Yamaha 2019-2020 Grizzly Service Manual

EBS20003
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-
cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• This Service Manual contains information regarding periodic maintenance to the emission control sys-
tem. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EBS30001
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal
& 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 re-

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

NOTICE age to the vehicle or other property.
I A TIP provides key information to make procedures easier or clearer.
EBS20002
YFM70GPAKNFM70GPHK/
YFM70GPLK
SERVICE MANUAL
©2019 by Yamaha Motor Corporation, U.S.A.
First edition, April 2018
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
LIT-11616-32-13
EBS20004
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
"1" is shown at the top of each page.
• Sub-section titles "2" appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams "3" at the start of each
removal and disassembly section.
• Numbers "4" are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols "5" indicate parts to be lubricated or replaced.
Refer to "SYMBOLS".
• A job instruction chart "6" accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
• Jobs "7" requiring more information (such as special tools and technical data) are described sequen-
tially.
1
CLUTCH CLUTCH
-
CLUTCH /
v .)_,1
""1
Clutcfl shoe IPlk:knua
1.5 mm (O.o6 In)
~ CMch al'lot tl'llclcnMa llfflll
..
:I.Nall;
• ON-way dutlch buring
1.0 mm (0.04 In) The on.way 411th bearing should be instal«I

n tit dlAcfl ca,rle, anent,ly vMl IN 'OUT
set martt ·o· fac:ing - .Id N cluectl housin9,
[~,=, ~,~~~,~ ...-

. . . •• . ..... • ...,~:~-
• ~~\
~ I
.-
\
4-+- +-=----•
••• r.l\. <
{ ) w -<lJ
AI HMBI.INO THE CLUTCH liOUUfG
I tnflllll
• a..t\no"1"
'V,.
tn.1talted depll'I ~. ..
2.S-2.Jmm(0.10-4.11 In>
·- .- .... ·,· m
•
'
:; ~ r IION-ffl ltlo ......
......~ · -<ll
s- ---- ---.• ~ .;i.. ...,...,...,.....,i

911
6--+----,~ ~
- ~--;;-;;;..;;.;;;
,o..,;;;;_;:;--,-..; _ ;;;
o.,,; -J"----;-;;:;; _;-_-I ' """"'-"" • ci...:ti Cilmtf HU rrbly
2. fn61all: ..... ·r· mm
.Oil•·,·mm "-... CMCh cwritf MMmbly fW1
' ...... '

... - - - - - - - < - - - c - , f - - - - - - - <
J'·· Ito H,m l1t ligl.,m, UO lb h)
~-' - - - - - - ~-....+-7
°'*".,........, TM C'kAffi center ••Mmbly nut n,, left,
..
Nl'ICI ttvuda. To dgtlett'I O'f ~t,l(fl Clfl'ltt
•• 11ftb1r nut. Mn k countetctoclairlfH..
U N • ~ ~ IOOl 'T k>nold h WICfl

ca,rief llllmt>ly
5·58
·-- 5-61
EBS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
A Serviceable with engine mounted -1 Gear oil

G)
1-
~ Filling fluid
~
Molybdenum disulfide oil
I Lubricant 1- Brake fluid

~
~ Special tool
~ Wheel bearing grease
~~ Tightening torque
~ Lithium-soap-based grease
Wear limit, clearance

-«M»I Molybdenum disulfide grease
w Engine speed
~ Silicone grease
-'
~ Electrical data
A Apply locking agent (LOCTITE®).
1-
m Engine oil • Replace the part with a new one.
E~l OOOl TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND

ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
FUEL SYSTEM
DRIVE TRAIN
ELECTRICAL SYSTEM
TROUBLESHOOTING
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER ..................................................... 1-1
MODEL LABEL .......................................................................................... 1-1
FEATURES ...................................................................................................... 1-2

INSTRUMENT FUNCTIONS ..................................................................... 1-2
IM PORTA NT INFORMATION ......................................................................... 1-5

PREPARATION FOR REMOVAL AND DISASSEMBLY ........................... 1-5
REPLACEMENT PARTS ........................................................................... 1-5
GASKETS, OIL SEALS AND 0-RINGS .................................................... 1-5
LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-5
BEARINGS AND OIL SEALS .................................................................... 1-6
CIRCLIPS .................................................................................................. 1-6
RUBBER PARTS ....................................................................................... 1-6
BASIC SERVICE INFORMATION ................................................................... 1-7

QUICK FASTENERS ................................................................................. 1-7
ELECTRICAL SYSTEM ............................................................................. 1-8
SPECIAL TOOLS .......................................................................................... 1-12

IDENTIFICATION
EBS20009
IDENTIFICATION
EBS30003
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number "1" is stamped
into the frame.
EBS30004
MODEL LABEL
The model label "1" is affixed at the location in
the illustration. This information will be needed to
order spare parts.
1-1
FEATURES
EBS20010
Odometer and tripmeters
FEATURES
EBS30008
INSTRUMENT FUNCTIONS t
Multi-function display I
1. Odometer/Tripmeter A/Tripmeter 8/Service

tripmeter/Error code display
2. "SELECT" button
3. "RESET" button
The odometer shows the total distance traveled

1. Speedometer by the vehicle.
2. Odometer/Tripmeter A/Tripmeter 8/Service The tripmeters show the distance traveled since
tripmeter/Error code display
they were last reset. The tripmeters can be used
3. Clock/Hour meterNoltage display/Coolant
temperature display
to record the distance traveled on a single trip, or
4. Fuelgauge
to estimate the distance that can be traveled
with a full tank of gas, etc. The seNice tripmeter
5. "MODE" button
6. "SELECT" button
shows the distance traveled since it was reset at
7. "RESET'' button
the last maintenance.
Push the "SELECT' button to switch between
The multi-function display is equipped with the the odometer "ODO", the tripmeters ''TRIP A"
following: and ''TRIP B", and the seNice tripmeter ".> " in
• speedometer the following order:
• odometer
• tripmeters ODO ~ TRIP A~ TRIP B ~ .> ~ ODO
• clock
• hour meter To reset a tripmeter, set the display to the trip-
• voltage display meter you want to reset, then push the "RESET'
• coolant temperature display button for 2 seconds.
•fuel gauge TIP~~~~~~~~~~~~~~~~
• brightness control mode • The odometer will lock at 199999.
• error code display • The tripmeters will reset and continue counting
after 9999.9 is reached.
Speedometer
The speedometer shows the vehicle's traveling
speed. The speedometer can be set to "MPH" or
"km/h". This also changes the odometer and trip-
meter units between miles and kilometers. To
change the display between "MPH" and "km/h",
turn the key to" o " (off), then while holding the
"SELECT' button pushed, turn the key to " 0 "
(on).
1-2
FEATURES
Clock, hour meter, voltage display and cool- Voltage display

ant temperature display
'
- ..... ..... i)
L
H
11...11...I I
N
TRIP AB ILILILlllLI £
1- ~VOLT IJJ
IL._1 _
1. Voltage display
1. Clock/Hour meterNoltage display/Coolant
temperature display This display shows the battery voltage. If the bat-
2. "MODE" button tery voltage is less than 1O volts, "Lo" is dis-
3. "SELECT" button played, and if the voltage is above 18 volts, "Hi"
4. "RESET' button is displayed.
ECB02020
The clock displays time in 12-hour format. The NOTICE

hour meter shows the total time the engine has
-------------
1f the voltage display indicates "LO" or "HI",
been running. The voltage display shows the there may be trouble with the battery
battery voltage. The coolant temperature display charging circuit or the battery may be faulty.
shows the temperature of the coolant. If this occurs, check or repair the vehicle.
Push the "MODE" button to switch between the
clock "CLOCK" the hour meter "HOUR" the
' ' Coolant temperature display
voltage display "VOLT", and the coolant tem-
perature display ",J," in the following order:
- ..... ..... it)
CLOCK~ HOUR~ VOLT~ ,J, ~ CLOCK
11...11...I I
To set the clock
1. Set the display to the clock.
MIL/Ll~1,I
ODO 11717171717 -
2. Push both the "SELECT' button and "RE- ~
SET' button for 2 seconds. The hour digits 1-~---& 7C °F

will start flashing.
3. Push the "RESET" button to set the hours.
1. Coolant temperature display
4. Push the "SELECT' button, and the minute
digits will start flashing. When the coolant is in normal operating tem-
5. Push the "RESET' button to set the minutes. perature range, the temperature is displayed.
6. Push the "SELECT' button, and then release When the coolant temperature rises, the coolant
it to start the clock. temperature display will begin to flash. If the
coolant temperature continues to rise, the mes-
sage "Hi" will flash.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• The coolant temperature display can be set to
"°C" or "°F". To switch the temperature units,
turn the key to" o "(off), then while holding the
"RESET' button pushed, turn the key to " 0 "
(on).
• The radiator fan turns on and off automatically
according to the coolant temperature.
1-3
FEATURES
Fuel gauge To adjust the brightness

1. Push the "SELECT' button for 2 seconds.
1
- ........ -~] 2. Push the "RESET' button to set the bright-
ness level.
11..II..I 1: 3. Push the "SELECT' button to confirm the se-

lected brightness level and exit the bright-
w 1111
A ..... .... IMPH
km/h:
Ii
I:
ness control mode.
000 -----
I 17 17 17 17 17
.) ':: £ :: Fault code display
TRIP AB I LI LI LI l_ll_l
'-----'-
VO_
CLOCK
'LT__
f.
H<.c....c
OU.__
Cl C:11_1 I_I '-' .°C
l 1._.l_11_1.._l._
'R_-:-._.-:_l _1_ 1 --
: :
'F- - -~____:
1
1. Fuelgauge
The fuel gauge indicates the amount of fuel in
the fuel tank. The display segments of the fuel
gauge disappear from "F" (full) towards "E"
(empty) as the fuel level decreases. When the
last segment starts flashing, approximately 4.0 L
(1.06 US gal, 0.88 Imp.gal) of fuel remains. Re-
fuel as soon as possible. 1. Fault code display
-
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ 2. Engine trouble warning light " 0 "
If the electrical circuit for the fuel gauge is not
working correctly, all display segments will flash This model is equipped with a self-diagnosis de-
repeatedly. If this occurs, check the electrical cir- vice for various electrical circuits.
cuit. Refer to "SIGNALING SYSTEM" on page If a problem is detected in any of those circuits,
9-17. the engine trouble warning light will come on or
flash , and the display will indicate a fault code.
If the display indicates a fault code, note the
Brightness control mode code number, and then check the fuel injection
1 system. Refer to "FUEL INJECTION SYSTEM"
on page 9-29.
ECB02030
- · - - . . . . ii
11..~FI..I I NOTICE
-------------
1f the display indicates a fault code, the vehi-
cle should be checked as soon as possible
in order to avoid engine damage.
:00000:
CLOCK f.
'j7-j-j:fiii1=-1 :c
VOLT HOUR~ I_I l_ll_l l_ll_l 'F
•
fl
1. Brightness level display
This mode allows you to adjust the brightness of

the multi-function meter unit when the vehicle is
stopped.
1-4
IMPORTANT INFORMATION
EBS20011
EBS30009
PREPARATION FOR REMOVAL AND

DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
EBS30011
GASKETS, OIL SEALS AND 0-RINGS

1. When overhauling the engine, replace all
gaskets, seals and 0-rings. All gasket surfac-
es, oil seal lips and 0-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
2. Use only the proper tools and cleaning equip- lips with grease.
ment.
Refer to "SPECIAL TOOLS" on page 1-12.
3. When disassembling, always keep mated '--- 2
parts together. This includes gears, cylinders, '---- 3
pistons and other parts that have been "mat- I
1 •
ed" through normal wear. Mated parts must
always be reused or replaced as an assem- 4
bly.
1. Oil
2. Lip
3. Spring
4. Grease
EBS30012
LOCK WASHERS/PLATES AND COTTER

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

Install bearings "1" and oil seals "2" so that the Check rubber parts for deterioration during in-
manufacturer's marks or numbers are visible. spection. Some of the rubber parts are sensitive
When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc. Do not al-
lips with a light coat of lithium-soap-based low any items other than the specified one to
grease. Oil bearings liberally when installing, if contact the parts.
appropriate.
ECB01260
NOTICE
-------------
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
EBS30014
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip "1", make sure the
sharp-edged corner "2" is positioned opposite
the thrust "3" that the circlip receives.
3
2
1-6
BASIC SERVICE INFORMATION
EBS20012

EBS30016
QUICK FASTENERS
··--:
.~...,
~
~
Rivet type
1. Remove:
• Quick fastener
TIP ~~~~~~~~~~~~~~
To remove the quick fastener, push its pin with a

screwdriver, then pull the fastener out. Screw type
1. Remove:
• Quick fastener
TIP ~~~~~~~~~~~~~~
To remove the quick fastener, loosen the screw

with a screwdriver, then pull the fastener out.
Ill
{.l7
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.
1IT..
ill
1-7
EC B01520
EBS30017
NOTICE
ELECTRICAL SYSTEM -------------
Be sure to connect the battery leads to the
Electrical parts handling correct battery terminals. Reversing the bat-
EC801460 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. "+"
EC B01530
NOTICE
-------------
When connecting the battery leads to the
ECB01510 battery, be sure to connect the positive bat-
NOTICE tery lead first, then the negative battery lead.
------------- If the negative battery lead is connected first
When disconnecting the battery leads from
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.
e
e
0
EC B01470
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.
1-8
..
EC8014SO
NOTICE Checking the electrical system

------------- TIP ~~~~~~~~~~~~~~
Hand Ie electrical components with special
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.
EC801490 EC.001440
NOTICE NOTICE
------------- - - - - - - - - - - - - -
EIectricaI components are very sensitive to Never insert the tester probes into the cou-
and can be damaged by static electricity. pler terminal slots. Always insert the probes
Therefore, never touch the terminals and be from the opposite end "a" of the coupler, tak-
sure to keep the contacts clean. ing care not to loosen or damage the leads.
ECB01500
TIP ~~~~~~~~~~~~~~
NOTICE
When resetting the ECU by turning the main -------------
switch to "OFF", be sure to wait approximately 5 For waterproof couplers, never insert the
seconds before turning the main switch back to tester probes directly into the coupler. When
"ON". performing any checks using a waterproof
coupler, use the specified test harness or a
suitable commercially available test har-
ness.
1-9
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 RusVstains ~ Connect and disconnect sev-
• Coupler eral times.
• Connector
ECB0154-0
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.
EC8015SO
NOTICE
-------------
When disconnecting a connector, do not pull
the leads. Hold both sections of the connec-
tor securely, and then disconnect the con-
nector.
1-10
Digital circuit tester (CD732)

90890-03243
: Model 88 Multimeter with ta-
chometer
YU-A1927
: TIP ~~~~~~~~~~~~~~
The resistance values shown were obtained at

the standard measuring temperature of 20 °C
(68 °F). If the measuring temperature is not 20
4. Check: °C (68 °F), the specified measuring conditions
• Continuity will be shown.
(with the digital circuit tester)
Digital circuit tester (CD732) Intake air temperature sensor re-

90890-03243 sistance
Model 88 Multimeter with ta- 5.40-6.60 k.Q at O 0 c (32 °F)
chometer 29o-390 Q at 80 °C (176 °F)
YU-A1927
TIP~~~~~~~~~~~~~~
• If there is no continuity, clean the terminals. ~

• When checking the wire harness, perform
steps (1) to (3).
1
I
tQ
" "
I
7
(00~
• 'i
•Asa quick remedy, use a contact revitalizer ~
available at most part stores. ·1 ) -- iiY,;.o

\ - )
D
<==Ql
D
<==Q)
5. Check:
• Resistance
1-11
SPECIAL TOOLS
EBS20013
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• For U.S.A. and Canada, use part number starting with "YM-", ''YU-", ''VS-", ''YK-", or "ACC-".
• For others, use part number starting with "90890-".
Reference
Tool name!Tool No. Illustration
pages
Digital circuit tester (CD732) 1-11 1-11 5-44
90890-03243 9-76
' 9-77
'
9-77
'
Model 88 Multimeter with tachometer 9-78
' 9-82
'
9-84
'
YU-A1927 9-84
' 9-85
'
9-85
'
9-86
' 9-86
'
9-87
'
9-87
' 9-88
'
9-88
'
9-89
' 9-90
'
9-90
'
9-90
' 9-91
'
9-91
'
9-92
' ' '
Thickness gauge 3-6

90890-03180
Feeler gauge set
YU-26900-9
Tappet adjusting tool 90890-01311 3-6

90890-01311
Six piece tappet set 3mm
YM-A5970
YM-A5970
Ring nut wrench 3-17 3-18

90890-01268 '
Spanner wrench
YU-01268
Belt tension gauge 3-19

90890-03170
Rear drive belt tension gauge
YM-03170
\.1 t
1-12
SPECIAL TOOLS
Reference
pages
Oil filter wrench 3-23
90890-01469
Oil filter wrench
YM-01469
Ball joint remover 4-58, 4-63

90890-01474
Ball joint remover
YM-01474
Ball joint remover attachment set 4-58, 4-63

0
90890-01480
Ball joint adapter set
YM-01480
0
Ball joint installer attachment 38mm 4-58
90890-01583
Ball joint installer attachment 38mm
YM-01583
Ball joint remover short shaft set 4-58

90890-01514
Ball joint remover short shaft set
YM-01514
Compression gauge 90890-03081

5-3
90890-03081
Engine compression tester
YU-33223
YU-33223
Compression gauge extension 73mm 5-3

90890-04082
Compression gauge extension 73mm
YM-04082
Slide hammer bolt (M6) 5-21 , 5-23

90890-01083
Slide hammer bolt 6 mm
YU-01083-1
1-13
SPECIAL TOOLS
Reference
pages
Weight 5-21
90890-01084 90890-01084
Weight
YU-01083-3
YU-01083-3
Valve spring compressor 5-25 5-29

90890-04019 '
Valve spring compressor
YM-04019
Valve spring compressor attachment (026) 5-25 5-29

90890-01243 '
Valve spring compressor adapter (26 mm)
YM-01253-1
Valve guide remover (06) 5-26

90890-04064
Valve guide remover (6.0 mm)
YM-04064-A
Valve guide installer (06) 5-26

90890-04065
Valve guide installer (6.0 mm)
YM-04065-A
Valve guide reamer (06) 5-26

90890-04066
Valve guide reamer (6.0 mm)
YM-04066
Piston pin puller set 90890-01304 5-32

90890-01304
Piston pin puller
YU-01304
0
M6x P1 . ~
YU-01304
1-14
SPECIAL TOOLS
Reference
pages
Rotor holding tool 5-39, 5-39 , 5-40 ,
90890-04166 5-41 , 5-52 , 5-57
Rotor holding tool
YM-04166
Flywheel puller 5-39

90890-01362
Heavy duty puller
YU-33270-B
Yamaha bond No. 1215 5-41 , 5-68

90890-85505
(Three bond No.1215®)
Secondary sheave holding tool (53mm) 5-52, 5-57

90890-04186
Secondary sheave holding tool (53mm)
YM-04186
Extension handle 5-52, 5-57

90890-04187
Extension handle
YM-04187
Sheave fixed block 5-52, 5-55

90890-04135
90890-04135
Sheave fixed bracket 00
YM-04135
YM-04135
Locknut wrench 5-52, 5-55

90890-01348
90890-01348
Locknut wrench
YM-01348
YM-01348
=
·===-e
I:::(
1-15
SPECIAL TOOLS
Reference
pages
Sheave spring compressor 5-52 5-55
90890-04134 90890-04134 '
Sheave spring compressor
YM-04134
YM-04134
Universal clutch holder 5-60 5-61

90890-04086 90890-04086 '
Universal clutch holder
YM-91042
YM-91042
Crankcase separating tool 5-72

90890-01135
90890-01135
Crankcase separator
YU-01135-B M8xP1.25
M8xP1.25
YU-01135-B
M5x P0.80
M6xP1.00
Crankshaft installer pot 5-74

90890-01274
90890-01274
Installing pot
YU-90058
YU-90058/YU-90059
I)
1-16
SPECIAL TOOLS
Reference
pages
Crankshaft installer bolt 5-74
90890-01275
Bolt
YU-90060
M1 4xP1.5
Adapter (M16) M14x P1. 5-74

