2014-2015 Yamaha Viking Service Manual PDF

2014
SERVICE MANUAL
YX70ME
YX70MHE
YX70MNE
YX70MPE
YX70MPHE
YX70MPNE
YXM700PE
YXM700PHE
YXM700DE
1XD-F8197-E0
EAS20071
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one 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
Designs and specifications are subject to change without notice.
EAS20081
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential person-
al injury 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

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

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

EAS20090
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Numbers “5” enclosed in parentheses indicate the quantities of parts.
• Symbols “6” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “7” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
• Jobs “8” requiring more information (such as special tools and technical data) are described sequen-
tially.
CLUTCH CLUTCH
EAS25061 EAS25070
• One-way clutch bearing
CLUTCH REMOVING T HE CLUTCH
Chafing/wear/damage → Replace.
1. Remove:
Removing the clutch • 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.
3 loosened.
2. Check:
• One-way clutch operation
190 Nm (19 m•kgf, 137 ft •lbf) a. Install the one-way clutch bearing and clutch
T.R.
5
carrier assembly to the clutch housing and
10 Nm (1.0 m•kgf, 7.2 ft •Ibf) hold the clutch carrier assembly.
T.R.
4
New b. When turning the clutch housing clockwise
2
“A”, it should turn freely; otherwise, the one-
4 1 way clutch assembly is faulty and must be re-
placed.
c. When turning the clutch housing counter-
3 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 M
(7) 3. Remove: placed.
E
• Clutch carrier assembly nut “1”
ECA1XD1019
NOTICE
7
The clutch carrier assembly nut has left-
hand threads. To loosen the clut ch carrier
E assembly nut, turn it clockwise .
TIP
5 LS
Use a clutch holding tool “2” to hold the clutch
carrier assembly.
6 Order Job/Parts to remove Q’ty Remarks

Refer to “PRIMARY AND SECONDARY
Universal clutch holder
90890-04086 EAS28990
CHECKING THE CLUTCH SHOE 2

Drive belt case YM-91042
SHEAVES” on page 5-50. 1. Check:
1 Clutch housing assembly 1 • Clutch shoe
2 Clutch housing assembly gasket 1 Damage/wear → Replace.
3 Dowel pin 2 a 2 Glazed areas → Sand with coarse sandpa-
4 Clutch carrier assembly nut 1 Left-hand threads per.
5 Clutch carrier assembly 1 TIP
For installation, reverse the removal proce- After sanding the glazed areas, clean the clutch
dure. with a cloth.
2. Measure:
1 • Clutch shoe thickness
Out of specification → Replace.
EAS1XD1102
CHECKING THE CLUTCH Clutch shoe thickness

1. Check: 1.5 mm (0.06 in)
• Clutch housing Limit
Damage/wear → Replace. 1.0 mm (0.04 in)
5-60 5-62
EAS20100
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil

G
Filling fluid Molybdenum disulfide oil

M
Lubricant Brake fluid

BF
Special tool B Wheel bearing grease
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
EAS20110
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...................................................................................................... 1-2
1
OUTLINE OF THE FI SYSTEM.................................................................1-2
FI SYSTEM................................................................................................1-3
OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM
(for EPS models) ......................................................................................1-5
INSTRUMENT FUNCTIONS ..................................................................... 1-7
IMPORTANT INFORMATION ......................................................................... 1-9

PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-9
REPLACEMENT PARTS...........................................................................1-9
GASKETS, OIL SEALS AND O-RINGS .................................................... 1-9
LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-9
BEARINGS AND OIL SEALS .................................................................. 1-10
CIRCLIPS ................................................................................................1-10
RUBBER PARTS.....................................................................................1-10
BASIC SERVICE INFORMATION.................................................................1-11

QUICK FASTENERS............................................................................... 1-11
ELECTRICAL SYSTEM...........................................................................1-12
SPECIAL TOOLS .......................................................................................... 1-16

IDENTIFICATION
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the frame.
EAS20150
MODEL LABEL
The model label “1” is affixed to the frame under
the driver seat. This information will be needed
to order spare parts.
1-1
FEATURES
EAS20170
FEATURES
EAS30340
OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In
the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion
chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the
respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating con-
ditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the
fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-
fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the en-
gine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase,
it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accom-
modate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place
of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by
the engine at all times by using a microprocessor that regulates the fuel injection volume according to
the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response,
better fuel economy, and reduced exhaust emissions.
1,2 3 4 5 6 7,8,9,10
16 15 14 13 11,12
1. Lean angle sensor 10. Throttle position sensor

2. ECU (engine control unit) 11. Spark plug
3. Fuel injection system relay 12. Coolant temperature sensor
4. Engine trouble warning light 13. Speed sensor
5. Ignition coil 14. Crankshaft position sensor
6. Air cut-off valve 15. Intake air temperature sensor
7. ISC (idle speed control) unit 16. Fuel pump
8. Intake air pressure sensor
9. Fuel injector
1-2
FEATURES
EAS1XD1054
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the energizing signal
from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into
the intake manifold only during the time the passage remains open. Therefore, the longer the length of
time the fuel injector is energized (injection duration), the greater the volume of fuel that is supplied.
Conversely, the shorter the length of time the fuel injector is energized (injection duration), the lesser
the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the
throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air temperature
sensor, coolant temperature sensor, lean angle sensor and speed sensor enable the ECU to determine
the injection duration. The injection timing is determined through the signals from the crankshaft posi-
tion sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times in
accordance with the driving conditions.
Illustration is for reference only.
C 5
4
1 6
2
A 7
3
13
15 8
B
14
12 11
10
1. Fuel pump 13. Throttle position sensor

2. Fuel injector 14. Intake air temperature sensor
3. Ignition coil 15. Air filter case
4. ECU (engine control unit)
A. Fuel system
5. Speed sensor
B. Air system
6. Lean angle sensor
C. Control system
7. Coolant temperature sensor
8. Catalytic converter
9. Crankshaft position sensor
11. Throttle body
12. ISC (idle speed control) unit
1-3
FEATURES
1-4
FEATURES
EAS1XD1055
OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
1 d 3
e c
f 5 a
b
5
1-5
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
ECA1XD1027
NOTICE
To prevent accidental damage to the EPS unit, it must not be disassembled.
1-6
FEATURES
EAS1XD1056
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”,
turn the key to “ ” (off), then push and hold the
1. “CLOCK” button “SELECT” button while turning the key to “ ”
2. “RESET” button (on).
3. “SELECT” button
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)
1. “SELECT” button
• a voltage display (which shows the battery volt-
2. “RESET” button
age)
3. “CLOCK” button
• a fuel meter
4. Clock/Hour meter/Voltage display
• a self-diagnosis device
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:
1. Set the display to the clock mode.
2
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.
1-7
FEATURES
Voltage display mode TIP

This fuel meter is equipped with a self-diagnosis
system. If a problem is detected in an electrical
circuit, all the display segments and fuel level
warning indicator start flashing. If this occurs,
check the electrical circuit.
Refer to “SIGNALING SYSTEM” on page 9-19.
Self-diagnosis device
1 2
This display shows the battery voltage.
“ ” appears for 1 second when the voltage
display mode is first selected, and then “ ” ap-
pears and the battery voltage is displayed.
If the battery voltage is less than 10 volts, “LO” is
displayed, and if the voltage is above 16 volts,
“HI” is displayed.
ECA1XD1054
NOTICE
If the voltage display indicates “LO” or “HI”, 1. Fault code display
there may be trouble with the battery charg- 2. Engine trouble warning light “ ”
ing circuit or the battery may be faulty. If this
occurs, check or repair the vehicle. This model is equipped with a self-diagnosis de-
Refer to “CHARGING SYSTEM” on page vice for various electrical circuits.
9-11. If a problem is detected in any of those circuits,
the engine trouble warning light comes on or
flashes, and the multi-function display indicates
Fuel meter a fault code.
1 If the multi-function display indicates a fault
code, note the code number, and then check the
fuel injection system.
Refer to “FUEL INJECTION SYSTEM” on page
9-33.
2 ECA1XD1055
NOTICE
3
If the multi-function display indicates a fault
code, the vehicle should be checked as soon
as possible in order to avoid engine damage.
1. Fuel level warning indicator
2. Fuel meter
3. “E” segment
The fuel meter indicates the amount of fuel in the
fuel tank. The display segments of the fuel meter
disappear from “F” (full) towards “E” (empty) as
the fuel level decreases. When the “E” segment
disappears and the fuel level warning indicator
flashes, refuel as soon as possible.
1-8
IMPORTANT INFORMATION
EAS20180
EAS20190
PREPARATION FOR REMOVAL AND

DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
EAS20210
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
lips with grease.
2. Use only the proper tools and cleaning equip-
ment.
Refer to “SPECIAL TOOLS” on page 1-16.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “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
EAS20220
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.
EAS20200
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.
1-9
EAS20230 EAS1XD1131
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.
ECA13300
NOTICE
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
EAS20240
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.
1-10
BASIC SERVICE INFORMATION
EAS30380

EAS30390
QUICK FASTENERS
Rivet type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, push its pin with a
screwdriver, then pull the fastener out. Screw type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, loosen the screw
with a screwdriver, then pull the fastener out.
2. Install:
• Quick fastener
TIP
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the part to be secured and push 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.
1-11
ECA16760
EAS30402
NOTICE
ELECTRICAL SYSTEM
Be sure to connect the battery leads to the
Electrical parts handling correct battery terminals. Reversing the bat-
ECA16600 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.
ECA16771
NOTICE
When connecting the battery leads to the
ECA16751 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.
ECA16610
NOTICE
Turn the main switch to “OFF” before dis-
TIP
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.
1-12
ECA16620
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.
ECA16630 ECA14371
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.
ECA16640
TIP NOTICE
When resetting the ECU by turning the main
For waterproof couplers, never insert the
switch to “OFF”, be sure to wait approximately 5
tester probes directly into the coupler. When
seconds before turning the main switch back to
performing any checks using a waterproof
“ON”.
coupler, use the specified test harness or a
suitable commercially available test har-
ness.
1-13
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
ECA16780
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.
ECA16790
NOTICE
When disconnecting a connector, do not pull
the leads. Hold both sections of the connec-
tor securely, and then disconnect the con-
nector.
1-14
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
1-15
SPECIAL TOOLS
EAS20260
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
TIP
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, “YS-”, “YK-”, or “ACC-”.
• For others, use part number starting with “90890-”.
Reference
Tool name/Tool No. Illustration
pages
Pocket tester 1-15, 9-89,
90890-03112 9-90, 9-91,
Analog pocket tester 9-93, 9-95,
YU-03112-C 9-98, 9-99,
9-100, 9-101,
9-102, 9-104,
9-105, 9-106,
9-107, 9-108
Thickness gauge 3-4
90890-03079
Narrow gauge set
YM-34483
Tappet adjusting tool 3-4

90890-01311
Six piece tappet set
YM-A5970
YM-A5970
ø8 ø9 ø10
ø3 ø4
Yamaha diagnostic tool 3-6, 9-37
90890-03215
Oil filter wrench 3-13

90890-01426
YU-38411
1-16
SPECIAL TOOLS
Reference
pages
Boots band installation tool 4-54, 8-9, 8-11,
90890-01526 8-23, 8-25
YM-01526
Ball joint remover 4-58, 4-62

90890-01474
YM-01474
Ball joint remover adapter set 4-58, 4-62

90890-01477
YM-01477
Base plate 35mm 45mm ø35 4-58, 4-62

90890-01553
YM-01553
110mm
12mm
Ball joint installer attachment 39mm 4-58, 4-62

90890-01555
YS-01881-A
ø39
Compression gauge 5-14

90890-03081
Engine compression tester
YU-33223
Slide hammer bolt 5-17, 5-19

90890-01083
Slide hammer bolt 6 mm
YU-01083-1
Weight 5-17
90890-01084
YU-01083-3
YU-01083-3
1-17
SPECIAL TOOLS
Reference
pages
Valve spring compressor 5-21, 5-26
90890-04019
YM-04019
Valve spring compressor attachment 5-21, 5-26

90890-01243
Valve spring compressor adapter (26 mm)
YM-01253-1
Valve guide remover (ø6) 5-22

90890-04064
Valve guide remover (6.0 mm)
YM-04064-A
Valve guide installer (ø6) 5-22

90890-04065
Valve guide installer (6.0 mm)
YM-04065-A
Valve guide reamer (ø6) 5-22

90890-04066
Valve guide reamer (6.0 mm)
YM-04066
Piston pin puller set 5-28

90890-01304
Piston pin puller
YU-01304
YU-01304
Sheave holder 5-34, 5-35,

90890-01701 5-36, 5-53,
Primary clutch holder 5-58
YS-01880-A
Flywheel puller 5-34

90890-01362
Heavy duty puller
YU-33270-B
1-18
SPECIAL TOOLS
Reference
pages
Yamaha bond No. 1215 5-36, 5-69,
90890-85505 8-27
(Three Bond No.1215®)
Digital circuit tester 5-39, 7-13,

90890-03174 9-101, 9-103
Model 88 Multimeter with tachometer
YU-A1927
Sheave fixed block 5-53, 5-57

90890-04135
Sheave fixed bracket
YM-04135
Locknut wrench 5-53, 5-57

90890-01348
YM-01348
Sheave spring compressor 5-53, 5-57

90890-04134
YM-04134
1-19
SPECIAL TOOLS
Reference
pages
Universal clutch holder 5-62, 5-63
90890-04086
YM-91042
Crankcase separating tool 5-73

90890-01135
Crankcase separator
YU-01135-B
Crankshaft installer pot 5-75

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

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

90890-04130
Adapter #13
YM-04059
1-20
SPECIAL TOOLS
Reference
pages
Spacer (crankshaft installer) 5-75
90890-04081
Pot spacer
YM-91044
YM-91044
Spacer 5-75
ø70
90890-04167
YM-04167
Coupling gear/middle shaft tool 5-87, 5-90

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

90890-04128
Middle gear bearing retainer
YM-04128
Ring nut wrench 5-88, 5-89

90890-01430
YM-38404
Final gear backlash band 5-91

90890-01511
Middle drive gear lash tool
YM-01230
1-21
SPECIAL TOOLS
Reference
pages
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 6-14

90890-04132
Water pump seal installer
YM-33221-A
Middle driven shaft bearing driver 6-14

90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058
Pressure gauge 7-4

90890-03153
YU-03153
Fuel pressure adapter 7-4

90890-03176
YM-03176
1-22
SPECIAL TOOLS
Reference
pages
Test harness- TPS (3P) 7-13
90890-03204
YU-03204
Universal joint holder 8-11, 8-14

90890-04062
YM-04062
Ring gear fix bolt (M10) 8-15

90890-01527
YM-01527
M10×P1.25
Gear lash measurement tool 8-15

90890-01475
YM-01475
Coupling gear holding tool (35) 8-25, 8-28

90890-01571
YM-01571
Ring gear fix bolt (M10 x 1.5) 8-26

90890-01572
YM-01572
M10×P1.50
Gear lash measurement tool 8-26

90890-01467
YM-01467
Ignition checker 9-99

90890-06754
Oppama pet-4000 spark checker
YM-34487
1-23
SPECIAL TOOLS
Reference
pages
Test harness-lean angle sensor (3P) 9-100
90890-03213
YU-03213
Test harness- speed sensor (3P) 9-102

90890-03208
YU-03208
Test harness S- pressure sensor 5S7 (3P) 9-105

90890-03211
YU-03211
1-24
SPECIAL TOOLS
1-25
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................2-2
CHASSIS SPECIFICATIONS ..........................................................................2-9
ELECTRICAL SPECIFICATIONS .................................................................2-12

2
TIGHTENING TORQUES .............................................................................. 2-14
GENERAL TIGHTENING TORQUE SPECIFICATIONS......................... 2-14
ENGINE TIGHTENING TORQUES......................................................... 2-15
CHASSIS TIGHTENING TORQUES.......................................................2-19
LUBRICATION AND SEALING POINTS ......................................................2-27

ENGINE................................................................................................... 2-27
LUBRICATION SYSTEM CHART AND DIAGRAMS.................................... 2-29

ENGINE OIL LUBRICATION CHART .....................................................2-29
LUBRICATION DIAGRAMS .................................................................... 2-31
COOLING SYSTEM DIAGRAMS .................................................................. 2-35
CABLE ROUTING ......................................................................................... 2-41

GENERAL SPECIFICATIONS
EAS29110
GENERAL SPECIFICATIONS
Model
Model 1XD2 (YX70ME [for CDN])
1XD5 (YX70MHE [for sun top models for CDN])
1XD7 (YX70MNE [for sun top models for CDN])
1XP2 (YX70MPE [for EPS models for CDN])
1XPA (YX70MPHE [for EPS/sun top models for
CDN])
1XPD (YX70MPNE [for EPS/sun top models for
CDN])
1XP3 (YXM700PE [for EPS models for CDN])
1XPB (YXM700PHE [for EPS/sun top models
for CDN])
1XD3 (YXM700DE [for sun top models for
CDN])
1XP4 (YXM700PE [for EPS/sun top models for
CDN])
Dimensions
Overall length 3100 mm (122.0 in)
Overall width 1570 mm (61.8 in)
Overall height 1880 mm (74.1 in)
(YX70ME/YX70MPE/YXM700DE/YXM700PE
[for Oceania])
1925 mm (75.8 in)
(YX70MHE/YX70MNE/YX70MPHE/YX70MPN
E/YXM700PE [for Europe]/YXM700PHE)
Seat height 793 mm (31.2 in)
Wheelbase 2135 mm (84.1 in)
Ground clearance 300 mm (11.8 in)
Minimum turning radius 4500 mm (177 in)
Weight
Curb weight 609.0 kg (1342 lb) (YX70ME/YXM700DE)
615.0 kg (1356 lb) (YX70MPE/YXM700PE [for
Oceania])
617.0 kg (1360 lb) (YX70MHE/YX70MNE)
623.0 kg (1373 lb)
(YX70MPHE/YX70MPNE/YXM700PE [for
Europe]/YXM700PHE)
Maximum loading limit 445 kg (981 lb)
(Total weight of rider, passengers, cargo,
accessories, and tongue)
2-1
ENGINE SPECIFICATIONS
EAS29120
Engine
Engine type Liquid cooled 4-stroke, SOHC
Displacement 686 cm³
Cylinder arrangement Single cylinder
Bore × stroke 102.0 × 84.0 mm (4.02 × 3.31 in)
Compression ratio 10.00 : 1
Standard compression pressure (at sea level) 500 kPa (5.0 kgf/cm², 71.1 psi)
Minimum–maximum 440–560 kPa (4.4–5.6 kgf/cm², 62.6–79.6 psi)
Starting system Electric starter
Fuel
Recommended fuel Regular unleaded gasoline only
Fuel tank capacity 36.7 L (9.70 US gal, 8.07 Imp.gal)
Engine oil
Lubrication system Wet sump
Recommended brand YAMALUBE
Type SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-
40 or 20W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Engine oil quantity
Total amount 2.60 L (2.75 US qt, 2.29 Imp.qt)
Without oil filter cartridge replacement 2.20 L (2.33 US qt, 1.94 Imp.qt)
With oil filter cartridge replacement 2.30 L (2.43 US qt, 2.02 Imp.qt)
Final gear oil

Type SAE 80 API GL-4 Hypoid gear oil
Quantity 0.40 L (0.42 US qt, 0.35 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)
Oil filter
Oil filter type Cartridge
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance Less than 0.12 mm (0.0047 in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.090–0.170 mm (0.0035–0.0067 in)
Limit 0.24 mm (0.0094 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.03–0.10 mm (0.0012–0.0039 in)
Limit 0.17 mm (0.0067 in)
Pressure check location Cylinder head
2-2
Cooling system
Radiator capacity (including all routes) 2.74 L (2.90 US qt, 2.41 Imp.qt)
Coolant reservoir capacity (up to the maximum level
mark) 0.28 L (0.30 US qt, 0.25 Imp.qt)
From low to full level 0.17 L (0.18 US qt, 0.15 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 85 °C (185 °F)
Valve lift (full open) 8.0 mm (0.31 in)
Radiator core
Width 400.0 mm (15.75 in)
Height 253.4 mm (9.98 in)
Depth 28.0 mm (1.10 in)
Water pump
Water pump type Single suction centrifugal pump
Reduction ratio 32/31 (1.032)
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
Combustion chamber volume 57.60–61.20 cm³ (3.51–3.73 cu.in)
Warpage limit 0.03 mm (0.0012 in)
Camshaft
Drive system Chain drive (right)
Camshaft lobe dimensions
Intake A 42.985–43.085 mm (1.6923–1.6963 in)
Limit 42.885 mm (1.6884 in)
Intake B 36.950–37.050 mm (1.4547–1.4587 in)
Limit 36.850 mm (1.4572 in)
Exhaust A 43.490–43.590 mm (1.7122–1.7161 in)
Limit 43.390 mm (1.7083 in)
Exhaust B 36.950–37.050 mm (1.4547–1.4587 in)
Limit 36.850 mm (1.4572 in)
2-3
Camshaft runout limit 0.015 mm (0.0006 in)
Timing chain
Tensioning system Automatic
Rocker arm/rocker arm shaft

Rocker arm inside diameter 12.000–12.018 mm (0.4724–0.4731 in)
Rocker arm shaft outside diameter 11.981–11.991 mm (0.4717–0.4721 in)
Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.037 mm (0.0004–0.0015 in)
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.09–0.13 mm (0.0035–0.0051 in)
Exhaust 0.16–0.20 mm (0.0063–0.0079 in)
Valve dimensions
Valve head diameter A (intake) 37.90–38.10 mm (1.4921–1.5000 in)
Valve head diameter A (exhaust) 31.90–32.10 mm (1.2559–1.2638 in)
A
Valve face width B (intake) 2.26 mm (0.0890 in)
Valve face width B (exhaust) 2.26 mm (0.0890 in)
Valve seat width C (intake) 1.00–1.20 mm (0.0394–0.0472 in)

Limit 1.60 mm (0.0630 in)
Valve seat width C (exhaust) 1.00–1.20 mm (0.0394–0.0472 in)
Limit 1.60 mm (0.0630 in)
Valve margin thickness D (intake) 0.80–1.20 mm (0.0315–0.0472 in)

Limit 0.4 mm (0.016 in)
Valve margin thickness D (exhaust) 0.80–1.20 mm (0.0315–0.0472 in)
Limit 0.4 mm (0.016 in)
Valve stem diameter (intake) 5.975–5.990 mm (0.2352–0.2358 in)

Limit 5.945 mm (0.2341 in)
2-4
Valve stem diameter (exhaust) 5.960–5.975 mm (0.2346–0.2352 in)

Limit 5.930 mm (0.2335 in)
Valve guide inside diameter (intake) 6.000–6.012 mm (0.2362–0.2367 in)
Limit 6.050 mm (0.2382 in)
Valve guide inside diameter (exhaust) 6.000–6.012 mm (0.2362–0.2367 in)
Limit 6.050 mm (0.2382 in)
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm(0.0031 in)
Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.100 mm(0.0039 in)
Valve stem runout 0.040 mm (0.0016 in)
Cylinder head valve seat width (intake) 1.00–1.20 mm (0.0394–0.0472 in)

Cylinder head valve seat width (exhaust) 1.00–1.20 mm (0.0394–0.0472 in)
Valve spring
Free length (intake) 40.38 mm (1.59 in)
Limit 38.36 mm (1.51 in)
Free length (exhaust) 40.38 mm (1.59 in)
Limit 38.36 mm (1.51 in)
Installed length (intake) 35.00 mm (1.38 in)
Installed length (exhaust) 35.00 mm (1.38 in)
Spring rate K1 (intake) 34.18 N/mm (3.49 kgf/mm, 195.16 lbf/in)
Spring rate K2 (intake) 44.14 N/mm (4.50 kgf/mm, 252.04 lbf/in)
Spring rate K1 (exhaust) 34.18 N/mm (3.49 kgf/mm, 195.16 lbf/in)
Spring rate K2 (exhaust) 44.14 N/mm (4.50 kgf/mm, 252.04 lbf/in)
Installed compression spring force (intake) 171.00–197.00 N (17.44–20.09 kgf, 38.44–
44.29 lbf)
Installed compression spring force (exhaust) 171.00–197.00 N (17.44–20.09 kgf, 38.44–
44.29 lbf)
Spring tilt (intake) 2.5°/1.8 mm (2.5°/0.07 in)
Spring tilt (exhaust) 2.5°/1.8 mm (2.5°/0.07 in)
Winding direction (intake) Clockwise

Winding direction (exhaust) Clockwise
Cylinder
Cylinder bore 102.000–102.010 mm (4.0157–4.0161 in)
Wear limit 102.080 mm (4.0189 in)
Taper limit 0.05 mm (0.002 in)
Out of round limit 0.05 mm (0.002 in)
2-5
Piston
Piston-to-cylinder clearance 0.030–0.055 mm (0.0012–0.0022 in)
Piston skirt diameter D 101.955–101.970 mm (4.0140–4.0146 in)
Height H 10.0 mm (0.39 in)
H
D
Offset 0.50 mm (0.0197 in)

Offset direction Intake side
Piston pin bore inside diameter 23.004–23.015 mm (0.9057–0.9061 in)
Limit 23.045 mm (0.9073 in)
Piston pin outside diameter 22.991–23.000 mm (0.9052–0.9055 in)
Limit 22.971 mm (0.9044 in)
Piston-pin-to-piston-pin-bore clearance 0.004–0.024 mm (0.0002–0.0009 in)
Limit 0.074 mm (0.0029 in)
Piston ring
Top ring
Ring type Barrel
Dimensions (B × T) 1.20 × 3.80 mm (0.05 × 0.15 in)
B
T
End gap (installed) 0.20–0.35 mm (0.008–0.014 in)

Limit 0.60 mm (0.024 in)
Ring side clearance 0.030–0.070 mm (0.0012–0.0028 in)
Limit 0.12 mm (0.0047 in)
2nd ring
Ring type Taper
B
T

Limit 1.25 mm (0.049 in)
Ring side clearance 0.030–0.070 mm (0.0012–0.0028 in)
Limit 0.13 mm (0.0051 in)
Oil ring
B
T
2-6
Crankshaft
Width A 74.92–75.00 mm (2.950–2.953 in)
Runout limit C 0.030 mm (0.0012 in)
Big end side clearance D 0.350–0.650 mm (0.0138–0.0256 in)
C C
Balancer
Balancer drive method Gear
Automatic centrifugal clutch

Clutch type Wet, centrifugal automatic
Clutch shoe thickness 1.5 mm (0.06 in)
Limit 1.0 mm (0.04 in)
Clutch housing inside diameter 150.0 mm (5.91 in)
Clutch-in revolution 1950–2050 r/min
Clutch-stall revolution 3550–3650 r/min
V-belt
V-belt width 33.0–33.6 mm (1.30–1.32 in)
Limit 32.5 mm (1.28 in)
Transmission
Transmission type V-belt automatic
Primary reduction system V-belt
Secondary reduction system Shaft drive
Secondary reduction ratio 41/21 × 17/12 × 33/9 (10.142)
Operation Right hand operation
Gear ratio 2.554–0.705 : 1
Low range 31/16 (1.938)
High range 30/21 (1.429)
Reverse gear 23/14 × 28/23 (2.000)
Drive axle runout limit 0.06 mm (0.0024 in)
Shifting mechanism
Shift mechanism type Shift drum and guide bar
Shift fork thickness 5.76–5.89 mm (0.2268–0.2319 in)
Decompression device
Device type Auto decomp
Air filter
Air filter element Wet element
Air filter oil grade Foam air filter oil or equivalent oil
2-7
Fuel pump
Pump type Electrical
Fuel injector
Model/quantity EAT291/1
Fuel injector resistance 11.5–12.5 Ω
Throttle body
Type/quantity 44EHS/1
ID mark 1XD1 00
Throttle valve size #100
Throttle position sensor

Resistance 2.64–6.16 kΩ
Fuel injection sensor

Crankshaft position sensor resistance 408.0–612.0 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)
Idling condition
Engine idling speed 1550–1650 r/min
Intake vacuum 32.7 kPa (245 mmHg, 9.7 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)
CO% (air induction system ON) 1%
CO% (air induction system OFF) 5.5–6.5 %
Air induction system

Solenoid resistance 20–24 Ω
Drive train
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 (0.002–0.0010 in)
2-8
CHASSIS SPECIFICATIONS
EAS29130
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)
Tread rear (STD) 1304.0 mm (51.34 in)
Tread front (STD) 1320.0 mm (51.97 in)
Toe-in (with tires touching the ground) 5.0–15.0 mm (0.20–0.59 in)
Front wheel
Wheel type Panel wheel
Rim size 12 × 6.0AT
Wheel material Steel
Wheel travel 205 mm (8.1 in)
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 25 × 8–12NHS
Manufacturer/model MAXXIS/MU09
Wear limit (front) 3.0 mm (0.12 in)
Rear tire
Type Tubeless
Size 25 × 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 0–300 kg (0–661 lb)
Front 75.0 kPa (0.750 kgf/cm², 11 psi)
Rear 90.0 kPa (0.900 kgf/cm², 13 psi)
Minimum
2-9

Front brake
Type Disc brake
Operation Unified brake
Front disc 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 0.1 mm (0.004 in)
Brake pad lining thickness (inner) 4.5 mm (0.18 in)
Brake pad lining thickness (outer) 4.5 mm (0.18 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
Brake pedal free play 0 mm (0 in)
Rear disc brake
Brake disc deflection limit 0.1 mm (0.004 in)
Brake pad lining thickness (inner) 4.3 mm (0.17 in)
Brake pad lining thickness (outer) 4.3 mm (0.17 in)
Caliper cylinder inside diameter 27.00 mm × 2
Specified brake fluid DOT 4
Parking brake
Type Disc
Brake pad lining thickness-inner 3.2 mm (0.13 in)
Brake pad lining thickness-outer 3.2 mm (0.13 in)
Front suspension
Type Double wishbone
Spring/shock absorber type Coil spring/gas-oil damper
Shock absorber travel 123.0 mm (4.84 in)
Spring free length 334.0 mm (13.15 in)
Installed length 277.0 mm (10.91 in)
Spring rate K1 28.00 N/mm (2.86 kgf/mm, 159.88 lbf/in)
Spring stroke K1 0.0–123.0 mm (0.00–4.84 in)
2-10
Rear suspension
Type Double wishbone
Spring/shock absorber type Coil spring/gas-oil damper
Rear shock absorber assembly travel 112.0 mm (4.41 in)
Spring free length 381.2 mm (15.01 in)
Installed length 316.2 mm (12.45 in)
2-11
ELECTRICAL SPECIFICATIONS
EAS29140
Voltage
System voltage 12 V
Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 5.0°/1600 r/min
Engine control unit

Model/manufacturer F8T85871/MITSUBISHI
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

Material Resin
Resistance 7.5–12.5 kΩ
AC magneto
Standard output 14.0 V, 36.4 A at 5000 r/min
Stator coil resistance 0.09–0.13 Ω
Rectifier/regulator
Regulator type Semi conductor-short circuit
Regulated voltage (DC) 14.3–14.7 V
Rectifier capacity (DC) 50.0 A
Withstand voltage 40.0 V
Battery
Model U1-H11L
Voltage, capacity 12 V, 28.0 Ah
Manufacturer GS
Ten hour rate charging current 2.8 A
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
2-12
Engine trouble warning light LED

EPS warning light LED (for EPS models)
High-range indicator light LED
Low-range indicator light LED
Differential gear lock indicator light LED
Helmet/seat belt indicator light 14 V, 0.85 W × 2
Electric starting system

System type Constant mesh
Starter motor
Power output 0.80 kW
Armature coil resistance 0.025–0.035 Ω
Brush overall length 12.5 mm (0.49 in)
Limit 5.00 mm (0.20 in)
Brush spring force 7.65–10.01 N (780–1021 gf, 27.54–36.03 oz)
Commutator diameter 28.0 mm (1.10 in)
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 (for Europe and Oceania)

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

Sender unit resistance (full) 19.0–21.0 Ω
Sender unit resistance (empty) 139.0–141.0 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)
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
2-13
TIGHTENING TORQUES
EAS20320
TIGHTENING TORQUES
EAS20330
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
A (nut) B (bolt) torques
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
2-14
TIGHTENING TORQUES
EAS20340
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)

Intake air pressure sensor screw M5 1 3.6 Nm (0.36 m·kgf, 2.6 ft·lbf)
Throttle position sensor screw M5 2 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Injector fuel rail screw M6 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Throttle cable locknut (throttle
M7 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
body end, air intake silencer side)
Throttle cable locknut (throttle
M6 1 0.8 Nm (0.08 m·kgf, 0.6 ft·lbf)
body end, throttle body side)
Throttle cable housing cover
M4 3 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
screw
Cylinder head stud bolt (exhaust
M8 2 15 Nm (1.5 m·kgf, 11 ft·lbf)
pipe)
Reed valve cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
l = 135
mm
(5.31 in),
Cylinder head bolt M9 4 35 Nm (3.5 m·kgf, 25 ft·lbf) l = 145
mm
(5.71 in)
M
l = 39 mm
Cylinder head bolt M9 2 38 Nm (3.8 m·kgf, 27 ft·lbf) (1.54 in)
E
Cylinder head bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Tappet cover bolt M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Camshaft sprocket cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 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)
Oil check bolt M8 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Camshaft sprocket bolt M7 2 20 Nm (2.0 m·kgf, 14 ft·lbf)
Decompression assembly bolt M7 2 20 Nm (2.0 m·kgf, 14 ft·lbf)
Valve adjusting screw locknut M6 4 14 Nm (1.4 m·kgf, 10 ft·lbf)
Bearing retainer bolt (camshaft) M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Cylinder bolt M10 4 See TIP. E
Cylinder bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Timing chain guide (intake side)
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
bolt
Timing chain tensioner cap bolt M16 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
2-15
TIGHTENING TORQUES
Thread
size
Timing chain tensioner bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pipe (crankcase to cylinder
M10 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
head) union bolt
M14 2 35 Nm (3.5 m·kgf, 25 ft·lbf)
head) union bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
head) bolt
Oil pipe union bolt (AC magneto
M8 2 18 Nm (1.8 m·kgf, 13 ft·lbf)
cover)
Thermostat outlet hose guide
M10 1 48 Nm (4.8 m·kgf, 35 ft·lbf)
bolt
Crankcase bolt M8 3 26 Nm (2.6 m·kgf, 19 ft·lbf)
Crankcase bolt M6 13 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Dipstick guide bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Engine oil drain bolt M14 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Crankcase plug M16 1 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Crankcase plug M14 1 18 Nm (1.8 m·kgf, 13 ft·lbf)
Oil filter cartridge M20 1 17 Nm (1.7 m·kgf, 12 ft·lbf) LS
Oil filter cartridge union bolt M20 1 30 Nm (3.0 m·kgf, 22 ft·lbf) E
Timing chain stopper guide (low-

M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
er) bolt
Bearing retainer bolt (crankcase) M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Oil pump bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Oil pump housing cover screw M5 1 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Water jacket joint bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Water pump outlet hose clamp
M5 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
screw
Water pump housing bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant drain bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Water pump air bleed bolt M6 1 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)
Crankshaft end accessing screw M36 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Timing mark accessing screw M14 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Drive select lever shift cable
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
bracket bolt (engine side)
AC magneto cover bolt M6 11 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
AC magneto rotor nut M16 1 60 Nm (6.0 m·kgf, 43 ft·lbf) E
AC magneto/crankshaft position
M5 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf) LT
sensor lead holder bolt
Starter clutch bolt M8 3 30 Nm (3.0 m·kgf, 22 ft·lbf) LT
2-16
TIGHTENING TORQUES
Thread
size
Use a
Oil pump driven sprocket nut M10 1 22 Nm (2.2 m·kgf, 16 ft·lbf) lock
washer.
Use a
lock
Balancer driven gear nut M18 1 85 Nm (8.5 m·kgf, 61 ft·lbf) washer.
E
Drive belt cover bolt M6 11 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
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
housing)
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 retain-
M36 1 90 Nm (9.0 m·kgf, 65 ft·lbf)
ing nut
Drive belt case bolt M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
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.
M
Drive select lever unit bolt M6 5 13 Nm (1.3 m·kgf, 9.4 ft·lbf)

Drive select lever shift cable
bracket bolt (drive select lever M8 2 16 Nm (1.6 m·kgf, 12 ft·lbf)
side)
Drive select lever shift cable lock-
M14 1 39 Nm (3.9 m·kgf, 28 ft·lbf)
nut
Shift arm bolt M6 1 14 Nm (1.4 m·kgf, 10 ft·lbf)
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)
Middle drive pinion gear nut M22 1 190 Nm (19 m·kgf, 137 ft·lbf) Stake.
Middle drive shaft bearing hous-
M8 4 32 Nm (3.2 m·kgf, 23 ft·lbf) LT
ing bolt
Middle drive shaft bearing retain- Stake.
M8 4 29 Nm (2.9 m·kgf, 21 ft·lbf)
er bolt LT
Front drive shaft yoke nut (middle

M16 1 190 Nm (19 m·kgf, 137 ft·lbf) LT
gear side)
Left-hand
Middle driven shaft bearing re- threads
M55 1 80 Nm (8.0 m·kgf, 58 ft·lbf)
tainer
LT
2-17
TIGHTENING TORQUES
Thread
size
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 threads
M60 1 130 Nm (13 m·kgf, 94 ft·lbf)
retainer
LT
Rear drive shaft yoke nut (middle

M16 1 190 Nm (19 m·kgf, 137 ft·lbf) LT
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)
Negative battery lead bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Spark plug M10 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Stator coil assembly bolt M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf) LT
Crankshaft position sensor bolt M5 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf) LT
Coolant temperature sensor M12 1 18 Nm (1.8 m·kgf, 13 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
Cylinder bolt
Temporarily tighten the cylinder bolts to 15 Nm (1.5 m·kgf, 11 ft·lbf), and then tighten them to 50 Nm
(5.0 m·kgf, 36 ft·lbf).
TIP
Cylinder head bolt
Tighten the cylinder head bolts to specification in the proper tightening sequence.
Cylinder head tightening sequence:
4
2 7 6
1 8
5
3
2-18
TIGHTENING TORQUES
EAS20350
CHASSIS TIGHTENING TORQUES

Thread
size
Engine mounting bolt M10 4 42 Nm (4.2 m·kgf, 30 ft·lbf)
Engine mounting bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Engine bracket nut M10 4 42 Nm (4.2 m·kgf, 30 ft·lbf)

Front fender and front grill bolt M6 6 4.0 Nm (0.40 m·kgf, 2.9 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 pipe holder bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front fender and electrical com-
M6 4 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
ponents tray bolt
Front grill and front guard bolt M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Front guard bolt M10 4 48 Nm (4.8 m·kgf, 35 ft·lbf)
Front guard cover screw M6 4 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Front grill and frame bolt M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Headlight screw M5 6 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Front fender and frame bolt M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Electrical components tray and
M6 4 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
frame bolt
Muffler heat protector plate bolt M8 2 17 Nm (1.7 m·kgf, 12 ft·lbf)
Side panel bolt M6 6 4.0 Nm (0.40 m·kgf, 2.9 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)
Starter relay lead bolt M6 2 3.6 Nm (0.36 m·kgf, 2.6 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
M6 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
models)
V-belt cooling intake duct joint 1
clamp screw (V-belt cooling in- M4 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
take duct side)
clamp screw (drive belt cover M6 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
side)
M4 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
clamp screw
V-belt cooling exhaust duct joint
clamp screw (V-belt cooling ex- M4 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
haust duct side)
V-belt cooling exhaust duct joint
clamp screw (drive belt cover M6 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
side)
Fuel tank retainer bolt M8 2 16 Nm (1.6 m·kgf, 12 ft·lbf)
2-19
TIGHTENING TORQUES
Thread
size
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 breather hose joint bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel pump nut M6 6 See TIP.
Throttle body joint clamp screw M5 2 2.8 Nm (0.28 m·kgf, 2.0 ft·lbf)
Air intake silencer joint clamp
M5 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
screw (throttle body side)
Air intake silencer joint clamp
M6 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
screw (air intake silencer side)
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 filter case bolt M6 3 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)
Door hinge nut M6 8 1.3 Nm (0.13 m·kgf, 0.94 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)
Front skid plate bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear skid plate bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Lower panel and floor board bolt M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Lower panel and frame bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Frame cross member bolt M8 4 17 Nm (1.7 m·kgf, 12 ft·lbf)
Exhaust pipe heat protector plate
M8 2 17 Nm (1.7 m·kgf, 12 ft·lbf)
bolt
Exhaust pipe heat protector plate
M6 2 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
bolt
Front wheel axle nut M24 2 350 Nm (35 m·kgf, 253 ft·lbf) Stake.
Front wheel nut M12 8 75 Nm (7.5 m·kgf, 54 ft·lbf)
Rear wheel axle nut M24 2 350 Nm (35 m·kgf, 253 ft·lbf) Stake.
Rear wheel nut M12 8 75 Nm (7.5 m·kgf, 54 ft·lbf)
Front brake disc guard bolt M6 6 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Front brake caliper bolt M10 4 48 Nm (4.8 m·kgf, 35 ft·lbf)
Front brake disc bolt M8 8 30 Nm (3.0 m·kgf, 22 ft·lbf) LT
Front brake caliper retaining pin

M8 2 22 Nm (2.2 m·kgf, 16 ft·lbf) LT
nut
Front brake pad bolt M10 4 17 Nm (1.7 m·kgf, 12 ft·lbf)
Front brake caliper guide pin M8 2 17 Nm (1.7 m·kgf, 12 ft·lbf)
Front brake caliper bleed screw M8 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Rear brake disc guard bolt M6 4 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Rear brake disc cleaning plate
M6 4 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
bolt
2-20
TIGHTENING TORQUES
Thread
size
Rear brake disc bolt M8 8 30 Nm (3.0 m·kgf, 22 ft·lbf) LT
Rear brake caliper bolt M10 4 48 Nm (4.8 m·kgf, 35 ft·lbf)

Rear brake caliper retaining pin
M8 2 22 Nm (2.2 m·kgf, 16 ft·lbf) LT
nut
Rear brake pad bolt M10 4 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)
Rear brake caliper bleed screw M8 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Brake pipe flare nut M10 4 19 Nm (1.9 m·kgf, 14 ft·lbf)
Front brake hose joint bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear 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 holder bolt M6 2 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 master cylinder reservoir
— 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
cap
Brake master cylinder reservoir
M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
clamp screw
Parking brake cable holder bolt M6 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Parking brake caliper guide pin M8 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
Parking brake caliper retaining
M8 1 22 Nm (2.2 m·kgf, 16 ft·lbf) LT
pin nut
Parking brake pad bolt M8 2 17 Nm (1.7 m·kgf, 12 ft·lbf)
Parking brake caliper arm nut 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)
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)
Throttle cable locknut (accelera-
M6 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
tor pedal end)
Parking brake lever bolt M6 2 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Parking brake caliper bolt M10 2 40 Nm (4.0 m·kgf, 29 ft·lbf)
Parking brake disc nut M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Parking brake cable locknut M6 2 16 Nm (1.6 m·kgf, 12 ft·lbf)
Front arm nut M10 8 45 Nm (4.5 m·kgf, 33 ft·lbf) LS
Front shock absorber assembly

M10 4 45 Nm (4.5 m·kgf, 33 ft·lbf)
nut
Steering knuckle nut M12 4 30 Nm (3.0 m·kgf, 22 ft·lbf)
Front arm protector bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Steering wheel nut M12 1 35 Nm (3.5 m·kgf, 25 ft·lbf)
2-21
TIGHTENING TORQUES
Thread
size
Steering column bolt (except for
M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
EPS models)
EPS unit bolt (for EPS models) M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
EPS unit bracket bolt (for EPS
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
models)
Steering joint bolt M8 2 27 Nm (2.7 m·kgf, 20 ft·lbf)
Steering assembly bolt M10 4 See TIP.
Tie-rod end locknut M12 2 40 Nm (4.0 m·kgf, 29 ft·lbf)
Steering knuckle and tie-rod end
M12 2 39 Nm (3.9 m·kgf, 28 ft·lbf)
nut
Rear arm nut M10 4 45 Nm (4.5 m·kgf, 33 ft·lbf) LS
Rear shock absorber assembly

M12 4 82 Nm (8.2 m·kgf, 59 ft·lbf)
nut
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 knuckle nut M12 2 85 Nm (8.5 m·kgf, 61 ft·lbf)
Rear arm protector bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear knuckle grease nipple M6 4 3.8 Nm (0.38 m·kgf, 2.8 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)
Front drive shaft universal joint
M16 1 150 Nm (15 m·kgf, 108 ft·lbf) LT
yoke 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 bracket nut M10 1 60 Nm (6.0 m·kgf, 43 ft·lbf)
Support bearing bracket bolt M8 2 18 Nm (1.8 m·kgf, 13 ft·lbf)
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 assembly bracket bolt M8 6 33 Nm (3.3 m·kgf, 24 ft·lbf)
Final drive assembly nut M12 3 105 Nm (10.5 m·kgf, 76 ft·lbf)
Rear drive shaft yoke nut (final
M14 1 97 Nm (9.7 m·kgf, 70 ft·lbf) LT
drive assembly side)
Final drive pinion gear bearing
M8 4 26 Nm (2.6 m·kgf, 19 ft·lbf)
housing bolt
Ring gear stopper nut M8 1 16 Nm (1.6 m·kgf, 12 ft·lbf) LT
Final drive case cover bolt M10 8 52 Nm (5.2 m·kgf, 38 ft·lbf)

Driver seat frame bolt M8 4 23 Nm (2.3 m·kgf, 17 ft·lbf)
2-22
TIGHTENING TORQUES
Thread
size
Center passenger seat frame bolt M8 4 23 Nm (2.3 m·kgf, 17 ft·lbf)
Outer passenger seat frame bolt M8 4 23 Nm (2.3 m·kgf, 17 ft·lbf)
Seat back bolt M6 9 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Headrest bolt M6 9 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Seat belt bolt M12 6 59 Nm (5.9 m·kgf, 43 ft·lbf)
Seat belt buckle bolt M12 3 59 Nm (5.9 m·kgf, 43 ft·lbf)
Seat belt guide bolt M11 3 59 Nm (5.9 m·kgf, 43 ft·lbf)
Passenger handhold bracket bolt M8 2 16 Nm (1.6 m·kgf, 12 ft·lbf)
Passenger handhold stopper nut M6 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Left floor board and frame bolt M6 6 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Center floor board and frame bolt M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Right floor board and frame bolt M6 6 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Center floor board and left floor
M6 4 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
board bolt
Center floor board and right floor
M6 5 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
board bolt
Instrument panel bolt M6 8 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Meter assembly nut M5 3 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Meter assembly bracket bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Glove compartment latch plate
M4 1 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
screw
Gas spring assembly ball stud
M8 2 16 Nm (1.6 m·kgf, 12 ft·lbf)
nut
Tail/brake light nut M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Cargo bed release lever bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Cargo bed release lever holder
M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
bolt
Cargo hook nut M6 8 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Tailgate shaft bolt M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Tailgate cable bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Tailgate cable bracket bolt M6 4 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Cargo bed heat protector plate
M6 5 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
bolt
Left side frame nut (front) M10 2 65 Nm (6.5 m·kgf, 47 ft·lbf)
Left side frame nut (rear) M10 1 48 Nm (4.8 m·kgf, 35 ft·lbf)
Right side frame nut (front) M10 2 65 Nm (6.5 m·kgf, 47 ft·lbf)
Right side frame nut (rear) M10 1 48 Nm (4.8 m·kgf, 35 ft·lbf)
Front top frame bolt M10 4 48 Nm (4.8 m·kgf, 35 ft·lbf)
Rear top frame bolt M10 4 48 Nm (4.8 m·kgf, 35 ft·lbf)
Rear center frame bolt M10 4 48 Nm (4.8 m·kgf, 35 ft·lbf)
2-23
TIGHTENING TORQUES
Thread
size
Rear left frame bolt M10 4 48 Nm (4.8 m·kgf, 35 ft·lbf)
Rear right frame bolt M10 4 48 Nm (4.8 m·kgf, 35 ft·lbf)
Sun top front bracket screw (for
M6 8 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
sun top models)
Sun top rear bracket screw (for
M6 8 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
sun top models)
Sun top lower bracket bolt (for
M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
sun top models)
Sun top lower bracket nut (for sun
M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
top models)
Intake air temperature sensor
M5 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
screw
Rectifier/regulator bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Ground lead bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Ignition coil bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Horn lead nut (for Europe and
— 2 2.3 Nm (023 m·kgf, 1.7 ft·lbf)
Oceania)
Horn nut (for Europe and Ocean-
M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
ia)
TIP
Enclosure bolt and nut
Tighten the enclosure bolts and nuts to specification in the proper tightening sequence.
Enclosure tightening sequence:

2
2 2
2
1
1 3
5
1 1
5 4
4
3
TIP
Steering assembly bolt
Tighten the steering assembly bolts to 48 Nm (4.8 m·kgf, 35 ft·lbf) in the proper tightening sequence.
2-24
TIGHTENING TORQUES
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.
Fuel pump tightening sequence:

2 4
5 6
3 1
TIP
Fuel tank bolt
Tighten the fuel tank bolts and fuel tank retainer bolts to specification in the proper tightening sequence.
Fuel tank tightening sequence:
3 4 5
1 2
TIP
Final drive assembly bolt and nut
Tighten the final drive assembly bolts and nuts to specification in the proper tightening sequence.
2-25
TIGHTENING TORQUES
Final drive assembly tightening sequence:

6 3
4 5
9 8 7 FWD
2 1
2-26
LUBRICATION AND SEALING POINTS
EAS20360

EAS20370
ENGINE
Lubrication point Lubricant/Sealant
Oil seal lips LS
Bearings E
O-rings LS
Cylinder head bolts M
Crankshaft pin E
Connecting rod big end thrust surface E
Crankshaft sprocket M
Inner race (crankshaft) E
Buffer boss (crankshaft) E
Crankshaft seal E
Piston pin E
Piston rings and ring grooves E
Valve stems and stem ends (intake and exhaust) M
Valve stem seals (intake and exhaust) M
Rocker arm shafts E
Camshaft lobes M
Decompressor lever pin E
Decompressor lever E
Rocker arms (intake and exhaust) M
Oil pump shaft E
O-ring (oil filter cartridge) LS
Water pump impeller shaft M
Dipstick mating surface E
Starter idler gear inner surface E
Starter idler gear shaft E
Starter wheel gear E
Torque limiter E
Clutch housing shaft end LS
Clutch carrier assembly E
One-way clutch bearing E
Clutch dog M
Reverse idle gear shaft E
Reverse idle gear E
2-27
Lubrication point Lubricant/Sealant

Middle driven shaft splines M
Shift drum E
Shift forks and shift fork guide bar E
Shift drum stopper ball E
Shift lever 1 and shift lever 2 E
Yamaha bond
AC magneto lead grommet No.1215 (Three bond
No.1215®)
Yamaha bond
Crankcase mating surface No.1215 (Three bond
No.1215®)
2-28
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20390

EAS20400
ENGINE OIL LUBRICATION CHART
9 9
6
11 10 8 7 5
4
3
1 2
2-29
1. Oil pan
2. Oil strainer
3. Oil pump assembly
4. Relief valve assembly
5. Oil cooler
6. Oil filter cartridge
7. Drive axle
8. Reverse idle gear shaft
9. Oil pipe (crankcase to cylinder head)
10. Crankshaft
11. Cylinder head
2-30
EAS20410
LUBRICATION DIAGRAMS
6 1
5 4 3 2
7 8
3 2
2-31
1. Oil pipe (crankcase to cylinder head)

2. Oil filter cartridge
3. Oil cooler
4. Oil strainer
5. Oil pump
6. Oil pipe (AC magneto cover)
7. Reverse idle gear shaft
8. Drive axle
9. Relief valve assembly
2-32
5 4 3
2-33
1. Camshaft
2. Crankshaft
3. Oil strainer
4. Oil pump
5. Oil pump driven sprocket
2-34
COOLING SYSTEM DIAGRAMS
EAS20420
1 2 3
6 5 4
2 5
2-35
1. Radiator
2. Radiator outlet hose
3. Radiator outlet pipe
4. Radiator inlet pipe
5. Radiator inlet hose
6. Radiator cap
2-36
1 2
5 4 3
3 6
2 4
2-37
1. Radiator outlet pipe

2. Water pump inlet hose
3. Thermostat outlet hose
4. Oil cooler outlet hose
5. Radiator inlet pipe
6. Thermostat
2-38
4 3 2
5 4
6
8
4 7
2-39

2. Water pump inlet hose
3. Water pump
4. Water pump outlet pipe
5. Oil cooler inlet hose
6. Oil cooler
7. Oil cooler outlet hose
8. Water pump outlet hose
9. Water jacket joint
2-40
CABLE ROUTING
EAS20430
CABLE ROUTING
Radiator view (right side)
1 2 A B 3 4
13
5
12
C
11
10 6
9
8 D
G E
2-41
CABLE ROUTING
1. Horn lead (for Europe and Oceania)

2. Wire harness
3. Radiator fan motor breather hose
4. Differential assembly breather hose
5. Coolant reservoir breather hose
6. Radiator outlet hose
7. Differential motor lead
8. Coolant reservoir hose
9. Radiator fan motor lead
10. Drive select lever shift cable
11. Parking brake cable
12. Ground lead
13. Auxiliary DC jack lead
A. Route the wire harness, starter motor lead,
negative battery lead, and horn lead (for Europe
and Oceania) into the electrical components tray.
B. Make sure that there is no slack in the coolant
reservoir breather hose in the area shown in the
illustration.
C. Fasten the coolant reservoir breather hose to the
radiator outlet hose with the plastic band. Align the
plastic band with the portion of the radiator outlet
hose where the hose begins to bend.
D. Fasten the differential assembly breather hose with
the holder on the radiator.
E. Fasten the coolant reservoir hose to the radiator
outlet hose with the plastic band. Align the plastic
band with the portion of the radiator outlet hose
where the hose begins to bend.
F. Fasten the radiator fan motor lead to the radiator
outlet hose with the plastic band.
G. Insert the projection on the wire harness holder
into the hole in the frame from the inside of the
frame.
H. Fasten the wire harness, starter motor lead,
negative battery lead, drive select lever shift cable,
and parking brake cable with the plastic band.
I. Fasten the wire harness, starter motor lead, and
negative battery lead with the plastic band.
Position the plastic band at the section of the wire
harness where the leads branch off from the
harness.
2-42
CABLE ROUTING
Radiator view (left side)
B C 10 11 12 13 2 13 D
5 6
4
3
4
2
1 5 6
3
7
8 9
9
3 E
A
9
3 F
2-43
CABLE ROUTING
1. Coolant reservoir hose

