → Clean with 600-grit sandpaper. chometer
2. Measure: YU-A1927
• Commutator diameter “a”
Out of specification → Replace the starter
Armature coil
motor.
Commutator resistance “1”
Commutator diameter limit 0.0250–0.0350 Ω
27.0 mm (1.06 in) Insulation resistance “2”
Above 1 MΩ
b. If any resistance is out of specification, re-

place the starter motor.
a
3. Measure:
• Mica undercut “a”
Out of specification → Cut the mica to the
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
proper measurement with a hacksaw blade
that has been grounded to fit the commutator. 5. Measure:
• Brush length “a”
Mica undercut (depth) Out of specification → Replace the brush set.
0.70 mm (0.03 in)
Brush overall length limit
TIP 5.0 mm (0.20 in)
The mica of the commutator must be undercut to
ensure proper operation of the commutator.
6. Check:
• Gear teeth
4. Measure: Damage/wear → Replace the armature as-
• Armature assembly resistances (commutator sembly.
and insulation) 7. Check:
Out of specification → Replace the starter • Bearing
motor. • Oil seal
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Damage/wear → Replace the starter motor
a. Measure the armature assembly resistances front cover.
with the digital circuit tester.
5-40
ELECTRIC STARTER
8. Check:
• Bushing
Damage/wear → Replace the starter motor
rear cover.
EBS30158
ASSEMBLING THE STARTER MOTOR

1. Install:
• Brush set “1”
TIP
Align the tab “a” on the brush set with the slot “b”
in the starter motor yoke.
2. Install:
• Starter motor yoke “1”
• Starter motor front cover “2”
• Starter motor rear cover “3”
Starter motor cover bolt

4.9 Nm (0.49 m·kgf, 3.5 ft·lbf)
T.
R.
TIP
Align the match marks “a” on the starter motor
yoke with the match marks “b” on the starter mo-
tor front and rear covers.
b a b
3
2 1
5-41
OIL PUMP SPROCKETS
EBS20114
OIL PUMP SPROCKETS

Removing the oil pump sprockets
D
FW
25 Nm (2.5 m•kgf, 18 ft•Ibf)
T.R
.
5
4
3
LT
1
2
25 Nm (2.5 m•kgf, 18 ft•Ibf) LT
T.R
.
LT
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

Refer to “AC MAGNETO AND STARTER
AC magneto rotor CLUTCH” on page 5-33.
1 Timing chain stopper guide (lower) 1
2 Oil pump driven sprocket 1
3 Washer 1
4 Oil pump drive sprocket 1
5 Chain 1
5-42
OIL PUMP SPROCKETS
EBS30524
REMOVING THE OIL PUMP DRIVE TIP

SPROCKET AND OIL PUMP DRIVEN Install the oil pump drive sprocket so that the
SPROCKET protruding portion “a” of the sprocket is facing to-
1. Loosen: ward the crankcase.
• Oil pump driven sprocket nut “1”
• Oil pump drive sprocket nut “2” a
2
1
1 2. Install:
• Washer “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Oil pump drive sprocket nut
a. Temporarily install the AC magneto rotor.
Refer to “AC MAGNETO AND STARTER TIP
CLUTCH” on page 5-33. Install the washer with its rounded side “a” facing
b. Hold the AC magneto rotor “3” with the rotor away from the crankcase.
holding tool “4” while loosening the oil pump
driven sprocket nut and oil pump drive
sprocket nut. a
Rotor holding tool
90890-04166
YM-04166
3. Install:
• Oil pump driven sprocket “1”
• Chain “2”
• Oil pump driven sprocket nut
4 TIP
3 Install the oil pump driven sprocket with the
“23A” mark “a” facing out.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30525
CHECKING THE OIL PUMP SPROCKETS

1. Check: 1
• Oil pump drive sprocket 2
• Oil pump driven sprocket
Cracks/wear/damage → Replace. a
EBS30526
INSTALLING THE OIL PUMP DRIVE

SPROCKET AND OIL PUMP DRIVEN
SPROCKET 4. Tighten:
1. Install: • Oil pump drive sprocket nut “1”
• Oil pump drive sprocket “1” • Oil pump driven sprocket nut “2”
5-43
OIL PUMP SPROCKETS
Oil pump drive sprocket nut

25 Nm (2.5 m·kgf, 18 ft·lbf)
T.
R.
LOCTITE®
Oil pump driven sprocket nut
25 Nm (2.5 m·kgf, 18 ft·lbf)
LOCTITE®
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Temporarily install the AC magneto rotor.
CLUTCH” on page 5-33.
b. Hold the AC magneto rotor “3” with the rotor
holding tool “4” while tightening the oil pump
drive sprocket nut and oil pump driven
sprocket nut.
Rotor holding tool

90890-04166
YM-04166
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-44
SHIFT LEVER
EBS20042
SHIFT LEVER
Removing the drive select lever shift rod and drive select lever
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
D
2 (3) FW
4 15 Nm (1.5 m•kgf, 11 ft•Ibf)
T.R
.
New
6
5
7
LS
15 Nm (1.5 m•kgf, 11 ft•Ibf)

T.R
.

Center cover/Under-seat storage compartment 4-6.
1 Drive select lever shift rod 1
2 Drive select lever knob 1
3 Drive select lever guide 1
4 Dust cover 1
5 Drive select lever 1
6 Spring 1
7 Shift arm 1
5-45
SHIFT LEVER
Removing the shift levers and stopper lever
D
FW
11 New
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
13 Nm (1.3 m•kgf, 9.4 ft•Ibf)
T.R
.
E
3 New
LS
7 6 New
2 5 New
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

LT
T.R
.
LS
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
10
9 8
E
14 Nm (1.4 m•kgf, 10 ft•Ibf)

T.R
.

1 Shift arm 1
2 Shift lever cover 1
3 Shift lever cover gasket 1
4 Dowel pin 1
5 Oil seal 1
6 Spacer 1
7 Shift lever 1 1
8 Stopper lever spring 1
9 Shift lever 2 1
10 Stopper lever 1
11 Spacer 1
5-46
SHIFT LEVER
EBS30163
CHECKING THE STOPPER LEVER 2

1. Check: 1
• Stopper lever b
4
• Stopper lever spring
Damage/wear → Replace. 5
EBS30164
a
CHECKING THE SHIFT LEVERS
3
1. Check:
• Shift lever 1 3. Install:
• Shift lever 2 • Shift lever 2 assembly “1”
Shift lever 2 bolt
EBS30165
14 Nm (1.4 m·kgf, 10 ft·lbf)
T.
INSTALLING THE SHIFT LEVERS
R.
1. Install:
TIP
• Spacer “1” New
Align the projection “a” on the shift drum with the
(into the crankcase “2”)
slit “b” in the stopper lever.
TIP
Press the spacer into the crankcase, making
sure that the slit “a” in the spacer is aligned with
the rib “b” on the crankcase. a
a b
1
2
b
1 New
4. Install:
• Shift lever 1 “1”
TIP
When installing shift lever 1, align the alignment
2. Install: mark “a” on shift lever 1 with the punch marks “b”
• Collar “1” (onto the stopper lever “2”) on shift lever 2 “2”.
• Shift lever 2 “3”
• Washer “4”
• Stopper spring “5” 1
TIP
• Make sure the projection “a” on the stopper le-
ver “2” facing toward the collar. a
• Install the shift lever 2 “3” with the marks “b”
facing the stopper spring. b 2
5. Install:
• Spacer “1” New
(into the shift lever cover “2”)
5-47
SHIFT LEVER
EBS30444
TIP ADJUSTING THE DRIVE SELECT LEVER
Press the spacer into the shift lever cover, mak- SHIFT ROD
ing sure that the slit “a” in the spacer is facing up- EWB03060
ward as shown in the illustration. NOTICE

Before moving the drive select lever, bring
the vehicle to a complete stop and take your
a
foot off the accelerator pedal. Otherwise, the
transmission may be damaged.
4 1 2 3
1 New
2
5
6. Install:
• Oil seal “1” New
(into the shift lever cover “2”)
Installed depth “a” 1. “N” (neutral)

1.0–1.5 mm (0.04–0.06 in) 2. “H” (high)
3. “L” (low)
4. “R” (reverse)
5. Drive select lever shift rod
New 1 1. Adjust:
a • Drive select lever shift rod
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Make sure the drive select lever and trans-
2 mission are in “N” (neutral).
b. Loosen both locknuts “1”.
ECB02460
NOTICE
7. Install:
The drive select lever shift rod locknut (drive
• Shift arm “1”
select lever side) has left-handed threads. To
TIP loosen the locknut, turn it clockwise.
Align the slit “a” in the shift arm with the projec-
tion “b” on shift lever 1. c. Turn the main switch to “ON”, and then adjust
the length “a” of the shift rod to the drive se-
lect lever can be shifted to each shift position
1 and that the appropriate indicator light comes
on when the lever is in each position.
b a
1 1
d. Tighten the locknuts.
5-48
SHIFT LEVER
Drive select lever shift rod lock-

nut
T.
R.
15 Nm (1.5 m·kgf, 11 ft·lbf)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-49
PRIMARY AND SECONDARY SHEAVES
EBS20043

Removing the primary and secondary sheaves
New 10
FW 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
D
.
9 New 11
100 Nm (10.0 m•kgf, 72 ft•Ibf)

T.R
.
6
8 (8)
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
New
LS
7
4
2 New
4
5
(10) *
3
190 Nm (19 m•kgf, 137 ft•lbf) 1
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) LS

T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
* Apply Shell Sunlight Grease 3®.

Under-seat compartment panel 4-6.
Refer to “GENERAL CHASSIS (10)” on
V-belt cooling ducts page 4-21.
1 Drive belt cover 1
2 Rubber gasket 1
3 Bearing housing 1
4 Dowel pin 2
5 Primary sheave assembly 1
6 V-belt 1
7 Primary fixed sheave 1
8 Secondary sheave assembly 1
9 Drive belt case 1
10 Rubber gasket 1
11 Rubber gasket 1
5-50
Disassembling the primary sheave
* Apply Yamaha Grizzly grease or Yamaha grease F.

1 Primary sheave cap 1
2 Primary sheave slider 4
3 Primary sheave cam 1
4 Primary sheave weight 8
5 Spacer 1
6 Oil seal 2
7 Primary sliding sheave 1 Hunterworks.com click to save
8 O-ring 1
High Power Greaseless Sheave Option: Please Contact Hunterworks.com 601-771-0070
5-51
Disassembling the secondary sheave
* Apply Yamaha grease H or POLYREX EM®

1 Secondary sheave spring retaining nut 1
2 Upper spring seat 1
3 Compression spring 1
4 Lower spring seat 1
5 Guide pin 4
6 Secondary sliding sheave 1
7 O-ring 2
8 Secondary fixed sheave 1
9 Oil seal 2
High Power Secondary Springs Available @ Hunterworks.com
5-52
EBS30167
REMOVING THE PRIMARY AND Sheave fixed block

SECONDARY SHEAVES 90890-04135
1. Loosen: Sheave fixed bracket
• Primary sheave assembly nut “1” YM-04135
TIP Locknut wrench
90890-01348
Use the rotor holding tool “2” to hold the primary
Locknut wrench
sheave. YM-01348
Rotor holding tool 90890-04134
90890-04166 Sheave spring compressor
YM-04166 YM-04134
b. Place the sheave fixed block in a vise and se-

cure it.
2 c. Tighten the sheave spring compressor nut “5”
and compress the spring.
d. Loosen the secondary sheave spring retain-
ing nut “1” with the locknut wrench “3”.
e. Remove the secondary sheave spring retain-
1 ing nut “1”.
f. Remove the sheave spring compressor and
locknut wrench.
2. Loosen:
• Secondary sheave assembly nut “1”
TIP 4 5
Shift the transmission into “R” (reverse), set the 1
parking brake, and then loosen the secondary
3
sheave assembly nut.
EBS30168
DISASSEMBLING THE SECONDARY

SHEAVE 2
1. Remove:
• Secondary sheave spring retaining nut “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Attach the sheave fixed block “2”, locknut
wrench “3” and sheave spring compressor “4”
to the secondary sheave assembly.
5-53
2. Check:
• Primary sliding sheave
• Primary fixed sheave
EBS30171
CHECKING THE PRIMARY SHEAVE

WEIGHTS
The following procedure applies to all of the pri-
mary sheave weights.
1. Check:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Primary sheave weight
EBS30169 Cracks/damage/wear → Replace.
CHECKING THE V-BELT 2. Measure:
1. Check: • Primary sheave weight outside diameter “a”
• V-belt “1” Out of specification → Replace.
Grease/oil → Clean the primary and second- Primary sheave weight outside
ary sheaves. diameter
2. Measure: 30 mm (1.18 in)
Limit
• V-belt width “a”
29.5 mm (1.16 in)
Out of specification → Replace.
V-belt width limit

32.5 mm (1.28 in)
EBS30172
CHECKING THE PRIMARY SHEAVE

SLIDERS
EBS30170
The following procedure applies to all of the pri-
CHECKING THE PRIMARY SHEAVE mary sheave sliders.
1. Check: 1. Check:
• Primary sliding sheave splines • Primary sheave slider
Wear/cracks/damage → Replace. Cracks/damage/wear → Replace.
• Primary sheave cam EBS30173
Cracks/damage → Replace. CHECKING THE SECONDARY SHEAVE
1. Check:
• Secondary fixed sheave
• Secondary sliding sheave
Cracks/damage/wear → Replace the sec-
ondary fixed and sliding sheaves as a set.
2. Check:
• Torque cam grooves “1”
Damage/wear → Replace the secondary
fixed and sliding sheaves as a set.
5-54
3. Check:
• Guide pins “2”
Damage/wear → Replace the secondary
fixed and sliding sheaves as a set.
2. Install:
• Oil seals “1” New
(into the primary sliding sheave “2”)
4. Check: Installed depth “a”

• Secondary sheave spring 0 mm (0 in)
Damage → Replace.
5. Measure: New 1
• Secondary sheave spring free length “a”
Out of specification → Replace the second-
ary sheave spring.
a a
Free length
130.6 mm (5.14 in)
Limit
128.0 mm (5.04 in)
2 1 New
3. Lubricate:
• Spacer inner surface
• Primary sliding sheave inner surface
Yamaha Grizzly grease or
Yamaha grease F
TIP
• Apply Yamaha Grizzly grease or Yamaha
EBS30174 grease F (2.5 g) to the inner surface of the
ASSEMBLING THE PRIMARY SHEAVE spacer.
1. Clean: • Apply Yamaha Grizzly grease or Yamaha
• Primary sliding sheave “1” grease F (2.5 g) to the inner surface of the pri-
• Spacer “2” mary sliding sheave.
• Primary sheave weights “3”
• Primary sheave cam
TIP
Remove any excess grease.
5-55
4. Install:
• Primary sheave weights “1”
TIP
Apply Yamaha Grizzly grease or Yamaha
grease F (90 g) to the whole outer surface of the
weights and install.
3. Install:
• Secondary sliding sheave
4. Install:
• Guide pins “1”
EBS30175
ASSEMBLING THE SECONDARY SHEAVE

1. Install:
• Oil seals “1” New
(into the secondary sliding sheave “2”)
Installed depth “a”

0 mm (0 in) 5. Lubricate:
• Guide pin grooves “1”
2 (with the recommended lubricant)
1 New Recommended lubricant

Yamaha grease H or POLYREX
a EM®
a
TIP
Apply Yamaha grease H or POLYREX EM® (5.0
New 1
g) to the guide pin grooves.
2. Lubricate:
• Secondary sliding sheave “1”
• Secondary fixed sheave “2”
Yamaha grease H or POLYREX
EM®
TIP
Apply Yamaha grease H or POLYREX EM® (15 6. Install:
g) to the inner surfaces of the secondary • Lower spring seat “1”
sheaves. • Compression spring “2”
• Upper spring seat “3”
• Secondary sheave spring retaining nut “4”
5-56
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Attach the sheave fixed block “5”, locknut a
wrench “6” and sheave spring compressor “7” 4
to the secondary sheave.
Sheave fixed block

90890-04135
Sheave fixed bracket
YM-04135
Locknut wrench
90890-01348
Locknut wrench e. Remove the sheave spring compressor, lock-
YM-01348 nut wrench, and sheave fixed block.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
90890-04134
Sheave spring compressor EBS30176
YM-04134 INSTALLING THE PRIMARY AND

SECONDARY SHEAVES
b. Place the sheave fixed block in a vise and se- 1. Install:
cure it. • Secondary sheave
c. Tighten the sheave spring compressor nut “8” • V-belt
and compress the spring. • Primary fixed sheave
d. Install the secondary sheave spring retaining • Primary sheave
nut “4” and tighten it to specification using the • Washer
locknut wrench. • Nuts
TIP
Secondary sheave spring retain-
• Be sure to push in the primary sheave cam “1”
ing nut
T.
when installing the primary sheave so that the

R.
90 Nm (9.0 m·kgf, 65 ft·lbf)

primary sheave weights “2” will be properly po-
TIP
sitioned “a”.
• Install the washer “3” with its rounded side “b”
Install the secondary sheave spring retaining nut
facing away from the primary shave assembly.
“4” with its tapered side “a” facing the secondary
• Tightening the bolts “4” (90101-06016) will
sheaves.
push the secondary sliding sheave away,
causing the gap between the secondary fixed
and sliding sheaves to widen.
• Install the V-belt so that its arrow points in the
8 direction of rotation as shown in the illustration.
7
4
1
6
3
2
2 a
1
5-57
b
3
4
3
1
B
4 4 3
1
A. Correct position
B. Incorrect position
3. Tighten:
• Primary sheave assembly nut “1”
Primary sheave assembly nut

190 Nm (19 m·kgf, 137 ft·lbf)
T.
R.
TIP
Use the rotor holding tool “2” to hold the primary
sheave.
2. Check:
• Primary sheave weights position Rotor holding tool
Out of specification → Repeat step (1). 90890-04166
TIP YM-04166
To check that the primary sheave weights “1”
are installed correctly, make sure that the sec-
ondary sheave “2”, primary sheave “3”, and V-
belt “4” are positioned as shown in the illustra-
tion. 2
4. Tighten:
• Secondary sheave assembly nut “1”
Secondary sheave assembly nut

100 Nm (10 m·kgf, 72 ft·lbf)
T.
R.
5-58
TIP
Shift the transmission into “L” (low) or “H” (high),
set the parking brake, and then tighten the sec-
ondary sheave assembly nut.
5. Lubricate:
• Bearing housing bearing inner surface and
ball
Shell Sunlight Grease 3®
TIP
Apply 2.3 g or more of Shell Sunlight Grease 3®
to the bearing inner surface and ball as shown in
the illustration.
5-59
CLUTCH
EBS20044
CLUTCH
Removing the clutch
FW
D
190 Nm (19 m•kgf, 137 ft•lbf)

T.R
.
5
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
4
2 New
3
(7)
E
E
LS

Drive belt case SHEAVES” on page 5-50.
1 Clutch housing assembly 1
2 Clutch housing assembly gasket 1
3 Dowel pin 2
4 Clutch carrier assembly nut 1 Left-hand threads
5 Clutch carrier assembly 1
5-60
CLUTCH
Disassembling the clutch housing assembly
6 New
7
9 8

1 Oil seal 1
2 Circlip 1
3 Bearing housing 1
4 Circlip 1
5 Bearing 1
6 Seal ring 1
7 One-way clutch bearing 1
8 Bearing 1
9 Clutch housing 1
5-61
CLUTCH
EBS30177
• One-way clutch bearing
REMOVING THE CLUTCH
Chafing/wear/damage → Replace.
1. Remove:
• Clutch housing assembly TIP
TIP
• Replace the one-way clutch bearing and clutch
housing as a set.
Working in crisscross pattern, loosen each bolt
• The one-way clutch bearing must be installed
1/4 of a turn. Remove them after all of them are
with the flange side facing inward.
loosened.
2. Check:
• One-way clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the one-way clutch bearing and clutch
carrier assembly to the clutch housing and
hold the clutch carrier assembly.
b. When turning the clutch housing clockwise
“A”, it should turn freely; otherwise, the one-
way clutch assembly is faulty and must be re-
placed.
c. When turning the clutch housing counter-
2. Straighten:
clockwise “B”, the clutch housing and crank-
• Punched portion “a” of the clutch carrier as-
shaft should engage; otherwise, the one-way
sembly nut “1”
clutch assembly is faulty and must be re-
3. Remove:
placed.
• Clutch carrier assembly nut “1”
ECB01710
NOTICE
The clutch carrier assembly nut has left-
hand threads. To loosen the clutch carrier
assembly nut, turn it clockwise.
TIP
Use a universal clutch holder “2” to hold the
clutch carrier assembly.
Universal clutch holder ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

90890-04086 EBS30179
Universal clutch holder CHECKING THE CLUTCH SHOE

YM-91042 1. Check:
• Clutch shoe
2
Glazed areas → Sand with coarse sandpa-
a per.
TIP
After sanding the glazed areas, clean the clutch
with a cloth.
2. Measure:
1 • Clutch shoe thickness
EBS30178
CHECKING THE CLUTCH Clutch shoe thickness limit

1. Check: 1.0 mm (0.04 in)
• Clutch housing
5-62
CLUTCH
1 New
2
a. Clutch shoe wear limit EBS30181
INSTALLING THE CLUTCH

EBS30180
ASSEMBLING THE CLUTCH HOUSING 1. Install:

1. Install: • Clutch carrier assembly
• Bearing “1” • Clutch carrier assembly nut “1” New
(into the clutch housing “2”)
Clutch carrier assembly nut
Installed depth “a” 190 Nm (19 m·kgf, 137 ft·lbf)
T.
R.
2.5–2.7 mm (0.10–0.11 in) ECB01720
NOTICE
a The clutch carrier assembly nut has left-
hand threads. To tighten the clutch carrier
2 assembly nut, turn it counterclockwise.
TIP
• Lubricate the threads of the clutch carrier as-
sembly nut with engine oil.
1 • Use a universal clutch holder “2” to hold the
clutch carrier assembly.
2. Install:
Universal clutch holder
• One-way clutch bearing 90890-04086
TIP Universal clutch holder
The one-way clutch bearing should be installed YM-91042
in the clutch housing with the “OUT SIDE” mark
“a” facing the clutch housing. 2. Lock the threads with a drift punch.
1 New
3. Install:
3. Install: • Dowel pins “1”
• Oil seal “1” New • Gasket New
(into the bearing housing “2”) • Clutch housing assembly
Installed depth “a” Clutch housing assembly bolt
0 mm (0 in) 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
5-63
CLUTCH
TIP
• Tighten the bolts in stages, using a crisscross
pattern.
• After tightening the bolts, check that the clutch
housing assembly rotates smoothly.
5-64
CRANKCASE
EBS20045
CRANKCASE
Separating the crankcase
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 17 Nm (1.7 m•kgf, 12 ft•Ibf) 18 Nm (1.8 m•kgf, 13 ft•Ibf)
T.R
T.R
T.R
D
.
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) E 35 Nm (3.5 m•kgf, 25 ft•Ibf) FW
T.R
.
T.R
.
LT
LT
New
New
E
48 Nm (4.8 m•kgf, 35 ft•Ibf)
T.R
.
New E
New
E
New
New
New
22 Nm (2.2 m•kgf, 16 ft•Ibf)
T.R
.
35 Nm (3.5 m•kgf, 25 ft•Ibf)

T.R
.
New New
68 Nm (6.8 m•kgf, 49 ft•Ibf) E
3
T.R
.
2
1
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
26 Nm (2.6 m•kgf, 19 ft•Ibf)

T.R
.
LT
E
15 Nm (1.5 m•kgf, 11 ft•Ibf) 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
T.R
.

Engine 5-5.
Refer to “CYLINDER HEAD, CYLINDER,
Cylinder head/Piston AND PISTON” on page 5-17.
AC magneto rotor CLUTCH” on page 5-33.
Refer to “ELECTRIC STARTER” on page
Starter motor 5-38.
Refer to “OIL PUMP SPROCKETS” on page
Oil pump sprockets 5-42.
Shift levers Refer to “SHIFT LEVER” on page 5-45.
Clutch carrier assembly Refer to “CLUTCH” on page 5-60.
1 Oil filter cartridge 1
2 Oil filter cartridge union bolt 1
3 Adapter 1
5-65
CRANKCASE
Separating the crankcase

7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 17 Nm (1.7 m•kgf, 12 ft•Ibf) 18 Nm (1.8 m•kgf, 13 ft•Ibf)
T.R
T.R
T.R
D
.
.
11
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) E 35 Nm (3.5 m•kgf, 25 ft•Ibf) FW
T.R
.
T.R
.
13 LT
LT
10 12
New 9
New
E
48 Nm (4.8 m•kgf, 35 ft•Ibf)
T.R
.
15
14
New E
New
E
New
5 New
New
22 Nm (2.2 m•kgf, 16 ft•Ibf)
T.R
.
35 Nm (3.5 m•kgf, 25 ft•Ibf)

8
T.R
.
New New
68 Nm (6.8 m•kgf, 49 ft•Ibf) 4 E 6
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
26 Nm (2.6 m•kgf, 19 ft•Ibf) 7

T.R
.
LT
E
T.R
T.R
.

4 Oil bypass valve 1
5 Oil pipe (crankcase) 1
6 Timing chain guide (intake side) 1
7 Timing chain 1
8 Speed sensor 1
9 Dipstick 1
10 Reverse switch 1
11 Gear position switch 1
12 Main gallery bolt 1
13 Thermostat outlet hose holder 1
14 Crankcase (left) 1
15 Crankcase (right) 1
5-66
CRANKCASE
Removing the crankcase bearings

1 2 New
3
LS
7
E E
7
4
LT
LT 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
E
E 7
6 7
E
E
E

Refer to “CRANKSHAFT AND OIL PUMP”
Crankshaft/Oil pump on page 5-71.
Middle drive shaft/Middle driven shaft Refer to “MIDDLE GEAR” on page 5-83.
Transmission Refer to “TRANSMISSION” on page 5-76.
1 Collar 1
2 O-ring 1
3 Oil seal 1
4 Bearing retainer 1
5 Spacer 1
6 Crankshaft seal 2
7 Bearing 9
5-67
CRANKCASE
EBS30182
SEPARATING THE CRANKCASE 2

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

CHAIN GUIDE
1. Check:
• Timing chain
Damage/stiffness → Replace the timing
chain and camshaft sprocket as a set.
2. Check:
A. Crankcase (right) • Timing chain guide (intake side)
B. Crankcase (left) Damage/wear → Replace.
2. Remove: EBS30185
• Crankcase (left) “1” CHECKING THE BEARINGS

TIP 1. Check:
• Remove the crankcase (left) with the crank- • Bearings
case separating tool “2”. Clean and lubricate, then rotate the inner
• Make sure the crankcase separating tool is race with a finger.
centered over the crankshaft. Roughness → Replace.
ECB01880
NOTICE
• To protect the end of the crankshaft, place
an appropriate sized socket between the
crankcase separating tool bolt and the
crankshaft.
• Do not tap on the crankshaft.
Crankcase separating tool

90890-01135
Crankcase separator
YU-01135-B
5-68
CRANKCASE
EBS30186
4. Fit the left crankcase onto the right crank-
CHECKING THE CRANKCASE
case. Tap lightly on the crankcase with a soft-
1. Thoroughly wash the crankcase halves in a
face hammer.
mild solvent. ECB01730
2. Thoroughly clean all the gasket surfaces and NOTICE

crankcase mating surfaces. Before tightening the crankcase bolts, make
3. Check: sure the transmission gears shift correctly
• Crankcase when the shift drum assembly is turned by
Cracks/damage → Replace. hand.
• Oil delivery passages
Obstruction → Blow out with compressed air. 5. Install:
• Crankcase bolts
EBS30187
6. Tighten:
ASSEMBLING THE CRANKCASE
• Crankcase bolts
1. Install:
• Oil seal “1” New Crankcase bolt (M8)
(into the left crankcase “2”) 26 Nm (2.6 m·kgf, 19 ft·lbf)
T.
R.
Crankcase bolt (M6)
Installed depth “a” 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
0.5–1.0 mm (0.02–0.04 in)
M8 × 40 mm “1”
M6 × 90 mm “2”
1 New M6 × 60 mm “3”
M6 × 30 mm “4”
a TIP
2 Tighten the bolts in stages, using a crisscross
pattern.
2. Thoroughly clean the crankcase mating sur-

faces.
3. Apply:
• Sealant “1”
(onto the crankcase mating surfaces)
Yamaha bond No. 1215

90890-85505
(Three bond No.1215®)
TIP
Do not allow any sealant to come into contact
with the oil gallery.
1 1
5-69
CRANKCASE
A • Adapter “2”
• Oil filter cartridge union bolt
2 3 4
Oil filter cartridge union bolt
68 Nm (6.8 m·kgf, 49 ft·lbf)
T.
R.
TIP
×3 ×2 ×1 Align the pin “a” in the adapter with the hole “b”
in the crankcase.
4 3
b
a
2 1 New
B
1 3 4
×3 ×2 ×6
3 1
4 4
3 4
A. Crankcase (left)
B. Crankcase (right)
7. Apply:
• 4-stroke engine oil
(onto the crankshaft pin, bearings and oil de-
livery hole)
8. Check:
• Crankshaft and transmission operation
Rough operation → Repair.
9. Install:
• O-ring “1” New (onto the adapter)
5-70
CRANKSHAFT AND OIL PUMP
EBS20046

Removing the crankshaft and oil pump
13 Nm (1.3 m•kgf, 9.4 ft•Ibf)
T.R
.
5
6
7
2
1
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

Separate.
Crankcase Refer to “CRANKCASE” on page 5-65.
1 Oil pump 1
2 Crankshaft 1
3 Balancer 1
4 Bearing 1
5 Plug 1
6 Spring 1
7 Steel ball 1
5-71
Disassembling the oil pump
6
E
2
5
4
1
5 Nm (0.5 m•kgf, 3.6 ft•Ibf)

T.R
.

1 Oil pump housing cover 1
2 Pin 1
3 Oil pump shaft 1
4 Oil pump inner rotor 1
5 Oil pump outer rotor 1
6 Oil pump housing 1
5-72
EBS30188
REMOVING THE CRANKSHAFT b

1. Remove:
1
• Crankshaft “1”
• Balancer “2”
TIP
• Remove the crankshaft with the crankcase 2
separating tool “3”. a
• Make sure the crankcase separating tool is 3
centered over the crankshaft.
• Remove the crankshaft “1” and balancer “2” at 1. Inner rotor
the same time. 2. Outer rotor
ECB01880 3. Oil pump housing
NOTICE
3. Check:
• To protect the end of the crankshaft, place • Oil pump operation
an appropriate sized socket between the Rough movement → Replace the oil pump.
crankcase separating tool bolt and the
crankshaft.
• Do not tap on the crankshaft.

90890-01135
Crankcase separator
YU-01135-B
2
EBS30190
1 CHECKING THE OIL STRAINER
1. Check:
• Oil strainer
Damage → Replace the oil pump.
Contaminants → Clean with solvent.
EBS30184
3 CHECKING THE RELIEF VALVE

EBS30189
1. Check:
CHECKING THE OIL PUMP • Steel ball “1”
1. Check: • Spring “2”
• Oil pump Damage/wear → Replace the defective
Cracks/damage/wear → Replace the oil part(s).
pump.
2. Measure:
• Inner-rotor-to-outer-rotor-tip clearance “a”
• Outer-rotor-to-oil-pump-housing clearance 2
“b”
1
Inner-rotor-to-outer-rotor-tip
clearance limit
0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing
clearance limit
0.24 mm (0.0094 in)
5-73
EBS30191
CHECKING THE CRANKSHAFT Recommended lubricant

1. Measure: Engine oil
• Crankshaft width “a”
Out of specification → Replace the crank- 2. Install:
shaft. • Oil pump housing “1”
• Oil pump outer rotor “2”
Crank assembly width • Oil pump inner rotor “3”
65.68–65.76 mm (2.586–2.589 in) • Oil pump shaft “4”
• Pin “5”
2. Measure:
• Crankshaft runout “b” TIP
Out of specification → Replace the crank- To install the oil pump shaft “4”, align the pin “5”
shaft. with the groove “a” in the inner rotor “3”.
Runout limit 1 2
0.030 mm (0.0012 in)
3
a
3. Measure:
• Big end side clearance “c”
Out of specification → Replace the crank-
shaft. a
4
Big end side clearance
5
0.090–0.500 mm (0.0035–0.0197
in) 3. Check:
• Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-73.
c
EBS30193
b b INSTALLING THE CRANKSHAFT
1. Install:
• Balancer “1”
• Crankshaft “2”
ECB01890
NOTICE
a
Apply engine oil to each bearing to protect
4. Check:
the crankshaft against scratches and to
• Crankshaft sprocket
make installation easier.
Damage/wear → Replace the crankshaft.
• Bearing TIP
Cracks/damage/wear → Replace. • Install the balancer “1” and crankshaft “2” at the
5. Check: same time.
• Crankshaft journal • Align the hole “a” in the balancer with the
Scratches/wear → Replace the crankshaft. punch mark “b” on the crankshaft.
• Crankshaft journal oil passage • Install the crankshaft with the crankshaft in-
Obstruction → Blow out with compressed air. staller pot “3”, crankshaft installer bolt “4”,
EBS30192
adapter (M16) “5”, and spacer (crankshaft in-
ASSEMBLING THE OIL PUMP staller) “6”.
1. Lubricate: • Hold the connecting rod at top dead center
• Inner rotor (TDC) with one hand while turning the nut of
• Outer rotor the crankshaft installer bolt with the other. Turn
• Oil pump shaft the crankshaft installer bolt until the crankshaft
(with the recommended lubricant) assembly bottoms against the bearing.
5-74
Crankshaft installer pot 3

90890-01274
Installing pot 1
YU-90058
Crankshaft installer bolt
90890-01275
Bolt
YU-90060 2
Adapter (M16)
90890-04130
Adapter #13
YM-04059
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044
1 a b
2
3
1 5
6
2
EBS30445
INSTALLING THE OIL PUMP

1. Install:
• Oil pump
Oil pump bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
TIP
Tighten the bolts to specification in the proper
tightening sequence as shown.
5-75
TRANSMISSION
EBS20047
TRANSMISSION
Removing the transmission, shift drum and shift forks
1 18 Nm (1.8 m•kgf, 13 ft•Ibf)
T.R
2
.
E 3 New
4
E
10
E
E
New
E E 9
8 5
E
7
E 6
M
New
M

Separate.
Middle driven gear Refer to “MIDDLE GEAR” on page 5-83.
1 Shift drum stopper bolt 1
2 Spring 1
3 Ball 1
4 Shift drum 1
5 Shift fork assembly 1
6 Shift fork “R” 1
7 Spring 1
8 Shift fork “L” 1
9 Shift fork guide bar 1
10 Secondary shaft 1
5-76
TRANSMISSION
Removing the transmission, shift drum and shift forks

18 Nm (1.8 m•kgf, 13 ft•Ibf)
T.R
.
E New
E
15
E
E
New
13
14 E E
12
11
E
E
M
New
M

11 Drive axle assembly 1
12 Collar 1
13 Reverse idle gear 1
14 Bearing 1
15 Reverse idle gear shaft 1
5-77
TRANSMISSION
Disassembling the drive axle assembly
8
New
9
M
LS
7
2 6
5
4
3
M
LS
New
New

1 Washer 1
2 Collar 1
3 High wheel gear 1
4 Washer 1
5 Clutch dog 1
6 Circlip 1
7 Washer 1
8 Collar 1
9 Low wheel gear 1
5-78
TRANSMISSION
Disassembling the drive axle assembly
New
M
LS
16
17
15
18
14
M 13
12
11
LS
10
New
New

10 Washer 1
11 Circlip 1
12 Middle drive gear 1
13 Circlip 1
14 Washer 1
15 Bearing 1
16 Reverse wheel gear 1
17 Collar 1
18 Drive axle 1
5-79
TRANSMISSION
EBS30194
REMOVING THE TRANSMISSION

1. Remove:
• Shift drum “1”
• Shift fork assembly “2” 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pull out the guide bar from the right crank-
case, and then remove the shift fork cam fol-
lowers. 2
b. Remove the shift drum.
c. Remove the shift fork assembly.
2. Check:
• Shift fork guide bar
1 Roll the shift fork guide bar on a flat surface.
Bends → Replace.
2 EWB02750
WARNING
Do not attempt to straighten a bent shift fork
guide bar.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30195
DISASSEMBLING THE DRIVE AXLE

1. Remove:
• Collar “1”
• Drive axle “2”
TIP
Press the drive axle end and remove the collar. 3. Check:
• Shift fork movement
(along the shift fork guide bar)
1 Rough movement → Replace the shift forks
and shift fork guide bar as a set.
EBS30196
CHECKING THE SHIFT FORKS

The following procedure applies to both of the 4. Check:
shift forks. • Spring
1. Check: Cracks/damage → Replace.
• Shift fork cam follower “1”
EBS30197
• Shift fork pawl “2” CHECKING THE SHIFT DRUM
Bends/damage/scoring/wear → Replace the 1. Check:
shift fork. • Shift drum grooves
Damage/scratches/wear → Replace the shift
drum.
5-80
TRANSMISSION
EBS30199
CHECKING THE SECONDARY SHAFT

1. Check:
• Gear teeth
Blue discoloration/pitting/wear → Replace.
EBS30200
ASSEMBLING THE DRIVE AXLE

1. Install:
• Washer “1”
EBS30198 • Circlip “2” New
CHECKING THE TRANSMISSION
TIP
1. Measure:
• Drive axle runout • Be sure the circlip sharp-edged corner “a” is
(with a centering device and dial gauge “1”) positioned opposite side to the washer and
Out of specification → Replace the drive axle. gear.
• Be sure the circlip ends “b” are positioned at
Drive axle runout limit axle spline groove “c”.
0.06 mm (0.0024 in)
New 2 b
1
c
a 1
2. Check:
• Transmission gears EBS30201
Blue discoloration/pitting/wear → Replace ASSEMBLING THE SHIFT FORK

the defective gear(s). 1. Install:
• Transmission gear dogs • Shift fork guide bar “1”
Cracks/damage/rounded edges → Replace • Shift fork “L” “2”
the defective gear(s). • Spring “3”
• Shift fork “R” “4”
• Circlips “5” New
TIP
Install the shift forks with the “R” mark “a” and “L”
mark “b” facing away from each other.
New 5 1
b
3 2
3. Check:
• Transmission gear engagement New 5
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission a
4
axle assemblies.
4. Check:
• Transmission gear movement
Rough movement → Replace the defective
part(s).
5-81
TRANSMISSION
EBS30202
INSTALLING THE SHIFT FORKS AND SHIFT

DRUM
1. Install:
• Reverse idle gear “1”
• Drive axle assembly “2”
• Secondary shaft “3”
• Shift fork assembly “4”
• Shift drum “5”
TIP
Install the shift fork assembly “4” with the “L”
mark “a” facing the right crankcase.
2
1 5
4
4 a
2. Check:
• Shift operation
Rough operation → Repair.
TIP
• Oil each gear and bearing thoroughly.
• Before assembling the crankcase, make sure
that the transmission is in neutral and that the
gears turn freely.
5-82
MIDDLE GEAR
EBS20048
MIDDLE GEAR
Removing the middle drive shaft
190 Nm (19 m•kgf, 137 ft•lbf)

T.R
.
38 Nm (3.8 m•kgf, 27 ft•Ibf)
T.R
.
LT
LT
9
LT
5
6
New
8 7
New 1
LT
LT
LT
LT
29 Nm (2.9 m•kgf, 21 ft•Ibf)

T.R
.