90890-04130
Adapter #13
YM-04059
M16XP1 .5
Spacer (crankshaft installer) 5-74

90890-04081
90890-04081 084
Pot spacer
YM-91044
YM-91044
Spacer 5-74
90890-01309 035
Pot spacer
YU-90059
Coupling gear/middle shaft tool 2 x22x1. 5-85, 5-85 , 5-88 ,

90890-01229 5-88
Gear holder
YM-01229
Bearing retainer wrench 5-86, 5-87

90890-04128
Middle gear bearing retainer
YM-04128
50X23X2.0
Ring nut wrench 5-86, 5-87

90890-01430
Ring nut wrench
YM-38404
047
Final gear backlash band 5-89, 8-29
90890-01511
Middle drive gear lash tool
YM-01230
1-17
SPECIAL TOOLS
Reference
pages
Radiator cap tester 90890-01325 6-4
90890-01325
Mityvac cooling system tester kit
YU-24460-A
YU-24460-A
Radiator cap tester adapter 6-4

90890-01352
90890-01352
Pressure tester adapter
YU-33984
YU-33984
Mechanical seal installer (033) 6-11

90890-04132
Water pump seal installer (033)
YM-33221-A
Middle driven shaft bearing driver 6-11

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

90890-03153
Pressure gauge
YU-03153
Fuel pressure adapter 7-7

90890-03176
Fuel pressure adapter
YM-03176
Yamaha diagnostic tool USB (US) 7-8 9-33

90890-03257 '
1-18
SPECIAL TOOLS
Reference
pages
Yamaha diagnostic tool (A/1) 7-8 9-33
90890-03262 '
OYAMAl'IA
Boots band installation tool 8-9 8-9 8-11

90890-01526 8-21' 8-21
' 8-23
'
Boots band installation tool
' '
YM-01526
Ring gear fix bolt (M10) 8-13

90890-01527
Ring gear fix bolt (M10)
YM-01527
M10xP1 .25
Gear lash measurement tool

90890-01475
.~-------
65
8-13
YM-01475
Ring gear fix bolt (M14) 8-29

90890-01524
Ring gear fix bolt (M14)
YM-01524
M14xP1 .5
Ignition checker 9-85

90890-06754
Oppama pet-4000 spark checker
YM-34487
1-19
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................ 2-2
CHASSIS SPECIFICATIONS .......................................................................... 2-6
ELECTRICAL SPECIFICATIONS ................................................................... 2-8
TIGHTENING TORQUES .............................................................................. 2-1 O

GENERAL TIGHTENING TORQUE SPECIFICATIONS ......................... 2-10
ENGi NE TIGHTEN ING TORQUES ......................................................... 2-11
CHASSIS TIGHTEN ING TORQUES ....................................................... 2-14
CABLE ROUTING ......................................................................................... 2-19

GENERAL SPECIFICATIONS
EBS20014
GENERAL SPECIFICATIONS
Model
Model B4F1 (YFM70GPLK)
B4FD (YFM70GPAK)
B4FG (YFM70GPHK)
Dimensions
Overall length 2070 mm (81.5 in)
Overall width 1230 mm (48.4 in) (YFM70GPAK,
YFM70GPHK)
1250 mm (49.2 in) (YFM70GPLK)
Overall height 1253 mm (49.3 in) (YFM70GPAK,
YFM70GPHK)
1270 mm (50.0 in) (YFM70GPLK)
Wheelbase 1250 mm (49.2 in)
Ground clearance 288 mm (11 .3 in) (YFM70GPAK, YFM70GPHK)
300 mm (11.8 in) (YFM70GPLK)
Minimum turning radius 3.7 m (12.14ft)
Maximum water depth 35 cm (14 in)
Weight
Curb weight 318.0 kg (701 lb) (YFM70GPAK, YFM70GPHK)
342.0 kg (754 lb) (YFM70GPLK)
Loading
Maximum loading limit 240.0 kg (530 lb)
Front carrier load limit 50.0 kg (110 lb)
Rear carrier load limit 90.0 kg (198 lb)
Storage compartment_ 1 location Center storage compartment
Load limit 4.0 kg (9 lb)
Storage compartment_2 location Front storage compartment
Storage compartment_3 location Rear storage compartment
Trailer hitch pulling load limit 5880 N (600 kgf, 1322 lbf)
Trailer hitch vertical load limit 147 N (15 kgf, 33 lbf)
2-1
ENGINE SPECIFICATIONS
EBS20015
Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train SOHC
Number of cylinders Single cylinder
Displacement 686 cm 3
Bore x stroke 102.0 x 84.0 mm (4.02 x 3.31 in)
Compression ratio 10.0 : 1
Compression pressure 435-560 kPa (4.4-5.6 kgf/cm 2 , 61.9-79.6 psi)
Lubrication system Wet sump
Starting system Electric starter
Fuel
Recommended fuel Regular unleaded gasoline only
Fuel tank capacity 18 L (4.8 US gal, 4.0 Imp.gal)
Fuel reserve amount 4.0 L (1.06 US gal, 0.88 Imp.gal)
Engine oil
Recommended brand YAMALUBE
SAE viscosity grades 5W-30, 1OW-30, 1OW-40, 15W-40, 20W-40,
20W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Quantity
Oil change 2.00 L (2.11 US qt, 1.76 Imp.qt)
With oil filter removal 2.1 O L (2.22 US qt, 1.85 Imp.qt)
Quantity (disassembled) 2.40 L (2.54 US qt, 2.11 Imp.qt)
Differential gear oil

Type Yamaha Friction Modified Plus Shaft Drive Oil
(Part No.: ACC-SHAFT-PL-32) or SAE 80 API
GL-4 Hypoid gear oil
Quantity 0.21 L (0.23 US qt, 0.19 Imp.qt)
Final gear oil

Type Yamaha Friction Modified Plus Shaft Drive Oil
(Part No.: ACC-SHAFT-PL-32) or SAE 80 API
Quantity 0.20 L (0.21 US qt, 0.18 Imp.qt)
Oil filter
Oil filter type Cartridge
Oil pump
Outer-rotor-to-inner-rotor-tip clearance 0-0.12 mm (0-0.0047 in)
Outer-rotor-to-inner-rotor-tip clearance limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.09-0.17 mm (0.0035-0.0067 in)
Outer-rotor-to-oil-pump-housing clearance limit 0.24 mm (0.0094 in)
2-2
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.03-0.1 O mm (0.0012-0.0039 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance limit 0.17 mm (0.0067 in)
Relief valve operating pressure 4.0 kPa (0.04 kgf/cm 2, 0.6 psi)
Cooling system
Coolant quantity
Radiator (including all routes) 1.99 L (2.1O US qt, 1.75 Imp.qt)
Coolant reservoir (up to the maximum level
mark) 0.24 L (0.25 US qt, 0.21 Imp.qt)
Radiator cap opening pressure 107.9-137.3 kPa (1.1-1 .4 kgf/cm 2, 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) 7.0 mm (0.28 in)
Water pump
Impeller shaft tilt limit 0.15 mm (0.006 in)
Spark plug (s)

Manufacturer/model NGK/CPR7EA-9
Spark plug gap 0.8-0.9 mm (0.031-0.035 in)
Cylinder head
Warpage limit 0.03 mm (0.0012 in)
Camshaft
Camshaft lobe dimensions
Lobe height (Intake) limit 42.885 mm (1.6884 in)
Lobe height (Exhaust) limit 43.390 mm (1.7083 in)
Camshaft runout limit 0.015 mm (0.0006 in)
Rocker arm/rocker arm shaft

Rocker arm inside diameter limit 12.033 mm (0.4737 in)
Rocker arm shaft outside diameter limit 11.950 mm (0.4705 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 seat contact width (intake) 1.00-1.20 mm (0.0394-0.0472 in)
Valve seat contact width (intake) limit 1.6 mm (0.06 in)
Valve seat contact width (exhaust) 1.00-1.20 mm (0.0394-0.0472 in)
Valve seat contact width (exhaust) limit 1.6 mm (0.06 in)
Valve stem diameter (intake) limit 5.945 mm (0.2341 in)
Valve stem diameter (exhaust) limit 5.930 mm (0.2335 in)
Valve-stem-to-valve-guide clearance (intake)
limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance
(exhaust) limit 0.100 mm (0.0039 in)
Valve stem runout 0.040 mm (0.0016 in)
2-3
Valve spring
Free length (intake) 40.38 mm (1.59 in)
Limit 35.00 mm (1.38 in)
Free length (exhaust) 40.38 mm (1.59 in)
Limit 35.00 mm (1.38 in)
Cylinder
Bore 102.000-102.010 mm (4.0157-4.0161 in)
Wear limit 102.060 mm (4.0181 in)
Piston
Piston-to-cylinder clearance 0.030-0.055 mm (0.0012-0.0022 in)
Diameter 101.955-101.970 mm (4.0140-4.0146 in)
Measuring point (from piston skirt bottom) 10.0 mm (0.39 in)
Piston pin bore inside diameter limit 23.045 mm (0.9073 in)
Piston pin outside diameter limit 22.971 mm (0.9044 in)
Piston ring
Top ring
End gap (installed) 0.20-0.35 mm (0.008-0.014 in)
End gap (installed) limit 0.60 mm (0.0236 in)
Ring side clearance 0.030-0.070 mm (0.0012-0.0028 in)
Ring side clearance limit 0.120 mm (0.0047 in)
2nd ring
End gap (installed) 0.75-0.90 mm (0.03-0.04 in)
End gap (installed) limit 1.25 mm (0.0492 in)
Ring side clearance 0.030-0.070 mm (0.0012-0.0028 in)
Ring side clearance limit 0.130 mm (0.0051 in)
Crankshaft
Crank assembly width 74.92-75.00 mm (2.950-2.953 in)
Runout limit 0.030 mm (0.0012 in)
Big end side clearance 0.350-0.650 mm (0.0138--0.0256 in)
Drivetrain
Primary reduction ratio 1.000
Secondary reduction ratio 10.142 (41/21 X 17/12 X 20/15 X 33/12)
Final drive Shaft
Clutch
Clutch type Wet, centrifugal, shoe
Clutch shoe thickness 1.5 mm (0.06 in)
Clutch shoe thickness limit 1.0 mm (0.04 in)
Clutch housing inside diameter 150.0 mm (5.91 in)
Clutch housing inside diameter limit 150.5 mm (5.93 in)
Compression spring free length limit 128.0 mm (5.04 in)
Weight outside diameter 30.0 mm (1.18 in)
Weight outside diameter limit 29.5 mm (1.16 in)
Clutch-in revolution 1950-2050 r/min
Clutch-stall revolution 3550-3650 r/min
Transmission
Transmission type CVT automatic with reverse
Main axle runout limit 0.08 mm (0.0032 in)
2-4
Drive axle runout limit 0.05 mm (0.0020 in)

Gear ratio
Low range 1.938 (31/16)
High range 1.148 (31/27)
Reverse gear 2.000 (23/14 X 28/23)
Transmission ratio 2.380-0.700 : 1
V-belt
V-belt width limit 31.3 mm (1.23 in)
Shaft drive
Middle gear backlash 0.10-0.30 mm (0.004-0.012 in)
Final gear backlash 0.10-0.20 mm (0.004-0.008 in)
Differential gear backlash 0.05-0.25 mm (0.002-0.01 O in)
Air filter
Air filter element Wet element
Air filter oil grade Foam air-filter oil
Fuel pump
Pump type Electrical
Throttle body
ID mark B4F100
Fuel injector
Fuel line pressure 300.0-390.0 kPa (3.0Q-3.90 kgf/cm 2 , 43.5-56.6
psi)
Resistance 12.0 Q
Air induction system

Solenoid resistance 18-22 Q
Idling condition
Engine idling speed 1550-1650 r/min
Coolant temperature 85-95 °C (185-203 °F)
Engine oil temperature 55-65 °C (131-149 °F)
Throttle lever free play 3.0-5.0 mm (0.12--0.20 in)
Speed limiter length 12.0 mm (0.47 in)
2-5
CHASSIS SPECIFICATIONS
EBS20016
Chassis
Caster angle 5.00 °
Camber angle 0.0 °
Kingpin angle 11.0 °
Kingpin offset 0.0 mm (0.00 in)
Trail 26.0 mm (1.02 in) (YFM70GPAK, YFM70GPHK)
27.0 mm (1.06 in) (YFM70GPLK)
Toe-in (with tires touching the ground) 0.0-10.0 mm (0.00-0.39 in)
Front track 1000.0 mm (39.37 in) (YFM70GPAK,
YFM70GPHK)
1005.0 mm (39.57 in) (YFM70GPLK)
Rear track 975.0 mm (38.39 in) (YFM70GPAK,
YFM70GPHK)
1000.0 mm (39.37 in) (YFM70GPLK)
Front wheel
Rim size 12 x 6.0 AT (YFM70GPAK, YFM70GPHK)
14 x 8.0 AT (YFM70GPLK)
Wheel material Aluminum
Radial wheel runout limit 0.5 mm (0.02 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Rear wheel
Rim size 12 x 7.5 AT (YFM70GPAK, YFM70GPHK)
14 x 8.0 AT (YFM70GPLK)
Wheel material Aluminum
Radial wheel runout limit 0.5 mm (0.02 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Front tire
Size AT26 x 8-12 (YFM70GPAK, YFM70GPHK)
AT27 x 10-14 (YFM70GPLK)
Manufacturer/model MAXXIS/MU05Y (YFM70GPAK, YFM70GPHK)
MAXXIS/MU01 (YFM70GPLK)
Wear limit (front) 3.0 mm (0.12 in)
Rear tire
Size AT26 x 10-12 (YFM70GPAK, YFM70GPHK)
Manufacturer/model MAXXIS/MU06Y (YFM70GPAK, YFM70GPHK)
Wear limit (rear) 3.0 mm (0.12 in)
Tire air pressure (measured on cold tires)

Vehicle load 0.0-240.0 kg (0-529 lb)
Recommended
Front 35.0 kPa (0.350 kgf/cm 2 , 5.0 psi)
Rear 30.0 kPa (0.300 kgf/cm2 , 4 .4 psi) (YFM70GPAK,
YFM70GPHK)
35.0 kPa (0.350 kgf/cm 2 , 5.0 psi) (YFM70GPLK)
2-6
Minimum
Front 32.0 kPa (0.320 kgf/cm 2, 4.6 psi)
Rear 27.0 kPa (0.270 kgf/cm2 , 4.0 psi) (YFM70GPAK,
YFM70GPHK)
32.0 kPa (0.320 kgf/cm 2 , 4.6 psi) (YFM70GPLK)
Front brake
Type Hydraulic disc brake
Brake disc thickness 3.5 mm (0.14 in)
Brake disc thickness limit 3.0 mm (0.12 in)
Brake disc runout limit 0.1 O mm (0.0039 in)
Brake pad lining thickness limit 1.0 mm (0.04 in)
Master cylinder inside diameter 12.70 mm (0.50 in)
Caliper cylinder inside diameter 33.96 mm (1.34 in)
Rear brake
Type Hydraulic disc brake
Brake disc thickness 3.5 mm (0.14 in)
Brake disc thickness limit 3.0 mm (0.12 in)
Brake disc runout limit 0.1 O mm (0.0039 in)
Brake pad lining thickness limit 1.0 mm (0.04 in)
Master cylinder inside diameter 12.70 mm (0.50 in)
Caliper cylinder inside diameter 33.96 mm (1.34 in)
Brake fluid
Specified brake fluid DOT4
Brake pedal free play 1.0-6.0 mm (0.04-0.24 in)
Front suspension
Type Double wishbone
Spring Coil spring
Shock absorber Hydraulic damper
Wheel travel 193 mm (7.6 in)
Spring preload
Adjusting system Mechanical adjustable type
Unit for adjustment Cam position
Adjustment value (Soft) 1
Adjustment value (STD) 2
Adjustment value (Hard) 5
Rear suspension
Type Double wishbone
Spring Coil spring
Shock absorber Hydraulic damper
Wheel travel 232 mm (9.1 in)
Spring preload
Adjusting system Mechanical adjustable type
Unit for adjustment Cam position
Adjustment value (Soft) 1
Adjustment value (STD) 2
Adjustment value (Hard) 5
2-7
ELECTRICAL SPECIFICATIONS
EBS20017
Voltage
System voltage 12 V
Engine control unit

Model F8T86671
Ignition system
Ignition system TCI
Ignition timing (B.T .D.C.) 5.0 °/1600 r/min
Crankshaft position sensor resistance 459-561 Q
Ignition coil
Primary coil resistance 2.16-2.64 Q
Secondary coil resistance 8.64-12.96 k.Q
Spark plug cap

Resistance 10.0 k.Q
Charging system
Charging system AC magneto
Standard output 14.0 V, 33.0 A at 5000 r/min
Standard output 14.0 V, 462 Wat 5000 r/min
Stator coil resistance 0.12-0.14 Q
Rectifier/regulator
Regulated voltage (DC) 14.3-14.7 V
Rectifier capacity (DC) 50.0 A
Battery
Model YTX20L-BS
Voltage, capacity 12V, 18.0Ah
Starter motor
Power output 0.80 kW
Brush overall length limit 6.50 mm (0.26 in)
Brush spring force 6.03-6.52 N (615-665 gf, 21.71-23.47 oz)
Mica undercut (depth) 0.70 mm (0.03 in)
Fuel sender unit

Sender unit resistance (full) 19.0-21.0 Q
Sender unit resistance (empty) 138.5-141.5Q
Fuel injection sensor

Intake air temperature sensor resistance 2210-2690 Q at 20 °C (2210-2690 Q at 68 °F)
Intake air temperature sensor resistance 290-354 Q at 80 °C (29o-354 Q at 176 °F)
Coolant temperature sensor resistance 2320-2590 Q at 20 °C (2320-2590 Q at 68 °F)
Coolant temperature sensor resistance 310-326 Q at 80 °C (31o-326 Q at 176 °F)
Lean angle sensor output voltage

Operating angle 65 °
2-8
Output voltage up to operating angle 3.6-4.5 V

Output voltage over operating angle 0.7-1.4 V
Auxiliary DC output
Jack capacity (cigarette lighter socket_ 1) 10.0 A (120 W)
Lights
Headlight LED
Handlebar-mounted light T1 SH, 35.0 W/36.5 W
Brake/tail light LED
Meter lighting LED
Neutral indicator light LED
High beam indicator light LED
Reverse indicator light LED
Coolant temperature warning light LED
Park indicator light LED
Engine trouble warning light LED
High-range indicator light LED
Low-range indicator light LED
Differential gear lock indicator light LED
EPS warning light LED
Battery voltage warning light LED
Fuses
Main fuse 40.0 A
Headlight fuse 10.0 A
Signaling system fuse 10.0 A
Ignition fuse 10.0 A
Radiator fan motor fuse 20.0 A
Auxiliary DC jack fuse 10.0 A
Fuel injection system fuse 15.0 A
Four-wheel-drive motor fuse 10.0 A
EPS fuse 40.0 A
Spere fuse 20.0 A
Spare fuse 15.0 A
Spare fuse 10.0 A
2-9
TIGHTENING TORQUES
EBS20018
TIGHTENING TORQUES
EBS30018
GENERAL TIGHTENING TORQUE

SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special com-
ponents or assemblies are provided for each
chapter of this manual. To avoid warpage, tight-
en multi-fastener assemblies in a crisscross pat-
tern and progressive stages until the specified
tightening torque is reached. Unless otherwise
specified, tightening torque specifications re-
quire clean , dry threads. Components should be
at room temperature.
0
A
A. Distance between flats

B. Outside thread diameter
General tightening torques

A (nut) B (bolt)
N,m kgf,m lb,ft
10 mm 6mm 6 0.6 4.4
12 mm 8mm 15 1.5 11
14mm 10 mm 30 3.0 22
17mm 12 mm 55 5.5 41
19 mm 14 mm 85 8.5 63
22mm 16 mm 130 13.0 96
2-10
TIGHTENING TORQUES
EBS30019
ENGINE TIGHTENING TORQUES