2. Wire harness
3. Throttle cable
4. Brake light switch lead
5. EPS motor lead (for EPS models)
6. EPS torque sensor lead (for EPS models)
9. Radiator inlet hose
10. Differential assembly breather hose
11. Coolant reservoir breather hose
12. Radiator fan motor breather hose
A. Fasten the coolant reservoir hose with the holder
on the radiator.
B. Route the right headlight lead and horn lead (for
Europe and Oceania) into the electrical
components tray, and then fasten the lead with the
holder on the electrical components tray.
C. Route the differential assembly breather hose,
coolant reservoir breather hose, and radiator fan
motor breather hose through the hole in the
electrical components tray. Make sure that the end
of each breather hose protrudes out of the
electrical components tray.
D. Fasten the right headlight lead and horn lead (for
Europe and Oceania) with the holder on the
electrical components tray.
E. Fasten the throttle cable to the radiator inlet hose
with the plastic band. Be sure to route the throttle
cable to the outside of the radiator inlet hose and
install the plastic band around the hose protector
of the radiator inlet hose, not the hose itself.
F. Fasten the throttle cable to the radiator inlet hose
with the plastic band. Be sure to route the throttle
cable to the inside of the radiator inlet hose and
install the plastic band around the hose protector
of the radiator inlet hose, not the hose itself.
2-44
CABLE ROUTING
Radiator view (top)
3
3 N
4
4 6
7
5 7
6 5
4 5 6 7 E
3 D E
C
1 2
B
A
F
M
17 H
12 11 10 9 G 8 G
K 13
J 14
15
16
2-45
CABLE ROUTING
1. Right headlight lead

3. Wire harness
4. Negative battery lead
5. Starter motor lead
8. Throttle cable
9. Meter assembly lead
10. Indicator light assembly lead
11. Parking brake switch lead
12. Main switch lead
15. Light switch lead
16. On-Command four-wheel-drive switch lead
17. Left headlight lead
A. Fasten the right headlight lead and horn lead (for
Europe and Oceania) to the frame with the plastic
band.
B. To the electrical components tray
C. Fasten the wire harness with the plastic band.
harness before the leads branch off from the
harness.
D. Fasten the wire harness and horn lead (for Europe
and Oceania) at the white mark on the harness
with the plastic band.
E. Fasten the wire harness, starter motor lead,
negative battery lead, drive select lever shift cable,
and parking brake cable with the plastic band.
F. To the horn switch (for Europe and Oceania)
G. Fasten the throttle cable with the plastic band.
H. Fasten the parking brake switch lead with the
plastic band.
I. Route the EPS torque sensor lead through the
frame, and then connect the coupler to the EPS
torque sensor. (For EPS models)
J. Fasten the wire harness with the plastic band.
harness before the leads branch off from the
harness.
K. Fasten the wire harness and EPS motor lead (for
EPS models) with the plastic band. Position the
plastic band at the section of the wire harness
before the leads branch off from the harness.
L. Route the EPS torque sensor lead and EPS motor
lead through the hole in the electrical components
tray, and then connect the couplers to the EPS
control unit. (For EPS models)
M. Fasten the left headlight lead to the frame with the
plastic band.
N. Insert the projection on the holder into the second
hole from the right in the frame, and then fasten the
wire harness with the holder.
2-46
CABLE ROUTING
Engine view (right side)
I
K 2 6
G 1
1 A 2 B 2
C
6
E
B
9 8 7 6 5 4 3
2-47
CABLE ROUTING
1. Wire harness
2. Final drive assembly breather hose
4. Intake air temperature sensor lead
5. Speed sensor lead
7. AC magneto lead
A. Route the final drive assembly breather hose
through the hole in the frame.
B. Fasten the final drive assembly breather hose with
the holder.
C. Fasten the wire harness with the plastic band.
Position the plastic band to the front of the split in
the wire harness.
D. Fasten the negative battery lead and starter motor
lead with the holder.
E. Fasten the wire harness to the frame with the
plastic band. Be sure to position the plastic band
above the bracket.
F. Route the wire harness in front of the frame, and
then fasten the wire harness to the frame with the
plastic band. Be sure to position the plastic band
under the bracket.
G. Route the wire harness to the inside of the frame.
H. Fasten the negative battery lead and starter motor
lead with the plastic band.
I. 10–30°
J. 50–60 mm (1.97–2.36 in)
K. Align the holder with the white mark on the final
drive assembly breather hose.
2-48
CABLE ROUTING
Engine view (left side)
4 6 E
10 11
5 6 7 8 9
4
3
2
B C
2-49
CABLE ROUTING
1. Seat belt switch lead

2. Gear position switch lead
3. Reverse switch lead
4. Throttle cable
5. Cylinder head breather hose
6. Throttle body breather hose
7. ISC unit lead
8. Coolant temperature sensor lead
9. Air induction system solenoid lead
10. Spark plug lead
11. Wire harness
A. Fasten the seat belt switch lead with the holder.
B. Route the seat belt switch lead to the left side of
the frame.
C. To the seat belt switch
D. Fasten the wire harness with the plastic band.
Position the plastic band near the ignition coil
bracket and at the section of the wire harness
before the leads branch off from the harness.
E. Make sure that the throttle body breather hose is
not pinched.
2-50
CABLE ROUTING
Engine view (top)
*A *B *C *D *E *F
9 9 10 10
9 10
1 2 3 4 B 5 6 C 7 D 8
*A *A
A E
*B *B
*C *C
*D *D
*D *D
*D *D
*E *E
*D *D
L 17 16 K J I H G 15 14 13 12 11
12 11 *F *F
10
1 M 13 13
2-51
CABLE ROUTING
1. Wire harness
4. Fuel pump lead
5. Fuel hose
6. TPS lead
7. Intake air pressure sensor lead
8. Air induction system hose (air cut-off valve to reed
valve cover)
9. Right tail/brake light lead
10. Left tail/brake light lead
11. Spark plug lead
12. Air induction system solenoid lead
13. Air induction system hose (air intake silencer to air
cut-off valve)
15. ISC unit lead
16. Throttle cable
17. Seat belt switch lead
A. To the fuel pump
B. Fasten the wire harness with the holder.
C. Fasten the hose protector of the fuel hose with the
holder.
D. Insert the projection on the holder into the hole in
the frame cross member from under the member,
and then fasten the wire harness with the holder.
E. Connect the right tail/brake light connectors. Make
sure that there is no slack in the lead between the
holders in the area shown in the illustration. Place
the slack in the lead to the outside of the outermost
holder.
F. Connect the left tail/brake light connectors. Make
sure that there is no slack in the lead between the
holders in the area shown in the illustration. Place
the slack in the lead to the outside of the outermost
holder.
G. Route the wire harness between the air induction
system hose (air intake silencer to air cut-off valve)
and the thermostat outlet hose.
H. Fasten the air induction system solenoid lead with
the holder under the frame cross member. Position
the holder at the section of the lead after the lead
branches off from the wire harness.
I. Fasten the spark plug lead to the air induction
with the holder. Align the holder with the portion of
the air induction system hose (air intake silencer to
air cut-off valve) where the hose begins to bend.
J. Route the spark plug lead above the air induction
and wire harness.
K. Fasten the wire harness with the holder. Position
the holder at the section of the wire harness before
the leads branch off from the harness.
L. Fasten the throttle cable at the white paint mark to
the hose protector of the thermostat outlet hose
with the plastic band. Align the plastic band with
the portion of the thermostat outlet hose where the
hose begins to bend.
M. Route the wire harness under the frame. Make
sure that the wire harness is not pinched between
the frame and the air intake silencer.
2-52
CABLE ROUTING
Final drive assembly view
4 D F E D 2
A 1 A
2 3
2-53
CABLE ROUTING
1. Wire harness
2. Final drive assembly breather hose
4. Rear brake hose
A. Fasten the wire harness with the holder.
B. Fasten the final drive assembly breather hose with
the holder.
C. Insert the projection on the holder into the hole in
the cargo bed, and then fasten the wire harness
with the holder.
D. Fasten the rear brake hose with the holder.
E. Fasten the rear brake hose and final drive
assembly breather hose with the holder. Position
the holder to the right of the centerline between the
holders securing the brake hose.
F. Centerline
2-54
CABLE ROUTING
Fuel tank view
B A
1
A 3
D 4
2-55
CABLE ROUTING
1. Fuel hose
2. Fuel pump lead
3. Fuel tank breather hose (fuel tank to fuel tank
breather hose joint)
4. Fuel tank breather hose (fuel tank breather hose
joint to air)
A. Fasten the grommet on the fuel hose with the
holder.
B. Fasten the fuel pump lead with the holder.
C. Insert the fuel tank breather hose (fuel tank
breather hose joint to air) into the hole in the frame.
D. 0–3.0 mm (0–0.12 in)
2-56
CABLE ROUTING
Front brake caliper view (left side)
2 B
2 3
2-57
CABLE ROUTING
1. Front brake pipe

2. Front brake hose
3. Rear brake pipe
A. Connect the front brake hose end that has a
projection to the left front brake caliper.
B. Fasten the front brake hose with the holder.
2-58
CABLE ROUTING
Front brake caliper view (top)
2
B
2-59
CABLE ROUTING
1. Front brake hose

2. Front brake pipe
3. Rear brake pipe
A. Face the paint mark upward.
B. Route the front brake hose under the front upper
arm.
C. Fasten the front brake hose with the holder.
2-60
CABLE ROUTING
Rear brake caliper view (left side)
B 2 B C
A 1
2-61
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. Face the paint mark forward.
2-62
CABLE ROUTING
Rear brake caliper view (top)
A 1 A
2 B
2-63
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. Right side
D. Connect the rear brake hose end that has a
projection to the right rear brake caliper.
2-64
CABLE ROUTING
Parking brake view
1 A
1
1
2-65
CABLE ROUTING

A. Fit the parking brake cable into the slit in the
parking brake lever.
B. Fit the parking brake cable into the holder on the
parking brake caliper.
2-66
CABLE ROUTING
Electrical components tray view
A B 3 4 5 6 7 8
1
24
8 7
23
17
22 23
21
1
20
1
19 9
18
17
10
9
16 11
12
15
C 13
14
15
14 13
E
2-67
CABLE ROUTING
1. Wire harness
2. Right headlight lead
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)
14. Left headlight lead
16. Lean angle sensor lead
18. Starter relay lead
19. Positive battery lead
20. EPS fuse (for EPS models)
21. ECU (engine control unit) lead
22. Main fuse
24. Fuse box
A. Fasten the right headlight lead with the holder on
the electrical components tray.
B. Fasten the wire harness and main fuse lead with a
plastic band, making sure to align the band with
the white tape on the harness.
C. Fasten the left headlight lead, EPS motor lead (for
EPS models), and EPS torque sensor lead (for
EPS models) with the holder on the electrical
components tray.
D. Place the slack in the leads in the electrical
components tray.
E. Connect the EPS motor coupler and EPS torque
sensor coupler, and then insert the projection on
each coupler into the hole in the electrical
components tray. (For EPS models)
2-68
CABLE ROUTING
2-69
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE ............................................................................3-1

INTRODUCTION .......................................................................................3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM ................................................................................ 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART .......................3-1
CHECKING THE FUEL LINE .................................................................... 3-3
ADJUSTING THE VALVE CLEARANCE .................................................. 3-3
CHECKING THE SPARK PLUG ............................................................... 3-5
CHECKING THE BREATHER HOSES .....................................................3-6
CHECKING THE EXHAUST SYSTEM......................................................3-6
ADJUSTING THE EXHAUST GAS VOLUME
(for Europe and Oceania) ......................................................................... 3-6
CLEANING THE SPARK ARRESTER ......................................................3-6
CHECKING THE AIR INDUCTION SYSTEM............................................3-7
CHECKING THE COOLING SYSTEM ......................................................3-7
3
CHECKING THE COOLANT LEVEL.........................................................3-8
CHANGING THE COOLANT..................................................................... 3-8
CLEANING THE AIR FILTER ELEMENT................................................ 3-10
CHECKING THE ENGINE OIL LEVEL....................................................3-12
CHANGING THE ENGINE OIL ...............................................................3-13
CHECKING THE FINAL GEAR OIL LEVEL ............................................3-14
CHANGING THE FINAL GEAR OIL........................................................ 3-15
CHECKING THE DIFFERENTIAL GEAR OIL LEVEL............................. 3-15
CHANGING THE DIFFERENTIAL GEAR OIL ........................................ 3-16
CHECKING THE FRONT BRAKE PADS ................................................ 3-16
CHECKING THE BRAKE FLUID LEVEL................................................. 3-16
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-17
CHECKING THE BRAKE HOSES AND BRAKE PIPES ......................... 3-18
ADJUSTING THE BRAKE PEDAL .......................................................... 3-19
LUBRICATING THE BRAKE PEDAL AND
ACCELERATOR PEDAL ........................................................................3-19
CHECKING THE REAR BRAKE PADS .................................................. 3-20
CHECKING THE PARKING BRAKE PADS ............................................3-20
ADJUSTING THE PARKING BRAKE LEVER.........................................3-20
CHECKING AND LUBRICATING THE CABLES .................................... 3-21
ADJUSTING THE ACCELERATOR PEDAL FREE PLAY ......................3-21
CHECKING THE V-BELT........................................................................3-22
REPLACING THE V-BELT ...................................................................... 3-23
CHECKING THE WHEELS ..................................................................... 3-23
CHECKING THE TIRES..........................................................................3-24
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES ............. 3-25
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................ 3-25
CHECKING THE STEERING SYSTEM .................................................. 3-26
ADJUSTING THE TOE-IN....................................................................... 3-26
LUBRICATING THE STEERING SHAFT ................................................ 3-27
CHECKING THE STABILIZER BUSHINGS ............................................3-27
LUBRICATING THE REAR KNUCKLE PIVOTS ..................................... 3-28
LUBRICATING THE DRIVE SHAFT UNIVERSAL JOINTS ....................3-28
CHECKING THE ENGINE MOUNT ........................................................ 3-28
CHECKING THE CONSTANT VELOCITY SHAFT ASSEMBLY
DUST BOOTS ........................................................................................ 3-28
CHECKING THE FASTENERS...............................................................3-29
PERIODIC MAINTENANCE
EAS20450
EAS20460
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a long-
er service life and reduce the need for costly overhaul work. This information applies to vehicles already
in service as well as to new vehicles that are being prepared for sale. All service technicians should be
familiar with this entire chapter.
EVU01640
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

• For vehicles not equipped with an odometer or hour meter, follow the month maintenance intervals.
• For vehicles equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance
intervals. However, keep in mind that if the vehicle isn’t used for a long period of time, the month 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.
EVU01650
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.

1 * Cooling system • Repair if necessary. √ √ √ √ √
• Replace coolant every 24 months.
• 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 • Check oil level/oil leakage. √ √

6 Differential gear oil • Replace.
• Check operation/brake pad wear/fluid leakage.

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

• Repair if necessary.
• Check bearing assemblies for looseness/damage.
14 * Wheel bearings √ √ √ √
• Replace if damaged.
Front and rear sus- • Check operation and for leakage.
15 * pension • Correct if necessary. √ √
• Check operation and for looseness/Replace if dam-

16 * Steering system aged. √ √ √ √ √
• Check toe-in/Adjust if necessary.
17 * Stabilizer bushes • Check for cracks or other damage, and replace if √ √ √

necessary.
Rear upper and lower
18 * • Lubricate with lithium-soap-based grease. √ √ √
knuckle pivots
Drive shaft universal
19 * joint • Lubricate with lithium-soap-based grease. √ √ √
20 * Engine mount • Check for cracks or damage. √ √ √

• Check bolt tightness.
Front and rear axle • Check for cracks or other damage, and replace if
21 * √ √
boots necessary.
Fittings and fasten- • Check all chassis fittings and fasteners.
22 * 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 master cylinder and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-2
EAS21030
CHECKING THE FUEL LINE 2

1. Lift the cargo bed.
2. Remove:
• Outer passenger seat frame 3
• Right passenger compartment panel
Refer to “GENERAL CHASSIS” on page 4-1.
3. Check:
• Fuel hose “1” 1
4
Cracks/damage → Replace.
Loose connection → Connect properly.
5. Disconnect:
• Spark plug cap
1 6. Remove:
• Spark plug
ECA13330
NOTICE
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from falling
into the cylinder.
4. Install: 7. Remove:
• Right passenger compartment panel • Crankshaft end accessing screw “1”
• Outer passenger seat frame • Timing mark accessing screw “2”
5. Lower the cargo bed. 2
EAS20520
ADJUSTING THE VALVE CLEARANCE

The following procedure applies to all of the 1
valves.
TIP
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured or 8. Measure:
adjusted, the piston must be at top dead center • Valve clearance
(TDC) on the compression stroke. Out of specification → Adjust.
1. Lift the cargo bed. Valve clearance (cold)
2. Remove: Intake
• Frame cross member 0.09–0.13 mm (0.0035–0.0051 in)
• Right rear panel Exhaust
Refer to “GENERAL CHASSIS” on page 4-1. 0.16–0.20 mm (0.0063–0.0079 in)
• Exhaust pipe heat protector plate
Refer to “ENGINE REMOVAL” on page 5-1. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3. Disconnect: a. Turn the crankshaft counterclockwise.
• Cylinder head breather hose “1” b. When the piston is at TDC on the compres-
4. Remove: sion stroke, align the “I” mark “a” on the AC
• Intake tappet cover “2” magneto rotor with the stationary pointer “b”
• Exhaust tappet cover “3” on the AC magneto cover.
• Camshaft sprocket cover “4”
3-3
c. Turn the adjusting screw “3” in direction “a” or

“b” with the tappet adjusting tool “4” until the
specified valve clearance is obtained.
Tappet adjusting tool

a 90890-01311
Six piece tappet set
b YM-A5970
Direction “a”
TIP Valve clearance is increased.
To position the piston at TDC on the compres- Direction “b”
sion stroke, align the “I” mark “c” on the camshaft Valve clearance is decreased.
sprocket with the stationary pointer “d” on the
cylinder head, as shown in the illustration.
d 3
b 4
c
1
a
2
• Hold the adjusting screw to prevent it from

moving and tighten the locknut to specifica-
c. Measure the valve clearance with the thick- tion.
ness gauge “1”.
Out of specification → Adjust. Valve adjusting screw locknut
14 Nm (1.4 m·kgf, 10 ft·lbf)
T.
R.
Thickness gauge
90890-03079 d. Measure the valve clearance again.
Narrow gauge set e. If the valve clearance is still out of specifica-
YM-34483 tion, repeat all of the valve clearance adjust-
ment steps until the specified clearance is
obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
10.Install:
• O-ring New
• Timing mark accessing screw
1 • O-ring New
• Crankshaft end accessing screw
Timing mark accessing screw

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
T.
R.
Crankshaft end accessing screw

9. Adjust:
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
• Valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
11.Install:
a. Loosen the locknut “1”.
• Spark plug
b. Insert the thickness gauge “2” between the
end of the adjusting screw and the valve tip.
3-4
ECA13330
TIP
NOTICE
Before installing the spark plug, clean the spark
Before removing the spark plug, blow away
plug and gasket surface.
any dirt accumulated in the spark plug well
with compressed air to prevent it from falling
Spark plug into the cylinder.
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
T.
R.
4. Check:
12.Connect: • Spark plug type
• Spark plug cap Incorrect → Change.
13.Install:
Manufacturer/model
• O-ring New NGK/CPR7EA-9
• Camshaft sprocket cover
• O-ring “1” New 5. Check:
• Intake tappet cover • Electrodes “1”
Damage/wear → Replace the spark plug.
• O-ring New
• Insulator “2”
• Exhaust tappet cover
Abnormal color → Replace the spark plug.
Camshaft sprocket cover bolt Normal color is medium-to-light tan.
10 Nm (1.0 m·kgf, 7.2 ft·lbf) 6. Clean:
T.
R.
Tappet cover bolt • Spark plug

10 Nm (1.0 m·kgf, 7.2 ft·lbf) (with a spark plug cleaner or wire brush)
7. Measure:
• 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)
1 New
14.Connect:
• Cylinder head breather hose
15.Install:
• Exhaust pipe heat protector plate
Refer to “ENGINE REMOVAL” on page 5-1.
• Right rear panel
• Frame cross member
Refer to “GENERAL CHASSIS” on page 4-1. 8. Install:
16.Lower the cargo bed. • Spark plug
EAS20690 Spark plug

CHECKING THE SPARK PLUG 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
T.
R.

2. Disconnect: TIP
• Spark plug cap Before installing the spark plug, clean the spark
3. Remove: plug and gasket surface.
• Spark plug
9. Connect:
• Spark plug cap
3-5
10.Lower the cargo bed.

3 5
EAS1XD1057
CHECKING THE BREATHER HOSES 1

5 4
2. Remove:
3. Check:
• Cylinder head breather hose “1” 2
• Throttle body breather hose “2”
Cracks/damage → Replace. 4. Lower the cargo bed.
Loose connection → Connect properly. EAS1XD2005
ECA1XD1016
ADJUSTING THE EXHAUST GAS VOLUME
NOTICE
(for Europe and Oceania)
Make sure the cylinder head breather hose
TIP
and throttle body breather hose are routed
correctly. • Be sure to set the CO density level to standard,
and then adjust the exhaust gas volume.
• To adjust the exhaust gas volume, use the CO
1 adjustment mode of the Yamaha diagnostic
tool. For more information, refer to the opera-
tion manual of the Yamaha diagnostic tool.
2 1. Connect the Yamaha diagnostic tool to the
coupler. For information about connecting the
Yamaha diagnostic tool, refer to “YAMAHA
DIAGNOSTIC TOOL” on page 9-37.
Yamaha diagnostic tool

4. Install: 90890-03215
Refer to “GENERAL CHASSIS” on page 4-1. EAS1XD2001
5. Lower the cargo bed. CLEANING THE SPARK ARRESTER

1. Clean:
EAS21080
CHECKING THE EXHAUST SYSTEM • Spark arrester

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1. Lift the cargo bed. EWA1XD1004
2. Check: WARNING
• Exhaust pipe “1” • Select a well-ventilated area free of com-
• Muffler “2” bustible materials.
• Muffler mount “3” • Always let the exhaust system cool before
• Springs “4” performing this operation.
Cracks/damage → Replace. • Do not start the engine when removing the
• Gaskets “5” tailpipe from the muffler.
Exhaust gas leaks → Replace.
3. Check: a. Remove the bolts “1”.
• Tightening torque b. Remove the tailpipe “2” by pulling it out of the
muffler and gasket “3”.
Exhaust pipe nut
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)
3-6

3. Check:
• Radiator “1”
1 1 • Coolant reservoir hose “2”
• Coolant reservoir “3”
• Radiator outlet hose “4”
2 • Radiator inlet hose “5”
• Radiator outlet pipe “6”
• Radiator inlet pipe “7”
• Thermostat outlet hose “8”
• Thermostat cover “9”
2 3 • Water pump inlet hose “10”
• Water pump housing “11”
• Water pump outlet pipe “12”
• Water pump outlet hose “13”
• Water jacket joint “14”
• Oil cooler inlet hose “15”
• Oil cooler “16”
• Oil cooler outlet hose “17”
c. Tap the tailpipe lightly with a soft-face ham- Coolant leakage → Replace any damaged
mer or suitable tool, then use a wire brush to hose and pipe
remove any carbon deposits from the spark Refer to “OIL COOLER” on page 6-1, “RADI-
arrester portion of the tailpipe and the inner ATOR” on page 6-4, “THERMOSTAT” on
contact surfaces of the muffler. page 6-8 and “WATER PUMP” on page 6-11.
d. Install a new gasket, and then insert the 7 5
tailpipe into the muffler and align the bolt
holes.
e. Install the bolts “1” and tighten them.
Spark arrester bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf) 6
T.
R.
4 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2
3
EAS1XD1013
CHECKING THE AIR INDUCTION SYSTEM

Refer to “CHECKING THE AIR INDUCTION
SYSTEM” on page 7-19. 8
EAS21120
9
CHECKING THE COOLING SYSTEM
1. Remove:
• Sun top (for sun top models)
• Side frames
• Hood
• Front fender
• Instrument panel
• Center passenger seat frame
• Center passenger compartment panel
• Center floor board
• Air filter case
Refer to “AIR FILTER CASE” on page 7-5.
3-7
17
a
14
12 10
13 b
16 15 11
4. Lower the cargo bed. 3. If the coolant is at or below the minimum level
5. Install: mark, remove the reservoir cap “1”, add cool-
• Air filter case ant or distilled water to the maximum level
Refer to “AIR FILTER CASE” on page 7-5. mark “a”, install the reservoir cap.
Coolant reservoir capacity (up to
• Center passenger compartment panel
the maximum level mark)
• Center passenger seat frame 0.28 L (0.30 US qt, 0.25 Imp.qt)
• Front fender
• Hood
• Side frames
• Sun top (for sun top models) 1
EAS21110 a
CHECKING THE COOLANT LEVEL
1. Place the vehicle on a level surface.
TIP
The coolant level must be checked on a cold en-
gine since the level varies with engine tempera-
EAS21130
ture. CHANGING THE COOLANT
2. Check: 1. Remove the hood.
• Coolant level 2. Lift the cargo bed.
The coolant level should be between the 3. Remove:
maximum level mark “a” and minimum level • Right rear panel
mark “b”. Refer to “GENERAL CHASSIS” on page 4-1.
Below the minimum level mark → Add the 4. Remove:
recommended coolant to the proper level. • Coolant reservoir cap “1”
ECA13470 5. Disconnect:
NOTICE • Coolant reservoir hose “2”
• Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant check, and if nec- 1
essary, correct the antifreeze concentra-
tion of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may 2
be used.
6. Drain:
• Coolant
(from the coolant reservoir)
3-8
7. Connect:
• Coolant reservoir hose Coolant drain bolt
8. Remove: 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
• Radiator cap “1”
EWA13030 12.Fill:
WARNING • Cooling system
A hot radiator is under pressure. Therefore, (with the specified amount of the recom-
do not remove the radiator cap when the en- mended coolant)
gine is hot. Scalding hot fluid and steam may
Recommended antifreeze
be blown out, which could cause serious in- High-quality ethylene glycol an-
jury. When the engine has cooled, open the tifreeze containing corrosion in-
radiator cap as follows: hibitors for aluminum engines
Place a thick rag or a towel over the radiator Mixing ratio
cap and slowly turn the radiator cap counter- 1:1 (antifreeze:water)
clockwise toward the detent to allow any re- Radiator capacity (including all
sidual pressure to escape. When the hissing routes)
sound has stopped, press down on the radi- 2.74 L (2.90 US qt, 2.41 Imp.qt)
ator cap and turn it counterclockwise to re- Coolant reservoir capacity (up to
move. the maximum level mark)
0.28 L (0.30 US qt, 0.25 Imp.qt)
1 Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
EWA13040
WARNING
• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
tor.
• If coolant splashes on your clothes, quickly
9. Remove: wash it away with water and then with soap
• Coolant drain bolt “1” and water.
(along with the copper washer) • If coolant is swallowed, induce vomiting
TIP and get immediate medical attention.
ECA13480
Place a container under the engine, and then re-
NOTICE
move the coolant drain bolt.
• Adding water instead of coolant lowers the
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.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
1
• If coolant comes into contact with painted
surfaces, immediately wash them with wa-
ter.
10.Drain: • Do not mix different types of antifreeze.
• Coolant
(from the engine and radiator) 13.Install:
11.Install: • Radiator cap
• Coolant drain bolt
(along with the copper washer New )
3-9
14.Fill: d. When coolant begins to flow out of the bolt

• Coolant reservoir hole, tighten the thermostat cover air bleed
(with the recommended coolant to the maxi- bolt to specification.
mum level mark “a”)
15.Install: Thermostat cover air bleed bolt
• Coolant reservoir cap “1” 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1 17.Start the engine, warm it up for ten minutes,
and then rev the engine five times.
18.Pour the recommended coolant into the radi-
a ator until it is full.
19.Stop the engine and allow it to cool. If the
coolant level has dropped after the engine
has cooled, add sufficient coolant until it
reaches the top of the radiator, and then in-
16.Bleed: stall the radiator cap.
• Cooling system 20.Check:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Coolant level
a. Loosen the water pump air bleed bolt “1”, Refer to “CHECKING THE COOLANT LEV-
without removing it, to allow all of the air to es- EL” on page 3-8.
cape from the air bleed bolt hole. 21.Start the engine, and then check for coolant
leakage.
22.Install:
• Right rear panel
1 24.Install the hood.
EAS20951
CLEANING THE AIR FILTER ELEMENT

1. Check:
• Check hoses “1”
b. When coolant begins to flow out of the bolt 2. Remove:
hole, tighten the water pump air bleed bolt to • Center passenger seat cushion
specification. Refer to “GENERAL CHASSIS” on page 4-1.
TIP
Water pump air bleed bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf) There are check hoses “1” at the bottom of the
T.
R.
air filter case and on the air intake duct. If dust

c. Loosen the thermostat cover air bleed bolt and/or water collects in these hoses, clean the
“2”, without removing it, to allow all of the air air filter element, filter frame, and air filter case.
to escape from the air bleed bolt hole.
È
1
3-10
É 3
2
1
A. Air filter case check hose 6. Check:

B. Air intake duct check hose • Air filter element
• Air filter element frame
3. Remove: • Air filter element holder
• Air filter case cover “1” Damage → Replace.
1 7. Clean:
• Air filter element
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Carefully wash the air filter element in sol-
vent.
EWA13020
WARNING
Never use low flash point solvents, such as
gasoline, to clean the air filter element. Such
solvents may cause a fire or an explosion.
4. Remove:
• Air filter element “1”
b. After cleaning, squeeze the air filter element

to remove the excess solvent.
5. Disassemble: ECA13430
• Air filter element holder “1” NOTICE

• Air filter element “2” Do not twist the air filter element when
• Air filter element frame “3” squeezing it.
ECA1XD1028
NOTICE
The engine should never be run without the
air filter; excessive piston and/or cylinder
wear may result.
c. Properly dispose of the used solvent.
3-11
d. Carefully wash the air filter element in soap 11.Install:

water. • Center passenger seat cushion
EAS28910
CHECKING THE ENGINE OIL LEVEL

2. Check the engine oil level on a cold engine.
TIP
If the engine was started before the oil level was
checked, be sure to warm up the engine suffi-
ciently, and then wait at least 10 minutes until
the oil settles for an accurate reading.
e. Thoroughly rinse the air filter element with
water, and then let it dry. 3. Lift the cargo bed.
ECA1XD1029
4. Check:
NOTICE • Engine oil level
Do not twist the air filter element when rins- The engine oil level should be between the
ing it. minimum level mark “a” and maximum level
f. Pour the recommended oil into a storage bag mark “b”.
large enough for the air filter element. Below the minimum level mark → Add the
recommended engine oil to the proper level.
Air filter oil grade ECA1XD1030
Foam air filter oil or equivalent NOTICE

oil Do not allow foreign materials to enter the
crankcase.
g. Place the air filter element into the storage
bag and repeatedly squeeze the element un- TIP
til the air filter element is saturated with oil. Insert the dipstick completely into the oil filler
TIP hole, and then remove it again to check the oil
level.
The air filter element should be wet but not drip-
ping.
b
a
Recommended brand
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ YAMALUBE
8. Assemble: Type
• Air filter element frame SAE 5W-30, 10W-30, 10W-40,
• Air filter element 15W-40, 20W-40 or 20W-50
• Air filter element holder Recommended engine oil grade
9. Install: API service SG type or higher,
JASO standard MA
• Air filter element assembly
10.Install:
• Air filter case cover
3-12
0 10 30 50 70 90 110 130 ˚F
SAE 5W-30
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 20W-40
2
SAE 20W-50
–20 –10 0 10 20 30 40 50 ˚C
ECA1XD1031
NOTICE
6. Drain:
• Engine oil
• Engine oil also lubricates the clutch and the (completely from the crankcase)
wrong oil types or additives could cause 7. If the oil filter cartridge is also to be replaced,
clutch slippage. Therefore, do not add any perform the following procedure.
chemical additives or use engine oils with a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
grade of “CD” or higher and do not use oils a. Remove the oil filter cartridge “1” with the oil
labeled “ENERGY CONSERVING II”. filter wrench “2”.
• Do not allow foreign materials to enter the
crankcase. Oil filter wrench
90890-01426
5. Check the engine oil level again. YU-38411
ECA1XD1032
NOTICE
Be sure the engine oil is at the correct level,
otherwise engine damage may result. 1
6. Lower the cargo bed. 2

EAS20780
CHANGING THE ENGINE OIL

1. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Remove:
• Right rear panel b. Lubricate the O-ring “3” of a new oil filter car-
Refer to “GENERAL CHASSIS” on page 4-1. tridge with a thin coat of engine oil.
ECA13390
4. Place a container under the engine oil drain NOTICE
bolt.
5. Remove: Make sure the O-ring “3” is positioned cor-
• Dipstick “1” rectly in the groove of the oil filter cartridge.
• Engine oil drain bolt “2”
(along with the gasket)
c. Tighten the new oil filter cartridge to specifi-

cation with the oil filter wrench.
3-13
b. Start the engine and keep it idling until engine

Oil filter cartridge oil starts to seep from the oil check bolt. If no
17 Nm (1.7 m·kgf, 12 ft·lbf) engine oil comes out after one minute, turn
T.
R.
the engine off so that it will not seize.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Check the engine oil passages, the oil filter
8. Install: cartridge and the oil pump for damage or
• Engine oil drain bolt leakage. Refer to “CRANKSHAFT AND OIL
(along with the gasket New ) PUMP” on page 5-71.
d. Start the engine after solving the problems
Engine oil drain bolt and check the engine oil pressure again.
30 Nm (3.0 m·kgf, 22 ft·lbf) e. Tighten the oil check bolt to specification.
T.
R.
9. Fill: Oil check bolt

• Crankcase 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
(with the specified amount of the recom-
mended engine oil) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
15.Install:
Engine oil quantity • Right rear panel
Total amount
2.60 L (2.75 US qt, 2.29 Imp.qt)
Without oil filter cartridge re- 16.Lower the cargo bed.
placement EAS21460
2.20 L (2.33 US qt, 1.94 Imp.qt) CHECKING THE FINAL GEAR OIL LEVEL
With oil filter cartridge replace- 1. Place the vehicle on a level surface.
ment 2. Remove:
2.30 L (2.43 US qt, 2.02 Imp.qt) • Final gear oil filter bolt “1”
10.Install:
3. Check:
• Dipstick
• Final gear oil level
11.Start the engine, warm it up for several min-
The final gear oil level should be up to the
utes, and then turn it off.
brim “2” of the hole.
12.Check:
Below the brim → Add the recommended fi-
• Engine
nal gear oil to the proper level.
(for engine oil leaks)
13.Check: Type
• Engine oil level SAE 80 API GL-4 Hypoid gear
Refer to “CHECKING THE ENGINE OIL oil
LEVEL” on page 3-12.
ECA1XD1017
14.Check:
NOTICE
• Engine oil pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Do not allow foreign material to enter the fi-
a. Slightly loosen the oil check bolt “1”. nal drive case.
1
1
3-14
4. Check: 6. Check:
• Final gear oil filler bolt gasket • Oil level
Damage → Replace. Refer to “CHECKING THE FINAL GEAR OIL
5. Install: LEVEL” on page 3-14.
• Final gear oil filler bolt 7. Install:
(along with the gasket) • Final gear oil filler bolt
Final gear oil filler bolt
23 Nm (2.3 m·kgf, 17 ft·lbf) Final gear oil filler bolt
T.
R.
23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
EAS21470
CHANGING THE FINAL GEAR OIL EAS1XD1014
1. Place the vehicle on a level surface. CHECKING THE DIFFERENTIAL GEAR OIL
2. Place a container under the final drive case. LEVEL
3. Remove: 1. Place the vehicle on a level surface.
• Final gear oil level check bolt “1” 2. Remove:
(along with the gasket) • Differential gear oil filler bolt “1”
• Final gear oil drain bolt “2” (along with the gasket)
(along with the gasket) 3. Check:
Completely drain the final drive case of its oil. • Differential gear oil level
The differential gear oil level should be up to
1
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
2 ECA1XD1007
NOTICE
4. Install: Do not allow foreign material to enter the dif-
• Final gear oil drain bolt ferential case.
(along with the gasket New )
1
Final gear oil drain bolt
23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
5. Fill:
2
• Final drive case
mended final gear oil)
Type
SAE 80 API GL-4 Hypoid gear 4. Check:
oil • Differential gear oil filler bolt gasket
Total amount Damage → Replace.
0.45 L (0.47 US qt, 0.40 Imp.qt)
5. Install:
Quantity
0.40 L (0.42 US qt, 0.35 Imp.qt) • Differential gear oil filler bolt
ECA1XD1017
NOTICE Differential gear oil filler bolt

23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
Do not allow foreign material to enter the fi-

R.
nal drive case.
3-15
EAS1XD1015 ECA1XD1007
CHANGING THE DIFFERENTIAL GEAR OIL NOTICE

1. Place the vehicle on a level surface. Do not allow foreign material to enter the dif-
2. Place a container under the differential case. ferential case.
3. Remove:
• Differential gear oil filler bolt “1” 6. Check:
(along with the gasket) • Oil level
• Differential gear oil drain bolt “2” Refer to “CHECKING THE DIFFERENTIAL
(along with the gasket) GEAR OIL LEVEL” on page 3-15.
Completely drain the differential case of its 7. Install:
oil. • Differential gear oil filler bolt
Differential gear oil filler bolt

23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
EAS21250
CHECKING THE FRONT BRAKE PADS

The following procedure applies to all of the front
brake pads.
1
1. Remove:
• Front wheels
Refer to “FRONT AND REAR WHEELS” on
page 4-25.
2. Operate the brake.
3. Check:
• Front brake pads
Wear indicator grooves “a” have almost dis-
appeared → Replace the brake pads and
brake pad spring as a set.
2 Refer to “FRONT AND REAR BRAKES” on
page 4-29.
4. Install:
a
• Differential gear oil drain bolt
(along with the gasket New )
Differential gear oil drain bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
5. Fill:
• Differential case
mended differential gear oil) 4. Install:
• Front wheels
Type Refer to “FRONT AND REAR WHEELS” on
SAE 80 API GL-4 Hypoid gear page 4-25.
oil
Total amount EAS21240
0.20 L (0.21 US qt, 0.18 Imp.qt) CHECKING THE BRAKE FLUID LEVEL
Quantity 1. Place the vehicle on a level surface.
0.18 L (0.19 US qt, 0.16 Imp.qt) TIP
When checking the brake fluid level, make sure
that the top of the brake master cylinder reser-
voir is horizontal.
3-16
2. Check: • brake operation is faulty.

• Brake fluid level
TIP
Below the minimum level mark “a” → Add the
specified brake fluid to the proper level. • Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir to overflow.
Specified brake fluid • When bleeding the hydraulic brake system,
DOT 4 make sure there is always enough brake fluid
before applying the brake. Ignoring this pre-
caution could allow air to enter the hydraulic
brake system, considerably lengthening the
bleeding procedure.
a • If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles
in the hose have disappeared.
1. Remove:
• Front wheels
EWA1XD1001 • Rear wheels
WARNING Refer to “FRONT AND REAR WHEELS” on
• Use only the designated brake fluid. Other page 4-25.
brake fluids may cause the rubber seals to 2. Bleed:
deteriorate, causing leakage and poor • Hydraulic brake system
brake performance. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the brake master cylinder reservoir to the
• Refill with the same type of brake fluid that
proper level with the specified brake fluid.
is already in the system. Mixing brake fluids
b. Install the diaphragm (brake master cylinder
may result in a harmful chemical reaction,
reservoir).
leading to poor brake performance.
c. Connect a clear plastic hose “1” tightly to the
• When refilling, be careful that water does
bleed screw “2”.
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil- È
ing point of the brake fluid and could cause 2
vapor lock.
ECA13540 1
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
TIP
In order to ensure a correct reading of the brake É
fluid level, make sure the top of the brake master 2
cylinder reservoir is horizontal.
1
EAS21350
BLEEDING THE HYDRAULIC BRAKE

SYSTEM
EWA13100
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.
• the brake fluid level is very low.
3-17
d. Place the other end of the hose into a con- 3. Check:

tainer. • Front brake pipe “2”
e. Slowly apply the brake several times. Cracks/damage → Replace.
f. Fully depress the brake pedal and hold it in 4. Check:
position. • Rear brake pipe “3”
g. Loosen the bleed screw. Cracks/damage → Replace.
TIP 5. Check:
Loosening the bleed screw will release the pres- • Rear brake hoses “4”
sure and cause the brake pedal to fully extend. Cracks/damage/wear → Replace.
h. Tighten the bleed screw, and then release

the brake pedal.
i. Repeat steps (e) to (h) until all of the air bub- 1 1
bles have disappeared from the brake fluid in
the plastic hose.
j. Tighten the bleed screw to specification.
Bleed screw
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
T.
R.
k. Fill the brake master cylinder reservoir to the

proper level with the specified brake fluid.
Refer to “CHECKING THE BRAKE FLUID 3
EWA13110
WARNING
After bleeding the hydraulic brake system, 2
check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Rear wheels
• Front wheels
page 4-25. 3
EAS1XD1048
CHECKING THE BRAKE HOSES AND

BRAKE PIPES
1. Remove:
• Sun top (for sun top models)
• Side frames
• Hood
• Front fender
• Center floor board 3
• Left rear panel
• Air filter case
2. Check:
• Front brake hoses “1”
Cracks/damage/wear → Replace.
3-18
4 4 2 1
6. Check: 2. Adjust:
• Brake hose holders • Brake pedal free play
Loose → Tighten the holder bolts. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1”.
Damage → Replace.
b. Turn the brake pedal rod “2” in direction “a” or
7. Place the vehicle in an upright position and
“b” until the correct free play is obtained.
apply the brake several times.
8. Check: Direction “a”
• Brake hoses Brake pedal free play is increased.
• Brake pipe Direction “b”
Brake fluid leakage → Replace any damaged Brake pedal free play is decreased.
hose and pipe.
Refer to “FRONT AND REAR BRAKES” on
page 4-29.
9. Install:
• Air filter case
b
Refer to “AIR FILTER CASE” on page 7-5. 1
• Left rear panel
• Instrument panel a
• Front fender 2
• Hood c. Tighten the locknut to specification.
• Side frames
• Sun top (for sun top models) Brake pedal rod locknut
Refer to “GENERAL CHASSIS” on page 4-1. 17 Nm (1.7 m·kgf, 12 ft·lbf)
T.
R.
EAS29190 EWA1XD1005
ADJUSTING THE BRAKE PEDAL WARNING

1. Check: After this adjustment is performed, lift the
• Brake pedal free play “a” front and rear wheels off the ground by plac-
Out of specification → Adjust. ing a block under the frame, and spin the
TIP front and rear wheels to ensure there is no
The end of the brake pedal rod “1” should lightly brake drag. If any brake drag is noticed per-
contact the brake master cylinder “2”. form the above steps again.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Brake pedal free play EAS1XD1058
0 mm (0 in) LUBRICATING THE BRAKE PEDAL AND
ACCELERATOR PEDAL
Lubricate the pivoting point and metal-to-metal
moving parts of the pedal.
Recommended lubricant
Lithium-soap-based grease
3-19
EAS21260 EAS29210
CHECKING THE REAR BRAKE PADS ADJUSTING THE PARKING BRAKE LEVER
The following procedure applies to all of the rear 1. Shift the drive select lever into low gear “L”.
brake pads. 2. Check:
1. Remove: • Parking brake lever free play “a”
• Rear wheels The maximum free play is equal to one click
Refer to “FRONT AND REAR WHEELS” on of the parking brake lever.
page 4-25. Incorrect → Adjust.
2. Operate the brake. a
3. Check:
• Rear brake pads
Wear indicator grooves “a” have almost dis-
appeared → Replace the brake pads and
brake pad spring as a set.
page 4-29.
a
3. Adjust:
• Parking brake lever free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Release the parking brake lever.
b. Slide back the rubber cover “1”.
c. Loosen the locknut “2”.
d. Turn the adjusting nut “3” in direction “a” or “b”
until the correct free play is obtained.
4. Install:
• Rear wheels Direction “a”
Refer to “FRONT AND REAR WHEELS” on Parking brake cable free play is in-
creased.
page 4-25.
Direction “b”
EAS1XD1059 Parking brake cable free play is de-
CHECKING THE PARKING BRAKE PADS creased.
1. Operate the brake.
2. Check:
• Parking brake pads
A wear indicator groove “a” has almost ap-
peared → Replace the brake pads and brake
a
pad spring as a set.
Refer to “PARKING BRAKE” on page 4-42. 1
2
b
3
3-20
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.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21690
CHECKING AND LUBRICATING THE

CABLES a
The following procedure applies to all of the in-
ner and outer cables.
EWA13270
3. Remove:
WARNING • Frame cross member
Damaged outer cable may cause the cable to Refer to “GENERAL CHASSIS” on page 4-1.
corrode and interfere with its movement. Re- 4. Adjust:
place damaged outer cable and inner cables • Accelerator pedal free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
as soon as possible. a. Remove the throttle cable housing cover “1”.
1. Check:
• Outer cable
Damage → Replace. 1
2. Check:
• Cable operation
Rough movement → Lubricate.
Engine oil or a suitable cable lu-
bricant
b. Slide back the rubber cover “2”.
TIP
Hold the cable end upright and pour a few drops d. Turn the adjusting nut “4” in direction “a” or “b”
of lubricant into the cable sheath or use a suit- until the specified accelerator pedal free play
able lubricating device. is obtained.
3. Apply:
• Lithium-soap-based grease Direction “a”
Accelerator pedal free play is in-
(onto end of the throttle cable and drive select
creased.
lever shift cable) Direction “b”
EAS20660 Accelerator pedal free play is de-
ADJUSTING THE ACCELERATOR PEDAL creased.
FREE PLAY
1. Check:
• Accelerator pedal free play “a” 2
Out of specification → Adjust. 4
b
Accelerator pedal free play
12.0–32.0 mm (0.47–1.26 in)
a
3
3-21
TIP
Throttle cable housing cover
If length “c” is 8.5 mm (0.33 in) or more, loosen screw
T.
locknut “5” and turn the adjusting nut “6” in direc-
R.
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
tion “d” or “e” until the specified accelerator ped-
al free play is obtained. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
Direction “d” • Frame cross member
Accelerator pedal free play is in- Refer to “GENERAL CHASSIS” on page 4-1.
creased. 6. Lower the cargo bed.
Direction “e”
Accelerator pedal free play is de- EAS1XD1060
creased. CHECKING THE V-BELT

2. Remove:
6 5 • Left rear panel
e • V-belt cooling ducts
3. Remove:
c d • Drive belt cover
SHEAVES” on page 5-50.
4. Check:
e. Tighten the locknuts to specification. • V-belt “1”
Throttle cable locknut (air intake Grease/oil → Clean the primary and second-
silencer side) ary sheaves.
T.
R.
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Refer to “REPLACING THE V-BELT” on

Throttle cable locknut (throttle page 3-23.
body side) 5. Measure:
0.8 Nm (0.08 m·kgf, 0.6 ft·lbf) • V-belt width “a”
f. Slide the rubber cover to its original position.
Refer to “REPLACING THE V-BELT” on
g. Check the throttle valve pulley stopper gap.
page 3-23.
TIP
When the accelerator pedal is fully depressed V-belt width
(throttle valve fully open), the gap “f” between 33.0–33.6 mm (1.30–1.32 in)
the throttle valve pulley “7” and the pulley stop- Limit
per “8” should be 1 mm (0.04 in) or less. 32.5 mm (1.28 in)
f
8
h. Install the throttle cable housing cover. 6. Install:

• Drive belt cover
3-22
7. Install: TIP
• V-belt cooling ducts Install the new V-belt so that its arrow faces the
• Left rear panel direction shown in the illustration.
8. Lower the cargo bed.
EAS1XD1061
REPLACING THE V-BELT

2. Remove:
• Left rear panel
• V-belt cooling ducts
d. Remove the bolts.
3. Remove:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Bearing housing
Refer to “PRIMARY AND SECONDARY EAS29350
CHECKING THE WHEELS

The following procedure applies to all of the
4. Replace:
wheels.
• V-belt
1. Check:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the bolts “1” (90101-06016) into the • Wheel “1”
secondary fixed sheave holes. Damage/bends → Replace.
EWA14990
TIP WARNING
Tightening the bolts “1” will push the secondary • Never attempt even small repairs to the
sliding sheave away, causing the gap between wheel.
the secondary fixed and sliding sheaves to wid- • Ride conservatively after installing a tire to
en. allow it to seat itself properly on the rim.
b. Remove the V-belt “2” from the primary 2. Measure:

sheave and secondary sheave. • Radial wheel runout
• Lateral wheel runout
Refer to “CHECKING THE WHEELS” on
page 4-26.
3. Check:
• Wheel bearings
Refer to “CHECKING THE STEERING
KNUCKLES AND FRONT WHEEL BEAR-
INGS” on page 4-57 and “CHECKING THE
REAR KNUCKLES AND REAR WHEEL
BEARINGS” on page 4-66.
c. Install a new V-belt.
3-23
EAS29340
CHECKING THE TIRES Tire air pressure (measured on

The following procedure applies to all of the cold tires)
tires. Recommended
EWA14940
Vehicle load
WARNING 0–300 kg (0–661 lb)
This model is equipped with low-pressure Front
tires. It is important that they be inflated cor- 75.0 kPa (0.750 kgf/cm², 11 psi)
rectly and maintained at the proper pres- Rear
sures. 90.0 kPa (0.900 kgf/cm², 13 psi)
Vehicle load
300–445 kg (661–981 lb)
Tire characteristics Front
EWA14950
75.0 kPa (0.750 kgf/cm², 11 psi)
WARNING Rear
Tire characteristics influence the handling of 125.0 kPa (1.250 kgf/cm², 18
vehicles. The tires listed below have been psi)
approved by Yamaha Motor Co., Ltd. for this Minimum
model. If other tire combinations are used, Vehicle load
they can adversely affect your vehicle’s han- 0–300 kg (0–661 lb)
dling characteristics and are therefore not Front
recommended. 70.0 kPa (0.700 kgf/cm², 10 psi)
Rear
85.0 kPa (0.850 kgf/cm², 12 psi)
Front tire Vehicle load
Type 300–445 kg (661–981 lb)
Tubeless Front
Size 70.0 kPa (0.700 kgf/cm², 10 psi)
25 × 8–12NHS Rear
Manufacturer/model 120.0 kPa (1.200 kgf/cm², 17
MAXXIS/MU09 psi)
Rear tire
Type
Tubeless Maximum loading limit
EWA14970
Size
WARNING
25 × 10–12NHS
Manufacturer/model Be extra careful of the vehicle balance and
MAXXIS/MU10 stability when towing a trailer.
Tire pressure Maximum loading limit

EWA1XD1023 445 kg (981 lb)
WARNING (Total weight of rider, passen-
• Tire pressure below the minimum specifi- gers, cargo, accessories, and
cation could cause the tire to dislodge from tongue)
Cargo bed
the rim under severe riding conditions.
272 kgf (600 lbf)
• Use no more than the following pressures Trailer hitch
when seating the tire beads. Pulling load (total weight of
Front trailer and cargo)
250 kPa (2.5 kgf/cm², 36 psi) 680 kgf (1500 lbf)
Rear Tongue weight (vertical weight
250 kPa (2.5 kgf/cm², 36 psi) on trailer hitch point)
Higher pressures and fast inflation may 50 kgf (110 lbf)
cause a tire to burst. Inflate the tires very
slowly and carefully. 1. Measure:
• Tire pressure
Out of specification → Adjust.
3-24
• Maintain proper tire pressures.

Tire air pressure (measured on • Set tire pressures when the tires are cold.
cold tires) • Tire pressures must be equal in both front
Recommended tires and equal in both rear tires.
Vehicle load
0–300 kg (0–661 lb) 2. Check:
Front • Tire surfaces
75.0 kPa (0.750 kgf/cm², 11 psi) Wear/damage → Replace.
Rear
90.0 kPa (0.900 kgf/cm², 13 psi) Wear limit (front)
Vehicle load 3.0 mm (0.12 in)
300–445 kg (661–981 lb) Wear limit (rear)
Front 3.0 mm (0.12 in)
75.0 kPa (0.750 kgf/cm², 11 psi)
Rear EWA1XD1006
125.0 kPa (1.250 kgf/cm², 18 WARNING

psi) It is dangerous to ride with a worn-out tire.
Minimum When the tire tread reaches the wear limit
Vehicle load “a”, replace the tire immediately.
0–300 kg (0–661 lb)
Front
70.0 kPa (0.700 kgf/cm², 10 psi)
Rear
85.0 kPa (0.850 kgf/cm², 12 psi)
Vehicle load
300–445 kg (661–981 lb)
Front
70.0 kPa (0.700 kgf/cm², 10 psi)
Rear
120.0 kPa (1.200 kgf/cm², 17
psi)
EAS29300
TIP CHECKING THE FRONT SHOCK ABSORBER

ASSEMBLIES
• Two tire pressure gauges are included as stan-
The following procedure applies to both of the
dard equipment. Use the lower range tire pres-
front shock absorber assemblies.
sure gauge “1” for the front wheels and the
1. Place the vehicle on a level place.
higher range tire pressure gauge for the rear
2. Check:
wheels.
• Front shock absorber assembly
• In order to insure an accurate reading, make
Refer to “CHECKING THE FRONT SHOCK
sure that the gauge is clean before use.
ABSORBER ASSEMBLIES” on page 4-61.
3. Check:
• Operation
Pump the front shock absorber assembly up
and down several times.
Unsmooth operation → Replace front shock
absorber assembly.
Refer to “FRONT ARMS AND FRONT
1 SHOCK ABSORBER ASSEMBLIES” on
page 4-59.
EAS29320
EWA14980
WARNING CHECKING THE REAR SHOCK ABSORBER

ASSEMBLIES
Uneven or improper tire pressure may ad-
versely affect the handling of this vehicle
rear shock absorber assemblies.
and may cause loss of control.
3-25
1. Place the vehicle on a level place.