Separate.
1 Middle drive shaft/Bearing housing assembly 1
2 Middle drive pinion gear nut 1
3 Middle drive pinion gear 1
Refer to “ALIGNING THE MIDDLE GEAR”
4 Middle drive pinion gear shim on page 5-92.
5 Middle drive shaft assembly 1
6 Middle driven gear 1
7 Circlip 1
8 Middle drive shaft 1
9 Middle drive shaft bearing housing assembly 1
5-83
MIDDLE GEAR
Removing the middle drive shaft
190 Nm (19 m•kgf, 137 ft•lbf)

T.R
.
38 Nm (3.8 m•kgf, 27 ft•Ibf)
T.R
.
LT
LT
LT
10
New
11 12 13
E
10
New
LT
LT
LT
LT
29 Nm (2.9 m•kgf, 21 ft•Ibf)

T.R
.

10 Bearing retainer 2
11 Bearing 1
12 Washer 1
13 Bearing housing 1
5-84
MIDDLE GEAR
Removing the middle driven shaft

190 Nm (19 m•kgf, 137 ft•lbf)
T.R
.
LT
New M
E 25 Nm (2.5 m•kgf, 18 ft•Ibf)
T.R
.
80 Nm (8.0 m•kgf, 58 ft•Ibf) 3
T.R
.
130 Nm (13 m•kgf, 94 ft•lbf)

T.R
.
4
9
6
T.R
. 190 Nm (19 m•kgf, 137 ft•lbf)
8
5
6
7
M

Rear drive shaft coupling gear nut (middle gear
1 1
side)
Rear drive shaft coupling gear (middle gear
2 1
side)
Front drive shaft coupling gear nut (middle gear
3 1
side)
Front drive shaft coupling gear (middle gear
4 1
side)
5 Middle driven pinion gear assembly 1
Refer to “ALIGNING THE MIDDLE GEAR”
6 Middle driven pinion gear shim on page 5-92.
7 Middle driven pinion gear 1
8 Bearing 1
9 Oil seal 1
5-85
MIDDLE GEAR
Removing the middle driven shaft

190 Nm (19 m•kgf, 137 ft•lbf)
T.R
.
LT
New 14 15 M
17
16
E 25 Nm (2.5 m•kgf, 18 ft•Ibf)
T.R
.
80 Nm (8.0 m•kgf, 58 ft•Ibf)
T.R
.
130 Nm (13 m•kgf, 94 ft•lbf)

T.R
.
13
12
11
T.R
. 190 Nm (19 m•kgf, 137 ft•lbf)
10

10 Middle driven pinion gear bearing retainer 1 Left-hand threads
11 Bearing 1
12 O-ring 1
13 Bearing housing 1
14 Oil seal 1
15 Middle driven shaft bearing retainer 1 Left-hand threads
16 Bearing 1
17 Middle driven shaft 1
5-86
MIDDLE GEAR
EBS30203
REMOVING THE MIDDLE DRIVE SHAFT Coupling gear/middle shaft tool

1. Straighten: 90890-01229
• Punched portion of the middle drive pinion Gear holder
gear nut YM-01229
2. Loosen:
• Middle drive pinion gear nut “1”
TIP
Wrap the middle drive shaft in a folded rag, and
then secure it in a vise. 2
3
2. Remove:
• Front drive shaft coupling gear nut “1”
• Washer
• Front drive shaft coupling gear “2”
TIP
3. Remove: Use the coupling gear/middle shaft tool “3” to
• Middle drive pinion gear nut hold the front drive shaft coupling gear.
• Middle drive pinion gear
• Shim(s)
4. Remove: Coupling gear/middle shaft tool
90890-01229
• Middle driven gear “1”
Gear holder
• Circlip YM-01229
• Middle drive shaft “2”
TIP
Press the middle drive shaft end and remove the
middle driven gear.
2
1
1
3
3. Remove:
• Bearing housing assembly “1”
2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the surface of the bearing housing as-
EBS30204 sembly.
REMOVING THE MIDDLE DRIVEN SHAFT b. Place the bearing housing assembly onto a
1. Remove: hydraulic press.
• Rear drive shaft coupling gear nut “1” ECB01900
• Washer NOTICE
• Rear drive shaft coupling gear “2” • Never directly press the middle driven pin-
TIP ion gear end with a hydraulic press, this will
Use the coupling gear/middle shaft tool “3” to result in damage to the middle driven pin-
hold the rear drive shaft coupling gear. ion gear thread.
5-87
MIDDLE GEAR
• Install a suitable socket “2” on the middle

driven pinion gear end to protect the thread Ring nut wrench
from damage. 90890-01430
Ring nut wrench
c. Press the middle driven pinion gear end and YM-38404
remove the bearing housing.
ECB01750
NOTICE
The middle driven shaft bearing retainer has
left-hand threads. To loosen the retainer turn
it clockwise.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2
4. Remove:
• Middle driven pinion gear bearing retainer
• Bearing
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wrap the bearing housing in a folded rag “1”,
and then secure the bearing housing edge in
a vise.
b. Attach the bearing retainer wrench “2”.
Bearing retainer wrench

90890-04128
YM-04128 3
ECB01740
NOTICE
6. Remove:
The middle driven pinion gear bearing retain- • Middle driven shaft “1”
er has left-hand threads. To loosen the re- (with bearing)
tainer, turn it clockwise.
EBS30205
c. Remove the bearing retainer and bearing. CHECKING THE PINION GEARS
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1. Check:
• Drive pinion gear teeth
5. Remove:
• Driven pinion gear teeth
• Oil seal “1”
Pitting/galling/wear → Replace.
• Middle driven shaft bearing retainer “2”
2. Check:
TIP • Bearings
Attach the ring nut wrench “3”. Pitting/damage → Replace.
5-88
MIDDLE GEAR
EBS30206
INSTALLING THE BEARING AND OIL SEALS Ring nut wrench

1. Install: 90890-01430
• Bearing “1” Ring nut wrench
• Oil seal “2” New YM-38404
(into the bearing housing “3”) ECB01760
NOTICE
Installed depth “a” of bearing
0.9–1.4 mm (0.035–0.055 in) The middle driven shaft bearing retainer has
Installed depth “b” of oil seal left-hand threads. To tighten the retainer turn
1.0–1.5 mm (0.039–0.059 in) it counterclockwise.
a 1
3
1
2 New
b
2. Install:
• Oil seal “1” New
(into the crankcase “2”)
Installed depth “a” of oil seal

1.0–1.5 mm (0.039–0.059 in)
a 1 New
2
2. Install:
• Middle driven pinion gear bearing retainer “1”
2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wrap the bearing housing in a folded rag, and
then secure the bearing housing edge in a
vise.
b. Attach the bearing retainer wrench “2”.
EBS30207
INSTALLING THE MIDDLE DRIVEN SHAFT Bearing retainer wrench

90890-04128
1. Install:
• Middle driven shaft bearing retainer “1” YM-04128
Middle driven shaft bearing re-
c. Tighten the bearing retainer.
tainer
T.
R.
80 Nm (8.0 m·kgf, 58 ft·lbf) Middle driven pinion gear bearing

LOCTITE® retainer
T.
R.
130 Nm (13 m·kgf, 94 ft·lbf)

TIP LOCTITE®
Attach the ring nut wrench “2”.
5-89
MIDDLE GEAR
ECB01770
NOTICE
The middle driven pinion gear bearing retain-
er has left-hand threads. To tighten the re-
tainer turn it counterclockwise.
1
2
1
3
5. Install:
• Rear drive shaft coupling gear “1”
• Washer
2 • Rear drive shaft coupling gear nut “2”
Rear drive shaft coupling gear

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ nut (middle gear side)
T.
R.
3. Install: 190 Nm (19 m·kgf, 137 ft·lbf)
• Middle driven pinion gear shim(s) “1” LOCTITE®
• Bearing housing “2”
TIP TIP
• Install the shim(s) so that the tabs are posi- Use the coupling gear/middle shaft tool “3” to
tioned as shown in the illustration. hold the rear drive shaft coupling gear.
• Make sure that the arrow “a” on the bearing
housing points upward. Coupling gear/middle shaft tool
90890-01229
a Gear holder
YM-01229
1
1 2
4. Install:
• Front drive shaft yoke “1”
• Washer 3
• Front drive shaft yoke nut “2” EBS30208
INSTALLING THE MIDDLE DRIVE SHAFT

Front drive shaft coupling gear 1. Install:
nut (middle gear side)
T.
• Circlip
R.
190 Nm (19 m·kgf, 137 ft·lbf)

LOCTITE® • Middle driven gear “1”
(onto the middle drive shaft “2”)
TIP
Installed depth “a” of middle
Use the coupling gear/middle shaft tool “3” to driven gear
hold the front drive shaft coupling gear. 24.7–24.9 mm (0.972–0.980 in)
Coupling gear/middle shaft tool

90890-01229
Gear holder
YM-01229
5-90
MIDDLE GEAR
a TIP
• Wrap the middle drive shaft in a folded rag, and
then secure it in a vise.
• Lock the threads with a drift punch.
1 2
2. Install:
• Washer “1”
• Bearing “2”
• Bearing retainers “3”
• Bearing retainer bolts “4” New
EBS30209
Middle drive shaft bearing retain- MEASURING THE MIDDLE GEAR

er bolt BACKLASH
T.
R.
29 Nm (2.9 m·kgf, 21 ft·lbf) 1. Measure:

LOCTITE® • Middle gear backlash
TIP Refer to “ALIGNING THE MIDDLE GEAR” on
• Install the washer “1” with its rounded side “a” page 5-92.
facing away from the bearing.
Middle gear backlash
• Stake the bearing retainer bolts at the cutouts
0.10–0.30 mm (0.004–0.012 in)
“b” in the bearing retainers “3”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
4 New a. Temporarily install the right crankcase.
3
2 b. Wrap a rag “1” around a screwdriver “2”, and
then insert it into the installation hole “a” of the
right crankcase speed sensor to hold the mid-
1
dle driven gear.
1 a
New 4
2
b b
a
3 1
3
c. Attach the final gear backlash band “3” and
4 New dial gauge “4”.
New 4
b Final gear backlash band
90890-01511
3. Tighten: Middle drive gear lash tool
• Middle drive pinion gear nut “1” New YM-01230
Middle drive pinion gear nut

190 Nm (19 m·kgf, 137 ft·lbf)
T.
R.
5-91
MIDDLE GEAR
4
A
3
b a
a. 39.3 mm (1.55 in)
b. 25.3 mm (1.00 in)
d. Measure the gear lash while rotating the mid-
dle driven shaft back and forth.
TIP
Measure the gear lash at 4 positions. Rotate the
middle driven gear 90° each time. B
e. If the gear lash is incorrect, adjust the gear
lash by middle driven pinion gear shim(s). 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
A. Middle drive pinion gear shim thickness
EBS30210
ALIGNING THE MIDDLE GEAR B. Middle driven pinion gear shim thickness
TIP ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Aligning the middle gear is necessary when any a. Position the middle gears with the appropri-
of the following parts are replaced: ate shim(s) that has had its respective thick-
• Crankcase ness calculated from information marked on
• Middle drive pinion gear the crankcase, bearing housings, and pinion
• Middle driven pinion gear gears.
• Middle driven shaft bearing housing b. To find middle drive pinion gear shim thick-
• Middle drive shaft bearing housing ness “A”, use the following formula.
Middle drive pinion gear shim thickness
1. Select: “A” = “e” + “d” - “b” - “c” - “a”
• Middle drive pinion gear shim(s) “1”
• Middle driven pinion gear shim(s) “2” “a” = a numeral (usually a decimal number)
on the bearing housing is either added to or
2 subtracted from “0.6”
“b” = 17.0
“c” = 55.0
“d” = a numeral (usually a decimal number)
on the crankcase (left) specifies a thickness
of “65.0”
“e” = a numeral (usually a decimal number)
on the crankcase (right) specifies a thickness
of “9.0”
Example:
If the bearing housing is marked “-02”,
“a” is 0.58
5-92
MIDDLE GEAR
Middle drive pinion gear shim

Thickness (mm)
0.50 0.55 0.60 0.70 0.80 0.90 1.00
c. To find middle driven pinion gear shim thick-

ness “B”, use the following formula.
Middle driven pinion gear shim thickness
“B” = “f” - “g” + “h” - “i” - “j”
a
“f” = a numeral (usually a decimal number) on
“b” is 17.0 the bearing housing is either added to or sub-
“c” is 55.0 tracted from “89.5”
If the crankcase (left) is marked “64.96”, TIP
“d” is 64.96
After replacing any part in the middle driven pin-
ion gear assembly, the overall length of the as-
sembly will change. Therefore, be sure to
measure distance “f” to select the correct middle
driven pinion gear shim thickness.
d
f
If the crankcase (right) is marked “9.01”,
“e” is 9.01
“g” = a numeral (usually a decimal number)

on the middle driven pinion gear is either add-
e ed to or subtracted from “61.0”
“h” = a numeral (usually a decimal number)
on the middle driven pinion gear is either add-
ed to or subtracted from “80.5”
“i” = a numeral (usually a decimal number) on
Therefore, “A” is 1.39. the right crankcase specifies a thickness of
“A” = 9.01 + 64.96 - 17.0 - 55.0 - 0.58 “99.98”
= 1.39 “j” = a numeral (usually a decimal number) on
Round off hundredths digit and select appro- the left crankcase specifies a thickness of
priate shim(s). “8.12”
In the above example, the calculated shim Example:
thickness is 1.39 mm. The following chart in- If the bearing housing is marked “+03”,
structs you, however, to round off 9 to 10. “f” is 89.53
Hundredth Rounded value
0, 1, 2 0
3, 4, 5, 6, 7 5
8, 9 10
Shims are supplied in the following thickness-

es.
5-93
MIDDLE GEAR
If the driven pinion gear is marked “+02”, Therefore, “B” is 0.81.

“g” is 61.02 “B” = 89.53 - 61.02 + 80.40 - 99.98 - 8.12 =
0.81
Round off hundredth digit and select appro-
priate shim(s).
In the above example, the calculated shim
thickness is 0.81 mm. The chart instructs
you, however, to round off 1 to 0.
g Hundredth Rounded value
0, 1, 2 0
3, 4, 5, 6, 7 5
If the driven pinion gear is marked “-10”, 8, 9 10
“h” is 80.40
Shims are supplied in the following thickness-
es.
Middle driven pinion gear shim

Thickness (mm)
0.10 0.15 0.20 0.30 0.40 0.50 0.60
TIP
h
• If the specified middle gear backlash cannot be
obtained with a calculated shim thickness, in-
If the right crankcase is marked “99.98”, crease or decrease the shim thickness.
“i” is 99.98 • If the shim thickness is increased, the actual
middle gear backlash will increase and, if the
shim thickness is decreased, the actual middle
gear backlash will decrease.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
If the left crankcase is marked “8.12”,

“j” is 8.12
5-94
MIDDLE GEAR
5-95
COOLING SYSTEM
OIL COOLER...................................................................................................6-1
CHECKING THE OIL COOLER ................................................................6-3
INSTALLING THE HORN (except for CDN)..............................................6-3
RADIATOR ...................................................................................................... 6-4

CHECKING THE RADIATOR.................................................................... 6-6
INSTALLING THE RADIATOR..................................................................6-6
THERMOSTAT ................................................................................................6-8
CHECKING THE THERMOSTAT.............................................................. 6-9
INSTALLING THE THERMOSTAT............................................................ 6-9
WATER PUMP...............................................................................................6-11
DISASSEMBLING THE WATER PUMP.................................................. 6-12
CHECKING THE WATER PUMP ............................................................ 6-12
ASSEMBLING THE WATER PUMP........................................................ 6-12
INSTALLING THE WATER JACKET JOINT ...........................................6-13
6
OIL COOLER
EBS20050
OIL COOLER
Removing the oil cooler
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
T.R
.
3 6

T.R
T.R
.

Floor boards 4-6.
Front grill 4-12.
Air filter case Refer to “AIR FILTER CASE” on page 7-5.
Drain.
page 3-14.
1 Oil cooler outlet hose 1
2 Oil cooler inlet hose 1
3 Horn 1 Except for CDN
4 Oil cooler guard 1
5 Oil cooler 1
6 Oil cooler bracket 1
6-1
OIL COOLER
Removing the oil cooler
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
10
9
T.R
.
8
7
12
11

T.R
T.R
.

7 Oil inlet hose 1
8 Oil outlet hose 1
9 Oil inlet pipe 1
10 Oil outlet pipe 1
11 Oil cooler outlet pipe 1
12 Oil cooler inlet pipe 1
6-2
OIL COOLER
EBS30211
CHECKING THE OIL COOLER

1. Check:
• Oil cooler fins
Obstruction → Clean.
Apply compressed air to the rear of the oil
cooler.
Damage → Repair or replace.
TIP
Straighten any flattened fins with a thin, flat-head
screwdriver.
2. Check:
• Oil cooler hoses
• Oil cooler pipes
• Oil hoses
• Oil pipes
EBS30575
INSTALLING THE HORN (except for CDN)

1. Install:
• Horn
Horn bolt (except for CDN)

7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.
TIP
Align the projection “a” on the oil cooler guard
with the slot “b” on the horn bracket.
b
a
6-3
RADIATOR
EBS20051
RADIATOR
Removing the radiator
T.R
T.R
.
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
9 8
(4)
6
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
T.R
.
4
3 5
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Oil cooler Refer to “OIL COOLER” on page 6-1.
Drain.
page 3-9.
1 Radiator cap 1
2 Coolant reservoir hose 1
3 Coolant reservoir breather hose 1
4 Coolant reservoir cap 1
5 Coolant reservoir 1
6 Radiator inlet hose 1
7 Radiator outlet hose 1
8 Thermostat outlet hose 1
9 Water pump inlet hose 1
6-4
RADIATOR
Removing the radiator
T.R
T.R
.
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

15
T.R
.
11
13
14
16 10
12 (4)
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)

T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

10 Radiator inlet pipe 1
11 Radiator outlet pipe 1
12 Radiator fan motor coupler 1 Disconnect.
13 Radiator bracket 1
14 Radiator 1
15 Radiator fan motor breather hose 1
16 Radiator fan 1
6-5
RADIATOR
EBS30213
CHECKING THE RADIATOR

1. Check:
• Radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the radia-
tor.
Damage → Repair or replace.
TIP
Straighten any flattened fins with a thin, flat-head
screwdriver. b. Apply the specified pressure for ten seconds
and make sure there is no drop in pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” on page 9-29.
EBS30214
INSTALLING THE RADIATOR

1. Install:
2. Check: • Radiator outlet pipe “1”
• Radiator hoses • Radiator inlet pipe “2”
• Radiator pipes TIP
Align the punch marks “a” on the radiator inlet
3. Measure:
pipe and outlet pipe with the hose clamp.
• Radiator cap opening pressure
Below the specified pressure → Replace the
a
radiator cap.
Radiator cap opening pressure

107.9–137.3 kPa (1.1–1.4
kgf/cm², 15.6–19.9 psi)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the radiator cap tester “1” and radiator
cap tester adapter “2” to the radiator cap “3”.
Radiator cap tester

90890-01325 1
Mityvac cooling system tester kit
YU-24460-A 2
Radiator cap tester adapter
90890-01352 a
Pressure tester adapter
YU-33984
2. Fill:
• Cooling system
mended coolant)
6-6
RADIATOR
Refer to “CHANGING THE COOLANT” on

page 3-9.
3. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
4. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-6.
6-7
THERMOSTAT
EBS20052
THERMOSTAT
Removing the thermostat
20 Nm (2.0 m•kgf, 14 ft•Ibf)

T.R
.
1
2
New
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
5
LS
New 4
New

Drain.
page 3-9.
1 Coolant temperature sensor coupler 1 Disconnect.
2 Coolant temperature sensor 1
3 Thermostat outlet hose 1 Disconnect.
4 Thermostat cover 1
5 Thermostat 1
6-8
THERMOSTAT
EBS30215
• Thermostat housing (cylinder head)
CHECKING THE THERMOSTAT
• Thermostat outlet hose
1. Check:
• Thermostat
Does not open at 69–73 °C (156–163°F) → EBS30216
Replace. INSTALLING THE THERMOSTAT

1. Install:
• Copper washer New
• Coolant temperature sensor
ECB01910
NOTICE
Use extreme care when handling the coolant
temperature sensor. Replace any part that
was dropped or subjected to a strong im-
pact.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Coolant temperature sensor

a. Suspend the thermostat “1” in a container “2” 20 Nm (2.0 m·kgf, 14 ft·lbf)
T.
R.
filled with water.
b. Slowly heat the water “3”. 2. Install:
c. Place a thermometer “4” in the water. • Thermostat “1”
d. While stirring the water, observe the thermo- • Gasket “2” New
stat and thermometer indicated temperature. • Thermostat cover “3”
Thermostat cover bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
TIP
Install the thermostat with its breather hole “a”
facing up.
a
3
1
8 mm 2 New
(0.31 in)
LS
71±2°C 84°C 3. Fill:

(159±3°F) (183°F) • Cooling system
A. Fully closed mended coolant)
B. Fully open Refer to “CHANGING THE COOLANT” on
TIP page 3-9.
4. Check:
If the accuracy of the thermostat is in doubt, re-
• Cooling system
place it. A faulty thermostat could cause serious
Leak → Repair or replace any faulty part.
overheating or overcooling.
5. Measure:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Radiator cap opening pressure
2. Check: Below the specified pressure → Replace the
• Thermostat cover radiator cap.
6-9
THERMOSTAT
Refer to “CHECKING THE RADIATOR” on

page 6-6.
6-10
WATER PUMP
EBS20053
WATER PUMP
Removing the water pump
D
FW
8 New 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
7
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
11 New
13
New 14 New
9 6 New
5
(8)
1
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 12
T.R
10
.
2 3 LS
E 4 New
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
New
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
T.R
.

T.R
.
T.R
.

Engine 5-5.
1 Water jacket joint 1
2 Water pump outlet hose 1
3 Water pump outlet pipe 1
4 Water pump breather hose 1
5 Water pump housing 1
6 Gasket 1
7 AC magneto cover 1
8 AC magneto cover gasket 1
9 Impeller 1 Left-hand threads.
10 Washer 1
11 Impeller shaft 1
12 Mechanical seal 1
13 Bearing 1
14 Oil seal 1
6-11
WATER PUMP
EBS30217
DISASSEMBLING THE WATER PUMP TIP

1. Remove: Install the oil seal with a socket that matches its
• Mechanical seal “1” outside diameter.
TIP
Remove the mechanical seal from the inside of Installed depth of oil seal “a”
the AC magneto cover. 0 mm (0 in)
2 New
1 1
2. Remove: 2. Install:
• Bearing “1” • Mechanical seal “1” New
• Oil seal “2” ECB02410
TIP NOTICE
Remove the bearing and oil seal from the inside Never lubricate the mechanical seal surface
of the AC magneto cover. with oil or grease.
TIP
Use the special tools and a press to press the
mechanical seal straight in until its flange “a”
touches the AC magneto cover.

2 90890-01581
1 YM-01581
Middle driven shaft bearing driv-
EBS30218
er
CHECKING THE WATER PUMP 90890-04058
1. Check: Middle drive bearing installer 40
• Water pump housing cover & 50 mm
• AC magneto cover YM-04058
• Impeller
• Impeller shaft A
3
• Water pump outlet pipe
• Water pump outlet hose 2
1 New
2. Check: a a
• Bearing
Rough movement → Replace.
EBS30219
ASSEMBLING THE WATER PUMP

1. Install: A. Push down
• Bearing “1” 2. Mechanical seal installer
• Oil seal “2” New 3. Middle driven shaft bearing driver
(into the AC magneto cover)
6-12
WATER PUMP
3. Install:
• Impeller “1”
Impeller
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
TIP
After installation, check that the impeller shaft ro-
tates smoothly.
4. Install:
• AC magneto cover
CLUTCH” on page 5-33.
EBS30471
INSTALLING THE WATER JACKET JOINT

1. Install:
• Clamps “1” (onto the water pump outlet hose)
• Water pump outlet hose “2” (onto the water
jacket joint)
• Water jacket joint “3”
TIP
Tighten the clamp screw of each clamp “1” until
4 slots remain in the area “a” of the clamp as
Water jacket joint bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
b a
1
2
1
b. upward
6-13
FUEL SYSTEM
FUEL TANK..................................................................................................... 7-1

REMOVING THE FUEL TANK ..................................................................7-2
REMOVING THE FUEL PUMP .................................................................7-2
CHECKING THE FUEL PUMP BODY.......................................................7-2
CHECKING THE FUEL TANK BREATHER HOSE JOINT .......................7-2
INSTALLING THE FUEL PUMP................................................................7-3
INSTALLING THE FUEL TANK.................................................................7-3
CHECKING THE FUEL PRESSURE ........................................................7-4
AIR FILTER CASE .......................................................................................... 7-5

INSTALLING THE AIR FILTER CASE ......................................................7-7
THROTTLE BODY........................................................................................... 7-8

REMOVING THE THROTTLE BODY......................................................7-11
CHECKING THE FUEL INJECTOR ........................................................ 7-11
CHECKING THE THROTTLE BODY ......................................................7-11
CHECKING THE THROTTLE BODY JOINT...........................................7-11
INSTALLING THE THROTTLE BODY ....................................................7-11
ADJUSTING THE THROTTLE POSITION SENSOR..............................7-13
AIR INDUCTION SYSTEM ............................................................................7-14

CHECKING THE AIR INDUCTION SYSTEM..........................................7-17
INSTALLING THE AIR INDUCTION SYSTEM........................................ 7-17
7
FUEL TANK
EBS20054
FUEL TANK
Removing the fuel tank
T.R
T.R
.
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 5 4
T.R
.
(6)
1
2 11
3
6
1 New
7 9
7
10
10
10
8
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Rear panel (right) 4-1.
Under-seat storage compartment 4-6.
1 Fuel tank breather hose 2
2 Fuel tank breather hose joint 1
3 Fuel pump coupler 1 Disconnect.
4 Fuel hose connector holder 1
5 Fuel hose 1
6 Fuel tank retainer 1
7 Damper 2
8 Fuel tank bracket 1
9 Fuel tank 1
10 Damper 4
11 Fuel pump 1
7-1
FUEL TANK
EBS30221
REMOVING THE FUEL TANK

1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Remove:
• Fuel hose connector holder
• Fuel hose
EWB03050
WARNING
Cover fuel hose connections with a cloth
when disconnecting them. Residual pres-
sure in the fuel lines could cause fuel to EBS30222
spurt out when removing the hose. REMOVING THE FUEL PUMP
ECB01560
1. Remove:
NOTICE • Fuel pump bracket
• Fuel pump
Although the fuel has been removed from
• Fuel pump gasket
the fuel tank, be careful when removing the ECB01450
fuel hose, since there may be fuel remaining NOTICE

in it. • Do not drop the fuel pump or give it a
TIP strong shock.
• To disconnect the fuel hose from the fuel • Do not touch the base section of the fuel
pump, remove the fuel hose connector holder, sender.
insert a flat-head screwdriver, etc., in the slot
EBS30223
part “a” of the fuel hose connector cover “1”, CHECKING THE FUEL PUMP BODY
slide the cover in the direction of the arrow, and 1. Check:
then disconnect the fuel hose. • Fuel pump body
• To disconnect the fuel hose from the fuel rail, Obstruction → Clean.
slide the fuel hose connector cover “2” on the Cracks/damage → Replace the fuel pump.
end of the hose in direction of the arrow shown,
press the two buttons “3” on the sides of the EBS30224
connector, and then disconnect the hose. CHECKING THE FUEL TANK BREATHER
• Before removing the hose, place a few rags in HOSE JOINT
the area under where it will be removed. 1. Check:
• Fuel tank breather hose joint
Damage/faulty → Replace.
TIP
• Check that air flows smoothly in the direction of
the arrow shown when the hose joint is posi-
tioned as shown in the illustration “A”.
• Check that air does not flow in the direction of
the arrow shown when the hose joint is posi-
tioned as shown in the illustration “B”.
7-2
FUEL TANK
È a É a 2 4
a
5 6
3 b 1
a. upward EBS30226
INSTALLING THE FUEL TANK

EBS30225
1. Install:
INSTALLING THE FUEL PUMP
• Dampers “1”
1. Install:
TIP
• Fuel pump gasket “1” New
Fit the projection “a” on the dampers into the
TIP
hole “b” in the frame.
• Always use a new fuel pump gasket.
• Install the fuel pump gasket with the lip side “a” 1
facing upward.
1
1
a
New 1 a 1
b
2. Install:
• Fuel tank “1”
• Fuel tank bracket “2”
2. Install: • Fuel tank bracket bolts “3”
• Fuel pump • Fuel tank bolts “4”
• Fuel pump bracket • Fuel tank retainer “5”
• Fuel tank retainer bolts “6”
Fuel pump nut
7 Nm (0.7 m·kgf, 5.1 ft·lbf) TIP
T.
R.
Finger tighten the fuel tank bolts and fuel tank re-
TIP tainer bolts.
• Do not damage the installation surfaces of the
fuel tank when installing the fuel pump. 2 6 6
5
• Install the fuel pump in the direction shown in 3
4
the illustration.
• Install the fuel pump bracket by aligning the 1
projections “a” on the fuel pump with the pro-
jection “b” on the fuel tank.
• Tighten the nuts to specification in the proper
tightening sequence as shown.
4 4
3. Tighten:
• Fuel tank bracket bolts
• Fuel tank bolts
• Fuel tank retainer bolts
7-3
FUEL TANK

Fuel tank bracket bolt 4-19.
7 Nm (0.7 m·kgf, 5.1 ft·lbf) b. Disconnect the fuel hose “1” from the fuel rail.
T.
R.
Fuel tank bolt Refer to “REMOVING THE THROTTLE

7 Nm (0.7 m·kgf, 5.1 ft·lbf)
BODY” on page 7-11.
Fuel tank retainer bolt
16 Nm (1.6 m·kgf, 12 ft·lbf) c. Connect the pressure gauge “2” and adapter
“3” to the fuel rail and fuel hose.
4. Install:
Pressure gauge
• Fuel hose
90890-03153
• Fuel hose connector holder “1” Pressure gauge
• Fuel pump coupler YU-03153
ECB02010
Fuel pressure adapter
NOTICE
90890-03176
When installing the fuel hose, make sure that Fuel pressure adapter
it is securely connected, and that the fuel YM-03176
hose holder is in the correct position, other-
wise the fuel hose will not be properly in-
1
stalled.
TIP
• Install the fuel hose connector holder “1” se-
curely onto the fuel pump until a distinct “click”
is heard, and then make sure that it does not
come loose. 2
• To install the fuel hose onto the fuel rail, slide
3
the fuel hose connector cover “2” on the end of
the hose in direction of the arrow shown. d. Start the engine.
e. Measure the fuel pressure.
Out of specification → Replace the fuel
pump.
Fuel line pressure at idling

300–390 kPa (3.0–3.9 kgf/cm²,
42.7–55.5 psi)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30227
CHECKING THE FUEL PRESSURE

1. Check:
• Fuel pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the cargo bed.
7-4
AIR FILTER CASE
EBS20055
AIR FILTER CASE

Removing the air filter case and air intake duct
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
1 2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
T.R
.
New
6
7
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf) 6
T.R
.
8 9 8 New
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
2 3 4 1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
T.R
.

Floor boards 4-6.
1 Air filter case cover 1
2 Air filter element holder 1
3 Air filter element 1
4 Air filter element frame 1
5 Intake air temperature sensor coupler 1 Disconnect.
6 Air filter case joint clamp screw 2 Loosen.
7 Air filter case joint 1
8 Air intake duct joint clamp screw 2 Loosen.
9 Air intake duct joint 1
7-5
AIR FILTER CASE
Removing the air filter case and air intake duct

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
T.R
.
New
12
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)

T.R
.
11
New
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
10
T.R
.
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
T.R
.

10 Air filter case 1
11 Intake air temperature sensor 1
12 Air intake duct 1
7-6
AIR FILTER CASE
EBS30228
INSTALLING THE AIR FILTER CASE

1. Install:
• Air intake duct joint “1”
(to the air filter case “2”)
TIP
Align the projection “a” on the air intake duct joint
between the projections “b” on the air filter case.
a
2
1
2. Install:
• Air filter case joint “1”
(to the air filter case)
TIP
Align the projection “a” on the air filter case joint
with the slot “b” on the air intake silencer “2”.
2
b
a
7-7
THROTTLE BODY
EBS20056
THROTTLE BODY
Removing the throttle body assembly
3.5 Nm (0.35 m•kgf, 2.5 ft•Ibf)
T.R
.
1 2.8 Nm (0.28 m•kgf, 2.0 ft•Ibf)
T.R
.
4 3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)
T.R
.
8
2
New
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
T.R
.
7 3
LS 5 6
9
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
T.R
.
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)

T.R
.

Cargo bed 4-19.
1 Intake air pressure sensor coupler 1 Disconnect.
2 Throttle position sensor coupler 1 Disconnect.
3 Throttle body breather hose 1
4 Fuel injector coupler 1 Disconnect.
5 ISC (Idle Speed Control) unit coupler 1 Disconnect.
6 Throttle cable housing cover 1
7 Throttle cable 1 Disconnect.
8 Fuel hose 1 Disconnect.
9 Cylinder head breather hose 1
7-8
THROTTLE BODY
Removing the throttle body

11 3.5 Nm (0.35 m•kgf, 2.5 ft•Ibf)
T.R
.
2.8 Nm (0.28 m•kgf, 2.0 ft•Ibf)
T.R
.
3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)
T.R
.
10 13 12
14
12
10
New
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
T.R
.
LS
17
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)

T.R
.
15
16
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)

T.R
.