Thread
Item • Q'ty Tightening torque Remarks
size
Exhaust pipe nut MB 2 20 N-m (2.0 kgf-m, 15 lb-ft)
Muffler bolt MB 1 33 N-m (3.3 kgf-m, 24 lb-ft)
Muffler bracket bolt MB 2 20 N-m (2.0 kgf-m, 15 lb-ft)
Spark arrester bolt M6 4 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Exhaust pipe protector bolt M6 2 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Crankshaft end accessing screw M36 1 2.0 N-m (0.20 kgf-m, 1.5 lb-ft)
Timing mark accessing screw M14 1 1.5 N-m (0.15 kgf-m, 1.1 lb-ft)
AC magneto cover bolt M6 11 10 N-m (1.0 kgf-m, 7.4 lb-ft)
AC magneto rotor nut M16 1 60 N-m (6.0 kgf-m, 44 lb-ft)
AC magneto/crankshaft position
sensor lead holder bolt
M5 2 7 N-m (0.7 kgf-m, 5.2 lb-ft) -G
Starter clutch bolt MB 3 30 N-m (3.0 kgf-m, 22 lb-ft) -G
Drive belt cover bolt M6 12 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Drive belt case bolt M6 8 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Bearing housing bolt (primary
sheave assembly)
M6 4 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Bearing retainer bolt (bearing hous-

M6 1 1o N-m (1.0 kgf-m, 7.4 lb-ft)
ing)
Primary sheave assembly nut M16 1 100 N-m (10 kgf-m, 74 lb-ft)
Secondary sheave assembly nut M16 1 140 N-m (14 kgf-m, 103 lb-ft)
Secondary sheave spring retaining
nut
M36 1 90 N-m (9.0 kgf-m, 66 lb-ft)
Clutch housing assembly bolt M6 9 10 N-m (1.0 kgf-m, 7.4 lb-ft)

Lett-hand
thread
Clutch carrier assembly nut M22 1 190 N-m (19 kgf-m, 140 lb-ft)
Stake.
-«MJt-1
See TIP.
Cylinder bolt M10 4 50 N-m (5.0 kgf-m, 37 lb-ft)
--11€]
Cylinder bolt M6 2 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Cylinder head stud bolt (exhaust
pipe)
MB 2 15 N-m (1.5 kgf-m, 11 lb-ft)
Reed valve cover bolt M6 2 10 N-m (1.0 kgf-m, 7.4 lb-ft) -G

Cylinder head bolt M9 4 35 N-m (3.5 kgf-m, 26 lb-ft) -«MJt-1
Cylinder head bolt M9 2 38 N-m (3.8 kgf-m, 28 lb-ft) --11€]
Cylinder head bolt M6 2 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Tappet cover bolt M6 8 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Camshaft sprocket cover bolt M6 2 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Thermostat cover bolt M6 2 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Oil check bolt MB 1 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Air bleed bolt (cylinder head) M6 1 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Camshaft sprocket bolt M7 2 20 N-m (2.0 kgf-m, 15 lb-ft)
2-11
TIGHTENING TORQUES
Thread
size
Decompressor assembly bolt M7 2 20 N-m (2.0 kgf-m, 15 lb-ft)
Valve adjusting screw locknut M6 4 14 N-m (1.4 kgf-m, 10 lb-ft)
Bearing retainer bolt (camshaft) M6 2 1o N-m (1.0 kgf-m, 7.4 lb-ft) -G
Timing chain guide bolt (intake side) M6 2 10 N-m (1.0 kgf-m, 7.4 lb-ft) -G
Timing chain tensioner cap bolt M16 1 20 N-m (2.0 kgf-m, 15 lb-ft)
Timing chain tensioner bolt M6 2 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Oil delivery pipe 1 union bolt MB 2 18 N-m (1.8 kgf-m, 13 lb-ft)
Oil delivery pipe 2 union bolt M14 2 35 N-m (3.5 kgf-m, 26 lb-ft)
Oil delivery pipe 2 union bolt M10 1 20 N-m (2.0 kgf-m, 15 lb-ft)
Oil delivery pipe 2 bolt M6 1 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Crankcase bolt MB 3 26 N-m (2.6 kgf-m, 19 lb-ft)
Crankcase bolt (I = 60 mm (2.36 in)) M6 4 1o N-m (1.0 kgf-m, 7.4 lb-ft)
Crankcase bolt (I = 30 mm (6.68 in)) M6 9 1o N-m (1.0 kgf-m, 7.4 lb-ft)
Dipstick guide bolt M6 1 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Engine oil drain bolt M14 1 33 N-m (3.3 kgf-m, 24 lb-ft)
Oil filter cartridge M20 1 17 N-m (1.7 kgf-m, 13 lb-ft)
Oil filter cartridge union bolt M20 1 75 N-m (7.5 kgf-m, 55 lb-ft) -,@
Timing chain guide bolt (lower) M6 2 10 N-m (1.0 kgf-m, 7.4 lb-ft) -G
Bearing retainer bolt (crankcase) M6 2 10 N-m (1.0 kgf-m, 7.4 lb-ft) -G
Oil pump bolt M6 3 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Oil pump housing cover screw M5 1 5 N-m (0.5 kgf-m, 3.7 lb-ft)
Use a lock
Oil pump driven gear nut M10 1 22 N-m (2.2 kgf-m, 16 lb-ft)
washer.
Intake air pressure sensor screw M6 1 3.5 N-m (0.35 kgf-m, 2.6 lb-ft)
Throttle position sensor screw M5 2 3.5 N-m (0.35 kgf-m, 2.6 lb-ft)
Fuel rail screw M6 2 5 N-m (0.5 kgf-m, 3.7 lb-ft)
Use a lock
Balancer driven gear nut M18 1 85 N-m (8.5 kgf-m, 63 lb-ft)
washer.
Water pump housing bolt M6 3 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Coolant drain bolt M6 1 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Water pump air bleed bolt M6 1 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Water pump outlet pipe bolt M6 1 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Water jacket joint bolt M6 2 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Shift lever cover bolt M6 4 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Shift lever 2 assembly bolt M6 1 14 N-m (1.4 kgf-m, 10 lb-ft)
Shift drum stopper bolt M14 1 20 N-m (2.0 kgf-m, 15 lb-ft)
Stopper lever stopper bolt M14 1 20 N-m (2.0 kgf-m, 15 lb-ft)
Middle drive pinion gear nut M22 1 190 N-m (19 kgf-m, 140 lb-ft) Stake.
Middle drive shaft bearing housing
bolt
MB 4 32 N-m (3.2 kgf-m, 24 lb-ft) -G
Middle drive shaft bearing retainer Stake.
MB 4 29 N-m (2.9 kgf-m, 21 lb-ft)
bolt -G
2-12
TIGHTENING TORQUES
Thread
size
Front drive shaft yoke nut (middle
M16 1 115 N-m (11.5 kgf-m, 85 lb-ft)
gear side)
Left-hand
Middle driven shaft bearing retainer M55 1 80 N-m (8.0 kgf-m, 59 lb-ft) thread
-G
Middle driven pinion gear bearing
MB 4 25 N-m (2.5 kgf-m, 18 lb-ft)
housing bolt
Left-hand
Middle driven pinion gear bearing re-
M60 1 130 N-m (13 kgf-m, 96 lb-ft) thread
tainer
-G
Rear drive shaft yoke nut (middle
gear side)
M16 1 150 N-m (15 kgf-m, 111 lb-ft) -G
Starter motor bolt M6 2 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Starter motor lead nut M6 1 11 N-m (1.1 kgf-m, 8.1 lb-ft)
Spark plug M10 1 13 N-m (1.3 kgf-m, 9.6 lb-ft)
Stator coil assembly bolt M6 3 7 N-m (0.7 kgf-m, 5.2 lb-ft) -G
Crankshaft position sensor bolt M5 2 7 N-m (0.7 kgf-m, 5.2 lb-ft) -G
Coolant temperature sensor M12 1 18 N-m (1.8 kgf-m, 13 lb-ft)
Gear position switch bolt M6 2 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Reverse switch M10 1 17 N-m (1.7 kgf-m, 13 lb-ft)
Speed sensor bolt M6 1 10 N-m (1.0 kgf-m, 7.4 lb-ft)
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Temporarily tighten the cylinder bolts to 15 N-m (1.5 kgf -m, 11 lb-ft) and then tighten them to 50 N-m
(5.0 kgf -m, 37 lb-ft).
Cylinder head tightening sequence:
2-13
TIGHTENING TORQUES
EBS30020
CHASSIS TIGHTENING TORQUES

Thread
size
Engine mounting bolt (front upper
side)
M6 2 10 N-m (1.0 kgf-m, 7.4 lb-ft) -G
Engine mounting bolt (front lower
side)
M10 2 42 N-m (4.2 kgf-m, 31 lb-ft)
Engine mounting bolt (rear upper

side)
M6 2 10 N-m (1.0 kgf-m, 7.4 lb-ft) -G
Engine mounting bolt (rear lower
side)
M10 2 42 N-m (4.2 kgf-m, 31 lb-ft)
Rubber damper nut (front side) M10 2 42 N-m (4.2 kgf-m, 31 lb-ft)
Rubber damper nut (rear side) M10 2 42 N-m (4.2 kgf-m, 31 lb-ft)
Trailer hitch bolt M10 4 55 N-m (5.5 kgf-m, 41 lb-ft)
Drive select lever unit bolt M6 2 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Drive select lever guide bolt M6 1 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Shift arm bolt M6 1 14 N-m (1.4 kgf-m, 10 lb-ft) -G
Left-hand
Drive select lever shift rod locknut M6 1 8 N-m (0.8 kgf-m, 5.9 lb-ft)
thread
Drive select lever shift rod locknut
(shift arm side)
M6 1 8 N-m (0.8 kgf-m, 5.9 lb-ft)
Brake pedal free play adjusting nut MB 1 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Brake pedal height adjuster locknut M6 1 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Radiator bolt M6 2 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Coolant reservoir bolt M6 2 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Fuel tank bolt M6 4 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Fuel pump nut M6 6 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Fuel tank breather hose joint bolt M6 1 3.5 N-m (0.35 kgf-m, 2.6 lb-ft)
Throttle body joint clamp screw
(throttle body side)
M5 1 2.8 N-m (0.28 kgf-m, 2.1 lb-ft)
Throttle body joint clamp screw (cyl-

inder head side)
M5 1 3.0 N-m (0.30 kgf-m, 2.2 lb-ft)
Skid plate bolt M6 8 7 N-m (0.7 kgf-m, 5.2 lb-ft)

Footrest bracket bolt MB 4 16 N-m (1.6 kgf-m, 12 lb-ft)
Footrest board bolt M6 8 8 N-m (0.8 kgf-m, 5.9 lb-ft)
Footrest board bolt (left) M6 1 4.0 N-m (0.40 kgf-m, 3.0 lb-ft)
Footrest board nut M6 10 4.0 N-m (0.40 kgf-m, 3.0 lb-ft)
Top cover bolt M6 2 4.0 N-m (0.40 kgf-m, 3.0 lb-ft)
Top cover screw M5 4 0.4 N-m (0.04 kgf-m, 0.30 lb-ft)
Side panel bolt M6 2 2.5 N-m (0.25 kgf-m, 1.8 lb-ft)
Air filter case bolt M6 2 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Air filter case joint clamp screw
M5 1 3.5 N-m (0.35 kgf-m, 2.6 lb-ft)
Air filter case joint clamp screw (air

filter case side)
M5 1 0.8 N-m (0.08 kgf-m, 0.59 lb-ft)
Air intake duct clamp screw M5 1 0.8 N-m (0.08 kgf-m, 0.59 lb-ft)
2-14
TIGHTENING TORQUES
Thread
size
Storage compartment bolt M6 1 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Front carrier bolt MB 4 34 N-m (3.4 kgf-m, 25 lb-ft)
Front carrier bolt M6 2 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Front guard bolt MB 4 34 N-m (3.4 kgf-m, 25 lb-ft)
Front carrier bracket bolt MB 2 34 N-m (3.4 kgf-m, 25 lb-ft)
Front guard cover bolt M6 4 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Front guard cover bolt M6 2 4.0 N-m (0.40 kgf-m, 3.0 lb-ft)
Front grill bolt M6 2 8 N-m (0.8 kgf-m, 5.9 lb-ft)
Front grill bolt M6 2 4.0 N-m (0.40 kgf-m, 3.0 lb-ft)
Front fender bolt M6 2 8 N-m (0.8 kgf-m, 5.9 lb-ft)
Main switch locknut M27 1 1.5 N-m (0.15 kgf-m, 1.1 lb-ft)
Headlight cover bolt M5 4 4.0 N-m (0.40 kgf-m, 3.0 lb-ft)
Headlight unit screw M5 4 1.5 N-m (0.15 kgf-m, 1.1 lb-ft)
Front fender inner panel bolt M6 5 4.0 N-m (0.40 kgf-m, 3.0 lb-ft)
Front fender inner panel nut M6 2 4.0 N-m (0.40 kgf-m, 3.0 lb-ft)
Rear carrier bolt M10 2 60 N-m (6.0 kgf-m, 44 lb-ft)
Rear carrier bolt MB 2 34 N-m (3.4 kgf-m, 25 lb-ft)
Rear carrier bolt M6 2 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Rear carrier bracket bolt M10 2 60 N-m (6.0 kgf-m, 44 lb-ft)
Rear fender bolt M6 4 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Rear fender bolt M6 2 4.0 N-m (0.40 kgf-m, 3.0 lb-ft)
Rear fender bracket bolt M6 2 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Rear storage compartment bracket
screw
M5 2 4.0 N-m (0.40 kgf-m, 3.0 lb-ft)
Tail/brake light unit nut M5 2 2.8 N-m (0.28 kgf-m, 2.1 lb-ft)
Front wheel nut M10 8 55 N-m (5.5 kgf-m, 41 lb-ft)
Front wheel axle nut M20 2 260 N-m (26 kgf-m, 192 lb-ft) Stake.
Rear wheel nut M10 8 55 N-m (5.5 kgf-m, 41 lb-ft)
Rear wheel axle nut M20 2 260 N-m (26 kgf-m, 192 lb-ft) Stake.
Brake hose joint bolt M6 2 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Brake pipe locknut M10 4 19 N-m (1.9 kgf-m, 14 lb-ft)
Front brake caliper bolt MB 4 30 N-m (3.0 kgf-m, 22 lb-ft)
Front brake disc bolt MB 8 30 N-m (3.0 kgf-m, 22 lb-ft) -CJ
Rear brake caliper bolt MB 4 30 N-m (3.0 kgf-m, 22 lb-ft)
Rear brake disc bolt MB 8 30 N-m (3.0 kgf-m, 22 lb-ft) -CJ
Brake hose union bolt M10 6 27 N-m (2.7 kgf-m, 20 lb-ft)
Brake pad holding bolt M6 4 17 N-m (1. 7 kgf-m, 13 lb-ft)
Brake pad holding bolt plug M10 4 2.5 N-m (0.25 kgf-m, 1.8 lb-ft)
Brake caliper guide pin MB 4 17 N-m (1.7 kgf-m, 13 lb-ft)
Brake caliper retaining pin nut MB 4 22 N-m (2.2 kgf-m, 16 lb-ft)
Brake caliper bleed screw MB 4 5 N-m (0.5 kgf-m, 3.7 lb-ft)
2-15
TIGHTENING TORQUES
Thread
size
Steering knuckle and front upper
M12 2 30 N-m (3.0 kgf-m, 22 lb-ft)
arm nut
Steering knuckle and front lower arm
M12 2 30 N-m (3.0 kgf-m, 22 lb-ft)
nut
Steering knuckle and tie-rod nut M10 2 25 N-m (2.5 kgf-m, 18 lb-ft)
Front upper arm nut
Front lower arm nut
M10
M10
4
4
55 N-m (5.5 kgf-m, 41 lb-ft)
55 N-m (5.5 kgf-m, 41 lb-ft)
...
-...
Front shock absorber assembly nut M10 4 45 N-m (4.5 kgf-m, 33 lb-ft)
Front brake disc guard screw (for
M6 6 7 N-m (0.7 kgf-m, 5.2 lb-ft)
YFM70GPAK/YFM70GPHK)
Front brake disc guard bolt (for
M6 6 11 N-m (1.1 kgf-m, 8.1 lb-ft)
YFM70GPLK)
Front brake hose holder bolt M6 4 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Front arm protector bolt M6 2 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Rear knuckle nut M10 4 45 N-m (4.5 kgf-m, 33 lb-ft)
Rear upper arm nut M10 4 55 N-m (5.5 kgf-m, 41 lb-ft) l@tl
Rear lower arm nut
Rear shock absorber assembly nut
M10
M10
4
4
55 N-m (5.5 kgf-m, 41 lb-ft)
45 N-m (4.5 kgf-m, 33 lb-ft)
-...
Rear brake disc guard screw (for
YFM70GPAK/YFM70GPHK)
M6 6 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Rear brake disc guard bolt (for

YFM70GPLK)
M6 6 11 N-m (1.1 kgf-m, 8.1 lb-ft)
Rear brake hose guide bolt M6 4 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Rear brake disc cleaning plate bolt M6 4 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Rear arm protector bolt M6 4 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Rear arm protector nut M6 2 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Stabilizer joint nut M10 4 56 N-m (5.6 kgf-m, 41 lb-ft)
Stabilizer holder bolt MB 4 30 N-m (3.0 kgf-m, 22 lb-ft)
Handlebar cover bolt M6 1 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Meter cover nut M5 3 4.0 N-m (0.40 kgf-m, 3.0 lb-ft)
Handle mounted light screw M5 2 1.3 N-m (0.13 kgf-m, 0.95 lb-ft)
Handlebar holder bolt MB 4 20 N-m (2.0 kgf-m, 15 lb-ft)
Front brake master cylinder holder
bolt
M6 2 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Rear brake master cylinder holder

bolt
M6 2 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Brake fluid reservoir cap screw M4 4 1.5 N-m (0.15 kgf-m, 1.1 lb-ft)
Throttle lever assembly screw M5 2 4.0 N-m (0.40 kgf-m, 3.0 lb-ft)
Throttle lever assembly cover bolt M4 3 1.5 N-m (0.15 kgf-m, 1.1 lb-ft)
Front brake light switch screw M4 1 1.2 N-m (0.12 kgf-m, 0.88 lb-ft)
Rear brake light switch screw M4 1 1.2 N-m (0.12 kgf-m, 0.88 lb-ft)
Handlebar switch screw (left) M5 2 3.5 N-m (0.35 kgf-m, 2.6 lb-ft)
Front brake lever pivot bolt M6 1 6 N-m (0.6 kgf-m, 4.4 lb-ft) ~
2-16
TIGHTENING TORQUES
Thread
size
Front brake lever pivot nut M6 1 6 N-m (0.6 kgf-m, 4.4 lb-ft)
Rear brake lever pivot bolt M6 1 6 N-m (0.6 kgf-m, 4.4 lb-ft) -@tit
Rear brake lever pivot nut M6 1 6 N-m (0.6 kgf-m, 4.4 lb-ft)
Steering stem bolt MB 2 23 N-m (2.3 kgf-m, 17 lb-ft)
Steering stem bracket bolt M10 2 51 N-m (5.1 kgf-m, 38 lb-ft) -CJ
Bearing retainer (steering stem) M42 1 40 N-m (4.0 kgf-m, 30 lb-ft)
Steering stem pinch bolt MB 1 35 N-m (3.5 kgf-m, 26 lb-ft) -CJ
EPS unit bolt MB 4 30 N-m (3.0 kgf-m, 22 lb-ft) -CJ
Pitman arm nut M16 1 21 o N-m (21 kgf-m, 155 lb-ft)
EPS motor cover bolt M6 2 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Pitman arm and tie-rod nut M10 2 25 N-m (2.5 kgf-m, 18 lb-ft)
Tie-rod end locknut (pitman arm
M10 2 15 N-m (1.5 kgf-m, 11 lb-ft)
side)
Tie-rod end locknut (front wheel Lett-hand
M10 2 15 N-m (1.5 kgf-m, 11 lb-ft)
side) thread
Differential assembly nut M10 1 66 N-m (6.6 kgf-m, 49 lb-ft)
Differential assembly bolt M10 2 55 N-m (5.5 kgf-m, 41 lb-ft) -CJ
Differential gear oil filler bolt M14 1 23 N-m (2.3 kgf-m, 17 lb-ft)
Differential gear oil drain bolt M10 1 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Differential case cover bolt MB 5 24 N-m (2.4 kgf-m, 18 lb-ft)
Differential motor bolt M6 3 11 N-m (1.1 kgf-m, 8.1 lb-ft)
Front drive shaft yoke nut (differen-
tial case side)
M14 1 62 N-m (6.2 kgf-m, 46 lb-ft) -CJ
Final drive assembly nut M10 2 66 N-m (6.6 kgf-m, 49 lb-ft)
Final gear oil filler bolt M14 1 23 N-m (2.3 kgf-m, 17 lb-ft)
Final gear oil drain bolt M14 1 23 N-m (2.3 kgf-m, 17 lb-ft)
Final gear oil level check bolt MB 1 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Final drive case cover bolt MB 11 23 N-m (2.3 kgf-m, 17 lb-ft)
Final drive pinion gear bearing hous-
ing bolt
MB 4 23 N-m (2.3 kgf-m, 17 lb-ft) -CJ
Electrical components tray bolt M6 3 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Positive battery lead bolt M6 1 3.6 N-m (0.36 kgf-m, 2.7 lb-ft)
Starter motor lead bolt M6 1 3.6 N-m (0.36 kgf-m, 2.7 lb-ft)
Lean angle sensor bolt M5 2 2.5 N-m (0.25 kgf-m, 1.8 lb-ft)
EPS control unit screw M6 1 2.5 N-m (0.25 kgf-m, 1.8 lb-ft)
Battery holding bracket fitting screw M6 2 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Battery holding bracket nut M6 2 7 N-m (0.7 kgf-m, 5.2 lb-ft)
ECU (engine control unit) screw M6 1 2.5 N-m (0.25 kgf-m, 1.8 lb-ft)
Intake air temperature sensor screw M5 1 1.5 N-m (0.15 kgf-m, 1.1 lb-ft)
Rectifier/regulator bolt M6 2 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Ignition coil bolt M6 2 9 N-m (0.9 kgf-m, 6.6 lb-ft)
Frame ground bolt M6 1 7 N-m (0.7 kgf-m, 5.2 lb-ft)
2-17
TIGHTENING TORQUES
2-18
CABLE ROUTING
EBS20022
CABLE ROUTING
Handlebar (front view 1)
2-19
CABLE ROUTING
1. Front brake hose