2. Check:
• Rear shock absorber assembly
Refer to “CHECKING THE REAR SHOCK
ABSORBER ASSEMBLIES” on page 4-69.
3. Check:
• Operation
Pump the rear shock absorber assembly up
and down several times.
Unsmooth operation → Replace rear shock
absorber assembly. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Refer to “REAR ARMS AND REAR SHOCK 4. Raise the front end of the vehicle so that
ABSORBER ASSEMBLIES” on page 4-67. there is no weight on the front wheels.
EAS29280 5. Check:
CHECKING THE STEERING SYSTEM • Ball joints and wheel bearings
1. Place the vehicle on a level surface. Move the wheels laterally back and forth.
2. Check: Excessive free play → Replace the front
• Steering column (except for EPS models) arms (upper and lower) and/or wheel bear-
• EPS unit (for EPS models) ings.
• Steering wheel nut
Move the steering wheel up and down, and
back and forth.
Excessive play → Check that the steering
column bolts, EPS unit bolts, or steering
wheel nut are tightened to specification.
Refer to “STEERING SYSTEM” on page
4-52.
EAS29290
ADJUSTING THE TOE-IN

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

3. Check: ground)
5.0–15.0 mm (0.20–0.59 in)
• Tie-rod ends
Free play → Replace the tie-rod end.
TIP
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the steering wheel left until it stops. Before measuring the toe-in, make sure that the
b. Move the steering wheel slightly to the right tire pressure is correct.
and left. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
c. Check for play in the tie-rod ends. a. Mark both front tire tread centers.
d. Turn the steering wheel right until it stops. b. Face the steering wheel straight ahead.
e. Move the steering wheel slightly to the left c. Measure the width “A” between the marks.
and right. d. Rotate the front tires 180° until the marks are
f. Check for play in the tie-rod ends. exactly opposite one another.
e. Measure the width “B” between the marks.
f. Calculate the toe-in using the formula given
below.
3-26
Toe-in = “B” – “A” 2 2

1 1
g. If the toe-in is incorrect, adjust it.
d. Tighten the tie-rod end locknuts to specifica-

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
C. Forward WHEEL” on page 4-15.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS1XD1062
3. Adjust: LUBRICATING THE STEERING SHAFT

• Toe-in Lubricate the pivoting point and metal-to-metal
EWA1XD1007 moving parts of the shaft.
WARNING
• Be sure that both tie-rods are turned the Recommended lubricant
same amount. If not, the vehicle will drift Lithium-soap-based grease
right or left even though the steering wheel
is straight. This may lead to mishandling
and an accident.
• After setting the toe-in to specification, run
the vehicle slowly for some distance with
both hands lightly holding the steering
wheel and check that the steering wheel re-
sponds correctly. If not, turn either the right
or left tie-rod within the toe-in specification.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Mark both tie-rods ends.
EAS1XD1063
This reference point will be needed during CHECKING THE STABILIZER BUSHINGS
adjustment. 1. Check:
b. Loosen the tie-rod end locknuts “1” of both • Stabilizer bushings
tie-rods. Damage/wear → Replace.
c. The same number of turns should be given to Refer to “REAR KNUCKLES AND STABILIZ-
both the right and left tie-rods “2” until the ER” on page 4-64.
specified toe-in is obtained. This is to keep
the length of the tie-rods the same.
3-27
EAS1XD1064
LUBRICATING THE REAR KNUCKLE

PIVOTS
1. Remove:
• Rear arm protectors
2. Lubricate:
• Rear knuckle pivots
Lithium-soap-based grease
EAS1XD1065
CHECKING THE ENGINE MOUNT

1. Check:
• Engine brackets
• Engine mounting bolts
• Engine bracket nuts
Loosen → Tighten.
Refer to “ENGINE REMOVAL” on page 5-1.
EAS29270
EAS1XD1016
CHECKING THE CONSTANT VELOCITY
LUBRICATING THE DRIVE SHAFT
SHAFT ASSEMBLY DUST BOOTS
UNIVERSAL JOINTS
1. Check:
1. Remove:
• Dust boots “1”
Damage → Replace.
Refer to “FRONT CONSTANT VELOCITY
• Air filter case
SHAFT ASSEMBLIES, DIFFERENTIAL AS-
SEMBLY AND FRONT DRIVE SHAFT” on
2. Lubricate:
page 8-3 and “REAR CONSTANT VELOCI-
• Drive shaft universal joint
TY SHAFT ASSEMBLIES, FINAL DRIVE
Recommended lubricant ASSEMBLY AND REAR DRIVE SHAFT” on
Lithium-soap-based grease page 8-17.
A
1 1
3-28
1 1
A. Front
B. Rear
EAS1XD1066
CHECKING THE FASTENERS

1. Check:
• Fasteners
Damage/pitting → Replace.
3-29
CHASSIS
GENERAL CHASSIS.......................................................................................4-1
INSTALLING THE DOOR..........................................................................4-3
REMOVING THE SEATS ..........................................................................4-5
ADJUSTING THE DRIVER SEAT POSITION...........................................4-5
INSTALLING THE SEATS......................................................................... 4-5
INSTALLING THE SEAT BELTS............................................................... 4-8
INSTALLING THE ENCLOSURE ............................................................ 4-11
REMOVING THE STEERING WHEEL....................................................4-15
INSTALLING THE STEERING WHEEL .................................................. 4-15
INSTALLING THE V-BELT COOLING DUCTS....................................... 4-21
DISASSEMBLING THE CARGO BED ....................................................4-24
ASSEMBLING THE CARGO BED .......................................................... 4-24
FRONT AND REAR WHEELS ...................................................................... 4-25

REMOVING THE WHEELS..................................................................... 4-26
REMOVING THE WHEEL HUBS ............................................................ 4-26
CHECKING THE WHEELS ..................................................................... 4-26
CHECKING THE WHEEL HUBS............................................................. 4-27
INSTALLING THE BRAKE DISCS .......................................................... 4-27
4
INSTALLING THE WHEEL HUBS........................................................... 4-27
INSTALLING THE WHEELS ................................................................... 4-28
FRONT AND REAR BRAKES....................................................................... 4-29

INTRODUCTION .....................................................................................4-36
CHECKING THE BRAKE DISCS ............................................................ 4-36
REPLACING THE BRAKE PADS............................................................ 4-37
DISASSEMBLING THE BRAKE CALIPERS ...........................................4-38
CHECKING THE BRAKE CALIPERS .....................................................4-38
ASSEMBLING THE BRAKE CALIPERS ................................................. 4-38
INSTALLING THE BRAKE CALIPERS ...................................................4-39
CHECKING THE BRAKE MASTER CYLINDER ..................................... 4-40
CHECKING THE BRAKE PIPES............................................................. 4-40
INSTALLING THE BRAKE MASTER CYLINDER ................................... 4-40
PARKING BRAKE......................................................................................... 4-42

REMOVING THE PARKING BRAKE CALIPER ...................................... 4-47
CHECKING THE PARKING BRAKE CALIPER....................................... 4-47
CHECKING THE PARKING BRAKE DISC ............................................. 4-47
REPLACING THE PARKING BRAKE PADS ..........................................4-47
INSTALLING THE PARKING BRAKE CALIPER..................................... 4-48
INSTALLING THE PARKING BRAKE LEVER ........................................ 4-48
PEDAL ASSEMBLY ......................................................................................4-49

INSTALLING THE PEDAL ASSEMBLY .................................................. 4-51
STEERING SYSTEM .....................................................................................4-52
CHECKING THE STEERING JOINT.......................................................4-54
CHECKING THE TIE-ROD ENDS........................................................... 4-54
INSTALLING THE STEERING SYSTEM ................................................ 4-54
STEERING KNUCKLES................................................................................ 4-56

REMOVING THE STEERING KNUCKLES ............................................. 4-57
CHECKING THE STEERING KNUCKLES AND
FRONT WHEEL BEARINGS .................................................................. 4-57
CHECKING THE STEERING KNUCKLE BALL JOINTS ........................ 4-57
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES ............. 4-59

CHECKING THE FRONT ARMS............................................................. 4-61
HANDLING THE FRONT SHOCK ABSORBER ASSEMBLIES.............. 4-61
DISPOSING OF A FRONT SHOCK ABSORBER ASSEMBLY............... 4-61
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES ............. 4-61
CHECKING THE FRONT ARM BALL JOINTS ....................................... 4-62
INSTALLING THE FRONT ARMS AND FRONT SHOCK
ABSORBER ASSEMBLIES .................................................................... 4-63
REAR KNUCKLES AND STABILIZER ......................................................... 4-64

CHECKING THE REAR KNUCKLES AND REAR WHEEL
BEARINGS ............................................................................................. 4-66
CHECKING THE STABILIZER................................................................4-66
INSTALLING THE STABILIZER..............................................................4-66
REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES ................. 4-67

CHECKING THE REAR ARMS ...............................................................4-69
HANDLING THE REAR SHOCK ABSORBER ASSEMBLIES ................ 4-69
DISPOSING OF A REAR SHOCK ABSORBER ASSEMBLY ................. 4-69
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................ 4-69
INSTALLING THE REAR ARMS AND REAR SHOCK
ABSORBER ASSEMBLIES .................................................................... 4-70
GENERAL CHASSIS
EAS21830
GENERAL CHASSIS
Removing the skid plates
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
Order Job/Parts to remove Q’ty Remarks

1 Front skid plate 1
2 Rear skid plate 1
For installation, reverse the removal proce-
dure.
4-1
GENERAL CHASSIS
Removing the doors and side panels
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
1.3 Nm (0.13 m•kgf, 0.94 ft•Ibf)
T.R
.
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.
5 4
3 (4)
6
(4)
1
2
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

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 Lift the cargo bed.
dure.
4-2
GENERAL CHASSIS
EAS1XD1019
INSTALLING THE DOOR

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

1.3 Nm (0.13 m·kgf, 0.94 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 latch so that it fully
engages the bar “2” on the frame when the door
is closed.
Make sure that the spring force of the door hinge
can close the door without latching it when the
door is opened less than 60°.
Door handle latch nut

7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.
4-3
GENERAL CHASSIS
Removing the seats
6 Nm (0.6 m•kgf, 4.3 ft•Ibf)
T.R
.
5
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
6
(3)
1
(3)
(3) (3)
(3)
(3) (3)
(4)
(3) (4) New
(4)
New
3
6
2
4
23 Nm (2.3 m•kgf, 17 ft•Ibf)
T.R
.

1 Seat cushion 3
2 Center passenger seat frame 1
3 Driver seat frame 1
4 Outer passenger seat frame 1
5 Seat back 3
6 Shoulder holster 2
7 Headrest 3
dure.
4-4
GENERAL CHASSIS
EAS1XD1017
REMOVING THE SEATS 2

seats.
1. Remove:
• Seat cushion “1” b
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ c
a. Lift the front of the seat cushion. d
b. Pull the cushion off.
a
b. Forward position
1 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.
EAS1XD1049
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ADJUSTING THE DRIVER SEAT POSITION
The driver seat can be adjusted to one of three 3. Install:
positions to suit the driver’s preference. • Driver seat cushion
1. Remove: Refer to “INSTALLING THE SEATS” on page
• Driver seat cushion 4-5.
Refer to “REMOVING THE SEATS” on page EAS1XD1018
4-5. INSTALLING THE SEATS

2. Adjust: The following procedure applies to all of the
• Driver seat position seats.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1. Install:
a. Remove the driver seat frame bolts “1”. • Seat cushion “1”
EWA1XD1008
1 WARNING
A loose seat could cause the operator to lose
control, or cause the operator or passengers
1 to fall.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Insert the projections “a” on the rear of the
seat cushion under the seat frame.
b. Insert the projection “b” on the front of the
cushion into the grommet while pushing the
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.
4-5
GENERAL CHASSIS
1
b a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-6
GENERAL CHASSIS
Removing the seat belts
59 Nm (5.9 m•kgf, 43 ft•Ibf) 2

T.R
.
3
7
6
59 Nm (5.9 m•kgf, 43 ft•Ibf)

T.R
.
59 Nm (5.9 m•kgf, 43 ft•Ibf)

T.R
.

Refer to “Removing the doors and side pan-
Side panels els”.
1 Set belt switch coupler 1 Disconnect.
2 Driver seat belt 1
3 Driver seat belt buckle 1
4 Center passenger seat belt 1
5 Center passenger seat belt buckle 1
6 Outer passenger seat belt 1
7 Outer passenger seat belt buckle 1
dure.
4-7
GENERAL CHASSIS
EAS1XD1067
INSTALLING THE SEAT BELTS

1. Install:
• Seat belts
Seat belt bolt

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

59 Nm (5.9 m·kgf, 43 ft·lbf)
TIP
• Install the seat belt anchor plates “1” so that
they contact the stoppers “a”.
• Fit the projection “b” on each seat belt “2” into
the holes “c” in the frame.
4-8
GENERAL CHASSIS
Removing the sun top (for sun top models)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

1
T.R
.
2 New
6
1
2 New
(4)
1
(4) (4)
1
New 2 3 7 New
(4) (4)
(4)
(4) 4
(4)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)

T.R
T.R
.

1 Sun top lower bracket 2
2 Damper 4
3 Sun top rear bracket 4
4 Sun top front bracket 4
5 Sun top 1
6 Damper 4
7 Damper 4
dure.
4-9
GENERAL CHASSIS
Removing the enclosure

48 Nm (4.8 m•kgf, 35 ft•Ibf)
48 Nm (4.8 m•kgf, 35 ft•Ibf)
T.R
.
T.R
.
1
2
4
48 Nm (4.8 m•kgf, 35 ft•Ibf)
T.R
.
5
7
48 Nm (4.8 m•kgf, 35 ft•Ibf)
T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf) 65 Nm (6.5 m•kgf, 47 ft•Ibf)

T.R
T.R
.
.

Headrests Refer to “Removing the seats”.
Seat belts Refer to “Removing the seat belts”.
For sun top models
Sun top Refer to “Removing the sun top (for sun top
models)”.
1 Rear top frame 1
2 Front top frame 1
3 Rear right frame 1
4 Rear left frame 1
5 Right side frame 1
6 Left side frame 1
7 Rear center frame 1
dure.
4-10
GENERAL CHASSIS
EAS1XD1068
INSTALLING THE ENCLOSURE 7

1. Install:
• Rear center frame “1” 6
• Right side frame “2”
• Left side frame “3”
• Rear right frame “4”
• Rear left frame “5”
• Front top frame “6”
• Rear top frame “7”
TIP
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Do not fully tighten the bolts and nuts. 2. Tighten:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Rear right frame bolts
a. Install the rear center frame “1”. • Rear left frame bolts
• Front top frame bolts
1 • Rear top frame bolts
• Right side frame nuts (front)
• Left side frame nuts (front)
• Rear center frame bolts
• Right side frame nut (rear)
• Left side frame nut (rear)
TIP
Tighten the bolts and nuts in the proper se-
quence as shown ( 1, 2, and so on).
b. Install the right side frame “2” and left side
frame “3”.
Rear right frame bolt
2 3 48 Nm (4.8 m·kgf, 35 ft·lbf)
T.
R.
Rear left frame bolt

48 Nm (4.8 m·kgf, 35 ft·lbf)
Front top frame bolt
48 Nm (4.8 m·kgf, 35 ft·lbf)
Rear top frame bolt
48 Nm (4.8 m·kgf, 35 ft·lbf)
Right side frame nut (front)
65 Nm (6.5 m·kgf, 47 ft·lbf)
Left side frame nut (front)
c. Install the rear right frame “4” and rear left 65 Nm (6.5 m·kgf, 47 ft·lbf)
frame “5”. Rear center frame bolt
48 Nm (4.8 m·kgf, 35 ft·lbf)
5 Right side frame nut (rear)
48 Nm (4.8 m·kgf, 35 ft·lbf)
4
Left side frame nut (rear)
48 Nm (4.8 m·kgf, 35 ft·lbf)
2
2 2
2
1
1 3
d. Install the front top frame “6” and rear top 5
1 1
frame “7”.
5 4
4
3
4-11
GENERAL CHASSIS
Removing the hood and battery

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf) 1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf) 4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
T.R
.
.
T.R
.
1
2
5
4 10
6 3
9
9
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.
7
2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)
T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf) 8

T.R
.

Front skid plate Refer to “Removing the skid plates”.
1 Hood 1
2 Air intake duct cover 1
Disconnect.
ECA1XD1033
NOTICE
3 Negative battery lead 1
First disconnect the negative battery
lead, then disconnect the positive lead.
4 Positive battery lead 1 Disconnect.

5 Battery band 2
6 Battery 1
7 Front guard 1
8 Front guard cover 2
9 Headlight coupler 2 Disconnect.
10 Front grill 1
dure.
4-12
GENERAL CHASSIS
Removing the front fender and instrument panel

35 Nm (3.5 m•kgf, 25 ft•Ibf) 4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
T.R
.
.
3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf) 4 3 7
T.R
.
5
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
11
6
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf) (7)
T.R
.
8
12
9 10
(6)
(6) 2
1
3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)
T.R
.
(4)
(4)
T.R
.
16 Nm (1.6 m•kgf, 12 ft•Ibf)
2.3 Nm (0.23 m•kgf, 1.7 ft•Ibf)

T.R
.
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

T.R
.

For sun top models
models)”.
Side frames Refer to “Removing the enclosure”.
Hood Refer to “Removing the hood and battery”.
1 Front fender 1
2 Passenger handhold 1
3 Steering wheel cover 1
4 Steering wheel 1
5 Meter assembly 1
6 Meter assembly bracket 1
7 Parking brake lever rubber cover 1
8 On-Command four-wheel-drive switch 1
9 Light switch 1
10 Main switch 1
11 Indicator light assembly 1
12 Auxiliary DC jack 1
4-13
GENERAL CHASSIS
Removing the front fender and instrument panel

T.R
T.R
.
.
3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
14
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf) (7)

T.R
.
(6)
(6)
13
3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)
T.R
.
(4)
(4)
T.R
.
16 Nm (1.6 m•kgf, 12 ft•Ibf)
2.3 Nm (0.23 m•kgf, 1.7 ft•Ibf)

T.R
.
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

T.R
.

13 Horn switch 1 For Europe and Oceania
14 Instrument panel 1
dure.
4-14
GENERAL CHASSIS
EAS1XD1069
REMOVING THE STEERING WHEEL

1
1. Turn the steering wheel so that it is straight
and the front wheels are pointing straight
ahead.
2. Remove:
• Steering wheel cover “1”
TIP
While pushing the ends of the projections “a” 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.
EAS1XD1070
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.
4-15
GENERAL CHASSIS
Removing the floor boards and panels

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

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

Seat frames Refer to “Removing the seats”.
Refer to “Removing the doors and side pan-
Side panels els”.
Seat belts Refer to “Removing the seat belts”.
For sun top models
models)”.
Refer to “Removing the front fender and in-
Instrument panel strument panel”.
1 Rubber cover 1
2 Center floor board 1
3 Left floor board 1
4 Right floor board 1
5 Left lower panel 1
6 Right lower panel 1
4-16
GENERAL CHASSIS
Removing the floor boards and panels

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

T.R
.
(5)
(4)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 10 11
T.R
.

7 Center passenger compartment panel 1
8 Left passenger compartment panel 1
9 Right passenger compartment panel 1
10 Left rear panel 1
11 Right rear panel 1
dure.
4-17
GENERAL CHASSIS
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
For sun top models

models)”.
Refer to “Removing the front fender and in-
Instrument panel strument panel”.
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 (electronic power steering) control unit 1 For EPS models
8 Fuse box 1
9 Differential motor relay 2 1
4-18
GENERAL CHASSIS
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
.
3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf)

T.R
.
15
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
dure.
4-19
GENERAL CHASSIS
Removing the V-belt cooling ducts
59 Nm (5.9 m•kgf, 43 ft•Ibf)
T.R
.
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
T.R
.
4
6
2
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf) 1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
T.R
T.R
.
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

T.R
.
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)

T.R
.

Frame cross member Refer to “Removing the cargo bed”.
1 V-belt cooling exhaust duct 1
2 V-belt cooling exhaust duct joint 1
3 Outer passenger seat belt bolt 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
dure.
4-20
GENERAL CHASSIS
EAS1XD1020
INSTALLING THE V-BELT COOLING DUCTS

1. Install:
• V-belt cooling intake duct joint 2 “1”
• V-belt cooling intake duct joint 1 “2”
• V-belt cooling exhaust duct joint “3”
TIP
• Align the projection “a” on V-belt cooling intake
duct joint 2 with the lib on the crankcase.
• Fit the projection “b” on the V-belt cooling 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.
1
a
2 b
4-21
GENERAL CHASSIS
Removing the cargo bed
5
16 Nm (1.6 m•kgf, 12 ft•Ibf)
T.R
.
17 Nm (1.7 m•kgf, 12 ft•Ibf)

T.R
.
1
(4)
16 Nm (1.6 m•kgf, 12 ft•Ibf)

T.R
.

1 Frame cross member 1 Lift the cargo bed.
2 Tail/brake light connector 6 Disconnect.
TIP
3 Gas spring assembly 1 Install the gas spring assembly so that the
cylinder end is pointing upward.
4 Pin 2
5 Cargo bed assembly 1
dure.
4-22
GENERAL CHASSIS
Disassembling the cargo bed

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
(7)
8 2
3
3
4
3
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
3
(7)
5
1
5
6
7
4
9 Nm (0.9 m•kgf, 6.5 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) (5) 9 7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
T.R
.
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)

T.R
.

1 Cargo bed left panel 1
2 Cargo bed right panel 1
3 Cargo hook 4
4 Tail/brake light 2
5 Tailgate cable 2
6 Tailgate 1
7 Tailgate shaft 1
8 Cargo bed release lever 1
9 Cargo bed heat protector plate 1
For assembly, reverse the disassembly pro-
cedure.
4-23
GENERAL CHASSIS
EAS1XD1021
DISASSEMBLING THE CARGO BED 25˚

1. Remove:
• Tailgate “1”
TIP 1
Align the slot “a” in the left end of the tailgate
b
shaft with the flat portions of the projection “b” on
the cargo bed, and then lift the left end of the tail-
gate.
c a
25˚
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Tailgate cables “1”
1
Tailgate cable bolt
a 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.
TIP
b
Connect the straight end “a” of each tailgate ca-
EAS1XD1022
ble to the tailgate “2”, and the offset end “b” to
ASSEMBLING THE CARGO BED the cargo bed “3”.
1. Install:
• Tailgate shaft “1” 3
1 b
Tailgate shaft bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
a
R.
TIP
Install the tailgate shaft so that the end with the
slot “a” is pointing to the left.
2
1
a
2. Install:
• Tailgate “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the right end of the tailgate shaft onto the
projection “a” on the cargo bed.
b. Align the slot “b” in the left end of the tailgate
shaft with the flat portions of the projection “c”
on the cargo bed, and then fit the tailgate
shaft onto the projection.
4-24
FRONT AND REAR WHEELS
EAS21870

Removing the wheels and brake discs
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
dure.
4-25
EAS21890
• Wheel
REMOVING THE WHEELS
Refer to “CHECKING THE TIRES” on page
3-24 and “CHECKING THE WHEELS” on
2. Elevate:
page 3-23.
• Wheels EWA15000
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-
EAS1XD1023 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 4-57 and “CHECKING THE
Do not apply the brake pedal when removing the REAR KNUCKLES AND REAR WHEEL
brake caliper. BEARINGS” on page 4-66.
4. Remove:
• Wheel hub “1” Radial wheel runout limit
2.0 mm (0.08 in)
TIP Lateral wheel runout limit
Use a general puller “2” to separate the wheel 2.0 mm (0.08 in)
hub and constant velocity shaft.
EAS29380
CHECKING THE WHEELS

wheels.
1. Check:
• Tire
4-26
TIP
Install the brake disc so that the recessed por-
tion of the bolt hole faces away from the hub.
EAS29410
INSTALLING THE WHEEL HUBS

wheel hubs.
1. Install:
• Wheel hub “1”
TIP
EAS29390 Tap lightly on the wheel hub with a plastic ham-
CHECKING THE WHEEL HUBS mer until five threads on the end of the constant
The following procedure applies to all of the velocity shaft will be exposed when the washer
wheel hubs. 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
Wheel axle nut

350 Nm (35 m·kgf, 253 ft·lbf)
T.
EAS1XD1071
R.
INSTALLING THE BRAKE DISCS

The following procedure applies to all of the TIP
brake discs. • Do not apply oil to the threads of the nut.
1. Install: • After tightening the nut, stake the collar of the
• Brake disc nut into the notch of the shaft.
Brake disc bolt

30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.
LOCTITE®
4-27
3. Check:
• Brake disc
Refer to “CHECKING THE BRAKE DISCS”
on page 4-36.
EAS29420
INSTALLING THE WHEELS

wheels.
1. Tighten:
• Wheel nuts “1”
Wheel nut
75 Nm (7.5 m·kgf, 54 ft·lbf)
T.
R.
EWA1XD1009
WARNING
Tapered wheel nuts “1” are used for both the
front and rear wheels. Install each nut with
its tapered side towards the wheel.
4-28
FRONT AND REAR BRAKES
EAS22210

Removing the front brake pads
FW
D
48 Nm (4.8 m•kgf, 35 ft•Ibf)
T.R
1
.
1
T.R
.
17 Nm (1.7 m•kgf, 12 ft•Ibf)

the front brake calipers.
Front wheel page 4-25.
1 Brake caliper bolt 2
2 Brake pad bolt 2
3 Brake pad 2
4 Brake pad spring 1
dure.
4-29
Removing the rear brake pads
FW 48 Nm (4.8 m•kgf, 35 ft•Ibf)

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

4
T.R
.

the rear brake calipers.
Rear wheel page 4-25.
2 Brake pad bolt 2
3 Brake pad 2
dure.
4-30
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 3-17.
1 Union bolt 1
2 Copper washer 2
3 Brake hose 1 Disconnect.
4 Brake pad bolt 2 Loosen.
6 Brake caliper 1
dure.
4-31
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 Union bolt 1
2 Copper washer 2
3 Brake hose 1 Disconnect.
4 Brake pad bolt 2 Loosen.
6 Brake caliper 1
dure.
4-32
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
cedure.
4-33
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
5 Brake caliper guide pin 1
6 Brake caliper retaining pin 1
8 Brake caliper piston dust seal 2
10 Bleed screw 1
cedure.
4-34
Removing the brake master cylinder
3.5 Nm (0.35 m•kgf, 2.5 ft•Ibf) 19 Nm (1.9 m•kgf, 14 ft•Ibf)
T.R
.
T.R
.
2 5
4
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 Brake master cylinder reservoir float 1
5 Rear brake pipe 1 Disconnect.
6 Front brake pipe 1 Disconnect.
7 Brake master cylinder 1
dure.
4-35
EAS22220
INTRODUCTION
EWA14100
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- 4. Measure:

sembly. • Brake disc thickness “a”
• Never use solvents on internal brake com- Measure the brake disc thickness at a few dif-
ponents. ferent locations.
• Use only clean or new brake fluid for clean- Out of specification → Replace.
ing brake components.
Brake disc thickness limit
• Brake fluid may damage painted surfaces
3.5 mm (0.14 in)
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
• FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get im-
mediate medical attention.
EAS22240
CHECKING THE BRAKE DISCS

brake discs. 5. Adjust:
1. Remove: • Brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Wheels a. Remove the brake disc.
Refer to “FRONT AND REAR WHEELS” on b. Rotate the brake disc by one bolt hole.
page 4-25. c. Install the brake disc.
2. Check:
• Brake disc Brake disc bolt
Damage/galling → Replace. 30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.
3. Measure: LOCTITE®
• Brake disc deflection
Out of specification → Correct the brake disc TIP
deflection or replace the brake disc. Install the brake disc so that the recessed por-
tion of the bolt hole faces away from the hub.
Brake disc deflection limit
0.1 mm (0.004 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the dial gauge at a right angle against
the brake disc surface.
b. Measure the deflection 3.0 mm (0.12 in) be-
low the edge of the brake disc.
4-36
d. Measure the brake disc deflection.

e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be brought
a
within specification, replace the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• Wheels
page 4-25. 2. Install:
• Brake pad spring
EAS22250
• Brake pads
REPLACING THE BRAKE PADS
The following procedure applies to all of the TIP
brake calipers. Always install new brake pads and brake pad
TIP spring as a set.
When replacing the brake pads, it is not neces- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
sary to disconnect the brake hose or disassem- a. Connect a clear plastic hose “1” tightly to the
ble the brake caliper. bleed screw “2”. Put the other end of the hose
into an open container.
1. Measure: b. Loosen the bleed screw and push the brake
• Brake pad wear limit “a” caliper pistons into the brake caliper with your
Out of specification → Replace the brake finger.
pads as a set.
1
Front brake
Brake pad lining thickness (in-
ner)
4.5 mm (0.18 in)
Limit 2
1.0 mm (0.04 in)
Brake pad lining thickness (out-
er)
4.5 mm (0.18 in)
Limit c. Tighten the bleed screw.
1.0 mm (0.04 in)
Rear brake Bleed screw
Brake pad lining thickness (in- 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
T.
R.
ner)
4.3 mm (0.17 in) d. Install the brake pad spring and brake pads.
Limit
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1.0 mm (0.04 in)
Brake pad lining thickness (out- 3. Install:
er) • Brake pad bolts
4.3 mm (0.17 in) • Brake caliper
Limit
1.0 mm (0.04 in) Brake pad bolt
17 Nm (1.7 m·kgf, 12 ft·lbf)
T.
R.
Brake caliper bolt

48 Nm (4.8 m·kgf, 35 ft·lbf)
4. Check:
Below the minimum level mark → Add the
specified brake fluid to the proper level.
4-37
Refer to “CHECKING THE BRAKE FLUID b. Remove the brake caliper piston dust seals
LEVEL” on page 3-16. and piston seals.
5. Check: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Brake pedal operation EAS22390
Soft or spongy feeling → Bleed the brake sys- CHECKING THE BRAKE CALIPERS
tem. The following procedure applies to all of the
Refer to “BLEEDING THE HYDRAULIC brake calipers.
Recommended brake component replace-
EAS22350 ment schedule
DISASSEMBLING THE BRAKE CALIPERS
Brake pads If necessary
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
1. Remove:
is 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 2 (brake caliper body)
Obstruction → Blow out with compressed air.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EWA1XD1010
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 seals and
EWA13550
brake caliper piston dust 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
EAS22410
ASSEMBLING THE BRAKE CALIPERS

a
brake calipers.
4-38
EWA1XD1011
• When installing the right rear brake hose
WARNING onto the right rear brake caliper, make sure
• Before installation, all internal brake com- that the projection “d” on the brake hose
ponents should be cleaned and lubricated contacts the rib on the brake caliper.
with clean or new brake fluid.
• Never use solvents on internal brake com- È
ponents as they will cause the brake caliper
piston seals and brake caliper piston dust
seals to swell and distort.
• Whenever a brake caliper is disassembled, 2
replace the brake caliper piston seals and
brake caliper piston dust seals.
3
a
Specified brake fluid 1
DOT 4
É
EAS22440
INSTALLING THE BRAKE CALIPERS

brake calipers. 2
1. Install: b
• Brake caliper “1”
(temporarily) 3
• Copper washers New 1
• Brake hose “2”
• Brake hose union bolt “3”
Ê
Brake hose union bolt
27 Nm (2.7 m·kgf, 20 ft·lbf)
T.
R.
2
EWA1XD1022
WARNING
c
Proper brake hose routing is essential to in- 3
sure safe vehicle operation. Refer to “CABLE
ROUTING” on page 2-41. 1
ECA1XD1008
NOTICE
Ë
• When installing the left front brake hose
onto the left front brake caliper, fit the pro-
2
jection “a” on the brake hose into the slot in
the brake caliper.
d
• When installing the right front brake hose
onto the right front brake caliper, make 3
sure that the pipe section “b” on the end of
the brake hose contacts the rib on the 1
brake caliper.
• When installing the left rear brake hose A. Left front brake
onto the left rear brake caliper, fit the pipe B. Right front brake
section “c” on the end of the brake hose C. Left rear brake
into the slot in the brake caliper. D. Right rear brake
2. Remove:
• Brake caliper
4-39
3. Install: 7. Check:
• Brake pads • Brake pedal operation
• Brake pad spring Soft or spongy feeling → Bleed the brake sys-
• Brake pad bolts tem.
• Brake caliper Refer to “BLEEDING THE HYDRAULIC
Refer to “REPLACING THE BRAKE PADS” BRAKE SYSTEM” on page 3-17.
on page 4-37.
EAS1XD1072
CHECKING THE BRAKE MASTER

Brake pad bolt
17 Nm (1.7 m·kgf, 12 ft·lbf) CYLINDER
T.
1. Check:
R.
Brake caliper bolt

48 Nm (4.8 m·kgf, 35 ft·lbf) • Brake master cylinder
Damage/scratches/wear → Replace.
4. Fill: • Brake fluid delivery passages
• Brake master cylinder reservoir (brake master cylinder body)
(with the specified amount of the specified Obstruction → Blow out with compressed air.
brake fluid) 2. Check:
• Brake master cylinder reservoir
Specified brake fluid Cracks/damage → Replace the brake master
DOT 4 cylinder.
EWA1XD1021
• Brake master cylinder reservoir diaphragm
WARNING • Brake master cylinder reservoir diaphragm
holder
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
3. Check:
deteriorate, causing leakage and poor
• Brake pipes
brake performance.
is already in the system. Mixing brake fluids EAS1XD1050
may result in a harmful chemical reaction, CHECKING THE BRAKE PIPES

leading to poor brake performance. The following procedure applies to both of the
• When refilling, be careful that water does brake pipes.
not enter the brake master cylinder reser- 1. Check:
voir. Water will significantly lower the boil- • Brake pipe end (flare nut)
ing point of the brake fluid and could cause Damage → Replace the brake master cylin-
vapor lock. der, brake pipes, and related parts as a set.
ECA13540
NOTICE
5. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
6. Check: EAS1XD1073
• Brake fluid level INSTALLING THE BRAKE MASTER
Below the minimum level mark → Add the CYLINDER
specified brake fluid to the proper level. 1. Install:
Refer to “CHECKING THE BRAKE FLUID • Brake master cylinder
LEVEL” on page 3-16. • Brake pipes
4-40

Brake master cylinder bolt BRAKE SYSTEM” on page 3-17.
16 Nm (1.6 m·kgf, 12 ft·lbf)
T.
R.
Brake pipe flare nut

19 Nm (1.9 m·kgf, 14 ft·lbf)
EWA1XD1012
WARNING
Proper brake pipe routing is essential to in-
sure safe vehicle operation. Refer to “CABLE
ROUTING” on page 2-41.
2. Fill:
• Brake master cylinder reservoir
(with the specified amount of the specified
brake fluid)
Specified brake fluid

DOT 4
EWA13540
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
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.
ECA13540
NOTICE
3. Bleed:
• Brake system
4. Check:
Below the minimum level mark → Add the
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
5. Check:
• Brake pedal operation
Soft or spongy feeling → Bleed the brake sys-
tem.
4-41
PARKING BRAKE
EAS1XD1074
PARKING BRAKE
Removing the parking brake pads
D
FW
7
1
5
2
9 5
8
40 Nm (4.0 m•kgf, 29 ft•Ibf)

T.R
.
4
17 Nm (1.7 m•kgf, 12 ft•Ibf)
3
T.R
.
17 Nm (1.7 m•kgf, 12 ft•Ibf)

T.R
.

Refer to “GENERAL CHASSIS” on page
Rear skid plate 4-1.
1 Parking brake caliper bolt 2
2 Parking brake caliper 1
3 Parking brake cable (parking brake caliper end) 1 Disconnect.
4 Spring 1
5 Parking brake pad bolt 2
6 Parking brake pad 2
8 Parking brake caliper arm nut 1
9 Parking brake caliper arm 1
dure.
4-42
PARKING BRAKE
Removing the parking brake caliper
D
FW
40 Nm (4.0 m•kgf, 29 ft•Ibf)

T.R
.

Rear skid plate 4-1.
1 Parking brake caliper bolt 2
2 Parking brake caliper 1
3 Parking brake cable (parking brake caliper end) 1 Disconnect.
dure.
4-43
PARKING BRAKE
Disassembling the parking brake caliper
17 Nm (1.7 m•kgf, 12 ft•Ibf)

17 Nm (1.7 m•kgf, 12 ft•Ibf)
T.R
.
T.R
.
S
2
10
New 7 11
8
S
14 New
LT
S 13
12
22 Nm (2.2 m•kgf, 16 ft•Ibf)
T.R
.
4
New
3
1
S 9
12 Nm (1.2 m•kgf, 8.7 ft•Ibf) 6
T.R
.
5
17 Nm (1.7 m•kgf, 12 ft•Ibf)
T.R
.

1 Spring 1
2 Parking brake pad bolt 2
3 Parking brake pad 2
5 Parking brake caliper arm nut 1
6 Parking brake caliper arm 1
8 Push rod 1
9 Parking brake caliper arm shaft 1 Left-hand threads
11 Parking brake caliper guide pin 1
12 Parking brake caliper retaining pin 1
13 Parking brake cable holder 1
cedure.
4-44
PARKING BRAKE
Removing the parking brake lever
13 Nm (1.3 m•kgf, 9.4 ft•Ibf)
T.R
.
16 Nm (1.6 m•kgf, 12 ft•Ibf)

T.R
.

Sun top/Side frames/Hood/Front fender/Instru- Refer to “GENERAL CHASSIS” on page
ment panel 4-1.
1 Parking brake switch 1
2 Parking brake lever 1
3 Parking brake cable (parking brake lever end) 1 Disconnect.
dure.
4-45
PARKING BRAKE
Removing the parking brake disc
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)
T.R
.

Refer to “REAR CONSTANT VELOCITY
SHAFT ASSEMBLIES, FINAL DRIVE AS-
Final drive assembly SEMBLY AND REAR DRIVE SHAFT” on
page 8-17.
1 Parking brake disc 1
dure.
4-46
PARKING BRAKE
EAS1XD1075
REMOVING THE PARKING BRAKE CALIPER Brake pad lining thickness-inner

1. Move the parking brake lever to the released 3.2 mm (0.13 in)
position, and then loosen the parking brake Limit
cable adjuster so that the parking brake cable 1.0 mm (0.04 in)
is slack. Brake pad lining thickness-outer
3.2 mm (0.13 in)
EAS1XD1076
Limit
CHECKING THE PARKING BRAKE CALIPER 1.0 mm (0.04 in)
1. Check:
• Brake caliper piston
Scratches/rust/wear → Replace.
• Brake caliper body
Cracks/damage → Replace the parking
brake caliper. a
EAS1XD1077
CHECKING THE PARKING BRAKE DISC

1. Check:
• Brake disc
Galling/damage → Replace.
2. Measure: 2. Install:
• Brake disc deflection • Brake pad spring
• Brake disc thickness “a” • Parking brake pads
Out of specification → Replace. • Parking brake pad bolts
Brake disc deflection limit Parking brake pad bolt

0.10 mm (0.004 in) 17 Nm (1.7 m·kgf, 12 ft·lbf)
T.
R.
Brake disc thickness limit

3.0 mm (0.12 in) TIP
Always install new brake pads and brake pad
TIP spring as a set.
Measure the deflection 3.0 mm (0.12 in) below
3. Adjust:
the edge of the brake disc.
• Brake pad clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a
a. Fully turn in the parking brake caliper arm
shaft “1”.
EAS1XD1078
REPLACING THE PARKING BRAKE PADS

1. Measure:
• Brake pad wear limit “a” TIP
Out of specification → Replace the brake The parking brake arm shaft has left hand
pads and brake pad spring as a set. threads. To turn in the shaft, turn it counterclock-
wise.
b. Install the parking brake caliper arm “2” onto
the parking brake caliper arm shaft, and then
rotate the arm until it contacts the stopper “a”.
4-47
PARKING BRAKE
2. Adjust:
2 • Parking brake cable free play
a Refer to “ADJUSTING THE PARKING
BRAKE LEVER” on page 3-20.
EAS1XD1051
INSTALLING THE PARKING BRAKE LEVER

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

c. Install the parking brake caliper arm nut “3”, 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
T.
R.
and then temporarily tighten it.
2. Adjust:
• Parking brake lever free play
Refer to “ADJUSTING THE PARKING
3 BRAKE LEVER” on page 3-20.
d. Insert a suitable tool “4” with a thickness of

4.7 mm (0.19 in) between the brake pads “5”,
and then finger tighten the push rod “6”.
5
e. Tighten the parking brake caliper arm nut.
Parking brake caliper arm nut

17 Nm (1.7 m·kgf, 12 ft·lbf)
T.
R.
f. Install the spring.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1XD1079
INSTALLING THE PARKING BRAKE

CALIPER
1. Install:
• Parking brake caliper
Parking brake caliper bolt

40 Nm (4.0 m·kgf, 29 ft·lbf)
T.
R.
4-48
PEDAL ASSEMBLY
EAS1XD1080
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
.

ment panel 4-1.
Drain.
Brake master cylinder page 4-29.
Refer to “STEERING SYSTEM” on page
Steering joint 4-52.
1 Brake light switch 1
2 Throttle cable 1 Disconnect.
3 Pedal assembly 1
dure.
4-49
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
cedure.
4-50
PEDAL ASSEMBLY
EAS1XD1052
INSTALLING THE PEDAL ASSEMBLY

1. Adjust: 1 2
b
• Throttle cable length “a”
Throttle cable length a

5.5–6.5 mm (0.22–0.26 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting nut “1” until the specified
length is obtained.
b. Tighten the locknut “2” to specification. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Throttle cable locknut

2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
T.
R.
a
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• Accelerator pedal free play
Refer to “ADJUSTING THE ACCELERATOR
PEDAL FREE PLAY” on page 3-21.
3. Adjust:
• Brake pedal free play
Refer to “ADJUSTING THE BRAKE PEDAL”
on page 3-19.
4. Adjust:
• Brake light operation timing
TIP
Adjustment is correct when the brake light
comes on by depressing the brake pedal less
than 5.0–10.0 mm (0.20–0.39 in).
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the main body “1” of the brake light
switch so that it does not rotate and turn the
adjusting nut “2” in direction “a” or “b” until the
brake light comes on at the proper time.
Direction “a”
Brake light comes on sooner.
Direction “b”
Brake light comes on later.
4-51
STEERING SYSTEM
EAS1XD1081
STEERING SYSTEM
Removing the steering assembly
T.R
T.R
.
.
3
40 Nm (4.0 m•kgf, 29 ft•Ibf)
T.R
.
(4)
4
2 5
6 1
1
New
(4)
New
27 Nm (2.7 m•kgf, 20 ft•Ibf)

T.R
.
New 40 Nm (4.0 m•kgf, 29 ft•Ibf)

T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf)

T.R
.
39 Nm (3.9 m•kgf, 28 ft•Ibf)

T.R
.
39 Nm (3.9 m•kgf, 28 ft•Ibf)

T.R
.

ment panel 4-1.
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
For EPS models
ECA1XD1009
NOTICE
5 EPS unit 1
The EPS unit should not be disassem-
bled.
6 Steering joint 1
4-52
STEERING SYSTEM
Removing the steering assembly
T.R
T.R
.
.
40 Nm (4.0 m•kgf, 29 ft•Ibf)
T.R
.
(4)
9
7
7
9
New
10 (4)
New
8 27 Nm (2.7 m•kgf, 20 ft•Ibf)

T.R
.
New 40 Nm (4.0 m•kgf, 29 ft•Ibf)

T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf)

T.R
.
39 Nm (3.9 m•kgf, 28 ft•Ibf)

T.R
.
10
39 Nm (3.9 m•kgf, 28 ft•Ibf)
T.R
.

7 Tie-rod end locknut 2
8 Steering assembly 1
9 Tie-rod end 2
10 Dust boot 2
dure.
4-53
STEERING SYSTEM
EAS1XD1082
b. Crimp the portion “c” of the boot band with the
CHECKING THE STEERING JOINT
boots band installation tool “2”.
1. Check:
• Steering joint Boots band installation tool
Rough movement → Replace. 90890-01526
YM-01526
EAS1XD1083
CHECKING THE TIE-ROD ENDS

The following procedure applies to both of the ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
tie-rod ends. 2. Install:
1. Check: • Steering assembly “1”
• Tie-rod end free play and movement
Rough movement → Replace the tie-rod end. Steering assembly bolt
48 Nm (4.8 m·kgf, 35 ft·lbf)
T.
R.
TIP
Tighten the steering assembly bolts in the prop-
er tightening sequence as shown.
FWD
4 2
1
2. Check:
• Tie-rod end
Bends/damage → Replace.
Rubber boot damage → Replace the tie-rod
end. 1 3
EAS29650
3. Install:
INSTALLING THE STEERING SYSTEM • Steering joint “1”
1. Install: • Steering column “2” (except for EPS models)
• Dust boots • EPS unit “2” (for EPS models)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the tabs “a” into the holes “b” in the boot Steering column bolt (except for
band “1”. EPS models)
T.
R.
21 Nm (2.1 m·kgf, 15 ft·lbf)

a EPS unit bolt (for EPS models)
21 Nm (2.1 m·kgf, 15 ft·lbf)
Steering joint bolt
27 Nm (2.7 m·kgf, 20 ft·lbf)
1
4-54
STEERING SYSTEM
TIP
• Align the alignment mark “a” on the steering
assembly shaft and the alignment mark “b” on
the steering joint with the alignment mark “c” on
the steering assembly housing.
• Fit the steering joint onto the steering column
shaft or EPS unit shaft so that the bolt hole “d”
in the joint is aligned with the area “e” on the
shaft that does not have splines.
1 b
1
d
e
4. Adjust:
• Toe-in
Refer to “ADJUSTING THE TOE-IN” on page
3-26.
4-55
STEERING KNUCKLES
EAS1XD1084
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
7 New
8
9
1
New
30 Nm (3.0 m•kgf, 22 ft•Ibf)
T.R
LS
.
New
New 5 4
8
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 4-25.
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
dure.
4-56
STEERING KNUCKLES
EAS29670
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.
ECA1XD1010
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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1XD1086
CHECKING THE STEERING KNUCKLE BALL

JOINTS
steering knuckle ball joints.
1. Check:
EAS1XD1085
• 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”.
EWA15040
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
4-57
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
2 10 Base plate 35 mm
YM-01553
d. Measure the ball joint bore inside diameter Ball joint installer at- 90890-01555
11
“a”. tachment 39 mm YS-01881-A
Out of specification → Replace the steering
knuckle.
8 11
Ball joint bore inside diameter 7
9
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
rubber boot. f. Hold the base plate “10” in place while turning
in the long bolt “6” to install the new ball joint
Ball joint remover “5” into the steering knuckle “4”.
90890-01474 g. Remove the special tools.
YM-01474 h. Install a new circlip.
Ball joint remover adapter set ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
90890-01477
YM-01477
Base plate 35mm
90890-01553
YM-01553
Ball joint installer attachment
39mm
90890-01555
YS-01881-A
4-58
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES
EAS29710

Removing the front arms and front shock absorber assemblies
5 LS 7 45 Nm (4.5 m•kgf, 33 ft•Ibf)
T.R
7
.
5
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
LS
7
LS
2
9
9
6 LS
8
New
5
4
5 30 Nm (3.0 m•kgf, 22 ft•Ibf)
3
T.R
.
45 Nm (4.5 m•kgf, 33 ft•Ibf)
T.R
.
30 Nm (3.0 m•kgf, 22 ft•Ibf)

T.R
.
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
4-59
Removing the front arms and front shock absorber assemblies

LS 45 Nm (4.5 m•kgf, 33 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
LS
LS 10
13
13 10 10
LS
14 New
New
12
12 16 30 Nm (3.0 m•kgf, 22 ft•Ibf)
T.R
.
16
11 15 New 45 Nm (4.5 m•kgf, 33 ft•Ibf)

T.R
.
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 Bushing 2
14 Circlip 1
15 Ball joint 1
16 Bushing 2
dure.
4-60
EAS29730
damage or personal injury that may result
CHECKING THE FRONT ARMS
from improper handling of the front shock
absorber assemblies.
front upper arms and front lower arms.
• Do not tamper or attempt to open the front
1. Check:
shock absorber assemblies.
• Front arm free play
• Do not subject the front shock absorber as-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the front arm side play “A” by moving semblies 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 assemblies in any way. If the front
shock absorber assemblies are damaged,
damping performance will suffer.
A
EAS1XD1088
DISPOSING OF A FRONT SHOCK

ABSORBER ASSEMBLY
Gas pressure must be released before dispos-
ing of a front shock absorber assembly. To re-
A
lease the gas pressure, drill a 2–3 mm (0.08–
b. Check the front arm vertical movement “B” by 0.12 in) hole through the front shock absorber at
moving it up and down. a point 60–70 mm (2.4–2.8 in) from its end as
If the vertical movement is tight or rough, or if shown.
there is binding, check the bushings. EWA1XD1014
WARNING
Oil and metal chips may be expelled together
with the gas from the shock absorber assem-
bly; therefore, wear eye protection to prevent
B eye damage.
B
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Front upper arm
• Front lower arm
3. Check: EAS29760
• Bushings CHECKING THE FRONT SHOCK ABSORBER
Wear/damage → Replace. ASSEMBLIES
EAS1XD1087
HANDLING THE FRONT SHOCK ABSORBER front shock absorber assemblies.
ASSEMBLIES 1. Check:
EWA1XD1013
WARNING Oil leaks/gas leaks → Replace the front
These front shock absorber assemblies con- shock absorber assembly.
tain highly compressed nitrogen gas. Before • Front shock absorber rod
handling the front shock absorber assem- Bends/damage → Replace the front shock
blies, read and make sure you understand absorber assembly.
the following information. The manufacturer • Spring
cannot be held responsible for property Move the spring up and down.
4-61
Fatigue → Replace the front shock absorber TIP

assembly. • Always use a new ball joint.
EAS29770 • Do not tap or damage the top of the ball joint or
CHECKING THE FRONT ARM BALL JOINTS rubber boot.
front arm ball joints. Ball joint remover
1. Check: 90890-01474
• Ball joint (front upper arm) YM-01474
Damage/pitting → Replace the ball joint. Ball joint remover adapter set
Rubber boot damage → Replace the ball 90890-01477
joint. YM-01477
Rough movement → Replace the ball joint. Base plate 35mm
90890-01553
YM-01553
Ball joint installer attachment
39mm
90890-01555
YS-01881-A
No. Tool name Tool No.

6 Long bolt
90890-01474
7 Body
YM-01474
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 8 Guide bolt
a. Clean the surface of the front upper arm.
b. Remove the circlip “1”. 90890-01477
9 Installer washer
YM-01477
90890-01553
10 Base plate 35 mm
YM-01553
Ball joint installer at- 90890-01555
11
tachment 39 mm YS-01881-A
1
8 11
7 9
c. Remove the ball joint “2”. 6

TIP
Use a suitable socket “3” to separate the ball
joint “2” from the front upper arm “4”. 10
8
3
6
7
4 8
9
11
2 10
8
4
5
d. Attach the special tools and a new ball joint
“5” to the front upper arm “4”.
4-62
e. Hold the base plate “10” in place while turning

in the long bolt “6” to install the new ball joint
“5” into the front upper arm “4”.
f. Remove the special tools.
g. Install a new circlip.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6,7
EAS29790
INSTALLING THE FRONT ARMS AND 5

FRONT SHOCK ABSORBER ASSEMBLIES
The following procedure applies to both of the 1
front upper arms, front lower arms, and front
6,7
1. Install: 3,4
8
• Front upper arm
• Front lower arm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the front upper arm “1” and front lower
arm “2”. 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.
45 Nm (4.5 m·kgf, 33 ft·lbf)
TIP
• Install the front shock absorber assembly so
that the warning label is facing out.
• Be sure to position the front shock absorber
bolts “6” so that the bolt heads face forward.
c. Install the steering knuckle and nuts “8”.
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

45 Nm (4.5 m·kgf, 33 ft·lbf)
T.
R.
4-63
REAR KNUCKLES AND STABILIZER
EAS29800

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

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

T.
R.
4
New 6
7 3 5
4
8 7
4
5
4
1 LS
2 85 Nm (8.5 m•kgf, 61 ft •Ibf)
T.
R.

the rear knuckles.
Rear wheel hub page 4-25.
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
4-64
Removing the rear knuckles and stabilizer
FW
D 85 Nm (8.5 m•kgf, 61 ft •Ibf)
T.
R.
10 11
12
10 11
60 Nm (6.0 m•kgf, 43 ft •Ibf)

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

T.
R.
LS
85 Nm (8.5 m•kgf, 61 ft •Ibf)
T.
R.

10 Stabilizer holder 2
11 Bushing 2
12 Stabilizer 1
dure.
4-65
EAS1XD1089 EAS29830
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
EWA15040 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.
ECA1XD1010
NOTICE
Do not strike the inner race or balls of the
bearing. Contact should be made only with
the outer race.
h. Install the new oil seals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS29820
CHECKING THE STABILIZER

1. Check:
• Stabilizer
Bends/cracks/damage → Replace.
4-66
REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES
EAS29840

Removing the rear arms and rear shock absorber assemblies
3 82 Nm (8.2 m•kgf, 59 ft •Ibf)
FW
T.
R.
D
3
LS
8
6
6 LS
5 8
7 LS
5 2
7 Nm (0.7 m•kgf, 5.1 ft •Ibf)
T.
R.
85 Nm (8.5 m•kgf, 61 ft•Ibf)

T.R
.
3 45 Nm (4.5 m•kgf, 33 ft •Ibf)

T.
R.
82 Nm (8.2 m•kgf, 59 ft •Ibf) 4

T.
R.
85 Nm (8.5 m•kgf, 61 ft•Ibf)

T.R
3
.
7 Nm (0.7 m•kgf, 5.1 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 4-64.
1 Rear arm protector 1
2 Rear brake hose holder 1
3 Nut/Bolt (rear shock absorber) 2/2
4 Rear shock absorber 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
4-67
Removing the rear arms and rear shock absorber assemblies

82 Nm (8.2 m•kgf, 59 ft •Ibf)
FW
T.
R.
D
LS
13
LS
13 LS
10
10 10
7 Nm (0.7 m•kgf, 5.1 ft •Ibf)
T.
R.
85 Nm (8.5 m•kgf, 61 ft•Ibf) 10

T.R
.
12 13
13
45 Nm (4.5 m•kgf, 33 ft •Ibf)
12
T.
R.
82 Nm (8.2 m•kgf, 59 ft •Ibf)

T.
R.
9 85 Nm (8.5 m•kgf, 61 ft•Ibf)

T.R
.
11 9
7 Nm (0.7 m•kgf, 5.1 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
dure.
4-68
EAS29850
damage or personal injury that may result
CHECKING THE REAR ARMS
from improper handling of the rear shock ab-
sorber assemblies.
rear upper arms and rear lower arms.
• Do not tamper or attempt to open the rear
1. Check:
• Rear arm free play
• Do not subject the rear shock absorber as-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the rear arm side play “A” by moving it semblies 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 assemblies in any way. If the rear
shock absorber assemblies are damaged,
A damping performance will suffer.
EAS1XD1091
DISPOSING OF A REAR SHOCK ABSORBER

ASSEMBLY
Gas pressure must be released before dispos-
A
ing of a rear shock absorber assembly. To re-
lease the gas pressure, drill a 2–3 mm (0.08–
b. Check the rear arm vertical movement “B” by 0.12 in) hole through the rear shock absorber at
moving it up and down. a point 40–50 mm (1.6–2.0 in) from its end as
If the vertical movement is tight or rough, or if shown.
there is binding, check the bushings. EWA1XD1016
WARNING
Oil and metal chips may be expelled together
B with the gas from the shock absorber assem-
bly; therefore, wear eye protection to prevent
eye damage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Rear upper arm
• Rear lower arm
3. Check:
• Bushings EAS29860
Wear/damage → Replace. CHECKING THE REAR SHOCK ABSORBER

ASSEMBLIES
EAS1XD1090 The following procedure applies to both of the
HANDLING THE REAR SHOCK ABSORBER rear shock absorber assemblies.
ASSEMBLIES 1. Check:
EWA1XD1015
WARNING • Rear shock absorber assembly

Oil leaks/gas leaks → Replace the rear shock
These rear shock absorber assemblies con-
absorber assembly.
tain highly compressed nitrogen gas. Before
• Rear shock absorber rod
handling the rear shock absorber assem-
Bends/damage → Replace the rear shock
blies, read and make sure you understand
absorber assembly.
the following information. The manufacturer
• Spring
cannot be held responsible for property
Move the spring up and down.
4-69
Fatigue → Replace the rear shock absorber

assembly.
EAS29870
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 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 3,4
a. Install the rear upper arm “1” and rear lower 8,9
arm “2”.
TIP
• Lubricate the rear upper and lower arm bolts 3,4 6,7
“3” with lithium-soap-based grease.
2
• Be sure to position the rear upper and lower
arm bolts “3” so that the bolt heads face for- 8,9
ward.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Temporarily tighten the rear upper and lower
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 warning label is facing rearward.
• Be sure to position the rear shock absorber
bolts “6” so that the bolt heads face forward.
c. Install the rear knuckle bolts “8”, and nuts “9”.
Rear knuckle nut

85 Nm (8.5 m·kgf, 61 ft·lbf)
T.
R.
d. Tighten the rear upper and lower arm nuts “4”

to specification.
Rear arm nut

45 Nm (4.5 m·kgf, 33 ft·lbf)
T.
R.
4-70
4-71
ENGINE
ENGINE REMOVAL ........................................................................................5-1

INSTALLING THE EXHAUST PIPE AND MUFFLER................................5-2
INSTALLING THE ENGINE....................................................................... 5-7
CYLINDER HEAD............................................................................................ 5-8

REMOVING THE CYLINDER HEAD.......................................................5-10
CHECKING THE CYLINDER HEAD .......................................................5-10
CHECKING THE CAMSHAFT SPROCKET............................................5-11
CHECKING THE TAPPET COVERS AND CAMSHAFT
SPROCKET COVER .............................................................................. 5-11
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-11
INSTALLING THE CYLINDER HEAD .....................................................5-12
MEASURING THE COMPRESSION PRESSURE..................................5-14
ROCKER ARMS AND CAMSHAFT ..............................................................5-16

REMOVING THE ROCKER ARMS AND CAMSHAFT............................ 5-17
CHECKING THE CAMSHAFT.................................................................5-17
CHECKING THE DECOMPRESSION SYSTEM..................................... 5-18
CHECKING THE ROCKER ARMS AND ROCKER ARM
SHAFTS .................................................................................................5-18
INSTALLING THE CAMSHAFT AND ROCKER ARMS .......................... 5-18
VALVES AND VALVE SPRINGS.................................................................. 5-20

5
REMOVING THE VALVES...................................................................... 5-21
CHECKING THE VALVES AND VALVE GUIDES ..................................5-21
CHECKING THE VALVE SEATS ............................................................ 5-23
CHECKING THE VALVE SPRINGS........................................................ 5-24
INSTALLING THE VALVES .................................................................... 5-25
CYLINDER AND PISTON.............................................................................. 5-27

REMOVING THE PISTON ...................................................................... 5-28
CHECKING THE CYLINDER AND PISTON ...........................................5-28
CHECKING THE PISTON RINGS........................................................... 5-29
CHECKING THE PISTON PIN ................................................................5-30
INSTALLING THE PISTON AND CYLINDER .........................................5-30
AC MAGNETO AND STARTER CLUTCH ....................................................5-32

REMOVING THE AC MAGNETO ROTOR.............................................. 5-34
REMOVING THE STARTER CLUTCH ...................................................5-34
CHECKING THE STARTER CLUTCH ....................................................5-35
CHECKING THE TORQUE LIMITER......................................................5-35
INSTALLING THE STARTER CLUTCH .................................................. 5-35
INSTALLING THE AC MAGNETO ROTOR ............................................5-35
ELECTRIC STARTER ...................................................................................5-37

CHECKING THE STARTER MOTOR .....................................................5-39
ASSEMBLING THE STARTER MOTOR................................................. 5-40
BALANCER GEARS AND OIL PUMP GEARS ............................................5-41
REMOVING THE BALANCER DRIVEN GEAR AND
OIL PUMP DRIVEN SPROCKET ........................................................... 5-43
CHECKING THE OIL PUMP GEARS......................................................5-43
CHECKING THE BALANCER GEARS ...................................................5-43
INSTALLING THE BALANCER DRIVE GEAR, BALANCER
DRIVEN GEAR, AND OIL PUMP DRIVEN SPROCKET........................ 5-43
SHIFT LEVER................................................................................................5-45
CHECKING THE STOPPER LEVER ......................................................5-48
CHECKING THE SHIFT LEVERS........................................................... 5-48
INSTALLING THE SHIFT LEVERS......................................................... 5-48
ADJUSTING THE DRIVE SELECT LEVER SHIFT CABLE ....................5-48
PRIMARY AND SECONDARY SHEAVES....................................................5-50

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

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

REMOVING THE MIDDLE DRIVE SHAFT ............................................. 5-87
REMOVING THE MIDDLE DRIVEN SHAFT...........................................5-87
CHECKING THE PINION GEARS .......................................................... 5-88
INSTALLING THE BEARING AND OIL SEALS ...................................... 5-89
INSTALLING THE MIDDLE DRIVEN SHAFT .........................................5-89
INSTALLING THE MIDDLE DRIVE SHAFT ............................................5-90
MEASURING THE MIDDLE GEAR BACKLASH..................................... 5-91
ALIGNING THE MIDDLE GEAR ............................................................. 5-92
ENGINE REMOVAL
EAS23711
ENGINE REMOVAL
Removing the muffler and exhaust pipe
17 Nm (1.7 m•kgf, 12 ft•Ibf) 8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
T.R
.
T.R
.
20 Nm (2.0 m•kgf, 14 ft•Ibf)

2
T.R
.
New 8
6 LT
5 7
3
17 Nm (1.7 m•kgf, 12 ft•Ibf)

T.R
.
23 Nm (2.3 m•kgf, 17 ft•Ibf)

4
T.R
.

1 Exhaust pipe heat protector plate 1 Lift the cargo bed.
2 Muffler heat protector plate 1
3 Spring 2
4 Muffler 1
5 Gasket 1
6 Muffler mount 1
7 Exhaust pipe 1
8 Gasket 1
dure.
5-1
ENGINE REMOVAL
EAS1XD1025
INSTALLING THE EXHAUST PIPE AND

MUFFLER 1
1. Install:
• Gasket “1” New
(muffler side)
ECA1XD1012
NOTICE
Be careful not to damage the muffler contact
1
surface of the gasket.
TIP
Install the gasket completely onto the exhaust
pipe “2” by pushing the side “a” of the gasket. If
the gasket is difficult to install, tap lightly on the
gasket with a soft-face hammer.
New 1 2
2. Install:
• Muffler mount “1”
Installed length “a”

34 mm (1.34 in)
a
1
3. Install:
• Springs “1”
TIP
Install the springs so that the spring ends are
pointing inward as shown in the illustration.
5-2
ENGINE REMOVAL
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
.