10 Air intake silencer joint clamp screw 2 Loosen.
11 Air intake silencer joint 1
12 Throttle body joint clamp screw 2 Loosen.
13 Throttle body assembly 1
14 Throttle body joint 1
Air induction system solenoid hose (air intake si-
15 1 Disconnect.
lencer to air induction system solenoid)
16 Air filter case joint clamp screw 1 Loosen.
17 Air intake silencer 1
7-9
THROTTLE BODY
Disassembling the throttle body assembly

3.6 Nm (0.36 m•kgf, 2.6 ft•Ibf)
T.R
.
1
5 Nm (0.5 m•kgf, 3.6 ft•Ibf)
T.R
.
4
3.5 Nm (0.35 m•kgf, 2.5 ft•Ibf) New

T.R
.
3 5
New
New

1 Intake air pressure sensor 1
2 Intake air pressure sensor hose 1
3 Throttle position sensor 1
4 Fuel rail 1
5 Fuel injector 1
6 Throttle body 1
7-10
THROTTLE BODY
EBS30229 EBS30231
REMOVING THE THROTTLE BODY CHECKING THE THROTTLE BODY

1. Disconnect: 1. Check:
• Fuel hose • Throttle body
EWB03050
Cracks/damage → Replace the throttle body.
WARNING 2. Check:
Cover fuel hose connections with a cloth • Fuel passages
when disconnecting them. Residual pres- Obstructions → Clean.
sure in the fuel lines could cause fuel to ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
spurt out when removing the hose. a. Wash the throttle body in a petroleum- based
ECB01700
solvent.
NOTICE Do not use any caustic carburetor cleaning
• Be sure to disconnect the fuel hose by solution.
hand. Do not forcefully disconnect the b. Blow out all of the passages with compressed
hose with tools. air.
• Although the fuel has been removed from ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
the fuel tank, be careful when removing the EBS30232
fuel hose, since there may be fuel remain- CHECKING THE THROTTLE BODY JOINT
ing in it. 1. Check:
• Throttle body joint
TIP Cracks/damage → Replace.
• To disconnect the fuel hose from the fuel rail,
EBS30233
slide the fuel hose connector cover “1” on the INSTALLING THE THROTTLE BODY
end of the hose in direction of the arrow shown, 1. Install:
press the two buttons “2” on the sides of the • Air intake silencer “1”
connector, and then disconnect the hose.
• Before disconnecting the hose, place a few Air filter case joint clamp screw
rags in the area under where it will be discon- 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
T.
R.
nected.
TIP
Align the projection “a” on the air filter case joint
“2” with the slot “b” on the air intake silencer.
b
a
2
EBS30427
CHECKING THE FUEL INJECTOR

1
1. Check:
• Fuel injector 2. Install:
Obstruction → Replace and check the fuel • Throttle body joint “1”
pump/fuel supply system.
Deposit → Replace. Throttle body joint clamp screw
Damage → Replace. (cylinder head side)
T.
R.
2. Check: 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)

• Fuel injector resistance
Refer to “CHECKING THE FUEL INJEC- TIP
TOR” on page 9-108. Align the projection “a” on the cylinder head with
the slot “b” in the throttle body joint.
7-11
THROTTLE BODY
a Air intake silencer joint clamp

screw (air intake silencer side)
T.
R.
b 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
1 Air intake silencer joint clamp
screw (throttle body side)
3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
TIP
• Align the projection “a” on the throttle body as-
sembly between the tabs “b” on the air intake
3. Install:
silencer joint.
• Throttle body joint clamp “1”
• Align the projection “c” on the air intake silenc-
TIP er joint with the slot “d” in the air intake silencer.
Align the projection on the throttle body joint with
the gap in throttle body joint clamp.
b
1
a
1
4. Install:
• Throttle body assembly “1”
Throttle body joint clamp screw

T.
R.
2.8 Nm (0.28 m·kgf, 2.0 ft·lbf)

b
TIP c d
Align the projection “a” on the throttle body as- a
sembly between the tabs “b” on the throttle body 6. Connect:
joint. • Fuel hose
ECB01920
b NOTICE
a When installing the fuel hose, make sure that
1 it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
the correct position, otherwise the fuel hose
b will not be properly installed.
TIP
• Connect the fuel hose securely onto the fuel
rail until a distinct “click” in heard.
5. Install:
• To connect the fuel hose onto the fuel rail, slide
• Air intake silencer joint “1”
the fuel hose connector cover “1” on the end of
the hose in direction of the arrow shown.
7-12
THROTTLE BODY
Throttle position sensor output

voltage
0.63–0.73 V
f. After adjusting the throttle position sensor an-

gle, tighten the throttle position sensor
screws “2”.
Throttle position sensor screw

1
3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
T.
R.
EBS30234
ADJUSTING THE THROTTLE POSITION

2
SENSOR
EWB03070
WARNING
• Handle the throttle position sensor with
special care. 1
• Never subject the throttle position sensor 2
to strong shocks. If the throttle position
sensor is dropped, replace it.
1. Check:
• Throttle position sensor ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Refer to “CHECKING THE THROTTLE PO-
SITION SENSOR” on page 9-106.
2. Adjust:
• Throttle position sensor angle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the test harness– TPS (3P) “1” to
the throttle position sensor and wire harness
as shown.
b. Connect the digital circuit tester to the test
harness– TPS (3P).

90890-03204
YU-03204
Digital circuit tester
90890-03174
Model 88 Multimeter with ta-
chometer
YU-A1927
• Positive tester probe

yellow (wire harness color)
• Negative tester probe
black/blue (wire harness color)
c. Turn the main switch to “ ” (on).

d. Measure the throttle position sensor voltage.
e. Adjust the throttle position sensor angle so
that the voltage is within the specified range.
7-13
AIR INDUCTION SYSTEM
EBS20057
1 2 3
1. Air intake silencer

2. Air induction system hose (air intake silencer
to air cut-off valve)
3. Air cut-off valve
4. Air induction system hose (air cut-off valve to
reed valve cover)
5. Reed valve
7-14
Removing the air cut-off valve
9 Nm (0.9 m•kgf, 6.5 ft•Ibf)

T.R
.

Cargo bed 4-19.
1 Air induction system solenoid coupler 1 Disconnect.
Air induction system hose (air cut-off valve to
2 1
reed valve cover)
Air induction system hose (air intake silencer to
3 1
air cut-off valve)
4 Air cut-off valve 1
5 Air cut-off valve bracket 1
7-15
Removing the reed valve
LT
LT
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

1 Reed valve cover 1
2 Reed valve assembly 1
3 Reed valve plate 1
7-16
EBS30235
2. Check:
CHECKING THE AIR INDUCTION SYSTEM
• Reed valve
• Reed valve stopper
Air injection
• Reed valve seat
The air induction system burns unburned ex-
Cracks/damage → Replace the reed valve
haust gases by injecting fresh air (secondary air)
assembly.
into the exhaust port, reducing the emission of
3. Check:
hydrocarbons. When there is negative pressure
• Air cut-off valve
at the exhaust port, the reed valve opens, allow-
ing secondary air to flow into the exhaust port.
4. Check:
The required temperature for burning the un-
• Air induction system solenoid
burned exhaust gases is approximately 600 to
Refer to “CHECKING THE AIR INDUCTION
700 °C (1112 to 1292 °F).
SYSTEM SOLENOID” on page 9-108.
Air cut-off valve EBS30236
The air cut-off valve is controlled by the signals INSTALLING THE AIR INDUCTION SYSTEM
from the ECU in accordance with the combus- 1. Install:
tion conditions. Ordinarily, the air cut-off valve • Reed valve plate “1”
opens to allow the air to flow during idle and TIP
closes to cut-off the flow when the vehicle is be- Align the notch “a” in the reed valve plate with
ing driven. However, if the coolant temperature the projection “b” of the reed valve seat on the
is below the specified value, the air cut-off valve cylinder head.
remains open and allows the air to flow into the
exhaust pipe until the temperature becomes a
higher than the specified value.
b 1
B
A. From the air intake silencer

B. To the reed valve
1. Check:
• Hoses
Loose connections → Connect properly.
7-17
DRIVE TRAIN
TROUBLESHOOTING.....................................................................................8-1
CHECKING NOISES ................................................................................. 8-2
TROUBLESHOOTING CHART .................................................................8-3
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL

ASSEMBLY AND FRONT DRIVE SHAFTS................................................... 8-4
DISASSEMBLING THE UNIVERSAL JOINTS........................................ 8-10
DISASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-10
CHECKING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-11
ASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-11
REMOVING THE FRONT DRIVE SHAFT YOKE.................................... 8-12
REMOVING THE DIFFERENTIAL GEAR ASSEMBLY........................... 8-13
CHECKING THE FRONT DRIVE SHAFT ............................................... 8-13
CHECKING THE DIFFERENTIAL ASSEMBLY ...................................... 8-13
CHECKING THE DIFFERENTIAL MOTOR OPERATION ......................8-13
ASSEMBLING THE FRONT DRIVE SHAFT...........................................8-14
ASSEMBLING THE DIFFERENTIAL ASSEMBLY ..................................8-14
ASSEMBLING THE UNIVERSAL JOINT ................................................ 8-15
MEASURING THE DIFFERENTIAL GEAR BACKLASH......................... 8-16
ADJUSTING THE DIFFERENTIAL GEAR BACKLASH .......................... 8-17
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE

ASSEMBLY AND REAR DRIVE SHAFT .....................................................8-18
DISASSEMBLING THE REAR CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-25
CHECKING THE REAR CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-25
ASSEMBLING THE REAR CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-25
DISASSEMBLING THE FINAL DRIVE ASSEMBLY ...............................8-27
CHECKING THE REAR DRIVE SHAFT.................................................. 8-28
CHECKING THE FINAL DRIVE ASSEMBLY..........................................8-28
ADJUSTING THE RING GEAR STOPPER............................................. 8-28
MEASURING THE FINAL GEAR BACKLASH ........................................ 8-29
ADJUSTING THE FINAL GEAR BACKLASH .........................................8-29
8
ASSEMBLING THE FINAL DRIVE ASSEMBLY ..................................... 8-30
INSTALLING THE FINAL DRIVE ASSEMBLY........................................ 8-31
TROUBLESHOOTING
EBS20058
TROUBLESHOOTING
The following conditions may indicate damaged shaft drive components:
Symptoms Possible Causes
1. A pronounced hesitation or “jerky” movement A. Bearing damage.
during acceleration, deceleration, or sustained B. Improper gear backlash.
speed. (This must not be confused with engine C. Gear tooth damage.
surging or transmission characteristics.) D. Broken drive shaft.
2. A “rolling rumble” noticeable at low speed; a high- E. Broken gear teeth.
pitched whine; a “clunk” from a shaft drive com- F. Seizure due to lack of lubrication.
ponent or area. G. Small foreign objects lodged between the moving
3. A locked-up condition of the shaft drive train parts.
mechanism, no power transmitted from the en-
gine to the front and/or rear wheels.
TIP
Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite subtle and
difficult to distinguish from normal vehicle operating noise. If there is reason to believe these compo-
nents are damaged, remove the components and check them.
8-1
TROUBLESHOOTING
EBS30237
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING NOISES a. Clean the entire vehicle thoroughly, then dry
1. Investigate any unusual noises. it.
b. Apply a leak detection compound or dry pow-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
der spray to the shaft drive.
The following “noises” may indicate a me-
c. Road test the vehicle for the distance neces-
chanical defect:
sary to locate the leak.
a. A “rolling rumble” noise during coasting, ac-
Leakage → Check the component housing,
celeration, or deceleration. The noise in-
gasket, and/or seal for damage.
creases with front and/or rear wheel speed,
Damage → Replace the component.
but it does not increase with higher engine or
transmission speeds. TIP
Diagnosis: Possible wheel bearing damage. • An apparent oil leak on a new or nearly new ve-
Refer to “TROUBLESHOOTING CHART” on hicle may be the result of a rust-preventative
page 8-3. coating or excessive seal lubrication.
b. A “whining” noise that varies with accelera- • Always clean the vehicle and recheck the sus-
tion and deceleration. pected location of an apparent leakage.
Diagnosis: Possible incorrect reassembly,
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
too little gear backlash.
Refer to “MEASURING THE DIFFERENTIAL
GEAR BACKLASH” on page 8-16 or “MEA-
SURING THE FINAL GEAR BACKLASH” on
page 8-29.
EWB02900
WARNING
Insufficient gear backlash is extremely de-
structive to the gear teeth. If a test ride, fol-
lowing reassembly, indicates these
symptoms, stop riding immediately to mini-
mize gear damage.
c. A slight “thunk” evident at low speed opera-
tion. This noise must be distinguished from
normal vehicle operation.
Diagnosis: Possible broken gear teeth.
EWB02910
WARNING
Stop riding immediately if broken gear teeth
are suspected. This condition could result in
the shaft drive assembly locking up, causing
a loss of control and possible injury to the
rider.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Drained oil
Drained oil shows large amounts of metal
particles → Check the bearing for seizure.
TIP
A small amount of metal particles in the oil is nor-
mal.
3. Check:
• Oil leakage
8-2
TROUBLESHOOTING
EBS30238
TROUBLESHOOTING CHART
When basic conditions (a) and (b) described in “CHECKING NOISES” exist, check the following points:
YES → Replace the wheel bearing. (Refer to
1. Elevate and spin both wheels. Feel “STEERING KNUCKLES” on page 4-52
for wheel bearing damage. and “REAR KNUCKLES AND STABILIZ-
ER” on page 4-60.)
NO ↓
2. Check the wheel nuts and axle nuts NO → Torque to specification. (Refer to “FRONT
for tightness. AND REAR WHEELS” on page 4-23.
YES ↓
NO → Constant velocity shaft bearings and differ-
3. Check the front constant velocity
ential bearings are probably not damaged.
shaft assemblies. Feel for bearing
Repeat the test or remove the individual
damage.
components.
YES ↓
NO → Adjust per instructions. (Refer to “AD-
4. Check the parking brake adjust-
JUSTING THE PARKING BRAKE” on
ment.
page 3-21.)
YES ↓
NO → Constant velocity shaft bearings and final
5. Check the rear constant velocity
gear bearings are probably not damaged.
shaft assemblies. Feel for bearing
Repeat the test or remove the individual
damage.
components.
YES ↓
Remove the shaft drive components.
8-3
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN-
TIAL ASSEMBLY AND FRONT DRIVE SHAFTS
EBS20059
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL

ASSEMBLY AND FRONT DRIVE SHAFTS
Removing the front constant velocity shaft assemblies, differential assembly, and front drive shafts
18 Nm (1.8 m•kgf, 13 ft •Ibf) 60 Nm (6.0 m•kgf, 43 ft •Ibf)
T.R
.
T.R
.
150 Nm (15 m•kgf, 108 ft •lbf)
T.R
.
105 Nm (10.5 m•kgf, 76 ft •lbf)
T.R
.
LS
New 2 LS
New
1
New
LT New
LS
LS
New
New
LS
LS 1 New
LS
New
New
LS 3 60 Nm (6.0 m•kgf, 43 ft •Ibf)
T.R
.

Floor boards 4-6.
Front skid plate/Front guard 4-12.
Air filter case Refer to “AIR FILTER CASE” on page 7-5.
Refer to “STEERING KNUCKLES” on page
Steering knuckles 4-52.
Drain.
Differential gear oil Refer to “CHANGING THE DIFFERENTIAL
GEAR OIL” on page 3-17.
1 Front constant velocity shaft assembly 2
2 Differential motor coupler 1 Disconnect.
3 Differential assembly breather hose 1 Disconnect.
8-4
Removing the front constant velocity shaft assemblies, differential assembly, and front drive shafts
18 Nm (1.8 m•kgf, 13 ft •Ibf) 60 Nm (6.0 m•kgf, 43 ft •Ibf)
T.R
.
T.R
.
T.R
.
150 Nm (15 m•kgf, 108 ft •lbf)
105 Nm (10.5 m•kgf, 76 ft •lbf)
T.R
.
LS
New LS
9 New
New
LT New 6 LS
LS
8 7 9
New
8 New
LS
10
LS
New 4
12 11 15 14 New
LS
13 New
LS
60 Nm (6.0 m•kgf, 43 ft •Ibf)
T.R
.

4 Differential assembly 1
5 Support bearing bracket 1
6 Front drive shaft (differential side) 1
7 Dust seal 1
8 Universal joint 2
9 Universal joint yoke 2
10 Front drive shaft (middle gear side) 1
11 Support bearing housing 1
12 Support bearing rubber 1
13 Oil seal 1
14 Oil seal 1
15 Bearing 1
8-5
Disassembling the front constant velocity shaft assemblies
6 New
7
4 New
New 2
3
New 1
New 8
New 9
A: Wheel side
B: Differential side

the front constant velocity shaft assemblies.
1 Boot band 1
2 Boot band 1
3 Dust boot 1
4 Clip 1
5 Double offset joint 1
6 Circlip 1
7 Ball bearing 1
8 Boot band 1
9 Boot band 1
8-6
Disassembling the front constant velocity shaft assemblies
13
12 New
10 11
A: Wheel side
B: Differential side

10 Dust boot 1
11 Constant velocity joint 1
12 Clip 1
13 Constant velocity shaft 1
8-7
Disassembling the differential assembly
1
11 Nm (1.1 m•kgf, 8.0 ft•Ibf)
New
T.R
.
LS
62 Nm (6.2 m•kgf, 45 ft•Ibf)
T.R
.
LS
New
LS
2
5
3
New
10
*
7 LS
8 New
*
6 (3) 24 Nm (2.4 m•kgf, 17 ft•Ibf)
9
T.R
.
LS
New
23 Nm (2.3 m•kgf, 17 ft•Ibf)
T.R
.
New 4
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 24 Nm (2.4 m•kgf, 17 ft•Ibf)

T.R
.
T.R
.
* SAE 80 API GL-4 Hypoid gear oil

1 Differential motor 1
2 Front drive shaft yoke nut (differential case side) 1
3 Front drive shaft yoke (differential case side) 1
4 Bracket 1
5 Differential case cover 1
6 Differential gear assembly 1
Refer to “ADJUSTING THE DIFFEREN-
7 Differential gear assembly shim TIAL GEAR BACKLASH” on page 8-17.
8 Bearing 1
9 Bearing 1
10 Oil seal 1
8-8
Disassembling the differential assembly
11 Nm (1.1 m•kgf, 8.0 ft•Ibf)

New
T.R
.
15 LS
62 Nm (6.2 m•kgf, 45 ft•Ibf)
T.R
.
LS
New
LS
New
11
13
* 12
16 14 LS
New
*
(3) 24 Nm (2.4 m•kgf, 17 ft•Ibf)
T.R
.
15 LS
New
23 Nm (2.3 m•kgf, 17 ft•Ibf)
T.R
.
New
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 24 Nm (2.4 m•kgf, 17 ft•Ibf)
T.R
.
T.R
.
* SAE 80 API GL-4 Hypoid gear oil

11 Clip 1
12 Differential pinion gear 1
13 Bearing 1
14 Bearing 1
15 Oil seal 2
16 Differential case 1
8-9
EBS30239
DISASSEMBLING THE UNIVERSAL JOINTS A

1. Remove: 5
• Universal joint
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the circlips “1”
b. Place the universal joint in a press. 2
c. With a suitable diameter pipe “2” beneath the
universal joint yoke “3”, press the bearing “4” 1
into the pipe as shown.
TIP A
It may be necessary to lightly tap the universal 4
joint yoke with a punch.
3
A. Differential side
2. Remove:
• Boot bands “1”
TIP
Use the boot band installation tool “2”.

90890-01526
YM-01526
d. Repeat the steps for the opposite bearing.

e. Remove the universal joint. 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1
EBS30240
DISASSEMBLING THE FRONT CONSTANT

VELOCITY SHAFT ASSEMBLIES
front constant velocity shaft assemblies.
1. Remove: B. Wheel side
• Boot bands 3. Remove:
• Clip “1” • Dust boot
• Double offset joint “2” • Constant velocity joint
• Circlip “3” • Clip
• Ball bearing “4”
TIP
• Dust boot “5”
Secure the constant velocity shaft in a vise, and
TIP
then remove the constant velocity joint using
Before removing the clip, slide the dust boot hammers.
away from the double offset joint.
8-10
B A
New 1
A
B. Wheel side 3
EBS30241
CHECKING THE FRONT CONSTANT

front constant velocity shaft assemblies.
New 1
1. Check:
• Double offset joint splines 2
• Constant velocity joint splines
A
• Constant velocity shaft splines
Wear/damage → Replace.
2. Check:
• Dust boots
ECB01590
NOTICE
Always use a new boot band.
3. Check:
• Balls and ball races A. Wheel side
• Inner surface of double offset joint
Pitting/wear/damage → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
EBS30242
• Dust boot
ASSEMBLING THE FRONT CONSTANT
• Ball bearing “1”
The following procedure applies to both of the • Circlip “2” New
front constant velocity shaft assemblies. • Double offset joint “3”
1. Install: • Clip “4” New
• Clip “1” New TIP
• Constant velocity joint “2” • Securely install the circlip into the groove in the
• Constant velocity shaft “3” constant velocity shaft.
• Dust boot • Securely install the clip into the groove in the
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ double offset joint.
a. Install a new clip.
b. Install the constant velocity joint.
TIP
• Install the clip into the groove in the constant
velocity shaft as shown.
• Secure the constant velocity joint in a vise, and
then fit the constant velocity shaft into the con-
stant velocity joint using a soft-face hammer.
8-11
B ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 a. Install the dust boots.
b. Install the boot bands “4” and “5”.
TIP
2 New Use the boot band installation tool “6”.

90890-01526
YM-01526
B
6
3
4
4 New
B. Differential side
3. Apply: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Molybdenum disulfide grease 5. Check:
(into the double offset joint, constant velocity • Thrust movement free play
joint, and dust boots) Excessive play → Replace the constant ve-
locity shaft assembly.
Molybdenum disulfide grease
60–80 g (2.1–2.8 oz) per dust
boot (wheel side)
35–55 g (1.2–1.9 oz) per dust
boot (differential side)
TIP
Molybdenum disulfide grease is included in the
repair kit.
4. Install:
• Dust boots “1” EBS30243
• Boot bands “2”, “3”, “4”, “5” New REMOVING THE FRONT DRIVE SHAFT
TIP
YOKE
1. Remove:
The dust boots should be fastened with the boot
• Front drive shaft yoke
bands “3” and “5” at the grooves in the constant
velocity shaft. TIP
Use the universal joint holder “1” to hold the front
drive shaft yoke, then loosen the front drive shaft
yoke nut.

90890-04062
YM-04062
8-12
• Differential case cover
TIP
When the differential case and/or the differential
case cover are replaced, be sure to adjust the
shim of the differential gear assembly.
2. Check:
1 • Gear teeth
Pitting/galling/wear → Replace.
EBS30244 TIP
REMOVING THE DIFFERENTIAL GEAR When the differential pinion gear and/or the dif-
ASSEMBLY ferential assembly are replaced, be sure to ad-
1. Remove: just the shim of the differential gear assembly.
• Differential gear assembly “1”
ECB01570 3. Check:
NOTICE • Bearings
The ring gear and differential gear are as- Damage → Replace.
sembled into a proper unit at the factory by EBS30247
means of specialized equipment. Do not at- CHECKING THE DIFFERENTIAL MOTOR
tempt to disassemble this unit. Disassembly OPERATION
will result in the malfunction of the unit. 1. Check:
• Differential motor operation
Does not operate → Replace.
ECB01930
1 NOTICE
Do not disassemble the differential motor or
remove the differential motor pinion gear.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect two C-size batteries to the differen-
tial motor terminals “1” (as shown in the illus-
trations).
ECB01940
EBS30245
NOTICE
CHECKING THE FRONT DRIVE SHAFT
1. Check: • Do not use a 12 V battery to operate the dif-
• Drive shaft splines ferential motor pinion gear.
Wear/damage → Replace. • Do not connect the batteries to the differen-
EWB03040 tial motor when it is installed in the differen-
WARNING tial case. The differential motor should be
Do not attempt to straighten a bent shaft; checked when it is removed from the differ-
this may dangerously weaken it. ential case.
2. Check:
• Support bearing
Damage → Replace.
3. Check:
• Support bearing housing
• Support bearing rubber
EBS30246
CHECKING THE DIFFERENTIAL ASSEMBLY

1. Check:
• Differential case
8-13
A
3V Installed depth of oil seal “a”
-0.5–0.5 mm (-0.020–0.020 in)
1 3 a a 4
B
3V
1 1
3
2
1
a
A. Check that the differential motor pinion gear
“2” turns counterclockwise. 2
B. Check that the differential motor pinion gear
“2” turns clockwise.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Differential case

EBS30248 4. Differential case cover
ASSEMBLING THE FRONT DRIVE SHAFT
1. Install: 2. Measure:
• Oil seal “1” • Gear backlash
• Oil seal “2” Refer to “MEASURING THE DIFFERENTIAL
GEAR BACKLASH” on page 8-16.
Installed depth of oil seal “a” 3. Install:
1.0–1.5 mm (0.039–0.059 in) • Differential motor
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slide the shift fork sliding gear “1”, which is in-
a 1 stalled to the differential case cover, to the
right front constant velocity shaft assembly
side as shown in the illustration to put it into
3 the 2WD mode.
a 2
3. Support bearing housing

EBS30249
ASSEMBLING THE DIFFERENTIAL

ASSEMBLY
1. Install: b. Connect two C-size batteries to the differen-
• Oil seals “1” tial motor terminal “2” to operate the differen-
• Oil seal “2” tial motor pinion gear “3”. Operate the
differential motor pinion gear until the mark
8-14
“a” on the differential motor pinion gear is
aligned with the mark “b” on the differential
motor case.
ECB01650
NOTICE
Do not use a 12 V battery to operate the dif-
ferential motor pinion gear.
2
b
5. Install:
a
• Front drive shaft yoke
3 • Washer
• Front drive shaft yoke nut
Front drive shaft yoke nut

3V 62 Nm (6.2 m·kgf, 45 ft·lbf)
T.
R.
c. Insert 6 mm bolts “4” into the differential mo- TIP
tor “5” and use them as a guide to set the mo-
Use the universal joint holder “1” to hold the front
tor on the differential case cover “6” so that
drive shaft yoke, then tighten the front drive shaft
the shift fork sliding gear “7” does not move.
ECB01950 yoke nut.
NOTICE
If the position of the shift fork sliding gear is Universal joint holder
moved, the position of the differential gear 90890-04062
assembly and the indicator light display may Universal joint holder
differ, and the 2WD or differential lock mode YM-04062
may not be activated.
4 5
4
4
7
6
1
EBS30250
d. Remove the 6 mm bolts, and then install the ASSEMBLING THE UNIVERSAL JOINT
motor with the differential motor bolts. 1. Install:
• Universal joint
Differential motor bolt ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
11 Nm (1.1 m·kgf, 8.0 ft·lbf) a. Install the universal joint into the front drive
T.
R.
shaft yoke.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Differential assembly operation
Unsmooth operation → Replace the differen-
tial assembly.
Insert the double offset joint into the differen-
tial assembly, and turn the gears back and
forth.
8-15
EBS30251
MEASURING THE DIFFERENTIAL GEAR

BACKLASH
1. Secure the differential case in a vise or anoth-
er supporting device.
2. Remove:
• Drain bolt
• Gasket
3. Install:
• Ring gear fix bolt (M10) “1”
(into the drain bolt hole)
b. Apply lithium-soap-based grease to the bear-
ings. Ring gear fix bolt (M10)
c. Install the bearing “1” onto the front drive 90890-01527
shaft yoke. Ring gear fix bolt (M10)
ECB01670
YM-01527
NOTICE
The needles can easily fall out of their races, ECB01250
so check each bearing carefully. Slide the NOTICE

universal joint driven yoke assembly back Finger tighten the bolt until it holds the ring
and forth on the bearings. If a needle is out of gear. Otherwise, the ring gear will be dam-
place, the yoke will not go all the way onto aged.
the bearings. 4. Attach:
• Gear lash measurement tool “2”
• Dial gauge “3”

90890-01475
YM-01475
1 3
d. Press each bearing into the front drive shaft

yoke using a suitable socket.
TIP 2
The bearing must be inserted far enough into the
universal joint yoke and front drive shaft yoke so
that the circlip can be installed.
a
e. Install new circlips “2” into the groove of each
bearing. a. Measuring point is 31.0 mm (1.22 in)
5. Measure:
• Gear backlash
Gently rotate the differential pinion gear from
engagement to engagement.
Differential gear backlash

0.05–0.25 mm (0.002–0.010 in)
TIP
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Measure the gear backlash at four positions. Ro-
tate the differential pinion gear 90° each time.
8-16
EBS30252
ADJUSTING THE DIFFERENTIAL GEAR

BACKLASH
1. Remove:
• Differential gear assembly shim(s) “1”
• Differential gear assembly “2”
1
2. Adjust:
• Gear backlash
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Select the suitable shims using the following
chart.
Differential gear backlash is
Thinner shim
increased.
Differential gear backlash is
Thicker shim
decreased.
Differential gear assembly shims

Thickness (mm)
0.1 0.2 0.3 0.4
b. Measure the differential gear backlash again.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-17
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
EBS20060
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE

ASSEMBLY AND REAR DRIVE SHAFT
Removing the rear constant velocity shaft assemblies, final drive assembly, and rear drive shaft
New
7
6
New
LS
2
3
LS
New
5
1 (4) 4
33 Nm (3.3 m•kgf, 24 ft•Ibf)

T.R
.
105 Nm (10.5 m•kgf, 76 ft•lbf) 33 Nm (3.3 m•kgf, 24 ft•Ibf)

T.R
T.R
.
.

Refer to “REAR KNUCKLES AND STABI-
Rear knuckles LIZER” on page 4-60.
Drain.
Final gear oil Refer to“CHANGING THE FINAL GEAR
OIL” on page 3-16.
1 Rear constant velocity shaft assembly 2
2 Final drive assembly breather hose 1 Disconnect.
3 Parking brake cable 1 Disconnect.
4 Final drive assembly bracket (upper side) 1
5 Final drive assembly 1
6 Rear drive shaft 1
7 Spring 1
8-18
Removing the rear constant velocity shaft assemblies, final drive assembly, and rear drive shaft
New
11
10
New
LS 8
9
LS
New
(4)
33 Nm (3.3 m•kgf, 24 ft•Ibf) 12

T.R
.
105 Nm (10.5 m•kgf, 76 ft•lbf) 33 Nm (3.3 m•kgf, 24 ft•Ibf)

T.R
T.R
.
.

8 Damper 1
9 Rear drive shaft coupling sleeve 1
10 Dust seal 1
11 Dust seal 1
12 Final drive assembly bracket (lower side) 1
8-19
Disassembling the rear constant velocity shaft assemblies
5 New
6
3 New
New 2
7
New 1
New 8 New
New 9
A: Wheel side
B: Final drive side

the rear constant velocity shaft assemblies.
1 Boot band 1
2 Boot band 1
3 Clip 1
4 Double offset joint 1
5 Circlip 1
6 Ball bearing 1
7 Dust boot 1
8 Boot band 1
9 Boot band 1
8-20
Disassembling the rear constant velocity shaft assemblies
New
New
New
New
13
New 12 New
10 11
New
A: Wheel side
B: Final drive side

10 Dust boot 1
11 Constant velocity joint 1
12 Clip 1
13 Constant velocity shaft 1
8-21
Disassembling the final drive assembly
97 Nm (9.7 m•kgf, 70 ft•Ibf)
T.R
.
28 Nm (2.8 m•kgf, 20 ft•Ibf)
T.R
.
LT (10)
28 Nm (2.8 m•kgf, 20 ft•Ibf)
*
T.R
.
New LT
LT
LS (6)
(4)
New
*
LS
New
New
3
4
7
9
6
* 8
2 5 4 New
16 Nm (1.6 m•kgf, 12 ft•Ibf)
New New
1
T.R
.
LT 23 Nm (2.3 m•kgf, 17 ft•Ibf)

T.R
.
LS (8)
New 52 Nm (5.2 m•kgf, 38 ft•Ibf)
T.R
.
* Apply Yamaha bond No. 1215 (90890-85505).

1 Ring gear stopper 1
2 Ring gear bearing housing 1
3 Ring gear bearing housing gasket 1
4 Dowel pin 2
Final drive ring gear shim (ring gear bearing
5 housing side)
6 Final drive ring gear 1
7 Final drive ring gear shim (final drive case side)
8 Bearing 1
9 Bearing 1
8-22
97 Nm (9.7 m•kgf, 70 ft•Ibf)
T.R
.
11 28 Nm (2.8 m•kgf, 20 ft•Ibf)

12
T.R
.
18
LT (10)
13 28 Nm (2.8 m•kgf, 20 ft•Ibf)
*
T.R
.
16
New LT
LT
LS 17 (6)
(4)
New
16 *
LS
19 15
New
New 14 10
*
New
16 Nm (1.6 m•kgf, 12 ft•Ibf)
New New
T.R
.

T.R
.
LS 10 (8)
T.R
.

10 Oil seal 2
Rear drive shaft coupling gear nut (final drive
11 1
assembly side)
Rear drive shaft coupling gear (final drive as-
12 1
sembly side)
13 Final drive case cover assembly 1
14 Final drive case cover gasket 1
15 Dowel pin 2
16 Parking brake kit Refer to “PARKING BRAKE” on page 4-40.
17 Final drive case cover 1
18 Oil seal 1
19 Final drive pinion gear assembly 1
8-23
97 Nm (9.7 m•kgf, 70 ft•Ibf)
T.R
.
28 Nm (2.8 m•kgf, 20 ft•Ibf)
T.R
.
LT (10)
28 Nm (2.8 m•kgf, 20 ft•Ibf)
*
T.R
.
New LT
LT
LS (6)
(4)
New
*
21
23
20 LS
24
22
25
26 New
New
* 27
New
16 Nm (1.6 m•kgf, 12 ft•Ibf)
New New
T.R
.

T.R
.
LS (8)
T.R
.

20 Circlip 1
21 Final drive pinion gear bearing housing 1
22 Final drive pinion gear 1
23 Bearing 1
24 Final drive pinion gear shim
25 Bearing 1
26 Bearing 1
27 Final drive case 1
8-24
EBS30253
3. Remove:
DISASSEMBLING THE REAR CONSTANT
• Dust boot
• Constant velocity joint
• Clip
rear constant velocity shaft assemblies.
1. Remove: TIP
• Boot bands “1” Secure the constant velocity shaft in a vise, and
Use the boot band installation tool “2”. then remove the constant velocity joint using
hammers.
90890-01526 B
YM-01526
2
1
B. Wheel side
EBS30254
CHECKING THE REAR CONSTANT

2. Remove: The following procedure applies to both of the
• Clip “1” rear constant velocity shaft assemblies.
• Double offset joint “2” 1. Check:
• Circlip “3” • Double offset joint splines
• Ball bearing “4” • Constant velocity joint splines
• Dust boot “5” • Constant velocity shaft splines
TIP Wear/damage → Replace.
Before removing the clip, slide the dust boot 2. Check:
away from the double offset joint. • Dust boots
A ECB01590
5 NOTICE
Always use a new boot band.
3. Check:
• Balls and ball races
2 • Inner surface of double offset joint
Pitting/wear/damage → Replace.
1
EBS30255
ASSEMBLING THE REAR CONSTANT

A
4 VELOCITY SHAFT ASSEMBLIES
rear constant velocity shaft assemblies.
3 1. Install:
• Clip “1” New
• Constant velocity joint “2”
• Constant velocity shaft “3”
• Dust boot
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
A. Final drive side a. Install a new clip.
8-25
b. Install the constant velocity joint. B
TIP 1
• Install the clip into the groove in the constant
velocity shaft as shown. 2 New
• Secure the constant velocity joint in a vise, and
then fit the constant velocity shaft into the con-
stant velocity joint using a soft-face hammer.
New 1 B
3 3
4 New
A
3
B. Final drive side
3. Apply:
• Molybdenum disulfide grease
(into the double offset joint, constant velocity
New 1 joint, and dust boots)
2
Molybdenum disulfide grease
A 60–80 g (2.1–2.8 oz) per dust
boot (wheel side)
55–75 g (1.9–2.6 oz) per dust
boot (final drive side)
TIP
Molybdenum disulfide grease is included in the
repair kit.
4. Install:
• Dust boots “1”
A. Wheel side
• Boot bands “2”, “3” New
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ TIP
2. Install: The dust boots should be fastened with the boot
• Dust boot bands “2” and “3” at the grooves in the constant
• Ball bearing “1” velocity shaft.
• Circlip “2” New
• Double offset joint “3”
• Clip “4” New
TIP 2 3
• Securely install the circlip into the groove in the
constant velocity shaft.
• Securely install the clip into the groove in the
double offset joint.
8-26
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the dust boots.
b. Install the boot bands “2” and “3”.
Use the boot band installation tool “4”.