2. Throttle cable
3. Rear brake cable
4. Rear brake hose
5. Front brake light switch lead
6. On-Command four-wheel-drive motor switch and
differential gear lock switch lead
7. Meter assembly lead
8. Rear brake light switch lead
9. Handlebar switch lead (left)
A. Adjust the front brake hose, throttle cable and rear
brake hose so that the slack in the hoses and cable
is positioned below the handle mounted light cover
and to the front of the steering stem.
B. Pass the rear brake hose through the guide.
C. Pass the rear brake cable through the guide.
D. Pass the front brake hose and throttle cable
through the guide.
E. Route the leads on top of where the cables cross.
F. Route the throttle cable to the outside of the front
brake hose.
G. Pass the leads through the holder.
H. Do not fasten the throttle cable or rear brake cable.
Make sure that the throttle cable and rear brake
cable are not twisted around the other leads.
I. To handle mounted light
2-20
CABLE ROUTING
Handlebar (front view

. 2)
[I]@----
[I] 8~---1~;,?
',-
' w ,
'
I
' '' \
'
'
'' I
,.J-\
.... - --~ .. \ '
'
,,' ,\ '
'\
I
'
-- ' E
'I ''
'I
''
'\
,-
,'
\
~- \
'~'
'
' '
...
'I ' ,
\ '
'
I
I' '' I
'I
'
'
'
- -- 6
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I
'
'
I
' '
'
I ' '
'
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' ''' I
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L '
<D O 0
LJ
2-21
CABLE ROUTING
1. Front brake light switch lead

2. On-Command four-wheel-drive motor switch and
differential gear lock switch lead
3. Rear brake light switch lead
4. Handlebar switch lead (left)
5. Differential case breather hose
6. Radiator fan motor breather hose
7. Radiator fan motor lead
8. Final drive case breather hose
9. Throttle body breather hose
A. Fasten the front brake light switch lead and On-
Command four-wheel-drive motor switch and
differential gear lock switch lead with the plastic
band, making sure to route the lead under the
handlebar and to face the end of the band forward .
Align the plastic band with the portion of the
handlebar where the handlebar begins to bend.
B. Fasten the rear brake light switch lead and
handlebar switch lead (left) with the plastic band,
making sure to route the lead under the handlebar
and to face the end of the band forward. Align the
plastic band with the portion of the handlebar
where the handlebar begins to bend.
C. Pass the differential case breather hose through
the hole on the battery cover.
D. Pass the radiator fan motor breather hose through
the hole on the battery cover.
E. Route the radiator fan motor breather hose and
differential case breather hose in front of the frame .
F. Fasten the differential case breather hose to the
frame with the plastic band, making sure to face
the end of the band inward.
G. Route the differential case breather hose to the
inside of the frame.
H. To differential assembly
I. Pass the final drive case breather hose through the
hole on the battery cover.
J. Pass the throttle body breather hose through the
hole on the battery cover.
K. Fasten the front brake light switch lead, rear brake
light switch lead, On-Command four-wheel-drive
motor switch and differential gear lock switch lead
and handlebar switch lead (left) with the clamp in
front of the steering stem. Be sure to fasten the
clamp above the couplers and fasten it around the
protective sleeves of the leads, not the leads
themselves.
2-22
CABLE ROUTING
. (left side view)

Engine
13
18
3
2
6
8
1
F 1 1
2-23
CABLE ROUTING
1. Coolant reservoir hose

4. Ground lead
5. Coolant reservoir breather hose
7. TPS lead
8. Intake air pressure sensor lead
10. AC magneto/crankshaft position sensor lead
11 . Speed sensor lead
12. Water pump breather hose
13. Radiator outlet hose
14. Differential motor lead
15. EPS torque sensor lead
16. Air induction system solenoid lead
17. Gear position switch lead
18. Reverse switch lead
19. Negative battery lead
20. Starter motor lead
21 . Wire harness
A. Face the end of the coolant reservoir breather
hose downward.
B. Pass the AC magneto/crankshaft position sensor
lead through the right side of lead holder.
C. Make sure that there is no slack in the AC
magneto/crankshaft position sensor lead and
speed sensor lead in the area shown in the
illustration.
D. Pass the AC magneto/crankshaft position sensor
lead through the holder.
E. Fasten the radiator outlet hose to the frame with
the plastic band, making sure to face the end of the
band inward.
F. Place the differential motor lead and EPS torque
sensor lead in the holder, and then insert the ends
of the holder into the hole in the stay on the frame.
G. Route the differential case breather hose to the
inside of the frame.
H. Fasten the differential case breather hose to the
frame with the plastic band, making sure to face
the end of the band inward.
I. Connect the air induction system solenoid coupler
to the air cut-off valve assembly.
J. Attach the ground lead terminal to the frame using
the bolt.
K. Route the radiator fan motor breather hose and
differential case breather hose to the inside of the
radiator outlet hose.
L. Face the end of the plastic band inward.
M. Pass the hose and leads through the guide in the
order listed.
N. Route the final drive case breather hose above the
reverse switch lead and negative battery lead.
0 . Route the speed sensor lead and AC magneto/
crankshaft position sensor lead above the reverse
switch lead.
2-24
CABLE ROUTING
Engine (right side view 1)
G 19 1 [El 14 15
2-25
CABLE ROUTING

2. ISC unit lead
7. Coolant temperature sensor lead
8. Throttle cable
9. Wire harness
10. Main switch lead
11 . Auxiliary DC jack lead
12. Ignition coil lead
13. EPS motor coupler
15. EPS torque sensor coupler
16. Radiator inlet hose
17. Radiator fan motor lead
18. Spark plug lead
19. Brake pedal cable
20. Gear position switch lead
21 . Speed sensor lead
22. Reverse switch lead
A. Route the ISC unit lead to the inside of the fuel
hose and AC magneto/crankshaft position sensor
lead.
B. Route the throttle body breather hose under the
throttle cable.
C. Pass the final drive case breather hose and throttle
body breather hose through the hole on the battery
cover.
D. Route the radiator fan motor lead between the
electrical components tray and the radiator inlet
hose.
E. Fasten the radiator fan motor lead and radiator fan
motor breather hose to the frame with the plastic
band, making sure to face the end of the band
inward. Be sure to fasten the plastic band around
the protective sleeve of the lead, not the lead itself.
F. Route the spark plug lead to the inside of the rear
brake cable.
G. Fasten the hose, leads, and wire harness with the
plastic band, making sure to position the band near
the split in the wire harness.
H. Face the end of the plastic band inward.
I. 0-10
J. Insert the projection on each coupler into the hole
in the frame from the inside of the frame.
K. Fasten the spark plug lead with the larger diameter
section.
2-26
CABLE ROUTING
Engine (right side view 2),.----------..._
B 1 [g 2 3 4 5 6
"
( 0
• I
\ :
. I
I \ •.
.I
\' I
1
. '\ . .
1 '-. I.
.
\
•• I ..I
..I
\'.
\\
\_··- ·== ··-··- ··-··-··-··- ··-·· ........
.. ·--.. - ··-··-··-··7_;.r- .
...1...,,,..-
II =::
8 7
2-27
CABLE ROUTING
1. Tail/brake light lead

2. Fuel tank breather hose
3. Circuit breaker
4. Rectifier/regulator lead
6. Wire harness
7. Speed sensor lead
9. Fuel hose
10. Fuel pump lead
A. To tail/brake light
B. Fasten the tail/brake light lead to the frame with a
plastic locking tie, making sure to face the end of
the tie downward.
C. Route the tail/brake light lead to the outside of the
frame.
D. Install the plastic band near the split in the wire
harness.
E. Make sure that there is slack in the AC magneto/
crankshaft position sensor lead in the shown in the
illustration.
F. Face the end of the plastic band downward.
2-28
CABLE ROUTING
Electrical components tray (top view)
1
8
-'/---.JI
L J
I ',c,,,a,;-'
I
=\-=11.,,I _ J
6
2-29
CABLE ROUTING
1. Headlight lead (left) L. Pass the coolant reservoir breather hose through
2. Four-wheel-drive motor relay 1 the guides on the electrical components tray and
3. Four-wheel-drive motor relay 2 route it under the positive battery lead and starter
motor lead.
4. Headlight relay 1
M. Route the hoses under the positive battery lead,
5. Battery
and then route them upward, to the inside of the
6. ECU (Engine Control Unit) coolant reservoir breather hose.
7. Negative battery lead N. Fasten the coolant reservoir breather hose with the
8. Headlight lead (right) holder on the electrical components tray.
9. Radiator fan motor lead 0. Route the hoses under the positive battery lead,
10. EPS (electric power steering) control unit and then route them upward, to the inside of the
11 . Auxiliary DC jack lead coolant reservoir breather hose.
12. Main switch lead P. Pass the hoses and ground lead through the
opening in the electrical components tray.
13. EPS control unit lead
Q . Route the coolant reservoir breather hose above
14. Radiator fan motor relay
the other hoses.
15. Fuel injection system relay
R. Route the hoses to the inside of the screw.
19. EPS motor lead
20. EPS torque sensor lead
21 . Starter motor lead
23. Yamaha diagnostic tool coupler
24. Wire harness
25. Lean angle sensor lead
26. Coolant reservoir breather hose
27. Fuse box
28. Main fuse
29. EPS fuse
30. Starter relay
31 . Positive battery lead
32. Ground lead
A. To headlight (left)
B. Connect the headlight coupler, and then fasten the
coupler with the holder on the electrical
components tray.
C. To headlight (right)
D. Route the negative battery lead along the guide on
the electrical components tray.
E. Place the couplers on the inside of the electrical
components tray.
F. To main switch and auxiliary DC jack
G. Route the final drive case breather hose above the
leads in the electrical components tray.
H. Route the starter motor lead above the leads in the
electrical components tray.
I. Fasten the EPS control unit leads with the holder.
J. Fasten the meter assembly lead and EPS control
unit lead with the twist tie.
K. Fasten the handlebar switch lead (left), On-
Command four-wheel-drive motor switch and
differential gear lock switch lead, front brake light
switch lead, and rear brake light switch lead with
the holder.
2-30
CABLE ROUTING
Engine (top view)
A 4
®-
@
® 6
1 7
-ffiJ
-®
1
Q
-®
® I I I: ~
-
@) l - -®
@)
\(lj .r•
'
'
'
• •
' '
(j])
@----+-
2-31
CABLE ROUTING
1. Throttle cable
2. Rear brake cable
3. Rear brake hose
4. Front brake hose
9. Coolant temperature sensor lead
10. W ire harness
11 . ISC unit lead
12. Rectifier/regulator lead
13. AC magneto lead
14. Fuel hose
15. Circu it breaker
16. Tail/brake light lead
17. Fuel pump lead
18. Intake air temperature sensor lead
19. TPS lead
20. Intake air pressure sensor lead
21 . Fuel injector lead
A. Route the throttle cable between the air duct and
the frame.
B. Fasten the throttle body breather hose with the
holder.
C. Make sure that the fuel hose and fuel pump lead
are not pinched between the frame and the rear
fender.
2-32
CABLE ROUTING
Front and rear brake hoses
,,>:>,
/ ,'
,' /
4 / ,'
,' /
/ ,'
,' /
. / ; ,,
-· , 1
. :."' / ,, /
··: /
' '
B
1
'
...... ,,,, I I
,;:::_:.J-,?.Ai~·~~-~/--~ ' '
I-- • ,• ~$ J~
,,/~ _(;i~:,~
,· ./,Y'
- "--
:0 .. -- ,,/
-- "',,. -
: ;,P,, ,,,,,,,
' /
r------,
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r- -- --- -- -, __o. •
- - ..
·_ - -rr ·-,
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- I. .. >-.
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__,
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-
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- - - - - - ~ . . : . = . ; . : _ _ ~ - - ~ \ - - - ~ -- .-~~,~~~~-
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- -- - -- - -- - -- - -- -- -·~ -------
- - .-.--- -- - --- ----- - ---- -- --- - -~-_)
..
2-33
CABLE ROUTING
1. Front brake pipe

2. Front brake hose
3. Rear brake pipe
4. Rear brake hose
A. Face the mark on the front brake pipe upward.
B. Route the front brake hose above the frame.
C. Pass the front brake hose through the holder.
D. Fasten the front brake hose with the holder.
E. Connect the end of the front brake hose that is
identified by the green paint mark to the left front
brake caliper.
F. Pass the rear brake pipe through the holder.
G. Fasten the rear brake hose with the holder.
H. Route the rear brake hose above the frame.
I. Connect the end of the rear brake hose that is
identified by the green paint mark to the left rear
brake caliper.
2-34
CABLE ROUTING
2-35
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 .................................................................... 3-4
CHECKING THE SPARK PLUG ............................................................... 3-4
ADJUSTING THE VALVE CLEARANCE .................................................. 3-4
CHECKING THE BREATHER HOSES ..................................................... 3-7
CHECKING THE EXHAUST SYSTEM ...................................................... 3-7
CLEANING THE SPARK ARRESTER ...................................................... 3-7
CHECKING THE AIR INDUCTION SYSTEM ............................................ 3-8
CLEANING THE AIR FILTER ELEMENT .................................................. 3-8
CHECKING THE FRONT BRAKE PADS ................................................ 3-10
CHECKING THE REAR BRAKE PADS .................................................. 3-10
ADJUSTING THE FRONT DISC BRAKE ................................................ 3-10
ADJUSTING THE REAR DISC BRAKE .................................................. 3-10
CHECKING THE FRONT BRAKE HOSES ............................................. 3-11
CHECKING THE REAR BRAKE HOSES ................................................ 3-12
CHECKING THE BRAKE FLUID LEVEL ................................................. 3-12
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-13
CHECKING THE WHEELS ..................................................................... 3-14
CHECKING THE TIRES .......................................................................... 3-14
CHECKING THE V-BELT ........................................................................ 3-16
REPLACING THE V-BELT ...................................................................... 3-16
CHECKING THE FASTENER ................................................................. 3-17
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES ............. 3-17
ADJUSTING THE FRONT SHOCK ABSORBER ASSEMBLIES ............ 3-17
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES ................ 3-17
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY .................. 3-18
CHECKING THE STABILIZER BUSHING .............................................. 3-18
LUBRICATING THE REAR KNUCKLE PIVOTS ..................................... 3-18
LUBRICATING THE STEERING SHAFT ................................................ 3-18
CHECKING THE STEERING SYSTEM .................................................. 3-19
ADJUSTING THE TOE-IN ....................................................................... 3-20
CHECKING THE ENGINE MOUNT ........................................................ 3-21
CHECKING THE CONSTANT VELOCITY SHAFT ASSEMBLY DUST
BOOTS ................................................................................................... 3-21
CHECKING THE ENGINE OIL LEVEL .................................................... 3-22
CHANGING THE ENGINE OIL ............................................................... 3-22
CHECKING THE DIFFERENTIAL GEAR OIL LEVEL ............................. 3-24
CHANGING THE DIFFERENTIAL GEAR OIL ........................................ 3-24
CHECKING THE FINAL GEAR OIL LEVEL ............................................ 3-25
CHANGING THE FINAL GEAR OIL ........................................................ 3-25
CHECKING THE COOLING SYSTEM .................................................... 3-26
CHECKING THE COOLANT LEVEL ....................................................... 3-27
CHANGING THE COOLANT ................................................................... 3-27
CHECKING AND LUBRICATING THE CABLES .................................... 3-29
LUBRICATING THE LEVERS ................................................................. 3-30
LUBRICATING THE PEDAL ................................................................... 3-30
ADJUSTING THE DRIVE SELECT LEVER SHIFT ROD ........................ 3-30
ADJUSTING THE THROTTLE LEVER FREE PLAY .............................. 3-31
ADJUSTING THE SPEED LIMITER ........................................................ 3-31
REPLACING THE HANDLE MOUNTED LIGHT BULB ........................... 3-32
ADJUSTING THE HEADLIGHT AND HANDLE MOUNTED LIGHT
BEAMS ................................................................................................... 3-33
PERIODIC MAINTENANCE
EBS20023
EBS30024
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EBS30025
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals
instead.
• For odometer or hour meter-equipped vehicles, follow the month maintenance interval if the ATV isn't
ridden for the stated distance or engine operating hours.
• 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
NO. ITEM Whichever
JOB comes first km (ml) 240 1300 2500 2500 5000
(150) (800) (1600) (1600) (3200)
c:;>
hours 20 80 160 160 320
• Check fuel hoses for cracks or other damage, and re-
1 * Fuel line place if necessary.
• Check condition and clean, regap, or replace if nee-
" " "
2 Spark plug
essary.
" " " " "
3 * Valves
Crankcase breather
• Check valve clearance and adjust if necessary.
• Check breather hose for cracks or other damage, and " " " "
4 *
system replace if necessary.
• Check for leakage and replace gasket(s) if neces-
" " "
sary.
5 * Exhaust system
• Check for looseness and tighten all screw clamps
and joints if necessary. " " "
6 Spark arrester • Clean.
• Check the air cut-off valve, reed valve, and hose for " " "
7 * Air Induction system damage.
• Replace any damaged parts if necessary. " " " " "
EBS30026
GENERAL MAINTENANCE AND LUBRICATION CHART

TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals
instead.
• For odometer or hour meter-equipped vehicles, follow the month maintenance interval if the ATV isn't
ridden for the stated distance or engine operating hours.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
3-1
INITIAL EVERY
month 1 3 6 6 12
NO. ITEM Whichever
JOB 240 1300 2500 2500 5000
comes first km (ml)
(150) (800) (1600) (1600) (3200)
¢
hours 20 80 160 160 320
Every 2Q-40 hours (more often in wet or
1 Air filter element • Clean and replace if necessary. dusty areas)
• Check operation and correct if necessary.
• Check fluid level and ATV for fluid leakage, and cor- ,/ ,/ ,/ ,/ ,/
2 * Front brake rect if necessary.
• Replace brake pads. Whenever worn to the limit

• Check operation and correct if necessary.
• Check brake pedal free play and adjust if necessary. ,/ ,/ ,/ ,/ ,/
3 * Rear brake • Check fluid level and ATV for fluid leakage, and cor-
rect if necessary.
• Replace brake pads. Whenever worn to the limit
• Check for cracks or other damage, and replace if nee- ,/ ,/ ,/ ,/
4 * Brake hoses essary.
• Replace. Every 4 years
5 * Brake fluid • Change. Every 2 years