Cargo bed/Frame cross member/Seat Refer to “GENERAL CHASSIS” on page
frames/Rear panels/Center passenger compart- 4-1.
ment panel/V-belt cooling ducts
Disconnect.
Drive select lever shift cable Refer to “SHIFT LEVER” on page 5-45.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-8.
Disconnect.
Thermostat outlet hose Refer to “THERMOSTAT” on page 6-8.
Disconnect.
Water pump inlet hose Refer to “WATER PUMP” on page 6-11.
Disconnect.
Oil cooler outlet hose
Refer to “OIL COOLER” on page 6-1.
Disconnect.
Air induction system hose (air cut-off valve to Refer to “AIR INDUCTION SYSTEM” on
reed valve cover) page 7-15.
5-3
ENGINE REMOVAL
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
1
.
3
5
8 7

Air intake silencer Refer to “THROTTLE BODY” on page 7-8.
Refer to “REAR CONSTANT VELOCITY
SHAFT ASSEMBLIES, FINAL DRIVE AS-
Rear drive shaft SEMBLY AND REAR DRIVE SHAFT” on
page 8-17.
1 Spark plug cap 1 Disconnect.
2 Coolant temperature sensor coupler 1 Disconnect.
3 Reverse switch coupler 1 Disconnect.
4 Gear position switch coupler 1 Disconnect.
5 Engine ground lead 1 Disconnect.
6 Starter motor lead 1 Disconnect.
7 Speed sensor coupler 1 Disconnect.
8 Crankshaft position sensor coupler 1 Disconnect.
9 AC magneto coupler 2 Disconnect.
dure.
5-4
ENGINE REMOVAL
Removing the engine
LT 1
2
7
6
LT
5
1 2
3 7
LT
LT
T.R
.
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 42 Nm (4.2 m•kgf, 30 ft•Ibf)

T.R
T.R
.
.

1 Engine mounting bolt (front) 2
2 Engine mounting bolt (front) 2
3 Engine bracket nut (rear) 2
ECA1XD1034
NOTICE
Make sure that the engine does not strike
the brake pipe when removing it.
4 Engine 1
TIP
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
5-5
ENGINE REMOVAL
Removing the engine
8
LT
LT
8 LT
LT
T.R
.
T.R
.

T.R
T.R
.
.

8 Engine mounting bolt (rear) 2
9 Engine bracket (rear) 2
dure.
5-6
ENGINE REMOVAL
EAS23720
INSTALLING THE ENGINE

1. Install:
• Engine brackets (rear) “1”
(onto the engine) 6
• Engine mounting bolts (rear) (M10) “2”
• Engine mounting bolts (rear) (M6) “3”
TIP
Before installing the engine, tighten the engine
mounting bolts (rear) to specification.
2
Engine mounting bolt (rear) (M10) 9
42 Nm (4.2 m·kgf, 30 ft·lbf) 8
T.
R.
Engine mounting bolt (rear) (M6)

10 Nm (1.0 m·kgf, 7.2 ft·lbf) 3
LOCTITE® 5
4 2 1
2. Install: 7 9 8 3
• Engine brackets (front) “4”
(onto the frame)
• Engine bracket nuts (front) “5”
• Engine “6”
• Engine bracket nuts (rear) “7”
• Engine mounting bolts (front) (M10) “8”
ECA1XD1011
NOTICE
Make sure that the engine does not strike the
brake pipe when installing it.
TIP
Do not fully tighten the bolts and nuts.
3. Tighten:
• Engine bracket nuts (front) “5”
• Engine bracket nuts (rear) “7”
Engine bracket nuts (front)

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

42 Nm (4.2 m·kgf, 30 ft·lbf)
Engine mounting bolt (front)
(M10)
42 Nm (4.2 m·kgf, 30 ft·lbf)
Engine mounting bolt (front) (M6)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
5-7
CYLINDER HEAD
EAS24100
CYLINDER HEAD
Removing the cylinder head
13 Nm (1.3 m•kgf, 9.4 ft•Ibf)

T.R
.
20 Nm (2.0 m•kgf, 14 ft•Ibf)
T.R
35 Nm (3.5 m•kgf, 25 ft•Ibf)
.
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
M
20 Nm (2.0 m•kgf, 14 ft•Ibf)
1
T.R
.
(4)
2
LS 3
New
LS
New
New
(4)
New
LS

T.R
.
T.R
.
LS
New

T.R
T.R
.

Right rear panel/Frame cross member 4-1.
Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-1.
Disconnect.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-13.
Oil pipe (crankcase to cylinder head) Refer to “OIL COOLER” on page 6-1.
Drain.
page 3-8.
Thermostat/Coolant temperature sensor Refer to “THERMOSTAT” on page 6-8.
Throttle body assembly Refer to “THROTTLE BODY” on page 7-8.
Refer to “AIR INDUCTION SYSTEM” on
Reed valve assembly page 7-15.
1 Spark plug cap 1 Disconnect.
2 Spark plug 1
3 Cylinder head breather hose 1 Disconnect.
5-8
CYLINDER HEAD
Removing the cylinder head
13 Nm (1.3 m•kgf, 9.4 ft•Ibf)
T.R
.
20 Nm (2.0 m•kgf, 14 ft•Ibf)
T.R
35 Nm (3.5 m•kgf, 25 ft•Ibf)
.
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
M
20 Nm (2.0 m•kgf, 14 ft•Ibf)
T.R
.
(4)
5
LS
New 11
6 10 LS
7
New
New
48
14 9
(4) 12
New
5 LS

13 New
T.R
.
T.R
.
LS
New

T.R
T.R
.

4 Camshaft sprocket cover 1
5 Tappet cover 2
6 Oil check bolt 1
7 Timing chain tensioner cap bolt 1
8 Timing chain tensioner 1
9 Timing chain tensioner gasket 1
10 Camshaft sprocket 1
11 Decompressor assembly 1
12 Cylinder head 1
13 Cylinder head gasket 1
14 Dowel pin 2
dure.
5-9
CYLINDER HEAD
EAS24130
4. Remove:
REMOVING THE CYLINDER HEAD
• Timing chain tensioner
1. Align:
• “I” mark “a” on the AC magneto rotor
• Camshaft sprocket
(with the stationary pointer “b” on the AC
• Timing chain
magneto cover)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
TIP
a. Turn the crankshaft counterclockwise. To prevent the timing chain from falling into the
crankcase, fasten it with a wire.
5. Remove:
• Cylinder head
a
TIP
b • Loosen the bolts in the proper sequence as
shown.
• Loosen each bolt 1/2 of a turn at a time. After
all of the bolts are fully loosened, remove them.
b. When the piston is at TDC on the compres-

sion stroke, align the “I” mark “c” on the cam-
shaft sprocket with the stationary pointer “d”
on the cylinder head. 1 2 3 4
d
c
×2 ×2 ×2 ×2
4
2 7 6
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Loosen: 1 8
• Camshaft sprocket bolts “1” 5
3
• Decompressor assembly bolts “2”
TIP
While holding the AC magneto rotor nut with a
wrench, loosen the camshaft sprocket bolts and Cylinder head bolts “1”
decompressor assembly bolts. Length: 135 mm (5.31 in)
Cylinder head bolts “2”
Length: 145 mm (5.71 in)
1
EAS24160
CHECKING THE CYLINDER HEAD

2 1. Eliminate:
• Combustion chamber carbon deposits
3. Loosen: (with a rounded scraper)
• Timing chain tensioner cap bolt
5-10
CYLINDER HEAD
ECA1XD1035
c. If the limit is exceeded, resurface the cylinder
NOTICE head as follows.
Do not use a sharp instrument; otherwise, d. Place a 400–600 grit wet sandpaper on the
the following may be damaged or scratched: surface plate and resurface the cylinder head
• Spark plug bore threads using a figure-eight sanding pattern.
• Valve seats TIP
To ensure an even surface, rotate the cylinder
head several times.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1XD1092
CHECKING THE CAMSHAFT SPROCKET

1. Check:
• Camshaft sprocket
More than 1/4 tooth wear “a” → Replace the
camshaft sprocket and the timing chain as a
2. Check: set.
• Cylinder head
Damage/scratches → Replace.
• Cylinder head water jacket
Mineral deposits/rust → Eliminate.
3. Measure:
• Cylinder head warpage
Out of specification → Resurface the cylinder
head.
Warpage limit
0.03 mm (0.0012 in) a. 1/4 tooth
b. Correct
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1. Timing chain roller
a. Place a straightedge “1” and a thickness 2. Camshaft sprocket
gauge “2” across the cylinder head.
EAS23940
CHECKING THE TAPPET COVERS AND

CAMSHAFT SPROCKET COVER
tappet covers.
1. Check:
• Tappet cover
• Camshaft sprocket cover
Damage/wear → Replace.
EAS24190
CHECKING THE TIMING CHAIN TENSIONER

1. Check:
1
2 Cracks/damage → Replace.
2. Check:
• One-way cam operation
Rough movement → Replace the timing
chain tensioner.
3. Check:
• Timing chain tensioner cap bolt
b. Measure the warpage. Damage/wear → Replace.
5-11
CYLINDER HEAD
• Spring
• One-way cam
• Timing chain tensioner rod 1 2 3 4
Damage/wear → Replace the timing chain
tensioner.
×2 ×2 ×2 ×2
4 2 3 1
5
7 2 3
8 1
4
EAS24230 6
INSTALLING THE CYLINDER HEAD
1. Install:
• Dowel pins 4 2 3 1
• Cylinder head gasket New
2. Install: 3. Install:
• Cylinder head • Decompressor assembly
• Cylinder head bolts • Camshaft sprocket
(onto the camshaft)
Cylinder head bolt “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
35 Nm (3.5 m·kgf, 25 ft·lbf) a. Install the decompressor assembly onto the
T.
R.
Cylinder head bolt “2” camshaft, and then finger tighten the decom-
35 Nm (3.5 m·kgf, 25 ft·lbf) pressor assembly bolts “1”.
Cylinder head bolt “3” b. Turn the crankshaft counterclockwise.
38 Nm (3.8 m·kgf, 27 ft·lbf) c. Align the “I” mark “a” on the AC magneto rotor
Cylinder head bolt “4”
with the stationary pointer “b” on the AC mag-
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
neto cover.
Cylinder head bolts “1” d. Align the “I” mark “c” on the camshaft sprock-
Length: 135 mm (5.31 in) et with the stationary pointer “d” on the cylin-
Cylinder head bolts “2” der head.
Length: 145 mm (5.71 in) e. Install the timing chain “2” onto the camshaft
Cylinder head bolts “3” sprocket “3”, and install the camshaft sprock-
Length: 39 mm (1.54 in) et onto the camshaft, and then finger tighten
Cylinder head bolts “4” the camshaft sprocket bolts “4”.
TIP
• Lubricate the threads and mating surface of
the cylinder head bolts “1” and “2” with molyb- a
denum disulfide grease. b
• Lubricate the threads and mating surface of
the cylinder head bolts “3” with engine oil.
• Tighten the cylinder head bolts in the proper
tightening sequence as shown ( 1, 2, and
so on) and torque them in two stages.
5-12
CYLINDER HEAD
d. Install the spring “5”, a new copper washer

d “6”, and the timing chain tensioner cap bolt
4 “7”.
c
2
1 Timing chain tensioner cap bolt
20 Nm (2.0 m·kgf, 14 ft·lbf)
T.
4
R.
6 New
3 5 7
TIP 3
When installing the camshaft sprocket, be sure 4 New
to keep the timing chain as tight as possible on
the exhaust side.
ECA1XD1036
NOTICE
Do not turn the crankshaft when installing ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
the camshaft to avoid damage or improper 5. Turn:
valve timing. • Crankshaft
f. Remove the wire from the timing chain. (several turns counterclockwise)
6. Check:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• “I” mark “a”
4. Install:
Align the “I” mark on the AC magneto rotor
with the stationary pointer “b” on the AC mag-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the timing chain tensioner cap bolt, neto cover.
copper washer, and spring. • “I” mark “c”
b. Release the timing chain tensioner one-way Align the “I” mark on the camshaft sprocket
cam “1” and push the timing chain tensioner with the stationary pointer “d” on the cylinder
rod “2” all the way into the timing chain ten- head.
sioner housing. Out of alignment → Correct.
Refer to the installation steps above.
1 a
2
c. Install the timing chain tensioner housing “3”
and a new gasket “4” onto the cylinder.
d
Timing chain tensioner bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf) c
T.
R.
TIP
Install the gasket with its beaded side facing the
timing chain tensioner.
5-13
CYLINDER HEAD
7. Tighten: EAS20710
MEASURING THE COMPRESSION

• Camshaft sprocket bolts “1”
PRESSURE
• Decompressor assembly bolts “2”
TIP
Camshaft sprocket bolt Insufficient compression pressure will result in a
20 Nm (2.0 m·kgf, 14 ft·lbf) loss of performance.
T.
R.
Decompressor assembly bolt

20 Nm (2.0 m·kgf, 14 ft·lbf) 1. Measure:
• Valve clearance
ECA1XD1026
NOTICE Refer to “ADJUSTING THE VALVE CLEAR-
Be sure to tighten the camshaft sprocket ANCE” on page 3-3.
bolts to specification to avoid the possibility 2. Start the engine, warm it up for several min-
of the bolts coming loose and damaging the utes, and then turn it off.
engine. 3. Lift the cargo bed.
4. Disconnect:
TIP
• Spark plug cap
• While holding the AC magneto rotor nut with a 5. Remove:
wrench, tighten the camshaft sprocket bolts • Spark plug
and decompressor assembly bolts. ECA1XD1037
• After tightening the decompressor assembly NOTICE

bolts, check that decompressor assembly Before removing the spark plug, use com-
moves smoothly. pressed air to blow away any dirt accumulat-
ed in the spark plug well to prevent it from
falling into the cylinder.
1 6. Attach:
• Compression gauge “1”
Compression gauge
90890-03081
Engine compression tester
2 YU-33223
7. Measure:
8. Measure: • Compression pressure
• Valve clearance Out of specification → Refer to steps (b) and
Out of specification → Adjust. (c).
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-3. Standard compression pressure
(at sea level)
500 kPa (5.0 kgf/cm², 71.1 psi)
Minimum–maximum
440–560 kPa (4.4–5.6 kgf/cm²,
62.6–79.6 psi)
5-14
CYLINDER HEAD
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. With the throttle wide open, crank the engine
until the reading on the compression gauge
stabilizes.
EWA1XD1017
WARNING
To prevent sparking, ground the spark plug
lead before cranking the engine.
b. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces and piston crown for
carbon deposits.
Carbon deposits → Eliminate.
c. If the compression pressure is below the min-
imum specification, pour a teaspoonful of en-
gine oil into the spark plug bore and measure
again.
Refer to the following table.
Compression pressure (with oil applied into
the cylinder)
Reading Diagnosis
Higher than without Piston ring(s) wear or
oil damage → Repair.
Piston, valves, cylin-
der head gasket or
Same as without oil piston ring(s) possi-
bly defective → Re-
pair.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Install:
• Spark plug
Spark plug
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
T.
R.
TIP
Before installing the spark plug, clean the spark
plug and gasket surface.
9. Connect:
• Spark plug cap
5-15
ROCKER ARMS AND CAMSHAFT
EAS1XD1093

Removing the rocker arms and camshaft
5 14 Nm (1.4 m•kgf, 10 ft•Ibf)
T.R
.
6
14 Nm (1.4 m•kgf, 10 ft•Ibf) 5
T.R
.
3
6
5 M
5
6 2 E
6
4
E
M
10
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
9
T.R
.
M 7 E
1
E
2
8
E LT

Cylinder head Refer to “CYLINDER HEAD” on page 5-8.
1 Bearing retainer 1
2 Rocker arm shaft 2
3 Intake rocker arm 1
4 Exhaust rocker arm 1
5 Locknut 4
6 Valve adjusting screw 4
ECA1XD1038
NOTICE
7 Camshaft 1
Do not disassemble the camshaft assem-
bly.
8 Decompressor lever 1
9 Decompressor lever pin 1
10 Bearing 1
dure.
5-16
EAS23770
REMOVING THE ROCKER ARMS AND Camshaft lobe dimensions

CAMSHAFT Intake A
1. Loosen: 42.985–43.085 mm (1.6923–
• Locknuts 1.6963 in)
• Valve adjusting screws Limit
2. Remove: 42.885 mm (1.6884 in)
• Intake rocker arm shaft Intake B
• Exhaust rocker arm shaft 36.950–37.050 mm (1.4547–
• Intake rocker arm 1.4587 in)
Limit
• Exhaust rocker arm
36.850 mm (1.4572 in)
TIP Exhaust A
Remove the rocker arm shafts with the slide 43.490–43.590 mm (1.7122–
hammer bolt “1” and weight “2”. 1.7161 in)
Limit
43.390 mm (1.7083 in)
Slide hammer bolt
Exhaust B
90890-01083
36.950–37.050 mm (1.4547–
Slide hammer bolt 6 mm
1.4587 in)
YU-01083-1
Limit
Weight
36.850 mm (1.4572 in)
90890-01084
YU-01083-3
2 1
EAS23840
CHECKING THE CAMSHAFT

1. Check:
• Camshaft lobes
Blue discoloration/pitting/scratches → Re-
place the camshaft.
2. Measure:
• Camshaft lobe dimensions “a” and “b”
Out of specification → Replace the camshaft.
3. Measure:
• Camshaft runout
Out of specification → Replace the camshaft.
Camshaft runout limit

0.015 mm (0.0006 in)
5-17
Rocker arm inside diameter

12.000–12.018 mm (0.4724–
0.4731 in)
EAS1XD1094
CHECKING THE DECOMPRESSION SYSTEM

1. Check:
• Decompression system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the decompression system with the 4. Measure:
camshaft sprocket installed on the decom- • Rocker arm shaft outside diameter
pressor lever and the decompressor lever pin Out of specification → Replace.
“1” installed in the camshaft.
Rocker arm shaft outside diame-
b. Check that the decompressor lever pin “1” ter
projects from the camshaft. 11.981–11.991 mm (0.4717–
c. Check that the decompressor cam “2” moves 0.4721 in)
smoothly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Calculate:
EAS23880 • Rocker-arm-to-rocker-arm-shaft clearance
CHECKING THE ROCKER ARMS AND Out of specification → Replace the defective
ROCKER ARM SHAFTS part(s).
rocker arms and rocker arm shafts. Rocker-arm-to-rocker-arm-shaft
1. Check: clearance
• Rocker arm 0.009–0.037 mm (0.0004–0.0015
in)
2. Check:
TIP
• Rocker arm shaft
Blue discoloration/excessive wear/pit- Calculate the clearance by subtracting the rock-
ting/scratches → Replace or check the lubri- er arm shaft outside diameter from the rocker
cation system. arm inside diameter.
3. Measure:
EAS24040
• Rocker arm inside diameter
INSTALLING THE CAMSHAFT AND ROCKER
ARMS
1. Install:
• Bearing “1”
(into the cylinder head “2”)
5-18
TIP TIP
• Apply engine oil to the bearing. Install the camshaft so that the pins “a” become
• Install the bearing so that the seal “a” is facing horizontal.
the camshaft.
1
Installed depth
0 mm (0 in)
2
1 a
5. Lubricate:
• Rocker arms
a • Rocker arm shafts
b
b. Installed depth Rocker arm inner surface
2. Lubricate: Molybdenum disulfide grease
Rocker arm shaft
• Camshaft
Engine oil
• Decompressor lever pin
• Decompressor lever 6. Install:
• Exhaust rocker arm “1”
Camshaft • Exhaust rocker arm shaft “2”
Molybdenum disulfide oil • Intake rocker arm
Camshaft bearing, decompressor • Intake rocker arm shaft
lever pin, decompressor lever TIP
Engine oil • Use a slide hammer bolt “3” to install the rocker
arm shaft.
3. Install: • Make sure the rocker arm shafts are complete-
• Decompressor lever pin “1” ly pushed into the cylinder head.
• Decompressor lever “2”
TIP
Slide hammer bolt
Install the decompressor lever pin and decom- 90890-01083
pressor lever into the camshaft “3” as shown in Slide hammer bolt 6 mm
the illustration. YU-01083-1
3
1
3
2
4. Install:
• Camshaft “1”
5-19
VALVES AND VALVE SPRINGS
EAS24270

Removing the valves and valve springs
1 1
2 2
3 3
2 2
3 M 6 3
6 M
New
New 7
6 6
7
M New New M
7 7
8
8
5
4
4
5
M

Refer to “ROCKER ARMS AND CAM-
Camshaft SHAFT” on page 5-16.
1 Valve cotter 8
2 Valve spring retainer 4
3 Valve spring 4
4 Exhaust valve 2
5 Intake valve 2
6 Valve stem seal 4
7 Valve spring seat 4
8 Valve guide 4
dure.
5-20
EAS24280
REMOVING THE VALVES

valves and related components.
TIP
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal.
1. Check:
• Valve sealing
Leakage at the valve seat → Check the valve 3. Remove:
face, valve seat, and valve seat width. • Valve spring retainer “1”
Refer to “CHECKING THE VALVE SEATS” • Valve spring “2”
on page 5-23. • Valve “3”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Valve stem seal “4”
a. Pour a clean solvent “a” into the intake and • Valve spring seat “5”
exhaust ports. TIP
b. Check that the valves properly seal. Identify the position of each part very carefully so
TIP that it can be reinstalled in its original place.
There should be no leakage at the valve seat “1”.
EAS24290
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE VALVES AND VALVE
2. Remove: GUIDES
• Valve cotters The following procedure applies to all of the
valves and valve guides.
TIP
1. Measure:
Remove the valve cotters by compressing the • Valve-stem-to-valve-guide clearance
valve spring with the valve spring compressor Out of specification → Replace the valve
“1” and the valve spring compressor attachment guide.
“2”.
• Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” -
Valve spring compressor Valve stem diameter “b”
90890-04019
YM-04019
Valve spring compressor attach-
ment
90890-01243
Valve spring compressor adapt-
er (26 mm)
YM-01253-1
5-21
b. Install a new valve guide with the valve guide

Valve-stem-to-valve-guide clear- installer “2” and valve guide remover “1”.
ance (intake)
0.010–0.037 mm (0.0004–0.0015 Valve guide position
in) 12.7–13.1 mm (0.50–0.52 in)
Limit
0.080 mm(0.0031 in)
Valve-stem-to-valve-guide clear-
ance (exhaust)
0.025–0.052 mm (0.0010–0.0020
in)
Limit
0.100 mm(0.0039 in)
a. Valve guide position

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.
TIP
After replacing the valve guide, reface the valve
2. Replace:
seat.
• Valve guide
TIP
Valve guide remover (ø6)
To ease valve guide removal and installation, 90890-04064
and to maintain the correct fit, heat the cylinder Valve guide remover (6.0 mm)
head to 100 °C (212 °F) in an oven. YM-04064-A
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Valve guide installer (ø6)
a. Remove the valve guide with the valve guide 90890-04065
remover “1”. Valve guide installer (6.0 mm)
YM-04065-A
Valve guide reamer (ø6)
90890-04066
Valve guide reamer (6.0 mm)
YM-04066
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
5-22
4. Check: EAS24300
CHECKING THE VALVE SEATS

• Valve face
Pitting/wear → Grind the valve face.
valves and valve seats.
• Valve stem end
1. Eliminate:
Mushroom shape or diameter larger than the
• Carbon deposits
body of the valve stem → Replace the valve.
(from the valve face and valve seat)
5. Measure:
2. Check:
• Valve margin thickness “a”
• Valve seat
Out of specification → Replace the valve.
Pitting/wear → Replace the cylinder head.
Valve margin thickness D (intake) 3. Measure:
0.80–1.20 mm (0.0315–0.0472 in) • Valve seat width C “a”
Limit Out of specification → Replace the cylinder
0.4 mm (0.016 in) head.
Valve margin thickness D (ex-
haust) Valve seat width C (intake)
0.80–1.20 mm (0.0315–0.0472 in) 1.00–1.20 mm (0.0394–0.0472 in)
Limit Limit
0.4 mm (0.016 in) 1.60 mm (0.0630 in)
Valve seat width C (exhaust)
1.00–1.20 mm (0.0394–0.0472 in)
Limit
1.60 mm (0.0630 in)
6. Measure:
• Valve stem runout
Out of specification → Replace the valve.
TIP
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• When installing a new valve, always replace a. Apply blue layout fluid “b” onto the valve face.
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.
5-23
TIP
Where the valve seat and valve face contacted
one another, the blue layout fluid will have been
removed.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Lap:
• Valve face
• Valve seat
TIP
After replacing the cylinder head or replacing the e. Apply a fine lapping compound to the valve
valve and valve guide, the valve seat and valve face and repeat the above steps.
face should be lapped. f. After every lapping procedure, be sure to
clean off all of the lapping compound from the
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ valve face and valve seat.
a. Apply a coarse lapping compound “a” to the
g. Apply blue layout fluid “b” onto the valve face.
valve face.
ECA13790
NOTICE
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
h. Install the valve into the cylinder head.

i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width “c” again. If the
valve seat width is out of specification, reface
b. Apply molybdenum disulfide oil onto the and lap the valve seat.
valve stem.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Install the valve into the cylinder head. EAS24310
d. Turn the valve until the valve face and valve CHECKING THE VALVE SPRINGS
seat are evenly polished, then clean off all of The following procedure applies to all of the
the lapping compound. valve springs.
TIP 1. Measure:
For the best lapping results, lightly tap the valve • Valve spring free length “a”
seat while rotating the valve back and forth be- Out of specification → Replace the valve
tween your hands. spring.
5-24
Free length (intake) Spring tilt (intake)

40.38 mm (1.59 in) 2.5°/1.8 mm (2.5°/0.07 in)
Limit Spring tilt (exhaust)
38.36 mm (1.51 in) 2.5°/1.8 mm (2.5°/0.07 in)
Free length (exhaust)
40.38 mm (1.59 in)
Limit a
38.36 mm (1.51 in)
EAS24340
INSTALLING THE VALVES

valves and related components.
2. Measure: 1. Deburr:
• Compressed valve spring force “a” • Valve stem end
Out of specification → Replace the valve (with an oil stone)
spring.
Installed compression spring

force (intake)
171.00–197.00 N (17.44–20.09
kgf, 38.44–44.29 lbf)
Installed compression spring
force (exhaust)
171.00–197.00 N (17.44–20.09
kgf, 38.44–44.29 lbf)
Installed length (intake)
35.00 mm (1.38 in) 2. Lubricate:
Installed length (exhaust) • Valve stem “1”
35.00 mm (1.38 in)
• Valve stem seal “2” New
(with the recommended lubricant)
Molybdenum disulfide oil
b. Installed length
3. Measure:
• Valve spring tilt “a”
Out of specification → Replace the valve
spring. 3. Install:
• Valve spring seat “1”
• Valve stem seal “2” New
5-25
• Valve “3”
• Valve spring “4”
• Valve spring retainer “5”
(into the cylinder head)
TIP
• Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch “a”
facing up.
5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a soft-face
hammer.
ECA13800
NOTICE
Hitting the valve tip with excessive force
could damage the valve.
b. Smaller pitch
4. Install:
• Valve cotters
TIP
Install the valve cotters by compressing the
valve spring with the valve spring compressor
“1” and the valve spring compressor attachment
“2”.
Valve spring compressor

90890-04019
YM-04019
Valve spring compressor attach-
ment
90890-01243
Valve spring compressor adapt-
er (26 mm)
YM-01253-1
5-26
CYLINDER AND PISTON
EAS24350
CYLINDER AND PISTON

Removing the cylinder and piston
1st 15 Nm (1.5 m•kgf, 11 ft•lbf)
T.R
2nd 50 Nm (5.0 m•kgf, 36 ft•lbf)
.
E E
1
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
2
E
E
7
8 3 New
9
10 4
New 5
4
6
New 5
E

Water jacket joint Refer to “WATER PUMP” on page 6-11.
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
dure.
5-27
CYLINDER AND PISTON
EAS24380
REMOVING THE PISTON TIP

1. Remove: When removing a piston ring, open the end gap
• Piston pin clips “1” with your fingers and lift the other side of the ring
• Piston pin “2” over the piston crown.
• Piston “3”
ECA13810
NOTICE
Do not use a hammer to drive the piston pin
out.
TIP
• Before removing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
the piston pin clips from falling into the crank-
case.
• Before removing the piston pin, deburr the pis- EAS24400
ton pin clip grooves and the piston pin bore ar- CHECKING THE CYLINDER AND PISTON
ea. If both areas are deburred and the piston 1. Check:
pin is still difficult to remove, remove it with the • Piston wall
piston pin puller set “4”. • Cylinder wall
Vertical scratches → Replace the cylinder,
and replace the piston and piston rings as a
Piston pin puller set set.
90890-01304 2. Measure:
Piston pin puller
• Piston-to-cylinder clearance
YU-01304
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the cylinder bore with the cylinder
bore gauge.
2 1
TIP
Measure the cylinder bore by taking side-to-side
and front-to-back measurements of the cylinder.
Then, find the average of the measurements.
Cylinder bore
102.000–102.010 mm (4.0157–
4.0161 in)
Wear limit
2. Remove: 102.080 mm (4.0189 in)
• Top ring Taper limit
• 2nd ring 0.05 mm (0.002 in)
• Oil ring Out of round limit
0.05 mm (0.002 in)
5-28
CYLINDER AND PISTON
Cylinder bore = maximum of D1–D6 TIP

Taper limit = maximum of D1 or D2 - maxi- Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
mum of D5 or D6
ring grooves and piston rings.
Out of round limit = maximum of D1, D3 or D5
- minimum of D2, D4 or D6 Top ring
Ring side clearance
b. If out of specification, replace the cylinder, 0.030–0.070 mm (0.0012–0.0028
and replace the piston and piston rings as a in)
set. Limit
c. Measure piston skirt diameter “a” with a mi- 0.12 mm (0.0047 in)
crometer. 2nd ring
Ring side clearance
Piston skirt diameter D 0.030–0.070 mm (0.0012–0.0028
101.955–101.970 mm (4.0140– in)
4.0146 in) Limit
0.13 mm (0.0051 in)
b. 10.0 mm (0.39 in) from the bottom edge of the

piston 2. Install:
• Piston ring
d. If out of specification, replace the piston and
(into the cylinder)
piston rings as a set.
e. Calculate the piston-to-cylinder clearance TIP
with the following formula. Level the piston ring into the cylinder with the
• Piston-to-cylinder clearance = piston crown.
Cylinder bore -
Piston skirt diameter
Piston-to-cylinder clearance
0.030–0.055 mm (0.0012–0.0022
in)
f. If out of specification, replace the cylinder,

and replace the piston and piston rings as a
set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a. 50 mm (1.97 in)
EAS24430
CHECKING THE PISTON RINGS 3. Measure:

1. Measure: • Piston ring end gap
• Piston ring side clearance Out of specification → Replace the piston
Out of specification → Replace the piston ring.
and piston rings as a set.
5-29
CYLINDER AND PISTON
TIP
The oil ring expander end gap cannot be mea-
sured. If the oil ring rail gap is excessive, replace
all three piston rings.
Top ring
End gap (installed)
0.20–0.35 mm (0.008–0.014 in)
Limit
0.60 mm (0.024 in)
2nd ring 4. Calculate:
End gap (installed) • Piston-pin-to-piston-pin-bore clearance
0.75–0.90 mm (0.03–0.04 in) Out of specification → Replace the piston pin
Limit and piston as a set.
1.25 mm (0.049 in) • Piston-pin-to-piston-pin-bore clearance =
Oil ring Piston pin bore diameter “b” -
End gap (installed) Piston pin outside diameter “a”
0.20–0.70 mm (0.01–0.03 in)
EAS24440 Piston-pin-to-piston-pin-bore
CHECKING THE PISTON PIN clearance
1. Check: 0.004–0.024 mm (0.0002–0.0009
• Piston pin in)
Blue discoloration/grooves → Replace the Limit
piston pin, and then check the lubrication sys- 0.074 mm (0.0029 in)
tem.
EAS24450
2. Measure:
INSTALLING THE PISTON AND CYLINDER
• Piston pin outside diameter “a”
1. Install:
Out of specification → Replace the piston pin.
• Lower oil ring rail “1”
Piston pin outside diameter • Oil ring expander “2”
22.991–23.000 mm (0.9052– • Upper oil ring rail “3”
0.9055 in) • 2nd ring “4”
Limit • Top ring “5”
22.971 mm (0.9044 in) TIP
Be sure to install the piston rings so that the
manufacturer marks or numbers face up.
3. Measure:
• Piston pin bore diameter “b”
Out of specification → Replace the piston. 2. Install:
• Piston “1”
Piston pin bore inside diameter • Piston pin “2”
23.004–23.015 mm (0.9057–
0.9061 in) • Piston pin clips “3” New
Limit TIP
23.045 mm (0.9073 in) • Apply engine oil to the piston pin.
5-30
CYLINDER AND PISTON
• Make sure the punch mark “a” on the piston • Pass the timing chain and timing chain guide
points towards the exhaust side of the cylinder. (exhaust side) through the timing chain cavity.
• Before installing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
the clips from falling into the crankcase. 1
2 7. Install:
3 New • Cylinder bolts “1”
• Cylinder bolts (timing chain side) “2”
3. Install: TIP
• Cylinder gasket New • Lubricate the threads and mating surface of
• Dowel pins the cylinder bolts “1” with engine oil.
4. Lubricate: • Finger tighten the bolts.
• Piston 8. Tighten:
• Piston rings • Cylinder bolts “1”
• Cylinder • Cylinder bolts (timing chain side) “2”
Cylinder bolt
Recommended lubricant 1st
T.
Engine oil
R.
15 Nm (1.5 m·kgf, 11 ft·lbf)

2nd
5. Offset: 50 Nm (5.0 m·kgf, 36 ft·lbf)
• Piston ring end gaps Cylinder bolt (timing chain side)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
a
135˚
45˚ 2
e b
45˚ 45˚
45˚ 45˚
d c E 1 1 E
a. Upper oil ring rail 2

b. Top ring
c. Oil ring expander
d. Lower oil ring rail
e. 2nd ring
A. Exhaust side
6. Install:
• Cylinder “1”
• Timing chain guide (exhaust side)
TIP
• While compressing the piston rings with one
hand, install the cylinder with the other hand.
5-31
AC MAGNETO AND STARTER CLUTCH
EAS1XD1095

Removing the AC magneto and starter clutch
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
18 Nm (1.8 m•kgf, 13 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
1 4
7 2
LT
LT New
(3)
New
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
LT (11)
New
6 E
5 New
3
LS
E
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
T.R
.
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

T.R
.
LT
6 (3)
30 Nm (3.0 m•kgf, 22 ft•Ibf)
T.R
.
E E
60 Nm (6.0 m•kgf, 43 ft•Ibf)
T.R
.

Right rear panel 4-1.
Drain.
page 3-13.
Drain.
page 3-8.
Water pump housing Refer to “WATER PUMP” on page 6-11.
1 Stator coil coupler 2 Disconnect.
3 AC magneto cover 1
4 Oil pipe (AC magneto cover) 1
5 AC magneto cover gasket 1
6 Dowel pin 2
7 Lead holder 1
5-32
Removing the AC magneto and starter clutch

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
18 Nm (1.8 m•kgf, 13 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
LT
LT New
(3)
8
New
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
LT
9 (11)
New
E
18 New
12 10
15 LS
E
11
14 18 New 2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
T.R
.
13 1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

T.R
.
LT
17 (3)
16 30 Nm (3.0 m•kgf, 22 ft•Ibf)
T.R
.
E E
60 Nm (6.0 m•kgf, 43 ft•Ibf)
T.R
.

8 Crankshaft position sensor 1
9 Stator coil 1
10 Torque limiter 1
11 Starter idle gear 1
12 Starter idle gear shaft 1
13 AC magneto rotor 1
14 Starter clutch 1
15 Woodruff key 1
16 Starter wheel gear 1
17 Washer 1
18 Bushing 2
dure.
5-33
EAS24490 ECA13880
REMOVING THE AC MAGNETO ROTOR NOTICE

1. Remove: To protect the end of the crankshaft, place an
• AC magneto cover appropriate sized socket between the fly-
TIP wheel puller set center bolt and the crank-
Loosen each bolt 1/4 of a turn at a time, in stag- shaft.
es and in a crisscross pattern. After all of the
TIP
bolts are fully loosened, remove them.
• Use the flywheel puller “2”.
• Make sure the flywheel puller is centered over
the AC magneto rotor.
Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B
1
2. Remove:
• AC magneto rotor nut “1”
• Washer 2
TIP
• Hold the AC magneto rotor “2” with the sheave
holder “3” while loosening the AC magneto ro-
tor nut.
• Do not allow the sheave holder to touch the
projection on the rotor. EAS24560
REMOVING THE STARTER CLUTCH

1. Remove:
Sheave holder
• Starter clutch bolts “1”
90890-01701
Primary clutch holder TIP
YS-01880-A • Hold the AC magneto rotor “2” with the sheave
holder “3” while removing the starter clutch
bolts.
3
projection on the AC magneto rotor.
Sheave holder
90890-01701
Primary clutch holder
1
YS-01880-A
2
3. Remove: 1
• AC magneto rotor “1”
(with the starter clutch)
• Woodruff key
3
2
5-34
EAS24570
CHECKING THE STARTER CLUTCH TIP

1. Check: • Be sure to install the starter clutch (outer ring)
• Starter clutch rollers so that its side with the arrow mark “a” is facing
Damage/wear → Replace. outward.
2. Check: • While holding the AC magneto rotor “2” with
• Starter idle gear the sheave holder “3”, tighten the starter clutch
• Starter wheel gear bolts.
Burrs/chips/roughness/wear → Replace the • Do not allow the sheave holder to touch the
defective part(s). projection on the AC magneto rotor.
3. Check:
• Starter clutch gear contact surfaces Sheave holder
Damage/pitting/wear → Replace the defec- 90890-01701
tive part(s). Primary clutch holder
4. Check: YS-01880-A
• Starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter wheel gear onto the starter 1
clutch, and then hold the starter clutch.
b. When turning the starter wheel gear counter-
clockwise “A”, the starter clutch and the start-
er wheel gear should engage; otherwise, the
starter clutch is faulty and must be replaced.
c. When turning the starter wheel gear clock- 3
2
wise “B”, it should turn freely; otherwise, the
starter clutch is faulty and must be replaced.
B a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS1XD1097
EAS1XD1096 INSTALLING THE AC MAGNETO ROTOR

CHECKING THE TORQUE LIMITER 1. Install:
1. Check: • Woodruff key
• Torque limiter • AC magneto rotor
Damage/wear → Replace. • Washer
TIP • AC magneto rotor nut
Do not disassemble the torque limiter. TIP
• Clean the tapered portion of the crankshaft and
EAS24600 the AC magneto rotor hub.
INSTALLING THE STARTER CLUTCH • When installing the AC magneto rotor, make
1. Install: sure the woodruff key is properly seated in the
• Starter clutch keyway of the crankshaft.
• Starter clutch bolts “1” • Lubricate the threads of the crankshaft with en-
gine oil.
Starter clutch bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.
LOCTITE®
5-35
• After installing the AC magneto rotor, check

that the AC magneto rotor rotates smoothly. If AC magneto cover bolt
not, reinstall the woodruff key and AC magneto 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
rotor.
TIP
2. Tighten: • Align the slot “a” in the impeller shaft “1” with
• AC magneto rotor nut “1” the projection “b” on the oil pump shaft “2”.
AC magneto rotor nut • Tighten the AC magneto cover bolts in stages,
60 Nm (6.0 m·kgf, 43 ft·lbf) using a crisscross pattern.
T.
R.
TIP 2
• Hold the AC magneto rotor “2” with the sheave
holder “3” while tightening the AC magneto ro- b
tor nut.
projection on the AC magneto rotor. a 1
Sheave holder
90890-01701
YS-01880-A
1
2
3. Apply:
• Sealant
(onto the crankshaft position sensor/stator
assembly lead grommet)
Yamaha bond No. 1215

90890-85505
4. Install:
• AC magneto cover
5-36
ELECTRIC STARTER
EAS24780
ELECTRIC STARTER
Removing the starter motor
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
4.9 Nm (0.49 m•kgf, 3.5 ft•Ibf)
T.R
.
1
FW
D

Frame cross member 4-1.
Air intake silencer Refer to “THROTTLE BODY” on page 7-8.
1 Negative battery lead 1 Disconnect.
2 Starter motor lead 1 Disconnect.
3 Starter motor 1
dure.
5-37
ELECTRIC STARTER
Disassembling the starter motor
4.9 Nm (0.49 m•kgf, 3.5 ft•Ibf)

T.R
.
New
New
1

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
cedure.
5-38
ELECTRIC STARTER
EAS24790
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING THE STARTER MOTOR a. Measure the armature assembly resistances
1. Check: with the digital circuit tester.
• Commutator
Dirt → Clean with 600-grit sandpaper. Digital circuit tester
2. Measure: 90890-03174
• Commutator diameter “a” Model 88 Multimeter with ta-
Out of specification → Replace the starter chometer
motor. YU-A1927
Commutator diameter
28.0 mm (1.10 in) Armature coil
Limit Commutator resistance “1”
27.0 mm (1.06 in) 0.0250–0.0350 Ω
Insulation resistance “2”
Above 1 MΩ
b. If any resistance is out of specification, re-

a place the starter motor.
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:
Mica undercut (depth) • Brush length “a”
0.70 mm (0.03 in) Out of specification → Replace the brush set.
TIP Brush overall length

12.5 mm (0.49 in)
The mica of the commutator must be undercut to Limit
ensure proper operation of the commutator. 5.00 mm (0.20 in)
4. Measure:
• Armature assembly resistances (commutator 6. Measure:
and insulation) • Brush spring force
Out of specification → Replace the starter Out of specification → Replace the brush set.
motor.
5-39
ELECTRIC STARTER
TIP
Brush spring force
7.65–10.01 N (780–1021 gf, Align the match marks “a” on the starter motor
27.54–36.03 oz) yoke with the match marks “b” on the starter mo-
tor front and rear covers.
b a b
3
2 1
7. Check:
• Gear teeth
Damage/wear → Replace the armature as-
sembly.
8. Check:
• Bushing
• Bearing
• Oil seal
Damage/wear → Replace the starter motor.
EAS24800
ASSEMBLING THE STARTER MOTOR

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

4.9 Nm (0.49 m·kgf, 3.5 ft·lbf)
T.
R.
5-40
BALANCER GEARS AND OIL PUMP GEARS
EAS1XD1098

Removing the balancer gears and oil pump gears
85 Nm (8.5 m•kgf, 61 ft•Ibf)
T.R
.
E
4
2
1 New
5
3 New
New
22 Nm (2.2 m•kgf, 16 ft•Ibf)

T.R
.

Drain.
page 3-13.
Drain.
page 3-8.
Water pump housing Refer to “WATER PUMP” on page 6-11.
Refer to “AC MAGNETO AND STARTER
Starter wheel gear CLUTCH” on page 5-32.
1 Lock washer 1
2 Balancer driven gear 1
3 Lock washer 1
4 Oil pump drive gear 1
5 Oil pump driven sprocket 1
5-41
Removing the balancer gears and oil pump gears
7 8 85 Nm (8.5 m•kgf, 61 ft•Ibf)
T.R
.
E
6
E 10
11 12
9 New
22 Nm (2.2 m•kgf, 16 ft•Ibf)

T.R
.

6 Chain 1
7 Straight key 1
8 Spacer 1
9 Plate 1
10 Balancer drive gear 1
11 Spring 8
12 Pin 4
dure.
5-42
EAS1XD1026
REMOVING THE BALANCER DRIVEN GEAR

AND OIL PUMP DRIVEN SPROCKET
1. Straighten the lock washer tabs.
2. Loosen:
• Balancer driven gear nut “1”
• Oil pump driven sprocket nut “2”
TIP
Place a aluminum plate “3” between the teeth of
the balancer drive gear “4” and balancer driven
gear “5”, and then loosen the nuts. 2. Install:
• Spacer
1 • Oil pump drive gear
3 • Oil pump driven sprocket “1”
• Chain “2”
TIP
4 5
Install the oil pump driven sprocket with the
“3B4” mark “a” facing out.
2
EAS1XD1053
2
CHECKING THE OIL PUMP GEARS
1. Check:
• Oil pump drive gear
• Oil pump driven sprocket 1
Cracks/wear/damage → Replace. a
EAS1XD1027
CHECKING THE BALANCER GEARS 3. Install:

1. Check: • Balancer driven gear “1”
• Balancer drive gear TIP
• Balancer driven gear
Align the punch mark “a” on the balancer drive
Damage/wear → Replace the balancer drive
gear “2” with the punch mark “b” on the balancer
gear and balancer driven gear as a set.
driven gear.
Excessive noise during operation → Replace
the balancer drive gear and balancer driven
gear as a set. b 1
EAS1XD1028
INSTALLING THE BALANCER DRIVE GEAR, a

BALANCER DRIVEN GEAR, AND OIL PUMP
DRIVEN SPROCKET
1. Install:
• Balancer drive gear 2
(onto the buffer boss)
• Pins
• Springs 4. Install:
• Oil pump driven sprocket nut “1”
TIP
• Balancer driven gear nut “2”
• Align the punch mark “a” on the balancer drive
gear with the hole “b” in the buffer boss. • Lock washers New
• Be sure to install a pin to every other spring.
5-43
Oil pump driven sprocket nut

22 Nm (2.2 m·kgf, 16 ft·lbf)
T.
R.
Balancer driven gear nut

85 Nm (8.5 m·kgf, 61 ft·lbf)
TIP
• Apply the engine oil to the threads of shafts
and nuts.
• Place a aluminum plate “3” between the teeth
of the balancer drive gear “4” and balancer
driven gear “5”, and then tighten the nuts.
2
4
3
1
5. Bend the lock washer tabs along the balancer

driven gear nut and oil pump driven sprocket
nut.
5-44
SHIFT LEVER
EAS1XD1029
SHIFT LEVER
Removing the drive select lever unit and drive select lever shift cable
2 13 Nm (1.3 m•kgf, 9.4 ft•Ibf)
T.R
.
13 Nm (1.3 m•kgf, 9.4 ft•Ibf)
T.R
.
LS
39 Nm (3.9 m•kgf, 28 ft•Ibf)
T.R
.
1
3 FW
D
16 Nm (1.6 m•kgf, 12 ft•Ibf)
T.R
.

ment panel 4-1.
1 Drive select lever shift cable 1 Disconnect.
2 Drive select lever unit 1
3 Drive select lever shift cable bracket 1
dure.
5-45
SHIFT LEVER
Disassembling the drive select lever unit
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
1
6
4
LS
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
LS

1 Drive select lever knob 1
2 Drive select lever guide 1
3 Dust cover 1
4 Drive select lever 1
5 Spring 1
6 Shift arm 1
7 Drive select lever unit housing 1
dure.
5-46
SHIFT LEVER
Removing the shift levers and stopper lever
14 Nm (1.4 m•kgf, 10 ft•Ibf)
T.R
.
E
5 New
7
4 New LS 1
2
E
3
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
LS
10
9 8
E

T.R
T.R
.

1 Drive select lever shift cable 1 Disconnect.
2 Shift arm 1
4 Shift lever cover 1
5 Shift lever cover gasket 1
6 Dowel pin 1
7 Shift lever 1 1
8 Stopper lever spring 1
9 Shift lever 2 1
10 Stopper lever 1
dure.
5-47
SHIFT LEVER
EAS25430
3. Install:
CHECKING THE STOPPER LEVER
1. Check: • Oil seal “1” New
• Stopper lever (into the shift lever cover “2”)
Installed depth “a”
• Stopper lever spring
1.0–1.5 mm (0.04–0.06 in)
EAS25440
CHECKING THE SHIFT LEVERS

1. Check:
New 1
• Shift lever 1
• Shift lever 2 a
EAS1XD1030 2
INSTALLING THE SHIFT LEVERS
1. Install:
• Shift lever 2 assembly “1”
4. Install:
Shift lever 2 bolt • Shift arm “1”
14 Nm (1.4 m·kgf, 10 ft·lbf) TIP
T.
R.
Align the slit “a” in the shift arm with the projec-
TIP tion “b” on shift lever 1.
Align the projection “a” on the shift drum with the
slit “b” in the stopper lever.
b 1
1 a
b EAS1XD1031
ADJUSTING THE DRIVE SELECT LEVER

2. Install: SHIFT CABLE
• Shift lever 1 “1” EWA1XD1002
TIP WARNING
When installing shift lever 1, align the alignment Before moving the drive select lever, bring
mark “a” on shift lever 1 with the punch marks “b” the vehicle to a complete stop and take your
on shift lever 2 “2”. foot off the accelerator pedal. Otherwise the
transmission may be damaged.
1. Check:
a 1 • Drive select lever free play “a”
Out of specification → Adjust the drive select
lever shift cable.
Drive select lever free play

b Less than 4 mm (0.16 in)
5-48
SHIFT LEVER
a b
a a
5 1
2. Check:
• Drive select lever shift cable length “a” 3 L
L 2
Out of specification → Adjust. H
H
Drive select lever shift cable N N
length
165 mm (6.50 in) R R
TIP
When checking the drive select lever shift cable
length, shift the drive select lever into “N” (neu-
e. Tighten the locknut to specification.
tral).
Drive select lever shift cable lock-
nut
T.
R.
39 Nm (3.9 m·kgf, 28 ft·lbf)
f. Tighten the drive select lever shift cable

bracket bolts to specification.
a Drive select lever shift cable
bracket bolt
T.
R.
16 Nm (1.6 m·kgf, 12 ft·lbf)
3. Adjust: g. Turn the main switch to “ ” (on), and then

• Drive select lever shift cable length check that the drive select lever can be shift-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ed to each shift position and that the appropri-
a. Loosen the drive select lever shift cable ate indicator light comes on when the lever is
bracket bolts “1”. in each position.
b. Set the drive select lever “2” and shift lever “3” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
in “N” (neutral) position.
d. Turn the adjusting nut “5” in direction “a” or “b”
until the specified cable length is obtained.
Direction “a”
Shift cable length is increased.
Direction “b”
Shift cable length is decreased.
5-49
PRIMARY AND SECONDARY SHEAVES
EAS1XD1099

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

T.R
.
6
8 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
(8)
T.R
.
New
LS
7 E
4
5
3
(11)
190 Nm (19 m•kgf, 137 ft•lbf) 1

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

T.R
.
T.R
New 2
.