90890-01526
YM-01526 2
1
2. Remove:
• Rear drive shaft coupling gear (final drive as-
4 sembly side) “1”
TIP
2
Push up the rear drive shaft coupling gear using
suitable tools as shown in the illustration.
ECB02420
NOTICE
Be careful not to damage the oil seal with the
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
tips of the tools.
5. Check:
• Thrust movement free play
Excessive play → Replace the constant ve- 1
locity shaft assembly.
3. Remove:
• Final drive pinion gear assembly “1”
TIP
EBS30428 • Remove the final drive pinion gear assembly
DISASSEMBLING THE FINAL DRIVE with the crankshaft installer pot “2”, crankshaft
ASSEMBLY installer bolt “3”, adapter (M14) “4”, and suit-
1. Remove: able rubber-covered base “5”.
• Rear drive shaft coupling gear nut (final drive • Use a suitable rubber-covered base to protect
assembly side) “1” the mating surface of the final drive case from
• Washer damage.
TIP
• Secure the final drive assembly in a vise.
• Use the coupling gear holding tool (35) “2” to
hold the rear drive shaft coupling gear.

90890-01571
YM-01571
8-27
EBS30257
Crankshaft installer pot CHECKING THE REAR DRIVE SHAFT

90890-01274 1. Check:
Installing pot • Drive shaft splines
YU-90058 • Coupling sleeve splines
Crankshaft installer bolt Wear/damage → Replace.
90890-01275 EWB03040
Bolt WARNING
YU-90060 Do not attempt to straighten a bent shaft;
Adapter (M14) this may dangerously weaken it.
90890-04059
Adapter #10 EBS30258
YM-90069 CHECKING THE FINAL DRIVE ASSEMBLY
1. Check:
• Final drive case
3
• Final drive case cover
2 Cracks/damage → Replace.
4 5 TIP
When the final drive case and/or the final drive
case cover are replaced, be sure to adjust the
shim of the final drive pinion gear and/or ring
1 gear.
2. Check:
4. Remove: • Gear teeth
• Final drive pinion gear “1” Pitting/galling/wear → Replace the final drive
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ pinion gear and ring gear as a set.
a. Clean the outside surface of the final drive
TIP
pinion gear.
b. Place the final drive gear in a hydraulic press. When the final drive pinion gear and ring gear
ECB01580 are replaced, be sure to adjust the shim of the fi-
NOTICE nal drive pinion gear and/or ring gear.
• Never directly press the gear end with a hy- 3. Check:
draulic press, this will result in damage to • Bearings
the gear thread. Damage → Replace.
• Install the suitable socket on the gear end
to protect the thread from damage. EBS30259
ADJUSTING THE RING GEAR STOPPER

c. Press the gear end and remove the final drive 1. Install:
pinion gear. • Ring gear stopper “1”
• Ring gear stopper nut “2”
2 TIP
• Apply Yamaha bond No.1215 to the ring gear
stopper threads.
1 • Apply LOCTITE® to the nut threads.
2. Adjust:
• Ring gear stopper clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Finger tighten the ring gear stopper until it
2. Suitable socket contacts the ring gear “3”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-28
2 1 1
b. Turn the ring gear stopper 120° counterclock- 3. Attach:
wise. • Gear lash measurement tool “1”
• Dial gauge “2”

90890-01467
YM-01467
c. Tighten the ring gear stopper nut “3”.
Ring gear stopper nut 1

16 Nm (1.6 m·kgf, 12 ft·lbf)
T.
R.
LOCTITE®
b a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30260
a. Measuring point is 21.6 mm (0.85 in)
MEASURING THE FINAL GEAR BACKLASH b. Measuring point is 31.5 mm (1.24 in)
1. Remove:
4. Measure:
• Final drive case cover assembly
• Gear backlash
• Filler bolt
Gently rotate the final drive pinion gear from
• Gasket
engagement to engagement.
2. Install:
• Ring gear fix bolt (M10 × 1.5) “1” Final gear backlash
(into the filler bolt hole) 0.13–0.23 mm (0.005–0.009 in)
Ring gear fix bolt (M10 x 1.5) TIP
90890-01572
Ring gear fix bolt (M10 x 1.5) • While pulling the final drive pinion gear outward
YM-01572 and gently turning the gear back and forth,
measure the backlash.
ECB01250
• Measure the gear backlash at four positions.
NOTICE Rotate the final drive pinion gear 90° each
Finger tighten the bolt until it holds the ring time.
gear. Otherwise, the ring gear will be dam-
aged. EBS30261
ADJUSTING THE FINAL GEAR BACKLASH

1. Remove:
• Final drive ring gear “1”
• Bearings “2”
8-29
• Final drive ring gear shim (ring gear bearing EBS30429
ASSEMBLING THE FINAL DRIVE

housing side) “3”
ASSEMBLY
• Final drive ring gear shim (final drive case
1. Install:
side) “4”
• Final drive pinion gear assembly “1”
4 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2 a. Install the crankcase separating tool “2”.
1
2 90890-01135
3 Crankcase separator
YU-01135-B
b. Screw in the center bolt “3” of the crankcase

separating tool several turns to press the final
2. Adjust: drive pinion gear assembly slightly into the fi-
• Gear backlash nal drive case “4”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ TIP
a. Select a suitable shim(s) using the following Press the final drive pinion gear assembly until
chart. the four final drive pinion gear assembly bolts
Thinner shim
Final gear backlash is in- can be installed.
creased.
Final gear backlash is de- 3
Thicker shim
creased. 2
b. If increased by more than 0.2 mm (0.008 in):
Reduce the final drive ring gear shim (ring
1
gear bearing housing side) “3” thickness by
0.2 mm (0.008 in) for every 0.2 mm (0.008 in) 4
that the final drive ring gear shim (final drive
case side) “4” is increased.
c. If reduced by more than 0.2 mm (0.008 in):
Increase the final drive ring gear shim (ring c. Tighten the final drive pinion gear bearing
gear bearing housing side) “3” thickness by housing bolts in stages using a crisscross
0.2 mm (0.008 in) for every 0.2 mm (0.008 in) pattern until the final drive pinion gear assem-
that the final drive ring gear shim (final drive bly is pressed completely into the final drive
case side) “4” is decreased. case.
Final drive ring gear shims (ring Final drive pinion gear bearing
gear bearing housing side) “3” housing bolt
T.
R.
Thickness (mm) 28 Nm (2.8 m·kgf, 20 ft·lbf)

0.2 0.3 LOCTITE®
TIP ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Be sure to use one of each of the final drive ring 2. Apply:

gear shim (ring gear bearing housing side) “3” • Sealant
and final drive ring gear shim (final drive case (onto the washer contact surface and splines
side) “4” to obtain the shim thickness. of the final drive pinion gear)
Yamaha bond No. 1215

Final drive ring gear shims (final 90890-85505
drive case side) “4” (Three bond No.1215®)
Thickness (mm)
0.2 0.3
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-30
(upper side)
T.
R.
33 Nm (3.3 m·kgf, 24 ft·lbf)
Final drive assembly nut (upper
side)
105 Nm (10.5 m·kgf, 76 ft·lbf)
Final drive assembly nut (lower
side)
105 Nm (10.5 m·kgf, 76 ft·lbf)
3. Install: (lower side)
• Rear drive shaft coupling gear (final drive as- 33 Nm (3.3 m·kgf, 24 ft·lbf)
sembly side) “1”
TIP
Rear drive shaft coupling gear Tighten the bolts and nuts to specification in the
nut (final drive assembly side) proper tightening sequence shown.
T.
R.
97 Nm (9.7 m·kgf, 70 ft·lbf)

LOCTITE®
2
TIP
• Secure the final drive assembly in a vise.
• Use the coupling gear holding tool (35) “2” to FWD
89
hold the rear drive shaft coupling gear. 1 3
4 5
90890-01571 2 17 3
6
YM-01571
2
1
EBS30263
INSTALLING THE FINAL DRIVE ASSEMBLY

1. Install
• Final drive assembly bracket (upper side) “1”
• Final drive assembly “2”
• Final drive assembly bracket (lower side) “3”
8-31
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 9-1

CIRCUIT DIAGRAM .................................................................................. 9-1
TROUBLESHOOTING ..............................................................................9-3
ELECTRIC STARTING SYSTEM .................................................................... 9-5

CIRCUIT DIAGRAM .................................................................................. 9-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......................... 9-7
TROUBLESHOOTING ..............................................................................9-8
CHARGING SYSTEM....................................................................................9-11
CIRCUIT DIAGRAM ................................................................................ 9-11
TROUBLESHOOTING ............................................................................9-13
LIGHTING SYSTEM ......................................................................................9-15

CIRCUIT DIAGRAM ................................................................................ 9-15
SIGNALING SYSTEM ...................................................................................9-19

CIRCUIT DIAGRAM (except for EPS models) ........................................ 9-19
CIRCUIT DIAGRAM (for EPS models)....................................................9-21
COOLING SYSTEM....................................................................................... 9-29

CIRCUIT DIAGRAM ................................................................................ 9-29
FUEL INJECTION SYSTEM..........................................................................9-33

CIRCUIT DIAGRAM (except for EPS models) ........................................ 9-33
CIRCUIT DIAGRAM (for EPS models)....................................................9-35
ECU SELF-DIAGNOSTIC FUNCTION....................................................9-37
TROUBLESHOOTING METHOD............................................................ 9-38
YAMAHA DIAGNOSTIC TOOL ...............................................................9-39
TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM) ............9-41
FUEL PUMP SYSTEM...................................................................................9-65

CIRCUIT DIAGRAM ................................................................................ 9-65
2WD/4WD SELECTING SYSTEM.................................................................9-69

9
CIRCUIT DIAGRAM ................................................................................ 9-69
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)...........9-73
CIRCUIT DIAGRAM ................................................................................ 9-73
EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION .....................9-75
EPS WARNING LIGHT DURING NORMAL OPERATION......................9-75
DIAGNOSTIC MODE .............................................................................. 9-76
SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)......................9-78
TROUBLESHOOTING DETAILS (EPS SYSTEM) ..................................9-79
ELECTRICAL COMPONENTS...................................................................... 9-83

CHECKING THE SWITCHES .................................................................9-89
CHECKING THE BULBS AND BULB SOCKETS ................................... 9-92
REPLACING THE HEADLIGHT BULBS ................................................. 9-93
ADJUSTING THE HEADLIGHT BEAMS................................................. 9-94
CHECKING THE FUSES ........................................................................9-94
CHECKING AND CHARGING THE BATTERY....................................... 9-95
CHECKING THE RELAYS ...................................................................... 9-97
CHECKING THE SPARK PLUG CAP ...................................................9-100
CHECKING THE IGNITION COIL .........................................................9-100
CHECKING THE IGNITION SPARK GAP.............................................9-101
CHECKING THE CRANKSHAFT POSITION SENSOR........................9-101
CHECKING THE LEAN ANGLE SENSOR............................................9-102
CHECKING THE STARTER MOTOR OPERATION .............................9-102
CHECKING THE STATOR COIL ..........................................................9-103
CHECKING THE RECTIFIER/REGULATOR ........................................9-103
CHECKING THE FUEL SENDER .........................................................9-103
CHECKING THE FUEL METER/FUEL LEVEL WARNING LIGHT .......9-104
CHECKING THE SPEED SENSOR ......................................................9-104
CHECKING THE PARKING BRAKE BUZZER......................................9-105
CHECKING THE RADIATOR FAN MOTOR .........................................9-105
CHECKING THE RADIATOR FAN MOTOR CIRCUIT BREAKER .......9-105
CHECKING THE COOLANT TEMPERATURE SENSOR.....................9-106
CHECKING THE THROTTLE POSITION SENSOR .............................9-106
CHECKING THE INTAKE AIR PRESSURE SENSOR .........................9-107
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ..................9-107
CHECKING THE FUEL INJECTOR ......................................................9-108
CHECKING THE AIR INDUCTION SYSTEM SOLENOID ....................9-108
CHECKING THE DIFFERENTIAL MOTOR POSITION SWITCH .........9-109
CHECKING THE EPS MOTOR (for EPS models) ................................9-109
CHECKING THE EPS TORQUE SENSOR (for EPS models) ..............9-110
EBS30264
EBS20074
A
B B
68 B
P Br/Y L G/W
OFF
A 70 B L
ON 69 B C
B Br L Br/Y W B
Br W Br/Y
(B) L Br/Y R/Y R/W L/B R/G G/R W/G Y/B R
(B)
B G/W 71 Y/R O/B B P/L L/B Br/L O
Br/Y B Br/Y B
(B) Br/R 22
O Br/Y Br
B/L Gy Gy B/L
G/W O 23 32 P Br
W W W B R Gy
CIRCUIT DIAGRAM
B O/B O/B P (Gy)

Gy B 1 Br/W W Gy P Y/G P/W Sb O/L Y/W B/G Gy/G W/B L/R B/W G/R Br/R Br/R
(Gy) (B) Br/Y R/W R R R/L
Lg G/Y R/L G/W Y L/Y Y/L Y W/R B/R L B/L L/W R/W
R/W Br/Y O/B
W W W W W W (B) R/W
24 R/L R (Gy)
R (B)
W W R/W
(Gy) (Gy) 2 3 (Gy)
W W
Br/Y R/W Br/W Br/W B/L
IGNITION SYSTEM
R/G R/G
W W W/G R/W R/G P/L P/L 25 G/W
Br/W B/L
14 Br/L R/W P/L 20
(Gy) (Gy) B B/W R/W W/G W/G (B)
Y/W (B) Br/L Br/L G/Y G/Y B/L
Br/R Br/R
Br/R 26 33
G/Y B/L
Br/R
Br/R R/W Y/W Y/W
Br/R Br/R Br/R Br/R 19
Br/Y (B)
B/W W
B R/L
B R/W
21
B/W R/Y L L/Y
B B W L/Y
Y/R L W
W B/L R/W R/W R/W R/W R/W R/W L L L L L
Br/R B Y/B 27 B/L
R R L B/L B/L B/L B/L B/L B/L B/L B/L B/L G/W G/W G/W
G/R (W)
R 9 L/R
4 BB B R R Br/B L/Y B/L
B (B)
Br/R R/L Y Y Y 28 B/L Y L
P/W L
R Br/B Br/R L/R
R R Br/B O/L (B)
Br/L
5 B/G
B B W/B L
R 8
B B 10 B/R P P 29 B/L P L
Br/L
13 Sb B/L B/L
34
BBB Br/R
Br/R B L/Y Gy/G Lg (B) G/W R/W
Br/R G/W R/W
P/W B/G Gy/G W/R L/B G/W R/W
B
11 W/B
R/B Br/R R/Y Sb W/R L/W L R/W
B A B 15 O/L B/Y Br/B B/R G/R Y/G Y/G B/L R/W
30 L Y/G B/L R/W
B/Y L Gy W L/W G/R B/L
Y/L B/L B/L
Br/R 17 L/B
6 Br/B L/R (Gy) B/L L
R B/L L
(off)
12 R/Y L/Y R/L 18 L/B B/L L
B 16 L
(on) R/L B/L
(B) 2WD B/W B B/L L
(start) L W 4WD
L/W G/R L/R
Gy DIFF LOCK 31
67 7 B/Y Y/B B B
Br/R B (B) B
Br/R R/B Br/R L/Y (W)
Br/R B Y/B B/G P/W W/B B/R B O/L Br/B B/Y L/R B
R/L L/Y Br/R W/R Sb
9-1
R B/W
Y/R (B) (B) (Gy) Gy/G G/R L/W
R/L RR B
B/W B L/B
Br/R Y/R R
(B)
R R
R/L
Br/L
Br/L
Br/L W/B
66 64
Br
63 Y Y Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y

Br/Y
B/W B/W B/W B/W B/W B/W R/L R/L R/L L/Y L/Y L/Y
62 Br/Y
R/W
R/W Br/R
W/B Br Br/R
39 (B)
R/W
61 Y Br/Y
R/B R Br/Y Y Br
(B) 40 34
52 L 51 B/W Y
L 60 Br/B B/W Y
Br (off)
Br/R Br/L 55 B/W Y
Br Y R/W Y/L B/W
Br/Y B/W B/W
59 (B) B/W Br/Y
56 G W/B G G/R O/B
65 R R R/L Br/Y
Br/B B R/L Br/Y
L Y Br/R Br/R R/L Br/Y
58 Y Br/R 41 L/Y Br/Y
W/B B B Br/R Br/R
L B Br/R B G/R R/L O/B L/Y Br/Y
L/Y Br/Y
Br/R
Y (B)
Y Y 42
B
B R/W L O/B R/W
L 50 49
Y 53 43 Y/L Br/Y B/W
Y G B L 36 Br/Y
(B) Lg B
44 Lg
(B)
B B B B/W Br
B G
G B Br/Y
R/L B B/W O/B 45 L/B B Lg
B 35
(B)
(Gy)
Y LL B BB
Y L Y Y G Y G
46 37 L
38
B
54 54 47 B L/B
57 57 G Y G Y
B B
48
Y G B B Y G
B B
B B
B B
B B B B
B
B
IGNITION SYSTEM
IGNITION SYSTEM
1. Crankshaft position sensor

5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
21.ECU (Engine Control Unit)
22.Ignition coil
23.Spark plug
30.Lean angle sensor
34.Joint coupler
60.Ignition fuse
B. Wire harness
C. Negative battery sub-wire harness
9-2
IGNITION SYSTEM
EBS30265
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Hood
2. Cargo bed
3. Passenger seat frame
4. Passenger seat belt buckle rubber cover
1. Check the fuses. NG →

(Main and ignition)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 9-94.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 9-95.
OK ↓
3. Check the spark plug. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug.
PLUG” on page 3-6.
OK ↓
4. Check the ignition spark gap. OK →
Refer to “CHECKING THE IGNI- Ignition system is OK.
TION SPARK GAP” on page 9-101.
NG ↓
5. Check the spark plug cap. NG →
Refer to “CHECKING THE SPARK Replace the spark plug cap.
PLUG CAP” on page 9-100.
OK ↓
6. Check the ignition coil. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coil.
TION COIL” on page 9-100.
OK ↓
7. Check the crankshaft position sen- NG →
sor.
Replace the crankshaft position sen-
Refer to “CHECKING THE CRANK-
sor/stator assembly.
SHAFT POSITION SENSOR” on
page 9-101.
OK ↓
9-3
IGNITION SYSTEM
8. Check the main switch. NG →

Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 9-89.
OK ↓
9. Check the lean angle sensor. NG →
Refer to “CHECKING THE LEAN Replace the lean angle sensor.
ANGLE SENSOR” on page 9-102.
OK ↓
10.Check the entire ignition system NG →
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 9-1.
OK ↓
Replace the ECU.
9-4
EBS30266
EBS20075
A
B B
68 B
P Br/Y L G/W
OFF
A 70 B L
ON 69 B C
B Br L Br/Y W B
Br W Br/Y
(B)
Br/Y B Br/Y B
(B) Br/R 22
O Br/Y Br
B/L Gy Gy B/L
G/W O 23 32 P Br
W W W B R Gy
CIRCUIT DIAGRAM
B O/B O/B P (Gy)

R/W Br/Y O/B
W W W W W W (B) R/W
24 R/L R (Gy)
R (B)
W W R/W
(Gy) (Gy) 2 3 (Gy)
W W
R/G R/G
Br/W B/L
14 Br/L R/W P/L 20
Br/R Br/R
Br/R 26 33
G/Y B/L
Br/R
Br/R R/W Y/W Y/W
Br/Y (B)
B/W W
B R/L
B R/W
21
B/W R/Y L L/Y
B B W L/Y
Y/R L W
Br/R B Y/B 27 B/L
G/R (W)
R 9 L/R
B (B)
P/W L
R Br/B Br/R L/R
R R Br/B O/L (B)
Br/L
5 B/G
B B W/B L
R 8
Br/L
13 Sb B/L B/L
34
ELECTRIC STARTING SYSTEM
BBB Br/R
Br/R G/W R/W
B
11 W/B
30 L Y/G B/L R/W
Y/L B/L B/L
Br/R 17 L/B
R B/L L
(off)
B 16 L
(on) R/L B/L
(B) 2WD B/W B B/L L
(start) L W 4WD
L/W G/R L/R
Gy DIFF LOCK 31
67 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
9-5
R B/W
R/L RR B
B/W B L/B
Br/R Y/R R
(B)
R R
R/L
Br/L
Br/L
Br/L W/B
66 64
Br

Br/Y
62 Br/Y
R/W
R/W Br/R
W/B Br Br/R
39 (B)
R/W
61 Y Br/Y
R/B R Br/Y Y Br
(B) 40 34
52 L 51 B/W Y
L 60 Br/B B/W Y
Br (off)
Br/R Br/L 55 B/W Y
Br Y R/W Y/L B/W
Br/Y B/W B/W
59 (B) B/W Br/Y
56 G W/B G G/R O/B
65 R R R/L Br/Y
Br/B B R/L Br/Y
W/B B B Br/R Br/R
L/Y Br/Y
Br/R
Y (B)
Y Y 42
B
B R/W L O/B R/W
L 50 49
Y G B L 36 Br/Y
(B) Lg B
44 Lg
(B)
B B B B/W Br
B G
G B Br/Y
B 35
(B)
(Gy)
Y LL B BB
Y L Y Y G Y G
46 37 L
38
B
54 54 47 B L/B
57 57 G Y G Y
B B
48
Y G B B Y G
B B
B B
B B
B B B B
B
B

5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
11.Starter relay
12.Starter motor
17.Gear position switch
34.Joint coupler
56.Brake light switch
60.Ignition fuse
62.Signaling system fuse
B. Wire harness
9-6
EBS30267
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the main switch is set to “ ” (start), the starter motor can only operate if at least one of the following
conditions is met:
• The transmission is in neutral (the neutral circuit of the gear position switch is closed).
• The brake pedal is pressed (the brake light switch circuit is closed).
11
10
1
5
3
6
4
1. Battery
2. Main fuse
3. Ignition fuse
4. Main switch
6. Signaling system fuse
7. Brake light switch
8. ECU (Engine Control Unit)
9. Gear position switch
10.Starter relay
11.Starter motor
9-7
EBS30268
TROUBLESHOOTING
The starter motor fails to turn.
TIP
1. Hood
2. Cargo bed

(Main, ignition, and signaling sys-
tem) Replace the fuse(s).
ES” on page 9-94.
OK ↓
page 9-95.
OK ↓
3. Check the starter motor operation. OK →
Starter motor is OK. Perform the electric
Refer to “CHECKING THE START-
starting system troubleshooting, starting
ER MOTOR OPERATION” on page
with step 5.
9-102.
NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-40.
OK ↓
5. Check the starter relay. NG →
Refer to “CHECKING THE RE- Replace the starter relay.
LAYS” on page 9-97.
OK ↓
6. Check the load control relay. NG →
Refer to “CHECKING THE RE- Replace the load control relay.
OK ↓
OK ↓
8. Check the brake light switch. NG →
Refer to “CHECKING THE Replace the brake light switch.
OK ↓
9-8
9. Check the gear position switch. NG →

Refer to “CHECKING THE Replace the gear position switch.
OK ↓
10.Check the entire starting system NG →
page 9-5.
OK ↓
Replace the ECU.
9-9
9-10
EBS30269
EBS20076
A
B B
68 B
P Br/Y L G/W
OFF
A 70 B L
ON 69 B C
B Br L Br/Y W B
Br W Br/Y
(B)
Br/Y B Br/Y B
(B) Br/R 22
O Br/Y Br
B/L Gy Gy B/L
G/W O 23 32 P Br
W W W B R Gy
CIRCUIT DIAGRAM
B O/B O/B P (Gy)

R/W Br/Y O/B
W W W W W W (B) R/W
24 R/L R (Gy)
R (B)
W W R/W
(Gy) (Gy) 2 3 (Gy)
W W
R/G R/G
Br/W B/L
14 Br/L R/W P/L 20
CHARGING SYSTEM

Br/R Br/R
Br/R 26 33
G/Y B/L
Br/R
Br/R R/W Y/W Y/W
Br/Y (B)
B/W W
B R/L
B R/W
21
B/W R/Y L L/Y
B B W L/Y
Y/R L W
Br/R B Y/B 27 B/L
G/R (W)
R 9 L/R
B (B)
P/W L
R Br/B Br/R L/R
R R Br/B O/L (B)
Br/L
5 B/G
B B W/B L
R 8
Br/L
13 Sb B/L B/L
34
BBB Br/R
Br/R G/W R/W
B
11 W/B
30 L Y/G B/L R/W
Y/L B/L B/L
Br/R 17 L/B
R B/L L
(off)
B 16 L
(on) R/L B/L
(B) 2WD B/W B B/L L
(start) L W 4WD
L/W G/R L/R
Gy DIFF LOCK 31
67 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
R B/W
9-11
R/L RR B
B/W B L/B
Br/R Y/R R
(B)
R R
R/L
Br/L
Br/L
Br/L W/B
66 64
Br

Br/Y
62 Br/Y
R/W
R/W Br/R
W/B Br Br/R
39 (B)
R/W
61 Y Br/Y
R/B R Br/Y Y Br
(B) 40 34
52 L 51 B/W Y
L 60 Br/B B/W Y
Br (off)
Br/R Br/L 55 B/W Y
Br Y R/W Y/L B/W
Br/Y B/W B/W
59 (B) B/W Br/Y
56 G W/B G G/R O/B
65 R R R/L Br/Y
Br/B B R/L Br/Y
W/B B B Br/R Br/R
L/Y Br/Y
Br/R
Y (B)
Y Y 42
B
B R/W L O/B R/W
L 50 49
Y G B L 36 Br/Y
(B) Lg B
44 Lg
(B)
B B B B/W Br
B G
G B Br/Y
B 35
(B)
(Gy)
Y LL B BB
Y L Y Y G Y G
46 37 L
38
B
54 54 47 B L/B
57 57 G Y G Y
B B
48
Y G B B Y G
B B
B B
B B
B B B B
B
B
CHARGING SYSTEM
CHARGING SYSTEM
2. AC magneto
3. Rectifier/regulator
5. Frame ground
8. Battery
9. Main fuse
B. Wire harness
9-12
CHARGING SYSTEM
EBS30270
TROUBLESHOOTING
The battery is not being charged.
TIP
1. Hood
2. Passenger seat frame
3. Passenger seat belt buckle rubber cover
1. Check the fuse. NG →

(Main)
Replace the fuse.
ES” on page 9-94.
OK ↓
page 9-95.
OK ↓
3. Check the stator coil. NG →
Replace the crankshaft position sen-
Refer to “CHECKING THE STATOR
sor/stator assembly.
COIL” on page 9-103.
OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI-
Replace the rectifier/regulator.
FIER/REGULATOR” on page
9-103.
OK ↓
5. Check the entire charging system NG →
page 9-11.
OK ↓
The charging system circuit is OK.
9-13
CHARGING SYSTEM
9-14
EBS30271
EBS20077
A
B B
68 B
P Br/Y L G/W
OFF
A 70 B L
ON 69 B C
B Br L Br/Y W B
Br W Br/Y
(B)
Br/Y B Br/Y B
(B) Br/R 22
O Br/Y Br
B/L Gy Gy B/L
G/W O 23 32 P Br
W W W B R Gy
CIRCUIT DIAGRAM
B O/B O/B P (Gy)

R/W Br/Y O/B
W W W W W W (B) R/W
24 R/L R (Gy)
R (B)
W W R/W
(Gy) (Gy) 2 3 (Gy)
W W
R/G R/G
W
LIGHTING SYSTEM
W W/G R/W R/G P/L P/L 25 G/W

Br/W B/L
14 Br/L R/W P/L 20
Br/R Br/R
Br/R 26 33
G/Y B/L
Br/R
Br/R R/W Y/W Y/W
Br/Y (B)
B/W W
B R/L
B R/W
21
B/W R/Y L L/Y
B B W L/Y
Y/R L W
Br/R B Y/B 27 B/L
G/R (W)
R 9 L/R
B (B)
P/W L
R Br/B Br/R L/R
R R Br/B O/L (B)
Br/L
5 B/G
B B W/B L
R 8
Br/L
13 Sb B/L B/L
34
BBB Br/R
Br/R G/W R/W
B
11 W/B
30 L Y/G B/L R/W
Y/L B/L B/L
Br/R 17 L/B
R B/L L
(off)
B 16 L
(on) R/L B/L
(B) 2WD B/W B B/L L
(start) L W 4WD
L/W G/R L/R
Gy DIFF LOCK 31
67 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
R B/W
9-15
R/L RR B
B/W B L/B
Br/R Y/R R
(B)
R R
R/L
Br/L
Br/L
Br/L W/B
66 64
Br

Br/Y
62 Br/Y
R/W
R/W Br/R
W/B Br Br/R
39 (B)
R/W
61 Y Br/Y
R/B R Br/Y Y Br
(B) 40 34
52 L 51 B/W Y
L 60 Br/B B/W Y
Br (off)
Br/R Br/L 55 B/W Y
Br Y R/W Y/L B/W
Br/Y B/W B/W
59 (B) B/W Br/Y
56 G W/B G G/R O/B
65 R R R/L Br/Y
Br/B B R/L Br/Y
W/B B B Br/R Br/R
L/Y Br/Y
Br/R
Y (B)
Y Y 42
B
B R/W L O/B R/W
L 50 49
Y G B L 36 Br/Y
(B) Lg B
44 Lg
(B)
B B B B/W Br
B G
G B Br/Y
B 35
(B)
(Gy)
Y LL B BB
Y L Y Y G Y G
46 37 L
38
B
54 54 47 B L/B
57 57 G Y G Y
B B
48
Y G B B Y G
B B
B B
B B
B B B B
B
B
LIGHTING SYSTEM
LIGHTING SYSTEM

5. Frame ground
6. Main switch
8. Battery
9. Main fuse
52.Light switch
53.Headlight relay
54.Headlight
57.Tail/brake light
60.Ignition fuse
63.Headlight fuse
B. Wire harness
9-16
LIGHTING SYSTEM
EBS30272
TROUBLESHOOTING
Any of the following fail to light: headlight or taillight.
TIP
1. Hood
1. Check the condition of each bulb NG →

and bulb socket.
Refer to “CHECKING THE BULBS Replace the bulb(s) and bulb socket(s).
AND BULB SOCKETS” on page
9-92.
OK ↓
(Main, ignition, and headlight)
Replace the fuse(s).
ES” on page 9-94.
OK ↓
page 9-95.
OK ↓
OK ↓
5. Check the light switch. NG →
Refer to “CHECKING THE Replace the light switch.
OK ↓
6. Check the headlight relay. NG →
Refer to “CHECKING THE RE- Replace the headlight relay.
OK ↓
OK ↓
9-17
LIGHTING SYSTEM
8. Check the entire lighting system NG →

page 9-15.
OK ↓
The lighting system circuit is OK.
9-18
EBS30273
EBS20078
A
B B
68 B
P Br/Y L G/W
OFF
A 70 B L
ON 69 B C
B Br L Br/Y W B
Br W Br/Y
(B)
Br/Y B Br/Y B
(B) Br/R 22
O Br/Y Br
B/L Gy Gy B/L
G/W O 23 32 P Br
W W W B R Gy
B O/B O/B P (Gy)
R/W Br/Y O/B
W W W W W W (B) R/W
24 R/L R (Gy)
R (B)
W W R/W
(Gy) (Gy) 2 3 (Gy)
W W
R/G R/G
Br/W B/L
14 Br/L R/W P/L 20
Y/W Br/L Br/L G/Y G/Y B/L
SIGNALING SYSTEM
(B)
Br/R Br/R
Br/R 26 33
G/Y B/L
Br/R
Br/R R/W Y/W Y/W
Br/Y (B)
B/W W
B R/L
B R/W
21
B/W R/Y L L/Y
B B W L/Y
Y/R L W
Br/R B Y/B 27 B/L
G/R (W)
R 9 L/R
B (B)
P/W L
R Br/B Br/R L/R
R R Br/B O/L (B)
Br/L
5 B/G
B B W/B L
R 8
Br/L
13 Sb B/L B/L
34
BBB Br/R
Br/R G/W R/W
B
11 W/B
30 L Y/G B/L R/W
Y/L B/L B/L
Br/R 17 L/B
CIRCUIT DIAGRAM (except for EPS models)
R B/L L
(off)
B 16 L
(on) R/L B/L
(B) 2WD B/W B B/L L
(start) L W 4WD
L/W G/R L/R
Gy DIFF LOCK 31
67 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
R B/W
9-19
R/L RR B
B/W B L/B
Br/R Y/R R
(B)
R R
R/L
Br/L
Br/L
Br/L W/B
66 64
Br

Br/Y
62 Br/Y
R/W
R/W Br/R
W/B Br Br/R
39 (B)
R/W
61 Y Br/Y
R/B R Br/Y Y Br
(B) 40 34
52 L 51 B/W Y
L 60 Br/B B/W Y
Br (off)
Br/R Br/L 55 B/W Y
Br Y R/W Y/L B/W
Br/Y B/W B/W
59 (B) B/W Br/Y
56 G W/B G G/R O/B
65 R R R/L Br/Y
Br/B B R/L Br/Y
W/B B B Br/R Br/R
L/Y Br/Y
Br/R
Y (B)
Y Y 42
B
B R/W L O/B R/W
L 50 49
Y G B L 36 Br/Y
(B) Lg B
44 Lg
(B)
B B B B/W Br
B G
G B Br/Y
B 35
(B)
(Gy)
Y LL B BB
Y L Y Y G Y G
46 37 L
38
B
54 54 47 B L/B
57 57 G Y G Y
B B
48
Y G B B Y G
B B
B B
B B
B B B B
B
B
SIGNALING SYSTEM
SIGNALING SYSTEM

5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
26.Coolant temperature sensor
27.Speed sensor
31.Parking brake switch
32.Parking brake buzzer
33.Reverse switch
34.Joint coupler
35.Seat belt switch
36.Indicator light assembly
37.Helmet indicator light
38.Seat belt indicator light
39.Meter assembly
40.Multi-function meter
42.Coolant temperature warning light
43.Parking brake indicator light
44.Reverse indicator light
45.Neutral indicator light
46.High-range indicator light
47.Low-range indicator light
49.Fuel sender
57.Tail/brake light
60.Ignition fuse
61.Backup fuse
68.Horn switch
69.Horn
70.Backup light
71.Backup light relay
A. Optional
B. Wire harness
9-20
EBS30352
A
B B
B
75 P Br/Y L G/W
OFF
A 77 B L
ON 76 B C
B Br L Br/Y W B
Br W Br/Y B
(B) L Br/Y R/Y O/W R/W L/B R/G G/R W/G Y/B R
(B)
Br/Y B Br/Y B B B
(B) 23 (B) (B)

Br/R
O Br/Y Br
C D
B/L Gy Gy B/L
G/W O 24 33 P Br
W W W B R Gy
B O/B O/B P (Gy)
R/W Br/Y O/B
W W W W W W (B) R/W
25 R/L R (Gy)
R (B)
W W R/W
(Gy) (Gy) 2 3 (Gy) G/W
W W O/W
R/G R/G G/W
W W W/G R/W R/G P/L P/L G/W
26 Br/W B/L G/W
15 Br/L R/W P/L 21
Br/R Br/R
Br/R 27 34
G/Y B/L
Br/R
Br/R R/W Y/W Y/W
Br/Y R (B)
B/W W
B R/L
B R/W
22
B/W R/Y L L/Y
B B W L/Y
Y/R L W
W B/L
Br/R B Y/B 28 B/L
R R R/B L
G/R B/L R/W R/W R/W R/W R/W R/W L L L L L
R R (W)
9 10 L/R B/L B/L B/L B/L B/L B/L B/L B/L W W W
4 BB B R R R R/B Br/B L/Y B/L
B Br/R R/L Y Y Y 29 B/L Y L
P/W
CIRCUIT DIAGRAM (for EPS models)
R R Br/R L/R L (B)

R R Br/B Br/B O/L (B)
Br/L
5 B/G
B B W/B L
R 8
Br/L
14 Sb B/L B/L
35
BBB Br/R
Br/R B L/Y Gy/G Lg (B) R/W
Br/R W R/W
P/W B/G Gy/G W/R L/B W R/W
B
12 W/B
R/B Br/R R/Y Sb W/R L/W L W R/W
31 L Y/G B/L R/W
B/Y L Gy W L/W G/R Y/L B/L
B/L B/L
Br/R 18 L/B
R B/L L
(off)
B 17 L
(on) R/L B/L
(B) 2WD B/W B B/L L
(start) L W 4WD
L/W G/R L/R
Gy DIFF LOCK 32
74 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
R B/W
9-21
R/L RR B
B/W B L/B
Br/R Y/R R 36
(B) G R
R R B W 38 37 B R
(Gy)
R/L B R (Gy)
Br/L
G R B W R B
Br/L B R
(Gy)
Br/L W/B
GR B WR B
73 71
Br R G B R
R B
W B
70 (Gy) Y Y Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
Br/Y R/B
W B/W B/W B/W B/W B/W B/W R/L R/L R/L L/Y L/Y L/Y
Br/Y G
R/W
69 R Br G/R W/B
R/W Br/R B B 40 O O/W
W/B Br Br/R
45 (B)
L/B L/B
R/W
68 Y Br/Y
R/B G L/B Br O
Y Br O/W R L/B
R/B R (B) Br/Y 46 G W G/R 39 35
59 L 58 G/R W
(Gy) (Gy) B/W Y
L 67 Br/B (B) B/W Y
Br (off)
Br/R Br/L 62 B/W Y
Br Y R/W Y/L B/W
Br/Y B/W B/W
66 (B) B/W Br/Y
63 G W/B G G/R O/B
72 R R R/L Br/Y
Br/B B R/L Br/Y
W/B B B Br/R Br/R
L/Y Br/Y
Br/R
Y (B)
Y Y 48
B
B R/W L O/B G/R R/W
L 57 56
Y G B L 42 Br/Y
(B) Lg B
50 Lg
(B)
B B B B/W Br
B G
G B Br/Y
B 41
(B)
(Gy)
Y LL B BB
Y L Y Y G Y G
52 43 L
44
B
61 61 53 B L/B
64 64 G Y G Y
B B
54
Y G B B Y G
55
B B G/R
B B
B B
B B B B
B
B
SIGNALING SYSTEM
SIGNALING SYSTEM

5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
28.Speed sensor
32.Parking brake switch
33.Parking brake buzzer
34.Reverse switch
35.Joint coupler
41.Seat belt switch
42.Indicator light assembly
43.Helmet indicator light
44.Seat belt indicator light
45.Meter assembly
48.Coolant temperature warning light
49.Parking brake indicator light
50.Reverse indicator light
51.Neutral indicator light
52.High-range indicator light
53.Low-range indicator light
56.Fuel sender
64.Tail/brake light
67.Ignition fuse
68.Backup fuse
75.Horn switch (except for CDN)
76.Horn (except for CDN)
77.Backup light
78.Backup light relay
A. Optional
B. Wire harness
9-22
SIGNALING SYSTEM
EBS30274
TROUBLESHOOTING
• Any of the following fail to light: warning light, brake light or an indicator light.
• The fuel meter fails to come on.
• The speedometer fails to operate.
• The parking brake buzzer fails to sound.
• The horn fails to sound. (except for CDN)
TIP
1. Hood
2. Heat protector
3. Air filter case

(Main, ignition, backup, and signal-
ing system) Replace the fuse(s).
ES” on page 9-94.
OK ↓
page 9-95.
OK ↓
OK ↓
OK ↓
5. Check the entire signaling system NG →
wiring.
Refer to “CIRCUIT DIAGRAM (ex- Properly connect or replace the wire har-
cept for EPS models)” on page 9-19 ness.
and “CIRCUIT DIAGRAM (for EPS
models)” on page 9-21.
OK ↓
Check the condition of each of the sig-
naling system circuits. Refer to
“Checking the signaling system”.
9-23
SIGNALING SYSTEM
Checking the signaling system

The tail/brake lights fail to come on.
1. Check the tail/brake light bulbs and NG →
sockets.
Replace the tail/brake light bulb, socket or
Refer to “CHECKING THE BULBS
both.
AND BULB SOCKETS” on page
9-92.
OK ↓
2. Check the brake light switch. NG →
Refer to “CHECKING THE Replace the brake light switch.
OK ↓
wiring.
OK ↓
This circuit is OK.
The neutral, high-range, and/or low-range indicator light fails to come on.
1. Check the gear position switch. NG →
Refer to “CHECKING THE Replace the gear position switch.
OK ↓
wiring.
OK ↓
Replace the meter assembly or ECU.
The reverse indicator light fails to come on.