• Check runout and for damage, and replace if neces- ,/ ,/ ,/ ,/
6 * Wheels sary.
• Check tread depth and for damage, and replace if
necessary. ,/ ,/ ,/ ,/
7 * Tires • Check air pressure and balance, and correct if neces-
sary.
• Check for looseness or damage, and replace if nee- ,/ ,/ ,/ ,/
8 * Wheel hub bearings essary.
V-belt • Check for wear, cracks or other damage, and replace ,/ ,/ ,/ ,/

9 *
if necessary.
Chassis fasteners • Make sure that all nuts, bolts, and screws are proper- ,/ ,/ ,/ ,/ ,/
10 *
ly tightened.
Shock absorber as- • Check operation and correct if necessary. ,/ ,/ ,/
11 *
semblles • Check for oil leakage and replace if necessary.
• Check for cracks or other damage, and replace if nee- ,/ ,/ ,/
12 * Stabilizer bushes essary.
13 * Rear knuckle pivots • Lubricate with lithium-soap-based grease. ,/ ,/ ,/

14 * Steering shaft • Lubricate with lithium-soap-based grease. ,/ ,/ ,/
• Check operation and repair or replace if damaged. ,/ ,/ ,/ ,/ ,/
15 * Steering system • Check toe-in and adjust if necessary.
• Check for cracks or other damage, and replace if nee- ,/ ,/ ,/
16 * Engine mount essary.
17 * • Check for cracks or other damage, and replace if nee- ,/ ,/ ,/ ,/ ,/

Axle boots
essary.
• Change. ,/ ,/ ,/ ,/
18 Engine oil • Check ATV for oil leakage, and correct if necessary.
En3.1ne oil filter car- ,/ ,/ ,/
19 trl ge • Replace.
20 Differential gear oil • Change. ,/ ,/

• Check ATV for oil leakage, and correct if necessary.
• Change. ,/ ,/
21 Fl nal gear oil • Check ATV for oil leakage, and correct if necessary.
• Check coolant level and ATV for coolant leakage, and ,/ ,/ ,/ ,/ ,/
22 Cooling system correct if necessary.
• Replace coolant. Every 2 years
Moving parts and ca- ,/ ,/ ,/ ,/
23 *
bies
• Lubricate.
• Check operation.
24 * Throttle lever • Check throttle lever free play, and adjust if necessary. ,/ ,/ ,/ ,/ ,/
• Lubricate cable and lever housing.
3-2
INITIAL EVERY
month 1 3 6 6 12
NO. ITEM Whichever
JOB 240 1300 2500 2500 5000
comes first km (ml)
(150) (800) (1600) (1600) (3200)
¢
hours 20 80 160 160 320
Front and rear brake ,/ ,/ ,/ ,/ ,/
25 * • Check operation and correct if necessary.
switches
Lights and switches • Check operation and correct if necessary. ,/ ,/ ,/ ,/ ,/

26 *
• Adjust headlight beams.
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 cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-3
EBS30027
4. Check:
CHECKING THE FUEL LINE
• Spark plug type
1. Remove:
Incorrect~ Change.
• Side panel (right)
Refer to "GENERAL CHASSIS (1 )" on page Manufacturer/model
4-1. NGK/CPR7EA-9
• Rear fender
Refer to "GENERAL CHASSIS (3)" on page 5. Check:
4-8. • Electrodes "1"
• V-belt cooling exhaust duct Damage/wear ~ Replace the spark plug.
Refer to "ENGINE REMOVAL (1 )" on page • Insulator "2"
5-4. Abnormal color ~ Replace the spark plug.
2. Check: Normal color is medium-to-light tan .
• Fuel hose "1" 6. Clean:
Cracks/damage ~ Replace. • Spark plug
Loose connection ~ Connect properly. (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)
3. Install:
• V-belt cooling exhaust duct
Refer to "ENGINE REMOVAL (1 )" on page >
5-4. I ' I
• Rear fender - 2
Refer to "GENERAL CHASSIS (3)" on page
4-8.
Refer to "GENERAL CHASSIS (1 )" on page 8. Install:
4-1. • Spark plug
EBS30029 Spark plug

CHECKING THE SPARK PLUG 13 N,m (1.3 kgf,m, 9.6 lb,ft)
1. Remove:
• Side panel (right) TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Refer to "GENERAL CHASSIS (1 )" on page Before installing the spark plug, clean the spark
4-1. plug and gasket surface.
2. Disconnect:
9. Connect:
• Spark plug cap
• Spark plug cap
3. Remove:
• Spark plug 1O.lnstall:
ECB01270 • Side panel (right)
NOTICE Refer to "GENERAL CHASSIS (1)" on page
------------ 4-1 .
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well EBS30028
with compressed air to prevent it from falling ADJUSTING THE VALVE CLEARANCE
into the cylinder. The following procedure applies to all of the
valves.
3-4
TIP ~~~~~~~~~~~~~~
• Valve clearance adjustment should be made

on a cold engine, at room temperature.
• When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Remove:
• Side panels (left and right)
Refer to "GENERAL CHASSIS (1 )" on page
4-1. 6. Measure:
• Front fender • Valve clearance
Refer to "GENERAL CHASSIS (3)" on page Out of specification ~ Adjust.
4-8.
• Footrest board Valve clearance (cold)
Refer to "GENERAL CHASSIS (4)" on page Intake
4-11. 0.09-0.13 mm (0.0035-0.0051 in)
• Storage compartment Exhaust
Refer to "GENERAL CHASSIS (5)" on page 0.16-0.20 mm (0.0063-0.0079 in)
4-17.
a. Turn the crankshaft counterclockwise.
2. Remove:
b. When the piston is at TDC on the com-
• Intake tappet cover "1"
pression stroke, align the "I" mark "a" on
• Exhaust tappet cover
the AC magneto rotor with the stationary
• Camshaft sprocket cover "2"
pointer "b" on the AC magneto cover.
b '-....:
3. Disconnect:
TIP ~~~~~~~~~~~~~~
• Spark plug cap "1"
4. Remove: To position the piston at TDC on the compres-
• Spark plug "2" sion stroke, align the "I" mark "d' on the camshaft
sprocket with the stationary pointer "d" on the
~ cylinder head, as shown in the illustration.
5. Remove:
• Timing mark accessing screw "1"
• Crankshaft end accessing screw "2" c. Measure the valve clearance with a thick-
ness gauge "1".
Out of specification ~ Adjust.
3-5
• Crankshaft end accessing screw

Thickness gauge
90890-03180 Timing mark accessing screw
Feeler gauge set 1.5 N,m (0.15 kgf,m, 1.1 lb,ft)
YU-26900-9 Crankshaft end accessing screw
2.0 N,m (0.20 kgf,m, 1.5 lb,ft)
9. Install:
• Spark plug
()
Spark plug
13 N,m (1.3 kgf,m, 9.6 lb,ft)
1a.Connect:
• Spark plug cap
11.lnstall:
7. Adjust: •
•
0-rings "1" ·~tm
Camshaft sprocket cover
• Valve clearance
a. Loosen the locknut "1". • Intake tappet cover
b. Insert a thickness gauge "2" between the • Exhaust tappet cover
end of the adjusting screw and the valve
Camshaft sprocket cover bolt
tip. 1O N,m (1.0 kgf,m, 7.4 lb,ft)
c. Turn the adjusting screw "3" with the tap- Tappet cover bolt
pet adjusting tool "4" until the specified 1O N,m (1.0 kgf,m, 7.4 lb,ft)
valve clearance is obtained.
Tappet adjusting tool

90890-01311
Six piece tappet set
0
YM-A5970
12.lnstall:
• Storage compartment
4-17.
• Footrest board
d. Hold the adjusting screw to prevent it from Refer to "GENERAL CHASSIS (4)" on page
moving and tighten the locknut to specifi- 4-11 .
cation. • Front fender
Valve adjusting screw locknut 4-8.
14 N,m (1.4 kgf,m, 1O lb,ft) • Side panels (left and right)
e. Measure the valve clearance again. 4-1 .
f. If the valve clearance is still out of specifi-
cation, repeat all of the valve clearance
adjustment steps until the specified clear-
ance is obtained.
8. Install:
• Timing mark accessing screw
3-6
EBS30030
CHECKING THE BREATHER HOSES Exhaust pipe nut '7"

1. Remove: 20 N-m (2.0 kgf-m, 15 lb·ft)
• Side panel (left) Muffler bracket bolt "8"
Refer to "GENERAL CHASSIS (1 )" on page 20 N-m (2.0 kgf-m, 15 lb·ft)
4-1. Muffler bolt "9"
• Storage compartment 33 N-m (3.3 kgf-m, 24 lb·ft)
Refer to "GENERAL CHASSIS (5)" on page Exhaust pipe protector bolt "10"
4-17. 7 N-m (0.7 kgf-m, 5.2 lb·ft)
2. Check:
• Cylinder head breather hose "1"
• Throttle body breather hose "2"
Cracks/damage ~ Replace.
Loose connection ~ Connect properly.
ECB01680
NOTICE
------------
Make sure the cylinder head breather hose is
routed correctly.
3. Install:
EBS30032
4-17.
CLEANING THE SPARK ARRESTER
• Side panel (left) 1. Clean:
Refer to "GENERAL CHASSIS (1 )" on page • Spark arrester
4-1. EWB03080
EBS30031
& WARNING
CHECKING THE EXHAUST SYSTEM • Select a well-ventilated area free of com-
1. Check: bustible materials.
• Exhaust pipe "1" • Always let the exhaust system cool before
• Muffler "2" performing this operation.
• Exhaust pipe protector "3" • Do not start the engine when removing the
• Muffler bracket "4" tailpipe from the muffler.
• Springs "5" a. Remove the bolts "1".
Cracks/damage ~ Replace. b. Remove the tailpipe "2" by pulling it out of
• Gaskets "6" the muffler and gasket "3".
Exhaust gas leaks ~ Replace.
2. Check:
• Tightening torque
3-7
2. Remove:
• Seat
3 Refer to "GENERAL CHASSIS (1)" on page
0 0 2 4-1 .
3. Remove:
• Air filter case cover "1"
;::::.-
0 0
c. Tap the tailpipe lightly with a soft-face

hammer or suitable tool, then use a wire
brush to remove any carbon deposits from
the spark arrester portion of the tailpipe
and the inner contact surfaces of the muf-
fler.
d. Install a new gasket, and then insert the 4. Remove:
tailpipe into the muffler and align the bolt • Air filter element assembly "1"
holes.
e. Install the bolts "1" and tighten them.
Spark arrester bolt

1O N,m (1.0 kgf,m, 7.4 lb,ft)
EBS30033
CHECKING THE AIR INDUCTION SYSTEM

Refer to "CHECKING THE AIR INDUCTION
SYSTEM" on page 7-12.
EBS30037 5. Disassemble:
CLEANING THE AIR FILTEA ELEMENT • Air filter element holder "1"
1. Check: • Air filter element "2"
• Air filter check hose "1" • Air filter element frame "3"
ECB01800
TIP _ _ _ _ _ _ _ _ _ _ _ _ _~
NOTICE
There is an air filter check hose "1" at the bottom ------------
of the air filter case. If dust and/or water collects The engine should never be run without the
in this hose, empty the hose and clean the air fil- air filter; excessive piston and/or cylinder
ter element, filter frame , and air filter case. wear may result.
3-8
3
1
6. Check: e. Thoroughly rinse the air filter element with

• Air filter element water, and then let it dry.
• Air filter element frame ECB01290
• Air filter element holder NOTICE

-------------
Damage ~ Replace. Do not twist the air filter element when
7. Clean: squeezing it.
• Air filter element f. Pour the recommended oil into a storage
a. Carefully wash the air filter element in sol- bag large enough for the air filter element.
vent.
EWB02760
Air filter oil grade
& WARNING Foam air-filter oil
Never use low flash point solvents, such as
gasoline, to clean the air filter element. Such g. Place the air filter element into the storage
solvents may cause a fire or an explosion. bag and repeatedly squeeze the element
until the air filter element is saturated with
oil.
TIP - - - - - - - - - - - - - - - ~
The air filter element should be wet but not drip-
.
ping.
b. After cleaning, squeeze the air filter ele-

ment to remove the excess solvent.
ECB01290
NOTICE
-------------
Do not twist the air filter element when
squeezing it. 8. Assemble:
• Air filter element frame
• Air filter element
• Air filter element holder
9. Install:
• Air filter element assembly
1O.lnstall:
• Air filter case cover
11.lnstall:
• Seat
c. Properly dispose of the used solvent. 4-1 .
d. Carefully wash the air filter element in
soap water.
3-9
EBS30044
4. Install:
CHECKING THE FRONT BRAKE PADS
• Rear wheels
The following procedure applies to all of the front
Refer to "REAR WHEELS" on page 4-23.
brake pads.
1. Remove: EBS30580
• Front wheels ADJUSTING THE FRONT DISC BRAKE

Refer to "FRONT WHEELS" on page 4-20. 1. Check:
2. Operate the brake. • Front brake lever free play "a"
3. Check: Out of specification ~ Bleed the front brake
• Front brake pads system.
Wear indicator grooves "a" have almost dis- Refer to "BLEEDING THE HYDRAULIC
appeared ~ Replace the brake pads and BRAKE SYSTEM" on page 3-13.
brake pad spring as a set.
Front brake lever free play (lever
Refer to "FRONT BRAKE" on page 4-26.
end)
~ ~~ - - - O mm (0 in)
ad
;-,r+ a
Q
•
4. Install:
• Front wheels
Refer to "FRONT WHEELS" on page 4-20.
EBS30581
EBS30050 ADJUSTING THE REAR DISC BRAKE

CHECKING THE REAR BRAKE PADS EWB03730
The following procedure applies to all of the rear & WARNING

brake pads. Always adjust both the brake pedal and the
1. Remove: rear brake lever whenever adjusting the rear
• Rear wheels brake.
1. Check:
2. Operate the brake.
• Rear brake lever free play "a"
3. Check:
Out of specification ~ Bleed the rear brake
• Rear brake pads
Wear indicator grooves "a" have almost dis- system.
appeared ~ Replace the brake pads and Refer to "BLEEDING THE HYDRAULIC
brake pad spring as a set. BRAKE SYSTEM" on page 3-13.
Refer to "REAR BRAKE" on page 4-37. Rear brake lever free play (lever
. . end)
&~ O mm (0 in)
3-10
2. Check: TIP ~~~~~~~~~~~~~~~

• Brake pedal free play "a" When checking the brake pedal free play, make
Out of specification ~ Adjust. sure that the brake lever bracket "6" does not
Brake pedal free play move.
1.0-6.0 mm (0.04-0.24 in)
u
,,
/ ,/ 0 ,-
, ,, ,
I
'
---?-'-
,. - ......i....J_ _ J _ ~ i '
'' ' '

''
6 '''
3. Adjust: 4
• Brake pedal free play
a. Remove the front fender inner panel
(right).
Refer to "GENERAL CHASSIS (3)" on ~,r'\
page 4-8. 5 4
b. Slide back the rubber boot.
c. Loosen the adjusting nut "1" and locknut
"2''.
d. Turn the adjusting nut "1" until the rear h. Slide the rubber boot to its original posi-
brake cable "3" is obtained. tion .
e. While holding the locknut "2", tighten the EWB03740
adjusting nut "1 ". £ WARNING

After this adjustment is performed, lift the
Brake pedal free play adjusting front and rear wheels off the ground by plac-
nut ing a block under the engine, and spin the
7 N-m (0.7 kgf-m, 5.2 lb-ft) rear wheels to ensure there is no brake drag.
If any brake drag is noticed perform the
above steps again.
i. Install the front fender inner panel (right).
Refer to "GENERAL CHASSIS (3)" on
page 4-8.
EBS30461
CHECKING THE FRONT BRAKE HOSES

The following procedure applies to all of the
brake hoses and brake hose clamps.
1. Check:
f. Check that there is a gap "a" between the • Front brake hoses "1"
rear brake cable joint (rear brake master Cracks/damage/wear ~ Replace.
cylinder side) "4" and the pin "5" is 0.1-0.5
mm (0.004--0.020 in).
g. Check that the brake pedal free play is
within the specified limits.
3-11
1 1
2. Check:
• Brake hose holders
Loose ~ Tighten the holder bolt.
3. Apply the brake several times.
4. Check:
• Brake hoses
Brake fluid leakage ~ Replace the damaged
hose.
Refer to "REAR BRAKE'' on page 4-37.
EBS30045
2. Check: CHECKING THE BRAKE FLUID LEVEL
• Brake hose holders 1. Place the vehicle on a level surface.
Loose ~ Tighten the holder bolt.
TIP ~~~~~~~~~~~~~~
3. Apply the brake several times.
4. Check: When checking the brake fluid level, make sure
• Brake hoses that the top of the brake fluid reservoir is horizon-
Brake fluid leakage ~ Replace the damaged tal.
hose. 2. Check:
Refer to "FRONT BRAKE" on page 4-26. • Brake fluid level
EBS30582
Below the minimum level mark "a"~ Add the
CHECKING THE REAR BRAKE HOSES specified brake fluid to the proper level.
Specified brake fluid
brake hoses and brake hose clamps.
D0T4
1. Check:
• Rear brake hoses "1"
Cracks/damage/wear ~ Replace.
3-12
• When bleeding the hydraulic brake system,

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.
• 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
J I c, /J in the hose have disappeared.
A. Front brake 1. Bleed:
B. Rear brake • Hydraulic brake system
EWB02790 a. Fill the brake fluid reservoir to the proper
& WARNING level with the specified brake fluid.
• Use only the designated brake fluid. Other b. Install the diaphragm (brake fluid reser-
brake fluids may cause the rubber seals to voir) .
deteriorate, causing leakage and poor c. Connect a clear plastic hose "1" tightly to
brake performance. the bleed screw "2".
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
2 1
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
ECB01320
NOTICE
-------------
Brake fluid may damage painted surfaces [ID
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
TIP - - - - - - - - - - - - - - - ~
In order to ensure a correct reading of the brake
fluid level, make sure the top of the brake fluid
reservoir is horizontal.
EBS30046
BLEEDING THE HYDRAULIC BRAKE A. Front brake

SYSTEM B. Rear brake
EWB028DO
& WARNING d. Place the other end of the hose into a con-
Bleed the hydraulic brake system whenever: tainer.
• the system is disassembled. e. Slowly apply the brake several times.
• a brake hose is loosened, disconnected or f. Fully pull the brake lever and hold it in po-
replaced. sition.
• the brake fluid level is very low. g. Loosen the bleed screw.
• brake operation is faulty. TIP - - - - - - - - - - - - - - - ~
TIP~~~~~~~~~~~~~~
Loosening the bleed screw will release the pres-
sure and cause the brake lever to touch the
• Be careful not to spill any brake fluid or allow
the brake fluid reservoir to overflow. throttle grip.
3-13
h. Tighten the bleed screw, and then release REAR KNUCKLES AND REAR WHEEL
the brake lever. BEARINGS" on page 4-67.
i. Repeat steps (e) to (h) until all of the air
EBS30058
bubbles have disappeared from the brake CHECKING THE TIRES
fluid in the plastic hose. The following procedure applies to all of the
.
J. Tighten the bleed screw to specification . tires.
EWB02960
Brake caliper bleed screw & WARNING

5 N,m (0.5 kgf,m, 3.7 lb,ft)
This model is equipped with low-pressure
k. Fill the brake fluid reservoir to the proper tires. It is important that they be inflated cor-
level with the specified brake fluid. rectly and maintained at the proper pres-
Refer to "CHECKING THE BRAKE FLUID sures.
LEVEL" on page 3-12.
EWB02810
Tire characteristics
& WARNING EWB02970
After bleeding the hydraulic brake system, & WARNING

check the brake operation. Tire characteristics influenc.e the handling of
vehicles. The tires listed below have been
EBS30057 approved by Yamaha Motor Co., Ltd. for this
CHECKING THE WHEELS model. If other tire combinations are used,
The following procedure applies to all of the they can adversely affect your vehicle's han-
wheels. dling characteristics and are therefore not
1. Check: recommended.
• Wheel "1"
Damage/bends ~ Replace. Front tire
EWB03010
& WARNING Size