Frame cross member/Left rear panel/V-belt Refer to “GENERAL CHASSIS” on page
cooling ducts 4-1.
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
dure.
5-50
Disassembling the primary sheave

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
8 O-ring 1
cedure.
* Apply Yamaha Grizzly grease or Yamaha grease F.
5-51
Disassembling the secondary sheave

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
cedure.
* Apply Yamaha grease H or POLYREX EM®
5-52
EAS1XD1100
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 sheave holder “2” to hold the primary
YM-01348
sheave. Sheave spring compressor
90890-04134
Sheave holder YM-04134
90890-01701
Primary clutch holder b. Place the sheave fixed block in a vise and se-
YS-01880-A cure it.
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-
ing nut “1”.
1 f. Remove the sheave spring compressor and
2 locknut wrench.
4 5
2. Loosen: 1
• Secondary sheave assembly nut “1”
TIP 3
Shift the transmission into “R” (reverse), set the
parking brake, and then loosen the secondary
sheave assembly nut.
2
EAS24640
DISASSEMBLING THE SECONDARY

SHEAVE
1. Remove:
• Secondary sheave spring retaining nut “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Attach the sheave fixed block “2”, locknut
wrench “3” and sheave spring compressor “4”
to the secondary sheave assembly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-53
EAS24670
1. Check:
CHECKING THE V-BELT
• Primary sheave weight
1. Check:
• V-belt “1”
2. Measure:
• Primary sheave weight outside diameter “a”
Grease/oil → Clean the primary and second-
ary sheaves.
2. Measure: Primary sheave weight outside
• V-belt width “a” diameter
Out of specification → Replace. 30 mm (1.18 in)
Limit
V-belt width 29.5 mm (1.16 in)
33.0–33.6 mm (1.30–1.32 in)
Limit
32.5 mm (1.28 in)
EAS24700
CHECKING THE PRIMARY SHEAVE

SLIDERS
EAS24680
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
Cracks/damage → Replace. EAS24710
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.
2. Check: 3. Check:
• Primary sliding sheave • Guide pins “2”
• Primary fixed sheave Damage/wear → Replace the secondary
Cracks/damage → Replace. fixed and sliding sheaves as a set.
EAS24690
CHECKING THE PRIMARY SHEAVE

WEIGHTS
The following procedure applies to all of the pri-
mary sheave weights.
5-54
2. Install:
• Oil seals “1” New
(into the primary sliding sheaver “2”)

0 mm (0 in)
New 1
4. Check:
• Secondary sheave spring
a a
Damage → Replace.
5. Measure:
• Secondary sheave spring free length “a”
Out of specification → Replace the second- 1 New
2
ary sheave spring.
3. Lubricate:
Free length • Spacer inner surface
130.6 mm (5.14 in) • Primary sliding sheave inner surface
Limit
128.0 mm (5.04 in) Recommended lubricant
Yamaha Grizzly grease or
Yamaha grease F
TIP
• Apply Yamaha Grizzly grease or Yamaha
grease F (2.5 g) to the inner surface of the
spacer.
• Apply Yamaha Grizzly grease or Yamaha
grease F (2.5 g) to the inner surface of the pri-
mary sliding sheave.
EAS24720
ASSEMBLING THE PRIMARY SHEAVE

1. Clean:
• Primary sliding sheave “1”
• Spacer “2”
• Primary sheave weights “3”
• Primary sheave cam
TIP
Remove any excess grease.
4. Install:
• Primary sheave weights “1”
TIP
Apply Yamaha Grizzly grease or Yamaha
grease F (90 g) to the whole outer surface of the
weights and install.
5-55
3. Install:
• Secondary sliding sheave
4. Install:
• Guide pins “1”
EAS24730
ASSEMBLING THE SECONDARY SHEAVE

1. Install:
• Oil seals “1” New
(into the secondary sliding sheave “2”) 5. Lubricate:
• Guide pin grooves “1”
Installed depth “a” (with the recommended lubricant)
0 mm (0 in)
Yamaha grease H or POLYREX
2 EM®
1 New
TIP
a Apply Yamaha grease H or POLYREX EM® (5.0
a g) to the guide pin grooves.
New 1
2. Lubricate:
• Secondary sliding sheave “1”
• Secondary fixed sheave “2”
Yamaha grease H or POLYREX
EM® 6. Install:
• Lower spring seat “1”
TIP • Compression spring “2”
Apply Yamaha grease H or POLYREX EM® (15 • Upper spring seat “3”
g) to the inner surfaces of the secondary • Secondary sheave spring retaining nut “4”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
sheaves. a. Attach the sheave fixed block “5”, locknut
wrench “6” and sheave spring compressor “7”
to the secondary sheave.
5-56
Sheave fixed block a

90890-04135 4
Sheave fixed bracket
YM-04135
Locknut wrench
90890-01348
YM-01348
Sheave spring compressor
90890-04134
YM-04134
e. Remove the sheave spring compressor, lock-
b. Place the sheave fixed block in a vise and se-
nut wrench, and sheave fixed block.
cure it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Tighten the sheave spring compressor nut “8”
and compress the spring. EAS1XD1101
d. Install the secondary sheave spring retaining INSTALLING THE PRIMARY AND
nut “4” and tighten it to specification using the SECONDARY SHEAVES
locknut wrench. 1. Install:
• Secondary sheave
Secondary sheave spring retain- • V-belt
ing nut • Primary fixed sheave
T.
R.
90 Nm (9.0 m·kgf, 65 ft·lbf) • Primary sheave

TIP
TIP • Be sure to push in the primary sheave cam “1”
Install the secondary sheave spring retaining nut when installing the primary sheave so that the
“4” with its tapered side “a” facing the secondary primary sheave weights “2” will be properly po-
sheaves. sitioned “a”.
• Tightening the bolts “3” (90101-06016) will
push the secondary sliding sheave away,
causing the gap between the secondary fixed
8 and sliding sheaves to widen.
7 • Install the V-belt so that its arrow points in the
4
direction of rotation as shown in the illustration.
6 1
3
1
2 a
5-57
Sheave holder
90890-01701
YS-01880-A
2. Check:
• Primary sheave weights position 2 1
Out of specification → Repeat step (1).
TIP
To check that the primary sheave weights “1”
are installed correctly, make sure that the sec- 4. Tighten:
ondary sheave “2”, primary sheave “3”, and V- • Secondary sheave assembly nut “1”
belt “4” are positioned as shown in the illustra-
tion. Secondary sheave assembly nut
T.
R. 100 Nm (10.0 m·kgf, 72 ft·lbf)
A
TIP
Shift the transmission into “L” (low) or “H” (high),
2 set the parking brake, and then tighten the sec-
ondary sheave assembly nut.
4
3
1
B
2
1
5. Lubricate:
4 3 • Bearing housing oil seal inner surface
1 (with the recommended lubricant)
A. Correct position Recommended lubricant

B. Incorrect position Lithium-soap-based grease
3. Tighten:
TIP
• Primary sheave assembly nut “1”
Apply 2.3 g or more of lithium-soap-based
Primary sheave assembly nut grease to the groove in the oil seal as shown in
190 Nm (19 m·kgf, 137 ft·lbf) the illustration.
T.
R.
TIP
Use the sheave holder “2” to hold the primary
sheave.
5-58
LS
5-59
CLUTCH
EAS25061
CLUTCH
Removing the clutch
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 M
(7)
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
dure.
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
cedure.
5-61
CLUTCH
EAS25070
• 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”
ECA1XD1019
NOTICE
The clutch carrier assembly nut has left-
hand threads. To loosen the clutch carrier
assembly nut, turn it clockwise.
TIP
Use a clutch holding tool “2” to hold the clutch
carrier assembly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Universal clutch holder
EAS28990
90890-04086
CHECKING THE CLUTCH SHOE
YM-91042
1. Check:
• Clutch shoe
a 2 Glazed areas → Sand with coarse sandpa-
per.
TIP
After sanding the glazed areas, clean the clutch
with a cloth.
2. Measure:
1 • Clutch shoe thickness
EAS1XD1102
CHECKING THE CLUTCH Clutch shoe thickness

1. Check: 1.5 mm (0.06 in)
• Clutch housing Limit
Damage/wear → Replace. 1.0 mm (0.04 in)
5-62
CLUTCH
1 New
2
a. Clutch shoe wear limit EAS1XD1104
INSTALLING THE CLUTCH

EAS1XD1103
1. Install:
ASSEMBLING THE CLUTCH HOUSING
• Clutch carrier assembly
1. Install:
• 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) ECA1XD1020
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 molybdenum disulfide grease.
1 • Use a clutch holding tool “2” to hold the clutch
carrier assembly.
2. Install:
• One-way clutch bearing Universal clutch holder
90890-04086
TIP YM-91042
The one-way clutch bearing should be installed
in the clutch housing with the “OUT SIDE” mark 2. Lock the threads with a drift punch.
“a” facing the clutch housing.
2
1 New
3. Install:
• Dowel pins
3. Install:
• Gasket New
• Oil seal “1” New
• Clutch housing assembly
(into the bearing housing “2”)
Clutch housing assembly bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
0 mm (0 in)
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
EAS25540
CRANKCASE
Separating the crankcase

T.R
T.R
.
.
17 Nm (1.7 m•kgf, 12 ft•Ibf)
T.R
.
E
LS
New New
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
26 Nm (2.6 m•kgf, 19 ft•Ibf)
T.R
.
LS 8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf)
T.R
.
LT
(3)
LS
New
LT
New New
30 Nm (3.0 m•kgf, 22 ft•Ibf)
T.R
.
42 Nm (4.2 m•kgf, 30 ft•Ibf)

T.R
1
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

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

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

LT
T.R
.

T.R
.
T.R
.

Engine Refer to “ENGINE REMOVAL” on page 5-1.
Oil cooler Refer to “OIL COOLER” on page 6-1.
Refer to “CYLINDER AND PISTON” on page
Piston 5-27.
Refer to “AC MAGNETO AND STARTER
Starter wheel gear CLUTCH” on page 5-32.
Refer to “ELECTRIC STARTER” on page
Starter motor 5-37.
Refer to “BALANCER GEARS AND OIL
Balancer gears/Oil pump gears PUMP GEARS” on page 5-41.
Shift levers Refer to “SHIFT LEVER” on page 5-45.
Drive belt case SHEAVES” on page 5-50.
Clutch carrier assembly Refer to “CLUTCH” on page 5-60.
1 Timing chain guide (intake side) 1
2 Timing chain stopper guide (lower) 1
5-65
CRANKCASE
Separating the crankcase
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 18 Nm (1.8 m•kgf, 13 ft•Ibf) 5

T.R
T.R
.
.
8 17 Nm (1.7 m•kgf, 12 ft•Ibf)
T.R
.
7 9 E
LS
New New
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
26 Nm (2.6 m•kgf, 19 ft•Ibf)
T.R
.
11
LS 8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf)
T.R
.
12
LT
(3)
LS
12 New
4
LT
10 New New
30 Nm (3.0 m•kgf, 22 ft•Ibf)
T.R
.
42 Nm (4.2 m•kgf, 30 ft•Ibf)

T.R
.
13
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
6
LT
T.R
LT
.
10
LS
3
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) LT
LT
T.R
.

T.R
.
T.R
.

3 Timing chain 1
4 Speed sensor 1
5 Dipstick 1
6 Relief valve assembly 1
7 Reverse switch 1
8 Gear position switch 1
9 Thermostat outlet hose guide 1
10 Engine bracket 2
11 Left crankcase 1
12 Dowel pin 2
13 Right crankcase 1
dure.
5-66
CRANKCASE
Removing the crankcase bearings
New LS
LS
E
1
2 4 LT
LT
New 3
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
7
LT
.
7
E
7
6 7
5
7
E
E
7
E
7
7
E E

Refer to “CRANKSHAFT AND OIL PUMP”
Crankshaft/Oil pump on page 5-71.
Transmission Refer to “TRANSMISSION” on page 5-76.
Middle drive shaft/Middle driven shaft Refer to “MIDDLE GEAR” on page 5-83.
1 Collar 1
2 O-ring 1
3 Oil seal 1
5 Spacer 1
6 Crankshaft seal 2
7 Bearing 9
dure.
5-67
CRANKCASE
EAS25560
SEPARATING THE CRANKCASE

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.
2. Check:
• Timing chain guide (intake side)
EAS1XD1105
CHECKING THE RELIEF VALVE

1. Check:
• Spring seat “1”
• Spring “2”
B • Relief valve body “3”
• Relief valve “4”
Damage/wear → Replace the defective
part(s).
4
3
2
1
A. Right crankcase
B. Left crankcase
2. Remove:
• Left crankcase
• Dowel pins EAS1XD1106
ECA13900 CHECKING THE BEARINGS
NOTICE 1. Check:
Tap on one side of the crankcase with a soft- • Bearings
face hammer. Tap only on reinforced por- Clean and lubricate, then rotate the inner
tions of the crankcase, not on the crankcase race with a finger.
mating surfaces. Work slowly and carefully Roughness → Replace.
and make sure the crankcase halves sepa-
rate evenly.
EAS24180
CHECKING THE TIMING CHAIN AND TIMING

CHAIN GUIDE
1. Check:
• Timing chain
Damage/stiffness → Replace the timing
chain and camshaft sprocket as a set.
5-68
CRANKCASE
EAS25580
CHECKING THE CRANKCASE

a 1
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and 2
crankcase mating surfaces.
3. Check: 2
• Crankcase
• Oil delivery passages
Obstruction → Blow out with compressed air.
5. Fit the left crankcase onto the right crank-
EAS25700 case. Tap lightly on the crankcase with a soft
ASSEMBLING THE CRANKCASE hammer.
1. Install: ECA1XD1021
NOTICE
(into the left crankcase “2”) Before installing and torquing the crankcase
bolts, be sure to check whether the transmis-
Installed depth “a” sion is functioning properly by manually ro-
1.0–1.5 mm (0.04–0.06 in) tating the shift drum in both directions.
6. Install:
• Crankcase bolts
1 New 7. Tighten:
• Crankcase bolts
a
Crankcase bolt “1”
2 26 Nm (2.6 m·kgf, 19 ft·lbf)
T.
R.
Crankcase bolt “2”, “3”

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
M8 × 40 mm “1”
M6 × 60 mm “2”
2. Thoroughly clean the crankcase mating sur- M6 × 30 mm “3”
faces.
TIP
3. Apply:
• Sealant “1” Tighten the bolts in stages, using a crisscross
(onto the crankcase mating surfaces) pattern.
Yamaha bond No. 1215

90890-85505
TIP
• Apply two coats of sealant to the area “a”
shown in the illustration.
• Do not allow any sealant to come into contact
with the oil gallery.
4. Install:
• Dowel pins “2”
5-69
CRANKCASE
2 3
×2 ×3
2
3
3
B
1 2 3
×3 ×2 ×6
3
2
1
3
2 3
A. Left crankcase
B. Right crankcase
8. Apply:
• 4-stroke engine oil
(onto the crankshaft pin, bearings and oil de-
livery hole)
9. Check:
• Crankshaft and transmission operation
Rough operation → Repair.
5-70
CRANKSHAFT AND OIL PUMP
EAS1XD1107

Removing the crankshaft and oil pump
2 New
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
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 Oil pump gasket 1
3 Balancer 1
4 Crankshaft 1
dure.
5-71
Disassembling the oil pump
1
E
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
cedure.
5-72
EAS1XD1108
REMOVING THE CRANKSHAFT Inner-rotor-to-outer-rotor-tip

1. Remove: clearance
• Crankshaft “1” Less than 0.12 mm (0.0047 in)
TIP Limit
• Remove the crankshaft with the crankcase 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing
separating tool “2”.
clearance
• Make sure the crankcase separating tool is 0.090–0.170 mm (0.0035–0.0067
centered over the crankshaft. in)
ECA1XD1039 Limit
NOTICE 0.24 mm (0.0094 in)
• To protect the end of the crankshaft, place Oil-pump-housing-to-inner-and-
an appropriate sized socket between the outer-rotor clearance
0.03–0.10 mm (0.0012–0.0039 in)
crankcase separating tool bolt and the
Limit
crankshaft. 0.17 mm (0.0067 in)
• Do not tap on the crankshaft.
Crankcase separating tool

90890-01135
Crankcase separator
YU-01135-B
EAS24960
CHECKING THE OIL PUMP

1. Check:
• Oil pump
Cracks/damage/wear → Replace the oil
pump.
1. Inner rotor
2. Measure:
2. Outer rotor
• Inner-rotor-to-outer-rotor-tip clearance “a”
3. Oil pump housing
• Outer-rotor-to-oil-pump-housing clearance
“b” 3. Check:
• Oil-pump-housing-to-inner-rotor-and-outer- • Oil pump operation
rotor clearance “c” Rough movement → Replace the oil pump.
Out of specification → Replace the oil pump.
5-73
c
b b
EAS24990
CHECKING THE OIL STRAINER

1. Check:
• Oil strainer
Damage → Replace the oil pump.
Contaminants → Clean with solvent.
EAS1XD1109
CHECKING THE CRANKSHAFT a

1. Measure:
• Crankshaft width A “a”
Out of specification → Replace the crank-
shaft. 4. Check:
• Crankshaft sprocket
Width A Damage/wear → Replace the crankshaft.
74.92–75.00 mm (2.950–2.953 in) • Bearing
Cracks/damage/wear → Replace the crank-
2. Measure: shaft.
• Crankshaft runout C “b” 5. Check:
Out of specification → Replace the crank- • Crankshaft journal
shaft. Scratches/wear → Replace the crankshaft.
• Crankshaft journal oil passage
Runout limit C Obstruction → Blow out with compressed air.
0.030 mm (0.0012 in)
EAS25010
3. Measure: ASSEMBLING THE OIL PUMP

• Big end side clearance D “c” 1. Lubricate:
Out of specification → Replace the crank- • Inner rotor
shaft. • Outer rotor
• Oil pump shaft
Big end side clearance D (with the recommended lubricant)
0.350–0.650 mm (0.0138–0.0256
in) Recommended lubricant
Engine oil
2. Install:
• Oil pump housing “1”
• Oil pump outer rotor “2”
• Oil pump inner rotor “3”
• Oil pump shaft “4”
• Pin “5”
TIP
To install the oil pump shaft “4”, align the pin “5”
with the groove “a” in the inner rotor “3”.
5-74
ECA1XD1040
1 2 NOTICE
Apply engine oil to each bearing to protect
3
a the crankshaft against scratches and to
make installation easier.
TIP
a
Hold the connecting rod at top dead center
4
(TDC) with one hand while turning the nut of the
5 crankshaft installer bolt with the other. Turn the
crankshaft installer bolt until the crankshaft as-
3. Check:
sembly bottoms against the bearing.
• Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-73.
EAS1XD1110
INSTALLING THE CRANKSHAFT

1. Install:
• Crankshaft “1”
TIP
Install the crankshaft with the crankshaft installer
pot “2”, crankshaft installer bolt “3”, adapter
(M16) “4”, spacer (crankshaft installer) “5”, and
spacer “6”.
Crankshaft installer pot

90890-01274
Installing pot
YU-90058
Crankshaft installer bolt
90890-01275
Bolt
YU-90060
Adapter (M16)
90890-04130
Adapter #13
YM-04059
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044
Spacer
90890-04167
YM-04167
6
5
2 3
5-75
TRANSMISSION
EAS26241
TRANSMISSION
Removing the transmission, shift drum and shift forks
1
2 18 Nm (1.8 m•kgf, 13 ft•Ibf)
T.R
.
3 New
4 E
10
E New
9
8
7
E
6
New E
5 E

Separate.
Middle driven gear Refer to “MIDDLE GEAR” on page 5-83.
1 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
.
New
E
15
E New
13
14
12
E
11
New E

11 Drive axle assembly 1
12 Collar 1
13 Reverse idle gear 1
14 Bearing 1
15 Reverse idle gear shaft 1
dure.
5-77
TRANSMISSION
Disassembling the drive axle assembly
9
8
7
New 6
5
4
3
M
2
M
1
M
M
M 16
M
M 15
14
13 New
12
10
11 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
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
5-78
TRANSMISSION
Disassembling the drive axle assembly
M
M
17
M
M 18
M
M
M

17 Collar 1
18 Drive axle 1
cedure.
5-79
TRANSMISSION
EAS26250
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
Roll the shift fork guide bar on a flat surface.
Bends → Replace.
EWA12840
WARNING
Do not attempt to straighten a bent shift fork
guide bar.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1XD1133
DISASSEMBLING THE DRIVE AXLE

1. Remove:
• Collar “1”
• Drive axle “2”
TIP
Press the drive axle end and remove the collar. 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.
EAS26260
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”
EAS1XD1111
• 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
4. Check:
• Transmission gear movement
Rough movement → Replace the defective
part(s).
5. Check:
• Circlips
Bends/damage/looseness → Replace.
EAS1XD1112
CHECKING THE SECONDARY SHAFT

1. Check:
EAS26300 • Gear teeth
CHECKING THE TRANSMISSION Blue discoloration/pitting/wear → Replace.
1. Measure:
• Drive axle runout EAS1XD1113
(with a centering device and dial gauge “1”) ASSEMBLING THE DRIVE AXLE ASSEMBLY
Out of specification → Replace the drive axle. 1. Install:
• Washer “1”
Drive axle runout limit • Circlip “2” New
0.06 mm (0.0024 in) TIP
• Be sure the circlip sharp-edged corner “a” is
positioned opposite side to the washer and
gear.
• Be sure the circlip ends “b” are positioned at
axle spline groove “c”.
New 2 b
2. Check:
• Transmission gears
Blue discoloration/pitting/wear → Replace
the defective gear(s). c
a 1
• Transmission gear dogs
Cracks/damage/rounded edges → Replace EAS1XD1114
the defective gear(s). ASSEMBLING THE SHIFT FORK ASSEMBLY
1. Install:
• Shift fork guide bar “1”
• Shift fork “L” “2”
• Spring “3”
• Shift fork “R” “4”
• Circlips “5” New
TIP
Install the shift forks with the “28P” mark “a” and
“5B4” mark “b” facing each other.
3. Check:
• Transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission
axle assemblies.
5-81
TRANSMISSION
New 5 1
3 2
b
New 5
a
4
EAS1XD1115
INSTALLING THE SHIFT FORKS AND SHIFT

DRUM
1. Install:
• Reverse idle gear “1”
• Drive axle assembly “2”
• Secondary shaft “3”
• Shift fork assembly “4”
• Shift drum “5”
TIP
Install the shift fork assembly “4” with the “L”
mark “a” facing the right crankcase.
2 4
5
1
4
a
2. Check:
• Shift operation
Rough operation → Repair.
TIP
• Oil each gear and bearing thoroughly.
• Before assembling the crankcase, make sure
that the transmission is in neutral and that the
gears turn freely.
5-82
MIDDLE GEAR
EAS25711
MIDDLE GEAR
Removing the middle drive shaft
190 Nm (19 m•kgf, 137 ft•lbf)

T.R
.
32 Nm (3.2 m•kgf, 23 ft•Ibf)
T.R
.
LT
LT
9
LT
5
10 6
New
8 7
11 12
E
10
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
11 Bearing 1
12 Washer 1
5-83
MIDDLE GEAR
Removing the middle drive shaft
190 Nm (19 m•kgf, 137 ft•lbf)

T.R
.
32 Nm (3.2 m•kgf, 23 ft•Ibf)
T.R
.
LT
LT
LT
New
13
E
New
LT
LT LT
LT
29 Nm (2.9 m•kgf, 21 ft•Ibf)

T.R
.

13 Bearing housing 1
dure.
5-84
MIDDLE GEAR
Removing the middle driven shaft
190 Nm (19 m•kgf, 137 ft•lbf)
T.R
.
LT
25 Nm (2.5 m•kgf, 18 ft•Ibf)
T.R
.
80 Nm (8.0 m•kgf, 58 ft•Ibf) 5
T.R
.
130 Nm (13 m•kgf, 94 ft•lbf)

T.R
.
6
9
4
12
11
T.R
.
190 Nm (19 m•kgf, 137 ft•lbf)
10
8
4
7

Separate.
1 Rear drive shaft yoke nut (middle gear side) 1
2 Rear drive shaft yoke (middle gear side) 1
3 Middle driven pinion gear assembly 1
Refer to “ALIGNING THE MIDDLE GEAR”
4 Middle driven pinion gear shim on page 5-92.
5 Front drive shaft yoke nut (middle gear side) 1
6 Front drive shaft yoke (middle gear side) 1
7 Middle driven pinion gear 1
8 Bearing 1
9 Oil seal 1
10 Middle driven pinion gear bearing retainer 1 Left-hand threads
11 Bearing 1
12 O-ring 1
5-85
MIDDLE GEAR
Removing the middle driven shaft
190 Nm (19 m•kgf, 137 ft•lbf)
T.R
.
LT
15 17
16
25 Nm (2.5 m•kgf, 18 ft•Ibf)
T.R
.
14
80 Nm (8.0 m•kgf, 58 ft•Ibf)
T.R
.
130 Nm (13 m•kgf, 94 ft•lbf)

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

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
dure.
5-86
MIDDLE GEAR
EAS1XD1116
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 2
then secure it in a vise.
3
2. Remove:
• Front drive shaft yoke nut “1”
• Washer
• Front drive shaft yoke “2”
TIP
3. Remove: Use the coupling gear/middle shaft tool “3” to
• Middle drive pinion gear nut hold the front drive shaft coupling sleeve.
• 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
2
3. Remove:
• Bearing housing assembly “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the surface of the bearing housing as-
EAS1XD1117 sembly.
REMOVING THE MIDDLE DRIVEN SHAFT b. Place the bearing housing assembly onto a
1. Remove: hydraulic press.
• Rear drive shaft yoke nut “1” ECA1XD1041
• Washer NOTICE
• Rear drive shaft yoke “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 sleeve. 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
YM-38404
c. Press the middle driven pinion gear end and
remove the bearing housing. ECA1XD1023
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
Middle gear bearing retainer 3
YM-04128
ECA1XD1022
6. Remove:
NOTICE
• Middle driven shaft “1”
The middle driven pinion gear bearing retain- (with bearing)
er has left-hand threads. To loosen the re-
tainer, turn it clockwise.
EAS1XD1118
CHECKING THE PINION GEARS

c. Remove the bearing retainer and bearing. 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:
• O-ring
TIP
Damage → Replace.
Attach the ring nut wrench “3”.
5-88
MIDDLE GEAR
• Bearings
Pitting/damage → Replace. Ring nut wrench
90890-01430
EAS1XD1119 YM-38404
INSTALLING THE BEARING AND OIL SEALS
1. Install: ECA1XD1024
• Bearing “1” NOTICE

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

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

90890-04128
Middle gear bearing retainer
YM-04128
EAS1XD1120
INSTALLING THE MIDDLE DRIVEN SHAFT c. Tighten the bearing retainer.

1. Install:
• Middle driven shaft bearing retainer “1” Middle driven pinion gear bearing
retainer
T.
R.
Middle driven shaft bearing re- 130 Nm (13 m·kgf, 94 ft·lbf)

tainer LOCTITE®
T.
R.
80 Nm (8.0 m·kgf, 58 ft·lbf)

LOCTITE®
TIP
Attach the ring nut wrench “2”.
5-89
MIDDLE GEAR
ECA1XD1025
NOTICE
The middle driven pinion gear bearing retain-
er has left-hand threads. To tighten the re-
1
tainer turn it counterclockwise.
1 2
3
5. Install:
• Rear drive shaft yoke “1”
• Washer
2 • Rear drive shaft yoke nut “2”
Rear drive shaft yoke 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
TIP TIP
Install the shim(s) so that the tabs are positioned Use the coupling gear/middle shaft tool “3” to
as shown in the illustration. hold the rear drive shaft yoke.
Coupling gear/middle shaft tool

1 90890-01229
Gear holder
YM-01229
1 1
4. Install:
• Front drive shaft yoke “1”
• Washer 2
• Front drive shaft yoke nut “2”
3
Front drive shaft yoke nut (mid-
dle gear side) EAS1XD1121
T.
INSTALLING THE MIDDLE DRIVE SHAFT

R.
190 Nm (19 m·kgf, 137 ft·lbf)

LOCTITE® 1. Install:
• Circlip
TIP • Middle driven gear “1”
(onto the middle drive shaft “2”)
Use the coupling gear/middle shaft tool “3” to
hold the front drive shaft yoke. Installed depth “a” of middle
driven gear
Coupling gear/middle shaft tool 24.7–24.9 mm (0.972–0.980 in)
90890-01229
Gear holder
YM-01229
5-90
MIDDLE GEAR
EAS25890
a MEASURING THE MIDDLE GEAR

BACKLASH
1. Measure:
• Middle gear backlash
Refer to “ALIGNING THE MIDDLE GEAR” on
page 5-92.
1 2
Middle gear backlash
0.10–0.30 mm (0.004–0.012 in)
2. Tighten:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Bearing retainer bolts “1” New a. Temporarily install the right crankcase.
Middle drive shaft bearing retain- b. Wrap a rag “1” around a screwdriver “2”, and
er bolt then insert it into the installation hole “a” of the
T.
right crankcase speed sensor to hold the mid-

R.
29 Nm (2.9 m·kgf, 21 ft·lbf)

LOCTITE® dle driven gear.
TIP
Stake the bearing retainer bolts at the cutouts “a”
in the bearing retainers “2”.
New 1
a a
2
2 c. Attach the final gear backlash band “3” and
1 New dial gauge “4”.
New 1
a Final gear backlash band
90890-01511
3. Tighten: Middle drive gear lash tool
YM-01230
• Middle drive pinion gear nut “1” New
Middle drive pinion gear nut

190 Nm (19 m·kgf, 137 ft·lbf)
T.
R.
4
TIP
• Wrap the middle drive shaft in a folded rag, and
3
then secure it in a vise.
• Lock the threads with a drift punch.
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.
5-91
MIDDLE GEAR
e. If the gear lash is incorrect, adjust the gear

lash by middle driven pinion gear shim(s). a
k
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS25930
ALIGNING THE MIDDLE GEAR

TIP
Aligning the middle gear is necessary when any
of the following parts are replaced:
• Crankcase
• Middle drive pinion gear
• Middle driven pinion gear
• Middle driven shaft bearing housing e d
• Middle drive shaft bearing housing
b c
1. Select:
A
• Middle drive pinion gear shim(s) “1”
• Middle driven pinion gear shim(s) “2”
2 1
h
i g
f
j B
A. Middle drive pinion gear shim thickness

B. Middle driven pinion gear shim thickness
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Position the middle gears with the appropri-
ate shim(s) that has had its respective thick-
ness calculated from information marked on
the crankcase, bearing housings, and pinion
gears.
b. To find middle drive pinion gear shim thick-
ness “A”, use the following formula.
Middle drive pinion gear shim thickness
“A” = “e” + “d” + “a” - “c” - “b” - “k”
“a” = a numeral (usually a decimal number)

on the bearing housing is either added to or
subtracted from “0.9”
“b” = 17.0
“c” = 55.0
“d” = a numeral (usually a decimal number)
on the left crankcase specifies a thickness of
“65.0”
5-92
MIDDLE GEAR
“e” = a numeral (usually a decimal number) Hundredth Rounded value

on the right crankcase specifies a thickness
of “9.0” 0, 1, 2 0
“k” = 1.5 3, 4, 5, 6, 7 5
Example:
8, 9 10
If the bearing housing is marked “+01”,
“a” is 0.91 Shims are supplied in the following thickness-
es.
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.
a Middle driven pinion gear shim thickness
“B” = “f” - “g” + “h” - “i” - “j”
“b” is 17.0
“f” = a numeral (usually a decimal number) on
“c” is 55.0
the bearing housing is either added to or sub-
If the left crankcase is marked “64.96”,
tracted from “89.5”
“d” is 64.96
TIP
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
d
driven pinion gear shim thickness.
If the right crankcase is marked “9.01”, f

“e” is 9.01
“g” = a numeral (usually a decimal number)

e on the middle driven pinion gear is either add-
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”
“k” is 1.5 “i” = a numeral (usually a decimal number) on
Therefore, “A” is 1.38. the right crankcase specifies a thickness of
“A” = 9.01 + 64.96 + 0.91 - 55.0 - 17.0 - 1.5 “99.98”
= 1.38 “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 1.38 mm. The following chart in- If the bearing housing is marked “+03”,
structs you, however, to round off 8 to 10. “f” is 89.53
5-93
MIDDLE GEAR
If the driven pinion gear is marked “+02”, Therefore, “B” is 0.93.

“g” is 61.02 “B” = 89.53 - 61.02 + 80.52 - 99.98 - 8.12 =
0.93
Round off hundredth digit and select appro-
priate shim(s).
In the above example, the calculated shim
thickness is 0.93 mm. The chart instructs
you, however, to round off 3 to 5.
g Hundredth Rounded value
0, 1, 2 0
3, 4, 5, 6, 7 5
If the driven pinion gear is marked “+02”, 8, 9 10
“h” is 80.52
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 OIL COOLER .............................................................. 6-3
RADIATOR ...................................................................................................... 6-4

CHECKING THE RADIATOR.................................................................... 6-6
INSTALLING THE RADIATOR..................................................................6-6
INSTALLING THE HORN (for Europe and Oceania) ................................6-6
THERMOSTAT ................................................................................................6-8
CHECKING THE THERMOSTAT.............................................................. 6-9
INSTALLING THE THERMOSTAT............................................................ 6-9
WATER PUMP...............................................................................................6-11
DISASSEMBLING THE WATER PUMP.................................................. 6-13
CHECKING THE WATER PUMP ............................................................ 6-13
ASSEMBLING THE WATER PUMP........................................................ 6-13
INSTALLING THE AC MAGNETO COVER ............................................6-14
6
OIL COOLER
EAS26410
OIL COOLER
Removing the oil cooler
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
20 Nm (2.0 m•kgf, 14 ft•Ibf)

T.R
.
18 Nm (1.8 m•kgf, 13 ft•Ibf)
T.R
.
New
New
New
New
35 Nm (3.5 m•kgf, 25 ft•Ibf)
T.R
.
New
2 New
4 1 LS
18 Nm (1.8 m•kgf, 13 ft•Ibf)

3
T.R
.
17 Nm (1.7 m•kgf, 12 ft•Ibf) LS 30 Nm (3.0 m•kgf, 22 ft•Ibf)

T.R
T.R
.

Rear skid plate/Right rear panel/Center passen- Refer to “GENERAL CHASSIS” on page
ger compartment panel 4-1.
Air filter case Refer to “AIR FILTER CASE” on page 7-5.
Drain.
page 3-13.
Drain.
page 3-8.
Water pump outlet pipe/Oil cooler inlet hose Refer to “WATER PUMP” on page 6-11.
1 Oil filter cartridge 1
2 Oil filter cartridge union bolt 1
3 Oil cooler 1
4 Oil cooler outlet hose 1
6-1
OIL COOLER
Removing the oil cooler

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
20 Nm (2.0 m•kgf, 14 ft•Ibf)

T.R
.
18 Nm (1.8 m•kgf, 13 ft•Ibf)
T.R
.
New
5
New
6
New
New
35 Nm (3.5 m•kgf, 25 ft•Ibf)
T.R
.
New
New
LS
18 Nm (1.8 m•kgf, 13 ft•Ibf)

T.R
.
17 Nm (1.7 m•kgf, 12 ft•Ibf) LS 30 Nm (3.0 m•kgf, 22 ft•Ibf)

T.R
T.R
.

5 Oil pipe (crankcase to cylinder head) 1
6 Oil pipe (AC magneto cover) 1
dure.
6-2
OIL COOLER
EAS26420
CHECKING THE OIL COOLER Oil filter cartridge union bolt

1. Check: 30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.
• Oil cooler
Cracks/damage → Replace. 4. Fill:
2. Check: • Cooling system
• Oil cooler outlet hose (with the specified amount of the recom-
• Oil pipe (crankcase to cylinder head) mended coolant)
• Oil pipe (AC magneto cover) Refer to “CHANGING THE COOLANT” on
Cracks/damage/wear → Replace. page 3-8.
• Crankcase
EAS26430
INSTALLING THE OIL COOLER (with the specified amount of the recom-
1. Clean: mended engine oil)
• Mating surfaces of the oil cooler and the Refer to “CHANGING THE ENGINE OIL” on
crankcase page 3-13.
(with a cloth dampened with lacquer thinner) 5. Check:
2. Install: • Cooling system
• Oil cooler outlet hose “1” Leaks → Repair or replace any faulty part.
(to the oil cooler) 6. Measure:
• Radiator cap opening pressure
TIP
Below the specified pressure → Replace the
Install the oil cooler outlet hose with the white radiator cap.
paint mark “a” facing in the direction shown in Refer to “CHECKING THE RADIATOR” on
the illustration. page 6-6.
1 a
3. Install:
• Gasket New
• Oil cooler “1”
• Oil filter cartridge union bolt “2”
TIP
Fit the projection “a” on the oil cooler between
the projections “b” on the crankcase.
a b
b 1
6-3
RADIATOR
EAS26380
RADIATOR
Removing the radiator
T.R
T.R
.
.
6
4 1
(4)
2
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Side frames/Front fender/Instrument panel/Cen-
ter passenger compartment panel/Center floor Refer to “GENERAL CHASSIS” on page
board/Left floor board/Right floor board/Electri- 4-1.
cal components tray
Drain.
page 3-8.
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 inlet pipe 1
8 Radiator outlet hose 1
6-4
RADIATOR
Removing the radiator

7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 12 7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
T.R
.
.
11
10 15 14
(4)
13
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)

T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

9 Radiator outlet pipe 1
10 Radiator fan motor coupler 1 Disconnect.
11 Horn 1 For Europe and Oceania
12 Radiator bracket 1
13 Radiator 1
14 Radiator fan 1
15 Radiator fan motor breather hose 1
dure.
6-5
RADIATOR
EAS26390
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.
EAS26400
INSTALLING THE RADIATOR

1. Fill:
2. Check: • Cooling system
• Radiator hoses (with the specified amount of the recom-
• Radiator pipes mended coolant)
Cracks/damage/wear → Replace. Refer to “CHANGING THE COOLANT” on
3. Measure: page 3-8.
• Radiator cap opening pressure 2. Check:
Below the specified pressure → Replace the • Cooling system
radiator cap. Leaks → Repair or replace any faulty part.
3. Measure:
Radiator cap opening pressure
107.9–137.3 kPa (1.1–1.4
kgf/cm², 15.6–19.9 psi) Below the specified pressure → Replace the
radiator cap.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Refer to “CHECKING THE RADIATOR” on
a. Install the radiator cap tester “1” and radiator page 6-6.
cap tester adapter “2” to the radiator cap “3”.
EAS1XD2002
INSTALLING THE HORN (for Europe and

Radiator cap tester
90890-01325 Oceania)
Mityvac cooling system tester kit 1. Install:
YU-24460-A • Horn “1”
Radiator cap tester adapter
90890-01352 Horn nut
Pressure tester adapter 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.
YU-33984
TIP
Fit the slot “a” in the horn with the projection “b”
on the radiator bracket.
6-6
RADIATOR
b
a
1
6-7
THERMOSTAT
EAS26440
THERMOSTAT
Removing the thermostat
LS
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 2
T.R
.
New
New 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
4 5
18 Nm (1.8 m•kgf, 13 ft•Ibf)
T.R
.
1 New

Drain.
page 3-8.
1 Thermostat outlet hose 1
2 Thermostat cover 1
3 Thermostat 1
4 Coolant temperature sensor coupler 1 Disconnect.
5 Coolant temperature sensor 1
dure.
6-8
THERMOSTAT
EAS26450
• Thermostat housing (cylinder head)
CHECKING THE THERMOSTAT
• Thermostat outlet hose
1. Check:
• Thermostat
Does not open at 69–73 °C (156–163°F) → EAS1XD1122
Replace. INSTALLING THE THERMOSTAT

1. Install:
• Copper washer New
• Coolant temperature sensor
Coolant temperature sensor

18 Nm (1.8 m·kgf, 13 ft·lbf)
T.
R.
ECA1XD1042
NOTICE
Use extreme care when handling the coolant
temperature sensor. Replace any part that
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suspend the thermostat “1” in a container “2” was dropped or subjected to a strong im-
filled with water. pact.
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-
• O-ring “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.
2 New a
1
3
7 mm
(0.28 in)
LS
71±2°C 85°C 3. Fill:

(159±3°F) (185°F) • Cooling system
A. Fully closed
mended coolant)
B. Fully open
Refer to “CHANGING THE COOLANT” on
TIP page 3-8.
If the accuracy of the thermostat is in doubt, re- 4. Check:
place it. A faulty thermostat could cause serious • Cooling system
overheating or overcooling. Leak → Repair or replace any faulty part.
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
EAS26500
WATER PUMP
Removing the water pump
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
LS
LS New
E
(11) 7
2 New
3 M New
4 New 8
6
5
New
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf) LS
T.R
.

T.R
.

T.R
.
T.R
.

Center compartment panel/Right side cov- Refer to “GENERAL CHASSIS” on page
er/Right rear cover/Rear skid plate 4-1.
Drain.
page 3-13.
Drain.
page 3-8.
1 Water pump inlet hose 1
2 Water jacket joint 1
3 Water pump outlet hose 1
4 Water pump outlet pipe 1
5 Oil cooler inlet hose 1
6 Water pump breather hose 1
7 Water pump housing 1
8 Gasket 1
6-11
WATER PUMP
Removing the water pump
15
14 New 10 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
LS
21 New 13
20 11
16
15 12
19
LS New
17
9
E
(11)
New 18
M New
New
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf) LS
T.R
.

T.R
.

T.R
.
T.R
.

9 Dowel pin 2
11 AC magneto coupler 2 Disconnect.
13 AC magneto cover 1
14 AC magneto cover gasket 1
15 Dowel pin 2
16 Circlip 1
17 Impeller shaft 1
18 Mechanical seal (impeller side) 1
19 Mechanical seal (housing side) 1
20 Bearing 1
21 Oil seal 1
dure.
6-12
WATER PUMP
EAS26510 EAS26540
DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP

1. Remove: 1. Check:
• Mechanical seal (impeller side) “1” • Water pump housing cover
(from the impeller, with a thin, flat-head • AC magneto cover
screwdriver) • Impeller shaft
TIP • Oil cooler inlet hose
Do not scratch the impeller shaft. • Water pump outlet pipe
• Water pump outlet hose
2. Check:
• Bearing
Rough movement → Replace.
EAS26560
ASSEMBLING THE WATER PUMP

1. Install:
(into the AC magneto cover)
2. Remove: TIP
• Mechanical seal (housing side) “1” • Before installing the oil seal, apply tap water or
TIP coolant onto its outer surface.
Remove the mechanical seal (housing side) • Install the oil seal with a socket that matches its
from the inside of the AC magneto cover. outside diameter.
Installed depth of oil seal “a”

8.1–8.7 mm (0.32–0.34 in)
1 New
1
3. Remove:
• Bearing “1” a
• Oil seal “2”
TIP 2. Install:
Remove the bearing and oil seal from the inside • Mechanical seal (housing side) “1” New
of the AC magneto cover. ECA1XD1056
NOTICE
Never lubricate the mechanical seal (hous-
ing side) surface with oil or grease.
TIP
Use the special tools and a press to press the
2 mechanical seal (housing side) straight in until it
touches the water pump housing.
1
6-13
WATER PUMP
TIP
Mechanical seal installer
90890-04132 If the surface “a” of the mechanical seal (impeller
Water pump seal installer side) that contacts the mechanical seal (housing
YM-33221-A side) is dirty, clean it.
Middle driven shaft bearing driv-
er Impeller shaft tilt limit
90890-04058 0.15 mm (0.006 in)
Middle drive bearing installer 40
& 50 mm
YM-04058
A
3
2
1 New
1. Straightedge
2. Impeller
A. Push down 5. Install:

2. Mechanical seal installer • Impeller “1”
3. Middle driven shaft bearing driver • Circlip New
3. Install: TIP
• Mechanical seal (impeller side) “1” New After installation, check that the impeller shaft ro-
tates smoothly.
TIP
Before installing the mechanical seal (impeller
side), apply tap water or coolant onto its outer
surface.
EAS1XD1008
INSTALLING THE AC MAGNETO COVER

1. Install:
4. Measure:
• Impeller shaft tilt • AC magneto cover gasket “2” New
Out of specification → Repeat steps (3) and • AC magneto cover “3”
(4). TIP
ECA1XD1057
Align the slit “a” on the impeller shaft with the
NOTICE projection “b” on the oil pump driven sprocket.
Make sure the mechanical seal (impeller
side) is flush with the impeller.
6-14
WATER PUMP
1 3 2 New
a
2. Install:
• Gasket “2” New
• Water pump housing “3”
TIP
Install the bolt “4” to the water pump housing,
and then install the water pump housing to the
AC magneto cover.
1 2 New
3
3. Fill:
• Cooling system
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-8.
4. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
5. Measure:
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-6.
6-15
FUEL SYSTEM
FUEL TANK..................................................................................................... 7-1

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

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

REMOVING THE THROTTLE BODY ASSEMBLY .................................7-11
CHECKING THE INJECTOR .................................................................. 7-11
CHECKING THE THROTTLE BODY ......................................................7-11
CHECKING THE THROTTLE BODY JOINT...........................................7-11
INSTALLING THE THROTTLE BODY ASSEMBLY................................7-11
ADJUSTING THE THROTTLE POSITION SENSOR..............................7-12
AIR INDUCTION SYSTEM ............................................................................7-15

CHECKING THE AIR INDUCTION SYSTEM..........................................7-19
INSTALLING THE AIR INDUCTION SYSTEM........................................ 7-19
7
FUEL TANK
EAS26620
FUEL TANK
Removing the fuel tank
T.R
.
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 4
5
T.R
.
(6)
1 11
2 3
1 New
7
7
9
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
.

Outer passenger seat frame/Right side pan- Refer to “GENERAL CHASSIS” on page
el/Right rear cover 4-1.
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 2
11 Fuel pump 1
dure.
7-1
FUEL TANK
EAS26630
REMOVING THE FUEL TANK

1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Remove:
• Fuel hose connector holder
• Fuel hose
EWA15910
WARNING
Cover fuel hose connections with a cloth
when disconnecting them. Residual pres-
sure in the fuel lines could cause fuel to EAS26640
spurt out when removing the hose. REMOVING THE FUEL PUMP
ECA1XD1001
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 ECA14720
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 slotted head screwdriver, etc., in the
EAS26670
slot part “a” of the fuel hose connector cover CHECKING THE FUEL PUMP BODY
“1”, slide the cover in the direction of the arrow, 1. Check:
and then disconnect the fuel hose. • Fuel pump body
• To disconnect the fuel hose from the injector Obstruction → Clean.
fuel rail, slide the fuel hose connector cover “2” Cracks/damage → Replace the fuel pump.
on the end of the hose in direction of the arrow
shown, press the two buttons “3” on the sides EAS1XD1005
of the connector, and then disconnect the CHECKING THE FUEL TANK BREATHER
hose. HOSE JOINT
• Before removing the hose, place a few rags in 1. Check:
the area under where it will be removed. • 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 EAS1XD1006
INSTALLING THE FUEL TANK

EAS26700
INSTALLING THE FUEL PUMP 1. Install:

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

7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.
Fuel tank retainer bolt

16 Nm (1.6 m·kgf, 12 ft·lbf)
TIP
Tighten the bolts in the proper tightening se-
quence as shown.
3 4 5 EAS1XD1123
CHECKING THE FUEL PRESSURE

1. Check:
• Fuel pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the frame cross member.
b. Disconnect the fuel hose “1” from the injector
1 2 fuel rail.
4. Install: Refer to “REMOVING THE THROTTLE
• Fuel hose BODY ASSEMBLY” on page 7-11.
• Fuel hose connector holder “1” c. Connect the pressure gauge “2” and adapter
• Fuel pump coupler “3” to the fuel injector rail and fuel hose.
ECA1XD1053
NOTICE Pressure gauge

90890-03153
When installing the fuel hose, make sure that YU-03153
it is securely connected, and that the fuel Fuel pressure adapter
hose connector cover is in the correct posi- 90890-03176
tion, otherwise the fuel hose will not be prop- YM-03176
erly installed.
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.
• To install the fuel hose onto the injector fuel 2
rail, slide the fuel hose connector cover “2” on
the end of the hose in direction of the arrow 3
shown. 1
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)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-4
AIR FILTER CASE
EAS1XD1007
AIR FILTER CASE

Removing the air filter case and air intake duct
1 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
.
6
New
7
6
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)

T.R
New
.
8 9 8
2 1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

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

T.R
.

Side frames/Front fender/Instrument panel/Side Refer to “GENERAL CHASSIS” on page
panels/Center passenger compartment pan- 4-1.
el/Floor boards
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
12
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
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)

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

10 Intake air temperature sensor 1
11 Air filter case 1
12 Air intake duct 1
dure.
7-6
AIR FILTER CASE
EAS1XD1124
INSTALLING THE AIR FILTER CASE

1. Install:
• Air filter case joint “1”
(to the air filter case)
• Air filter case
TIP
Align the projection “a” on the air filter case joint
with the slot “b” on the air intake silencer “2”.
b
2
7-7
THROTTLE BODY
EAS26970
THROTTLE BODY
Removing the throttle body
11 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 2.8 Nm (0.28 m•kgf, 2.0 ft•Ibf)
T.R
.
10 8
10
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
.

Frame cross member 4-1.
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 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
10 Air intake silencer joint clamp screw 2 Loosen.
11 Air intake silencer joint 1
7-8
THROTTLE BODY
Removing the throttle body

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
.
2.8 Nm (0.28 m•kgf, 2.0 ft•Ibf)
T.R
.
13 14
12
New
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf) 12
T.R
.
LS
17
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
T.R
.
16 15
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)

T.R
.