1. Check the reverse switch. NG →
Refer to “CHECKING THE Replace the reverse switch.
OK ↓
9-24
SIGNALING SYSTEM

wiring.
OK ↓
The parking brake indicator light fails to come on.

1. Check the parking brake switch. NG →
Refer to “CHECKING THE Replace the parking brake switch.
OK ↓
wiring.
OK ↓
The coolant temperature warning light fails to come on.

1. Check the coolant temperature sen- NG →
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 9-106.
OK ↓
wiring.
OK ↓
The fuel meter fails to come on.

1. Check the fuel sender. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump assembly.
SENDER” on page 9-103.
OK ↓
9-25
SIGNALING SYSTEM

wiring.
OK ↓
Replace the meter assembly.
The speedometer fails to come on.

1. Check the speed sensor. NG →
Refer to “CHECKING THE SPEED Replace the speed sensor.
SENSOR” on page 9-104.
OK ↓
wiring.
OK ↓
The helmet/seat belt indicator light fails to come on.

1. Check the seat belt switch. NG →
Refer to “CHECKING THE Replace the driver seat belt buckle.
OK ↓
wiring.
OK ↓
Replace the indicator light assembly or
ECU.
The parking brake buzzer fails to sound.

1. Check the parking brake buzzer. NG →
Refer to “CHECKING THE PARK-
Replace the parking brake buzzer.
ING BRAKE BUZZER” on page
9-105.
OK ↓
9-26
SIGNALING SYSTEM

wiring.
OK ↓
Replace the ECU.
The horn fails to sound. (except for CDN)

. 1. Check the horn switch. NG →
Refer to “CHECKING THE Replace the horn switch.
OK ↓
. 2. Check the entire signaling system NG →
wiring.
OK ↓
Replace the horn.
9-27
SIGNALING SYSTEM
9-28
EBS30275
EBS20079
A
B B
68 B
P Br/Y L G/W
OFF
A 70 B L
ON 69 B C
B Br L Br/Y W B
Br W Br/Y
(B)
Br/Y B Br/Y B
(B) Br/R 22
O Br/Y Br
B/L Gy Gy B/L
G/W O 23 32 P Br
W W W B R Gy
CIRCUIT DIAGRAM
B O/B O/B P (Gy)

R/W Br/Y O/B
W W W W W W (B) R/W
24 R/L R (Gy)
R (B)
W W R/W
(Gy) (Gy) 2 3 (Gy)
W W
R/G R/G
COOLING SYSTEM

Br/W B/L
14 Br/L R/W P/L 20
Br/R Br/R
Br/R 26 33
G/Y B/L
Br/R
Br/R R/W Y/W Y/W
Br/Y (B)
B/W W
B R/L
B R/W
21
B/W R/Y L L/Y
B B W L/Y
Y/R L W
Br/R B Y/B 27 B/L
G/R (W)
R 9 L/R
B (B)
P/W L
R Br/B Br/R L/R
R R Br/B O/L (B)
Br/L
5 B/G
B B W/B L
R 8
Br/L
13 Sb B/L B/L
34
BBB Br/R
Br/R G/W R/W
B
11 W/B
30 L Y/G B/L R/W
Y/L B/L B/L
Br/R 17 L/B
R B/L L
(off)
B 16 L
(on) R/L B/L
(B) 2WD B/W B B/L L
(start) L W 4WD
L/W G/R L/R
Gy DIFF LOCK 31
67 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
R B/W
9-29
R/L RR B
B/W B L/B
Br/R Y/R R
(B)
R R
R/L
Br/L
Br/L
Br/L W/B
66 64
Br

Br/Y
62 Br/Y
R/W
R/W Br/R
W/B Br Br/R
39 (B)
R/W
61 Y Br/Y
R/B R Br/Y Y Br
(B) 40 34
52 L 51 B/W Y
L 60 Br/B B/W Y
Br (off)
Br/R Br/L 55 B/W Y
Br Y R/W Y/L B/W
Br/Y B/W B/W
59 (B) B/W Br/Y
56 G W/B G G/R O/B
65 R R R/L Br/Y
Br/B B R/L Br/Y
W/B B B Br/R Br/R
L/Y Br/Y
Br/R
Y (B)
Y Y 42
B
B R/W L O/B R/W
L 50 49
Y G B L 36 Br/Y
(B) Lg B
44 Lg
(B)
B B B B/W Br
B G
G B Br/Y
B 35
(B)
(Gy)
Y LL B BB
Y L Y Y G Y G
46 37 L
38
B
54 54 47 B L/B
57 57 G Y G Y
B B
48
Y G B B Y G
B B
B B
B B
B B B B
B
B
COOLING SYSTEM
COOLING SYSTEM
5. Frame ground
6. Main switch
8. Battery
9. Main fuse
34.Joint coupler
58.Radiator fan motor fuse
60.Ignition fuse
65.Radiator fan motor
66.Radiator fan motor circuit breaker
67.Radiator fan motor relay
B. Wire harness
9-30
COOLING SYSTEM
EBS30276
TROUBLESHOOTING
The radiator fan motor fails to turn.
TIP
1. Hood
2. Heat protector

(Main, radiator fan motor, and igni-
tion) Replace the fuse(s).
ES” on page 9-94.
OK ↓
page 9-95.
OK ↓
OK ↓
4. Check the radiator fan motor. NG →
Refer to “CHECKING THE RADIA- Replace the radiator fan motor.
TOR FAN MOTOR” on page 9-105.
OK ↓
5. Check the radiator fan motor relay. NG →
Refer to “CHECKING THE RE- Replace the radiator fan motor relay.
OK ↓
6. Check the radiator fan motor circuit NG →
breaker.
Replace the radiator fan motor circuit
Refer to “CHECKING THE RADIA-
breaker.
TOR FAN MOTOR CIRCUIT
BREAKER” on page 9-105.
OK ↓
7. Check the coolant temperature sen- NG →
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 9-106.
OK ↓
9-31
COOLING SYSTEM
8. Check the entire cooling system NG →

page 9-29.
OK ↓
Replace the ECU.
9-32
EBS30277
EBS20080
A
B B
68 B
P Br/Y L G/W
OFF
A 70 B L
ON 69 B C
B Br L Br/Y W B
Br W Br/Y
(B)
Br/Y B Br/Y B
(B) Br/R 22
O Br/Y Br
B/L Gy Gy B/L
G/W O 23 32 P Br
W W W B R Gy
B O/B O/B P (Gy)
R/W Br/Y O/B
W W W W W W (B) R/W
24 R/L R (Gy)
R (B)
W W R/W
(Gy) (Gy) 2 3 (Gy)
W W
R/G R/G
Br/W B/L
14 Br/L R/W P/L 20
Br/R Br/R
Br/R 26 33
G/Y B/L
Br/R
Br/R R/W Y/W Y/W
Br/Y (B)
B/W W
B R/L
B R/W
21
B/W R/Y L L/Y
B B W L/Y
Y/R L W
Br/R B Y/B 27 B/L
G/R
FUEL INJECTION SYSTEM
R (W)
9 L/R
B (B)
P/W L
R Br/B Br/R L/R
R R Br/B O/L (B)
Br/L
5 B/G
B B W/B L
R 8
Br/L
13 Sb B/L B/L
34
BBB Br/R
Br/R G/W R/W
B
11 W/B
30 L Y/G B/L R/W
Y/L B/L B/L
Br/R 17 L/B
CIRCUIT DIAGRAM (except for EPS models)
R B/L L
(off)
B 16 L
(on) R/L B/L
(B) 2WD B/W B B/L L
(start) L W 4WD
L/W G/R L/R
Gy DIFF LOCK 31
67 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
R B/W
9-33
R/L RR B
B/W B L/B
Br/R Y/R R
(B)
R R
R/L
Br/L
Br/L
Br/L W/B
66 64
Br

Br/Y
62 Br/Y
R/W
R/W Br/R
W/B Br Br/R
39 (B)
R/W
61 Y Br/Y
R/B R Br/Y Y Br
(B) 40 34
52 L 51 B/W Y
L 60 Br/B B/W Y
Br (off)
Br/R Br/L 55 B/W Y
Br Y R/W Y/L B/W
Br/Y B/W B/W
59 (B) B/W Br/Y
56 G W/B G G/R O/B
65 R R R/L Br/Y
Br/B B R/L Br/Y
W/B B B Br/R Br/R
L/Y Br/Y
Br/R
Y (B)
Y Y 42
B
B R/W L O/B R/W
L 50 49
Y G B L 36 Br/Y
(B) Lg B
44 Lg
(B)
B B B B/W Br
B G
G B Br/Y
B 35
(B)
(Gy)
Y LL B BB
Y L Y Y G Y G
46 37 L
38
B
54 54 47 B L/B
57 57 G Y G Y
B B
48
Y G B B Y G
B B
B B
B B
B B B B
B
B

5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
10.Fuel injection system fuse
13.Fuel injection system relay
14.Air induction system solenoid
19.Yamaha diagnostic tool coupler
20.ISC (Idle Speed Control) unit
22.Ignition coil
23.Spark plug
24.Fuel injector
25.Intake air temperature sensor
27.Speed sensor
28.TPS (throttle position sensor)
29.Intake air pressure sensor
34.Joint coupler
39.Meter assembly
41.Engine trouble warning light
50.Fuel pump
60.Ignition fuse
61.Backup fuse
B. Wire harness
9-34
EBS30353
A
B B
B
75 P Br/Y L G/W
OFF
A 77 B L
ON 76 B C
B Br L Br/Y W B
Br W Br/Y B
(B)
Br/Y B Br/Y B B B
(B) 23 (B) (B)

Br/R
O Br/Y Br
C D
B/L Gy Gy B/L
G/W O 24 33 P Br
W W W B R Gy
B O/B O/B P (Gy)
R/W Br/Y O/B
W W W W W W (B) R/W
25 R/L R (Gy)
R (B)
W W R/W
(Gy) (Gy) 2 3 (Gy) G/W
W W O/W
R/G R/G G/W
26 Br/W B/L G/W
15 Br/L R/W P/L 21
Br/R Br/R
Br/R 27 34
G/Y B/L
Br/R
Br/R R/W Y/W Y/W
Br/Y R (B)
B/W W
B R/L
B R/W
22
B/W R/Y L L/Y
B B W L/Y
Y/R L W
W B/L
Br/R B Y/B 28 B/L
R R R/B L
R R (W)
P/W
CIRCUIT DIAGRAM (for EPS models)
R R Br/R L/R L (B)

Br/L
5 B/G
B B W/B L
R 8
Br/L
14 Sb B/L B/L
35
BBB Br/R
Br/R W R/W
B
12 W/B
31 L Y/G B/L R/W
B/L B/L
Br/R 18 L/B
R B/L L
(off)
B 17 L
(on) R/L B/L
(B) 2WD B/W B B/L L
(start) L W 4WD
L/W G/R L/R
Gy DIFF LOCK 32
74 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
R B/W
9-35
R/L RR B
B/W B L/B
Br/R Y/R R 36
(B) G R
R R B W 38 37 B R
(Gy)
R/L B R (Gy)
Br/L
G R B W R B
Br/L B R
(Gy)
Br/L W/B
GR B WR B
73 71
Br R G B R
R B
W B
Br/Y R/B
Br/Y G
R/W
69 R Br G/R W/B
W/B Br Br/R
45 (B)
L/B L/B
R/W
68 Y Br/Y
R/B G L/B Br O
Y Br O/W R L/B
R/B R (B) Br/Y 46 G W G/R 39 35
59 L 58 G/R W
(Gy) (Gy) B/W Y
L 67 Br/B (B) B/W Y
Br (off)
Br/R Br/L 62 B/W Y
Br Y R/W Y/L B/W
Br/Y B/W B/W
66 (B) B/W Br/Y
63 G W/B G G/R O/B
72 R R R/L Br/Y
Br/B B R/L Br/Y
W/B B B Br/R Br/R
L/Y Br/Y
Br/R
Y (B)
Y Y 48
B
B R/W L O/B G/R R/W
L 57 56
Y G B L 42 Br/Y
(B) Lg B
50 Lg
(B)
B B B B/W Br
B G
G B Br/Y
B 41
(B)
(Gy)
Y LL B BB
Y L Y Y G Y G
52 43 L
44
B
61 61 53 B L/B
64 64 G Y G Y
B B
54
Y G B B Y G
55
B B G/R
B B
B B
B B B B
B
B

5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
15.Air induction system solenoid
20.Yamaha diagnostic tool coupler
21.ISC (Idle Speed Control) unit
23.Ignition coil
24.Spark plug
25.Fuel injector
26.Intake air temperature sensor
28.Speed sensor
29.TPS (throttle position sensor)
30.Intake air pressure sensor
35.Joint coupler
45.Meter assembly
47.Engine trouble warning light
57.Fuel pump
67.Ignition fuse
68.Backup fuse
B. Wire harness
9-36
EBS30278
ECU SELF-DIAGNOSTIC FUNCTION

The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is
operating normally. If this function detects a malfunction in the system, it immediately operates the en-
gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider
that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is
stored in the memory of the ECU.
• To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
comes on when the main switch is being turned to start the engine.
• If a malfunction is detected in the system by the self-diagnostic function, the ECU provides an appro-
priate substitute characteristic operation, and alerts the rider of the detected malfunction by illuminat-
ing the engine trouble warning light.
• After the engine has been stopped, the lowest fault code number appears on the multi-function meter
display. Once a fault code has been displayed, it remains stored in the memory of the ECU until it is
deleted.
Engine trouble warning light indication and fuel injection system operation
Warning light indication ECU operation Fuel injection operation Vehicle operation
Warning provided when
Flashing* Operation stopped Cannot be operated
unable to start engine
Operated with substitute
Can or cannot be operat-
characteristics in accor-
Remains on Malfunction detected ed depending on the fault
dance with the descrip-
code
tion of the malfunction
* The warning light flashes when any one of the conditions listed below is present and the main switch
is turned to “ ” (start):
Fuel injector
12: Crankshaft position sensor 39:
(open or short-circuit)
Lean angle sensor Lean angle sensor
30: 41:
(latch up detected) (open or short-circuit)
ECU internal malfunction
33: Faulty ignition 50:
(faulty ECU memory)
Checking for a defective engine trouble warning light bulb

The engine trouble warning light comes on for around 2 seconds after the main switch has been turned
to “ ” (on). If the warning light does not come on under these conditions, the warning light (LED) may
be defective.
ECU detects an abnormal signal from a sensor

If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-
nates the engine trouble warning light and provides the engine with alternate operating instructions that
are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue to operate or stop operating, depending on the conditions.
9-37
EBS30279
The engine operation is not normal, but the
TROUBLESHOOTING METHOD
engine trouble warning light does not come
on.
The engine operation is not normal and the
1. Check the operation of the following sensors
engine trouble warning light comes on.
and actuators in the diagnostic mode.
1. Check:
Refer to “TROUBLESHOOTING DETAILS
• Fault code number
(FUEL INJECTION SYSTEM)” on page 9-41
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the fault code number displayed on and “SELF-DIAGNOSTIC FUNCTION AND
the multi-function meter. DIAGNOSTIC CODE TABLE” on page 10-7.
b. Identify the faulty system with the fault code. 01: Throttle position sensor signal (throttle angle)
c. Identify the probable cause of the malfunc- 30: Ignition coil
tion. 36: Fuel injector
48: Air induction system solenoid
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check and repair the probable cause of mal- If a malfunction is detected in the sensors or
function. actuators, repair or replace all faulty parts.
Fault code No. No fault code No.
If no malfunction is detected in the sensors
and actuators, check and repair inner parts of
Check and repair. Refer Check and repair. the engine.
to “TROUBLESHOOT-
ING DETAILS (FUEL
INJECTION SYS-
TEM)” on page 9-41.
Monitor the operation of
the sensors and actua-
tors in the diagnostic
mode.
Refer to “TROUBLE-
SHOOTING DETAILS
(FUEL INJECTION
SYSTEM)” on page
9-41 and “SELF-DIAG-
NOSTIC FUNCTION
AND DIAGNOSTIC
CODE TABLE” on page
10-7.
3. Perform the reinstatement action for the fuel

injection system.
Refer to “Confirmation of service completion”
of table in “TROUBLESHOOTING DETAILS
(FUEL INJECTION SYSTEM)” on page 9-41.
4. Turn the main switch to “ ” (off) and back to
“ ” (on), then check that no fault code num-
ber is displayed.
TIP
If another fault code are displayed, repeat steps
(1) to (4) until no fault code number is displayed.
5. Erase the malfunction history in the diagnos-
tic mode (code No. 62). Refer to “SELF-DI-
AGNOSTIC FUNCTION AND DIAGNOSTIC
CODE TABLE” on page 10-7.
TIP
Turning the main switch to “ ” (off) will not
erase the malfunction history.
9-38
EBS30280
YAMAHA DIAGNOSTIC TOOL

This model uses the Yamaha diagnostic tool to identify malfunctions.
For information about using the Yamaha diagnostic tool, refer to the operation manual that is included
with the tool.

90890-03231
Features of the Yamaha diagnostic tool

You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional meth-
ods.
By connecting the adapter interface, which is connected to the USB port of a computer, to a vehicle’s
ECU using the communication cable, you can display information that is necessary for identifying mal-
functions and for maintenance to display on the computer. The displayed information includes the sen-
sor output data and information recorded in the ECU.
Functions of the Yamaha diagnostic tool
Fault diagnosis mode: Fault codes recorded on the ECU are read, and the contents are dis-
played.
Function diagnostic mode: Check the operation of the output value of each sensor and actuator.
Inspection mode: Determine whether each sensor or actuator is functioning properly.
Monitoring mode: Displays a graph of sensor output values for actual operating condi-
tions.
Logging mode: Records and saves the sensor output value in actual driving conditions.
View log: Displays the logging data.
ECU rewrite: If necessary, the ECU is rewritten using ECU rewrite data provided by
Yamaha.
Ignition timing adjustment, etc. cannot be changed from the vehicle’s
original state.
However, the diagnostic tool cannot be used to freely change the basic vehicle functions, such as ad-
justing the ignition timing.
Connecting the Yamaha diagnostic tool
Remove the protective cap, and then connect the Yamaha diagnostic tool to the coupler “1”.
TIP
When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter
and indicators will be different from the normal operation.
9-39
Operation of the Yamaha diagnostic tool (Malfunction mode)

Malfunction results are displayed in the top part of the window area.
3 4 5 6 7 8 9 10 11 12
1. Recovered
The item list of the malfunction detected in the past (already recovered) are displayed.
2. Detected
The item list of the malfunction currently occurred are displayed.
3. Code
The following icons and the fault code numbers for the detected malfunctions are displayed.
A B
A. Detected malfunction
B. Recovered malfunction
4. ECU
The types of the control units are displayed.
9-40
5. Item
The item names of the detected malfunction are displayed.
6. Condition
The current conditions are displayed. (Detected/Recovered)
7. Symptom
The symptoms of the detected malfunction are displayed.
8. Diagnosis code
The diagnosis codes related to the detected malfunction are displayed.
9. FFD (only for models that can display freeze frame data)
The mark “ ” is displayed when the freeze frame data is available.
10.ECU conduction time (hour: minute: second)
The total ECU conduction time (total hours the vehicle’s main switch was ON) when the malfunction
was detected is displayed.
11.Number of main switch operation after detection
The number of times the main switch was turned on between the malfunction detection and code
reading is displayed.
12.Number of occurrences
The number of malfunction occurrences between the malfunction detection and code reading is dis-
played.
EBS30281
TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM)

This section describes the measures per fault code number displayed on the multi-function meter dis-
play. Check and service the items or components that are the probable cause of the malfunction fol-
lowing the order given.
After the check and service of the malfunctioning part has been completed, reset the multi-function me-
ter display according to the “Confirmation of service completion”.
Fault code No.:
Fault code number displayed on the multi-function meter when the engine failed to work normally.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “SELF-DIAGNOS-
TIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 10-7.
Fault code No. 12

Fault code No. 12
Crankshaft position sensor: no normal signals are received from the

Item
crankshaft position sensor.
Unable to start engine
Fail-safe system
Unable to drive vehicle
Diagnostic code No. —
Indicated —
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of crankshaft posi- Improperly connected → Con- Crank the engine.
tion sensor coupler. nect the coupler securely or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played → Service is finished.
the coupler. Fault code number is displayed
Disconnect the coupler and → Go to item 2.
check the pins (bent or broken
terminals and locking condition
of the pins).
9-41
Fault code No. 12
Crankshaft position sensor: no normal signals are received from the

Item
crankshaft position sensor.
2 Connection of ECU coupler. Improperly connected → Con- Crank the engine.
Check the locking condition of nect the coupler securely or re- Fault code number is not dis-
the coupler. place the wire harness. played → Service is finished.
Disconnect the coupler and Fault code number is displayed
check the pins (bent or broken → Go to item 3.
of the pins).
3 Wire harness continuity. Open or short circuit → Replace Crank the engine.
the wire harness. Fault code number is not dis-
Between crankshaft position played → Service is finished.
sensor coupler and ECU cou- Fault code number is displayed
pler. → Go to item 4.
gray–gray
Between crankshaft position
sensor coupler and joint cou-
pler.
black/blue–black/blue
Between joint coupler and ECU
coupler.
4 Installed condition of crank- Improperly installed sensor → Crank the engine.
shaft position sensor. Reinstall or replace the sensor. Fault code number is not dis-
Check for looseness or pinch- played → Service is finished.
ing. Fault code number is displayed
→ Go to item 5.
5 Defective crankshaft position Check the crankshaft position Crank the engine.
sensor. sensor. Fault code number is not dis-
Refer to “CHECKING THE played → Service is finished.
CRANKSHAFT POSITION Fault code number is displayed
SENSOR” on page 9-101. → Go to item 6.
Replace if defective.
6 Malfunction in ECU. Replace the ECU.
Fault code No. 13

TIP
If fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number
“13” first.
Fault code No. 13
Item Intake air pressure sensor: open or short circuit detected.

Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 03
Indicated Displays the intake air pressure.
Turn and hold the main switch in the “ ” (start) position, then press the
Procedure
accelerator pedal. (If the display value changes, the performance is OK.)
9-42
Fault code No. 13

1 Connection of intake air pres- Improperly connected → Con- Turn the main switch to “ ”
sure sensor coupler. nect the coupler securely or re- (on).
Check the locking condition of place the wire harness. Fault code number is not dis-
the coupler. played → Service is finished.
of the pins).
2 Connection of ECU coupler. Improperly connected → Con- Turn the main switch to “ ”
Check the locking condition of nect the coupler securely or re- (on).
the coupler. place the wire harness. Fault code number is not dis-
Disconnect the coupler and played → Service is finished.
check the pins (bent or broken Fault code number is displayed
terminals and locking condition → Go to item 3.
of the pins).
3 Wire harness continuity. Open or short circuit → Replace Turn the main switch to “ ”
the wire harness. (on).
Between intake air pressure Fault code number is not dis-
sensor coupler and ECU cou- played → Service is finished.
pler. Fault code number is displayed
pink–pink → Go to item 4.
Between intake air pressure
pler.
blue–blue
coupler.
blue–blue
4 Installed condition of intake air Improperly installed sensor → Turn the main switch to “ ”
pressure sensor. Reinstall or replace the sensor. (on).
Check for looseness or pinch- Fault code number is not dis-
ing. played → Service is finished.
Fault code number is displayed
→ Go to item 5.
9-43
Fault code No. 13

5 Defective intake air pressure Execute the diagnostic mode. Turn the main switch to “ ”
sensor. (Code No. 03) (on).
When engine is stopped: Fault code number is not dis-
Atmospheric pressure at the played → Service is finished.
current altitude and weather Fault code number is displayed
conditions is indicated. → Go to item 6.
At sea level: Approx. 101 kPa
(757.6 mmHg, 29.8 inHg)
1000 m (3300 ft) above sea lev-
el: Approx. 90 kPa (675.1
mmHg, 26.6 inHg)
mmHg, 23.6 inHg)
mmHg, 20.7 inHg)
When engine is cranking: Make
sure that the indication value
changes.
The value does not change
when engine is cranking. →
Check the intake air pressure
sensor.
Refer to “CHECKING THE IN-
TAKE AIR PRESSURE SEN-
SOR” on page 9-107.
Fault code No. 14

TIP
“13” first.
Fault code No. 14
Intake air pressure sensor: hose system malfunction (clogged or de-

Item
tached hose).
Fail-safe system
Indicated Displays the intake air pressure.
Turn and hold the main switch in the “ ” (start) position, then press the
Procedure
accelerator pedal. (If the display value changes, the performance is OK.)
1 Condition of intake air pressure Clogged or detached hose → Start the engine and let it idle
sensor hose. Repair or replace the sensor for approximately 5 seconds.
Check the intake air pressure hose. Fault code number is not dis-
sensor hose condition. played → Service is finished.
→ Go to item 2.
9-44
Fault code No. 14
Intake air pressure sensor: hose system malfunction (clogged or de-

Item
tached hose).
2 Defective intake air pressure Execute the diagnostic mode.
sensor. (Code No. 03)
When engine is stopped:
Atmospheric pressure at the
current altitude and weather
conditions is indicated.
At sea level: Approx. 101 kPa
(757.6 mmHg, 29.8 inHg)
mmHg, 26.6 inHg)
mmHg, 23.6 inHg)
mmHg, 20.7 inHg)
When engine is cranking: Make
sure that the indication value
changes.
The value does not change
when engine is cranking. →
Check the intake air pressure
sensor.
TAKE AIR PRESSURE SEN-
SOR” on page 9-107.
Fault code No. 15

TIP
“15” first.
Fault code No. 15
Item Throttle position sensor: open or short circuit detected.

Fail-safe system
Throttle position sensor signal
Indicated
• 14–20 (fully closed position)
Procedure Check with throttle valve fully closed.
1 Connection of throttle position Improperly connected → Con- Turn the main switch to “ ”
sensor coupler. nect the coupler securely or re- (on).
of the pins).
9-45
Fault code No. 15
Item Throttle position sensor: open or short circuit detected.

of the pins).
Between throttle position sensor Fault code number is not dis-
coupler and ECU coupler. played → Service is finished.
yellow–yellow Fault code number is displayed
Between throttle position sensor → Go to item 4.
coupler and joint coupler.
blue–blue
coupler.
blue–blue
4 Installed condition of throttle po- Improperly installed sensor → Turn the main switch to “ ”
sition sensor. Reinstall or adjust the sensor. (on).
Check for looseness or pinch- Refer to “ADJUSTING THE Fault code number is not dis-
ing. THROTTLE POSITION SEN- played → Service is finished.
SOR” on page 7-13. Fault code number is displayed
→ Go to item 5.
5 Throttle position sensor resis- Measure the throttle position Turn the main switch to “ ”
tance. sensor resistance. (on).
Refer to “CHECKING THE Fault code number is not dis-
THROTTLE POSITION SEN- played → Service is finished.
SOR” on page 9-106. Fault code number is displayed
→ Go to item 6.
6 Defective throttle position sen- Check throttle position sensor Turn the main switch to “ ”
sor. signal. (on).
Execute the diagnostic mode. Fault code number is not dis-
(Code No. 01) played → Service is finished.
When the throttle valve is fully Fault code number is displayed
closed: → Go to item 7.
A value of 14–20 is indicated.
An indicated value is out of the
specified range → Replace the
throttle position sensor.
Fault code No. 16

TIP
• If fault code numbers “15” and “16” are both indicated, take the actions specified for fault code number
“15” first.
“16” first.
9-46
Fault code No. 16
Item Throttle position sensor: stuck throttle position sensor is detected.

Fail-safe system
Throttle position sensor signal
Indicated
• 14–20 (fully closed position)
Procedure Check with throttle valve fully closed.
1 Installed condition of throttle po- Improperly installed sensor → Turn the main switch to “ ”
sition sensor. Reinstall or adjust the sensor. (on), then press the accelerator
Check for looseness or pinch- Refer to “ADJUSTING THE pedal.
ing. THROTTLE POSITION SEN- Fault code number is not dis-
SOR” on page 7-13. played → Service is finished.
→ Go to item 2.
2 Defective throttle position sen- Check throttle position sensor Turn the main switch to “ ”
sor. signal. (on), then operate the throttle.
Execute the diagnostic mode. Fault code number is not dis-
(Code No. 01) played → Service is finished.
When the throttle valve is fully Fault code number is displayed
closed: → Go to item 3.
A value of 14–20 is indicated.
An indicated value is out of the
specified range → Replace the
throttle position sensor.
Fault code No. 21

TIP
“21” first.
Fault code No. 21
Item Coolant temperature sensor: open or short circuit detected.

Fail-safe system
Indicated Displays the coolant temperature.
Compare the actually measured coolant temperature with the indicated
Procedure
value.
9-47
Fault code No. 21
Item Coolant temperature sensor: open or short circuit detected.

1 Connection of coolant tempera- Improperly connected → Con- Turn the main switch to “ ”
ture sensor coupler. nect the coupler securely or re- (on).
of the pins).
of the pins).
Between coolant temperature Fault code number is not dis-
green/yellow–green/yellow → Go to item 4.
Between coolant temperature
pler.
coupler.
4 Installed condition of coolant Improperly installed sensor → Turn the main switch to “ ”
temperature sensor. Reinstall or replace the sensor. (on).
→ Go to item 5.
5 Defective coolant temperature Execute the diagnostic mode. Turn the main switch to “ ”
When engine is cold: Fault code number is not dis-
Displayed temperature is close played → Service is finished.
to the ambient temperature. Fault code number is displayed
The displayed temperature is → Go to item 6.
not close to the ambient tem-
perature → Check the coolant
temperature sensor.
Refer to “CHECKING THE
COOLANT TEMPERATURE
Fault code No. 22

TIP
“22” first.
9-48
Fault code No. 22
Item Intake air temperature sensor: open or short circuit detected.

Fail-safe system
Indicated Displays the intake air temperature.
Compare the actually measured intake air temperature with the indicated
Procedure
value.
1 Connection of intake air tem- Improperly connected → Con- Turn the main switch to “ ”
perature sensor coupler. nect the coupler securely or re- (on).
of the pins).
of the pins).
Between intake air temperature Fault code number is not dis-
brown/white–brown/white → Go to item 4.
Between intake air temperature
pler.
coupler.
4 Installed condition of intake air Improperly installed sensor → Turn the main switch to “ ”
temperature sensor. Reinstall or replace the sensor. (on).
→ Go to item 5.
9-49
Fault code No. 22
Item Intake air temperature sensor: open or short circuit detected.

5 Defective intake air temperature Execute the diagnostic mode. Turn the main switch to “ ”
When engine is cold: Fault code number is not dis-
Displayed temperature is close played → Service is finished.
to the ambient temperature. Fault code number is displayed
The displayed temperature is → Go to item 6.
not close to the ambient tem-
perature. → Check the intake
air temperature sensor.
TAKE AIR TEMPERATURE
Fault code No. 30

Fault code No. 30
Item Latch up detected.