AT26 x 8-12 (YFM70GPAK,
• Never attempt even small repairs to the YFM70GPHK)
wheel. AT27 x 10-14 (YFM70GPLK)
• Ride conservatively after installing a tire to Manufacturer/model
allow it to seat itself properly on the rim. MAXXIS/MU05Y (YFM70GPAK,
YFM70GPHK)
Rear tire
Size
AT26 x 10-12 (YFM70GPAK,
YFM70GPHK)
Manufacturer/model
MAXXIS/MU06Y (YFM70GPAK,
YFM70GPHK)
2. Measure:
• Radial wheel runout Tire pressure
• Lateral wheel runout EWB02980
Refer to "CHECKING THE FRONT & WARNING

WHEELS" on page 4-21 and "CHECKING • Tire pressure below the minimum specifi-
THE REAR WHEELS" on page 4-24. cation could cause the tire to dislodge from
3. Check: the rim under severe riding conditions.
• Wheel bearings • Use no more than the following pressures
Refer to "CHECKING THE STEERING when seating the tire beads.
KNUCKLES AND FRONT WHEEL BEAR- Front
INGS" on page 4-57 and "CHECKING THE 250 kPa (2.5 kgf/cm2 ) (36 psi)
3-14
Rear
250 kPa (2.5 kgf/cm 2 ) (36 psi) Maximum loading limit
Higher pressures and fast inflation may 240.0 kg (530 lb)
cause a tire to burst. Inflate the tires very Front carrier load limit
50.0 kg (110 lb)
slowly and carefully.
Rear carrier load limit
90.0 kg (198 lb)
Tire air pressure (measured on Storage compartment_ 1 location
cold tires) Center storage compartment
Vehicle load Load limit
0.0-240.0 kg (0-529 lb) 4.0 kg (9 lb)
Recommended Storage compartment_2 location
Front Front storage compartment
35.0 kPa (0.350 kgf/cm 2 , 5.0 Load limit
psi) 0.5 kg (1 lb)
Rear Storage compartment_3 location
30.0 kPa (0.300 kgf/cm 2 , 4.4 Rear storage compartment
psi) (YFM70GPAK, Load limit
YFM70GPHK) 2.0 kg (4 lb)
35.0 kPa (0.350 kgf/cm 2 , 5.0 Trailer hitch pulling load limit
psi) (YFM70GPLK) 5880 N (600 kgf, 1322 lbf)
Minimum Trailer hitch vertical load limit
Front 147 N (15 kgf, 33 lbf)
32.0 kPa (0.320 kgf/cm 2 , 4.6
psi) 1. Measure:
Rear • Tire pressure
27.0 kPa (0.270 kgf/cm 2 , 4.0 Out of specification ~ Adjust.
psi) (YFM70GPAK,
TIP ~~~~~~~~~~~~~~
YFM70GPHK)
32.0 kPa (0.320 kgf/cm 2 , 4.6 • The tire pressure gauge "1" is included as stan-
psi) (YFM70GPLK) dard equipment.
• In order to insure an accurate reading, make
Maximum loading limit
sure that the gauge is clean before use.
EWB02990
& WARNING
Be extra careful of the vehicle balance and
stability when towing a trailer.
EWB03000
& WARNING
Uneven or improper tire pressure may ad-
versely affect the handling of this vehicle
and may cause loss of control.
• Maintain proper tire pressures.
• Set tire pressures when the tires are cold.
• Tire pressures must be equal in both front
tires and equal in both rear tires.
2. Check:
• Tire surfaces
Wear/damage ~ Replace.
3-15
Refer to "REPLACING THE V-BELT' on

Wear limit (front) page 3-16.
3.0 mm (0.12 in)
Wear limit (rear) V-belt width limit
3.0 mm (0.12 in) 31.3 mm (1.23 in)
EWB03100
& WARNING 2
It is dangerous to ride with a worn-out tire. a
When the tire tread reaches the wear limit, re-
place the tire immediately.
r--- ,
I ' - -- - -
a
2. Plastic board
3. Ruler
4. Install:
• Drive belt cover
Refer to "PRIMARY AND SECONDARY
a. Wear limit SHEAVES" on page 5-49.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ EBS30056
The arrow mark "1" on the tire must point in the REPLACING THE V-BELT
direction of wheel rotation . 1. Remove:
SHEAVES" on page 5-49.
2. Replace:
• V-belt
a. Install the bolts "1" (90101-06016) into the
secondary fixed sheave holes.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Tightening the bolts "1" will push the secondary
sliding sheave away, causing the gap between
EBS30055
the secondary fixed and sliding sheaves to wid-
CHECKING THE V-BELT en.
1. Remove: .__1.0 mm (0.04 in)
Refer to "PRIMARY AND SECONDARY ~-~!mllmmm
~-l
""'1-r 6 mm
"'+-' (0.24 in)
45 mm (1.77 in)
2. Check:
• V-belt "1"
Grease/oil ~ Clean the primary and second-
ary sheaves. 1
Refer to "REPLACING THE V-BELT' on
page 3-16. b. Remove the V-belt "2" from the primary
3. Measure: sheave and secondary sheave.
• V-belt width "a"
Out of specification ~ Replace.
3-16
EBS30430
ADJUSTING THE FRONT SHOCK

ABSORBER ASSEMBLIES
The following procedure applies to both of the
front shock absorber assemblies.
EWB03760
& WARNING
Always adjust the spring preload for both
front shock absorber assemblies to the
same setting. Uneven adjustment can cause
poor handling and loss of stability.
c. Install a new V-belt.
TIP ~~~~~~~~~~~~~~
1. Adjust:
• Spring preload
Install the new V-belt so that its arrow faces the
Turn the adjuster "1" in direction "a" or "b".
direction shown in the illustration.
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
0
0
Direction "a"
Spring preload is increased (suspen-
sion is harder).
Direction "b"
Spring preload is decreased (suspen-
d. Remove the bolts. sion is softer).
EBS30069
CHECKING THE FASTENER Spring preload

1. Check: Adjusting system
• Fasteners Mechanical adjustable type
Damage/pitting ~ Replace. Unit for adjustment
Refer to "GENERAL CHASSIS (1 )" on page Cam position
4-1. Adjustment value (Soft)
1
EBS30059
Adjustment value (STD)
CHECKING THE FRONT SHOCK ABSORBER 2
ASSEMBLIES Adjustment value (Hard)
The following procedure applies to both of the 5
1. Place the vehicle on a level place.
2. Check:
• Front shock absorber assembly
Refer to "CHECKING THE FRONT SHOCK
ABSORBER ASSEMBLIES" on page 4-62.
3. Check:
• Operation
Pump the front shock absorber assembly up
and down several times.
Unsmooth operation~ Replace front shock
absorber assembly. EBS30060
Refer to "FRONT ARMS AND FRONT CHECKING THE REAR SHOCK ABSORBER
SHOCK ABSORBER ASSEMBLIES" on ASSEMBLIES
page 4-60. The following procedure applies to both of the
rear shock absorber assemblies.
3-17
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. EBS30064
Refer to "REAR ARMS AND REAR SHOCK CHECKING THE STABILIZER BUSHING
ABSORBER ASSEMBLIES" on page 4-68. 1. Check:
• Stabilizer bushings
EBS30431
ADJUSTING THE REAR SHOCK ABSORBER Damage/wear ~ Replace.

Refer to "REAR KNUCKLES AND STABILIZ-
ASSEMBLY
The following procedure applies to both of the ER" on page 4-65.
rear shock absorber assemblies. EBS30065
EWB03770
LUBRICATING THE REAR KNUCKLE
AwARNING PIVOTS
Always adjust the spring preload for both 1. Lubricate:
rear shock absorber assemblies to the same • Rear knuckle pivots
setting. Uneven adjustment can cause poor
handling and loss of stability. Recommended lubricant
I Lithium-soap-based grease
1. Adjust:
• Spring preload
Turn the adjuster "1" in direction "a" or "b".
Ring nut wrench

90890-01268
Spanner wrench
YU-01268
Direction "a"
Spring preload is increased (suspen-
sion is harder). EBS30063
Direction "b" LUBRICATING THE STEERING SHAFT

Spring preload is decreased (suspen- Lubricate the pivoting point and metal-to-metal
sion is softer). moving parts of the shaft.
Recommended lubricant
Spring preload Lithium-soap-based grease
Adjusting system
Mechanical adjustable type
Unit for adjustment
Cam position
Adjustment value (Soft)
1
Adjustment value (STD)
2
Adjustment value (Hard)
5
3-18
EBS30061
CHECKING THE STEERING SYSTEM

1. Place the vehicle on a level surface.
2. Check:
• Steering assembly bushings
Move the handlebar up and down, and back
and forth.
Excessive play ~ Replace the steering stem
bushings.
6. Measure:
• Steering tension
Above specification ~ Adjust.
Steering tension
50 N (5.0 kgf)
a. Set the main switch to" o " (off).

b. Place the vehicle on a suitable stand so
3. Check: that the front wheels are elevated.
• Tie-rod ends c. Point the front wheels straight ahead.
Free play~ Replace the tie-rod end. d. Hold the belt tension gauge "1" at a 90°
a. Turn the handlebar left until it stops. angle to the handlebar, push the gauge
b. Move the handlebar slightly to the right against the handlebar, and then record the
and left. measurement when the handlebar starts
c. Check for play in the tie-rod ends. to turn .
d. Turn the handlebar right until it stops.
e. Move the handlebar slightly to the left and Belt tension gauge
right. 90890-03170
f. Check for play in the tie-rod ends. Rear drive belt tension gauge
--. YM-03170
4. Raise the front end of the vehicle so that

there is no weight on the front wheels. 7. Adjust:
5. Check: • Steering tension
• Ball joints and wheel bearings a. Remove the electrical components tray.
Move the wheels laterally back and forth . Refer to "GENERAL CHASSIS (4)" on
Excessive free play ~ Replace the front page 4-11.
arms (upper and lower) and/or wheel bear- b. Loosen the steering stem bracket bolts "1"
.
1ngs. and steering stem pinch bolt "2" complete-
ly.
3-19
EBS30062
TIP ~~~~~~~~~~~~~~
ADJUSTING THE TOE-IN
After loosening the bolts, be sure to check that 1. Place the vehicle on a level surface.
the steering stem moves smoothly on the serra- 2. Measure:
tions of the shaft of the EPS unit. • Toe-in
Toe-in (with tires touching the

ground)
0.0-10.0 mm (0.00-0.39 in)
TIP ~~~~~~~~~~~~~~
Before measuring the toe-in, make sure that the

tire pressure is correct.
a. Mark both front tire tread centers.
b. Face the handlebar straight ahead.
c. Measure the width "A" between the marks.
d. Rotate the front tires 180° until the marks
are exactly opposite one another.
e. Measure the width "B" between the marks.
f. Calculate the toe-in using the formula giv-
en below.
I Toe-in = "B" - "A"

I
c. Tighten the steering stem bracket bolts to g. If the toe-in is incorrect, adjust it.
specification.
Steering stem bracket bolt

51 N-m (5.1 kgf-m, 38 lb-ft)
LOCTITE®
d. Tighten the steering stem pinch bolt to

specification.
Steering stem pinch bolt

35 N-m (3.5 kgf-m, 26 lb-ft)
LOCTITE® A
e. Measure the steering tension again.
f. Repeat the above procedure until the •
steering tension is below specification.
C
Steering tension
50 N (5.0 kgf)
'u'
B
g. Install the electrical components tray. Re-
fer to "GENERAL CHASSIS (4)" on page
C. Forward
4-11 .
3. Adjust:
• Toe-in
3-20
EWB037SO
AwARNING
A B
• Be sure that both tie-rods are turned the
same amount. If not, the vehicle will drift
right or left even though the handlebar is
positioned straight. This may lead to mis-
handling and an accident.
• After setting the toe-in to specification, run
the vehicle slowly for some distance with
both hands lightly holding the handlebar
and check that the handlebar responds cor- 4. Check:
rectly. If not, turn either the right or left tie- • Handlebar
rod within the toe-in specification. TIP ~~~~~~~~~~~~~~
a. Mark both tie-rods ends. After adjusting the toe-in, the handlebar should
This reference point will be needed during be centered.
adjustment.
b. Loosen the tie-rod end locknuts "1" of both Refer to "INSTALLING THE HANDLEBAR"
on page 4-50.
tie-rods.
c. The same number of turns should be giv- EBS30067
en to both the right and left tie-rods "2" until CHECKING THE ENGINE MOUNT
the specified toe-in is obtained. This is to 1. Check:
keep the length of the tie-rods the same. • Rubber damper
,..----". Cracks/damage ~ Replace.
• Engine mounting bolts
• Rubber damper nuts
Loosen ~ Tighten.
Refer to "ENGINE REMOVAL (3)" on page
( 5-10.
EBS30068
CHECKING THE CONSTANT VELOCITY

SHAFT ASSEMBLY DUST BOOTS
) 2 1. Check:
d. Tighten the tie-rod end locknuts to specifi- • Dust boots "1"
cation. Damage ~ Replace.
Refer to "FRONT CONSTANT VELOCITY
Tie-rod end locknut (front wheel SHAFT ASSEMBLIES, DIFFERENTIAL AS-
side) SEMBLY AND FRONT DRIVE SHAFT' on
15 N,m (1.5 kgf,m, 11 lb,ft)
Tie-rod end locknut (pitman arm page 8-4 and "REAR CONSTANT VELOCI-
side) TY SHAFT ASSEMBLIES, FINAL DRIVE
15 N,m (1.5 kgf,m, 11 lb,ft) ASSEMBLY AND REAR DRIVE SHAFT' on
page 8-15.
TIP~~~~~~~~~~~~~~ 1h] L--
Adjust the tie-rod ends so that "A" and "B" are ~

equal.
l....._
1 1
3-21
Recommended brand
YAMALUBE
SAE viscosity grades
SW-30, 1OW-30, 1OW-40, 1SW-40,
20W-40, 20W-50
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
0 10 30 50 70 90 110 130 °F
A. Front .I .I I I .I
... .I
... .I .I
SAEOW-30 .. .... ..... ....
...
B. Rear ...
SAE 10W-30 ... .. ...
. ....
EBS30038
SAE 10W-~O
. ...
CHECKING THE ENGINE OIL LEVEL SAE fSW-40
... ...
1. Place the vehicle on a level surface. . ....
2. Check the engine oil level on a cold engine.
SAE20W-~O
. ....
..SAE 20W-50
.. ....
TIP~~~~~~~~~~~~~~ .
I I I I I I
If the engine was started before the oil level was -20 -10 0 10 20 30 40 so ·c
checked, be sure to warm up the engine suffi- EC B01820
ciently, and then wait at least 1O minutes until NOTICE

- - - - - - - - - - - - -
the oil settles for an accurate reading. • Engine oil also lubricates the clutch and the
wrong oil types or additives could cause
3. Remove:
clutch slippage. Therefore, do not add any
• Dipstick accessing cover
chemical additives or use engine oils with a
grade of "CD" or higher and do not use oils
4-11.
labeled "ENERGY CONSERVING 11".
4. Check:
• Do not allow foreign materials to enter the
• Engine oil level
crankcase.
The engine oil level should be between the
minimum level mark "a" and maximum level 5. Check the engine oil level again.
EC B01830
mark "b".
NOTICE
Below the minimum level mark """"7 Add the -------------
recommended engine oil to the proper level. Be sure the engine oil is at the correct level,
ECB01810 otherwise engine damage may result.
NOTICE
------------- 6. Install:
Do not allow foreign materials to enter the • Dipstick accessing cover
crankcase. Refer to "GENERAL CHASSIS (4)" on page
TIP~~~~~~~~~~~~~~
4-11 .
Insert the dipstick completely into the oil filler EBS30039
hole, and then remove it again to check the oil CHANGING THE ENGINE OIL
level. 1. Start the engine, warm it up for several min-
utes, and then turn it off.
2. Remove:
• Dipstick accessing cover
4-11 .
3. Place a container under the engine oil drain
bolt.
4. Remove:
- -b • Dipstick "1"
~ a • Engine oil drain bolt "2"
(along with the gasket)
3-22
c. Tighten the new oil filter cartridge to spec-

ification with the oil filter wrench.
Oil filter cartridge

17 N,m (1.7 kgf,m, 13 lb,ft)
7. Install:
• Engine oil drain bolt
(along with the gasket l~iWJ)
Engine oil drain bolt
5. Drain: 33 N,m (3.3 kgf,m, 24 lb,ft)
• Engine oil
(completely from the crankcase) 8. Fill:
6. If the oil filter cartridge is also to be replaced, • Crankcase
perform the following procedure. (with the specified amount of the recom-
a. Remove the oil filter cartridge "1" with the mended engine oil)
oil filter wrench "2".
Quantity
Oil filter wrench Quantity (disassembled)
90890-01469 2.40 L (2.54 US qt, 2.11 Imp.qt)
Oil filter wrench Oil change
YM-01469 2.00 L (2.11 US qt, 1.76 Imp.qt)
With oil filter removal
2.1 O L (2.22 US qt, 1.85 Imp.qt)
9. Install:
• Dipstick
1a.Start the engine, warm it up for several min-
utes, and then turn it off.
11.Check:
• Engine
(for engine oil leaks)
12.Check:
b. Lubricate the 0-ring "3" of a new oil filter • Engine oil level
cartridge with a thin coat of engine oil. Refer to "CHECKING THE ENGINE OIL
ECB01280 LEVEL" on page 3-22.
NOTICE 13.Check:
-------------
Make sure the 0-ring "3" is positioned cor- • Engine oil pressure
rectly in the groove of the oil filter cartridge. a. Remove the side panel (right).
page 4-1.
b. Slightly loosen the oil check bolt "1 ".
3-23
ECB01600
NOTICE
- - - - - - - - - - - - -
Take care not to allow foreign material to en-
ter the differential case.
c. Start the engine and keep it idling until en-

gine oil starts to seep from the oil check
bolt. If no engine oil comes out after one
minute, turn the engine off so that it will not 2
.
seize. 4. Check:
d. Check the engine oil passages, the oil fil- • Differential gear oil filler bolt gasket
ter cartridge and the oil pump for damage Damage ~ Replace.
or leakage. Refer to "CRANKSHAFT AND 5. Install:
OIL PUMP" on page 5-70. • Differential gear oil filler bolt
e. Start the engine after solving any prob- (along with the gasket)
lems and check the engine oil pressure
.
again. Differential gear oil filler bolt
f. Tighten the oil check bolt to specification . 23 N,m (2.3 kgf,m, 17 lb,ft)
Oil check bolt EBS30043
1O N,m (1.0 kgf,m, 7.4 lb,ft) CHANGING THE DIFFERENTIAL GEAR OIL
g. Install the side panel (right). 2. Place a container under the differential case.
Refer to "GENERAL CHASSIS (1)" on 3. Remove:
page 4-1 . • Differential gear oil filler bolt
14.lnstall: (along with the gasket)
• Dipstick accessing cover • Differential gear oil drain bolt "1"
Refer to "GENERAL CHASSIS (4)" on page (along with the gasket)
4-11. Completely drain the differential case of its
EBS30042
oil.
CHECKING THE DIFFERENTIAL GEAR OIL
LEVEL
1. Place the vehicle on a level surface. w
2. Remove:
• Differential gear oil filler bolt "1"
0(:-~-~-~ ;/ ~
(along with the gasket) o(c 1> :==:)Jo (g;J
C.::::<
3. Check:
• Differential gear oil level
The differential gear oil level should be up to u @v1
the brim "2" of the hole.
Below the brim~ Add the recommended dif- 4. Install:
ferential gear oil to the proper level. • Differential gear oil drain bolt
(along with the gasket l~iWJ)
Type
Yamaha Friction Modified Plus Differential gear oil drain bolt
Shaft Drive Oil (Part No.: ACC- 10 N,m (1.0 kgf,m, 7.4 lb,ft)
SHAFT-PL-32) or SAE 80 API
3-24
5. Fill:
• Differential case
(with the specified amount of the recom- LJ 1
mended differential gear oil)
I"?"~ .
2
Type
Yamaha Friction Modified Plus
Shaft Drive Oil (Part No.: ACC-
Quantity (disassembled)
0.23 L (0.24 US qt, 0.20 Imp.qt) 4. Check:
Quantity • Final gear oil level check bolt gasket
0.21 L (0.23 US qt, 0.19 Imp.qt) Damage ~ Replace.
5. Install:
ECB01600
• Final gear oil level check bolt
NOTICE (along with the gasket)
- - - - - - - - - - - -
ter the differential case. Final gear oil level check bolt
10 N,m (1.0 kgf,m, 7.4 lb,ft)
6. Check:
• Oil level EBS30041
Refer to "CHECKING THE DIFFERENTIAL CHANGING THE FINAL GEAR OIL