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
dure.
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
LS
New

1 Intake air pressure sensor 1
2 Intake air pressure sensor hose 1
3 Throttle position sensor 1
4 Injector fuel rail 1
5 Fuel injector 1
ECA1XD1043
NOTICE
6 Throttle body 1
The throttle body should not be disas-
sembled.

cedure.
7-10
THROTTLE BODY
EAS1XD1125 EAS26990
REMOVING THE THROTTLE BODY CHECKING THE THROTTLE BODY

ASSEMBLY 1. Check:
1. Disconnect: • Throttle body
• Fuel hose Cracks/damage → Replace the throttle body.
EWA15910
2. Check:
WARNING • Fuel passages
Cover fuel hose connections with a cloth Obstructions → Clean.
when disconnecting them. Residual pres- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
sure in the fuel lines could cause fuel to a. Wash the throttle body in a petroleum- based
spurt out when removing the hose. solvent.
ECA1XD1018
Do not use any caustic carburetor cleaning
NOTICE solution.
• Be sure to disconnect the fuel hose (injec- b. Blow out all of the passages with compressed
tor fuel rail side) by hand. Do not forcefully air.
disconnect the hose with tools. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Although the fuel has been removed from EAS21020
the fuel tank be careful when disconnecting CHECKING THE THROTTLE BODY JOINT
the fuel hose, since there may be fuel re- 1. Check:
maining in it. • Throttle body joint “1”
TIP
• To disconnect the fuel hose from the injector
1
fuel rail, slide the fuel hose connector cover “1”
on the end of the hose in direction of the arrow
shown, press the two buttons “2” on the sides
of the connector, and then disconnect the
hose.
• Before disconnecting the hose, place a few
rags in the area under where it will be discon-
nected.
EAS1XD1126
INSTALLING THE THROTTLE BODY

ASSEMBLY
1. Install:
• Throttle body joint “1”
TIP
Align the projection “a” on the cylinder head with
the slot “b” in the throttle body joint.
EAS26980
1
CHECKING THE INJECTOR
1. Check:
• Injector:
Obstruction → Replace and check the fuel b a
pump/fuel supply system.
Deposit → Replace.
Damage → Replace.
2. Check:
2. Install:
• Injector resistance
• Throttle body joint clamps “1”
Refer to “CHECKING THE FUEL INJEC-
TOR” on page 9-106.
7-11
THROTTLE BODY
TIP
Align the projections on the throttle body joint
with the gap in each throttle body joint clamp.
1
5. Install:
• Air intake silencer “1”
TIP
Align the projection “a” on the air filter case joint
3. Install:
“2” with the slot “b” on the air intake silencer.
• Throttle body assembly “1”
TIP b
Align the projection “a” on the throttle body as-
1
sembly between the tabs “b” on the throttle body
joint.
a
1
2
b a
b
6. Install:
• Air intake silencer joint “1”
TIP
Align the projection “a” on the throttle body as-
sembly between the tabs “b” on the air intake si-
4. Connect:
lencer joint.
• Fuel hose
ECA1XD1044
NOTICE
When connecting the fuel hose, make sure 1
that it is securely connected, and that the
fuel hose connector cover is in the correct
position, otherwise the fuel hose will not be
properly connected. b
b
TIP a
• Connect the fuel hose securely onto the injec- a
tor fuel rail until a distinct “click” in heard.
EAS27030
• To connect the fuel hose onto the injector fuel ADJUSTING THE THROTTLE POSITION
rail, slide the fuel hose connector cover “1” on SENSOR
the end of the hose in direction of the arrow EWA1XD1003
shown. WARNING
• Handle the throttle position sensor with
special care.
• Never subject the throttle position sensor
to strong shocks. If the throttle position
sensor is dropped, replace it.
7-12
THROTTLE BODY
1. Check:
• Throttle position sensor
Refer to “CHECKING THE THROTTLE PO-
SITION SENSOR” on page 9-104.
2. Adjust:
• Throttle position sensor angle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the test harness- TPS (3P) “1” to the
throttle position sensor and wire harness as
shown.
b. Connect the digital circuit tester (DC 20V) to
the test harness- TPS (3P).
Test harness- TPS (3P)

90890-03204
YU-03204
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.
Throttle position sensor output

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

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

3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-13
THROTTLE BODY
7-14
AIR INDUCTION SYSTEM
EAS27040
2 3 4
1
7-15
1. Air intake silencer

2. Air induction system hose (air intake silencer
to air cut-off valve)
3. Air cut-off valve
4. Air induction system hose (air cut-off valve to
reed valve cover)
5. Reed valve
7-16
Removing the air cut-off valve

1 Air induction system solenoid coupler 1 Disconnect.
Air induction system hose (air cut-off valve joint
2 1
to reed valve cover)
Air induction system hose (air intake silencer to
3 1
air cut-off valve)
4 Air cut-off valve 1
dure.
7-17
Removing the reed valve
LT
LT
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

Air induction system hose (air cut-off valve to Disconnect.
reed valve cover) Refer to “Removing the air cut-off valve”.
1 Reed valve cover 1
2 Reed valve assembly 1
3 Reed valve plate 1
dure.
7-18
EAS27060
2. Check:
• 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 9-106.
Air cut-off valve EAS27070
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
A. From the air intake silencer

B. To the reed valve
1. Check:
• Hoses
Loose connections → Connect properly.
7-19
DRIVE TRAIN
TROUBLESHOOTING.....................................................................................8-1
CHECKING NOISES ................................................................................. 8-1
TROUBLESHOOTING CHART .................................................................8-2
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES,

DIFFERENTIAL ASSEMBLY AND FRONT DRIVE SHAFT .......................... 8-3
DISASSEMBLING THE UNIVERSAL JOINTS.......................................... 8-9
DISASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES ........................................................................................... 8-9
CHECKING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-10
ASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-10
REMOVING THE FRONT DRIVE SHAFT YOKE.................................... 8-11
REMOVING THE DIFFERENTIAL GEAR ASSEMBLY........................... 8-12
CHECKING THE FRONT DRIVE SHAFT ............................................... 8-12
CHECKING THE DIFFERENTIAL ASSEMBLY ...................................... 8-12
CHECKING THE DIFFERENTIAL MOTOR OPERATION ......................8-12
ASSEMBLING THE DIFFERENTIAL ASSEMBLY ..................................8-13
ASSEMBLING THE UNIVERSAL JOINT ................................................ 8-14
MEASURING THE DIFFERENTIAL GEAR BACKLASH......................... 8-15
ADJUSTING THE DIFFERENTIAL GEAR BACKLASH .......................... 8-16
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE

ASSEMBLY AND REAR DRIVE SHAFT .....................................................8-17
DISASSEMBLING THE REAR CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-23
CHECKING THE REAR CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-23
ASSEMBLING THE REAR CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-24
DISASSEMBLING THE FINAL DRIVE PINION GEAR
ASSEMBLY ............................................................................................ 8-25
CHECKING THE REAR DRIVE SHAFT.................................................. 8-25
CHECKING THE FINAL DRIVE ASSEMBLY..........................................8-26
ADJUSTING THE RING GEAR STOPPER............................................. 8-26
MEASURING THE FINAL GEAR BACKLASH ........................................ 8-26
ADJUSTING THE FINAL GEAR BACKLASH .........................................8-27
8
ASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY............. 8-27
INSTALLING THE FINAL DRIVE ASSEMBLY........................................ 8-28
TROUBLESHOOTING
EAS29890
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 sus- B. Improper gear backlash.
tained speed. (This must not be confused C. Gear tooth damage.
with engine surging or transmission charac- D. Broken drive shaft.
teristics.) E. Broken gear teeth.
2. A “rolling rumble” noticeable at low speed; a F. Seizure due to lack of lubrication.
high-pitched whine; a “clunk” from a shaft G. Small foreign objects lodged between the
drive component or area. moving parts.
3. A locked-up condition of the shaft drive train
mechanism, 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.
EAS29900
c. A slight “thunk” evident at low speed opera-
CHECKING NOISES
tion. This noise must be distinguished from
1. Investigate any unusual noises.
normal vehicle operation.
Diagnosis: Possible broken gear teeth.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EWA13790
The following “noises” may indicate a me-
WARNING
chanical defect:
a. A “rolling rumble” noise during coasting, ac- Stop riding immediately if broken gear teeth
celeration, or deceleration. The noise in- are suspected. This condition could result in
creases with front and/or rear wheel speed, the shaft drive assembly locking up, causing
but it does not increase with higher engine or a loss of control and possible injury to the
transmission speeds. rider.
Diagnosis: Possible wheel bearing damage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Refer to “TROUBLESHOOTING CHART” on 2. Check:
page 8-2. • Drained oil
b. A “whining” noise that varies with accelera- Drained oil shows large amounts of metal
tion and deceleration. particles → Check the bearing for seizure.
Diagnosis: Possible incorrect reassembly,
TIP
too little gear backlash.
Refer to “MEASURING THE DIFFERENTIAL A small amount of metal particles in the oil is nor-
mal.
GEAR BACKLASH” on page 8-15 or “MEA-
SURING THE FINAL GEAR BACKLASH” on 3. Check:
page 8-26. • Oil leakage
EWA13780
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
WARNING a. Clean the entire vehicle thoroughly, then dry
Insufficient gear backlash is extremely de- it.
structive to the gear teeth. If a test ride, fol- b. Apply a leak detection compound or dry pow-
lowing reassembly, indicates these der spray to the shaft drive.
symptoms, stop riding immediately to mini- c. Road test the vehicle for the distance neces-
mize gear damage. sary to locate the leak.
Leakage → Check the component housing,
gasket, and/or seal for damage.
Damage → Replace the component.
8-1
TROUBLESHOOTING
TIP • Always clean the vehicle and recheck the sus-

• An apparent oil leak on a new or nearly new ve- pected location of an apparent leakage.
hicle may be the result of a rust-preventative ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
coating or excessive seal lubrication.
EAS29910
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 4-56
for wheel bearing damage. and “REAR KNUCKLES AND STABILIZ-
ER” on page 4-64.)
NO ↓
2. Check the wheel nuts and axle nuts NO → Torque to specification. (Refer to “FRONT
for tightness. AND REAR WHEELS” on page 4-25.
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 LEVER”
ment.
on page 3-20.)
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.
8-2
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN-
TIAL ASSEMBLY AND FRONT DRIVE SHAFT
EAS1XD1132
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL

ASSEMBLY AND FRONT DRIVE SHAFT
Removing the front constant velocity shaft assemblies, differential assembly, and front drive shaft

T.R
T.R
.
.
150 Nm (15 m•kgf, 108 ft•lbf)
T.R
.
105 Nm (10.5 m•kgf, 76 ft•lbf)
T.R
.
LS
2
New LS
New
1
New
LT New
LS
LS
New
New
LS LS
LS 1 New 4
LS 3 60 Nm (6.0 m•kgf, 43 ft•Ibf)

T.R
.

Sun top/Side frames/Front fender/Front
guard/Instrument panel/Center passenger com- Refer to “GENERAL CHASSIS” on page
partment panel/Center floor board/Front skid 4-1.
plate
Refer to “STEERING KNUCKLES” on page
Steering knuckles 4-56.
Drain.
Differential gear oil Refer to “CHANGING THE DIFFERENTIAL
GEAR OIL” on page 3-16.
1 Front constant velocity shaft assembly 2
2 Differential motor coupler 1 Disconnect.
3 Differential assembly breather hose 1 Disconnect.
4 Differential assembly 1
8-3
Removing the front constant velocity shaft assemblies, differential assembly, and front drive shaft

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 LS
9 New
5
8
New
LT New 6
LS
LS 7 9 New
New
8
LS LS
10
LS New
12 11
New 13 14 New
New 15
LS 60 Nm (6.0 m•kgf, 43 ft•Ibf)
T.R
.

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
dure.
8-4
Disassembling the front constant velocity shaft assemblies
6 New
7
4 New
New 2
3
New 1
New 8
New 9

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
8-5
Disassembling the front constant velocity shaft assemblies
13
12 New
10 11

10 Dust boot 1
11 Constant velocity joint 1
12 Clip 1
13 Constant velocity shaft 1
cedure.
A: Wheel side
B: Differential side
8-6
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

T.R
.
T.R
.

ECA1XD1002
NOTICE
1 Differential motor 1 Do not disassemble the differential motor
or remove the differential motor pinion
gear.
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 8-16.
8 Bearing 1
9 Bearing 1
10 Oil seal 1
8-7
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
T.R
.
T.R
.

11 Clip 1
12 Differential pinion gear 1
13 Bearing 1
14 Bearing 1
15 Oil seal 2
16 Differential case 1
cedure.
* SAE 80 API GL-4 Hypoid gear oil
8-8
EAS1XD1036
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 band “1”
TIP
Use the boot band installation tool “2”.
Boots band installation tool

90890-01526
YM-01526
d. Repeat the steps for the opposite bearing. 2

e. Remove the universal joint.
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS29930
DISASSEMBLING THE FRONT CONSTANT

VELOCITY SHAFT ASSEMBLIES
front constant velocity shaft assemblies. B. Wheel side
1. Remove:
• 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.
8-9
B A
New 1
A
B. Wheel side
3
EAS29960
CHECKING THE FRONT CONSTANT

front constant velocity shaft assemblies.
New 1
1. Check:
• Double offset joint splines 2
• Constant velocity joint splines
• Constant velocity shaft splines A
Wear/damage → Replace.
2. Check:
• Dust boots
ECA1XD1006
NOTICE
Always use new boot bands.
3. Check:
• Balls and ball races A. Wheel side
• Inner surface of double offset joint
Pitting/wear/damage → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
EAS29990
ASSEMBLING THE FRONT CONSTANT • Dust boot

VELOCITY SHAFT ASSEMBLIES • 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
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a new clip. double offset joint.
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 plastic hammer.
8-10
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
B
1 a. Install the dust boots.
b. Install the dust boot bands “4” and “5”.
TIP
2 New Use the boot band installation tool “6”.
Boots band installation tool

90890-01526
YM-01526
B
3 4
4 New
B. Differential side
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Apply: 5. Check:
• Molybdenum disulfide grease • Thrust movement free play
(into the double offset joint, constant velocity Excessive play → Replace the constant ve-
joint, and dust boots) 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: EAS1XD1035
• Dust boots “1” REMOVING THE FRONT DRIVE SHAFT

• Boot bands “2”, “3”, “4”, “5” New YOKE
1. Remove:
TIP
• Front drive shaft yoke
The dust boots should be fastened with the boot
TIP
bands “3” and “5” at the grooves in the constant
velocity shaft. Use the universal joint holder “1” to hold the front
drive shaft yoke, then loosen the front drive shaft
yoke nut.
Universal joint holder

90890-04062
YM-04062
8-11
EAS1XD1047
CHECKING THE DIFFERENTIAL ASSEMBLY

1. Check:
• Differential case
• Differential case cover
TIP
When the differential case and/or the differential
1 case cover are replaced, be sure to adjust the
shim of the differential gear assembly.
EAS1XD1046
2. Check:
REMOVING THE DIFFERENTIAL GEAR • Gear teeth
ASSEMBLY Pitting/galling/wear → Replace.
1. Remove:
TIP
• Differential gear assembly “1”
ECA1XD1003 When the differential pinion gear and/or the dif-
NOTICE ferential assembly are replaced, be sure to ad-
The differential gear assembly is assembled just the shim of the differential gear assembly.
into a proper unit at the factory by means of 3. Check:
specialized equipment. Do not attempt to • Bearings
disassemble this unit. Disassembly will re- Damage → Replace.
sult in the malfunction of the unit.
EAS1XD1038
CHECKING THE DIFFERENTIAL MOTOR

OPERATION
1 1. Check:
• Differential motor operation
Does not operate → Replace.
ECA1XD1045
NOTICE
Do not disassemble the differential motor or
remove the differential motor pinion gear.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EAS1XD1127 a. Connect two C-size batteries to the differen-
CHECKING THE FRONT DRIVE SHAFT tial motor terminals “1” (as shown in the illus-
1. Check: trations).
• Drive shaft splines ECA1XD1046
• Coupling sleeve splines NOTICE

Wear/damage → Replace. • Do not use a 12 V battery to operate the dif-
EWA15060
ferential motor pinion gear.
WARNING
• Do not connect the batteries to the differen-
Do not attempt to straighten a bent shaft; tial motor when it is installed in the differen-
this may dangerously weaken it. tial case.
2. Check: • The differential motor should be checked
• Support bearing when it is removed from the differential
Damage → Replace. case.
3. Check:
• Support bearing housing
• Support bearing rubber
8-12
A
3V
3
1
a
2 2
B
3V
3. Differential case
4. Differential case cover
2. Measure:
• Gear backlash
Refer to “MEASURING THE DIFFERENTIAL
GEAR BACKLASH” on page 8-15.
2 3. Install:
1 • Differential motor
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
A. Check that the differential motor pinion gear a. Slide the shift fork sliding gear “1”, which is in-
“2” turns counterclockwise.
stalled to the differential case cover, to the
B. Check that the differential motor pinion gear
“2” turns clockwise. right front constant velocity shaft assembly
side as shown in the illustration to put it into
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ the 2WD mode.
EAS1XD1039
ASSEMBLING THE DIFFERENTIAL

1
ASSEMBLY
1. Install:
• Oil seals “1”
• Oil seal “2”
Installed depth of oil seal “a”

-0.5–0.5 mm (-0.020–0.020 in)
3 a a 4 b. Connect two C-size batteries to the differen-

tial motor terminal “2” to operate the differen-
tial motor pinion gear “3”. Operate the
differential motor pinion gear until the mark
“a” on the differential motor pinion gear is
aligned with the mark “b” on the differential
motor case.
ECA1XD1013
1 1 NOTICE
Do not use a 12 V battery to operate the dif-
ferential motor pinion gear.
8-13
2
b
3V
c. Insert 6 mm bolts “4” into the differential mo- 5. Install:
tor “5” and use them as a guide to set the mo- • Front drive shaft yoke
tor on the differential case cover “6” so that • Washer
the shift fork sliding gear “7” does not move. • Front drive shaft yoke nut
ECA1XD1047
NOTICE Front drive shaft yoke nut

If the position of the shift fork sliding gear is 62 Nm (6.2 m·kgf, 45 ft·lbf)
T.
R.
moved, the position of the differential gear
assembly and the indicator light display may TIP
differ, and the 2WD or differential lock mode • Apply locking agent (LOCTITE®) to the nut
may not be activated. threads.
• Use the universal joint holder “1” to hold the
4 5 front drive shaft yoke, then tighten the front
4 drive shaft yoke nut.
4
7 Universal joint holder
90890-04062
6 YM-04062
d. Remove the 6 mm bolts, and then install the

motor with the differential motor bolts.
Differential motor bolt

11 Nm (1.1 m·kgf, 8.0 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1
4. Check:
EAS1XD1010
• Differential assembly operation
ASSEMBLING THE UNIVERSAL JOINT
Unsmooth operation → Replace the differen-
1. Install:
tial assembly.
• Universal joint
Insert the double offset joint into the differen-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
tial assembly, and turn the gears back and a. Install the universal joint into the front drive
forth. shaft yoke.
8-14
EAS1XD1040
MEASURING THE DIFFERENTIAL GEAR

BACKLASH
1. Secure the differential case in a vise or anoth-
er supporting device.
2. Remove:
• Drain plug
• Gasket
3. Install:
• Ring gear fix bolt (M10) “1”
(into the drain plug hole)
b. Apply lithium-soap-based grease to the bear-
ings. Ring gear fix bolt (M10)
c. Install the bearing “1” onto the front drive 90890-01527
shaft yoke. YM-01527
ECA1XD1015
NOTICE ECA16250
Check each bearing. The needles can easily NOTICE

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

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
a. Measuring point is 31.0 mm (1.22 in)
bearing.
5. Measure:
• Gear backlash
Gently rotate the differential pinion gear from
engagement to engagement.
Differential gear backlash

0.05–0.25 mm (0.002–0.0010 in)
TIP
Measure the gear backlash at four positions. Ro-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ tate the differential pinion gear 90° each time.
8-15
EAS1XD1034
ADJUSTING THE DIFFERENTIAL GEAR

BACKLASH
1. Remove:
• Differential gear assembly shim(s) “1”
• Differential gear assembly “2”
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.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-16
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
EAS1XD1024
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE

ASSEMBLY AND REAR DRIVE SHAFT
Removing the rear constant velocity shaft assemblies, final drive assembly, and rear drive shaft
105 Nm (10.5 m•kgf, 76 ft•lbf)

1
T.R
.
New
New
5 2
(4) LS
LS 4
33 Nm (3.3 m•kgf, 24 ft•Ibf) LS

T.R
.
3
33 Nm (3.3 m•kgf, 24 ft•Ibf)
T.R
.
1 New
105 Nm (10.5 m•kgf, 76 ft•lbf)
T.R
.

Rear skid plate Refer to“GENERAL CHASSIS” on page 4-1.
Refer to “REAR KNUCKLES AND STABI-
Rear knuckles LIZER” on page 4-64.
Parking brake caliper Refer to “PARKING BRAKE” on page 4-42.
Muffler Refer to“ENGINE REMOVAL” on page 5-1.
Drain.
Final gear oil Refer to “CHANGING THE FINAL GEAR
OIL” on page 3-15.
1 Rear constant velocity shaft assembly 2
2 Final drive assembly breather hose 1 Disconnect.
3 Final drive assembly bracket (upper side) 1
4 Final drive assembly 1
5 Spring 1
8-17
Removing the rear constant velocity shaft assemblies, final drive assembly, and rear drive shaft
105 Nm (10.5 m•kgf, 76 ft•lbf)
T.R
.
New
New
6
10 9
8 7
(4) LS
LS
33 Nm (3.3 m•kgf, 24 ft•Ibf) LS

T.R
.
33 Nm (3.3 m•kgf, 24 ft•Ibf)

T.R
.
11
New
105 Nm (10.5 m•kgf, 76 ft•lbf)
T.R
.

6 Rear drive shaft 1
7 Damper 1
8 Rear drive shaft coupling sleeve 1
9 Dust seal 1
10 Dust seal 1
11 Final drive assembly bracket (lower side) 1
dure.
8-18
Disassembling the rear constant velocity shaft assemblies
6 New
7
4 New
New 2
3
New 1
New 8 12 New
10 11
New 9

the rear 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
10 Dust boot 1
11 Constant velocity joint 1
12 Clip 1
8-19
Disassembling the rear constant velocity shaft assemblies
13

13 Constant velocity shaft 1
cedure.
A: Wheel side
B: Final drive side
8-20
Disassembling the final drive assembly
23 Nm (2.3 m•kgf, 17 ft•Ibf)

T.R
New
.
LS
New *
*
1 13
5 11 New
3
10
New 12
New
LS
8
New 6
LS
4
2 7
9
New (8)
* 52 Nm (5.2 m•kgf, 38 ft•Ibf)
T.R
.
LT
16 Nm (1.6 m•kgf, 12 ft•Ibf)
T.R
.
LT
(4)
LS
26 Nm (2.6 m•kgf, 19 ft•Ibf)

T.R
.
97 Nm (9.7 m•kgf, 70 ft•Ibf)

T.R
.

Parking brake disc Refer to “PARKING BRAKE” on page 4-42.
1 Final drive pinion gear assembly 1
2 Rear drive shaft yoke (final drive assembly side) 1
3 Final drive pinion gear 1
4 Final drive pinion gear shim
5 Collar 1
6 Oil seal 1
7 Bearing 1
8 Final drive pinion gear bearing housing 1
9 Ring gear stopper 1
10 Final drive case cover 1
11 Final drive case cover gasket 1
12 Oil seal 1
13 Final drive ring gear 1
8-21
Disassembling the final drive assembly
23 Nm (2.3 m•kgf, 17 ft•Ibf)

T.R
New
.
20
New 21
LS
19
New
15 *
* 18 17
16
14
19
New
LS
LS
New (8)
* 52 Nm (5.2 m•kgf, 38 ft•Ibf)
T.R
.
LT
16 Nm (1.6 m•kgf, 12 ft•Ibf)
T.R
.
LT
(4)
LS
26 Nm (2.6 m•kgf, 19 ft•Ibf)

T.R
.
97 Nm (9.7 m•kgf, 70 ft•Ibf)

T.R
.

Final drive ring gear shim (final drive case cover
14 side)
15 Final drive ring gear shim (final drive case side)
16 Bearing 1
17 Bearing 1
18 Bearing 1
19 Dowel pin 2
20 Final drive case 1
21 Oil seal 1
cedure.
* SAE 80 API GL-4 Hypoid gear oil
8-22
EAS30060
DISASSEMBLING THE REAR CONSTANT B

rear constant velocity shaft assemblies. 2
1. Remove: 1
• Boot bands
• Clip “1”
• Double offset joint “2”
• Circlip “3”
• Ball bearing “4”
• Dust boot “5” B. Wheel side
TIP 3. Remove:
Before removing the clip, slide the dust boot • Dust boot
away from the double offset joint. • Constant velocity joint
• Clip
A TIP
5 Secure the constant velocity shaft in a vise, and
then remove the constant velocity joint using
hammers.
2 B
A
4
B. Wheel side
EAS30330
CHECKING THE REAR CONSTANT

A. Final drive side The following procedure applies to both of the
rear constant velocity shaft assemblies.
2. Remove:
1. Check:
• Boot bands “1”
• Double offset joint splines
• Constant velocity joint splines
Boots band installation tool • Constant velocity shaft splines
90890-01526 Wear/damage → Replace.
YM-01526 2. Check:
• Dust boots
ECA1XD1006
NOTICE
Always use new boot bands.
3. Check:
• Balls and ball races
• Inner surface of double offset joint
Pitting/wear/damage → Replace.
8-23
EAS30070
• Ball bearing “1”
ASSEMBLING THE REAR CONSTANT
VELOCITY SHAFT ASSEMBLIES • Circlip “2” New
The following procedure applies to both of the • Double offset joint “3”
rear constant velocity shaft assemblies. • Clip “4” New
1. Install: TIP
• Clip “1” New • Securely install the circlip into the groove in the
• Constant velocity joint “2” constant velocity shaft.
• Constant velocity shaft “3” • Securely install the clip into the groove in the
• Dust boot double offset joint.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the clip. B
b. Install the constant velocity joint. 1
TIP
• Install the clip into the groove in the constant 2 New
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 plastic hammer.
A
B
New 1
3
3
4 New
A
3 B. Final drive side
3. Apply:
• Molybdenum disulfide grease
(into the double offset joint, constant velocity
joint, and dust boots)
New 1
Molybdenum disulfide grease
2 60–80 g (2.1–2.8 oz) per dust
boot (wheel side)
A
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”
• Boot bands “2”, “3”, “4”, “5” New
A. Wheel side
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
• Dust boot
8-24
TIP • Washer
The dust boots should be fastened with the boot • Rear drive shaft yoke “1”
bands “3” and “5” at the grooves in the constant TIP
velocity shaft. • Secure the final drive assembly in a vise.
• Use the coupling gear holding tool (35) “2” to
hold the rear drive shaft yoke.
Coupling gear holding tool (35)

90890-01571
YM-01571
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the dust boots.
b. Install the dust boot bands “4” and “5”.
Boots band installation tool 2

90890-01526 1
YM-01526 2. Remove:
• Final drive pinion gear “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside surface of the final drive
pinion gear.
6 b. Place the final drive gear in a hydraulic press.
ECA1XD1005
4 NOTICE
• Never directly press the gear end with a hy-
draulic press, this will result in damage to
the gear thread.
• Install a suitable socket “2” on the gear end
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ to protect the thread from damage.
5. Check: c. Press the gear end and remove the final drive
• Thrust movement free play pinion gear.
Excessive play → Replace the constant ve-
locity shaft assembly.
2
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30150
EAS1XD1043 CHECKING THE REAR DRIVE SHAFT
DISASSEMBLING THE FINAL DRIVE PINION 1. Check:
GEAR ASSEMBLY • Drive shaft splines
1. Remove: • Coupling sleeve splines
• Rear drive shaft yoke nut Wear/damage → Replace.
8-25
EWA15060
b. Turn the ring gear stopper 120° counterclock-
WARNING wise.
Do not attempt to straighten a bent shaft;
this may dangerously weaken it.
EAS1XD1044
CHECKING THE FINAL DRIVE ASSEMBLY

1. Check:
• Final drive case
• Final drive case cover
TIP
When the final drive case and/or the final drive c. Tighten the ring gear stopper nut “3”.
case cover are replaced, be sure to adjust the
shim of the final drive pinion gear and/or ring Ring gear stopper nut
gear. 16 Nm (1.6 m·kgf, 12 ft·lbf)
T.
R.
2. Check: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Gear teeth
Pitting/galling/wear → Replace the final drive
EAS1XD1033
MEASURING THE FINAL GEAR BACKLASH

pinion gear and ring gear as a set. 1. Remove:
TIP • Filler plug
When the final drive pinion gear and ring gear • Gasket
are replaced, be sure to adjust the shim of the fi- 2. Install:
nal drive pinion gear and/or ring gear. • Ring gear fix bolt (M10 × 1.5) “1”
(into the drain plug hole)
3. Check:
• Bearings Ring gear fix bolt (M10 x 1.5)
Damage → Replace. 90890-01572
EAS1XD1011
YM-01572
ADJUSTING THE RING GEAR STOPPER EAS1XD1012
1. Install: NOTICE
• Ring gear stopper “1”
Finger tighten the bolt until if holds the ring
• Nut
gear. Otherwise, the ring gear will be dam-
TIP
aged.
• Apply Yamaha bond No.1215 to the ring gear
stopper threads.
• Apply LOCTITE® to the nut threads.
2. Adjust:
• Ring gear stopper clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Finger tighten the ring gear stopper until it
contacts the ring gear “2”.
1
2
3. Attach:
• Gear lash measurement tool “1”
• Dial gauge “2”
1 Gear lash measurement tool

90890-01467
YM-01467
3
8-26
Reduce the final drive ring gear shim (final
2 drive case cover side) “4” thickness by 0.2
mm (0.008 in) for every 0.2 mm (0.008 in) that
the final drive ring gear shim (final drive case
side) “2” and thrust washer “3” are increased.
1 c. If reduced by more than 0.2 mm (0.008 in):
Increase the final drive ring gear shim (final
drive case cover side) “4” thickness by 0.2
a mm (0.008 in) for every 0.2 mm (0.008 in) that
the final drive ring gear shim (final drive case
a. Measuring point is 31.5 mm (1.24 in) side) “2” and thrust washer “3” are de-
creased.
4. Measure:
• Gear backlash Final drive ring gear shims (final
Gently rotate the final drive pinion gear from drive case cover side) “3”
engagement to engagement. Thickness (mm)
0.2 0.3
Final gear backlash
0.13–0.23 mm (0.005–0.009 in) TIP
Be sure to use one of each of the final drive ring
TIP gear shim (final drive case cover side) “3” and fi-
Measure the gear backlash at four positions. Ro- nal drive ring gear shim (final drive case side) “4”
tate the final drive pinion gear 90° each time. to obtain the shim thickness.
EAS30180
Final drive ring gear shims (final
ADJUSTING THE FINAL GEAR BACKLASH
drive case side) “4”
1. Remove: Thickness (mm)
• Final drive ring gear “1” 0.2 0.3
• Bearings “2”
• Final drive ring gear shim (final drive case ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
cover side) “3” EAS1XD1130
• Final drive ring gear shim (final drive case ASSEMBLING THE FINAL DRIVE PINION
side) “4” GEAR ASSEMBLY
4 1. Apply:
2 • Sealant
1 (onto the washer contact surface and splines
2 of the final drive pinion gear)
3 Yamaha bond No. 1215
90890-85505
2. Adjust:
• Gear backlash
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Select a suitable shim(s) using the following
chart.
Final gear backlash is in-
Thinner shim
creased.
Final gear backlash is de-
Thicker shim
creased.
b. If increased by more than 0.2 mm (0.008 in):
8-27
2. Install: TIP
• Rear drive shaft yoke (final drive case side) Tighten the bolts and nuts to specification in the
“1” proper tightening sequence shown.
Rear drive shaft yoke nut (final
drive assembly side) 6 3 1 3
T.
R.
97 Nm (9.7 m·kgf, 70 ft·lbf) 4 5

LOCTITE®
TIP 9 8 7 FWD
• Secure the rear differential assembly in a vise.
• Use the coupling gear holding tool (35) “2” to 2 1
hold the rear drive shaft yoke. 2
Coupling gear holding tool (35)

90890-01571
YM-01571
2
1
EAS1XD1045
INSTALLING THE FINAL DRIVE ASSEMBLY

1. Install
• Final drive assembly bracket (upper side) “1”
Final drive assembly bracket (up-

per side) bolt
T.
R.
33 Nm (3.3 m·kgf, 24 ft·lbf)
• Final drive assembly “2”
Final drive assembly nut (upper

side)
T.
R.
105 Nm (10.5 m·kgf, 76 ft·lbf)
• Final drive assembly bracket (lower side) “3”
Final drive assembly bolt (lower

side)
T.
R.
105 Nm (10.5 m·kgf, 76 ft·lbf)
Final drive assembly bracket bolt

(lower side)
T.
R.
33 Nm (3.3 m·kgf, 24 ft·lbf)
8-28
8-29
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 ..............................................................................9-9
CHARGING SYSTEM....................................................................................9-11
CIRCUIT DIAGRAM ................................................................................ 9-11
TROUBLESHOOTING ............................................................................9-13
LIGHTING SYSTEM ......................................................................................9-15

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

CIRCUIT DIAGRAM (for CDN)................................................................9-19
CIRCUIT DIAGRAM (for Europe and Oceania)....................................... 9-21
COOLING SYSTEM....................................................................................... 9-29

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

CIRCUIT DIAGRAM ................................................................................ 9-33
ECU SELF-DIAGNOSTIC FUNCTION....................................................9-35
TROUBLESHOOTING METHOD............................................................ 9-36
YAMAHA DIAGNOSTIC TOOL ...............................................................9-37
TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM) ............9-38
FUEL PUMP SYSTEM...................................................................................9-63

CIRCUIT DIAGRAM ................................................................................ 9-63
2WD/4WD SELECTING SYSTEM.................................................................9-67

CIRCUIT DIAGRAM ................................................................................ 9-67
9
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)...........9-71
CIRCUIT DIAGRAM ................................................................................ 9-71
EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION .....................9-73
EPS WARNING LIGHT DURING NORMAL OPERATION......................9-73
DIAGNOSTIC MODE .............................................................................. 9-74
SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)......................9-76
TROUBLESHOOTING DETAILS (EPS SYSTEM) ..................................9-77
ELECTRICAL COMPONENTS...................................................................... 9-81

CHECKING THE SWITCHES .................................................................9-87
CHECKING THE BULBS AND BULB SOCKETS ................................... 9-90
REPLACING THE HEADLIGHT BULBS ................................................. 9-91
ADJUSTING THE HEADLIGHT BEAMS................................................. 9-92
CHECKING THE FUSES ........................................................................9-92
CHECKING AND CHARGING THE BATTERY....................................... 9-93
CHECKING THE RELAYS ...................................................................... 9-95
CHECKING THE SPARK PLUG CAP .....................................................9-98
CHECKING THE IGNITION COIL ........................................................... 9-98
CHECKING THE IGNITION SPARK GAP............................................... 9-99
CHECKING THE CRANKSHAFT POSITION SENSOR.......................... 9-99
CHECKING THE LEAN ANGLE SENSOR............................................9-100
CHECKING THE STARTER MOTOR OPERATION .............................9-100
CHECKING THE STATOR COIL ..........................................................9-101
CHECKING THE RECTIFIER/REGULATOR ........................................9-101
CHECKING THE FUEL SENDER .........................................................9-101
CHECKING THE FUEL METER/FUEL LEVEL WARNING
LIGHT ...................................................................................................9-102
CHECKING THE SPEED SENSOR ......................................................9-102
CHECKING THE RADIATOR FAN MOTOR .........................................9-103
CHECKING THE RADIATOR FAN MOTOR CIRCUIT
BREAKER ............................................................................................9-103
CHECKING THE COOLANT TEMPERATURE SENSOR.....................9-103
CHECKING THE THROTTLE POSITION SENSOR .............................9-104
CHECKING THE INTAKE AIR PRESSURE SENSOR .........................9-105
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ..................9-105
CHECKING THE FUEL INJECTOR ......................................................9-106
CHECKING THE AIR INDUCTION SYSTEM SOLENOID ....................9-106
CHECKING THE DIFFERENTIAL MOTOR POSITION
SWITCH ...............................................................................................9-106
CHECKING THE EPS MOTOR (for EPS models) ................................9-107
CHECKING THE EPS TORQUE SENSOR (for EPS models) ..............9-107
EAS27100
EAS27090
A
B B
B
Br/Y L G/W
A 67 B L B C
L Br/Y W B
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 68 Y/R B P/L L/B Br/L O
Br/Y B Br/Y B
(B)
Br/R 22
B/L Gy Gy B/L
G/W O O
W W W B R Gy 23
Gy B B
CIRCUIT DIAGRAM
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
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 R R/L
R/W
W W W W
W W R (B) (B) R/W 24 R/L R
(Gy) W W R/W
(Gy) 2 3
W W (Gy)
Br/Y R/W
R/G R/G Br/W Br/W B/L
IGNITION SYSTEM
W W W/G R/W R/G P/L P/L G/W

25 Br/W B/L
14 Br/L R/W P/L 20
(Gy) (Gy) B B/W R/W W/G W/G
Y/W (B) Br/L Br/L (B)
G/Y G/Y B/L
32
26 G/Y B/L
R/W 19 Y/W Y/W
(B)
B/W W
R/L
R/W
21
R/Y L L/Y
Y/R W L/Y L W
W 27
Br/R Y/B B/L B/L
R R L B/L
G/R R/W R/W R/W R/W R/W R/W L L L L L
R 9 L/R B/L B/L B/L B/L B/L B/L B/L B/L
4 BB B R R Br/B L/Y B/L
B Br/R R/L Y Y Y 28 B/L Y L
P/W L
R Br/B Br/R L/R (B)
R R Br/B O/L (B)
Br/L
5 B/G
B W/B L
R 8 10 B/R P P 29 B/L P L
Br/L
13 Sb B/L B/L
33
Br/R
Br/R B L/Y Gy/G Lg R/W
Br/R (B)
R/W
P/W B/G Gy/G W/R L/B 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 L/W G/R G/R Y/G Y/G B/L R/W
30 L Y/G B/L R/W
B/Y Y/L B/L
B/L B/L
Br/R 17 L Gy W 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
66 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
R B/W
Y/R
9-1
(B) (B) (Gy) Gy/G G/R L/W
R/L B
B/W B L/B
Br/R Y/R (B)
R/L
Br/L W/B
65 63
Br
62 G/W G/W G/W Y Y 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
61 Br/Y
R/W
R/W Br/R
W/B Br Br/R
38 (B)
R/W
60 Y Br/Y
R/B R Br/Y Y Br
(B) 39 33
51 L 50 B/W G/W
L 59 Br/B B/W G/W
Br (off)
Br/R Br/L Br Y 54 B/W G/W
R/W Y/L B/W Y
Br/Y B/W B/W Y
58 (B) B/W Y
55 G W/B G G/R O/B
64 R R R/L Br/Y
Br/B B R/L Br/Y
57 L Y Br/R R/L Br/Y
Y B L/Y Br/Y
W/B B 40 L/Y Br/Y
L B Br/R B G/R R/L O/B
L/Y Br/Y
Y (B)
Y Y
B 41
B R/W L O/B R/W
L 49 48
Y 52 Y/L Br/Y B/W
Y G B L 42 35 Br/Y
(B) Lg
Lg B
(B)
B B B/W Br
G 43
G B Br/Y Br B
R/L B B/W O/B L/B B Lg
L
(Dg) 44 (B) 34
Y LL
Y Y G Y G 36 L
37
Y L
45 B
53 53 B L/B
56 56 G Y G Y 46
B B
B B
47
Y G Y G
B B
B B
IGNITION SYSTEM
IGNITION SYSTEM

5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
21.ECU (engine control unit)
22.Ignition coil
23.Spark plug
30.Lean angle sensor
33.Joint coupler
59.Ignition fuse
B. Wire harness
C. Negative battery sub-wire harness
9-2
IGNITION SYSTEM
EAS27120
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Hood
2. Right side panel
3. Right rear panel
1. Check the fuses. NG →

(Main and ignition)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 9-92.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 9-93.
OK ↓
3. Check the spark plug. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug.
PLUG” on page 3-5.
OK ↓
4. Check the ignition spark gap. OK →
Refer to “CHECKING THE IGNI- Ignition system is OK.
TION SPARK GAP” on page 9-99.
NG ↓
5. Check the spark plug cap. NG →
Refer to “CHECKING THE SPARK Replace the spark plug cap.
PLUG CAP” on page 9-98.
OK ↓
6. Check the ignition coil. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coil.
TION COIL” on page 9-98.
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 9-99.
OK ↓
8. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 9-87.
OK ↓
9-3
IGNITION SYSTEM
9. Check the lean angle sensor. NG →

Refer to “CHECKING THE LEAN Replace the lean angle sensor.
ANGLE SENSOR” on page 9-100.
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
EAS27170
EAS27160
A
B B
B
Br/Y L G/W
A 67 B L B C
L Br/Y W B
W Br/Y
(B)
Br/Y B Br/Y B
(B)
Br/R 22
B/L Gy Gy B/L
G/W O O
W W W B R Gy 23
Gy B B
CIRCUIT DIAGRAM
(Gy) (B) Br/Y R/W
R/W
W W W W
W W R (B) (B) R/W 24 R/L R
(Gy) W W R/W
(Gy) 2 3
W W (Gy)
Br/Y R/W
25 Br/W B/L
14 Br/L R/W P/L 20
G/Y G/Y B/L
32
26 G/Y B/L
R/W 19 Y/W Y/W
(B)
B/W W
R/L
R/W
21
R/Y L L/Y
Y/R W L/Y L W
W 27
Br/R Y/B B/L B/L
R R L B/L
P/W L
R Br/B Br/R L/R (B)
R R Br/B O/L (B)
Br/L
5 B/G
B W/B L
R 8 10 B/R P P 29 B/L P L
Br/L
13 Sb B/L B/L
33
Br/R
L/Y Lg R/W
ELECTRIC STARTING SYSTEM
Br/R B Gy/G (B)

Br/R R/W
B
11 W/B
30 L Y/G B/L R/W
B/Y Y/L B/L
B/L B/L
Br/R 17 L Gy W 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
66 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
R B/W
Y/R
9-5
(B) (B) (Gy) Gy/G G/R L/W
R/L B
B/W B L/B
Br/R Y/R (B)
R/L
Br/L W/B
65 63
Br

Br/Y
61 Br/Y
R/W
R/W Br/R
W/B Br Br/R
38 (B)
R/W
60 Y Br/Y
R/B R Br/Y Y Br
(B) 39 33
51 L 50 B/W G/W
L 59 Br/B B/W G/W
Br (off)
R/W Y/L B/W Y
Br/Y B/W B/W Y
58 (B) B/W Y
55 G W/B G G/R O/B
64 R R R/L Br/Y
Br/B B R/L Br/Y
Y B L/Y Br/Y
W/B B 40 L/Y Br/Y
L/Y Br/Y
Y (B)
Y Y
B 41
B R/W L O/B R/W
L 49 48
Y 52 Y/L Br/Y B/W
Y G B L 42 35 Br/Y
(B) Lg
Lg B
(B)
B B B/W Br
G 43
G B Br/Y Br B
L
(Dg) 44 (B) 34
Y LL
Y Y G Y G 36 L
37
Y L
45 B
53 53 B L/B
56 56 G Y G Y 46
B B
B B
47
Y G Y G
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
33.Joint coupler
55.Brake light switch
59.Ignition fuse
61.Signaling system fuse
B. Wire harness
9-6
EAS27180
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the main switch is set to “ ” (start), the starter motor can only operate if at least one of the following
conditions is met:
• The transmission is in neutral (the neutral circuit of the gear position switch is closed).
• The brake pedal is pressed (the brake light switch circuit is closed).
11
10
1
5
3
6
4
9-7
1. Battery
2. Main fuse
3. Ignition fuse
4. Main switch
6. Signaling system fuse
7. Brake light switch
9. Gear position switch
10.Starter relay
11.Starter motor
9-8
EAS27190
TROUBLESHOOTING
The starter motor fails to turn.
TIP
1. Hood

(Main, ignition, and signaling sys-
tem) Replace the fuse(s).
ES” on page 9-92.
OK ↓
page 9-93.
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.
9-100.
NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-39.
OK ↓
5. Check the starter relay. NG →
Refer to “CHECKING THE RE- Replace the starter relay.
LAYS” on page 9-95.
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 ↓
9-9
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.
9-10
EAS27210
EAS27200
A
B B
B
Br/Y L G/W
A 67 B L B C
L Br/Y W B
W Br/Y
(B)
Br/Y B Br/Y B
(B)
Br/R 22
B/L Gy Gy B/L
G/W O O
W W W B R Gy 23
Gy B B
CIRCUIT DIAGRAM
(Gy) (B) Br/Y R/W
R/W
W W W W
W W R (B) (B) R/W 24 R/L R
(Gy) W W R/W
(Gy) 2 3
W W (Gy)
Br/Y R/W
25 Br/W B/L
14 Br/L R/W P/L 20
CHARGING SYSTEM
G/Y G/Y B/L

32
26 G/Y B/L
R/W 19 Y/W Y/W
(B)
B/W W
R/L
R/W
21
R/Y L L/Y
Y/R W L/Y L W
W 27
Br/R Y/B B/L B/L
R R L B/L
P/W L
R Br/B Br/R L/R (B)
R R Br/B O/L (B)
Br/L
5 B/G
B W/B L
R 8 10 B/R P P 29 B/L P L
Br/L
13 Sb B/L B/L
33
Br/R
Br/R (B)
R/W
B
11 W/B
30 L Y/G B/L R/W
B/Y Y/L B/L
B/L B/L
Br/R 17 L Gy W 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
66 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
R B/W
Y/R (B) (B) (Gy) Gy/G G/R L/W
R/L B
9-11
B/W B L/B
Br/R Y/R (B)
R/L
Br/L W/B
65 63
Br

Br/Y
61 Br/Y
R/W
R/W Br/R
W/B Br Br/R
38 (B)
R/W
60 Y Br/Y
R/B R Br/Y Y Br
(B) 39 33
51 L 50 B/W G/W
L 59 Br/B B/W G/W
Br (off)
R/W Y/L B/W Y
Br/Y B/W B/W Y
58 (B) B/W Y
55 G W/B G G/R O/B
64 R R R/L Br/Y
Br/B B R/L Br/Y
Y B L/Y Br/Y
W/B B 40 L/Y Br/Y
L/Y Br/Y
Y (B)
Y Y
B 41
B R/W L O/B R/W
L 49 48
Y 52 Y/L Br/Y B/W
Y G B L 42 35 Br/Y
(B) Lg
Lg B
(B)
B B B/W Br
G 43
G B Br/Y Br B
L
(Dg) 44 (B) 34
Y LL
Y Y G Y G 36 L
37
Y L
45 B
53 53 B L/B
56 56 G Y G Y 46
B B
B B
47
Y G Y G
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
EAS27230
TROUBLESHOOTING
The battery is not being charged.
TIP
1. Hood
2. Right side panel
3. Right rear panel
1. Check the fuse. NG →

(Main)
Replace the fuse.
ES” on page 9-92.
OK ↓
page 9-93.
OK ↓
3. Check the stator coil. NG →
Replace the crankshaft position sen-
Refer to “CHECKING THE STATOR
sor/stator assembly.
COIL” on page 9-101.
OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI-
Replace the rectifier/regulator.
FIER/REGULATOR” on page
9-101.
OK ↓
5. Check the entire charging system NG →
page 9-11.
OK ↓
The charging system circuit is OK.
9-13
CHARGING SYSTEM
9-14
EAS27250
EAS27240
A
B B
B
Br/Y L G/W
A 67 B L B C
L Br/Y W B
W Br/Y
(B)
Br/Y B Br/Y B
(B)
Br/R 22
B/L Gy Gy B/L
G/W O O
W W W B R Gy 23
Gy B B
CIRCUIT DIAGRAM
(Gy) (B) Br/Y R/W
R/W
W W W W
W W R (B) (B) R/W 24 R/L R
(Gy) W W R/W
(Gy) 2 3
W W (Gy)
Br/Y R/W
25 Br/W B/L
LIGHTING SYSTEM
14 Br/L R/W P/L 20

G/Y G/Y B/L
32
26 G/Y B/L
R/W 19 Y/W Y/W
(B)
B/W W
R/L
R/W
21
R/Y L L/Y
Y/R W L/Y L W
W 27
Br/R Y/B B/L B/L
R R L B/L
P/W L
R Br/B Br/R L/R (B)
R R Br/B O/L (B)
Br/L
5 B/G
B W/B L
R 8 10 B/R P P 29 B/L P L
Br/L
13 Sb B/L B/L
33
Br/R
Br/R (B)
R/W
B
11 W/B
30 L Y/G B/L R/W
B/Y Y/L B/L
B/L B/L
Br/R 17 L Gy W 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
66 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
R B/W
R/L B
9-15
B/W B L/B
Br/R Y/R (B)
R/L
Br/L W/B
65 63
Br

Br/Y
61 Br/Y
R/W
R/W Br/R
W/B Br Br/R
38 (B)
R/W
60 Y Br/Y
R/B R Br/Y Y Br
(B) 39 33
51 L 50 B/W G/W
L 59 Br/B B/W G/W
Br (off)
R/W Y/L B/W Y
Br/Y B/W B/W Y
58 (B) B/W Y
55 G W/B G G/R O/B
64 R R R/L Br/Y
Br/B B R/L Br/Y
Y B L/Y Br/Y
W/B B 40 L/Y Br/Y
L/Y Br/Y
Y (B)
Y Y
B 41
B R/W L O/B R/W
L 49 48
Y 52 Y/L Br/Y B/W
Y G B L 42 35 Br/Y
(B) Lg
Lg B
(B)
B B B/W Br
G 43
G B Br/Y Br B
L
(Dg) 44 (B) 34
Y LL
Y Y G Y G 36 L
37
Y L
45 B
53 53 B L/B
56 56 G Y G Y 46
B B
B B
47
Y G Y G
B B
B B
LIGHTING SYSTEM
LIGHTING SYSTEM

5. Frame ground
6. Main switch
8. Battery
9. Main fuse
51.Light switch
52.Headlight relay
53.Headlight
56.Tail/brake light
59.Ignition fuse
62.Headlight fuse
B. Wire harness
9-16
LIGHTING SYSTEM
EAS27260
TROUBLESHOOTING
Any of the following fail to light: headlight or taillight.
TIP
1. Cargo bed left panel
2. Cargo bed right panel
3. Hood
1. Check the condition of each bulb NG →

and bulb socket.
Refer to “CHECKING THE BULBS Replace the bulb(s) and bulb socket(s).
AND BULB SOCKETS” on page
9-90.
OK ↓
(Main, ignition, and headlight)
Replace the fuse(s).
ES” on page 9-92.
OK ↓
page 9-93.
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
EAS27270
EAS1XD2004
A
B B
B
Br/Y L G/W
A 67 B L B C
L Br/Y W B
W Br/Y
(B)
Br/Y B Br/Y B
(B)
Br/R 22
B/L Gy Gy B/L
G/W O O
W W W B R Gy 23
Gy B B 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
1 Br/R
(Gy) (B) Br/Y R/W
R/W
W W W W
W W R (B) (B) R/W 24 R/L R
(Gy) W W R/W
(Gy) 2 3
W W (Gy)
Br/Y R/W
25 Br/W B/L
14 Br/L R/W P/L 20
G/Y G/Y B/L
SIGNALING SYSTEM
32
26 G/Y B/L
R/W 19 Y/W Y/W
CIRCUIT DIAGRAM (for CDN)
(B)
B/W W
R/L
R/W
21
R/Y L L/Y
Y/R W L/Y L W
W 27
Br/R Y/B B/L B/L
R R L B/L
P/W L
R Br/B Br/R L/R (B)
R R Br/B O/L (B)
Br/L
5 B/G
B W/B L
R 8 10 B/R P P 29 B/L P L
Br/L
13 Sb B/L B/L
33
Br/R
Br/R (B)
R/W
B
11 W/B
30 L Y/G B/L R/W
B/Y Y/L B/L
B/L B/L
Br/R 17 L Gy W 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
66 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
R B/W
R/L B
9-19
B/W B L/B
Br/R Y/R (B)
R/L
Br/L W/B
65 63
Br

Br/Y
61 Br/Y
R/W
R/W Br/R
W/B Br Br/R
38 (B)
R/W
60 Y Br/Y
R/B R Br/Y Y Br
(B) 39 33
51 L 50 B/W G/W
L 59 Br/B B/W G/W
Br (off)
R/W Y/L B/W Y
Br/Y B/W B/W Y
58 (B) B/W Y
55 G W/B G G/R O/B
64 R R R/L Br/Y
Br/B B R/L Br/Y
Y B L/Y Br/Y
W/B B 40 L/Y Br/Y
L/Y Br/Y
Y (B)
Y Y
B 41
B R/W L O/B R/W
L 49 48
Y 52 Y/L Br/Y B/W
Y G B L 42 35 Br/Y
(B) Lg
Lg B
(B)
B B B/W Br
G 43
G B Br/Y Br B
L
(Dg) 44 (B) 34
Y LL
Y Y G Y G 36 L
37
Y L
45 B
53 53 B L/B
56 56 G Y G Y 46
B B
B B
47
Y G Y G
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.Reverse switch
33.Joint coupler
34.Seat belt switch
36.Helmet indicator light
37.Seat belt indicator light
39.Multi-function meter
41.Coolant temperature warning light
42.Park indicator light
43.Reverse indicator light
44.Neutral indicator light
45.High-range indicator light
46.Low-range indicator light
48.Fuel sender
56.Tail/brake light
59.Ignition fuse
60.Backup fuse
67.Backup light
68.Backup light relay
A. Optional
B. Wire harness
9-20
EAS1XD2003
A
B B
B
67 P Br/Y L G/W
OFF
A 69 B L
ON 68 B C
B Br L Br/Y W B
Br W Br/Y
(B)
Br/Y B Br/Y B
(B)
Br/R 22
B/L Gy Gy B/L
G/W O O
W W W B R Gy 23
Gy B B 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
1 Br/R
(Gy) (B) Br/Y R/W
R/W
W W W W
W W R (B) (B) R/W 24 R/L R
(Gy) W W R/W
(Gy) 2 3
W W (Gy)
Br/Y R/W
25 Br/W B/L
14 Br/L R/W P/L 20
G/Y G/Y B/L
32
26 G/Y B/L
R/W 19 Y/W Y/W
(B)
B/W W
R/L
R/W
21
R/Y L L/Y
Y/R W L/Y L W
W 27
Br/R Y/B B/L B/L
R R L B/L
P/W L
R Br/B Br/R L/R (B)
R R Br/B O/L (B)
Br/L
5 B/G
B W/B L
R 8 10 B/R P P 29 B/L P L
Br/L
13 Sb B/L B/L
33
Br/R
Br/R (B)
R/W
B
11 W/B
30 L Y/G B/L R/W
B/Y Y/L B/L
B/L B/L
Br/R 17 L Gy W L/B
R B/L L
(off)
B 16 L
(on) R/L B/L
2WD
CIRCUIT DIAGRAM (for Europe and Oceania)
(B) B/W B B/L L

(start) L W 4WD
L/W G/R L/R
Gy DIFF LOCK 31
66 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
R B/W
R/L B
9-21
B/W B L/B
Br/R Y/R (B)
R/L
Br/L W/B
65 63
Br

Br/Y
61 Br/Y
R/W
R/W Br/R
W/B Br Br/R
38 (B)
R/W
60 Y Br/Y
R/B R Br/Y Y Br
(B) 39 33
51 L 50 B/W G/W
L 59 Br/B B/W G/W
Br (off)
R/W Y/L B/W Y
Br/Y B/W B/W Y
58 (B) B/W Y
55 G W/B G G/R O/B
64 R R R/L Br/Y
Br/B B R/L Br/Y
Y B L/Y Br/Y
W/B B 40 L/Y Br/Y
L/Y Br/Y
Y (B)
Y Y
B 41
B R/W L O/B R/W
L 49 48
Y 52 Y/L Br/Y B/W
Y G B L 42 35 Br/Y
(B) Lg
Lg B
(B)
B B B/W Br
G 43
G B Br/Y Br B
L
(Dg) 44 (B) 34
Y LL
Y Y G Y G 36 L
37
Y L
45 B
53 53 B L/B
56 56 G Y G Y 46
B B
B B
47
Y G Y G
B B
B B
SIGNALING SYSTEM
SIGNALING SYSTEM

5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
27.Speed sensor
31.Parking brake switch
32.Reverse switch
33.Joint coupler
34.Seat belt switch
36.Helmet indicator light
37.Seat belt indicator light
41.Coolant temperature warning light
42.Park indicator light
43.Reverse indicator light
44.Neutral indicator light
45.High-range indicator light
46.Low-range indicator light
48.Fuel sender
56.Tail/brake light
59.Ignition fuse
60.Backup fuse
67.Horn switch
68.Horn
69.Backup light
70.Backup light relay
A. Optional
B. Wire harness
9-22
SIGNALING SYSTEM
EAS27290
TROUBLESHOOTING
• Any of the following fail to light: warning light, brake light or an indicator light.
• The horn fails to sound. (For Europe and Oceania)
• The fuel meter fails to come on.
• The speedometer fails to operate.
TIP
1. Hood
2. Cargo bed left panel
3. Cargo bed right panel
4. Right/center passenger seat frame
5. Right/center passenger compartment panel
6. Right side panel
7. Right rear panel
8. Fuel tank
10.Sun top
11.Side frames
12.Front fender

(Main, ignition, signaling system,
and backup) Replace the fuse(s).
ES” on page 9-92.
OK ↓
page 9-93.
OK ↓
OK ↓
OK ↓
9-23
SIGNALING SYSTEM
5. Check the entire signaling system NG →

wiring.
Refer to “CIRCUIT DIAGRAM (for Properly connect or replace the wire har-
CDN)” on page 9-19 and “CIRCUIT ness.
DIAGRAM (for Europe and Ocean-
ia)” on page 9-21.
OK ↓
Check the condition of each of the sig-
naling system circuits. Refer to
“Checking the signaling system”.
Checking the signaling system

The tail/brake lights fail to come on.
1. Check the tail/brake light bulbs and NG →
sockets.
Replace the tail/brake light bulb, socket or
Refer to “CHECKING THE BULBS
both.
AND BULB SOCKETS” on page
9-90.
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 ↓
9-24
SIGNALING SYSTEM

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 ↓
wiring.
OK ↓
The park 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 9-103.
OK ↓
9-25
SIGNALING SYSTEM

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 9-101.
OK ↓
wiring.
OK ↓
Replace the meter assembly.
The speedometer fails to come on.

1. Check the speed sensor. NG →
Refer to “ELECTRICAL COMPO- Replace the speed sensor.
NENTS” on page 9-81.
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 ↓
9-26
SIGNALING SYSTEM

wiring.
OK ↓
Replace the indicator light assembly or
ECU.
The horn fails to sound (for Europe and Oceania).