Fail-safe system
Lean angle sensor output voltage
Indicated • 3.6–4.4 (upright)
• 0.7–1.3 (overturned)
Procedure Remove the lean angle sensor and incline it more than 65 degrees.
1 The vehicle has overturned. Raise the vehicle upright. Turn the main switch to “ ”
(on), then to “ ” (off), and then
back to “ ” (on).
Fault code number is not dis-
played → Service is finished.
→ Go to item 2.
2 Installed condition of lean an- Check the installed direction Turn the main switch to “ ”
gle sensor. and condition of the sensor. (on), then to “ ” (off), and then
back to “ ” (on).
→ Go to item 3.
3 Defective lean angle sensor. Execute the diagnostic mode. Turn the main switch to “ ”
(Code No. 08) (on) then to “ ” (off), and then
An indicated value is out of the back to “ ” (on).
specified range → Check the Fault code number is not dis-
lean angle sensor. played → Service is finished.
Replace if defective. Fault code number is displayed
Refer to “CHECKING THE → Go to item 4.
LEAN ANGLE SENSOR” on
page 9-102.
9-50
Fault code No. 33

Fault code No. 33
Ignition coil: open or short circuit detected in the primary lead of the
Item
ignition coil.
Fail-safe system
Actuates the ignition coil five times at one-second intervals.
Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen
come on each time the ignition coil is actuated.
Check that a spark is generated five times.
Procedure
• Connect an ignition checker.
1 Connection of ignition coil con- Improperly connected → Con- Start the engine and let it idle
nector. nect the connector securely or for approximately 5 seconds.
Check the locking condition of replace the wire harness. Fault code number is not dis-
the connector. played → Service is finished.
Disconnect the connector and Fault code number is displayed
of the pins).
2 Connection of ECU coupler. Improperly connected → Con- Start the engine and let it idle
Check the locking condition of nect the coupler securely or re- for approximately 5 seconds.
of the pins).
3 Wire harness continuity. Open or short circuit → Replace Start the engine and let it idle
the wire harness. for approximately 5 seconds.
Between ignition coil connector Fault code number is not dis-
and ECU coupler. played → Service is finished.
orange–orange Fault code number is displayed
→ Go to item 4.
4 Installed condition of ignition Improperly installed ignition coil Start the engine and let it idle
coil. → Reinstall or replace the igni- for approximately 5 seconds.
Check for looseness or pinch- tion coil. Fault code number is not dis-
→ Go to item 5.
5 Defective ignition coil. Measure the primary coil resis- Start the engine and let it idle
tance of the ignition coil. for approximately 5 seconds.
Replace if out of specification. Fault code number is not dis-
Refer to “CHECKING THE IG- played → Service is finished.
NITION COIL” on page 9-100. Fault code number is displayed
→ Go to item 6.
6 Malfunction in ECU. Execute the diagnostic mode.
(Code No. 30)
No spark → Replace the ECU.
9-51
Fault code No. 37

TIP
“21” first.
“22” first.
“46” first.
“42” first.
Fault code No. 37
Component other than ISC (Idle Speed Control) unit is defective

A
(ISC operating sound is heard).
Item
Defective ISC (Idle Speed Control) unit (ISC operating sound is
B
not heard).
Fail-safe system
Fully closes the ISC valve, and then opens the valve.
This operation takes approximately 3 seconds.
Actuation
The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen
come on during the operation.
Procedure The operating sound can be heard when ISC valve operates.
A-1 Locate the malfunction. Execute the diagnostic mode. ISC operating sound is heard →
(Code No. 54) Go to item A-2.
Fully closes the ISC (Idle Speed ISC operating sound is not
Control) valve, and then fully heard → Go to item B-2 for the
opens the valve. defective ISC (Idle Speed Con-
trol) unit.
A-2 Incorrect speed sensor signal. Check the speed sensor. Start the engine and let it idle
Execute the diagnostic mode. for approximately 10 seconds.
(Code No. 07) Fault code number is not dis-
Rotate the rear wheel by hand played → Service is finished.
and check that the indicated Fault code number is displayed
value increases. → Go to item A-3.
Value does not increase → Go
to fault code No. 42.
A-3 Throttle valve does not fully Check the throttle body. Start the engine and let it idle
close. Refer to “THROTTLE BODY” on for approximately 10 seconds.
page 7-8. Fault code number is not dis-
Check the throttle cable. played → Service is finished.
Refer to “ADJUSTING THE AC- Fault code number is displayed
CELERATOR PEDAL FREE → Go to item A-4.
PLAY” on page 3-22.
A-4 ISC valve is not moving correct- Replace the throttle body as- Start the engine and let it idle
ly. sembly. for approximately 10 seconds.
→ Go to item A-5.
9-52
Fault code No. 37

A
Item
B
not heard).
A-5 Malfunction in ECU. Replace the ECU.
Fault code No. 37

A
Item
B
not heard).
Fail-safe system
Fully closes the ISC valve, and then opens the valve.
This operation takes approximately 3 seconds.
Actuation
come on during the operation.
Procedure The operating sound can be heard when ISC valve operates.
B-1 Locate the malfunction. Execute the diagnostic mode. ISC operating sound is heard →
(Code No. 54) Go to item A-2 for the compo-
Fully closes the ISC (Idle Speed nent other than ISC (Idle Speed
Control) valve, and then fully Control) unit is defective.
opens the valve. ISC operating sound is not
heard → Go to item B-2.
B-2 Connection of ISC (Idle Speed Improperly connected → Con- Execute the diagnostic mode.
Control) unit coupler. nect the coupler securely or re- (Code No. 54)
Check the locking condition of place the wire harness. ISC operating sound is heard →
the coupler. Go to item B-8.
Disconnect the coupler and ISC operating sound is not
check the pins (bent or broken heard → Go to item B-3.
of the pins).
B-3 Connection of ECU coupler. Improperly connected → Con- Execute the diagnostic mode.
Check the locking condition of nect the coupler securely or re- (Code No. 54)
the coupler. place the wire harness. ISC operating sound is heard →
Disconnect the coupler and Go to item B-8.
check the pins (bent or broken ISC operating sound is not
terminals and locking condition heard → Go to item B-4.
of the pins).
9-53
Fault code No. 37

A
Item
B
not heard).
B-4 Wire harness continuity. Open or short circuit → Replace Execute the diagnostic mode.
the wire harness. (Code No. 54)
Between ISC (Idle Speed Con- ISC operating sound is heard →
trol) unit coupler and ECU cou- Go to item B-8.
pler. ISC operating sound is not
red/green–red/green heard → Go to item B-5.
pink/blue–pink/blue
white/green–white/green
brown/blue–brown/blue
Between ISC (Idle Speed Con-
trol) unit coupler and joint cou-
pler.
red/white–red/white
B-5 Installed condition of ISC (Idle Improperly installed ISC (Idle Execute the diagnostic mode.
Speed Control) unit. Speed Control) unit → Reinstall (Code No. 54)
Check for looseness or pinch- the ISC (Idle Speed Control) ISC operating sound is heard →
ing. unit. Go to item B-8.
ISC operating sound is not
B-6 ISC valve is not moving correct- Replace the throttle body as- Execute the diagnostic mode.
ly. sembly. (Code No. 54)
ISC operating sound is heard →
Go to item B-8.
ISC operating sound is not
B-7 Malfunction in ECU. Replace the ECU.
B-8 Delete the fault code. Start the engine and let it idle
for approximately 10 seconds.
Check that the fault code num-
ber is not displayed.
Fault code No. 39

Fault code No. 39
Item Fuel injector: open or short circuit detected.

Fail-safe system
Actuates fuel injector five times at one-second intervals.
Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen
come on each time the fuel injector is actuated.
Disconnect the fuel pump coupler, and then check that fuel injector is ac-
Procedure
tuated five times by listening for the operating sound.
9-54
Fault code No. 39
Item Fuel injector: open or short circuit detected.

1 Connection of fuel injector cou- Improperly connected → Con- Execute the diagnostic mode.
pler. nect the coupler securely or re- (Code No. 36)
Check the locking condition of place the wire harness. Operating sound → Go to item
the coupler. 6.
Disconnect the coupler and No operating sound → Go to
check the pins (bent or broken item 2.
of the pins).
2 Defective fuel injector. Measure the fuel injector resis- Execute the diagnostic mode.
tance. (Code No. 36)
Replace if out of specification. Operating sound → Go to item
Refer to “CHECKING THE 6.
FUEL INJECTOR” on page No operating sound → Go to
9-108. item 3.
3 Connection of ECU coupler. Improperly connected → Con- Execute the diagnostic mode.
Check the locking condition of nect the coupler securely or re- (Code No. 36)
the coupler. place the wire harness. Operating sound → Go to item
Disconnect the coupler and 6.
check the pins (bent or broken No operating sound → Go to
terminals and locking condition item 4.
of the pins).
4 Wire harness continuity. Open or short circuit → Replace Execute the diagnostic mode.
the wire harness. (Code No. 36)
Between fuel injector coupler Operating sound → Go to item
and ECU coupler. 6.
red–red No operating sound → Go to
Between fuel injector coupler item 5.
and joint coupler.
red/blue–red/blue
6 Delete the fault code. Start the engine and let it idle
for approximately 5 seconds.
Fault code No. 41

Fault code No. 41
Item Lean angle sensor: open or short circuit detected.

Fail-safe system
Lean angle sensor output voltage
Indicated • 3.6–4.4 (upright)
• 0.7–1.3 (overturned)
Procedure Remove the lean angle sensor and incline it more than 65 degrees.
9-55
Fault code No. 41
Item Lean angle sensor: open or short circuit detected.

1 Connection of lean angle sen- Improperly connected → Con- Turn the main switch to “ ”
sor coupler. nect the coupler securely or re- (on), then to “ ” (off), and then
Check the locking condition of place the wire harness. back to “ ” (on).
the coupler. Fault code number is not dis-
of the pins).
Check the locking condition of nect the coupler securely or re- (on), then to “ ” (off), and then
the coupler. place the wire harness. back to “ ” (on).
Disconnect the coupler and Fault code number is not dis-
check the pins (bent or broken played → Service is finished.
terminals and locking condition Fault code number is displayed
of the pins). → Go to item 3.
the wire harness. (on), then to “ ” (off), and then
Between lean angle sensor back to “ ” (on).
coupler and ECU coupler. Fault code number is not dis-
yellow/green–yellow/green played → Service is finished.
Between lean angle sensor Fault code number is displayed
coupler and joint coupler. → Go to item 4.
blue–blue
coupler.
blue–blue
4 Defective lean angle sensor. Execute the diagnostic mode. Turn the main switch to “ ”
(Code No. 08) (on), then to “ ” (off), and then
An indicated value is out of the back to “ ” (on).
specified range → Check the Fault code number is not dis-
lean angle sensor. played → Service is finished.
Replace if defective. Fault code number is displayed
Refer to “CHECKING THE → Go to item 5.
LEAN ANGLE SENSOR” on
page 9-102.
Fault code No. 42

TIP
“42” first.
Fault code No. 42
Speed sensor: no normal signals are received from the speed sen-
Item
sor.
Fail-safe system
Vehicle speed pulse
Indicated
0–999
9-56
Fault code No. 42
Item
sor.
Check that the number increases when the rear wheels are rotated. The
Procedure
number is cumulative and does not reset each time the wheel is stopped.
1 Connection of speed sensor Improperly connected → Con- Turn the main switch to “ ”
coupler. nect the coupler securely or re- (on), and then rotate the rear
Check the locking condition of place the wire harness. wheel by hand.
the coupler. Fault code number is not dis-
Disconnect the coupler and played → Go to item 6.
of the pins).
Check the locking condition of nect the coupler securely or re- (on), and then rotate the rear
the coupler. place the wire harness. wheel by hand.
Disconnect the coupler and Fault code number is not dis-
check the pins (bent or broken played → Go to item 6.
terminals and locking condition Fault code number is displayed
of the pins). → Go to item 3.
the wire harness. (on), and then rotate the rear
Between speed sensor coupler wheel by hand.
and ECU coupler. (except for Fault code number is not dis-
EPS models) played → Go to item 6.
white–white Fault code number is displayed
Between speed sensor coupler → Go to item 4.
and joint coupler. (for EPS mod-
els)
white–white
coupler. (for EPS models)
white–white
Between speed sensor coupler
and joint coupler.
blue–blue
coupler.
blue–blue
4 Defective speed sensor. Execute the diagnostic mode. Turn the main switch to “ ”
(Code No. 07) (on), and then rotate the rear
While the rear wheels and wheel by hand.
stopped, check that the indicat- Fault code number is not dis-
ed value does not change. played → Go to item 6.
Rotate the rear wheel by hand Fault code number is displayed
and check that the indicated → Go to item 5.
value increases.
Malfunction → Replace the
speed sensor.
9-57
Fault code No. 42
Item
sor.
6 Delete the fault code. Start the engine, and input the
vehicle speed signals by operat-
ing the vehicle at 20 to 30 km/h
(12 to 19 mph).
Fault code No. 43

Fault code No. 43
Fuel system voltage: incorrect voltage supplied to the fuel injector

Item
and fuel pump.
Fail-safe system
Diagnostic code No. 09, 50
Fuel system voltage (battery voltage)
Indicated
Approximately 12.0
09 Turn the main switch to “ ” (on), and then compare the actually mea-
Procedure sured battery voltage with the display value. (If the actually measured
battery voltage is low, recharge the battery.)
Actuates the fuel injection system relay five times at one-second inter-
vals.
Actuation come on each time the relay is actuated.
50 (When the relay is on, the “CHECK” indicator and “ ” on the Yamaha di-
agnostic tool screen go off. When the relay is off, the “CHECK” indicator
and “ ” on the Yamaha diagnostic tool screen come on.)
Check that the fuel injection system relay is actuated five times by listen-
Procedure
ing for the operating sound.
1 Connection of fuel injection sys- Improperly connected → Con- Start the engine and let it idle
tem relay coupler. nect the coupler securely or re- for approximately 5 seconds.
of the pins).
2 Connection of ECU coupler. Improperly connected → Con- Start the engine and let it idle
Check the locking condition of nect the coupler securely or re- for approximately 5 seconds.
of the pins).
9-58
Fault code No. 43
Fuel system voltage: incorrect voltage supplied to the fuel injector

Item
and fuel pump.
3 Wire harness continuity. Open or short circuit → Replace Start the engine and let it idle
the wire harness. for approximately 5 seconds.
Between fuel injection system Fault code number is not dis-
relay coupler and ECU coupler. played → Service is finished.
blue/red–blue/red Fault code number is displayed
Between fuel injection system → Go to item 4.
relay coupler and joint coupler.
red/blue–red/blue
coupler.
red/blue–red/blue
Between ECU coupler and joint
coupler.
Between joint coupler and back-
up fuse.
Between main switch coupler
and ECU coupler.
brown/red–brown/red
4 Defective fuel injection system Execute the diagnostic mode. Start the engine and let it idle
relay. (Code No. 50) for approximately 5 seconds.
No operating sound → Replace Fault code number is not dis-
the fuel injection system relay. played → Service is finished.
→ Go to item 5.
5 Defective fuel injection system Execute the diagnostic mode. Start the engine and let it idle
relay. (Code No. 09) for approximately 5 seconds.
Fuel system voltage is below Fault code number is not dis-
3 V → Replace the fuel injection played → Service is finished.
system relay. Fault code number is displayed
→ Go to item 6.
Fault code No. 44

Fault code No. 44
EEPROM fault code number: an error is detected while reading or

Item
writing on EEPROM.
Fail-safe system
The fault code No. 44 detected EEPROM errors are indicated.
Indicated
00 indication: Normal status
Procedure —
1 Locate the malfunction. Execute the diagnostic mode. —
(Code No. 60)
01 indication: Go to item 2
9-59
Fault code No. 44
EEPROM fault code number: an error is detected while reading or

Item
writing on EEPROM.
2 “01” is indicated in diagnostic Change the CO concentration, Turn the main switch to “ ”
mode (code No. 60). EEPROM and rewrite in EEPROM. (on).
data error for adjustment of CO Refer to “ADJUSTING THE EX- Fault code number is not dis-
concentration. HAUST GAS VOLUME” on played → Service is finished.
page 3-7. Fault code number is displayed
After this adjustment is made, → Repeat item 1. If the same
the memory is not recovered number is indicated, go to item
when the main switch is turned 3.
to “ ” (off).
Fault code No. 46

TIP
“46” first.
Fault code No. 46
Item Charging voltage is abnormal.

Fail-safe system
Indicated —
Procedure —
1 Malfunction in charging system. Check the charging system. Start the engine and let it idle
Refer to “CHARGING SYS- for approximately 5 seconds.
TEM” on page 9-11. Fault code number is not dis-
Defective rectifier/regulator or played → Service is finished.
AC magneto → Replace. Fault code number is displayed
Defective connection in the → Repeat the maintenance job.
charging system circuit → Prop-
erly connect or replace the wire
harness.
Fault code No. 50

Fault code No. 50
Faulty ECU (Engine Control Unit) memory. (When this malfunction is

Item
detected in the ECU, the fault code number might not appear.)
Fail-safe system
Indicated —
Procedure —
9-60
Fault code No. 50
Faulty ECU (Engine Control Unit) memory. (When this malfunction is

Item
detected in the ECU, the fault code number might not appear.)
1 Malfunction in ECU. Replace the ECU. Turn the main switch to “ ”
(on).
Fault code No. Er-1

Fault code No. Er-1
ECU (Engine Control Unit) internal malfunction (output signal error):

Item signals cannot be transmitted between the ECU and the multi-func-
tion meter.
Able to start engine (unable when ECU is malfunctioning)
Fail-safe system
Able to drive vehicle (unable when ECU is malfunctioning)
Indicated —
Procedure —
1 Connection of meter assembly Improperly connected → Con- Turn the main switch to “ ”
coupler. nect the coupler securely or re- (on).
of the pins).
of the pins).
Between meter assembly cou- Fault code number is not dis-
pler and ECU coupler. played → Service is finished.
yellow/blue–yellow/blue Fault code number is displayed
→ Go to item 4.
4 Defective meter assembly. Replace the meter assembly. Turn the main switch to “ ”
(on).
→ Go to item 5.
9-61
Fault code No. Er-2

Fault code No. Er-2

Item
no signals are received from the ECU within the specified duration.
Fail-safe system
Indicated —
Procedure —
of the pins).
of the pins).
→ Go to item 4.
(on).
→ Go to item 5.
Fault code No. Er-3

Fault code No. Er-3

Item
data from the ECU cannot be received correctly.
Fail-safe system
Indicated —
Procedure —
9-62
Fault code No. Er-3

Item
data from the ECU cannot be received correctly.
of the pins).
of the pins).
→ Go to item 4.
(on).
→ Go to item 5.
Fault code No. Er-4

Fault code No. Er-4
ECU (Engine Control Unit) internal malfunction (input signal error):

Item
non-registered data has been received from the meter assembly.
Fail-safe system
Indicated —
Procedure —
of the pins).
9-63
Fault code No. Er-4
ECU (Engine Control Unit) internal malfunction (input signal error):

Item
non-registered data has been received from the meter assembly.
of the pins).
→ Go to item 4.
(on).
→ Go to item 5.
9-64
EBS30282
EBS20081
A
B B
68 B
P Br/Y L G/W
OFF
A 70 B L
ON 69 B C
B Br L Br/Y W B
Br W Br/Y
(B)
Br/Y B Br/Y B
(B) Br/R 22
O Br/Y Br
B/L Gy Gy B/L
G/W O 23 32 P Br
W W W B R Gy
CIRCUIT DIAGRAM
B O/B O/B P (Gy)

R/W Br/Y O/B
W W W W W W (B) R/W
24 R/L R (Gy)
R (B)
W W R/W
(Gy) (Gy) 2 3 (Gy)
W W
R/G R/G
Br/W B/L
14 Br/L R/W P/L 20
Br/R Br/R
FUEL PUMP SYSTEM
Br/R 26 33
G/Y B/L
Br/R
Br/R R/W Y/W Y/W
Br/Y (B)
B/W W
B R/L
B R/W
21
B/W R/Y L L/Y
B B W L/Y
Y/R L W
Br/R B Y/B 27 B/L
G/R (W)
R 9 L/R
B (B)
P/W L
R Br/B Br/R L/R
R R Br/B O/L (B)
Br/L
5 B/G
B B W/B L
R 8
Br/L
13 Sb B/L B/L
34
BBB Br/R
Br/R G/W R/W
B
11 W/B
30 L Y/G B/L R/W
Y/L B/L B/L
Br/R 17 L/B
R B/L L
(off)
B 16 L
(on) R/L B/L
(B) 2WD B/W B B/L L
(start) L W 4WD
L/W G/R L/R
Gy DIFF LOCK 31
67 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
R B/W
9-65
R/L RR B
B/W B L/B
Br/R Y/R R
(B)
R R
R/L
Br/L
Br/L
Br/L W/B
66 64
Br

Br/Y
62 Br/Y
R/W
R/W Br/R
W/B Br Br/R
39 (B)
R/W
61 Y Br/Y
R/B R Br/Y Y Br
(B) 40 34
52 L 51 B/W Y
L 60 Br/B B/W Y
Br (off)
Br/R Br/L 55 B/W Y
Br Y R/W Y/L B/W
Br/Y B/W B/W
59 (B) B/W Br/Y
56 G W/B G G/R O/B
65 R R R/L Br/Y
Br/B B R/L Br/Y
W/B B B Br/R Br/R
L/Y Br/Y
Br/R
Y (B)
Y Y 42
B
B R/W L O/B R/W
L 50 49
Y G B L 36 Br/Y
(B) Lg B
44 Lg
(B)
B B B B/W Br
B G
G B Br/Y
B 35
(B)
(Gy)
Y LL B BB
Y L Y Y G Y G
46 37 L
38
B
54 54 47 B L/B
57 57 G Y G Y
B B
48
Y G B B Y G
B B
B B
B B
B B B B
B
B
FUEL PUMP SYSTEM
FUEL PUMP SYSTEM
5. Frame ground
6. Main switch
8. Battery
9. Main fuse
34.Joint coupler
50.Fuel pump
60.Ignition fuse
B. Wire harness
9-66
FUEL PUMP SYSTEM
EBS30283
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
1. Hood
2. Rear panel (right)
3. Under-seat storage compartment

(Main, fuel injection system, and ig-
nition) Replace the fuse(s).
ES” on page 9-94.
OK ↓
page 9-95.
OK ↓
OK ↓
4. Check the fuel injection system re- NG →
lay.
Replace the fuel injection system relay.
Refer to “CHECKING THE RE-
OK ↓
5. Check the fuel pump. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump assembly.
PUMP BODY” on page 7-2.
OK ↓
6. Check the entire fuel pump system NG →
page 9-65.
OK ↓
Replace the ECU.
9-67
FUEL PUMP SYSTEM
9-68
EBS30284
EBS20082
A
B B
68 B
P Br/Y L G/W
OFF
A 70 B L
ON 69 B C
B Br L Br/Y W B
Br W Br/Y
(B)
Br/Y B Br/Y B
(B) Br/R 22
O Br/Y Br
B/L Gy Gy B/L
G/W O 23 32 P Br
W W W B R Gy
CIRCUIT DIAGRAM
B O/B O/B P (Gy)

R/W Br/Y O/B
W W W W W W (B) R/W
24 R/L R (Gy)
R (B)
W W R/W
(Gy) (Gy) 2 3 (Gy)
W W
R/G R/G
Br/W B/L
14 Br/L R/W P/L 20
Br/R Br/R
Br/R 26 33
G/Y B/L
Br/R
Br/R R/W Y/W Y/W
Br/Y (B)
B/W W
B R/L
B R/W
21
B/W R/Y L L/Y
B B W L/Y
Y/R L W
Br/R B Y/B 27 B/L
G/R (W)
R 9 L/R
B (B)
P/W L
R Br/B Br/R L/R
R R Br/B O/L (B)
Br/L
5 B/G
B B W/B L
R 8
Br/L
13 Sb B/L B/L
34
BBB Br/R
Br/R
2WD/4WD SELECTING SYSTEM
G/W R/W
B
11 W/B
30 L Y/G B/L R/W
Y/L B/L B/L
Br/R 17 L/B
R B/L L
(off)
B 16 L
(on) R/L B/L
(B) 2WD B/W B B/L L
(start) L W 4WD
L/W G/R L/R
Gy DIFF LOCK 31
67 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
R B/W
9-69
R/L RR B
B/W B L/B
Br/R Y/R R
(B)
R R
R/L
Br/L
Br/L
Br/L W/B
66 64
Br

Br/Y
62 Br/Y
R/W
R/W Br/R
W/B Br Br/R
39 (B)
R/W
61 Y Br/Y
R/B R Br/Y Y Br
(B) 40 34
52 L 51 B/W Y
L 60 Br/B B/W Y
Br (off)
Br/R Br/L 55 B/W Y
Br Y R/W Y/L B/W
Br/Y B/W B/W
59 (B) B/W Br/Y
56 G W/B G G/R O/B
65 R R R/L Br/Y
Br/B B R/L Br/Y
W/B B B Br/R Br/R
L/Y Br/Y
Br/R
Y (B)
Y Y 42
B
B R/W L O/B R/W
L 50 49
Y G B L 36 Br/Y
(B) Lg B
44 Lg
(B)
B B B B/W Br
B G
G B Br/Y
B 35
(B)
(Gy)
Y LL B BB
Y L Y Y G Y G
46 37 L
38
B
54 54 47 B L/B
57 57 G Y G Y
B B
48
Y G B B Y G
B B
B B
B B
B B B B
B
B

5. Frame ground
6. Main switch
8. Battery
9. Main fuse
15.Differential motor relay 1
16.Differential motor
18.On-Command four-wheel-drive switch
34.Joint coupler
39.Meter assembly
48.On-Command differential gear lock indicator
light
51.Differential motor relay 2
59.Differential motor fuse
60.Ignition fuse
B. Wire harness
9-70
EBS30285
TROUBLESHOOTING
• The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential
gear lock indicator fails to come on.
• The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential
gear lock indicator flashes.
TIP
1. Hood
2. Skid plate
The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential gear

lock indicator fails to come on.
(Main, differential motor, ignition,
and signaling system) Replace the fuse(s).
ES” on page 9-94.
OK ↓
page 9-95.
OK ↓
OK ↓
4. Check the On-Command four- NG →
wheel-drive switch. Replace the On-Command four-wheel-
Refer to“CHECKING THE drive switch.
OK ↓
5. Check the differential motor relay 1. NG →
Refer to “CHECKING THE RE- Replace the differential motor relay 1.
OK ↓
6. Check the differential motor relay 2. NG →
Refer to “CHECKING THE RE- Replace the differential motor relay 2.
OK ↓
OK ↓
9-71
8. Check the differential motor opera- NG →

tion.
Refer to “CHECKING THE DIF- Replace the differential motor.
FERENTIAL MOTOR OPERATION”
on page 8-13.
OK ↓
9. Check the entire 2WD/4WD select- NG →
ing system wiring. Properly connect or replace the 2WD/4WD
Refer to “CIRCUIT DIAGRAM” on selecting system wiring.
page 9-69.
OK ↓
The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential gear

lock indicator flashes.
1. Check the differential motor posi- NG →
tion switch.
Refer to “CHECKING THE DIF- Replace the differential motor.
FERENTIAL MOTOR POSITION
SWITCH” on page 9-109.
OK ↓
2. Check the entire 2WD/4WD select- NG →
ing system wiring. Properly connect or replace the 2WD/4WD
Refer to “CIRCUIT DIAGRAM” on selecting system wiring.
page 9-69.
OK ↓
Replace the ECU.
9-72
EBS30286
EBS20083
A
B B
B
75 P Br/Y L G/W
OFF
A 77 B L
ON 76 B C
B Br L Br/Y W B
Br W Br/Y B
(B)
Br/Y B Br/Y B B B
(B) 23 (B) (B)

Br/R
O Br/Y Br
C D
B/L Gy Gy B/L
G/W O 24 33 P Br
W W W B R Gy
CIRCUIT DIAGRAM
B O/B O/B P (Gy)

R/W Br/Y O/B
W W W W W W (B) R/W
25 R/L R (Gy)
R (B)
W W R/W
(Gy) (Gy) 2 3 (Gy) G/W
W W O/W
R/G R/G G/W
26 Br/W B/L G/W
15 Br/L R/W P/L 21
Br/R Br/R
Br/R 27 34
G/Y B/L
Br/R
Br/R R/W Y/W Y/W
Br/Y R (B)
B/W W
B R/L
B R/W
22
B/W R/Y L L/Y
B B W L/Y
Y/R L W
W B/L
Br/R B Y/B 28 B/L
R R R/B L
R R (W)
R P/W L
R Br/R L/R (B)
Br/L
5 B/G
B B W/B L
R 8
Br/L
14 Sb B/L B/L
35
BBB Br/R
Br/R W R/W
B
12 W/B
31 L Y/G B/L R/W
B/L B/L
Br/R 18 L/B
R B/L L
(off)
B 17 L
(on) R/L B/L
(B) 2WD B/W B B/L L
(start) L W 4WD
L/W G/R L/R
Gy DIFF LOCK 32
74 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
R B/W
9-73
R/L RR B
B/W B L/B
Br/R Y/R R 36
(B) G R
R R B W 38 37 B R
(Gy)
R/L B R (Gy)
Br/L
G R B W R B
Br/L B R
(Gy)
Br/L W/B
GR B WR B
73 71
Br R G B R
R B
W B
Br/Y R/B
Br/Y G
R/W
69 R Br G/R W/B
W/B Br Br/R
45 (B)
L/B L/B
R/W
68 Y Br/Y
R/B G L/B Br O
Y Br O/W R L/B
R/B R (B) Br/Y 46 G W G/R 39 35
59 L 58 G/R W
(Gy) (Gy) B/W Y
L 67 Br/B (B) B/W Y
Br (off)
Br/R Br/L 62 B/W Y
Br Y R/W Y/L B/W
Br/Y B/W B/W
66 (B) B/W Br/Y
63 G W/B G G/R O/B
72 R R R/L Br/Y
Br/B B R/L Br/Y
W/B B B Br/R Br/R
L/Y Br/Y
Br/R
Y (B)
Y Y 48
B
B R/W L O/B G/R R/W
L 57 56
Y G B L 42 Br/Y
(B) Lg B
50 Lg
(B)
B B B B/W Br
B G
G B Br/Y
B 41
(B)
(Gy)
Y LL B BB
Y L Y Y G Y G
52 43 L
44
B
61 61 53 B L/B
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
64 64 G Y G Y
B B
54
Y G B B Y G
55
B B G/R
B B
B B
B B B B
B
B

5. Frame ground
6. Main switch
8. Battery
9. Main fuse
10.EPS fuse
28.Speed sensor
35.Joint coupler
36.EPS unit
37.EPS motor
38.EPS torque sensor
39.EPS self-diagnosis signal connector
40.EPS control unit
45.Meter assembly
55.EPS warning light
67.Ignition fuse
B. Wire harness
D. EPS control unit
9-74
EBS30287
EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION

The EPS control unit is equipped with a self-diagnostic function. If this function detects a malfunction in
the EPS system, it lights the EPS warning light to alert the rider that a malfunction has occurred in the
system. Once a malfunction has been detected, it becomes stored in the EPS control unit memory in
the form of a fault code.
• The EPS warning light comes on when the main switch is turned to “ ” (on), and then goes off once
the engine is started. If the warning light remains on or comes on after the engine is started, the EPS
system may be defective.
• The electrical circuit of the warning light can be checked by turning the main switch to “ ” (on). If the
warning light does not come on, the electrical circuit may be defective.
1
1. EPS warning light
TIP
If the steering usage is too heavy (i.e., excessive steering use when the vehicle is traveling at a slow
speed), the power assist is reduced to protect the EPS motor from overheating.
EBS30288
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 re-
mains on.
Furthermore, the warning light comes on whenever a malfunction has occurred.
TIP
The EPS system does not operate while the EPS warning light is on.
e
a d
g
f i
b
g
f
c
h
a. Main switch f. Off
b. EPS warning light (no malfunction detected) g. Comes on.
c. EPS warning light (malfunction detected) h. Initial lighting: 2 seconds
d. “ ” (off) i. Goes off.
e. “ ” (on)
9-75
EBS30289
DIAGNOSTIC MODE
Setting the diagnostic mode (present and past malfunctions)

1. Disconnect the EPS self-diagnosis signal connector “1”.
2. Turn the main switch to “ ” (on).
3. Select the signaling mode by grounding the EPS self-diagnosis signal connector (male side) to the
EPS control unit “2” or disconnecting it from the unit as follows.
1 2
• Present malfunction signaling mode

Ground the connector “1” quickly* to the EPS control unit “2” over 2 times.
* Quickly = from 20 to 76 ms interval
TIP
• Because the “quickly” intervals are approximately the same as the intervals when sliding the connec-
tor “1” across the area “a” of the EPS control unit “2”, this method can also be used to set the diag-
nostic mode.
• To set the diagnostic mode, this step should be started within 5 seconds and completed within 10 sec-
onds after the main switch is turned to “ON”.
The EPS warning light starts to show present fault codes.
• Past malfunction signaling mode
While the present malfunction mode is activated, briefly disconnect the connector “1”, ground it
again, and leave it grounded. The signaling mode is activated after 5 seconds.
The EPS warning light starts to show past fault codes.
4. Turn the main switch to “ ” (off) to cancel the diagnostic mode.
TIP
• The diagnostic mode can also be canceled by riding the vehicle at speeds above 2 km/h (1.2 mi/h).
• When the diagnostic mode is selected and during the initial lighting of the EPS warning light, the EPS
control unit does not receive input from the EPS self-diagnosis signal connector.
5. Connect the EPS self-diagnosis signal connector.
Identifying fault codes

When the diagnostic mode is activated, the fault codes determined by the fail-safe specifications are
signaled by the EPS warning light as follows.
• Present malfunction signaling mode: Currently detected fault codes are signaled.
• Past malfunction signaling mode: Both previously detected fault codes and currently detected fault
codes are signaled.
9-76
Signaling method
Example 1: Fault code No. 23
5
d d
a g i g
j k
b h
B
e A
c f
5 2 1 3 2
i
0.5 × 3 0.5 × 5
a. EPS self-diagnosis signal connector B. Display of the present malfunctions stops

b. Diagnostic mode when the past malfunction display mode is
c. EPS warning light selected.
d. Disconnected
e. On
f. Off
g. Grounded
h. Normal mode (diagnostic mode not activated)
i. Mode selection judgment
j. Present malfunction signaling mode
k. Past malfunction signaling mode
A. The EPS warning light comes on for 5
seconds during the diagnostic mode selection
judgment.
After the mode selection judgment is completed (present or past malfunction mode), the current fault
code signaling stops immediately, and then the first code of the mode is signaled 2 seconds later.
When a fault code is signaled, the EPS warning light goes off for 1 second between the units of 10 and
the units of 1 for the code. After a fault code is signaled, the warning light goes off for 3 seconds, and
then the next code is signaled.
Example 2: No malfunctions are detected
a c
f
d A
b e
5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5

g
a. EPS self-diagnosis signal connector f. Grounded

b. EPS warning light g. Mode selection judgment
c. Disconnected
A. The EPS warning light comes on for 5
d. Comes on seconds during the diagnostic mode selection
e. Goes off judgment.
9-77
After the mode selection judgment is completed (present display or past malfunction mode), the current
fault code signaling stops immediately, and then the EPS warning light starts flashing at 1.5-second in-
tervals.
Deleting fault codes

To delete fault codes, ground the EPS self-diagnosis signal connector 3 or more times within 5 seconds
while the present or past malfunction mode is activated. The currently selected mode remains active
after the fault codes of that mode are deleted.
b
a c
T1 T1 T1 T1 T1 T2
a. EPS self-diagnosis signal connector c. Grounded

b. Disconnected
T1: Connector grounded - - - - 0.1 T1 1.6 seconds

T2: Fault codes deleted - - - - - Maximum 1.5 seconds required
EBS30290
SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)

Fault code Probable cause of mal-
Item Symptom
No. function
• Open or short circuit in
11 wire harness.
13 No normal signals are received from • Malfunction in torque sen-
EPS torque sensor
15 the EPS torque sensor. sor.
16 • Malfunction in EPS control
unit.
wire harness.
No normal signals are received from • Malfunction in speed sen-
21 Speed sensor
the speed sensor. sor.
• Malfunction in EPS control
unit.
wire harness.
No normal signals are received from
22 Engine speed signal • Malfunction in ECU.
the ECU.
unit.
41
wire harness.
42 No normal signals are received from
EPS motor • Malfunction in EPS motor.
43 the EPS motor.
45
unit.
Relay contacts in the EPS control unit Malfunction in EPS control
52 EPS control unit
are welded together. unit.
9-78
Fault code Probable cause of mal-

Item Symptom
No. function
• Faulty battery.
• Malfunction in the
charging system.
53 EPS control unit Battery voltage has dropped. Refer to “CHARGING
unit.
Relay contacts in the EPS control unit Malfunction in EPS control
54 EPS control unit
are welded together. unit.
• Malfunction in the
charging system.
Battery voltage has increased.
Refer to “CHARGING
55 EPS control unit Abnormality exists between the EPS
and the ECU.
unit.
EBS30291
TROUBLESHOOTING DETAILS (EPS SYSTEM)

TIP
The malfunction history is stored even if the main switch is turned to “ ” (off), therefore, be sure to
erase the history (present and past malfunction signaling modes) after repairing the cause of the EPS
system malfunction. The malfunction history must be erased in the diagnostic mode. Refer to “DIAG-
NOSTIC MODE” on page 9-76.
Fault code No. 11, 13, 15, 16

Fault code No. 11, 13, Symptom EPS torque sensor: no normal signals are received from the
15, 16 EPS torque sensor.
Order Item/components and probable cause Check or maintenance job Reinstatement

method
1 Connections • Check the locking condition of the Turning the main
• EPS torque sensor coupler coupler. switch to “ ”
• Disconnect the coupler and check (off).
the pins (bent or broken terminals
and locking condition of the pins).
• If there is a malfunction, connect
the coupler securely or replace the
wire harness.
2 Open or short circuit in EPS torque sen- • Replace if there is an open or short
sor lead. circuit.
• Between EPS torque sensor cou-
pler and EPS control unit coupler.
white–white
red–red
green–green
black–black
3 Defective EPS torque sensor. • Replace if defective.
Refer to “CHECKING THE EPS
TORQUE SENSOR (for EPS mod-
els)” on page 9-110.
4 Malfunction in EPS control unit. Replace the EPS control unit.
9-79
Fault code No. 21

Fault code No. 21 Symptom Speed sensor: no normal signals are received from the speed
sensor.

method
1 Connections • Check the locking condition of the Starting the en-
• Speed sensor coupler coupler. gine and activat-
• EPS control unit coupler at the wire • Disconnect the coupler and check ing the vehicle
harness the pins (bent or broken terminals speed sensor by
and locking condition of the pins). operating the ve-
• If there is a malfunction, connect hicle above 5
the coupler securely or replace the km/h (3 mi/h), or
wire harness. turning the main
2 Open or short circuit in wire harness. • Replace if there is an open or short switch to “ ”
circuit. (off), then to “ ”
• Between speed sensor coupler (on), and then
and joint coupler. deleting the fault
white–white codes. Refer to
• Between joint coupler and EPS “DIAGNOSTIC
control unit coupler. MODE” on page
white–white 9-76.
3 Defective speed sensor. • Replace if defective.