GEAR OIL LEVEL" on page 3-24. 1. Place the vehicle on a level surface.
7. Install: 2. Place a container under the final drive case.
• Differential gear oil filler bolt 3. Remove:
(along with the gasket) • Final gear oil filler bolt "1"
Differential gear oil filler bolt
23 N,m (2.3 kgf,m, 17 lb,ft)
EBS30040
CHECKING THE FINAL GEAR OIL LEVEL

2. Remove:
• Final gear oil level check bolt "1"
3. Check:
• Final gear oil level
The final gear oil level should be up to the 4. Remove:
brim "2" of the hole. • Final gear oil level check bolt
Below the brim ~ Add the recommended fi- (along with the gasket)
nal gear oil to the proper level. • Final gear oil drain bolt "1"
Type Completely drain the final drive case of its oil.
Shaft Drive Oil (Part No.: ACC-
ECB01690
NOTICE
- - - - - - - - - - - -
ter the final drive case.
3-25
5. Install: • Radiator outlet hose "5"

• Final gear oil drain bolt • Water jacket joint "6"
(along with the gasket "•~~tw"'ao • Water pump outlet hose "7"
• Water pump outlet pipe "8"
Final gear oil drain bolt • Water pump housing "9"
23 N,m (2.3 kgf,m, 17 lb,ft) Cracks/damage ~ Replace.
Coolant leakage ~ Replace any damaged
6. Fill: hose and pipe
• Final drive case Refer to "RADIATOR" on page 6-2 and "WA-
(with the specified amount of the recom- TER PUMP" on page 6-8.
mended final gear oil)
Type
Shaft Drive Oil (Part No.: ACC- 2
Quantity (disassembled)
0.25 L (0.26 US qt, 0.22 Imp.qt) 3
Quantity
0.20 L (0.21 US qt, 0.18 Imp.qt)
ECB01690
NOTICE
------------
1
ter the final drive case.
7. Check:
• Oil level
Refer to "CHECKING THE FINAL GEAR OIL
8. Install:
• Final gear oil level check bolt
• Final gear oil filler bolt
(along with the gasket) 7
Final gear oil level check bolt

1O N,m (1.0 kgf,m, 7.4 lb,ft) 9
Final gear oil filler bolt 8
23 N,m (2.3 kgf,m, 17 lb,ft)
EBS30034
CHECKING THE COOLING SYSTEM

1. Remove: 3. Install:
• Front fenders • Footrest board (left)
Refer to "GENERAL CHASSIS (3)" on page Refer to "GENERAL CHASSIS (4)" on page
4-8. 4-11 .
• Footrest board (left) • Front fenders
Refer to "GENERAL CHASSIS (4)" on page Refer to "GENERAL CHASSIS (3)" on page
4-11. 4-8.
2. Check:
• Radiator "1"
• Radiator inlet hose "2"
• Coolant reservoir "3"
• Coolant reservoir hose "4"
3-26
EBS30035
CHECKING THE COOLANT LEVEL

TIP ~~~~~~~~~~~~~~
The coolant level must be checked on a cold en-

gine since the level varies with engine tempera-
ture.
2. Check:
• Coolant level
The coolant level should be between the
maximum level mark "a" and minimum level EBS30036
mark "b". CHANGING THE COOLANT

Below the minimum level mark ~ Add the 1. Remove:
recommended coolant to the proper level. • Side panels (left and right)
ECB01300 Refer to "GENERAL CHASSIS (1)" on page
NOTICE 4-1 .
-------------
• Adding water instead of coolant lowers the • Upper panel
antifreeze content of the coolant. If water is Refer to "GENERAL CHASSIS (2)" on page
used instead of coolant check, and if nec- 4-6.
essary, correct the antifreeze concentra- • Footrest board (left)
tion of the coolant. Refer to "GENERAL CHASSIS (4)" on page
• Use only distilled water. However, if dis- 4-11 .
tilled water is not available, soft water may 2. Remove:
be used. • Coolant reservoir cap "1"
/
0
I
FULL
a
LOW / b
0
I.
3. Disconnect:
3. If the coolant is at or below the minimum level • Coolant reservoir hose "1"
mark, remove the side panel (left).
Refer to "GENERAL CHASSIS (1 )" on page
4-1.
4. Remove the reservoir cap "1", add coolant or
distilled water to the maximum level mark, in-
stall the reservoir cap and then install the side
panel (left).
Coolant reservoir (up to the maxi-

mum level mark)
0.24 L (0.25 US qt, 0.21 Imp.qt)
4. Drain:
• Coolant
(fram the coolant reservoir)
5. Connect:
• Coolant reservoir hose
6. Remove:
• Radiator cap "1"
3-27
EWB02770
&WARNING Coolant drain bolt

A hot radiator is under pressure. Therefore, 10 N,m (1.0 kgf,m, 7.4 lb,ft)
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may 10.Fill:
be blown out, which could cause serious in- • Cooling system
jury. When the engine has cooled, open the (with the specified amount of the recom-
radiator cap as follows: mended coolant)
Place a thick rag or a towel over the radiator
Recommended antifreeze
cap and slowly turn the radiator cap counter- High-quality ethylene glycol an-
clockwise toward the detent to allow any re- tifreeze containing corrosion in-
sidual pressure to escape. When the hissing hibitors for aluminum engines
sound has stopped, press down on the radi- Mixing ratio
ator cap and turn it counterclockwise to re- 1 :1 (antifreeze:water)
move. Radiator (including all routes)
1.99 L (2.1 O US qt, 1.75 Imp.qt)
Coolant reservoir (up to the maxi-
mum level mark)
0.24 L (0.25 US qt, 0.21 Imp.qt)
Handling notes for coolant

Coolant is potentially harmful and should be
handled with special care.
EWB02780
& WARNING
__..\ • If coolant splashes in your eyes, thorough-
7. Remove: ly wash them with water and consult a doc-
• Coolant drain bolt "1" tor.
(along with the copper washer) • If coolant splashes on your clothes, quickly
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~
wash it away with water and then with soap
Place a container under the engine, and then re- and water.
move the coolant drain bolt. (Use a trough "2" or • If coolant is swallowed, induce vomiting
a similar object as shown to prevent coolant and get immediate medical attention.
from spilling on the engine guard.) EC B01310
NOTICE
\
- - - - - - - - - - - - -
/ • Adding water instead of coolant dilutes the
antifreeze concentration of the coolant. If
water is used instead of coolant; check,
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
- __-!
l - 1]1
be used.
-~ __,,,,:::.Z:..-~~::....~~~ • If coolant comes into contact with painted
surfaces, immediately wash them with wa-
8. Drain: ter.
• Coolant • Do not mix different types of antifreeze.
(from the engine and radiator)
11.lnstall:
9. Install:
• Radiator cap
• Coolant drain bolt 12.Fill:
(along with the copper washer l~c@) • Coolant reservoir
(with the recommended coolant to the maxi-
mum level mark)
3-28
13.lnstall:
• Coolant reservoir cap "1"
/
e. When coolant begins to flow out of the bolt

hole, tighten the thermostat cover air
14.Bleed: bleed bolt to specification.
• Cooling system
a. Remove the V-belt cooling exhaust duct Thermostat cover bolt
"1". 1O N,m (1.0 kgf,m, 7.4 lb,ft)
f. Install the V-belt cooling exhaust duct.

15.Start the engine, warm it up for ten minutes,
and then rev the engine five times.
16.Pour the recommended coolant into the radi-
ator until it is full.
17.Stop the engine and allow it to cool. If the
coolant level has dropped after the engine
has cooled, add sufficient coolant until it
reaches the top of the radiator, and then in-
stall the radiator cap.
b. Loosen the water pump air bleed bolt "2",
without removing it, to allow all of the air to 18.Check:
• Coolant level
escape from the air bleed bolt hole.
Refer to "CHECKING THE COOLANT LEV-
EL" on page 3-27.
/ 2 --1
19.Start the engine, and then check for coolant
leakage.
20.lnstall:
• Footrest board (left)
4-11 .
• Upper panel
4-6.
c. When coolant begins to flow out of the bolt • Side panels (left and right)
hole, tighten the water pump air bleed bolt Refer to "GENERAL CHASSIS (1)" on page
to specification. 4-1 .
Water pump air bleed bolt EBS30053
1O N,m (1.0 kgf,m, 7.4 lb,ft) CHECKING AND LUBRICATING THE

CABLES
d. Loosen the cylinder head air bleed bolt "3", The following procedure applies to all of the in-
without removing it, to allow all of the air to ner and outer cables.
escape from the air bleed bolt hole.
3-29
EWB02820
AwARNING
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Re-
place damaged outer cable and inner cables
as soon as possible.
1. Check:
• Outer cable
Damage ~ Replace.
2. Check:
• Cable operation 1. "N" (neutral)
-
Rough movement ~ Lubricate. 2. "H" (high)
3. "L" (low)
Recommended lubricant 4. "R" (reverse)
I Engine oil or a suitable cable lu- 5. "P" (park)
bricant 6. Drive select lever shift rod
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ 1. Adjust:
Hold the cable end upright and pour a few drops • Brake pedal free play
of lubricant into the cable sheath or use a suit- Refer to "ADJUSTING THE REAR DISC
able lubricating device. BRAKE" on page 3-10.
2. Remove:
3. Apply: • Handle mounted light cover
• Lithium-soap-based grease Refer to "REPLACING THE HANDLE
(onto end of the cable) MOUNTED LIGHT BULB" on page 3-32.
EBS304&1
• Side panel (left)
LUBRICATING THE LEVERS Refer to "GENERAL CHASSIS (1)" on page
Lubricate the pivoting point and metal-to-metal 4-1 .
moving parts of the levers. 3. Adjust:
• Drive select lever shift rod
l Recommended lubricant
Silicone grease Drive select lever shift rod:
a. Make sure the drive select lever and trans-
EBS30465 mission are in "N" (neutral).
LUBRICATING THE PEDAL b. Loosen both locknuts "1".
Lubricate the pivoting point and metal-to-metal c. Adjust the length "a" of the shift rod to 413
moving parts of the pedal. mm (16.3 in).
Recommended lubricant N
Lithium-soap-based grease
EBS30713
ADJUSTING THE DRIVE SELECT LEVER

SHIFT ROD
ECB02700
NOTICE
-------------
Before moving the drive select lever, bring
the vehicle to a complete stop and return the
throttle lever to its closed position. Other- d. Tighten the locknuts.
wise the transmission may be damaged.
3-30
Drive select lever shift rod lock-

nut
8 N,m (0.8 kgf,m, 5.9 lb,ft)
nut (shift arm side)
8 N,m (0.8 kgf,m, 5.9 lb,ft)
e. Start the engine, and then check that the

drive select lever can be shifted to each
shift position and that the appropriate indi-
cator light comes on when the lever is in d. Tighten the locknut.
each position. e. Slide the rubber cover to its original posi-
TIP ~~~~~~~~~~~~~~~
tion .
TIP~~~~~~~~~~~~~~~
If the neutral indicator light does not come on
when the drive select lever is in the "N" (neutral) If the free play cannot be adjusted here, adjust it
position, stop the engine. Then , with the drive at the handlebar side of the cable.
select lever in the "N" (neutral) position and with-
out opening the throttle, start the engine and Handlebar side
check that the neutral indicator light comes on. a. Slide back the rubber cover "1".
b. Loosen the locknut "2".
EBS30446 c. Turn the adjusting bolt "3" until the correct
ADJUSTING THE THROTTLE LEVER FREE free play is obtained.
PLAY
1. Check:
• Throttle lever free play "a"
Throttle lever free play

3.0-5.0 mm (0.12-0.20 in)
.- - - -
d. Tighten the locknut.
e. Slide the rubber cover to its original posi-
tion .
EWB03810
& WARNING
After adjusting the throttle cable free play,
start the engine and turn the handlebar to the
2. Remove: right and to the left to ensure that this does
• Storage compartment not cause the engine idling speed to change.
Refer to "GENERAL CHASSIS (5)" on page 4. Install:
4-17. • Storage compartment
3. Adjust: Refer to "GENERAL CHASSIS (5)" on page
• Throttle lever free play 4-17.
Throttle body side EBS30463
ADJUSTING THE SPEED LIMITER

a. Slide back the rubber cover "1 ".
The speed limiter keeps the throttle from becom-
b. Loosen the locknut "2" on the throttle body
ing fully-opened even when the throttle lever is
side.
applied to the maximum position. Screwing in
c. Turn the adjusting nut "3" until the correct
the adjusting screw stops the engine speed from
free play is obtained.
increasing.
3-31
1. Measure:
• Speed limiter length
Speed limiter length

12.0 mm (0.47 in)
2. Adjust:
~
• Speed limiter length "a"
a. Loosen the locknut "1".
b. Turn the adjuster "2" until the specified
3. Remove:
speed limiter length is obtained.
• Handle mounted light bulb holder "1"
• Handle mounted light bulb
EWB03940
2 A WARNING
Since the handle mounted light bulb gets ex-
tremely hot, keep flammable products and
your hands away from the bulb until it has
cooled down.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
\
Remove the handle mounted light bulb holder by
c. Tighten the locknut. pushing it in and turning it counterclockwise, and
EWB03830
then remove the defective bulb.
£ WARNING
• Particularly for a beginner rider, the speed
limiter should be screwed in completely. \
Screw it out little by little as their riding
technique improves. Never remove the
speed limiter for a beginning rider.
• For proper throttle lever operation, do not
turn out the adjuster more than the speci-
fied length. Also, always adjust the throttle
cable free play to within specification.
EBS30593
"'
4. Install:
REPLACING THE HANDLE MOUNTED LIGHT • Handle mounted light bulb l~fWJ
BULB Secure the new handle mounted light bulb
1. Remove: with the handle mounted light bulb holder.
• Quick fastener "1" ECB02990
• Handle mounted light cover "2" NOTICE

-------------
Avoid touching the glass part of the handle
mounted light bulb to keep it free from oil,
otherwise the transparency of the glass, the
life of the bulb and the luminous flux will be
adversely affected. If the handle mounted
light bulb gets soiled, thoroughly clean it
with a cloth moistened with alcohol or lac-
quer thinner.
5. Install:
• Handle mounted light bulb holder
2. Remove:
• Handle mounted light bulb cover "1"
3-32
TIP ~~~~~~~~~~~~~~
Install the handle mounted light bulb holder by

pushing it in and turning it clockwise.
6. Install:
• Cover at the rear of the handle mounted light
7. Install:
• Handle mounted light cover "1"
• Quick fastener
EBS30594
ADJUSTING THE HEADLIGHT AND HANDLE

MOUNTED LIGHT BEAMS
1. Adjust:
• Headlight and handle mounted light beam
(vertically)
a. Turn the adjusting screw "1".
[Al /,,------
~
A. Headlight (left and right)
B. Handle mounted light
3-33
CHASSIS
GENERAL CHASSIS (1) ................................................................................. 4-1

REMOVING THE BATTERY COVER ....................................................... 4-3
INSTALLING THE BATTERY COVER ...................................................... 4-3
REMOVING THE TOP COVER ................................................................. 4-3
INSTALLING THE TOP COVER ............................................................... 4-4
REMOVING THE SI DE PANELS .............................................................. 4-4
INSTALLING THE SIDE PAN ELS ............................................................. 4-5
GENERAL CHASSIS (2) ................................................................................. 4-6

REMOVING THE UPPER PAN EL ............................................................. 4-7
INSTALLING THE UPPER PAN EL ........................................................... 4-7
GENERAL CHASSIS (3) ................................................................................. 4-8

INSTALLING THE REAR FENDER ......................................................... 4-1 O
GENERAL CHASSIS (4) ............................................................................... 4-11

INSTALLING THE FOOTREST BOARDS ............................................... 4-16
GENERAL CHASSIS (5) ............................................................................... 4-17

INSTALLING THE AIR FILTER CASE .................................................... 4-19
FRONT WHEELS .......................................................................................... 4-20

REMOVING THE FRONT WHEELS ....................................................... 4-21
REMOVING THE FRONT WHEEL HUBS ............................................... 4-21
CH ECKi NG THE FRONT WHEELS ........................................................ 4-21
CHECKING THE FRONT WHEEL HUBS ............................................... 4-21
INSTALLING THE FRONT BRAKE DISCS ............................................. 4-22
INSTALLING THE FRONT WHEEL HUBS ............................................. 4-22
INSTALLING THE FRONT WHEELS ...................................................... 4-22
REAR WHEELS ............................................................................................. 4-23

REMOVING THE REAR WHEELS .......................................................... 4-24
REMOVING THE REAR WHEEL HUBS ................................................. 4-24
CH ECKi NG THE REAR WHEELS .......................................................... 4-24
CHECKING THE REAR WHEEL HUBS .................................................. 4-24
INSTALLING THE REAR BRAKE DISCS ............................................... 4-24
INSTALLING THE REAR WHEEL HUBS ................................................ 4-24
INSTALLING THE REAR WHEELS ........................................................ 4-25
FRONT BRAKE ............................................................................................. 4-26
INTRODUCTION ..................................................................................... 4-31
CHECKING THE FRONT BRAKE DISCS ............................................... 4-31
REPLACING THE FRONT BRAKE PADS .............................................. 4-32
DISASSEMBLING THE FRONT BRAKE CALIPERS .............................. 4-32
CHECKING THE FRONT BRAKE CALIPERS ........................................ 4-33
ASSEMBLING THE FRONT BRAKE CALIPERS .................................... 4-33
INSTALLING THE FRONT BRAKE CALIPERS ...................................... 4-33
CHECKING THE FRONT BRAKE MASTER CYLINDER ........................ 4-34
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-35
INSTALLING THE FRONT BRAKE MASTER CYLINDER ...................... 4-35
REAR BRAKE ............................................................................................... 4-37

INTRODUCTION ..................................................................................... 4-43
CHECKING THE REAR BRAKE DISCS ................................................. 4-43
REPLACING THE REAR BRAKE PADS ................................................. 4-43
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-44
DISASSEMBLING THE REAR BRAKE CALIPERS ................................ 4-44
CHECKING THE REAR BRAKE CALIPERS .......................................... 4-45
ASSEMBLING THE REAR BRAKE CALIPERS ...................................... 4-45
INSTALLING THE REAR BRAKE CALIPERS ........................................ 4-45
CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-46
ASSEMBLING THE REAR BRAKE MASTER CYLINDER ...................... 4-46
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-46
HANDLEBAR ................................................................................................ 4-48

REMOVING THE HANDLEBAR .............................................................. 4-50
CHECKING THE HANDLEBAR .............................................................. 4-50
INSTALLING THE HANDLEBAR ............................................................ 4-50
STEERING STEM .......................................................................................... 4-52

CHECKING THE STEERING STEM ....................................................... 4-54
INSTALLING THE STEERING STEM ..................................................... 4-54
INSTALLING THE PITMAN ARM ............................................................ 4-55
TIE-RODS AND STEERING KNUCKLES ..................................................... 4-56

REMOVING THE STEERING KNUCKLES ............................................. 4-57
CHECKING THE TIE-RODS ................................................................... 4-57
CHECKING THE STEERING KNUCKLES AND FRONT WHEEL
BEARINGS ............................................................................................. 4-57
CHECKING THE STEERING KNUCKLE BALL JOINTS ........................ 4-57
INSTALLING THE TIE-RODS ................................................................. 4-59
INSTALLING THE FRONT ARM PROTECTORS ................................... 4-59
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES ............. 4-60
CHECKING THE FRONT ARMS ............................................................. 4-62
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES ............. 4-62
CHECKING THE FRONT ARM BALL JOINTS ....................................... 4-62
INSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER
ASS EM BLI ES ......................................................................................... 4-63
INSTALLING THE FRONT ARM PROTECTORS ................................... 4-64
REAR KNUCKLES AND STABILIZER ......................................................... 4-65

CHECKING THE REAR KNUCKLES AND REAR WHEEL
BEARINGS ............................................................................................. 4-67
CH ECKi NG THE STABILIZER ................................................................ 4-67
INSTALLING THE REAR ARM PROTECTORS ..................................... 4-67
REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES ................. 4-68