1. Check the horn switch. NG →
Refer to “CHECKING THE Replace the horn switch.
OK ↓
wiring.
Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM (for
ness.
Europe and Oceania)” on page
9-21.
OK ↓
Replace the horn.
9-27
SIGNALING SYSTEM
9-28
EAS27310
EAS27300
A
B B
B
Br/Y L G/W
A 67 B L B C
L Br/Y W B
W Br/Y
(B)
Br/Y B Br/Y B
(B)
Br/R 22
B/L Gy Gy B/L
G/W O O
W W W B R Gy 23
Gy B B
CIRCUIT DIAGRAM
(Gy) (B) Br/Y R/W
R/W
W W W W
W W R (B) (B) R/W 24 R/L R
(Gy) W W R/W
(Gy) 2 3
W W (Gy)
Br/Y R/W
COOLING SYSTEM
25 Br/W B/L
14 Br/L R/W P/L 20
G/Y G/Y B/L
32
26 G/Y B/L
R/W 19 Y/W Y/W
(B)
B/W W
R/L
R/W
21
R/Y L L/Y
Y/R W L/Y L W
W 27
Br/R Y/B B/L B/L
R R L B/L
P/W L
R Br/B Br/R L/R (B)
R R Br/B O/L (B)
Br/L
5 B/G
B W/B L
R 8 10 B/R P P 29 B/L P L
Br/L
13 Sb B/L B/L
33
Br/R
Br/R (B)
R/W
B
11 W/B
30 L Y/G B/L R/W
B/Y Y/L B/L
B/L B/L
Br/R 17 L Gy W 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
66 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
R B/W
R/L B
9-29
B/W B L/B
Br/R Y/R (B)
R/L
Br/L W/B
65 63
Br

Br/Y
61 Br/Y
R/W
R/W Br/R
W/B Br Br/R
38 (B)
R/W
60 Y Br/Y
R/B R Br/Y Y Br
(B) 39 33
51 L 50 B/W G/W
L 59 Br/B B/W G/W
Br (off)
R/W Y/L B/W Y
Br/Y B/W B/W Y
58 (B) B/W Y
55 G W/B G G/R O/B
64 R R R/L Br/Y
Br/B B R/L Br/Y
Y B L/Y Br/Y
W/B B 40 L/Y Br/Y
L/Y Br/Y
Y (B)
Y Y
B 41
B R/W L O/B R/W
L 49 48
Y 52 Y/L Br/Y B/W
Y G B L 42 35 Br/Y
(B) Lg
Lg B
(B)
B B B/W Br
G 43
G B Br/Y Br B
L
(Dg) 44 (B) 34
Y LL
Y Y G Y G 36 L
37
Y L
45 B
53 53 B L/B
56 56 G Y G Y 46
B B
B B
47
Y G Y G
B B
B B
COOLING SYSTEM
COOLING SYSTEM
5. Frame ground
6. Main switch
8. Battery
9. Main fuse
33.Joint coupler
57.Radiator fan motor fuse
59.Ignition fuse
64.Radiator fan motor
65.Radiator fan motor circuit breaker
66.Radiator fan motor relay
B. Wire harness
9-30
COOLING SYSTEM
EAS27320
TROUBLESHOOTING
The radiator fan motor fails to turn.
TIP
1. Hood
2. Front skid plate
3. Frame cross member

(Main, ignition, and radiator fan mo-
tor) Replace the fuse(s).
ES” on page 9-92.
OK ↓
page 9-93.
OK ↓
OK ↓
4. Check the radiator fan motor. NG →
Refer to “CHECKING THE RADIA- Replace the radiator fan motor.
TOR FAN MOTOR” on page 9-103.
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 9-103.
OK ↓
7. Check the coolant temperature sen- NG →
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 9-103.
OK ↓
9-31
COOLING SYSTEM
8. Check the entire cooling system NG →

page 9-29.
OK ↓
Replace the ECU.
9-32
EAS27340
EAS27330
A
B B
B
Br/Y L G/W
A 67 B L B C
L Br/Y W B
W Br/Y
(B)
Br/Y B Br/Y B
(B)
Br/R 22
B/L Gy Gy B/L
G/W O O
W W W B R Gy 23
Gy B B
CIRCUIT DIAGRAM
(Gy) (B) Br/Y R/W
R/W
W W W W
W W R (B) (B) R/W 24 R/L R
(Gy) W W R/W
(Gy) 2 3
W W (Gy)
Br/Y R/W
25 Br/W B/L
14 Br/L R/W P/L 20
G/Y G/Y B/L
32
26 G/Y B/L
R/W 19 Y/W Y/W
(B)
B/W W
R/L
R/W
21
R/Y L L/Y
Y/R W L/Y L W
W 27
Br/R Y/B B/L B/L
R R L B/L
R
FUEL INJECTION SYSTEM
9 L/R B/L B/L B/L B/L B/L B/L B/L B/L

P/W L
R Br/B Br/R L/R (B)
R R Br/B O/L (B)
Br/L
5 B/G
B W/B L
R 8 10 B/R P P 29 B/L P L
Br/L
13 Sb B/L B/L
33
Br/R
Br/R (B)
R/W
B
11 W/B
30 L Y/G B/L R/W
B/Y Y/L B/L
B/L B/L
Br/R 17 L Gy W 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
66 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
R B/W
R/L B
9-33
B/W B L/B
Br/R Y/R (B)
R/L
Br/L W/B
65 63
Br

Br/Y
61 Br/Y
R/W
R/W Br/R
W/B Br Br/R
38 (B)
R/W
60 Y Br/Y
R/B R Br/Y Y Br
(B) 39 33
51 L 50 B/W G/W
L 59 Br/B B/W G/W
Br (off)
R/W Y/L B/W Y
Br/Y B/W B/W Y
58 (B) B/W Y
55 G W/B G G/R O/B
64 R R R/L Br/Y
Br/B B R/L Br/Y
Y B L/Y Br/Y
W/B B 40 L/Y Br/Y
L/Y Br/Y
Y (B)
Y Y
B 41
B R/W L O/B R/W
L 49 48
Y 52 Y/L Br/Y B/W
Y G B L 42 35 Br/Y
(B) Lg
Lg B
(B)
B B B/W Br
G 43
G B Br/Y Br B
L
(Dg) 44 (B) 34
Y LL
Y Y G Y G 36 L
37
Y L
45 B
53 53 B L/B
56 56 G Y G Y 46
B B
B B
47
Y G Y G
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
30.Lean angle sensor
33.Joint coupler
40.Engine trouble warning light
49.Fuel pump
59.Ignition fuse
60.Backup fuse
66.Radiator fan motor relay
B. Wire harness
9-34
EAS27350
ECU SELF-DIAGNOSTIC FUNCTION

The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is
operating normally. If this function detects a malfunction in the system, it immediately operates the 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 indica- Fuel injection opera-
ECU operation Vehicle operation
tion tion
Warning provided
Flashing* when unable to start Operation stopped Cannot be operated
engine
Operated with substi-
tute characteristics in Can or cannot be oper-
Remains on Malfunction detected accordance with the ated depending on the
description of the mal- fault code
function
* The warning light flashes when any one of the conditions listed below is present and the main switch
is turned to “ (on)”:
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.
9-35
EAS27400
5. Erase the malfunction history in the diagnos-
TROUBLESHOOTING METHOD
tic mode (code No. 62). Refer to “SELF-DI-
AGNOSTIC FUNCTION AND DIAGNOSTIC
The engine operation is not normal and the
CODE TABLE” on page 10-5.
engine trouble warning light comes on.
1. Check: TIP
• Fault code number Turning the main switch to “ ” (off) will not
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ erase the malfunction history.
a. Check the fault code number displayed on
the multi-function meter.
The engine operation is not normal, but the
b. Identify the faulty system with the fault code.
engine trouble warning light does not come
c. Identify the probable cause of the malfunc-
on.
tion.
1. Check the operation of the following sensors
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
and actuators in the diagnostic mode.
2. Check and repair the probable cause of mal- Refer to “TROUBLESHOOTING DETAILS
function. (FUEL INJECTION SYSTEM)” on page 9-38
Fault code No. No fault code No. and “SELF-DIAGNOSTIC FUNCTION AND
DIAGNOSTIC CODE TABLE” on page 10-5.
Check and repair. Check and repair.
Refer to “TROUBLE- 01: Throttle position sensor signal (throttle
SHOOTING DETAILS angle)
(FUEL INJECTION 30: Ignition coil
SYSTEM)” on page 36: Injector
9-38. 48: Air induction system solenoid
Monitor the opera-
tion of the sensors If a malfunction is detected in the sensors or
and actuators in the actuators, repair or replace all faulty parts.
diagnostic mode. If no malfunction is detected in the sensors
Refer to “TROUBLE- and actuators, check and repair inner parts of
SHOOTING DETAILS the engine.
(FUEL INJECTION
SYSTEM)” on page
9-38 and “SELF-DI-
AGNOSTIC FUNC-
TION AND
DIAGNOSTIC CODE
TABLE” on page
10-5.
3. Perform the reinstatement action for the fuel

injection system.
Refer to “Confirmation of service completion”
of table in “TROUBLESHOOTING DETAILS
(FUEL INJECTION SYSTEM)” on page 9-38.
4. Turn the main switch to “ ” (off) and back to
“ ” (on), then check that no fault code num-
ber is displayed.
TIP
If another fault code are displayed, repeat steps
(1) to (4) until no fault code number is displayed.
9-36
EAS1XD1003
YAMAHA DIAGNOSTIC TOOL

This model uses the Yamaha diagnostic tool to identify malfunctions.
For information about using the Yamaha diagnostic tool, refer to the operation manual that is
included with the tool.
Yamaha diagnostic tool

90890-03215
Features of the Yamaha diagnostic tool

You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional
methods.
By connecting the adapter interface, which is connected to the USB port of a computer, to a vehicle’s
ECU using the communication cable, you can display information that is necessary for identifying 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
displayed.
Function diagnostic mode: Check the operation of the output value of each sensor and actu-
ator.
Inspection mode: Determine whether each sensor or actuator is functioning prop-
erly.
Monitoring mode: Displays a graph of sensor output values for actual operating
conditions.
Logging mode: Records and saves the sensor output value in actual driving con-
ditions.
View log: Displays the logging data.
ECU rewrite: If necessary, the ECU is rewritten using ECU rewrite data provid-
ed by Yamaha.
Ignition timing adjustment, etc. cannot be changed from the vehi-
cle’s original state.
However, the diagnostic tool cannot be used to freely change the basic vehicle functions, such as
adjusting the ignition timing.
Connecting the Yamaha diagnostic tool
Remove the protective cap, and then connect the Yamaha diagnostic tool to the coupler “1”.
TIP
When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter
and indicators will be different from the normal operation.
9-37
EAS1XD1032
TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM)

This section describes the measures per fault code number displayed on the multi-function meter 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
meter display according to the “Confirmation of service completion”.
Fault code No.:
Fault code number displayed on the multi-function meter when the engine failed to work normally.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “SELF-DIAGNOS-
TIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 10-5.
Fault code No. 12
Crankshaft position sensor: no normal signals are received
Item
from the crankshaft position sensor.
Unable to start engine
Fail-safe system
Unable to drive vehicle
Diagnostic code No. —
Indicated —
Procedure —
Probable cause of mal- Confirmation of service
Item Maintenance job
function and check completion
1 Connection of crankshaft po- Improperly connected → Crank the engine.
sition sensor coupler. Connect the coupler secure- Fault code number is not dis-
Check the locking condition ly or replace the wire har- played → Service is finished.
of the coupler. ness. Fault code number is dis-
Disconnect the coupler and played → Go to item 2.
check the pins (bent or bro-
ken terminals and locking
condition of the pins).
2 Connection of ECU coupler. Improperly connected → Crank the engine.
Check the locking condition Connect the coupler secure- Fault code number is not dis-
of the coupler. ly or replace the wire har- played → Service is finished.
Disconnect the coupler and ness. Fault code number is dis-
check the pins (bent or bro- played → Go to item 3.
3 Wire harness continuity. Open or short circuit → Re- Crank the engine.
place the wire harness. Fault code number is not dis-
Between crankshaft position played → Service is finished.
sensor coupler and ECU Fault code number is dis-
coupler. played → 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.
9-38
Fault code No. 12

Crankshaft position sensor: no normal signals are received
Item
from the crankshaft position sensor.
4 Installed condition of crank- Improperly installed sensor Crank the engine.
shaft position sensor. → Reinstall or replace the Fault code number is not dis-
Check for looseness or sensor. played → Service is finished.
pinching. Fault code number is dis-
played → Go to item 5.
5 Defective crankshaft posi- Check the crankshaft posi- Crank the engine.
tion sensor. tion sensor. Fault code number is not dis-
Refer to “CHECKING THE played → Service is finished.
CRANKSHAFT POSITION Fault code number is dis-
SENSOR” on page 9-99. played → Go to item 6.
Replace if defective.
6 Malfunction in ECU. Replace the ECU.
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
Procedure press the accelerator pedal. (If the display value changes, the per-
formance is OK.)
1 Connection of intake air Improperly connected → Turn the main switch to “ ”
pressure sensor coupler. Connect the coupler secure- (on).
Check the locking condition ly or replace the wire har- Fault code number is not dis-
of the coupler. ness. played → Service is finished.
Disconnect the coupler and Fault code number is dis-
2 Connection of ECU coupler. Improperly connected → Turn the main switch to “ ”
Check the locking condition Connect the coupler secure- (on).
of the coupler. ly or replace the wire har- Fault code number is not dis-
Disconnect the coupler and ness. played → Service is finished.
check the pins (bent or bro- Fault code number is dis-
ken terminals and locking played → Go to item 3.
9-39
Fault code No. 13

Item Intake air pressure sensor: open or short circuit detected.
3 Wire harness continuity. Open or short circuit → Re- Turn the main switch to “ ”
place the wire harness. (on).
Between intake air pressure Fault code number is not dis-
sensor coupler and ECU played → Service is finished.
coupler. Fault code number is dis-
pink–pink played → Go to item 4.
Between intake air pressure
pler.
blue–blue
ECU coupler.
blue–blue
4 Installed condition of intake Improperly installed sensor Turn the main switch to “ ”
air pressure sensor. → Reinstall or replace the (on).
Check for looseness or sensor. Fault code number is not dis-
pinching. played → Service is finished.
Fault code number is dis-
5 Defective intake air pressure Execute the diagnostic Turn the main switch to “ ”
sensor. mode. (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 dis-
conditions is indicated. played → Go to item 6.
At sea level: Approx. 101 kPa
(757.6 mmHg, 29.8 inHg)
1000 m (3300 ft) above sea
level: Approx. 90 kPa (675.1
mmHg, 26.6 inHg)
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
INTAKE AIR PRESSURE
SENSOR” on page 9-105.
9-40
TIP
If fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number
“13” first.
Fault code No. 14

Intake air pressure sensor: hose system malfunction (clogged
Item
or detached hose).
Fail-safe system
Indicated Displays the intake air pressure.
Turn and hold the main switch in the “ ” (start) position, then
Procedure press the accelerator pedal. (If the display value changes, the per-
formance is OK.)
1 Condition of intake air pres- Clogged or detached hose Start the engine and let it idle
sure sensor hose. → Repair or replace the sen- for approximately 5 seconds.
Check the intake air pressure sor hose. Fault code number is not dis-
sensor hose condition. played → Service is finished.
2 Defective intake air pressure Execute the diagnostic
sensor. mode. (Code No. 03)
When engine is stopped:
Atmospheric pressure at the
current altitude and weather
conditions is indicated.
At sea level: Approx. 101 kPa
(757.6 mmHg, 29.8 inHg)
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.
INTAKE AIR PRESSURE
9-41
TIP
“13” 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 posi- Improperly connected → Turn the main switch to “ ”
tion sensor coupler. Connect the coupler secure- (on).
Between throttle position Fault code number is not dis-
sensor coupler and ECU played → Service is finished.
yellow–yellow played → Go to item 4.
Between throttle position
pler.
blue–blue
ECU coupler.
blue–blue
4 Installed condition of throttle Improperly installed sensor Turn the main switch to “ ”
position sensor. → Reinstall or adjust the (on).
pinching. Refer to “ADJUSTING THE played → Service is finished.
THROTTLE POSITION Fault code number is dis-
SENSOR” on page 7-12. played → Go to item 5.
9-42
Fault code No. 15

Item Throttle position sensor: open or short circuit detected.
5 Throttle position sensor re- Measure the throttle position Turn the main switch to “ ”
sistance. sensor resistance. (on).
Refer to “CHECKING THE Fault code number is not dis-
THROTTLE POSITION played → Service is finished.
SENSOR” on page 9-104. Fault code number is dis-
6 Defective throttle position Check throttle position sen- Turn the main switch to “ ”
sensor. sor signal. (on).
Execute the diagnostic Fault code number is not dis-
mode. (Code No. 01) played → Service is finished.
When the throttle valve is ful- Fault code number is dis-
ly closed: played → Go to item 7.
A value of 14–20 is indicat-
ed.
An indicated value is out of
the specified range → Re-
place the throttle position
sensor.
TIP
“15” first.
Fault code No. 16

Throttle position sensor: stuck throttle position sensor is de-
Item
tected.
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 Improperly installed sensor Turn the main switch to “ ”
position sensor. → Reinstall or adjust the (on), then press the acceler-
Check for looseness or sensor. ator pedal.
pinching. Refer to “ADJUSTING THE Fault code number is not dis-
THROTTLE POSITION played → Service is finished.
SENSOR” on page 7-12. Fault code number is dis-
9-43
Fault code No. 16

Throttle position sensor: stuck throttle position sensor is de-
Item
tected.
2 Defective throttle position Check throttle position sen- Turn the main switch to “ ”
sensor. sor signal. (on), then operate the throt-
Execute the diagnostic tle.
mode. (Code No. 01) Fault code number is not dis-
When the throttle valve is ful- played → Service is finished.
ly closed: Fault code number is dis-
A value of 14–20 is indicat- played → Go to item 3.
ed.
An indicated value is out of
the specified range → Re-
place the throttle position
sensor.
TIP
• If fault code numbers “15” and “16” are both indicated, take the actions specified for fault code number
“15” first.
“16” first.
Fault code No. 21

Item Coolant temperature sensor: open or short circuit detected.
Fail-safe system
Indicated Displays the coolant temperature.
Compare the actually measured coolant temperature with the
Procedure
meter display value.
1 Connection of coolant tem- Improperly connected → Turn the main switch to “ ”
perature sensor coupler. Connect the coupler secure- (on).
9-44
Fault code No. 21

Item Coolant temperature sensor: open or short circuit detected.
Between coolant tempera- Fault code number is not dis-
ture sensor coupler and ECU played → Service is finished.
green/yellow–green/yellow played → Go to item 4.
Between coolant tempera-
ture sensor coupler and joint
coupler.
ECU coupler.
4 Installed condition of coolant Improperly installed sensor Turn the main switch to “ ”
temperature sensor. → Reinstall or replace the (on).
5 Defective coolant tempera- Execute the diagnostic Turn the main switch to “ ”
ture sensor. mode. (Code No. 06) (on).
When engine is cold: Fault code number is not dis-
Displayed temperature is played → Service is finished.
close to the ambient temper- Fault code number is dis-
ature. played → Go to item 6.
The displayed temperature is
not close to the ambient tem-
perature → Check the cool-
ant temperature sensor.
COOLANT TEMPERATURE
TIP
“21” first.
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 in-
Procedure
dicated value.
9-45
Fault code No. 22

Item Intake air temperature sensor: open or short circuit detected.
1 Connection of intake air tem- Improperly connected → Turn the main switch to “ ”
perature sensor coupler. Connect the coupler secure- (on).
Between intake air tempera- Fault code number is not dis-
ture sensor coupler and ECU played → Service is finished.
brown/white–brown/white played → Go to item 4.
Between intake air tempera-
ture sensor coupler and joint
coupler.
ECU coupler.
4 Installed condition of intake Improperly installed sensor Turn the main switch to “ ”
air temperature sensor. → Reinstall or replace the (on).
5 Defective intake air tempera- Execute the diagnostic Turn the main switch to “ ”
ture sensor. mode. (Code No. 05) (on).
When engine is cold: Fault code number is not dis-
Displayed temperature is played → Service is finished.
close to the ambient temper- Fault code number is dis-
ature. played → Go to item 6.
The displayed temperature is
not close to the ambient tem-
perature. → Check the intake
air temperature sensor.
INTAKE AIR TEMPERA-
TURE SENSOR” on page
9-105.
9-46
TIP
“22” first.
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)
Remove the lean angle sensor and incline it more than 65 de-
Procedure
grees.
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.
2 Installed condition of lean Check the installed direction Turn the main switch to “ ”
angle sensor. and condition of the sensor. (on), then to “ ” (off), and
then back to “ ” (on).
3 Defective lean angle sensor. Execute the diagnostic Turn the main switch to “ ”
mode. (Code No. 08) (on) then to “ ” (off), and
An indicated value is out of then back to “ ” (on).
the specified range → Check Fault code number is not dis-
the lean angle sensor. played → Service is finished.
Replace if defective. Fault code number is dis-
Refer to “CHECKING THE played → Go to item 4.
LEAN ANGLE SENSOR” on
page 9-100.
Fault code No. 33

Ignition coil: open or short circuit detected in the primary lead
Item
of the ignition coil.
Fail-safe system
9-47
Fault code No. 33

Ignition coil: open or short circuit detected in the primary lead
Item
of the ignition coil.
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 Improperly connected → Start the engine and let it idle
connector. Connect the connector se- for approximately 5 seconds.
Check the locking condition curely or replace the wire Fault code number is not dis-
of the connector. harness. played → Service is finished.
Disconnect the connector Fault code number is dis-
and check the pins (bent or played → Go to item 2.
broken terminals and lock-
ing condition of the pins).
2 Connection of ECU coupler. Improperly connected → Start the engine and let it idle
Check the locking condition Connect the coupler secure- for approximately 5 seconds.
3 Wire harness continuity. Open or short circuit → Re- Start the engine and let it idle
place the wire harness. for approximately 5 seconds.
Between ignition coil connec- Fault code number is not dis-
tor and ECU coupler. played → Service is finished.
orange–orange Fault code number is dis-
4 Installed condition of ignition Improperly installed ignition Start the engine and let it idle
coil. coil → Reinstall or replace for approximately 5 seconds.
Check for looseness or the ignition coil. Fault code number is not dis-
5 Defective ignition coil. Measure the primary coil re- Start the engine and let it idle
sistance of the ignition coil. for approximately 5 seconds.
Replace if out of specifica- Fault code number is not dis-
tion. played → Service is finished.
Refer to “CHECKING THE Fault code number is dis-
IGNITION COIL” on page played → Go to item 6.
9-98.
6 Malfunction in ECU. Execute the diagnostic
mode. (Code No. 30)
No spark → Replace the
ECU.
9-48
Fault code No. 37

Component other than ISC (idle speed control) unit is de-
A
fective (ISC operating sound is heard).
Item
Defective ISC (idle speed control) unit (ISC operating sound is
B
not heard).
Fail-safe system
Actuates and fully closes the ISC valve, then opens it to the stand-
by opening position when the engine is started.
This operation takes approximately 3 seconds until it is compleat-
Actuation
ed.
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.
1 Locate the malfunction. Execute the diagnostic ISC operating sound is heard
mode. (Code No. 54) → Go to item 2.
Fully closes the ISC (idle ISC operating sound is not
speed control) valve, and heard → Go to item 2 in sec-
then fully opens the valve. tion B for the defective ISC
(idle speed control) unit.
2 Incorrect speed sensor sig- Check the speed sensor. Start the engine and let it idle
nal. Execute the diagnostic for approximately 10 sec-
mode. (Code No. 07) onds.
Rotate the rear wheel by Fault code number is not dis-
hand and check that the indi- played → Service is finished.
cated value increases. Fault code number is dis-
Value does not increase → played → Go to item 3.
Go to fault code No. 42.
3 Throttle valve does not fully Check the throttle body. Start the engine and let it idle
close. Refer to “THROTTLE BODY” for approximately 10 sec-
on page 7-8. onds.
Check the throttle cable. Fault code number is not dis-
Refer to “ADJUSTING THE played → Service is finished.
ACCELERATOR PEDAL Fault code number is dis-
FREE PLAY” on page 3-21. played → Go to item 4.
4 ISC valve is not moving cor- Replace the throttle body as- Start the engine and let it idle
rectly. sembly. for approximately 10 sec-
onds.
9-49
TIP
• Do not remove the ISC (idle speed control) valve.
“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
B
sound is not heard).
Fail-safe system
Actuates and fully closes the ISC valve, then opens it to the stand-
by opening position when the engine is started.
Actuation This operation takes approximately 3 seconds until it is completed.
screen come on during the operation.
Procedure The operating sound can be heard when ISC valve operates.
1 Locate the malfunction. Execute the diagnostic ISC operating sound is heard
mode. (Code No. 54) → Go to item 2 in section A
Fully closes the ISC (idle for the component other than
speed control) valve, and ISC (idle speed control) unit
then fully opens the valve. is defective.
ISC operating sound is not
heard → Go to item 2.
2 Connection of ISC (idle Improperly connected → Execute the diagnostic
speed control) unit coupler. Connect the coupler secure- mode. (Code No. 54)
Check the locking condition ly or replace the wire har- ISC operating sound is heard
of the coupler. ness. → Go to item 8.
Disconnect the coupler and ISC operating sound is not
check the pins (bent or bro- heard → Go to item 3.
3 Connection of ECU coupler. Improperly connected → Execute the diagnostic
Check the locking condition Connect the coupler secure- mode. (Code No. 54)
of the coupler. ly or replace the wire har- ISC operating sound is heard
Disconnect the coupler and ness. → Go to item 8.
check the pins (bent or bro- ISC operating sound is not
ken terminals and locking heard → Go to item 4.
9-50
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
B
sound is not heard).
4 Wire harness continuity. Open or short circuit → Re- Execute the diagnostic
place the wire harness. mode. (Code No. 54)
Between ISC (idle speed ISC operating sound is heard
control) unit coupler and → Go to item 8.
ECU coupler. ISC operating sound is not
red/green–red/green heard → Go to item 5.
pink/blue–pink/blue
white/green–white/green
brown/blue–brown/blue
Between ISC (idle speed
control) unit coupler and joint
coupler.
red/white–red/white
5 Installed condition of ISC Improperly installed ISC (idle Execute the diagnostic
(idle speed control) unit. speed control) unit → Rein- mode. (Code No. 54)
Check for looseness or stall the ISC (idle speed con- ISC operating sound is heard
pinching. trol) unit. → Go to item 8.
6 ISC valve is not moving cor- Replace the throttle body as- Execute the diagnostic
rectly. sembly. mode. (Code No. 54)
ISC operating sound is heard
→ Go to item 8.
8 Delete the fault code. Start the engine and let it idle
for approximately 10 sec-
onds.
Check that the fault code
number is not displayed.
TIP
• Do not remove the ISC (idle speed control) valve.
“21” first.
“22” first.
“46” first.
“42” first.
9-51
Fault code No. 39

Item Injector: open or short circuit detected.
Fail-safe system
Actuates 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.
Check that injector is actuated five times by listening for the oper-
Procedure
ating sound.
1 Connection of injector cou- Improperly connected → Execute the diagnostic
pler. Connect the coupler secure- mode. (Code No. 36)
Check the locking condition ly or replace the wire har- Operating sound → Go to
of the coupler. ness. item 6.
Disconnect the coupler and No operating sound → Go to
check the pins (bent or bro- item 2.
2 Defective injector. Measure the injector resis- Execute the diagnostic
tance. mode. (Code No. 36)
Replace if out of specifica- Operating sound → Go to
tion. item 6.
Refer to “CHECKING THE No operating sound → Go to
FUEL INJECTOR” on page item 3.
9-106.
3 Connection of ECU coupler. Improperly connected → Execute the diagnostic
Check the locking condition Connect the coupler secure- mode. (Code No. 36)
of the coupler. ly or replace the wire har- Operating sound → Go to
Disconnect the coupler and ness. item 6.
check the pins (bent or bro- No operating sound → Go to
ken terminals and locking item 4.
4 Wire harness continuity. Open or short circuit → Re- Execute the diagnostic
place the wire harness. mode. (Code No. 36)
Between injector coupler and Operating sound → Go to
ECU coupler. item 6.
red–red No operating sound → Go to
Between injector coupler and item 5.
joint coupler.
red/blue–red/blue
6 Delete the fault code. Start the engine and let it idle
for approximately 5 seconds.
9-52
Fault code No. 41

Item Lean angle sensor: open or short circuit detected.
Fail-safe system
Indicated • 3.6–4.4 (upright)
• 0.7–1.3 (overturned)
Remove the lean angle sensor and incline it more than 65 de-
Procedure
grees.
1 Connection of lean angle Improperly connected → Turn the main switch to “ ”
sensor coupler. Connect the coupler secure- (on), then to “ ” (off), and
Check the locking condition ly or replace the wire har- then back to “ ” (on).
of the coupler. ness. Fault code number is not dis-
Disconnect the coupler and played → Service is finished.
Check the locking condition Connect the coupler secure- (on), then to “ ” (off), and
of the coupler. ly or replace the wire har- then back to “ ” (on).
Disconnect the coupler and ness. Fault code number is not dis-
check the pins (bent or bro- played → Service is finished.
ken terminals and locking Fault code number is dis-
condition of the pins). played → Go to item 3.
place the wire harness. (on), then to “ ” (off), and
Between lean angle sensor then 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 dis-
coupler and joint coupler. played → Go to item 4.
blue–blue
ECU coupler.
blue–blue
4 Defective lean angle sensor. Execute the diagnostic Turn the main switch to “ ”
mode. (Code No. 08) (on), then to “ ” (off), and
An indicated value is out of then back to “ ” (on).
the specified range → Check Fault code number is not dis-
the lean angle sensor. played → Service is finished.
Replace if defective. Fault code number is dis-
Refer to “CHECKING THE played → Go to item 5.
LEAN ANGLE SENSOR” on
page 9-100.
9-53
Fault code No. 42

Speed sensor: no normal signals are received from the speed
Item
sensor.
Fail-safe system
Vehicle speed pulse
Indicated
0–999
Check that the number increases when the rear wheels are rotat-
Procedure ed. The number is cumulative and does not reset each time the
wheel is stopped.
1 Connection of speed sensor Improperly connected → Turn the main switch to “ ”
coupler. Connect the coupler secure- (on), and then rotate the rear
Check the locking condition ly or replace the wire har- wheel by hand.
of the coupler. ness. Fault code number is not dis-
Disconnect the coupler and played → Go to item 6.
Check the locking condition Connect the coupler secure- (on), and then rotate the rear
of the coupler. ly or replace the wire har- wheel by hand.
Disconnect the coupler and ness. Fault code number is not dis-
ken terminals and locking Fault code number is dis-
condition of the pins). played → Go to item 3.
place the wire harness. (on), and then rotate the rear
Between speed sensor cou- wheel by hand.
pler and ECU coupler. Fault code number is not dis-
white–white played → Go to item 6.
Between speed sensor cou- Fault code number is dis-
pler and joint coupler. played → Go to item 4.
blue–blue
ECU coupler.
blue–blue
4 Defective speed sensor. Execute the diagnostic Turn the main switch to “ ”
mode. (Code No. 07) (on), and then rotate the rear
While the rear wheels and wheel by hand.
stopped, check that the indi- Fault code number is not dis-
cated value does not played → Go to item 6.
change. Fault code number is dis-
Rotate the rear wheel by played → Go to item 5.
hand and check that the indi-
cated value increases.
Malfunction → Replace the
speed sensor.
9-54
Fault code No. 42

Speed sensor: no normal signals are received from the speed
Item
sensor.
6 Delete the fault code. Start the engine, and input
the vehicle speed signals by
operating the vehicle at 20 to
30 km/h (12 to 19 mph).
TIP
“42” first.
Fault code No. 43

Fuel system voltage: incorrect voltage supplied to the fuel in-
Item
jector 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
Procedure measured battery voltage with the display value. (If the actually
measured battery voltage is low, recharge the battery.)
Actuates the fuel injection system relay five times at one-second
intervals.
screen come on each time the relay is actuated.
Actuation
(When the relay is on, the “CHECK” indicator and “ ” on the
50 Yamaha diagnostic tool screen go off. When the relay is off, the
“CHECK” indicator and “ ” on the Yamaha diagnostic tool
screen come on.)
Check that the fuel injection system relay is actuated five times by
Procedure
listening for the operating sound.
1 Connection of fuel injection Improperly connected → Start the engine and let it idle
system relay coupler. Connect the coupler secure- for approximately 5 seconds.
9-55
Fault code No. 43

Fuel system voltage: incorrect voltage supplied to the fuel in-
Item
jector and fuel pump.
2 Connection of ECU coupler. Improperly connected → Start the engine and let it idle
Check the locking condition Connect the coupler secure- for approximately 5 seconds.
3 Wire harness continuity. Open or short circuit → Re- Start the engine and let it idle
place the wire harness. for approximately 5 seconds.
Between fuel injection sys- Fault code number is not dis-
tem relay coupler and ECU played → Service is finished.
blue/red–blue/red played → Go to item 4.
Between fuel injection sys-
tem relay coupler and joint
coupler.
red/blue–red/blue
ECU coupler.
red/blue–red/blue
Between ECU coupler and
joint coupler.
backup fuse.
Between main switch coupler
and ECU coupler.
brown/red–brown/red
4 Defective fuel injection sys- Execute the diagnostic Start the engine and let it idle
tem relay. mode. (Code No. 50) for approximately 5 seconds.
No operating sound → Re- Fault code number is not dis-
place the fuel injection sys- played → Service is finished.
tem relay. Fault code number is dis-
5 Defective fuel injection sys- Execute the diagnostic Start the engine and let it idle
tem relay. mode. (Code No. 09) for approximately 5 seconds.
Fuel system voltage is be- Fault code number is not dis-
low 3 V → Replace the fuel played → Service is finished.
injection system relay. Fault code number is dis-
Fault code No. 44

EEPROM fault code number: an error is detected while reading
Item
or writing on EEPROM.
Fail-safe system
9-56
Fault code No. 44

EEPROM fault code number: an error is detected while reading
Item
or writing on EEPROM.
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
2 “01” is indicated in diagnostic Change the CO concentra- Turn the main switch to “ ”
mode (code No. 60). EE- tion, and rewrite in EE- (on).
PROM data error for adjust- PROM. Fault code number is not dis-
ment of CO concentration. Refer to “ADJUSTING THE played → Service is finished.
EXHAUST GAS VOLUME Fault code number is dis-
(for Europe and Oceania)” played → Repeat item 1. If
on page 3-6. the same number is indicat-
After this adjustment is ed, go to item 3.
made, the memory is not re-
covered when the main
switch is turned to “ ” (off).
Fault code No. 46

Item Charging voltage is abnormal.
Fail-safe system
Indicated —
Procedure —
1 Malfunction in charging sys- Check the charging system. Start the engine and let it idle
tem. Refer to “CHARGING SYS- for approximately 5 seconds.
TEM” on page 9-11. Fault code number is not dis-
Defective rectifier/regulator played → Service is finished.
or AC magneto → Replace. Fault code number is dis-
Defective connection in the played → Repeat the mainte-
charging system circuit → nance job.
Properly connect or replace
the wire harness.
TIP
“46” first.
9-57
Fault code No. 50

Faulty ECU (engine control unit) memory. (When this malfunc-
Item tion is detected in the ECU, the fault code number might not
appear.)
Fail-safe system
Indicated —
Procedure —
1 Malfunction in ECU. Replace the ECU. Turn the main switch to “ ”
(on).
Fault code No. Er-1

ECU (engine control unit) internal malfunction (output signal
Item error): signals cannot be transmitted between the ECU and the
multi-function 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 assem- Improperly connected → Turn the main switch to “ ”
bly coupler. Connect the coupler secure- (on).
Between meter assembly Fault code number is not dis-
coupler and ECU coupler. played → Service is finished.
yellow/blue–yellow/blue Fault code number is dis-
9-58
Fault code No. Er-1

Item error): signals cannot be transmitted between the ECU and the
multi-function meter.
4 Defective meter assembly. Replace the meter assembly. Turn the main switch to “ ”
(on).
Fault code No. Er-2

Item error): no signals are received from the ECU within the speci-
fied duration.
Fail-safe system
Indicated —
Procedure —
(on).
9-59
Fault code No. Er-2

Item error): no signals are received from the ECU within the speci-
fied duration.
Fault code No. Er-3

Item
error): data from the ECU cannot be received correctly.
Fail-safe system
Indicated —
Procedure —
(on).
9-60
Fault code No. Er-4

ECU (engine control unit) internal malfunction (input signal er-
Item ror): non-registered data has been received from the meter as-
sembly.
Fail-safe system
Indicated —
Procedure —
(on).
9-61
9-62
EAS27560
EAS27550
A
B B
B
Br/Y L G/W
A 67 B L B C
L Br/Y W B
W Br/Y
(B)
Br/Y B Br/Y B
(B)
Br/R 22
B/L Gy Gy B/L
G/W O O
W W W B R Gy 23
Gy B B
CIRCUIT DIAGRAM
(Gy) (B) Br/Y R/W
R/W
W W W W
W W R (B) (B) R/W 24 R/L R
(Gy) W W R/W
(Gy) 2 3
W W (Gy)
Br/Y R/W
25 Br/W B/L
14 Br/L R/W P/L 20
G/Y G/Y B/L
32
FUEL PUMP SYSTEM
26 G/Y B/L
R/W 19 Y/W Y/W
(B)
B/W W
R/L
R/W
21
R/Y L L/Y
Y/R W L/Y L W
W 27
Br/R Y/B B/L B/L
R R L B/L
P/W L
R Br/B Br/R L/R (B)
R R Br/B O/L (B)
Br/L
5 B/G
B W/B L
R 8 10 B/R P P 29 B/L P L
Br/L
13 Sb B/L B/L
33
Br/R
Br/R (B)
R/W
B
11 W/B
30 L Y/G B/L R/W
B/Y Y/L B/L
B/L B/L
Br/R 17 L Gy W 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
66 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
R B/W
R/L B
9-63
B/W B L/B
Br/R Y/R (B)
R/L
Br/L W/B
65 63
Br

Br/Y
61 Br/Y
R/W
R/W Br/R
W/B Br Br/R
38 (B)
R/W
60 Y Br/Y
R/B R Br/Y Y Br
(B) 39 33
51 L 50 B/W G/W
L 59 Br/B B/W G/W
Br (off)
R/W Y/L B/W Y
Br/Y B/W B/W Y
58 (B) B/W Y
55 G W/B G G/R O/B
64 R R R/L Br/Y
Br/B B R/L Br/Y
Y B L/Y Br/Y
W/B B 40 L/Y Br/Y
L/Y Br/Y
Y (B)
Y Y
B 41
B R/W L O/B R/W
L 49 48
Y 52 Y/L Br/Y B/W
Y G B L 42 35 Br/Y
(B) Lg
Lg B
(B)
B B B/W Br
G 43
G B Br/Y Br B
L
(Dg) 44 (B) 34
Y LL
Y Y G Y G 36 L
37
Y L
45 B
53 53 B L/B
56 56 G Y G Y 46
B B
B B
47
Y G Y G
B B
B B
FUEL PUMP SYSTEM
FUEL PUMP SYSTEM
5. Frame ground
6. Main switch
8. Battery
9. Main fuse
10.Fuel injection system fuse
13.Fuel injection system relay
33.Joint coupler
49.Fuel pump
59.Ignition fuse
B. Wire harness
9-64
FUEL PUMP SYSTEM
EAS27570
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
1. Outer passenger seat frame
2. Right passenger compartment panel
3. Right side panel
4. Right rear panel
5. Fuel tank

(Main, ignition, and fuel injection
system) Replace the fuse(s).
ES” on page 9-92.
OK ↓
page 9-93.
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 9-63.
OK ↓
Replace the ECU.
9-65
FUEL PUMP SYSTEM
9-66
EAS30210
EAS30200
A
B B
B
Br/Y L G/W
A 67 B L B C
L Br/Y W B
W Br/Y
(B)
Br/Y B Br/Y B
(B)
Br/R 22
B/L Gy Gy B/L
G/W O O
W W W B R Gy 23
Gy B B
CIRCUIT DIAGRAM
(Gy) (B) Br/Y R/W
R/W
W W W W
W W R (B) (B) R/W 24 R/L R
(Gy) W W R/W
(Gy) 2 3
W W (Gy)
Br/Y R/W
25 Br/W B/L
14 Br/L R/W P/L 20
G/Y G/Y B/L
32
26 G/Y B/L
R/W 19 Y/W Y/W
(B)
B/W W
R/L
R/W
21
R/Y L L/Y
Y/R W L/Y L W
W 27
Br/R Y/B B/L B/L
R R L B/L
P/W L
R Br/B Br/R L/R (B)
R R Br/B O/L (B)
Br/L
5 B/G
B W/B L
R 8 10 B/R P P 29 B/L P L
Br/L
13 Sb B/L B/L
33
Br/R
Br/R (B)
R/W
Gy/G W/R
2WD/4WD SELECTING SYSTEM
11 P/W B/G W/B L/B R/W

B R/Y Sb W/R L/W L R/W
R/B Br/R O/L B/Y Br/B B/R
B A B 15 L/W G/R G/R Y/G Y/G L Y/G B/L B/L R/W
30 B/L R/W
B/Y Y/L B/L B/L
Br/R 17 L Gy W 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
66 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
R B/W
R/L B
9-67
B/W B L/B
Br/R Y/R (B)
R/L
Br/L W/B
65 63
Br

Br/Y
61 Br/Y
R/W
R/W Br/R
W/B Br Br/R
38 (B)
R/W
60 Y Br/Y
R/B R Br/Y Y Br
(B) 39 33
51 L 50 B/W G/W
L 59 Br/B B/W G/W
Br (off)
R/W Y/L B/W Y
Br/Y B/W B/W Y
58 (B) B/W Y
55 G W/B G G/R O/B
64 R R R/L Br/Y
Br/B B R/L Br/Y
Y B L/Y Br/Y
W/B B 40 L/Y Br/Y
L/Y Br/Y
Y (B)
Y Y
B 41
B R/W L O/B R/W
L 49 48
Y 52 Y/L Br/Y B/W
Y G B L 42 35 Br/Y
(B) Lg
Lg B
(B)
B B B/W Br
G 43
G B Br/Y Br B
L
(Dg) 44 (B) 34
Y LL
Y Y G Y G 36 L
37
Y L
45 B
53 53 B L/B
56 56 G Y G Y 46
B B
B B
47
Y G Y G
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
33.Joint coupler
50.Differential motor relay 2
58.Differential motor fuse
59.Ignition fuse
B. Wire harness
9-68
EAS30220
TROUBLESHOOTING
• The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential
gear lock indicator fails to come on.
• The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential
gear lock indicator flashes.
TIP
1. Hood
2. Front skid plate
The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential gear

lock indicator fails to come on.
(Main, ignition, signaling system,
and differential motor) Replace the fuse(s).
ES” on page 9-92.
OK ↓
page 9-93.
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 ↓
9-69
8. Check the differential motor opera- NG →

tion.
Refer to “CHECKING THE DIF- Replace the differential motor.
FERENTIAL MOTOR OPERATION”
on page 8-12.
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 9-67.
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 9-106.
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 9-67.
OK ↓
Replace the ECU.
9-70
EAS30240
EAS30230
A
B B
B
Br/Y L G/W
A 74 B L B C
L Br/Y W B
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) (B) (B)
Br/R 23 D C
B/L Gy Gy B/L
G/W O O
W W W B R Gy 24
Gy B B
CIRCUIT DIAGRAM
(Gy) (B) Br/Y R/W
R/W
W W W W
W W R (B) (B) R/W 25 R/L R
(Gy) W W R/W
(Gy) 2 3
W W O/W (Gy)
Br/Y R/W
26 Br/W B/L
15 Br/L R/W P/L 21
G/Y G/Y B/L
33
27 G/Y B/L
R/W 20 Y/W Y/W
(B)
B/W W
R/L
R/W
22
R/Y L L/Y
Y/R W L/Y L W
W 28
Br/R Y/B B/L 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 9 R
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
R P/W L
R Br/R L/R (B)
R R Br/B Br/B O/L (B)
Br/L
5 B/G
B W/B L
R 8 11 B/R P P 30 B/L P L
Br/L
14 Sb B/L B/L
34
Br/R
Br/R (B) 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
B A B 16 O/L B/Y Br/B B/R G/R Y/G Y/G B/L R/W
31 L Y/G B/L R/W
B/Y L/W G/R Y/L B/L
B/L B/L
Br/R 18 L Gy W 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
73 7 B/Y Y/B B B
Br/R B (B) B
R/L L/Y Br/R W/R Sb
R B/W
R/L B
9-71
B/W B L/B
Br/R Y/R (B)
35 G R B R
B W 37 36
R/L (Gy) (Gy)
G R B W
R B
Br/L W/B
GR B WR B
72 70
Br R G R B
W B
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
68 R Br G/R W/B
R/W Br/R B B 39 O O/W
W/B Br Br/R
44 (B)
L/B L/B
R/W
67 Y Br/Y
R/B G L/B Br O
Y Br O/W R L/B
R/B R (B) Br/Y 45 G W G/R 38 34
58 L 57 G/R W
(Gy) (Gy) (B) B/W G/W
L 66 Br/B (B) B/W G/W
Br (off)
R/W Y/L B/W Y
Br/Y B/W B/W Y
65 (B) B/W Y
62 G W/B G G/R O/B
71 R R R/L Br/Y
Br/B B R/L Br/Y
Y B 46 L/Y Br/Y
W/B B L/Y Br/Y
L/Y Br/Y
Y (B)
Y Y 47
B
B R/W L O/B G/R R/W
L 56 55
Y 59 48 Y/L Br/Y B/W
Y G B L 41 Br/Y
(B) Lg
Lg B
(B) 49
B B B/W Br
G
G B Br/Y Br B
R/L B B/W O/B 50 L/B B Lg
L
(Dg)
(B) 40
Y LL 51
Y Y G Y G 42 L
43
Y L
B
60 60 52 B L/B
EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
63 63 G Y G Y
B B
53
Y G B B Y G
54
B B G/R
B B

5. Frame ground
6. Main switch
8. Battery
9. Main fuse
10.EPS fuse
28.Speed sensor
34.Joint coupler
35.EPS unit
36.EPS motor
37.EPS torque sensor
38.EPS self-diagnosis signal connector
39.EPS (electric power steering) control unit
54.EPS warning light
66.Ignition fuse
B. Wire harness
D. EPS (electric power steering) control unit
9-72
EAS30250
EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION

The EPS control unit is equipped with a self-diagnostic function. If this function detects a malfunction in
the EPS system, it lights the EPS warning light to alert the rider that a malfunction has occurred in the
system. Once a malfunction has been detected, it becomes stored in the EPS control unit memory in
the form of a fault code.
• The EPS warning light comes on when the main switch is turned to “ ” (on), and then goes off once
the engine is started. If the warning light remains on or comes on after the engine is started, the EPS
system may be defective.
• The electrical circuit of the warning light can be checked by turning the main switch to “ ” (on). If the
warning light does not come on, the electrical circuit may be defective.
1
1. EPS warning light
TIP
If the steering usage is too heavy (i.e., excessive steering use when the vehicle is traveling at a slow
speed), the power assist is reduced to protect the EPS motor from overheating.
EAS30260
EPS WARNING LIGHT DURING NORMAL OPERATION

The EPS warning light comes on initially for 2 seconds after the main switch is turned to “ ” (on). 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.
9-73
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)
EAS30270
DIAGNOSTIC MODE
Setting the diagnostic mode (present and past malfunctions)

1. Turn the main switch to “ ” (on).
2. Disconnect the EPS self-diagnosis signal connector “1”.
3. Select the signaling mode by grounding the EPS self-diagnosis signal connector (male side) to the
EPS control unit “2” or disconnecting it from the unit as follows.
1
2
• Present malfunction signaling mode

Ground the EPS self-diagnosis signal connector within 5 seconds after setting the main switch to
“ ” (on), and leave it grounded. The signaling mode is activated after 5 seconds.
• Past malfunction signaling mode
While the present malfunction mode is activated, briefly disconnect the EPS self-diagnosis signal
connector, ground it again, and leave it grounded. The signaling mode is activated after 5 seconds.
4. Turn the main switch to “ ” (off) to cancel the diagnostic mode.
TIP
• The diagnostic mode can also be canceled by riding the vehicle at speeds above 2 km/h (1.2 mi/h).
• When the diagnostic mode is selected and during the initial lighting of the EPS warning light, the EPS
control unit does not receive input from the EPS self-diagnosis signal connector.
5. Connect the EPS self-diagnosis signal connector.
9-74
Identifying fault codes

When the diagnostic mode is activated, the fault codes determined by the fail-safe specifications are
signaled by the EPS warning light as follows.
• Present malfunction signaling mode: Currently detected fault codes are signaled.
• Past malfunction signaling mode: Both previously detected fault codes and currently detected fault
codes are signaled.
Signaling method
Example 1: Fault code No. 23
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 i. Mode selection judgment

b. Diagnostic mode j. Present malfunction signaling mode
c. EPS warning light k. Past malfunction signaling mode
d. Disconnected
A. The EPS warning light comes on for 5
e. On seconds during the diagnostic mode selection
f. Off judgment.
g. Grounded B. Display of the present malfunctions stops
h. Normal mode (diagnostic mode not activated) when the past malfunction display mode is
selected.
After the mode selection judgment is completed (present or past malfunction mode), the current fault
code signaling stops immediately, and then the first code of the mode is signaled 2 seconds later.
When a fault code is signaled, the EPS warning light goes off for 1 second between the units of 10 and
the units of 1 for the code. After a fault code is signaled, the warning light goes off for 3 seconds, and
then the next code is signaled.
Example 2: No malfunctions are detected
a c
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 g. Mode selection judgment

b. EPS warning light
A. The EPS warning light comes on for 5
c. Disconnected seconds during the diagnostic mode selection
d. Comes on judgment.
e. Goes off
f. Grounded
9-75
After the mode selection judgment is completed (present display or past malfunction mode), the current
fault code signaling stops immediately, and then the EPS warning light starts flashing at 1.5-second 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
EAS30280
SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)

Fault Probable cause of mal-
Item Symptom
code No. function
• Open or short circuit in
11 wire harness.
13 No normal signals are received • Malfunction in torque
EPS torque sensor
15 from the torque sensor. sensor.
16 • Malfunction in EPS con-
trol unit.
wire harness.
No normal signals are received • Malfunction in speed
21 Speed sensor
from the speed sensor. sensor.
• Malfunction in EPS con-
trol unit.
wire harness.
No normal signals are received
22 Engine speed signal • Malfunction in ECU.
from the ECU.
trol unit.
41 wire harness.
42 No normal signals are received • Malfunction in EPS mo-
EPS motor
43 from the EPS motor. tor.
45 • Malfunction in EPS con-
trol unit.
Relay contacts in the EPS control Malfunction in EPS con-
52 EPS control unit
unit are welded together. trol unit.
9-76
Fault Probable cause of mal-

Item Symptom
code No. function
• Faulty battery.
• Malfunction in the
charging system.
Refer to “CHARGING
53 EPS control unit Battery voltage has dropped.
SYSTEM” on page
9-11.
trol unit.
Relay contacts in the EPS control Malfunction in EPS con-
54 EPS control unit
unit are welded together. trol unit.
• Malfunction in the
charging system.
Battery voltage has increased. Refer to “CHARGING
55 EPS control unit Abnormality exists between the SYSTEM” on page
EPS and the ECU. 9-11.
trol unit.
EAS30290
TROUBLESHOOTING DETAILS (EPS SYSTEM)

TIP
The malfunction history is stored even if the main switch is turned to “ ” (off), therefore, be sure to
erase the history (present and past malfunction signaling modes) after repairing the cause of the EPS
system malfunction. The malfunction history must be erased in the diagnostic mode. Refer to “DIAG-
NOSTIC MODE” on page 9-74.
Fault code No. 11, Symptom EPS torque sensor: open or short circuit detected.
13,
15, 16
Order Item/components and probable Check or maintenance job Reinstatement
cause method
1 Connections • Check the coupler for any pins Turning the
• EPS torque sensor coupler that may have pulled out. main switch to
• Check the locking condition of “ ” (off).
the coupler.
• If there is a malfunction, repair it
and connect the coupler se-
curely.
2 Defective EPS torque sensor. • Replace if defective.
Refer to “CHECKING THE EPS
TORQUE SENSOR (for EPS
models)” on page 9-107.
3 Open or short circuit in EPS torque • Replace if there is an open or
sensor lead. short circuit.
• Between EPS torque sensor
coupler and EPS control unit
coupler.
white–white
red–red
green–green
black–black
9-77
Fault code No. 21 Symptom Speed sensor: open or short circuit detected.
cause method
1 Connections • Check the coupler for any pins Starting the en-
• Speed sensor coupler that may have pulled out. gine and acti-
• EPS control unit coupler at the wire • Check the locking condition of vating the
harness the coupler. vehicle speed
• If there is a malfunction, repair it sensor by oper-
and connect the coupler seating the vehi-
curely. cle above 5
2 Open or short circuit in wire harness. • Replace if there is an open or km/h (3 mi/h),
short circuit. or turning the
• Between speed sensor coupler main switch to
and joint coupler. “ ” (off), then
white–white to “ ” (on), and
• Between joint coupler and EPS then deleting
control unit coupler. the fault codes.
white–white Refer to “DIAG-
NOSTIC
3 Defective speed sensor. • Replace if defective. MODE” on
Refer to “CHECKING THE page 9-74.
SPEED SENSOR” on page
9-102.
Fault code No. 22 Symptom No normal signals are received from the ECU.
cause method
• EPS control unit coupler at the wire that may have pulled out. main switch to
harness • Check the locking condition of “ ” (off).
• ECU coupler at the wire harness the coupler.
curely.
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
9-78
Fault code No. 41, Symptom EPS motor: open or short circuit detected.
42,
43, 45
cause method
• EPS motor coupler that may have pulled out. main switch to
• Check the locking condition of “ ” (off).
the coupler.
curely.
2 Open or short circuit in EPS motor • Replace if there is an open or
lead. short circuit.
• Between EPS motor and EPS
control unit coupler.
red–red
black–black
3 Defective EPS motor. Replace if defective.
Refer to “CHECKING THE EPS
MOTOR (for EPS models)” on
page 9-107.
Fault code No. 52 Symptom Relay contacts in the EPS control unit are welded togeth-
er.
cause method
1 Malfunction in EPS control unit. Replace the EPS control unit. Turning the
main switch to
“ ” (off).
Fault code No. 53 Symptom Power supply to the EPS control unit is not normal (low
battery voltage).
cause method
1 Faulty battery. Replace or charge the battery. Turning the
Refer to “CHECKING AND main switch to
CHARGING THE BATTERY” on “ ” (off).
page 9-93.
2 Malfunction in rectifier/regulator or Replace if defective.
charging system. Refer to “CHECKING THE REC-
TIFIER/REGULATOR” on page
9-101.
3 Malfunction in EPS control unit. Replace the EPS control unit.
9-79
Fault code No. 54 Symptom Relay contacts in the EPS control unit are welded togeth-
er.
cause method
1 Malfunction in EPS control unit. Replace the EPS control unit. Turning the
main switch to
“ ” (off).
Fault code No. 55 Symptom Power supply to the EPS control unit is not normal (high
battery voltage).
Malfunction in control unit.
cause method
1 Faulty battery. Replace the battery. Turning the
Refer to “CHECKING AND main switch to
CHARGING THE BATTERY” on “ ” (off).
page 9-93.
2 Malfunction in rectifier/regulator. Replace if defective.
Refer to “CHECKING THE REC-
TIFIER/REGULATOR” on page
9-101.
3 Malfunction in EPS control unit. Replace the EPS control unit.
9-80
ELECTRICAL COMPONENTS
EAS27972
6
5
4 9
8
10
2
11
12
13
20
14
19
18 15
17 16
9-81
1. Radiator fan motor