Refer to “CHECKING THE SPEED
Fault code No. 22

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

method
• EPS control unit coupler at the wire coupler. switch to “ ”
harness • Disconnect the coupler and check (off).
• ECU coupler at the wire harness the pins (bent or broken terminals
wire harness.
2 Open or short circuit in wire harness. • Replace if there is an open or short
circuit.
• Between ECU coupler and EPS
control unit coupler.
orange/white–orange/white
9-80
Fault code No. 41, 42, 43, 45

Fault code No. 41, 42, Symptom EPS motor: no normal signals are received from the EPS motor.
43, 45

method
• EPS motor coupler coupler. switch to “ ”
• Disconnect the coupler and check (off).
the pins (bent or broken terminals
wire harness.
2 Open or short circuit in EPS motor lead. • Replace if there is an open or short
circuit.
• Between EPS motor and EPS con-
trol unit coupler.
red–red
black–black
3 Defective EPS motor. Replace if defective.
Refer to “CHECKING THE EPS MO-
TOR (for EPS models)” on page
9-109.
Fault code No. 52

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

method
1 Malfunction in EPS control unit. Replace the EPS control unit. Turning the main
switch to “ ”
(off).
Fault code No. 53

Fault code No. 53 Symptom Battery voltage has dropped.

method
1 Faulty battery. Replace or charge the battery. Turning the main
Refer to “CHECKING AND switch to “ ”
CHARGING THE BATTERY” on (off).
page 9-95.
2 Malfunction in rectifier/regulator or Replace if defective.
charging system. Refer to “CHECKING THE RECTIFI-
ER/REGULATOR” on page 9-103.
9-81
Fault code No. 54

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

method
1 Malfunction in EPS control unit. Replace the EPS control unit. Turning the main
switch to “ ”
(off).
Fault code No. 55

Fault code No. 55 Symptom Battery voltage has increased.
Abnormality exists between the EPS and the ECU.

method
1 Faulty battery. Replace the battery. Turning the main
Refer to “CHECKING AND switch to “ ”
CHARGING THE BATTERY” on (off).
page 9-95.
2 Malfunction in rectifier/regulator. Replace if defective.
Refer to “CHECKING THE RECTIFI-
ER/REGULATOR” on page 9-103.
9-82
ELECTRICAL COMPONENTS
EBS20084
7
6
5 8
4
10
11
3
12
13
14
1
15
21 16
20
18
19 17
9-83
1. Radiator fan motor

2. Lean angle sensor
4. Parking brake buzzer
5. Parking brake switch
6. Seat belt switch
8. Reverse switch
9. Intake air pressure sensor
10. TPS (throttle position sensor)
11. Fuel injector
12. ISC (Idle Speed Control) unit
13. Air induction system solenoid
14. Ignition coil
15. Coolant temperature sensor
17. Speed sensor
18. Fuel sender
19. Fuel pump
20. Intake air temperature sensor
21. Differential motor
9-84
3 4 5
6
1
14
7
13
10 9
12
11
9-85
1. Auxiliary DC jack
2. Meter assembly
3. Indicator light assembly
4. Main switch
5. On-Command four-wheel-drive switch
6. Light switch
7. EPS torque sensor (for EPS models)
8. EPS motor (for EPS models)
9. EPS control unit (for EPS models)
10. Radiator fan motor circuit breaker
11. Horn (except for CDN)
12. ECU (Engine Control Unit)
13. Rectifier/regulator
14. Battery
9-86
1 4
10
19 18 7
17 16 13 11
15 14
8
12 9
12
9-87

2. Fuel injection system relay
3. Radiator fan motor relay
4. Headlight relay
7. Fuel injection system fuse
8. Spare fuse
9. Starter relay
10. EPS fuse (for EPS models)
11. Main fuse
12. Fuse box
13. Radiator fan motor fuse
14. Headlight fuse
15. Signaling system fuse
16. Auxiliary DC jack fuse
17. Differential motor fuse
18. Ignition fuse
19. Backup fuse
9-88
EBS30292
CHECKING THE SWITCHES
3
L/W B G/R
2 2WD 4
4WD
1 Br/R R/B L/Y Br/R DIFF LOCK
L W
Br P (off) L/W G/R Gy
OFF (on) B
(B)
ON (start) (W)
9 8 7 6 5
Br L Y G/W
Br Y (off)
(B) B L
L/R B
9-89
1. Horn switch (except for CDN)

2. Main switch
3. On-Command four-wheel-drive switch
5. Reverse switch
6. Seat belt switch
7. Light switch
8. Parking brake switch
9-90
Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the
wiring connections and if necessary, replace the switch.
ECB01430
NOTICE
Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from
the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester
90890-03112
YU-03112-C
TIP
• Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back and forth between the switch positions a few times.
The switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated by
“ ”. There is continuity between the brown/red and red/black leads when the switch is set to
“ ” (on).
b
Br/R R/B L/Y Br/R
(off)
a (on)
(start)
Br/R R/B
L/Y Br/R
9-91
EBS30293
• Avoid touching the glass part of a headlight
CHECKING THE BULBS AND BULB
bulb to keep it free from oil, otherwise the
SOCKETS
transparency of the glass, the life of the
TIP bulb, and the luminous flux will be adverse-
Do not check any of the lights that use LEDs. ly affected. If the headlight bulb gets soiled,
Check each bulb and bulb socket for damage or thoroughly clean it with a cloth moistened
wear, proper connections, and also for continuity with alcohol or lacquer thinner.
between the terminals. 2. Check:
Damage/wear → Repair or replace the bulb, • Bulb (for continuity)
bulb socket or both. (with the pocket tester)
Improperly connected → Properly connect. No continuity → Replace.
No continuity → Repair or replace the bulb, bulb
socket or both. Pocket tester
90890-03112
Types of bulbs Analog pocket tester
The bulbs used on this vehicle are shown in the YU-03112-C
illustration.
• Bulbs “a” are used for the headlights and usu- TIP
ally use a bulb holder that must be detached Before checking for continuity, set the pocket
before removing the bulb. The majority of tester to “0” and to the “Ω × 1” range.
these types of bulbs can be removed from their ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
respective socket by turning them counter- a. Connect the positive tester probe to terminal
clockwise. “1” and the negative tester probe to terminal
• Bulbs “b” are used for tail/brake lights and can “2”, and check the continuity.
be removed from the socket by pushing and b. Connect the positive tester probe to terminal
turning the bulb counterclockwise. “1” and the negative tester probe to terminal
“3”, and check the continuity.
a b c. If either of the readings indicate no continuity,
replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the condition of the bulbs

bulbs.
1. Remove:
• Bulb Checking the condition of the bulb sockets
EWB02860
WARNING The following procedure applies to all of the bulb

sockets.
Since the headlight bulb gets extremely hot,
1. Check:
keep flammable products and your hands
• Bulb socket (for continuity)
away from the bulb until it has cooled down.
(with the pocket tester)
ECB01960
No continuity → Replace.
NOTICE
• Be sure to hold the socket firmly when re- Pocket tester
moving the bulb. Never pull the lead, other- 90890-03112
wise it may be pulled out of the terminal in Analog pocket tester
the coupler. YU-03112-C
9-92
TIP 4. Remove:
Check each bulb socket for continuity in the • Headlight bulb holder “1”
same manner as described in the bulb section; • Headlight bulb “2”
EWB02860
however, note the following. WARNING
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Since the headlight bulb gets extremely hot,
a. Install a good bulb into the bulb socket. keep flammable products and your hands
b. Connect the pocket tester probes to the re- away from the bulb until it has cooled down.
spective leads of the bulb socket.
c. Check the bulb socket for continuity. If any of TIP
the readings indicate no continuity, replace Unhook the headlight bulb holder, and then re-
the bulb socket. move the defective bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30294 1 2
REPLACING THE HEADLIGHT BULBS
headlight bulbs.
1. Remove:
• Headlight rear cover “1”
5. Install:
• Headlight bulb New
Secure the new headlight bulb with the head-
light bulb holder.
ECB01350
NOTICE
Avoid touching the glass part of the head-
2. Remove:
light bulb to keep it free from oil, otherwise
• Headlight bulb holder cover “1”
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
1
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
6. Install:
• Headlight bulb holder
7. Connect:
• Headlight coupler
8. Install:
3. Disconnect: • Headlight bulb holder cover
ECB01970
• Headlight coupler “1”
NOTICE
1 Make sure the headlight bulb holder cover is
securely fitted over the bulb holder and seat-
ed properly.
TIP
Pass the headlight lead “1” through the slot “a” in
the headlight unit as shown, and then reinstall
the bulb holder cover.
9-93
Amperage
No. Fuses Q’ty
rating
1 EPS (for EPS models) 40.0 A 1
1
a 2 Main 40.0 A 1
3 Radiator fan motor 25.0 A 1
4 Headlight 15.0 A 1
5 Backup 10.0 A 1
6 Fuel injection system 10.0 A 1
9. Install: 7 Ignition 10.0 A 1
• Headlight rear cover 8 Differential motor 10.0 A 1
EBS30295 9 Signaling system 10.0 A 1
ADJUSTING THE HEADLIGHT BEAMS 10 Auxiliary DC jack 10.0 A 1
11 Spare 25.0 A 1
headlights.
1. Adjust: 12 Spare 15.0 A 1
• Headlight beam (vertically) 13
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Spare 10.0 A 2
14
“b”.
2 1 6
Direction “a”
Headlight beam is raised.
Direction “b”
Headlight beam is lowered. 11 13 3
12 14
5 7 8 10 9 4
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and
check the continuity.
a b
TIP
Set the pocket tester selector to “Ω × 1”.
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Pocket tester

EBS30296
90890-03112
CHECKING THE FUSES Analog pocket tester
The following procedure applies to all of the fus- YU-03112-C
es.
ECB01980
b. If the pocket tester indicates “∞”, replace the
NOTICE fuse.
To avoid a short circuit, always set the main ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
switch to “OFF” when checking or replacing 3. Replace:

a fuse. • Blown fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1. Remove: a. Turn the main switch to “ ” (off).
• Hood b. Install a new fuse of the correct amperage
Refer to “GENERAL CHASSIS (6)” on page rating.
4-12. c. Set on the switches to verify if the electrical
2. Check: circuit is operational.
• Fuse
9-94
d. If the fuse immediately blows again, check ECB01990
the electrical circuit. NOTICE

EWB02850 • This is a VRLA (Valve Regulated Lead Acid)
WARNING battery. Never remove the sealing caps be-
Never use a fuse with an amperage rating cause the balance between cells will not be
other than that specified. Improvising or us- maintained and battery performance will
ing a fuse with the wrong amperage rating deteriorate.
may cause extensive damage to the electri- • Charging time, charging amperage and
cal system, cause the lighting and ignition charging voltage for a VRLA (Valve Regu-
systems to malfunction and could possibly lated Lead Acid) battery are different from
cause a fire. those of conventional batteries. The VRLA
(Valve Regulated Lead Acid) battery should
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
be charged according to the appropriate
4. Install: charging method. If the battery is over-
• Hood charged, the electrolyte level will drop con-
Refer to “GENERAL CHASSIS (6)” on page siderably. Therefore, take special care
4-12. when charging the battery.
EBS30297
CHECKING AND CHARGING THE BATTERY TIP

EWB02830 Since VRLA batteries are sealed, it is not possi-
WARNING ble to check the charge state of the battery by
Batteries generate explosive hydrogen gas measuring the specific gravity of the electrolyte.
and contain electrolyte which is made of poi- Therefore, the charge of the battery has to be
sonous and highly caustic sulfuric acid. checked by measuring the voltage at the battery
Therefore, always follow these preventive terminals.
measures: 1. Remove:
• Wear protective eye gear when handling or • Hood
working near batteries. Refer to “GENERAL CHASSIS (6)” on page
• Charge batteries in a well-ventilated area. 4-12.
• Keep batteries away from fire, sparks or 2. Disconnect:
open flames (e.g., welding equipment, • Battery leads
lighted cigarettes). (from the battery terminals)
• DO NOT SMOKE when charging or han- ECB01340
dling batteries. NOTICE

• KEEP BATTERIES AND ELECTROLYTE First, disconnect the negative battery lead
OUT OF REACH OF CHILDREN. “1”, and then positive battery lead “2”.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
2
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
1
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes and
get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical atten- 3. Remove:
tion. • Battery
4. Check:
• Battery charge
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a pocket tester to the battery termi-
nals.
9-95
• Positive tester probe → 5. Charge:

positive battery terminal • Battery
• Negative tester probe → (refer to the appropriate charging method)
negative battery terminal EWB02840
WARNING
TIP Do not quick charge a battery.
• The charge state of a VRLA (Valve Regulated ECB02000
Lead Acid) battery can be checked by measur- NOTICE
ing its open-circuit voltage (i.e., the voltage
• Do not use a high-rate battery charger
when the positive battery terminal is discon-
since it forces a high-amperage current
nected).
into the battery quickly and can cause bat-
• No charging is necessary when the open-cir-
tery overheating and battery plate damage.
cuit voltage equals or exceeds 12.8 V.
• If it is impossible to regulate the charging
b. Check the charge of the battery, as shown in current on the battery charger, be careful
the charts and the following example. not to overcharge the battery.
Example • When charging a battery, be sure to remove
Open-circuit voltage = 12.0 V it from the vehicle. (If charging has to be
Charging time = 6.5 hours done with the battery mounted on the vehi-
Charge of the battery = 20–30% cle, disconnect the negative battery lead
from the battery terminal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
• Make sure the battery charger lead clips are
in full contact with the battery terminal and
that they are not shorted. A corroded bat-
tery charger lead clip may generate heat in
the contact area and a weak clip spring may
A. Open-circuit voltage (V)
cause sparks.
B. Charging time (hours)
• If the battery becomes hot to the touch at
C. Relationship between the open-circuit voltage
and the charging time at 20 °C (68 °F) any time during the charging process, dis-
D. These values vary with the temperature, the connect the battery charger and let the bat-
condition of the battery plates, and the tery cool before reconnecting it. Hot
electrolyte level. batteries can explode!
• As shown in the following illustration, the
open-circuit voltage of a VRLA (Valve Reg-
ulated Lead Acid) battery stabilizes about
30 minutes after charging has been com-
pleted. Therefore, wait 30 minutes after
charging is completed before measuring
the open-circuit voltage.
A. Open-circuit voltage (V)

B. Charging condition of the battery (%)
C. Ambient temperature 20 °C (68 °F)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9-96
7. Connect:
• Battery leads
(to the battery terminals)
ECB01330
NOTICE
First, connect the positive battery lead “1”,
and then the negative battery lead “2”.
A. Open-circuit voltage (V) 2

1
B. Time (minutes)
C. Charging
D. Ambient temperature 20 °C (68 °F)
E. Check the open-circuit voltage.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
8. Check:
Charging method using a constant volt-
• Battery terminals
age charger
Dirt → Clean with a wire brush.
a. Measure the open-circuit voltage prior to
charging.
9. Install:
TIP • Hood
Voltage should be measured 30 minutes after Refer to “GENERAL CHASSIS (6)” on page
the engine is stopped. 4-12.
b. Connect a charger and ammeter to the bat- EBS30298
tery and start charging. CHECKING THE RELAYS

c. Make sure that the current is higher than the Check each switch for continuity with the pocket
standard charging current written on the bat- tester. If the continuity reading is incorrect, re-
tery. place the relay.
TIP
Pocket tester
If the current is lower than the standard charging
90890-03112
current written on the battery, this type of battery Analog pocket tester
charger cannot charge the VRLA (Valve Regu- YU-03112-C
lated Lead Acid) battery. A variable voltage
charger is recommended. 1. Disconnect the relay from the wire harness.
d. Charge the battery until the battery’s 2. Connect the pocket tester (Ω × 1) and battery
charging voltage is 15 V. (12 V) to the relay terminal as shown.
Check the relay operation.
TIP
Set the charging time at 20 hours (maximum).
e. Measure the battery open-circuit voltage after
leaving the battery unused for more than 30
minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• Battery
9-97
Starter relay Headlight relay

3 First step:
R
1
3
Br/B
R/Y L/Y 2
B
2 1 B G Y
Y
4 L
1. Positive battery terminal

2. Negative battery terminal 1. Positive tester probe
3. Positive tester probe 2. Negative tester probe
4. Negative tester probe 3. Negative tester probe
Result Result
Continuity Continuity
(between “3” and “4”) (between “1” and “2”)
No continuity
Load control relay (between “1” and “3”)
3 Second step:
4 + 3
5 +
2 4
1
2 1
B Br/R
Br/L B G Y
R Y
L

2. Negative battery terminal 1. Positive battery terminal
3. Positive tester probe 2. Negative battery terminal
4. Negative tester probe 3. Positive tester probe
4. Negative tester probe
Result 5. Negative tester probe
Continuity
(between “3” and “4”) Result
No continuity
(between “3” and “4”)
Continuity
9-98
Radiator fan motor relay Differential motor relay 1

First step:
1
3
Br/R
2
R/L Y/B B Br/R
R Br/R
B/Y
2. Negative battery terminal 1. Positive tester probe
3. Positive tester probe 2. Negative tester probe
4. Negative tester probe 3. Negative tester probe
Result Result
Continuity Continuity
(between “3” and “4”) (between “1” and “2”)
No continuity
Fuel injection system relay (between “1” and “3”)
3 Second step:
4 3
5 +
2 4
1
2
Br/R 1
Y/B B Br/R
Br/R
B/Y

2. Negative battery terminal 1. Positive battery terminal
3. Positive tester probe 2. Negative battery terminal
4. Negative tester probe 3. Positive tester probe
Result 5. Negative tester probe
Continuity
(between “3” and “4”) Result
No continuity
Continuity
9-99
Differential motor relay 2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Remove the spark plug cap from the spark
First step: plug lead.
b. Connect the pocket tester (Ω × 1k) to the
1
spark plug cap as shown.
3
Pocket tester
90890-03112
2 Analog pocket tester
G/R B Br/R YU-03112-C
Br/R
Br/B
1. Positive tester probe

Result
Continuity
No continuity
(between “1” and “3”) c. Measure the spark plug cap resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Second step:
EBS30300
3 CHECKING THE IGNITION COIL
5 + 1. Check:
4 • Primary coil resistance
2
1
Primary coil resistance
G/R B Br/R 2.16–2.64 Ω
Br/R
Br/B ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the ignition coil connectors from
1. Positive battery terminal the ignition coil terminals.
2. Negative battery terminal b. Connect the pocket tester (Ω × 1) to the igni-
3. Positive tester probe tion coil as shown.
Pocket tester
90890-03112
Result YU-03112-C
No continuity
(between “3” and “4”) • Positive tester probe →
Continuity brown/red “1”
(between “3” and “5”) • Negative tester probe →
orange “2”
EBS30299
CHECKING THE SPARK PLUG CAP

1. Check:
• Spark plug cap resistance
Resistance
10.0 kΩ
9-100
Minimum ignition spark gap

6.0 mm (0.24 in)
TIP
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the spark
plug.
c. Measure the primary coil resistance. b. Connect the ignition checker “1” as shown.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check: Ignition checker
90890-06754
• Secondary coil resistance
Oppama pet–4000 spark checker
Out of specification → Replace. YM-34487
Secondary coil resistance
8.64–12.96 kΩ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the igni-
tion coil.
b. Connect the pocket tester (Ω × 1k) to the ig-
nition coil as shown.
Pocket tester 2
90890-03112
2. Spark plug cap
YU-03112-C
c. Measure the ignition spark gap “a”.
• Positive tester probe → d. Crank the engine by turning the main switch
brown/red “1” to “ ” (start) and gradually increase the
• Negative tester probe → spark gap until a misfire occurs.
Spark plug lead “2”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30302
CHECKING THE CRANKSHAFT POSITION

SENSOR
1. Disconnect:
• Crankshaft position sensor coupler
(from the wire harness)
2. Check:
• Crankshaft position sensor resistance
Out of specification → Replace the crank-
shaft position sensor/stator assembly.
c. Measure the secondary coil resistance.
Crankshaft position sensor resis-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
tance
EBS30301
152–228 Ω
CHECKING THE IGNITION SPARK GAP
1. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Ignition spark gap a. Connect the pocket tester (Ω × 100) to the
Out of specification → Perform the ignition crankshaft position sensor coupler as shown.
system troubleshooting, starting with step 5.
Refer to “TROUBLESHOOTING” on page
9-3.
9-101
• Positive tester probe →

Pocket tester yellow/green (wire harness color)
90890-03112 • Negative tester probe →
Analog pocket tester black/blue (wire harness color)
YU-03112-C
1
gray “1”
• Negative tester probe → 65˚ 65˚
black “2”

d. Turn the lean angle sensor to 65°.
Gy B
e. Measure the lean angle sensor output volt-
age.
1 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Measure the crankshaft position sensor re- EBS30304
sistance. CHECKING THE STARTER MOTOR

OPERATION
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1. Check:
EBS30303
CHECKING THE LEAN ANGLE SENSOR • Starter motor operation

1. Remove: Does not operate → Perform the electric
• Lean angle sensor starting system troubleshooting, starting with
2. Check: step 4.
• Lean angle sensor output voltage Refer to “TROUBLESHOOTING” on page
Out of specification → Replace. 9-8.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Lean angle sensor output voltage a. Connect the positive battery terminal “1” and
Less than 65°: 3.55–4.45 V starter motor lead “2” with a jumper lead “3”.
EWB02920
More than 65°: 0.65–1.35 V
WARNING
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • A wire that is used as a jumper lead must
a. Connect the test harness– lean angle sensor have at least the same capacity of the bat-
(3P) “1” between the lean angle sensor and tery lead, otherwise the jumper lead may
wire harness as shown. burn.
b. Connect the pocket tester (DC 20 V) to the • This check is likely to produce sparks,
test harness– lean angle sensor (3P). therefore, make sure no flammable gas or
fluid is in the vicinity.
Test harness– lean angle sensor
(3P)
90890-03213
Test harness– lean angle sensor
(3P)
YU-03213
Pocket tester
90890-03112
YU-03112-C
b. Check the starter motor operation.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9-102
EBS30305
CHECKING THE STATOR COIL Charging voltage

1. Disconnect: above 14 V at 5000 r/min
• Stator coil couplers
(from the wire harness) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2. Check: a. Connect the engine tachometer to the spark
• Stator coil resistance plug lead.
Out of specification → Replace the crank- b. Connect the pocket tester (DC 20 V) to the
shaft position sensor/stator assembly. battery as shown.
Stator coil resistance Pocket tester

0.15–0.22 Ω 90890-03112
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ YU-03112-C
a. Connect the digital circuit tester to the stator
coil coupler as shown. • Positive tester probe →
positive battery terminal “1”
Digital circuit tester • Negative tester probe →
90890-03174 negative battery terminal “2”
chometer
1
YU-A1927

white “1” 2
1
• Negative tester probe →
white “2”

white “1”
white “3” c. Start the engine and let it run at approximate-
ly 5000 r/min.
• Positive tester probe → d. Measure the charging voltage.
white “2” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30307
white “3”
CHECKING THE FUEL SENDER
1. Disconnect:
• Fuel pump coupler
(from the wire harness)
2. Remove:
• Fuel pump assembly
(from the fuel tank)
W W W
3. Check:
• Fuel sender resistance
Out of specification → Replace the fuel pump
3 2 1
assembly.
b. Measure the stator coil resistance.
Sender unit resistance (full)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
19.00–21.00 Ω
EBS30306
Sender unit resistance (empty)
CHECKING THE RECTIFIER/REGULATOR 139.00–141.00 Ω
1. Check:
• Charging voltage ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Out of specification → Replace the rectifi- a. Connect the pocket tester (Ω × 10 or Ω × 100)
er/regulator. to the fuel sender terminals as shown.
9-103
Warning light comes on for a few seconds,

Pocket tester then goes off → Warning light is OK.
90890-03112 Warning light does not come on → Replace
Analog pocket tester the meter assembly.
YU-03112-C
Warning light flashes eight times, then goes
off for 3 seconds in a repeated cycle (mal-
orange/black “1”
function detected in fuel sender) → Replace
• Negative tester probe → the fuel pump assembly.
black/white “2”
1
R/L B B/W O/B
1 2 EBS30309
CHECKING THE SPEED SENSOR

b. Move the fuel sender float to minimum “3” 1. Check:
and maximum “4” level positions. • Speed sensor output voltage
Output voltage reading cycle

0.6 V–4.8 V–0.6 V–4.8 V–0.6 V
4
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the test harness– speed sensor (3P)
“1” between the speed sensor coupler and
wire harness as shown.
b. Connect the pocket tester (DC 20 V) to the
test harness– speed sensor (3P).

90890-03208
YU-03208
3 Pocket tester
90890-03112
YU-03112-C

c. Measure the fuel sender resistance. white (wire harness color)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ black/blue (wire harness color)
EBS30308
CHECKING THE FUEL METER/FUEL LEVEL

WARNING LIGHT
This model is equipped with a self-diagnosis de-
vice for the fuel level detection circuit.
1. Check:
• Fuel meter/fuel level warning light “1”
(Turn the main switch to “ ” [on].)
9-104
b. Connect the battery to the radiator fan motor

coupler as shown.
• Positive battery terminal →
1
blue “1”
• Negative battery terminal →
black “2”

d. Elevate the rear wheels and slowly rotate
them.
e. Measure the voltage (DC 20 V) of white and
black/blue. With each full rotation of the rear
wheels, the voltage reading should cycle
from 0.6 V to 4.8 V to 0.6 V to 4.8 V. c. Check the radiator fan motor movement.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30354
EBS30311
CHECKING THE PARKING BRAKE BUZZER CHECKING THE RADIATOR FAN MOTOR
1. Check: CIRCUIT BREAKER
• Parking brake buzzer 1. Remove:
Does not sound → Replace. • Radiator fan motor circuit breaker
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the parking brake buzzer coupler (from the wire harness)
from the wire harness.
b. Connect the battery to the parking brake
buzzer coupler as shown.
• Positive battery terminal →
brown “1”
• Negative battery terminal →
pink “2”
2. Check:
• Radiator fan motor circuit breaker resistance
P Br 1 Out of specification → Replace the radiator
2 fan motor circuit breaker.
Radiator fan motor circuit break-

er resistance
0–0.05 Ω at 25 °C (77 °F)
c. Check the parking brake buzzer sound.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. Connect the digital circuit tester to the radia-
EBS30310
tor fan motor circuit breaker as shown.
CHECKING THE RADIATOR FAN MOTOR
1. Check: Digital circuit tester
• Radiator fan motor 90890-03174
Faulty/rough movement → Replace. Model 88 Multimeter with ta-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ chometer
a. Disconnect the radiator fan motor coupler YU-A1927
from the wire harness.
9-105
3
1
b. Measure the radiator fan motor circuit break- d. Heat the coolant or let it cool down to the
er resistance. specified temperatures.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ e. Measure the coolant temperature sensor re-
EBS30312
sistance.
CHECKING THE COOLANT TEMPERATURE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
SENSOR 3. Install:
1. Remove: • Coolant temperature sensor
• Coolant temperature sensor
EWB02950
Coolant temperature sensor
WARNING T.
R.
20 Nm (2.0 m·kgf, 14 ft·lbf)
• Handle the coolant temperature sensor
with special care. EBS30313
• Never subject the coolant temperature sen- CHECKING THE THROTTLE POSITION
sor to strong shocks. If the coolant tem- SENSOR
perature sensor is dropped, replace it. 1. Remove:
• Throttle position sensor
2. Check: (from the throttle body)
• Coolant temperature sensor resistance EWB03070
Out of specification → Replace. WARNING

• Handle the throttle position sensor with
Coolant temperature sensor re- special care.
sistance
• Never subject the throttle position sensor
2.32–2.59 kΩ at 20 °C (68 °F)
310–326 Ω at 80 °C (176 °F) to strong shocks. If the throttle position
sensor is dropped, replace it.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 2. Check:
a. Connect the pocket tester (Ω × 1k or Ω × 100) • Throttle position sensor maximum resistance
to the coolant temperature sensor terminals Out of specification → Replace the throttle
as shown. position sensor.
Pocket tester Resistance
90890-03112 2.64–6.16 kΩ
YU-03112-C ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1k) to the
b. Immerse the coolant temperature sensor “1” throttle position sensor terminals as shown.
in a container filled with coolant “2”.
TIP Pocket tester
Make sure the coolant temperature sensor ter- 90890-03112
minals do not get wet. Analog pocket tester
YU-03112-C
c. Place a thermometer “3” in the coolant.
blue “1”
black/blue “2”
9-106
Test harness S– pressure sensor

5S7 (3P)
90890-03211
Test harness S– pressure sensor
5S7 (3P)
YU-03211
Digital circuit tester
90890-03174
chometer
b. Measure the throttle position sensor maxi- YU-A1927
mum resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Positive tester probe →
3. Install: pink (wire harness color)
• Throttle position sensor black/blue (wire harness color)
TIP
When installing the throttle position sensor, ad-
just its angle properly. Refer to “ADJUSTING 1
THE THROTTLE POSITION SENSOR” on page
7-13.
EBS30314
CHECKING THE INTAKE AIR PRESSURE

SENSOR
EWB03210
WARNING
• Handle the intake air pressure sensor with c. Turn the main switch to “ ” (on).
special care. d. Measure the intake air pressure sensor out-
• Never subject the intake air pressure sen- put voltage.
sor to strong shocks. If the intake air pres- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
sure sensor is dropped, replace it. EBS30315
1. Check: CHECKING THE INTAKE AIR

• Intake air pressure sensor output voltage TEMPERATURE SENSOR
Out of specification → Replace. 1. Remove:
• Intake air temperature sensor
Intake air pressure sensor output (from the air filter case.)
voltage EWB02940
3.594–3.684 V at 101 kPa (1.01 WARNING

kgf/cm², 14 psi) • Handle the intake air temperature sensor
with special care.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Never subject the intake air temperature
a. Connect the test harness S– pressure sensor
sensor to strong shocks. If the intake air
5S7 (3P) “1” between the intake air pressure
temperature sensor is dropped, replace it.
sensor and wire harness as shown.
b. Connect the digital circuit tester to the test 2. Check:
harness S– pressure sensor 5S7 (3P). • Intake air temperature sensor resistance
Intake air temperature sensor re-

sistance
5.40–6.60 kΩ at 0 °C (32 °F)
290–390 Ω at 80 °C (176 °F)
9-107
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Positive tester probe

a. Connect the pocket tester (Ω × 1k or Ω × 100) Fuel injector terminal “1”
to the intake air temperature sensor terminals • Negative tester probe
as shown. Fuel injector terminal “2”
Pocket tester
90890-03112
1 2
YU-03112-C
R/L R
b. Immerse the intake air temperature sensor
“1” in a container filled with water “2”.
TIP
Make sure that the intake air temperature sensor
terminals do not get wet.
c. Measure the fuel injector resistance.
c. Place a thermometer “3” in the water.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30317
3 CHECKING THE AIR INDUCTION SYSTEM

1 SOLENOID
1. Check:
• Air induction system solenoid resistance
2 Solenoid resistance
18.0–22.0 Ω
d. Heat the water or let it cool down to the spec- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

ified temperatures. a. Disconnect the air induction system solenoid
e. Measure the intake air temperature sensor coupler from the wire harness.
resistance. b. Connect the pocket tester (Ω × 1) to the air in-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
duction system solenoid terminals as shown.
EBS30316
Pocket tester
CHECKING THE FUEL INJECTOR
90890-03112
1. Check: Analog pocket tester
• Fuel injector resistance YU-03112-C
Out of specification → Replace the fuel injec-
tor. • Positive tester probe →
Air induction system solenoid terminal “1”
Fuel injector resistance • Negative tester probe →
11.5–12.5 Ω Air induction system solenoid terminal “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the fuel injector coupler from wire
2 1
harness.
b. Connect the pocket tester (Ω × 1) to the fuel
injector terminals as shown.
Br/Y R/W
Pocket tester
90890-03112
YU-03112-C
c. Measure the air induction system solenoid re-
sistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9-108
EBS30318
g. Check the differential motor position switch
CHECKING THE DIFFERENTIAL MOTOR
no continuity.
POSITION SWITCH
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1. Check:
• Differential motor position switch EBS30319
CHECKING THE EPS MOTOR (for EPS

models)
Pocket tester 1. Remove:
90890-03112 • EPS unit
Analog pocket tester 2. Check:
YU-03112-C • EPS motor
Out of specification → Replace the EPS unit.
TIP TIP
Check the differential motor position switch for The pocket tester and the analog pocket tester
continuity between the terminals “1” and “3” and readings are shown in the following table.
between the terminals “2” and “3” when the On-
Command four-wheel-drive switch is set to the Continuity
“2WD”, “4WD”, and “DIFF LOCK” positions. Positive tester probe → red “1”
Negative tester probe → black
2WD position “2”
No continuity No continuity
(between “1” and “3”) Positive tester probe → red “1”
(between “2” and “3”) Negative tester probe → EPS
4WD position motor body “3”
Continuity No continuity
(between “2” and “3”) Positive tester probe → black
No continuity “2”
(between “1” and “3”) Negative tester probe → EPS
DIFF LOCK position motor body “3”
Continuity
No continuity 2 1
3
B R
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1) to the EPS
motor coupler terminal and EPS motor body.
1 2 3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Pocket tester
a. Turn the main switch to “ ” (on). 90890-03112
b. Set the On-Command four-wheel-drive Analog pocket tester
switch to “2WD”, “4WD”, or “DIFF LOCK” po- YU-03112-C
sition.
c. Turn the main switch to “ ” (off). b. Check the EPS motor for continuity.
d. Disconnect the differential motor coupler. c. Check the EPS motor for no continuity.
e. Connect the pocket tester (Ω × 1) to the differ- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ential motor terminals.

f. Check the differential motor position switch
continuity.
9-109
EBS30320
CHECKING THE EPS TORQUE SENSOR (for

EPS models)
1. Remove:
• EPS unit
ECB01660
NOTICE
Make sure do not remove the torque sensor
and its protector from the EPS unit.
2. Check:
• EPS torque sensor resistance
Out of specification → Replace the steering
column.
EPS torque sensor

Coil resistance
0.875–1.625 kΩ (for EPS mod-
els)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1k) to the EPS
torque sensor coupler terminals as shown.
Pocket tester
90890-03112
YU-03112-C

red “1”
black “2”
1
2
G R
B W
b. Measure the EPS torque sensor resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9-110
9-111
TROUBLESHOOTING
TROUBLESHOOTING...................................................................................10-1
GENERAL INFORMATION ..................................................................... 10-1
STARTING FAILURES............................................................................10-1
INCORRECT ENGINE IDLING SPEED .................................................. 10-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......................... 10-2
FAULTY DRIVE TRAIN ...........................................................................10-3
FAULTY GEAR SHIFTING...................................................................... 10-4
SHIFT LEVER DOES NOT MOVE .......................................................... 10-4
JUMPS OUT OF GEAR...........................................................................10-4
FAULTY CLUTCH PERFORMANCE ......................................................10-4
OVERHEATING ......................................................................................10-4
OVERCOOLING......................................................................................10-5
POOR BRAKING PERFORMANCE........................................................ 10-5
FAULTY SHOCK ABSORBER ASSEMBLY............................................10-5
UNSTABLE HANDLING ..........................................................................10-5
FAULTY LIGHTING OR SIGNALING SYSTEM ...................................... 10-5
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE..........10-7

SELF-DIAGNOSTIC FUNCTION TABLE ................................................ 10-7
COMMUNICATION ERROR WITH THE METER ................................... 10-7
DIAGNOSTIC CODE: SENSOR OPERATION TABLE ........................... 10-8
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ......................10-9
10
TROUBLESHOOTING
EBS20085
Electrical system
TROUBLESHOOTING 1. Battery
EBS30321
• Discharged battery
GENERAL INFORMATION • Faulty battery
TIP 2. Fuse(s)
• Blown, damaged or incorrect fuse
The following guide for troubleshooting does not
• Improperly installed fuse
cover all the possible causes of trouble. It should
3. Spark plug
be helpful, however, as a guide to basic trouble-
• Incorrect spark plug gap
shooting. Refer to the relative procedure in this
• Incorrect spark plug heat range
manual for checks, adjustments, and replace-
• Fouled spark plug
ment of parts.
• Worn or damaged electrode
EBS30322
• Worn or damaged insulator
STARTING FAILURES • Faulty spark plug cap
4. Ignition coil
Engine • Cracked or broken ignition coil body
1. Cylinder and cylinder head • Broken or shorted primary or secondary coils
• Loose spark plug • Faulty spark plug lead
• Loose cylinder head or cylinder 5. Ignition system
• Damaged cylinder head gasket • Faulty ECU
• Damaged cylinder gasket • Faulty crankshaft position sensor
• Worn or damaged cylinder • Broken AC magneto rotor woodruff key
• Incorrect valve clearance 6. Switches and wiring
• Improperly sealed valve • Faulty main switch
• Incorrect valve-to-valve-seat contact • Broken or shorted wiring
• Incorrect valve timing • Faulty gear position switch
• Faulty valve spring • Improperly grounded circuit
• Seized valve • Loose connections
2. Piston and piston ring(s) • Faulty brake light switch
• Improperly installed piston ring 7. Starting system
• Damaged, worn or fatigued piston ring • Faulty starter motor
• Seized piston ring • Faulty starter relay
• Seized or damaged piston • Faulty starter clutch
3. Air filter EBS30323
• Improperly installed air filter INCORRECT ENGINE IDLING SPEED
• Clogged air filter element
4. Crankcase and crankshaft Engine
• Improperly assembled crankcase 1. Cylinder and cylinder head
• Seized crankshaft • Incorrect valve clearance
• Damaged valve train components
Fuel system 2. Air filter
1. Fuel tank • Clogged air filter element
• Empty fuel tank
• Clogged fuel tank breather hose joint Fuel system
• Clogged fuel tank breather hose joint hose 1. Throttle body
• Deteriorated or contaminated fuel • Damaged or loose throttle body joint
2. Fuel pump • Faulty ISC (Idle Speed Control) unit
• Faulty fuel pump • Improper throttle cable free play
• Faulty fuel injection system relay • Flooded throttle body
• Clogged or damaged fuel hose • Faulty air induction system
3. Throttle body
• Deteriorated or contaminated fuel
• Sucked-in air
10-1
TROUBLESHOOTING
Electrical system
1. Battery
• Discharged battery
• Faulty battery
2. Spark plug
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
3. Ignition coil
• Broken or shorted primary or secondary coils
• Faulty spark plug lead
• Cracked or broken ignition coil
4. Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
• Broken AC magneto rotor woodruff key
EBS30324
POOR MEDIUM-AND-HIGH-SPEED
PERFORMANCE
Refer to “STARTING FAILURES” on page 10-1.
Engine
1. Air filter
• Clogged air filter element
Fuel system
1. Fuel pump
• Faulty fuel pump
10-2
TROUBLESHOOTING
EBS30325
FAULTY DRIVE TRAIN

The following conditions may indicate damaged shaft drive components:
Symptoms Possible Causes
1. A pronounced hesitation or “jerky” movement A. Bearing damage.
during acceleration, deceleration, or sustained B. Improper gear backlash.
speed. (This must not be confused with engine C. Gear tooth damage.
surging or transmission characteristics.) D. Broken drive shaft.
2. A “rolling rumble” noticeable at low speed; a high- E. Broken gear teeth.
pitched whine; a “clunk” from a shaft drive com- F. Seizure due to lack of lubrication.
ponent or area. G. Small foreign objects lodged between the moving
3. A locked-up condition of the shaft drive mecha- parts.
nism, no power transmitted from the engine to the
front and/or rear wheels.
TIP
Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite subtle and
difficult to distinguish from normal vehicle operating noise. If there is reason to believe these compo-
nents are damaged, remove the components and check them.
10-3
TROUBLESHOOTING
EBS30326
Poor starting performance
FAULTY GEAR SHIFTING
1. V-belt
• V-belt slips
Shifting is difficult
• Oil or grease on the V-belt
Refer to “FAULTY CLUTCH PERFORMANCE”
2. Primary and secondary sheaves
on page 10-4.
• Faulty operation
EBS30327 • Worn pin groove
SHIFT LEVER DOES NOT MOVE • Worn pin
3. Clutch shoe
Shift drum and shift forks • Bent, damaged or worn clutch shoe
• Foreign object in a shift drum groove
• Seized shift fork Poor speed performance
• Bent shift fork guide bar 1. V-belt
• Oil or grease on the V-belt
Transmission 2. Primary pulley weight(s)
• Seized transmission gear • Faulty operation
• Foreign object between transmission gears • Worn primary pulley weight
• Improperly assembled transmission 3. Primary fixed sheave
EBS30328 • Worn primary fixed sheave
JUMPS OUT OF GEAR 4. Primary sliding sheave
• Worn primary sliding sheave
Shift forks 5. Secondary fixed sheave
• Worn shift fork • Worn secondary fixed sheave
6. Secondary sliding sheave
Shift drum • Worn secondary sliding sheave
• Incorrect axial play
EBS30330
• Worn shift drum groove
OVERHEATING
Transmission
Engine
• Worn gear dog
1. Clogged coolant passages
EBS30329 2. Cylinder head and piston
FAULTY CLUTCH PERFORMANCE • Heavy carbon buildup
3. Engine oil
Engine operates but vehicle will not move • Incorrect oil level
1. V-belt • Incorrect oil viscosity
• Bent, damaged or worn V-belt • Inferior oil quality
• Slipping V-belt
2. Primary sheave cam and primary sheave Cooling system
slider 1. Coolant
• Damaged or worn primary sheave cam • Low coolant level
• Damaged or worn primary sheave slider 2. Radiator
3. Clutch spring(s) • Damaged or leaking radiator
• Damaged clutch spring • Faulty radiator cap
4. Transmission gear(s) • Bent or damaged radiator fin
• Damaged transmission gear 3. Water pump
• Damaged or faulty water pump
Clutch slips 4. Thermostat
1. Clutch spring(s) • Thermostat stays closed
• Damaged, loose or worn clutch spring 5. Oil cooler
2. Clutch shoe(s) • Clogged or damaged oil cooler
• Damaged or worn clutch shoe 6. Hose(s) and pipe(s)
3. Primary sliding sheave • Damaged hose
• Seized primary sliding sheave • Improperly connected hose
10-4
TROUBLESHOOTING
• Damaged pipe • Bent or damaged damper rod

• Improperly connected pipe
EBS30334
UNSTABLE HANDLING
Fuel system 1. Steering wheel
1. Throttle body • Bent or improperly installed steering wheel
• Faulty throttle body 2. Steering components
• Damaged or loose throttle body joint • Incorrect toe-in
2. Air filter • Bent steering shaft
• Clogged air filter element • Improperly installed steering shaft
• Damaged bearing or bearing race
Chassis
• Bent tie-rods
1. Brake(s)
• Deformed steering knuckles
• Dragging brake
3. Shock absorber assembly(-ies)
• Faulty shock absorber spring
Electrical system
• Leaking gas
1. Spark plug
4. Tire(s)
• Uneven tire pressures (left and right)
• Incorrect tire pressure
2. Ignition system
• Uneven tire wear
• Faulty ECU
5. Wheel(s)
3. Radiator fan
• Damaged wheel bearing
• Faulty fan motor
• Bent or loose wheel axle
• Disconnected circuit breaker terminal
• Excessive wheel runout
• Faulty coolant temperature sensor
6. Frame
EBS30331 • Bent frame
OVERCOOLING • Damaged frame
Cooling system EBS30335
1. Thermostat FAULTY LIGHTING OR SIGNALING SYSTEM

• Thermostat stays open
Headlight does not come on
EBS30332 • Wrong headlight bulb
POOR BRAKING PERFORMANCE • Too many electrical accessories
• Worn brake pad • Hard charging
• Worn brake disc • Incorrect connection
• Air in hydraulic brake system • Improperly grounded circuit
• Leaking brake fluid • Poor contacts (light switch)
• Faulty brake caliper kit • Burnt-out headlight bulb
• Faulty brake caliper seal
• Loose union bolt Headlight bulb burnt out
• Damaged brake hose • Wrong headlight bulb
• Oil or grease on the brake disc • Faulty battery
• Oil or grease on the brake pad • Faulty rectifier/regulator
• Incorrect brake fluid level • Improperly grounded circuit
EBS30333
• Faulty light switch
FAULTY SHOCK ABSORBER ASSEMBLY • Headlight bulb life expired
Leaking gas Tail/brake light does not come on

• Bent or damaged damper rod • Wrong tail/brake light bulb
• Cracked or damaged shock absorber • Too many electrical accessories
• Damaged oil seal lip • Incorrect connection
• Burnt-out tail/brake light bulb
Malfunction
• Fatigued or damaged shock absorber spring
10-5
TROUBLESHOOTING
Tail/brake light bulb burnt out

• Wrong tail/brake light bulb
• Faulty battery
• Faulty brake light switch
• Tail/brake light bulb life expired
• Faulty rectifier/regulator
• Improperly grounded circuit
10-6
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EBS20086

EBS30336
SELF-DIAGNOSTIC FUNCTION TABLE

TIP
For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 9-38.
Fault code
Item
No.
Crankshaft position sensor: no normal signals are received from the crankshaft position sen-
12
sor.
13 Intake air pressure sensor: open or short circuit detected.
14 Intake air pressure sensor: hose system malfunction (clogged or detached hose).
15 Throttle position sensor: open or short circuit detected.
16 Throttle position sensor: stuck throttle position sensor is detected.
21 Coolant temperature sensor: open or short circuit detected.
22 Intake air temperature sensor: open or short circuit detected.
30 Latch up detected.
33 Ignition coil: open or short circuit detected in the primary lead of the ignition coil.
Component other than ISC (Idle Speed Control) unit is defective (ISC operating sound is
37 heard).
Defective ISC (Idle Speed Control) unit (ISC operating sound is not heard).
39 Fuel injector: open or short circuit detected.
41 Lean angle sensor: open or short circuit detected.
42 Speed sensor: no normal signals are received from the speed sensor.
43 Fuel system voltage: incorrect voltage supplied to the fuel injector and fuel pump.
44 EEPROM fault code number: an error is detected while reading or writing on EEPROM.
46 Charging voltage is abnormal.
Faulty ECU (Engine Control Unit) memory. (When this malfunction is detected in the ECU, the
50
fault code number might not appear.)
EBS30337
COMMUNICATION ERROR WITH THE METER

TIP
For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 9-38.
Fault code
Item
No.
ECU (Engine Control Unit) internal malfunction (output signal error): signals cannot be trans-
Er-1
mitted between the ECU and the multi-function meter.
ECU (Engine Control Unit) internal malfunction (output signal error): no signals are received
Er-2
from the ECU within the specified duration.
ECU (Engine Control Unit) internal malfunction (output signal error): data from the ECU cannot
Er-3
be received correctly.
ECU (Engine Control Unit) internal malfunction (input signal error): non-registered data has
Er-4
been received from the meter assembly.
10-7
EBS30338
DIAGNOSTIC CODE: SENSOR OPERATION TABLE

TIP
The diagnostic code numbers cannot be displayed on the multi-function meter. To display the diagnos-
tic code numbers, use the Yamaha diagnostic tool.
Diagnostic
Item Display Procedure
code No.
01 Throttle position sensor sig- Check with throttle valve fully
nal closed.
• Fully closed position 14–20
03 Intake air pressure Displays the intake air pres- Turn and hold the main
sure. switch in the “ ” (start) posi-
tion, then press the accelera-
tor pedal. (If the display value
changes, the performance is
OK.)
05 Intake air temperature When engine is cold: Dis- Compare the actually mea-
plays temperature closer to sured intake air temperature
ambient temperature. with the indicated value.
When engine is hot: Displays
ambient temperature 20 °C
(68 °F).
06 Coolant temperature When engine is cold: Dis- Compare the actually mea-
plays temperature closer to sured coolant temperature
ambient temperature. with the indicated value.
When engine is hot: Displays
current coolant temperature.
07 Vehicle speed pulse 0–999 Check that the number in-
creases when the rear
wheels are rotated. The
number is cumulative and
does not reset each time the
wheel is stopped.
08 Lean angle sensor Lean angle sensor output Remove the lean angle sen-
voltage sor and incline it more than
• Upright 3.6–4.4 65 degrees.
• Overturned 0.7–1.3
09 Fuel system voltage (battery Approximately 12.0 Turn the main switch to “ ”
voltage) (on), and then compare the
actually measured battery
voltage with the display val-
ue. (If the actually measured
battery voltage is low, re-
charge the battery.)
21 Gear position switch Shift the transmission.
• Transmission is in neutral ON
• Transmission is in gear OFF
60 EEPROM fault code display
• No history 00 —
• No malfunctions detected
(If the fault code 44 is indi-
cated, the ECU is defec-
tive.)
10-8
Diagnostic
Item Display Procedure
code No.
61 Malfunction history code dis-
play
• History exists Fault codes 12–50 —
• (If more than one code
number is detected, the
display alternates every
two seconds to show all the
detected code numbers.
When all code numbers are
shown, the display repeats
the same process.)
62 Malfunction history code era-
sure
• History exists • Displays the total number Save the malfunction history
of malfunctions, including to the computer, and then
the current malfunction, delete the fault codes.
that have occurred since
the history was last erased.
(For example, if there have
been three malfunctions,
“03” is displayed.)
70 Control number 0–254 [-] —
EBS30339
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diagnostic
Item Actuation Procedure
code No.
30 Ignition coil Actuates the ignition coil five Check that a spark is gener-
times at one-second inter- ated five times.
vals. • Connect an ignition check-
The “CHECK” indicator and er.
“ ” on the Yamaha diag-
nostic tool screen come on
each time the ignition coil is
actuated.
36 Fuel injector Actuates the fuel injector five Disconnect the fuel pump
times at one-second inter- coupler. Check that the fuel
vals. injector is actuated five times
The “CHECK” indicator and by listening for the operating
“ ” on the Yamaha diag- sound.
each time the fuel injector is
actuated.
48 Air induction system solenoid Actuates the air induction Check that the air induction
system solenoid five times at system solenoid is actuated
one-second intervals. five times by listening for the
The “CHECK” indicator and operating sound.
each time the air induction
system solenoid is actuated.
10-9
Diagnostic
Item Actuation Procedure
code No.
50 Fuel injection system relay Actuates the fuel injection Check that the fuel injection
system relay five times at system relay unit is actuated
one-second intervals. five times by listening for the
The “CHECK” indicator and operating sound.
each time the relay is actuat-
ed.
(When the relay is on, the
“CHECK” indicator and “ ”
on the Yamaha diagnostic
tool screen go off. When the
relay is off, the “CHECK” in-
dicator and “ ” on the
screen come on.)
51 Radiator fan motor relay Actuates the radiator fan mo- Check that the radiator fan
tor relay five times at five- motor relay is actuated five
second intervals. (2 seconds times by listening for the op-
on, 3 seconds off) erating sound.
The “CHECK” indicator and
each time the relay is actuat-
ed.
(When the relay is on, the
“CHECK” indicator and “ ”
on the Yamaha diagnostic
tool screen go off. When the
relay is off, the “CHECK” in-
dicator and “ ” on the
screen come on.)
54 ISC valve Fully closes the ISC valve, The operating sound can be
and then opens the valve. heard when ISC valve oper-
This operation takes approxi- ates.
mately 3 seconds.
The “CHECK” indicator and
during the operation.
10-10
EBS20008
55. Auxiliary DC jack YX70EPNG/YXE70WPXG/
WIRING DIAGRAM 56. Brake light switch YXE70WPHG/YXE700E 2016
YXE70WDXG 2016 57. Tail/brake light 1. Crankshaft position sensor
1. Crankshaft position sensor 58. Radiator fan motor fuse 2. AC magneto
2. AC magneto 59. Differential motor fuse 3. Rectifier/regulator
3. Rectifier/regulator 60. Ignition fuse 4. Load control relay
4. Load control relay 61. Backup fuse 5. Frame ground
5. Frame ground 62. Signaling system fuse 6. Main switch
6. Main switch 63. Headlight fuse 7. Engine ground
7. Engine ground 64. Auxiliary DC jack fuse 8. Battery
8. Battery 65. Radiator fan motor 9. Main fuse
9. Main fuse 66. Radiator fan motor circuit 10. EPS fuse
10. Fuel injection system fuse breaker 11. Fuel injection system fuse
11. Starter relay 67. Radiator fan motor relay 12. Starter relay
12. Starter motor 68. Horn switch 13. Starter motor
13. Fuel injection system relay 69. Horn 14. Fuel injection system relay
14. Air induction system solenoid 70. Backup light 15. Air induction system solenoid
15. Differential motor relay 1 71. Backup light relay 16. Differential motor relay 1
16. Differential motor A. Optional 17. Differential motor
17. Gear position switch B. Wire harness 18. Gear position switch
18. On-Command four-wheel-drive C. Negative battery sub-wire har- 19. On-Command four-wheel-drive
switch ness switch
19. Yamaha diagnostic tool coupler 20. Yamaha diagnostic tool coupler
20. ISC (Idle Speed Control) unit 21. ISC (Idle Speed Control) unit
21. ECU (Engine Control Unit) 22. ECU (Engine Control Unit)
22. Ignition coil 23. Ignition coil
23. Spark plug 24. Spark plug
24. Fuel injector 25. Fuel injector
25. Intake air temperature sensor 26. Intake air temperature sensor
26. Coolant temperature sensor 27. Coolant temperature sensor
27. Speed sensor 28. Speed sensor
28. TPS (throttle position sensor) 29. TPS (throttle position sensor)
29. Intake air pressure sensor 30. Intake air pressure sensor
30. Lean angle sensor 31. Lean angle sensor
31. Parking brake switch 32. Parking brake switch
32. Parking brake buzzer 33. Parking brake buzzer
33. Reverse switch 34. Reverse switch
34. Joint coupler 35. Joint coupler
35. Seat belt switch 36. EPS unit
36. Indicator light assembly 37. EPS motor
37. Helmet indicator light 38. EPS torque sensor
38. Seat belt indicator light 39. EPS self-diagnosis signal con-
39. Meter assembly nector
40. Multi-function meter 40. EPS control unit
41. Engine trouble warning light 41. Seat belt switch
42. Coolant temperature warning 42. Indicator light assembly
light 43. Helmet indicator light
43. Parking brake indicator light 44. Seat belt indicator light
44. Reverse indicator light 45. Meter assembly
45. Neutral indicator light 46. Multi-function meter
46. High-range indicator light 47. Engine trouble warning light
47. Low-range indicator light 48. Coolant temperature warning
48. On-Command differential gear light
lock indicator light 49. Parking brake indicator light
49. Fuel sender 50. Reverse indicator light
50. Fuel pump 51. Neutral indicator light
51. Differential motor relay 2 52. High-range indicator light
52. Light switch 53. Low-range indicator light
53. Headlight relay 54. On-Command differential gear
54. Headlight lock indicator light
55. EPS warning light EBS30002
56. Fuel sender COLOR CODE

57. Fuel pump B Black
58. Differential motor relay 2 Br Brown
59. Light switch G Green
60. Headlight relay Gy Gray
61. Headlight L Blue
62. Auxiliary DC jack Lg Light green
63. Brake light switch O Orange
64. Tail/brake light P Pink
R Red
65. Radiator fan motor fuse
Sb Sky blue
66. Four-wheel-drive motor fuse
W White
67. Ignition fuse
Y Yellow
68. Backup fuse B/G Black/Green
69. Signaling system fuse B/L Black/Blue
70. Headlight fuse B/R Black/Red
71. Auxiliary DC jack fuse B/W Black/White
72. Radiator fan motor B/Y Black/Yellow
73. Radiator fan motor circuit Br/B Brown/Black
breaker Br/L Brown/Blue
74. Radiator fan motor relay Br/R Brown/Red
75. Horn switch (except for CDN) Br/W Brown/White
76. Horn (except for CDN) Br/Y Brown/Yellow
77. Backup light G/R Green/Red
78. Backup light relay G/W Green/White
A. Optional G/Y Green/Yellow
B. Wire harness Gy/G Gray/Green
C. Negative battery sub-wire har- L/B Blue/Black
ness L/R Blue/Red
D. EPS control unit L/W Blue/White
L/Y Blue/Yellow
O/B Orange/Black
O/L Orange/Blue
O/W Orange/White
P/L Pink/Blue
P/W Pink/White
R/B Red/Black
R/G Red/Green
R/L Red/Blue
R/W Red/White
R/Y Red/Yellow
W/B White/Black
W/G White/Green
W/R White/Red
Y/B Yellow/Black
Y/G Yellow/Green
Y/L Yellow/Blue
Y/R Yellow/Red
Y/W Yellow/White
Brought to you by
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YXE70WDXG 2016 WIRING DIAGRAM YXE70WDXG 2016 SCHÉMA DE CÂBLAGE
A
B B
68 P
A Br/Y L
B
G/W
OFF
69 70 B L B C
ON
B Br L Br/Y W B
Br W Br/Y
(B)
Br/Y B Br/Y B
(B) Br/R 22
O Br/Y Br
B/L Gy Gy B/L
G/W O 23 32 P Br
W W W B R Gy O/B O/B P (Gy)
Gy B 1 B
(Gy) (B) Br/Y R/W
Br/W W Gy P Y/G P/W Sb O/L Y/W B/G Gy/G W/B L/R B/W G/R Br/R Br/R
R R R/L
W W W W W W (B)
R/W
R/W
24 R/L R
Br/Y O/B
(Gy)
R (B)
(Gy) (Gy) 2 W W
W W
3 R/W
(Gy)
R/G R/G
W W W/G R/W R/G P/L P/L 25 Br/W B/L G/W
(Gy) (Gy) B
14 B/W R/W
Br/L R/W P/L 20 W/G W/G (B)
Br/R Br/R
Br/R 26 33
G/Y B/L
Br/R
Br/R
Br/R Br/R Br/R Br/R R/W 19 Y/W Y/W
(B)
Br/Y B/W W
B
B
R/L
R/W
21
B/W R/Y L L/Y
B B W L/Y L W
Br/R B
R
Y/R
Y/B
L
W 27 B/L B/L
R/W R/W R/W R/W R/W R/W L L L L L
R G/R B/L B/L B/L B/L B/L B/L B/L B/L B/L G/W G/W G/W
R 9 L/R
(W)

(B)
B Br/R R/L Y
P/W
Y Y 28 B/L Y L
R Br/R L/R L
Br/L
5 R R Br/B
Br/B O/L
B/G
(B)
R B
B
B
B
8 10 13
W/B
B/R P P
L
29 B/L P L 34
Br/L B/L B/L
BBB Br/R Sb
Br/R
B
11 P/W B/G W/B Gy/G
Sb W/R
W/R
L/W
L/B
L
G/W
G/W
R/W
R/W
R/W
R/Y
R/B Br/R
B A B 15 O/L B/Y Br/B B/R
L/W G/R
G/R Y/G Y/G 30 L Y/G B/L B/L
B/L
R/W
R/W
Br/R 6 Br/B L/R
B/Y
17 L Gy W Y/L
L/B
B/L
(Gy)
B/L
B/L L
R
(off) B
12 R/Y L/Y R/L
16 18 L/B
B/L
B/L
L
L
R/L B/L L
(on) 2WD B/L L
(B) L W B/W B
(start)
67 Gy
L/W G/R 4WD
31 L/R
7 B/Y Y/B B
B (B)
B
DIFF LOCK
Br/R B
R/L L/Y Br/R W/R Sb
R B/W
R/L RR B
B/W B L/B
Br/R Y/R R
(B)
R R
R/L
Br/L
Br/L
Br/L W/B
66 64
Br
63 Br/Y
Y Y Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
R/W
62 Br/Y
R/W
W/B Br
Br/R 39 (B)
R/W
61 Y Br/Y
Br/R
R/B R (B) Br/Y

52
Y Br
51 40 34
L
L 60 Br 55 (off)
Br/B
B/W
B/W
B/W
Y
Y
Y
Br/R Br/L Br Y R/W Y/L B/W
59 (B) 56 Br/Y B/W B/W
65 R R
G W/B G
Br/B
G/R
B
O/B B/W
R/L
R/L
Br/Y
Br/Y
Br/Y
58 Y B
L Y Br/R Br/R
Br/R Br/R
Br/R 41 R/L
L/Y
Br/Y
Br/Y
W/B B L/Y Br/Y
L B Br/R B G/R R/L O/B
L/Y Br/Y
Br/R
Y
Y
Y
(B)
42
B
B R/W L
Y 53 L 50 49 43
O/B
Y/L Br/Y B/W
R/W
Y G B L
(B)
36 Br/Y
(B)
B B
44 Lg Lg B
B B B/W Br
G
G B Br/Y L
R/L B B/W O/B 45 L/B B L
B
(Gy)
(B) 35
Y L
Y LL
Y Y G Y G
B BB
46 37 L
38
54 54 47 B L/B
B
57 57 G G
B
Y
B
Y
48
Y G B B Y G
B B
B B
B B
B B B B
B
B
YXE70WDXG 2016 WIRING DIAGRAM YXE70WDXG 2016 SCHÉMA DE CÂBLAGE
A
68 A
OFF
69 70 B C
ON
(B)
(B)
71
(B) 22
23 32
(Gy)
1 (Gy) (B)
(B)
24 (Gy)
(B)
(Gy) (Gy) 2 3 (Gy)
25
(Gy) (Gy)
14 20
(B)
(B)
26 33
19 (B)
21
27
9 (W)
4 (B)
28
5 (B)
8 10 13 29 34
(B)
11
A 15 30
6 17 (Gy)
(off)
12 16 18
(on) 2WD
(B)
(start)
67
4WD
31
7 (B)
DIFF LOCK
(W)
(B) (B) (Gy)
(B)
66 64
63
62
39 (B)
61
(B)
52 51 40 34
60 55 (off)
59 (B) 56
65
58 41
(B)
42
53 50 49 43
(B)
36
(B) 44
45
(Gy)
(B) 35
46 37 38
54 54 47
57 57
48
YX70EPNG/YXE70WPXG/YXE70WPHG/YXE700E 2016 WIRING DIAGRAM YX70EPNG/YXE70WPXG/YXE70WPHG/YXE700E 2016 SCHÉMA DE CÂBLAGE
A
B B
75 P
A Br/Y L
B
G/W
OFF
76 77 B L B C
ON
B Br L Br/Y W B
Br W Br/Y B
(B)
Br/Y B Br/Y B
B G/W 78 Y/R O/B B P/L L/B Br/L O B B
(B) Br/R 23 (B) (B)
O Br/Y Br
C D
B/L Gy Gy B/L
G/W O 24 33 P Br
W W W B R Gy O/B O/B P (Gy)
Gy B 1 B
(Gy) (B) Br/Y R/W
Br/W W Gy P Y/G P/W Sb O/L Y/W B/G Gy/G W/B L/R B/W G/R Br/R Br/R
R R R/L
W W W W W W (B)
R/W
R/W
25 R/L R
Br/Y O/B
(Gy)
R (B)
(Gy) (Gy) 2 W W
W W
3 R/W
(Gy) G/W
Br/Y R/W O/W Br/W Br/W B/L
R/G R/G G/W
W W W/G R/W R/G P/L P/L 26 Br/W B/L G/W G/W
(Gy) (Gy) B
15 B/W R/W
Br/L R/W P/L 21 W/G W/G (B)
Br/R Br/R
Br/R 27 34
G/Y B/L
Br/R
Br/R
Br/R Br/R Br/R
R
Br/R R/W 20 Y/W Y/W
(B)
Br/Y B/W W
B
B
R/L
R/W
22
B/W R/Y L L/Y
B B W L/Y L W
Br/R B
R R/B
Y/R
Y/B
L
W 28 B/L B/L
R G/R B/L R/W R/W R/W R/W R/W R/W L L L L L
R 9 10 R
L/R
(W)

B/L B/L B/L B/L B/L B/L B/L B/L W W W
B Br/R R/L Y
P/W
Y Y 29 B/L Y L
R R Br/R L/R L (B)
Br/L
5 R R Br/B Br/B O/L
B/G
(B)
R B
B
B
B
8 11 14
W/B
B/R P P
L
30 B/L P L 35
Br/L B/L B/L
BBB Br/R Sb
Br/R
B
12 P/W B/G W/B Gy/G
Sb W/R
W/R
L/W
L/B
L
W
W
W
R/W
R/W
R/W
R/Y
R/B Br/R
B A B 16 O/L B/Y Br/B B/R
L/W G/R
G/R Y/G Y/G 31 L Y/G B/L B/L
B/L
R/W
R/W
Br/R 6 Br/B L/R
B/Y
18 L Gy W Y/L
L/B
B/L
(Gy)
B/L
B/L L
R
(off) B
13 R/Y L/Y R/L
17 19 L/B
B/L
B/L
L
L
R/L B/L L
(on) 2WD B/L L
(B) L W B/W B
(start)
74 Gy
L/W G/R 4WD
32 L/R
7 B/Y Y/B B
B (B)
B
DIFF LOCK
Br/R B
R/L L/Y Br/R W/R Sb
R B/W
R/L RR B
B L/B
Br/R Y/R R
(B)
B/W
36 G R
R R B W 38 37 B R
(Gy)
R/L B R (Gy)
Br/L
G R B W R B
Br/L B R
(Gy)
Br/L W/B
GR B WR B
73 71
Br R G B R
R B
70 Br/Y
W B
(Gy) Y Y Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
R/B
69 Br/Y G W
R/W
R/W Br/R 45
R
B B
Br
40 O
G/R
O/W
W/B
(B)
Br
R/W
68 Y Br/Y
W/B Br/R
L/B Br O
L/B L/B
R/B R (B) Br/Y

59
Y Br
58 46 R/B G
G W G/R
O/W R L/B
G/R W
39 35
L (Gy)
L 67 Br 62 (off)
Br/B (Gy)
(B)
B/W
B/W
B/W
Y
Y
Y
Br/R Br/L Br Y R/W Y/L B/W
66 (B) 63 Br/Y B/W B/W
72 R R
G W/B G
Br/B
G/R
B
O/B B/W
R/L
R/L
Br/Y
Br/Y
Br/Y
65 Y B
L Y Br/R Br/R
Br/R Br/R
Br/R 47 R/L
L/Y
Br/Y
Br/Y
W/B B L/Y Br/Y
L B Br/R B G/R R/L O/B
L/Y Br/Y
Br/R
Y
Y
Y
(B)
48
B
B R/W L
Y 60 L 57 56 49
O/B G/R R/W
Y/L Br/Y B/W
Y G B L
(B)
42 Br/Y
(B)
B B
50 Lg Lg B
B B B/W Br
G
G B Br/Y L
R/L B B/W O/B 51 L/B B L
B
(Gy)
(B) 41
Y L
Y LL
Y Y G Y G
B BB
52 43 L
44
61 61 53 B L/B
B
64 64 G G
B
Y
B
Y
54
Y G B B Y G
55
B B G/R
B B
B B
B B B B
B
B
YX70EPNG/YXE70WPXG/YXE70WPHG/YXE700E 2016 WIRING DIAGRAM YX70EPNG/YXE70WPXG/YXE70WPHG/YXE700E 2016 SCHÉMA DE CÂBLAGE
A
75 A
OFF
76 77 B C
ON
B
(B)
(B)
78
(B) 23 (B) (B)
C D
24 33
(Gy)
1 (Gy) (B)
(B)
25 (Gy)
(B)
(Gy) (Gy) 2 3 (Gy)
26
(Gy) (Gy)
15 21
(B)
(B)
27 34
20 (B)
22
28
9 10 (W)
4
29
(B)
5 (B)
8 11 14 30 35
(B)
12
A 16 31
6 18 (Gy)
(off)
13 17 19
(on) 2WD
(B)
(start)
74
4WD
32
7 (B)
DIFF LOCK
(W)
(B) (B) (Gy)
(B)
36
38 37
(Gy) (Gy)
(Gy)
73 71
70 (Gy)
69
45 B 40 (B)
68
(B)
59 58 46 39 35
(Gy)
67 62 (off)
(Gy)
(B)
66 (B) 63
72
65 47
(B)
48
60 57 56 49
(B)
42
(B) 50
51
(Gy)
(B) 41
52 43 44
61 61 53
64 64
54
55

Wolverine Yx70epng

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2016-17

IMPORTANT MANUAL INFORMATION

A WARNING indicates a hazardous situation which, if not avoided, could result

A NOTICE indicates special precautions that must be taken to avoid damage to

TIP A TIP provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

Filling fluid Molybdenum disulfide oil

Lubricant Brake fluid

Special tool B Wheel bearing grease

Tightening torque LS Lithium-soap-based grease

Wear limit, clearance M Molybdenum disulfide grease

Engine speed S Silicone grease

Electrical data Apply locking agent (LOCTITE®).

Engine oil New Replace the part with a new one.

IDENTIFICATION ............................................................................................ 1-1

IMPORTANT INFORMATION ......................................................................... 1-7

BASIC SERVICE INFORMATION...................................................................1-9

SPECIAL TOOLS .......................................................................................... 1-14

VEHICLE IDENTIFICATION NUMBER

1. Speed information from speed sensor b. Twists torsion bar

Voltage display mode Refer to “SIGNALING SYSTEM” on page 9-19.

This display shows the battery voltage.

1. Fuel level warning indicator

PREPARATION FOR REMOVAL AND

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS RUBBER PARTS

BASIC SERVICE INFORMATION

TIP Turn the main switch to “OFF” before dis-

NOTICE Checking the electrical system

Intake air temperature sensor re-

Valve lapper 90890-04101

Yamaha diagnostic tool 3-7, 9-39

Oil filter wrench 3-14

Oil pressure adapter H 3-15

Ring nut wrench 3-27, 3-29

Steering nut wrench 3-27, 3-30

Boots band installation tool 4-50, 8-10, 8-12,

Ball joint remover 4-54, 4-58

Ball joint remover adapter set 4-54, 4-58

Base plate 35mm 45mm ø35 4-54, 4-58

Ball joint installer attachment 39mm 4-54, 4-58

Compression gauge 90890-03081 5-1

Piston pin puller set 5-20

Valve spring compressor 5-27, 5-32

Valve spring compressor attachment 5-27, 5-32

Valve guide remover & installer set (ø5.5) 5-29

Valve guide remover & installer set (ø5.5) 5-29

Rotor holding tool 5-35, 5-35, 5-36,

Flywheel puller (M38 X P1.5) 5-35

Digital circuit tester 5-40, 7-13,

Sheave fixed block 5-53, 5-57

Sheave spring compressor 5-53, 5-57

Universal clutch holder 5-62, 5-63

Crankcase separating tool 5-68, 5-73, 8-30