3. Parking brake switch
4. Ignition coil
6. TPS (throttle position sensor)
7. Fuel injector
8. ISC (idle speed control)
9. Air induction system solenoid
10. Coolant temperature sensor
11. Reverse switch
13. Speed sensor
15. Intake air temperature sensor
16. Fuel sender
17. Fuel pump
18. Seat belt switch
20. Differential motor
9-82
4 5 6
2
8
14
13
11
10
12
9-83
1. Auxiliary DC jack
2. Battery
3. Meter assembly
4. Indicator light assembly
5. Main switch
6. On-Command four-wheel-drive switch
7. Light switch
8. EPS torque sensor (for EPS models)
9. EPS motor (for EPS models)
10. EPS (electric power steering) control unit (for
EPS models)
11. Radiator fan motor circuit breaker
12. Horn (for Europe and Oceania)
14. Rectifier/regulator
9-84
1 4
10
19 18 7
17 16 13 11
15 14
8
12 9
12
9-85

2. Fuel injection system relay
3. Radiator fan motor relay
4. Headlight relay
8. Spare fuse
9. Starter relay
10. EPS fuse (for EPS models)
11. Main fuse
12. Fuse box
13. Radiator fan motor fuse
14. Headlight fuse
15. Signaling system fuse
16. Auxiliary DC jack fuse
17. Differential motor fuse
18. Ignition fuse
19. Backup fuse
9-86
EAS27980
CHECKING THE SWITCHES
4
L/W B G/R
2 3 2WD
1 4WD
Br/R R/B L/Y Br/R DIFF LOCK
Br Y
L/R B
(off)
L/W G/R
(B) (on)
B
(start)
5
G/W
9 8 7 6
Br P Br L Y
OFF (off) L W
L B
ON Gy
(B)
9-87

2. Parking brake switch
3. Main switch
4. On-Command four-wheel-drive switch
5. Reverse switch
7. Seat belt switch
8. Light switch
9. Horn switch (for Europe and Oceania)
9-88
Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the
wiring connections and if necessary, replace the switch.
ECA14370
NOTICE
Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from
the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester
90890-03112
YU-03112-C
TIP
• Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back and forth between the switch positions a few times.
The switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated by
“ ”. 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
9-89
EAS27990 EWA1XD1018
CHECKING THE BULBS AND BULB WARNING

SOCKETS Since headlight bulbs get extremely hot,
TIP keep flammable products and your hands
Do not check any of the lights that use LEDs. away from them until they have cooled
down.
Check each bulb and bulb socket for damage or
ECA1XD1048
wear, proper connections, and also for continuity
NOTICE
between the terminals.
Damage/wear → Repair or replace the bulb, • Be sure to hold the socket firmly when re-
bulb socket or both. moving the bulb. Never pull the lead, other-
Improperly connected → Properly connect. wise it may be pulled out of the terminal in
No continuity → Repair or replace the bulb, bulb the coupler.
socket or both. • Avoid touching the glass part of a headlight
bulb to keep it free from oil, otherwise the
Types of bulbs transparency of the glass, the life of the
The bulbs used on this vehicle are shown in the bulb, and the luminous flux will be adverse-
illustration. ly affected. If the headlight bulb gets soiled,
• Bulbs “a” and “b” are used for the headlights thoroughly clean it with a cloth moistened
and usually use a bulb holder that must be de- with alcohol or lacquer thinner.
tached before removing the bulb. The majority 2. Check:
of these types of bulbs can be removed from • Bulb (for continuity)
their respective socket by turning them coun- (with the pocket tester)
terclockwise. No continuity → Replace.
• Bulbs “c” are used for tail/brake lights and can
be removed from the socket by pushing and Pocket tester
turning the bulb counterclockwise. 90890-03112
YU-03112-C
TIP
Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“2”, and check the continuity.
b. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“3”, and check the continuity.
c. If either of the readings indicate no continuity,
replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the condition of the bulbs

bulbs.
1. Remove:
• Bulb
9-90
Checking the condition of the bulb sockets 3. Disconnect:

The following procedure applies to all of the bulb • Headlight coupler “1”
sockets.
1. Check:
• Bulb socket (for continuity) 1
(with the pocket tester)
No continuity → Replace.
Pocket tester
90890-03112
YU-03112-C
4. Remove:
TIP
• Headlight bulb holder “1”
Check each bulb socket for continuity in the • Headlight bulb “2”
same manner as described in the bulb section; EWA13320
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.
TIP
c. Check the bulb socket for continuity. If any of
the readings indicate no continuity, replace Unhook the headlight bulb holder, and then re-
the bulb socket. move the defective bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21790
REPLACING THE HEADLIGHT BULBS

headlight bulbs. 1
1. Remove:
• Headlight rear cover “1”
2
1
5. Install:
• Headlight bulb New
Secure the new headlight bulb with the head-
light bulb holder.
ECA13690
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
9-91
8. Install: EAS28000
CHECKING THE FUSES

• Headlight bulb holder cover
ECA1XD1049 The following procedure applies to all of the fus-
NOTICE es.
ECA1XD1050
Make sure the headlight bulb holder cover is NOTICE
securely fitted over the bulb holder and seat-
To avoid a short circuit, always turn the main
ed properly.
switch to “ ” (off) when checking or replac-
TIP ing a fuse.
Pass the headlight lead “1” through the slot “a” in 1. Remove:
the headlight unit as shown, and then reinstall • Hood
the bulb holder cover. Refer to “GENERAL CHASSIS” on page 4-1.
2. Check:
• Fuse
Amperage
No. Fuses Q’ty
1 rating
1 EPS (for EPS models) 40.0 A 1
2 Main 40.0 A 1
3 Radiator fan motor 25.0 A 1
a 4 Headlight 15.0 A 1
9. Install: 5 Backup 10.0 A 1
• Headlight rear cover 6 Fuel injection system 10.0 A 1
EAS21810 7 Ignition 10.0 A 1
ADJUSTING THE HEADLIGHT BEAMS 8 Differential motor 10.0 A 1
headlights. 9 Signaling system 10.0 A 1
1. Adjust: 10 Auxiliary DC jack 10.0 A 1
• Headlight beam (vertically) 11 Spare 25.0 A 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw “1” in direction “a” or 12 Spare 15.0 A 1
“b”. 13
Spare 10.0 A 2
14
Direction “a”
Headlight beam is raised.
Direction “b” 2 1 6
Headlight beam is lowered.
11 13 3
12 14
5 7 8 10 9 4
a b ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and
1 check the continuity.
TIP
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Set the pocket tester selector to “Ω × 1”.
9-92
• Avoid bodily contact with electrolyte as it

Pocket tester can cause severe burns or permanent eye
90890-03112 injury.
Analog pocket tester FIRST AID IN CASE OF BODILY CONTACT:
YU-03112-C
EXTERNAL
b. If the pocket tester indicates “∞”, replace the • Skin — Wash with water.
fuse. • Eyes — Flush with water for 15 minutes and
get immediate medical attention.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
INTERNAL
3. Replace: • Drink large quantities of water or milk fol-
• Blown fuse lowed with milk of magnesia, beaten egg or
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the main switch to “ ” (off). vegetable oil. Get immediate medical atten-
b. Install a new fuse of the correct amperage tion.
rating. ECA1XD1051
c. Set on the switches to verify if the electrical NOTICE

circuit is operational. • This is a VRLA (Valve Regulated Lead Acid)
d. If the fuse immediately blows again, check battery. Never remove the sealing caps be-
the electrical circuit. cause the balance between cells will not be
EWA13310
maintained and battery performance will
WARNING deteriorate.
Never use a fuse with an amperage rating • Charging time, charging amperage and
other than that specified. Improvising or us- charging voltage for a VRLA battery are dif-
ing a fuse with the wrong amperage rating ferent from those of conventional batteries.
may cause extensive damage to the electri- The VRLA battery should be charged ac-
cal system, cause the lighting and ignition cording to the appropriate charging meth-
systems to malfunction and could possibly od. If the battery is overcharged, the
cause a fire. electrolyte level will drop considerably.
Therefore, take special care when charging
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
the battery.
4. Install:
• Hood TIP
Refer to “GENERAL CHASSIS” on page 4-1. Since VRLA batteries are sealed, it is not possi-
EAS28030
ble to check the charge state of the battery by
CHECKING AND CHARGING THE BATTERY measuring the specific gravity of the electrolyte.
EWA13290 Therefore, the charge of the battery has to be
WARNING checked by measuring the voltage at the battery
Batteries generate explosive hydrogen gas terminals.
and contain electrolyte which is made of poi-
1. Remove:
sonous and highly caustic sulfuric acid.
• Hood
Therefore, always follow these preventive
measures:
2. Disconnect:
• Wear protective eye gear when handling or
• Battery leads
working near batteries.
(from the battery terminals)
• Charge batteries in a well-ventilated area. ECA13640
• Keep batteries away from fire, sparks or NOTICE

open flames (e.g., welding equipment, First, disconnect the negative battery lead
lighted cigarettes). “1”, and then positive battery lead “2”.
• DO NOT SMOKE when charging or han-
dling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
9-93
D. These values vary with the temperature, the

2 condition of the battery plates, and the
electrolyte level.
3. Remove:
• Battery
4. Check:
• Battery charge
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ A. Open-circuit voltage (V)
a. Connect a pocket tester to the battery termi- B. Charging condition of the battery (%)
nals. C. Ambient temperature 20 °C (68 °F)
• Positive tester probe →
positive battery terminal ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Negative tester probe → 5. Charge:
negative battery terminal • Battery
(refer to the appropriate charging method)
TIP EWA13300
• The charge state of a VRLA (Valve Regulated WARNING

Lead Acid) battery can be checked by measur- Do not quick charge a battery.
ing its open-circuit voltage (i.e., the voltage ECA1XD1052
when the positive battery terminal is discon- NOTICE

nected). • Do not use a high-rate battery charger
• No charging is necessary when the open-cir- since it forces a high-amperage current
cuit voltage equals or exceeds 12.8 V. into the battery quickly and can cause bat-
b. Check the charge of the battery, as shown in tery overheating and battery plate damage.
the charts and the following example. • If it is impossible to regulate the charging
Example current on the battery charger, be careful
Open-circuit voltage = 12.0 V not to overcharge the battery.
Charging time = 6.5 hours • When charging a battery, be sure to remove
Charge of the battery = 20–30% it from the vehicle. (If charging has to be
done with the battery mounted on the vehi-
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-
A. Open-circuit voltage (V) tery charger lead clip may generate heat in
B. Charging time (hours) the contact area and a weak clip spring may
C. Relationship between the open-circuit voltage cause sparks.
and the charging time at 20 °C (68 °F)
9-94
• If the battery becomes hot to the touch at TIP

any time during the charging process, dis- Set the charging time at 20 hours (maximum).
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot e. Measure the battery open-circuit voltage after
batteries can explode! leaving the battery unused for more than 30
• As shown in the following illustration, the minutes.
open-circuit voltage of a VRLA (Valve Reg- 12.8 V or more --- Charging is complete.
ulated Lead Acid) battery stabilizes about 12.7 V or less --- Recharging is required.
30 minutes after charging has been com- Under 12.0 V --- Replace the battery.
pleted. Therefore, wait 30 minutes after
charging is completed before measuring ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
the open-circuit voltage. 6. Install:

• Battery
7. Connect:
• Battery leads
(to the battery terminals)
ECA13630
NOTICE
First, connect the positive battery lead “1”,
and then the negative battery lead “2”.
A. Open-circuit voltage (V)

B. Time (minutes)
C. Charging 2
D. Ambient temperature 20 °C (68 °F)
E. Check the open-circuit voltage.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Charging method using a constant volt- 8. Check:
age charger • Battery terminals
a. Measure the open-circuit voltage prior to Dirt → Clean with a wire brush.
charging. Loose connection → Connect properly.
TIP 9. Install:
Voltage should be measured 30 minutes after • Hood
the engine is stopped. Refer to “GENERAL CHASSIS” on page 4-1.
EAS28040
b. Connect a charger and ammeter to the bat-
CHECKING THE RELAYS
tery and start charging.
Check each switch for continuity with the pocket
c. Make sure that the current is higher than the
tester. If the continuity reading is incorrect, re-
standard charging current written on the bat-
place the relay.
tery.
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
1. Disconnect the relay from the wire harness.
charger is recommended.
2. Connect the pocket tester (Ω × 1) and battery
d. Charge the battery until the battery’s charg- (12 V) to the relay terminal as shown.
ing voltage is 15 V. Check the relay operation.
9-95
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
9-96
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
9-97
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: EAS28090
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
5. Negative tester probe 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”
EAS28060
CHECKING THE SPARK PLUG CAP

1. Check:
• Spark plug cap resistance
Resistance
7.5–12.5 kΩ
9-98
Refer to “TROUBLESHOOTING” on page

9-3.
Minimum ignition spark gap

6.0 mm (0.24 in)
TIP
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
c. Measure the primary coil resistance. a. Disconnect the spark plug cap from the spark
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ plug.
2. Check: b. Connect the ignition checker “1” as shown.
• Secondary coil resistance
Out of specification → Replace. Ignition checker
90890-06754
Secondary coil resistance Oppama pet–4000 spark checker
8.64–12.96 kΩ YM-34487
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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
90890-03112
YU-03112-C
2. Spark plug cap
brown/red “1” c. Measure the ignition spark gap “a”.
• Negative tester probe → d. Crank the engine by turning the main switch
Spark plug lead “2” to “ ” (start) and gradually increase the
spark gap until a misfire occurs.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28120
CHECKING THE CRANKSHAFT POSITION

SENSOR
1. Disconnect:
• Crankshaft position sensor coupler
(from the wire harness)
2. Check:
• Crankshaft position sensor resistance
c. Measure the secondary coil resistance. Out of specification → Replace the crank-
shaft position sensor/stator assembly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28930 Crankshaft position sensor resis-
CHECKING THE IGNITION SPARK GAP tance
1. Check: 408.0–612.0 Ω
• Ignition spark gap
Out of specification → Perform the ignition ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
system troubleshooting, starting with step 5. a. Connect the pocket tester (Ω × 100) to the
crankshaft position sensor coupler as shown.
9-99

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- EAS28940
sistance. CHECKING THE STARTER MOTOR

OPERATION
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1. Check:
EAS28130
• Starter motor operation
CHECKING THE LEAN ANGLE SENSOR
Does not operate → Perform the electric
1. Remove:
starting system troubleshooting, starting with
• Lean angle sensor
step 4.
2. Check:
Refer to “TROUBLESHOOTING” on page
• Lean angle sensor output voltage
9-9.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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”.
EWA13810
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
YU-03213
Pocket tester
90890-03112
YU-03112-C
9-100
b. Check the starter motor operation. EAS28170
CHECKING THE RECTIFIER/REGULATOR

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1. Check:
EAS28150
• Charging voltage
CHECKING THE STATOR COIL
Out of specification → Replace the rectifi-
1. Disconnect:
er/regulator.
• Stator coil couplers
(from the wire harness) Charging voltage
2. Check: above 14 V at 5000 r/min
• Stator coil resistance
Out of specification → Replace the crank- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
shaft position sensor/stator assembly. a. Connect the engine tachometer to the spark
plug lead.
Stator coil resistance b. Connect the pocket tester (DC 20 V) to the
0.09–0.13 Ω battery as shown.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Pocket tester

a. Connect the digital circuit tester to the stator 90890-03112
coil coupler as shown. Analog pocket tester
YU-03112-C
Digital circuit tester
90890-03174 • Positive tester probe →
Model 88 Multimeter with ta- positive battery terminal “1”
chometer • Negative tester probe →
YU-A1927 negative battery terminal “2”
white “1” 1
• Negative tester probe →
white “2”
2
white “1”
white “3”

white “2” c. Start the engine and let it run at approximate-
• Negative tester probe → ly 5000 r/min.
white “3” d. Measure the charging voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28230
CHECKING THE FUEL SENDER

1. Disconnect:
• Fuel pump coupler
2. Remove:
W W W • Fuel pump assembly
(from the fuel tank)
3 2 1 3. Check:
• Fuel sender resistance
b. Measure the stator coil resistance. Out of specification → Replace the fuel pump
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ assembly.
9-101
c. Measure the fuel sender resistance.

Sender unit resistance (full) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
19.0–21.0 Ω
EAS29040
Sender unit resistance (empty)
CHECKING THE FUEL METER/FUEL LEVEL
139.0–141.0 Ω
WARNING LIGHT
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ This model is equipped with a self-diagnosis de-
a. Connect the pocket tester (Ω × 10 or Ω × 100) vice for the fuel level detection circuit.
to the fuel sender terminals as shown. 1. Check:
• Fuel meter/fuel level warning light “1”
Pocket tester (Turn the main switch to “ ” [on].)
90890-03112 Warning light comes on for a few seconds,
Analog pocket tester then goes off → Warning light is OK.
YU-03112-C Warning light does not come on → Replace
the meter assembly.
• Positive tester probe → Warning light flashes eight times, then goes
orange/black “1” off for 3 seconds in a repeated cycle (mal-
function detected in fuel sender) → Replace
black/white “2”
the fuel pump assembly.
R/L B B/W O/B
1 2
b. Move the fuel sender float to minimum “3” EAS28240
and maximum “4” level positions. CHECKING THE SPEED SENSOR

1. Check:
• Speed sensor output voltage
Output voltage reading cycle

4 0.6 V–4.8 V–0.6 V–4.8 V–0.6 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the test harness- speed sensor (3P)
“1” between the speed sensor coupler and
wire harness as shown.
b. Connect the pocket tester (DC 20 V) to the
test harness- speed sensor (3P).
Test harness- speed sensor (3P)

90890-03208
YU-03208
3 Pocket tester
90890-03112
YU-03112-C
9-102

EAS1XD1128
CHECKING THE RADIATOR FAN MOTOR

white (wire harness color) CIRCUIT BREAKER
1. Remove:
• Radiator fan motor circuit breaker
1

d. Elevate the rear wheels and slowly rotate 2. Check:
them. • Radiator fan motor circuit breaker resistance
e. Measure the voltage (DC 20 V) of white and Out of specification → Replace the radiator
black/blue. With each full rotation of the rear fan motor circuit breaker.
wheels, the voltage reading should cycle
from 0.6 V to 4.8 V to 0.6 V to 4.8 V. Radiator fan motor circuit break-
er resistance
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
0–0.05 Ω at 25 °C (77 °F)
EAS28250
CHECKING THE RADIATOR FAN MOTOR ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

1. Check: a. Connect the digital circuit tester to the radia-
• Radiator fan motor tor fan motor circuit breaker as shown.
Faulty/rough movement → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Digital circuit tester
a. Disconnect the radiator fan motor coupler 90890-03174
from the wire harness. Model 88 Multimeter with ta-
b. Connect the battery (DC 12 V) as shown. chometer
YU-A1927
• Positive battery terminal →
blue “1”
• Negative battery terminal →
black “2”
b. Measure the radiator fan motor circuit break-

er resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Check the radiator fan motor movement. EAS28260
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE COOLANT TEMPERATURE

SENSOR
1. Remove:
9-103
EWA14130 EAS28300
WARNING CHECKING THE THROTTLE POSITION

• Handle the coolant temperature sensor SENSOR
with special care. 1. Remove:
• Never subject the coolant temperature sen- • Throttle position sensor
sor to strong shocks. If the coolant temper- (from the throttle body)
EWA1XD1019
ature sensor is dropped, replace it. WARNING
2. Check: • Handle the throttle position sensor with
• Coolant temperature sensor resistance special care.
Out of specification → Replace. • Never subject the throttle position sensor
to strong shocks. If the throttle position
Coolant temperature sensor re- sensor is dropped, replace it.
sistance
2.32–2.59 kΩ at 20 °C (68 °F) 2. Check:
310–326 Ω at 80 °C (176 °F) • Throttle position sensor maximum resistance
Out of specification → Replace the throttle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ position sensor.
a. Connect the pocket tester (Ω × 1k or Ω × 100)
to the coolant temperature sensor terminals Resistance
as shown. 2.64–6.16 kΩ
Pocket tester ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
90890-03112 a. Connect the pocket tester (Ω × 1k) to the
Analog pocket tester throttle position sensor terminals as shown.
YU-03112-C
Pocket tester
b. Immerse the coolant temperature sensor “1” 90890-03112
in a container filled with coolant “2”. Analog pocket tester
TIP YU-03112-C
Make sure the coolant temperature sensor ter-
minals do not get wet. • Positive tester probe →
blue “1”
c. Place a thermometer “3” in the coolant. • Negative tester probe →
black/blue “2”
3
1
d. Heat the coolant or let it cool down to the

specified temperatures.
b. Measure the throttle position sensor maxi-
e. Measure the coolant temperature sensor re-
mum resistance.
sistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
3. Install:
• Throttle position sensor
Coolant temperature sensor

18 Nm (1.8 m·kgf, 13 ft·lbf)
T.
R.
9-104
TIP
When installing the throttle position sensor, ad-
just its angle properly. Refer to “ADJUSTING
THE THROTTLE POSITION SENSOR” on page 1
7-12.
EAS28410
CHECKING THE INTAKE AIR PRESSURE

SENSOR
EWA1XD1020
WARNING c. Turn the main switch to “ ” (on).

• Handle the intake air pressure sensor with d. Measure the intake air pressure sensor out-
special care. put voltage.
• Never subject the intake air pressure sen- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
sor to strong shocks. If the intake air pres- EAS28420
sure sensor is dropped, replace it. CHECKING THE INTAKE AIR
1. Check: TEMPERATURE SENSOR
• Intake air pressure sensor output voltage 1. Remove:
Out of specification → Replace. • Intake air temperature sensor
(from the air filter case.)
EWA14110
Intake air pressure sensor output
voltage WARNING
3.594–3.684 V at 101 kPa (1.01 • Handle the intake air temperature sensor
kgf/cm², 14 psi) with special care.
• Never subject the intake air temperature
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ sensor to strong shocks. If the intake air
a. Connect the test harness S- pressure sensor
temperature sensor is dropped, replace it.
5S7 (3P) “1” between the intake air pressure
sensor and wire harness as shown. 2. Check:
b. Connect the pocket tester (DC 20 V) to the • Intake air temperature sensor resistance
test harness S- pressure sensor 5S7 (3P). Out of specification → Replace.
Test harness S- pressure sensor Intake air temperature sensor re-

5S7 (3P) sistance
90890-03211 5.40–6.60 kΩ at 0 °C (32 °F)
YU-03211 290–390 Ω at 80 °C (176 °F)
Pocket tester
90890-03112 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Analog pocket tester a. Connect the pocket tester (Ω × 1k or Ω × 100)
YU-03112-C to the intake air temperature sensor terminals
as shown.
Pocket tester
pink (wire harness color)
90890-03112
YU-03112-C
b. Immerse the intake air temperature sensor

“1” in a container filled with water “2”.
TIP
Make sure that the intake air temperature sensor
terminals do not get wet.
c. Place a thermometer “3” in the water.
9-105
EAS28370

3 SOLENOID
1 1. Check:
• Air induction system solenoid resistance
Solenoid resistance
2 20–24 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
d. Heat the water or let it cool down to the spec- a. Disconnect the air induction system solenoid
ified temperatures. coupler from the wire harness.
e. Measure the intake air temperature sensor b. Connect the pocket tester (Ω × 1) to the air in-
resistance. duction system solenoid terminals as shown.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Pocket tester
EAS1XD1004
90890-03112
CHECKING THE FUEL INJECTOR Analog pocket tester
1. Check: YU-03112-C
• Fuel injector resistance
Out of specification → Replace the fuel injec- • Positive tester probe →
tor. Air induction system solenoid terminal “1”
Fuel injector resistance Air induction system solenoid terminal “2”
11.5–12.5 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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.
Pocket tester
90890-03112
YU-03112-C
c. Measure the air induction system solenoid re-
• Positive tester probe sistance.
Injector terminal “1” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Negative tester probe EAS1XD1037
Injector terminal “2” CHECKING THE DIFFERENTIAL MOTOR
POSITION SWITCH
1. Check:
1 2 • Differential motor position switch
Pocket tester
90890-03112
YU-03112-C
c. Measure the fuel injector resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9-106
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
(between “2” and “3”) 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.
b. Check the EPS motor for continuity.
c. Turn the main switch to “ ” (off).
c. Check the EPS motor for no continuity.
d. Disconnect the differential motor coupler.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
e. Connect the pocket tester (Ω × 1) to the differ-
EAS30310
ential motor terminals.
CHECKING THE EPS TORQUE SENSOR (for
f. Check the differential motor position switch
EPS models)
continuity.
1. Remove:
g. Check the differential motor position switch
• EPS unit
no continuity. ECA1XD1014
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ NOTICE
EAS30300 Make sure do not remove the torque sensor
CHECKING THE EPS MOTOR (for EPS and its protector from the EPS unit.
models)
1. Remove: 2. Check:
• EPS unit • EPS torque sensor resistance
2. Check: Out of specification → Replace the steering
• EPS motor column.
Out of specification → Replace the EPS unit.
9-107
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.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9-108
9-109
TROUBLESHOOTING
TROUBLESHOOTING...................................................................................10-1
GENERAL INFORMATION ..................................................................... 10-1
STARTING FAILURES............................................................................10-1
INCORRECT ENGINE IDLING SPEED .................................................. 10-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......................... 10-2
FAULTY DRIVE TRAIN ...........................................................................10-2
FAULTY GEAR SHIFTING...................................................................... 10-2
SHIFT LEVER DOES NOT MOVE .......................................................... 10-2
JUMPS OUT OF GEAR...........................................................................10-2
FAULTY CLUTCH ...................................................................................10-3
OVERHEATING ......................................................................................10-3
OVERCOOLING......................................................................................10-4
POOR BRAKING PERFORMANCE........................................................ 10-4
FAULTY SHOCK ABSORBER ASSEMBLY............................................10-4
UNSTABLE HANDLING ..........................................................................10-4
FAULTY LIGHTING OR SIGNALING SYSTEM ...................................... 10-4
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE..........10-5
10
TROUBLESHOOTING
EAS28451
Electrical system
TROUBLESHOOTING 1. Battery
EAS28460
• 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
EAS28470
• 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 generator 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 EAS28490
• 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 • Improper throttle cable free play
• Faulty fuel pump • Flooded throttle body
• Faulty fuel injection system relay • Faulty air induction system
• Clogged or damaged fuel hose
3. Throttle body Electrical system
• Deteriorated or contaminated fuel 1. Battery
• Sucked-in air • Discharged battery
10-1
TROUBLESHOOTING
• Faulty battery • Broken generator rotor woodruff key

2. Spark plug
EAS28520
• Incorrect spark plug gap POOR MEDIUM-AND-HIGH-SPEED
• Incorrect spark plug heat range PERFORMANCE
• Fouled spark plug Refer to “STARTING FAILURES” on page 10-1.
• Worn or damaged electrode
• Worn or damaged insulator Engine
• Faulty spark plug cap 1. Air filter
3. Ignition coil • Clogged air filter element
• Broken or shorted primary or secondary coils
• Faulty spark plug lead Fuel system
• Cracked or broken ignition coil 1. Fuel pump
4. Ignition system • Faulty fuel pump
• Faulty ECU
• Faulty crankshaft position sensor
EAS30320
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 sus- B. Improper gear backlash.
tained speed. (This must not be confused C. Gear tooth damage.
with engine surging or transmission charac- D. Broken drive shaft.
teristics.) E. Broken gear teeth.
2. A “rolling rumble” noticeable at low speed; a F. Seizure due to lack of lubrication.
high-pitched whine; a “clunk” from a shaft G. Small foreign objects lodged between the
drive component or area. moving parts.
3. A locked-up condition of the shaft drive
mechanism, 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.
EAS28530 EAS28550
FAULTY GEAR SHIFTING JUMPS OUT OF GEAR
Shifting is difficult Shift forks

Refer to “FAULTY CLUTCH” on page 10-3. • Worn shift fork
EAS1XD1001
SHIFT LEVER DOES NOT MOVE Shift drum

• Incorrect axial play
Shift drum and shift forks • Worn shift drum groove
• Foreign object in a shift drum groove
• Seized shift fork Transmission
• Bent shift fork guide bar • Worn gear dog
Transmission
• Seized transmission gear
• Foreign object between transmission gears
• Improperly assembled transmission
10-2
TROUBLESHOOTING
EAS28580 EAS28600
FAULTY CLUTCH OVERHEATING
Engine operates but vehicle will not move Engine

1. V-belt 1. Clogged coolant passages
• Bent, damaged or worn V-belt 2. Cylinder head and piston
• Slipping V-belt • Heavy carbon buildup
2. Primary pulley cam and primary pulley slider 3. Engine oil
• Damaged or worn primary pulley cam • Incorrect oil level
• Damaged or worn primary pulley slider • Incorrect oil viscosity
3. Clutch spring(s) • Inferior oil quality
• Damaged clutch spring
4. Transmission gear(s) Cooling system
• Damaged transmission gear 1. Coolant
• Low coolant level
Clutch slips 2. Radiator
1. Clutch spring(s) • Damaged or leaking radiator
• Damaged, loose or worn clutch spring • Faulty radiator cap
2. Clutch shoe(s) • Bent or damaged radiator fin
• Damaged or worn clutch shoe 3. Water pump
3. Primary sliding sheave • Damaged or faulty water pump
• Seized primary sliding sheave 4. Thermostat
• Thermostat stays closed
Poor starting performance 5. Oil cooler
1. V-belt • Clogged or damaged oil cooler
• V-belt slips 6. Hose(s) and pipe(s)
• Oil or grease on the V-belt • Damaged hose
2. Primary sliding sheave • Improperly connected hose
• Faulty operation • Damaged pipe
• Worn pin groove • Improperly connected pipe
• Worn pin
3. Clutch shoe Fuel system
• Bent, damaged or worn clutch shoe 1. Throttle body
• Faulty throttle body
Poor speed performance • Damaged or loose throttle body joint
1. V-belt 2. Air filter
• Oil or grease on the V-belt • Clogged air filter element
2. Primary pulley weight(s)
• Faulty operation Chassis
• Worn primary pulley weight 1. Brake(s)
3. Primary fixed sheave • Dragging brake
• Worn primary fixed sheave
4. Primary sliding sheave Electrical system
• Worn primary sliding sheave 1. Spark plug
5. Secondary fixed sheave • Incorrect spark plug gap
• Worn secondary fixed sheave • Incorrect spark plug heat range
6. Secondary sliding sheave 2. Ignition system
• Worn secondary sliding sheave • Faulty ECU
3. Radiator fan
• Faulty fan motor
• Disconnected circuit breaker terminal
• Faulty coolant temperature sensor
10-3
TROUBLESHOOTING
EAS28610
6. Frame
OVERCOOLING
• Bent frame
• Damaged frame
Cooling system
1. Thermostat EAS28710
• Thermostat stays open FAULTY LIGHTING OR SIGNALING SYSTEM

EAS28620
Headlight does not come on
POOR BRAKING PERFORMANCE
• Wrong headlight bulb
• Worn brake pad
• Too many electrical accessories
• Worn brake disc
• Hard charging
• Air in hydraulic brake system
• Incorrect connection
• Leaking brake fluid
• Improperly grounded circuit
• Faulty brake caliper kit
• Poor contacts (main or light switch)
• Faulty brake caliper seal
• Burnt-out headlight bulb
• Loose union bolt
• Damaged brake hose Headlight bulb burnt out
• Oil or grease on the brake disc • Wrong headlight bulb
• Oil or grease on the brake pad • Faulty battery
• Incorrect brake fluid level • Faulty rectifier/regulator
EAS1XD1129 • Improperly grounded circuit
FAULTY SHOCK ABSORBER ASSEMBLY • Faulty main switch
• Faulty light switch
Leaking oil • Headlight bulb life expired
• Bent, damaged or rusty damper rod
• Cracked or damaged shock absorber Tail/brake light does not come on
• Damaged oil seal lip • Wrong tail/brake light bulb
• Too many electrical accessories
Malfunction • Incorrect connection
• Fatigued or damaged shock absorber spring • Burnt-out tail/brake light bulb
• Bent or damaged damper rod
EAS28670
Tail/brake light bulb burnt out
UNSTABLE HANDLING • Wrong tail/brake light bulb
1. Steering wheel • Faulty battery
• Bent or improperly installed steering wheel • Faulty brake light switch
2. Steering components • Tail/brake light bulb life expired
• Incorrect toe-in • Faulty rectifier/regulator
• Bent steering shaft • Improperly grounded circuit
• Improperly installed steering shaft
• Damaged bearing or bearing race
• Bent tie-rods
• Deformed steering knuckles
3. Shock absorber assembly(-ies)
• Faulty shock absorber spring
• Leaking oil or gas
4. Tire(s)
• Uneven tire pressures (left and right)
• Incorrect tire pressure
• Uneven tire wear
5. Wheel(s)
• Incorrect wheel balance
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout
10-4
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EAS1XD1002

Self-diagnostic function table
Fault Reference
Item
code No. pages
Crankshaft position sensor: no normal signals are received from the
12 9-38
crankshaft position sensor.
13 Intake air pressure sensor: open or short circuit detected. 9-39
Intake air pressure sensor: hose system malfunction (clogged or de-
14 9-41
tached hose).
15 Throttle position sensor: open or short circuit detected. 9-42
16 Throttle position sensor: stuck throttle position sensor is detected. 9-43
21 Coolant temperature sensor: open or short circuit detected. 9-44
22 Intake air temperature sensor: open or short circuit detected. 9-45
30 Latch up detected. 9-47
Ignition coil: open or short circuit detected in the primary lead of the
33 9-47
ignition coil.
Component other than ISC (idle speed control) unit is defective (ISC
9-49
operating sound is heard).
37
Defective ISC (idle speed control) unit (ISC operating sound is not
9-50
heard).
39 Injector: open or short circuit detected. 9-52
41 Lean angle sensor: open or short circuit detected. 9-53
42 Speed sensor: no normal signals are received from the speed sensor. 9-54
Fuel system voltage: incorrect voltage supplied to the fuel injector and
43 9-55
fuel pump.
EEPROM fault code number: an error is detected while reading or
44 9-56
writing on EEPROM.
46 Charging voltage is abnormal. 9-57
Faulty ECU (engine control unit) memory. (When this malfunction is
50 9-58
detected in the ECU, the fault code number might not appear.)
10-5
Communication error with the meter
Fault Reference
Item
code No. pages
ECU (engine control unit) internal malfunction (output signal error):
Er-1 signals cannot be transmitted between the ECU and the multi-function 9-58
meter.
ECU (engine control unit) internal malfunction (output signal error): no
Er-2 9-59
signals are received from the ECU within the specified duration.
ECU (engine control unit) internal malfunction (output signal error):
Er-3 9-60
data from the ECU cannot be received correctly.
ECU (engine control unit) internal malfunction (input signal error):
Er-4 9-61
non-registered data has been received from the meter.
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
signal
• Fully closed position 14–20 Check with throttle valve
fully closed.
03 Intake air pressure Displays the intake air Turn and hold the main
pressure. switch in the “ ” (start)
position, then press the
accelerator pedal. (If the
display value changes, the
performance is OK.)
05 Intake air temperature When engine is cold: Dis- Compare the actually
plays temperature closer measured intake air tem-
to ambient temperature. perature with the display
When engine is hot: Dis- value.
plays ambient temperature
20 °C (68 °F).
06 Coolant temperature When engine is cold: Dis- Compare the actually
plays temperature closer measured coolant temper-
to ambient temperature. ature with the display val-
When engine is hot: Dis- ue.
plays current coolant tem-
perature.
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.
10-6
Diagnostic
code No.
08 Lean angle sensor Lean angle sensor output Remove the lean angle
voltage sensor and incline it more
• Upright 3.6–4.4 than 65 degrees.
• Overturned 0.7–1.3
Fuel system voltage (bat- Approximately 12.0 Turn the main switch to
tery voltage) “ ” (on), and then com-
pare the actually mea-
sured battery voltage with
09
the display value. (If the
actually measured battery
voltage is low, recharge
the battery.)
21 Gear position switch Shift the transmission.
• Transmission is in neu- ON
tral
• Transmission is in gear OFF
60 EEPROM fault code dis-
play
• No history 00 —
• No malfunctions detect-
ed (If the fault code 44 is
indicated, the ECU is de-
fective.)
• History exists 01 (Cylinder fault code)
61 Malfunction history code
display
• 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 num-
bers.
When all code numbers
are shown, the display
repeats the same pro-
cess.)
10-7
Diagnostic
code No.
62 Malfunction history code
erasure
• History exists • Displays the total num- Save the malfunction his-
ber of malfunctions, in- tory to the computer, and
cluding the current then delete the fault
malfunction, that have codes.
occurred since the histo-
ry was last erased. (For
example, if there have
been three malfunc-
tions, “03” is displayed.)
70 Control number 0–254 [-] —
Diagnostic code: actuator operation table

Diagnostic
Item Actuation Procedure
code No.
30 Ignition coil Actuates the ignition coil Check that a spark is gen-
five times at one-second erated five times.
intervals. • Connect an ignition
The “CHECK” indicator checker.
and “ ” on the Yamaha
diagnostic tool screen
come on each time the ig-
nition coil is actuated.
36 Injector Actuates the injector five Check that the injector is
times at one-second inter- actuated five times by lis-
vals. tening for the operating
The “CHECK” indicator sound.
come on each time the
fuel injector is actuated.
48 Air induction system sole- Actuates the air induction Check that the air induc-
noid system solenoid five times tion system solenoid is ac-
at one-second intervals. tuated five times by
The “CHECK” indicator listening for the operating
and “ ” on the Yamaha sound.
come on each time the air
induction system solenoid
is actuated.
10-8
Diagnostic
Item Actuation Procedure
code No.
50 Fuel injection system relay Actuates the fuel injection Check that the fuel injec-
system relay five times at tion system relay unit is
one-second intervals. actuated five times by lis-
The “CHECK” indicator tening for the operating
and “ ” on the Yamaha sound.
come on each time the re-
lay is actuated.
(When the relay is on, the
“CHECK” indicator and
“ ” on the Yamaha diag-
nostic tool screen go off.
When the relay is off, the
nostic tool screen come
on.)
51 Radiator fan motor relay Actuates the radiator fan Check that the radiator fan
motor relay five times at motor relay is actuated
five-second intervals. (2 five times by listening for
seconds on, 3 seconds the operating sound.
off)
The “CHECK” indicator
come on each time the re-
lay is actuated.
(When the relay is on, the
nostic tool screen go off.
When the relay is off, the
nostic tool screen come
on.)
54 ISC valve Actuates and fully closes The operating sound can
the ISC valve, then opens be heard when ISC valve
it to the stand-by opening operates.
position when the engine
is started.
This operation takes ap-
proximately 3 seconds un-
til it is completed.
The “CHECK” indicator
come on during the opera-
tion.
10-9
EAS28740
54. Auxiliary DC jack EAS28750
WIRING DIAGRAM 55. Brake light switch COLOR CODE

YX70ME/YX70MHE/YX70MNE/ 56. Tail/brake light B Black
YXM700DE 2014 57. Radiator fan motor fuse Br Brown
1. Crankshaft position sensor 58. Differential motor fuse G Green
59. Ignition fuse Gy Gray
2. AC magneto
L Blue
3. Rectifier/regulator 60. Backup fuse
Lg Light green
4. Load control relay 61. Signaling system fuse O Orange
5. Frame ground 62. Headlight fuse P Pink
6. Main switch 63. Auxiliary DC jack fuse R Red
7. Engine ground 64. Radiator fan motor Sb Sky blue
8. Battery 65. Radiator fan motor circuit W White
9. Main fuse breaker Y Yellow
10. Fuel injection system fuse 66. Radiator fan motor relay B/G Black/Green
11. Starter relay 67. Horn switch (for Europe and B/L Black/Blue
Oceania) B/R Black/Red
12. Starter motor
B/W Black/White
13. Fuel injection system relay 68. Horn (for Europe and Oceania)
B/Y Black/Yellow
14. Air induction system solenoid 69. Backup light Br/B Brown/Black
15. Differential motor relay 1 70. Backup light relay Br/L Brown/Blue
16. Differential motor A. Optional Br/R Brown/Red
17. Gear position switch B. Wire harness Br/W Brown/White
18. On-Command four-wheel-drive C. Negative battery sub-wire har- Br/Y Brown/Yellow
switch ness G/R Green/Red
19. Yamaha diagnostic tool coupler G/W Green/White
20. ISC (idle speed control) unit G/Y Green/Yellow
21. ECU (engine control unit) Gy/G Gray/Green
L/B Blue/Black
22. Ignition coil
L/R Blue/Red
23. Spark plug L/W Blue/White
24. Fuel injector L/Y Blue/Yellow
25. Intake air temperature sensor O/B Orange/Black
26. Coolant temperature sensor O/L Orange/Blue
27. Speed sensor P/L Pink/Blue
28. TPS (throttle position sensor) P/W Pink/White
29. Intake air pressure sensor R/B Red/Black
30. Lean angle sensor R/G Red/Green
31. Parking brake switch R/L Red/Blue
R/W Red/White
32. Reverse switch
R/Y Red/Yellow
33. Joint coupler W/B White/Black
34. Seat belt switch W/G White/Green
35. Indicator light assembly W/R White/Red
36. Helmet indicator light Y/B Yellow/Black
37. Seat belt indicator light Y/G Yellow/Green
38. Meter assembly Y/L Yellow/Blue
39. Multi-function meter Y/R Yellow/Red
40. Engine trouble warning light Y/W Yellow/White
41. Coolant temperature warning
light
42. Parking brake indicator light
43. Reverse indicator light
44. Neutral indicator light
45. High-range indicator light
46. Low-range indicator light
47. On-Command differential gear
lock indicator light
48. Fuel sender
49. Fuel pump
51. Light switch
52. Headlight relay
53. Headlight
EAS1XD1041
52. Low-range indicator light EAS1XD1042
WIRING DIAGRAM 53. On-Command differential gear COLOR CODE

YX70MPE/YX70MPHE/ lock indicator light B Black
YX70MPNE/YXM700PE/ 54. EPS warning light Br Brown
YXM700PHE 2014 55. Fuel sender G Green
56. Fuel pump Gy Gray
L Blue
2. AC magneto 57. Differential motor relay 2
Lg Light green
3. Rectifier/regulator 58. Light switch O Orange
4. Load control relay 59. Headlight relay P Pink
5. Frame ground 60. Headlight R Red
6. Main switch 61. Auxiliary DC jack Sb Sky blue
7. Engine ground 62. Brake light switch W White
8. Battery 63. Tail/brake light Y Yellow
9. Main fuse 64. Radiator fan motor fuse B/G Black/Green
10. EPS fuse 65. Differential motor fuse B/L Black/Blue
66. Ignition fuse B/R Black/Red
B/W Black/White
12. Starter relay 67. Backup fuse
B/Y Black/Yellow
13. Starter motor 68. Signaling system fuse Br/B Brown/Black
14. Fuel injection system relay 69. Headlight fuse Br/L Brown/Blue
15. Air induction system solenoid 70. Auxiliary DC jack fuse Br/R Brown/Red
16. Differential motor relay 1 71. Radiator fan motor Br/W Brown/White
17. Differential motor 72. Radiator fan motor circuit Br/Y Brown/Yellow
18. Gear position switch breaker G/R Green/Red
19. On-Command four-wheel-drive 73. Radiator fan motor relay G/W Green/White
switch 74. Horn switch (for Europe and G/Y Green/Yellow
20. Yamaha diagnostic tool coupler Oceania) Gy/G Gray/Green
75. Horn (for Europe and Oceania) L/B Blue/Black
21. ISC (idle speed control) unit
L/R Blue/Red
22. ECU (engine control unit) 76. Backup light
L/W Blue/White
23. Ignition coil 77. Backup light relay L/Y Blue/Yellow
24. Spark plug A. Optional O/B Orange/Black
25. Fuel injector B. Wire harness O/L Orange/Blue
26. Intake air temperature sensor C. Negative battery sub-wire har- O/W Orange/White
27. Coolant temperature sensor ness P/L Pink/Blue
28. Speed sensor D. EPS (electric power steering) P/W Pink/White
29. TPS (throttle position sensor) control unit R/B Red/Black
30. Intake air pressure sensor R/G Red/Green
R/L Red/Blue
R/W Red/White
32. Parking brake switch R/Y Red/Yellow
33. Reverse switch W/B White/Black
34. Joint coupler W/G White/Green
35. EPS unit W/R White/Red
36. EPS motor Y/B Yellow/Black
37. EPS torque sensor Y/G Yellow/Green
38. EPS self-diagnosis signal con- Y/L Yellow/Blue
nector Y/R Yellow/Red
39. EPS (electric power steering) Y/W Yellow/White
control unit
40. Seat belt switch
41. Indicator light assembly
42. Helmet indicator light
43. Seat belt indicator light
44. Meter assembly
45. Multi-function meter
46. Engine trouble warning light
47. Coolant temperature warning
light
48. Parking brake indicator light
49. Reverse indicator light
50. Neutral indicator light
51. High-range indicator light
YX70ME/YX70MHE/YX70MNE/ YX70ME/YX70MHE/
YXM700DE 2014 WIRING DIAGRAM YX70MNE/YXM700DE 2014
SCHÉMA DE CÂBLAGE
A
B B
67 P
A Br/Y L
B
G/W
OFF
68 69 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
B/L Gy Gy B/L
G/W O O
W W W B R Gy 23
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/W
W W W W
W W R (B) (B) R/W 24 R/L R
(Gy) (Gy) 2 W W
W W
3 R/W
(Gy)
Br/Y R/W
W W
14
W/G R/W R/G
20
P/L P/L
25 Br/W B/L
G/W
Br/L R/W P/L
G/Y G/Y B/L
32
26 G/Y B/L
R/W 19 Y/W Y/W
(B)
B/W W
R/L
R/W
21
R/Y L L/Y
W L/Y L W
Br/R
R
Y/R
Y/B
L
W 27 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 L/R
B/L B/L B/L B/L B/L B/L B/L B/L
B Br/R R/L Y
P/W
Y Y 28 B/L Y L
R Br/R L/R L (B)
Br/L
5 R R Br/B
Br/B O/L
B/G
(B)
R B 8 10 13
W/B
B/R P P
L
29 B/L P L 33
Br/L B/L B/L
Br/R Sb
Br/R (B)
B
11 P/W B/G W/B Gy/G
Sb W/R
W/R
L/W
L/B
L
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)
66 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 B
B/W B L/B
Br/R Y/R (B)
R/L
Br/L W/B
65 63
Br
62 Br/Y
G/W G/W G/W Y Y Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
R/W
61 Br/Y
R/W
Br
Br/R 38 (B)
R/W
60 Y Br/Y
W/B Br/R
R/B R (B) Br/Y

51
Y Br
50 39 33
L
L 59 Br 54 (off)
Br/B
B/W
B/W
B/W
G/W
G/W
G/W
Br/R Br/L Br Y R/W Y/L B/W Y
58 (B) 55 Br/Y B/W B/W Y
64 R R
G W/B G
Br/B
G/R
B
O/B B/W
R/L
R/L
Y
Br/Y
Br/Y
L B
Y
W/B B B
Br/R B G/R R/L O/B
40 L/Y
L/Y
L/Y
Br/Y
Br/Y
Br/Y
Y (B)
Y
B R/W
B
Y
41
L
Y 52 L 49 48 O/B
Y/L Br/Y B/W
R/W
Y G B L 42 35 Br/Y
(B) Lg
Lg B
(B)
B
G
G
B B/W
43 B Br/Y Br B
Br

L
(Dg) 44 (B) 34
Y L
Y LL
Y Y G Y G 36 L
37
45 B
53 53 B L/B
56 56 G Y G Y 46
B B
B B
47
Y G Y G
B B
B B
YX70ME/YX70MHE/YX70MNE/ YX70ME/YX70MHE/
YXM700DE 2014 WIRING DIAGRAM YX70MNE/YXM700DE 2014
SCHÉMA DE CÂBLAGE
A
67 A
OFF
68 69 B C
ON
(B)
(B)
70
(B)
22
23
1 (Gy) (B)
(B) (B) 24
(Gy) (Gy) 2 3 (Gy)
14 20 25
(Gy) (Gy)
(B) (B)
32
26
19 (B)
21
27
9
4
28
(B)
5 (B)
8 10 13 29 33
(B)
11
A 15 30
6 17 (Gy)
(off)
12 16 18
(on) 2WD
(B)
(start)
66
4WD
31
7 (B)
DIFF LOCK
(W)
(B) (B) (Gy)
(B)
65 63
62
61
38 (B)
60
(B)
51 50 39 33
59 54 (off)
58 (B) 55
64
57
40
(B)
41
52 49 48
42 35
(B)
(B)
43
(Dg) 44 (B) 34
36 37
45
53 53
56 56 46
47
YX70MPE/YX70MPHE/YX70MPNE/ YX70MPE/YX70MPHE/YX70MPNE/
YXM700PE/YXM700PHE YXM700PE/YXM700PHE 2014
2014 WIRING DIAGRAM SCHÉMA DE CÂBLAGE
A
B B
74 P
A Br/Y L
B
G/W
OFF
75 76 B L B C
ON
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 G/W 77 Y/R B P/L L/B Br/L O B B
(B) (B) (B)
Br/R 23 D C
B/L Gy Gy B/L
G/W O O
W W W B R Gy 24
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/W
W W W W
W W R (B) (B) R/W 25 R/L R
(Gy) (Gy) 2 W W
W W
3 R/W
(Gy)
Br/Y R/W O/W
W W
15
W/G R/W R/G
21
P/L P/L
26 Br/W B/L
G/W
Br/L R/W P/L
G/Y G/Y B/L
33
27 G/Y B/L
R/W 20 Y/W Y/W
(B)
B/W W
R/L
R/W
22
R/Y L L/Y
W L/Y L W
Br/R
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
4 BB B R R R R/B Br/B L/Y B/L
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 8 11 14
W/B
B/R P P
L
30 B/L P L 34
Br/L B/L B/L
Br/R Sb
Br/R (B)
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)
73 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 B
B/W B L/B
Br/R Y/R (B)
35 G R B R
B W 37 36
R/L (Gy) (Gy)
G R B W
R B
Br/L W/B
GR B WR B
72 70
Br R G R B
69 W B
G/W G/W G/W Y Y Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
Br/Y R/B
68 Br/Y G W
R/W
R/W Br/R 44
R
B B
Br
39 O
G/R
O/W
W/B
(B)
Br
R/W
67 Y Br/Y
W/B Br/R
L/B Br O
L/B L/B
R/B R (B) Br/Y

58
Y Br
57 45 R/B G
G W G/R
O/W R L/B
G/R W
38 34
L (Gy)
L 66 Br 61 (off)
Br/B (Gy) (B)
(B)
B/W
B/W
B/W
G/W
G/W
G/W
Br/R Br/L Br Y R/W Y/L B/W Y
65 (B) 62 Br/Y B/W B/W Y
71 R R
G W/B G
Br/B
G/R
B
O/B B/W
R/L
R/L
Y
Br/Y
Br/Y
64 Y B
L Y Br/R 46 R/L
L/Y
Br/Y
Br/Y
W/B B L/Y Br/Y
L/Y Br/Y
Y
Y
Y
(B)
47
B
B R/W L
Y 59 L 56 55 48
O/B G/R R/W
Y/L Br/Y B/W
Y G B L
(B)
41 Br/Y
(B) 49 Lg Lg B
B B B/W Br
G
G B Br/Y Br B
R/L B B/W O/B 50 L/B L
B Lg
(Dg)
(B) 40
Y L
Y LL
Y Y G Y G
51 42 L
43
60 60 52 B L/B
B
63 63 G G
B
Y
B
Y
53
Y G B B Y G
54
B B G/R
B B
YX70MPE/YX70MPHE/YX70MPNE/ YX70MPE/YX70MPHE/YX70MPNE/
YXM700PE/YXM700PHE YXM700PE/YXM700PHE 2014
2014 WIRING DIAGRAM SCHÉMA DE CÂBLAGE
A
74 A
OFF
75 76 B C
ON
B
(B)
(B)
77
(B) (B) (B)
23 D C
24
1 (Gy) (B)
(B) (B) 25
(Gy) (Gy) 2 3 (Gy)
15 21 26
(Gy) (Gy)
(B) (B)
33
27
20 (B)
22
28
9 10
4
29
(B)
5 (B)
8 11 14 30 34
(B)
12
A 16 31
6 18 (Gy)
(off)
13 17 19
(on) 2WD
(B)
(start)
73
4WD
32
7 (B)
DIFF LOCK
(W)
(B) (B) (Gy)
(B)
35
37 36
(Gy) (Gy)
72 70
69
68
44 B 39 (B)
67
(B)
58 57 45 38 34
(Gy)
66 61 (off)
(Gy) (B)
(B)
65 (B) 62
71
64 46
(B)
47
59 56 55 48
(B)
41
(B) 49
50
(Dg)
(B) 40
51 42 43
60 60 52
63 63
53
54

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2014-2015 Yamaha Viking Service Manual PDF

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2014

IMPORTANT MANUAL INFORMATION

A WARNING indicates a hazardous situation which, if not avoided, could

A NOTICE indicates special precautions that must be taken to avoid

TIP A TIP provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

6 Order Job/Parts to remove Q’ty Remarks

CHECKING THE CLUTCH SHOE 2

CHECKING THE CLUTCH Clutch shoe thickness

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 ......................................................................... 1-9

BASIC SERVICE INFORMATION.................................................................1-11

SPECIAL TOOLS .......................................................................................... 1-16

VEHICLE IDENTIFICATION NUMBER

OUTLINE OF THE FI SYSTEM

1. Lean angle sensor 10. Throttle position sensor

1. Fuel pump 13. Throttle position sensor

1. Speed information from speed sensor b. Twists torsion bar

Voltage display mode TIP

PREPARATION FOR REMOVAL AND

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS RUBBER PARTS

BASIC SERVICE INFORMATION

NOTICE Checking the electrical system

Intake air temperature sensor re-

Tappet adjusting tool 3-4

Oil filter wrench 3-13

Ball joint remover 4-58, 4-62

Ball joint remover adapter set 4-58, 4-62

Base plate 35mm 45mm ø35 4-58, 4-62

Ball joint installer attachment 39mm 4-58, 4-62

Compression gauge 5-14

Slide hammer bolt 5-17, 5-19

Valve spring compressor attachment 5-21, 5-26

Valve guide remover (ø6) 5-22

Valve guide installer (ø6) 5-22

Valve guide reamer (ø6) 5-22

Piston pin puller set 5-28

Sheave holder 5-34, 5-35,

Flywheel puller 5-34

Digital circuit tester 5-39, 7-13,

Sheave fixed block 5-53, 5-57

Locknut wrench 5-53, 5-57

Sheave spring compressor 5-53, 5-57

Crankcase separating tool 5-73

Crankshaft installer pot 5-75

Crankshaft installer bolt 5-75

Adapter (M16) 5-75

Coupling gear/middle shaft tool 5-87, 5-90

Bearing retainer wrench 5-88, 5-89

Ring nut wrench 5-88, 5-89

Final gear backlash band 5-91