CH ECKi NG THE REAR ARMS ............................................................... 4-69
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES ................ 4-69
INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER
ASS EM BLI ES ......................................................................................... 4-69
GENERAL CHASSIS (1)
EBS20024
GENERAL CHASSIS (1)

Removing the skid plates
-~. 4.0 N·m (0.40 kgf·m, 3.0 lb-ft)
1,,. 4.0 N-m (0.40 kgf•m, 3.0 lb-ft)
.,
'
-------- ' 'r
' '
'
'
'
' .-- -
3
l:il '
'
/"'--.'
., 7 N·m (0. 7 kgf•m, 5.2 lb·ft)
Order Job/Parts to remove Q'ty Remarks
1 Front skid plate 1

2 Center skid plate 1
3 Rear skid plate 1
4-1
GENERAL CHASSIS (1)
Removing the seat and side panels

i, 0.4 N·m (0.04 kgf·m, 0.30 lb-ft)
.'
'
1...--------1
10 • . 4.0 N·m 0.40 k f·m, 3.0 lb-ft
'
'
,,;_ 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) ,,,,__ 9
J?>
I -,J 2.5 N·m (0.25 kgf·m, 1.8 lb-ft) V
1 Seat 1
2 Battery cover 1
3 Throttle body breather hose 1 Disconnect.
4 Final drive case breather hose 1 Disconnect.
5 Differential case breather hose 1 Disconnect.
6 Radiator fan motor breather hose 1 Disconnect.
7 Top cover 1
8 Storage compartment lid 1
9 Side panel (left) 1
10 Side panel (right) 1
4-2
GENERAL CHASSIS (1)
EBS30449
REMOVING THE BATTERY COVER

1. Remove:
• Battery cover "1"
EBS30451
REMOVING THE TOP COVER

1. Remove:
• Top cover "1"
a. Lift the rear of the battery cover to remove • Storage compartment lid "2"
the projections "a" on the cover from the
grommets "b". 2 ~~
b. Slide the battery cover rearward to unhook
its projections "c" from the holes "d" in the
upper panel.
a. Remove the quick fasteners, screws, and

bolts.
b. Slide the top cover rearward and lift it up to
unhook its projections "a" from the holes
"b" in the side panels.
EBS30450
\
INSTALLING THE BATTERY COVER
1. Install:
• Battery cover "1"
c. Place the top cover upside down.

d. Remove the storage compartment lid from
the left end of the hinge "3".
e. Remove the left end of the hinge from the
a. Fit the projections "a" on the battery cover
top cover, and then remove the hinge and
into the holes "b" in the upper panel. storage compartment lid from the top cov-
b. Fit the projections "c" on the battery cover
er.
into the grommets "d".
4-3
GENERAL CHASSIS (1)
\ \
.. ..
EBS30452 d. Fit the projections "a" on the top cover into
INSTALLING THE TOP COVER the holes "b" in the side panels and slide
1. Install: the cover forward.
• Storage compartment lid "1"
• Top cover "2"
Top cover bolt

4.0 N-m (0.40 kgf-m, 3.0 lb·ft)
e. Install the bolts, screws, and quick fasten-

ers.
EBS30453
REMOVING THE SIDE PANELS

~~ The following procedure applies to both of the
a. Place the top cover upside down. side panels.
b. Fit the right end of the hinge "3" into the The following procedure applies to both of the
storage compartment lid and top cover. side panels.
c. Fit the left end of the hinge into the top 1. Remove:
cover, and then fit the storage compart- • Side panel "1"
ment lid onto the left end of the hinge.
4-4
GENERAL CHASSIS (1)
a. Remove the bolt. a. Fit the projections "a" on the side panel
b. Lift the side panel and remove it. into the holes "b" in the front fender, fit the
[Al projections "c" on the panel into the holes
"d" in the footrest board, and fit the projec-
tion "e" on the panel into the hole ''f' in the
rear fender.
A. Left side
B. Right side
EBS30454
INSTALLING THE SIDE PANELS

The following procedure applies to both of the A. Right side
side panels. B. Left side
1. Install: b. Install the bolt.
• Side panel "1"
~ Side panel bolt

I&'~ 2.5 N-m (0.25 kgf-m, 1.8 lb·ft)
4-5
GENERAL CHASSIS (2)
EBS20087
GENERAL CHASSIS (2)

Removing the front carrier and front guard
~~--------
,, 7 N·m (0. 7 k f·m, 5.2 lb·ft)
5
·~, 34 N·m 3.4 k f·m, 25 lb-ft
r-- 4
10
'
I .
1)/
/
8
"\ 4.0 N·m (0.40 kgf·m, 3.0 lb-ft)
·. 34 N·m (3.4 kgf·m, 25 lb·ft)
'
l ,, 4.0 N·m (0.40 kgf·m, 3.0 lb-ft)
'\ 7 N·m (0.7 kgf·m, 5.2 lb-ft)
9

Front skid plate/Battery cover
4-1 .
1 Front carrier 1
2 Battery holding bracket 1
3 Battery lead 2 Disconnect
4 Battery 1
5 Upper panel 1
6 Front carrier bracket 2
7 Headlight coupler 2 Disconnect.
8 Headlight unit 2
9 Front guard cover 2
10 Front guard 1
4-6
GENERAL CHASSIS (2)
EBS30455
b. Install the quick fasteners.
REMOVING THE UPPER PANEL
1. Remove:
• Upper panel "1"
a. Remove the quick fasteners.

b. Slide the upper panel forward and lift it up
to remove it.
EBS30456
INSTALLING THE UPPER PANEL

1. Install:
• Upper panel "1"
a. Fit the projections "a" on the upper panel

into the holes "b" in the front fender, and
then slide the panel rearward.
4-7
GENERAL CHASSIS (3)
EBS20088
GENERAL CHASSIS (3)

Removing the front fenders and front grill
?,,. 8 N-m (0.8 kgf·m, 5.9 lb-ft)
~~~'
4 --t
•;, 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

c,® l
6i.... . _ .,,,,...,,
5
4
.,,, 8 N·m 0.8 k f·m, 5.9 lb-ft

··, 4.0 N·m 0.40 k f·m, 3.0 lb-ft
·,. 4.0 N·m 0.40 k f·m, 3.0 lb-ft

-, 8 N·m (0.8 kgf·m, 5.9 lb·ft) ,; 4.0 N·m 0.40 k f·m, 3.0 lb·ft
Order Job/Parts to remove Q 'ty Remarks

Front skid plate/Battery cover/Seat/Top cover/ Refer to "GENERAL CHASSIS (1)" on page
Side panels 4-1 .
Front carrier/Front guard
4-6.
1 Front fender inner panel 2
2 Main switch coupler 1 Disconnect.
3 Auxiliary DC jack coupler 1 Disconnect.
4 Front fender 2
5 Front grill 1
4-8
GENERAL CHASSIS (3)
Removing the rear carrier and rear fender

.,.., 3.5 N·m 0.35 k f·m, 2.6 lb-ft
·,, 7 N·m (0. 7 kgf·m, 5.2 lb-ft) 3
i
l
~ .....-------a-------,
ilJ , 7---- I ''., 4.0 N·m (0.40 kgf·m, 3.0 lb-ft)
// I
C> 1
~\.
.,. 60 N•m (6.0 kgf-m, 44 lb·ft)
.,., 7 N·m 0.7 k f·m, 5.2 lb·ft
-;. 4.0 N·m (0.40 kgf·m, 3.0 lb-ft)

Seat/Top cover/Side panels
4-1 .
1 Rear carrier bracket 2
2 Rear carrier 1
3 Rear storage compartment cover 1
4 Tail/brake light coupler 1 Disconnect.
5 Fuel tank breather hose 1 Disconnect.
6 Fuel tank breather hose joint 1
7 Fuel tank cap 1
8 Rear fender 1
4-9
GENERAL CHASSIS (3)
EBS30356
INSTALLING THE REAR FENDER

1. Install:
• Rear fender
~ li7 Rear fender bolt

~~ 7 N,m (0.7 kgf,m, 5.2 lb,ft)
TIP ~~~~~~~~~~~~~~
The bolts may be tightened to the specified

torque in any tightening sequence. However, in-
stall the front bolts "1" and tighten them tempo-
rarily before installing the rear bolts "2".
) 2
4-10
GENERAL CHASSIS (4)
EBS20089
GENERAL CHASSIS (4)

Removing the electrical components tray 1/2
, , 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) ~ t,. 7 N-m (0.7 kgf·m, 5.2 lb-ft)
,\, 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
~ 4
I s
fjfo
dd ,1 ~X~'V'/
/q,
3
"'· 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
o-L, - 1 -~ <S)R
Side panels 4-1 .
4-6.
Front fenders/Front grill
4-8.
Air intake duct/Storage compartment 4-17.
V-belt cooling exhaust ducW-belt cooling intake Refer to "ENGINE REMOVAL (1 )" on page
duct 5-4.
1 Battery holding bracket 1
2 Battery lead 2 Disconnect.
3 Battery 1
4 Lean angle sensor coupler 1 Disconnect.
5 Lean angle sensor 1
4-11
GENERAL CHASSIS (4)
Removing the electrical components tray 1/2

~\ 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) ~ · l,. 7 N-m (0.7 kgf·m, 5.2 lb-ft)
"< 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
10
,.. . 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
9
13
6 Four-wheel-drive motor relay 1 1

7 Four-wheel-drive motor relay 2 1
8 Headlight relay 1 1
9 EPS control unit coupler 5 Disconnect.
10 EPS (electric power steering) control unit 1
11 ECU coupler 2 Disconnect.
12 ECU (Engine Control Unit) 1
13 Radiator fan motor coupler 1 Disconnect.
4-12
GENERAL CHASSIS (4)
Removing the electrical components tray 212

,,, 7 N·m (0. 7 kgf·m, 5.2 lb·ft) 1~ .,....__8
,., 3.6 N·m (0.36 kgf·m, 2. 7 lb·ft)
~
'
I
• '
~ -
V
1 Starter relay coupler 1 Disconnect.

2 Starter relay 1
3 Fuse box 1
4 EPS fuse 1
5 Main fuse 1
6 Radiator fan motor relay 1
7 Fuel injection system relay 1
8 Headlight relay 2 1
9 Frame ground terminal 2
10 Air cut-off valve coupler 1 Disconnect.
4-13
GENERAL CHASSIS (4)
Removing the electrical components tray 212

· ,,, 7 N·m (0.7 kgf·m, 5.2 lb·ft) rJfP
-~ I
A~
-,
'gf'
,,, 3.6 N·m (0.36 kgf·m, 2. 7 lb·ft)
---~14
13
~
'
17
I
• '
~ -
V
11 Ignition coil connector 2 Disconnect.

12 Differential motor coupler 1 Disconnect.
13 Coolant reservoir breather hose 1 Disconnect.
14 Radiator fan motor breather hose 1 Disconnect.
16 Wire harness 1
17 Electrical components tray 1
4-14
GENERAL CHASSIS (4)
Removing the footrest boards
,,;, 16 N·m 1.6 k f·m, 12 ~:;y1 .,;J s N·m (0.8 kgf·m, 5.9 lb·ft) I
(5)
·~1
, ,. 4.0 N·m (0.40 kgf·m, 3.0 lb-ft)
t,. 4.0 N-m (0.40 kgf·m, 3.0 lb-ft)

4-1 .
1 Dipstick accessing cover 1
2 Footrest board 2
3 Footrest bracket 2
4-15
GENERAL CHASSIS (4)
EBS30357
INSTALLING THE FOOTREST BOARDS

footrest boards.
1. Install:
• Footrest board
~/JJ Footrest board bolt

~~ 8 N,m (0.8 kgf,m, 5.9 lb,ft)
TIP ~~~~~~~~~~~~~~
Tighten the footrest board bolts to the specified

torque in the proper tightening sequence as
shown.
4-16
GENERAL CHASSIS (5)
EBS20090
GENERAL CHASSIS (5)

Removing the air filter case
-.,,, -0.8---------~
N·m 0.08 k f·m, 0.59 lb·ft
,~, 17N·m 1.7k f·m,131b·ft
'·. 0.8 N·m 0.08 k f·m, 0.59 lb·ft
·. 3.5 N·m 0.35 k f·m, 2.6 lb·ft

-"', 7 N·m (0. 7 kgf·m, 5.2 lb·ft)
----. -.. 1O N·m 1.0 k f·m, 7.4 lb·ft

4-1 .
Rear fender
4-8.
1 Storage compartment 1
2 Air filter case cover 1
3 Air intake duct clamp screw 1 Loosen.
4 Air intake duct 1
5 Air filter element 1
6 Air filter element holder 1
7 Air filter element frame 1
8 Intake air temperature sensor coupler 1 Disconnect.
Air induction system hose
9 (air cut-off valve assembly to air filter case) 1 Disconnect.
4-17
GENERAL CHASSIS (5)
Removing the air filter case

-. ~ - - - - - - - - - ~
.,,, 0.8 N·m 0.08 k f·m, 0.59 lb·ft
,,, 17N·m 1.7k f·m,131b·ft
(2)
·. 3.5 N·m 0.35 k f·m, 2.6 lb·ft

-"', 7 N·m (0. 7 kgf·m, 5.2 lb·ft)
----- '·. 1O N·m 1.0 k f·m, 7.4 lb·ft
10 Cylinder head breather hose 1 Disconnect.

11 Air filter case joint clamp screw 2 Loosen.
12 Rectifier/regulator coupler 2 Disconnect.
13 Rectifier/regulator 1
14 Air filter case 1
15 Air filter case joint 1
16 Intake air temperature sensor 1
4-18
GENERAL CHASSIS (5)
EBS30457
INSTALLING THE AIR FILTEA CASE

1. Install:
• Intake air temperature sensor
• Air filter case 2
• Air filter case joint "1"
(to the air filter case)
Intake air temperature sensor

screw a
,
b
1.5 N-m (0.15 kgf-m, 1.1 lb·ft)
Air filter case bolt
1O N-m (1.0 kgf-m, 7.4 lb·ft)
3.5 N-m (0.35 kgf-m, 2.6 lb·ft)
(air filter case side)
0.8 N-m (0.08 kgf-m, 0.59 lb·ft)
TIP ~~~~~~~~~~~~~~
Fit the projection "a" on the air filter case joint be-
tween the projections "b" on the air filter case.
2. Connect:
• Cylinder head breather hose
• Air induction system hose (air cut-off valve
assembly to air filter case)
• Intake air temperature sensor coupler
3. Install:
• Air filter element assembly
• Air intake duct "1"
(to the air filter case cover)
• Air filter case cover
Air intake duct clamp screw

0.8 N-m (0.08 kgf-m, 0.59 lb·ft)
Storage compartment bolt
7 N-m (0.7 kgf-m, 5.2 lb-ft)
TIP ~~~~~~~~~~~~~~~
Fit the projection "a" on the air intake duct be-

tween the projections "b" on the air filter case
cover "2".
4-19
FRONT WHEELS
EBS20095
FRONT WHEELS
Removing the front wheels and brake discs
,;, 30 N·m 3.0 k f·m, 22 lb-ft
,, 260 N·m (26 kgf·m, 192 lb·ft)
4
3 l~fMJ
b,, 30 N·m (3.0 kgf·m, 22 lb-ft)
t,,. 55 N-m (5.5 kgf·m, 41 lb-ft)

The following procedure applies to both of
the front wheels.
Place the vehicle on a level surface.
1 Front wheel 1
2 Wheel cap 1
3 Front wheel axle nut 1
TIP
4 Front brake caliper assembly 1 Do not squeeze the front brake lever when
the brake caliper is off of the brake disc as
the brake pads will be forced shut.
5 Front wheel hub 1

6 Front brake disc 1
4-20
FRONT WHEELS
EBS30358
REMOVING THE FRONT WHEELS Radial wheel runout limit

1. Place the vehicle on a level surface. 0.5 mm (0.02 in)
2. Elevate: Lateral wheel runout limit
• Front wheels 0.5 mm (0.02 in)
TIP ~~~~~~~~~~~~~~
Place the vehicle on a suitable stand so that the

front wheels are elevated.
EBS30359
REMOVING THE FRONT WHEEL HUBS

'
front wheel hubs.
1. Straighten the wheel axle nut rib "a".
-- -- ----
a
1
2. Remove:
• Wheel axle nut
3. Remove:
• Front brake caliper 3. Check:
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ • Wheel balance
Out of balance ~ Adjust.
Do not operate the brake lever when removing EWB03020
the brake caliper. & WARNING

After replacing the tire, ride conservatively to
EBS30360
allow the tire to be properly seated in the rim.
CHECKING THE FRONT WHEELS
Failure to do so may cause an accident re-
The following procedure applies to both of the sulting in vehicle damage and possible inju-
front wheels.
ry.
1. Check:
• Tire
• Wheel
Refer to "CHECKING THE TIRES" on page
3-14 and "CHECKING THE WHEELS" on
page 3-14.
2. Measure:
• Radial wheel runout "1"
• Lateral wheel runout "2"
Over the specified limit ~ Replace the wheel
or check the wheel bearing play.
Refer to "CHECKING THE STEERING EBS-10361
KNUCKLES AND FRONT WHEEL BEAR- CHECKING THE FRONT WHEEL HUBS
INGS" on page 4-57. The following procedure applies to both of the
front wheel hubs.
1. Check:
• Wheel hub "1"
4-21
FRONT WHEELS
• Splines (wheel hub) "2"

Wear/damage ~ Replace the wheel hub.
2
2. Check:
• Brake disc
EBS30362 Refer to "CHECKING THE FRONT BRAKE
INSTALLING THE FRONT BRAKE DISCS DISCS" on page 4-31 .
EBS30364
front brake discs.
INSTALLING THE FRONT WHEELS
1. Install: 1. Install:
• Brake disc • Wheel
Front brake disc bolt TIP _ _ _ _ _ _ _ _ _ _ _ _ __
30 N,m (3.0 kgf,m, 22 lb,ft) The arrow mark "1" on the tire must point in the
LOCTITE® direction of wheel rotation .
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Install the brake disc so that the recessed por-
tion of the bolt hole faces away from the hub.
.' ' --
2. Tighten:
• Wheel nuts "1"
Front wheel nut

55 N,m (5.5 kgf,m, 41 lb,ft)
EBS30363
INSTALLING THE FRONT WHEEL HUBS EW B03130
The following procedure applies to both of the & WARNING

front wheel hubs.
Tapered wheel nuts are used for both the
1. Install:
front and rear wheels. Install each nut with
• Wheel axle nut i~tWJ its tapered side towards the wheel.
Front wheel axle nut
260 N,m (26 kgf,m, 192 lb,ft) [j~ ~
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Do not apply oil to the threads of the nut. ,-S-u.J
_
,--,-""."":C"'"_..;__ - - ,-,-..;
~~-~ \\
\
• After tightening the nut, stake the collar of the
nut into the notch of the shaft.
1 ~~' I
4-22
REAR WHEELS
EBS20096
REAR WHEELS
Removing the rear wheels and brake discs
t\, 30 N·m (3.0 kgf·m, 22 lb·ft)
,,,.. 260 N·m 26 k f·m ' 192 lb·ft
6
5 3 l~fMJ
4
\ . 30 N·m (3.0 kgf·m, 22 lb·ft)
~. 55 N·m (5.5 kgf·m, 41 lb·ft)

the rear wheels.
Place the vehicle on a level surface.
1 Rear wheel 1
2 Wheel cap 1
3 Rear wheel axle nut 1
TIP
Do not squeeze the rear brake lever and
4 Rear brake caliper assembly 1 brake pedal when the brake caliper is off of
the brake disc as the brake pads will be
forced shut.
5 Rear wheel hub 1

6 Rear brake disc 1
4-23
REAR WHEELS
EBS30365
3. Check:
REMOVING THE REAR WHEELS
• Wheel balance
Refer to "CHECKING THE FRONT
2. Elevate:
WHEELS" on page 4-21.
• Rear wheels
TIP ~~~~~~~~~~~~~~ EBS30368
CHECKING THE REAR WHEEL HUBS

Place the vehicle on a suitable stand so that the
rear wheels are elevated.
rear wheel hubs.
3. Remove: 1. Check:
• Rear brake calipers • Wheel hub "1"
TIP~~~~~~~~~~~~~~ Cracks/damage ~ Replace.
Do not apply the brake lever and depress the • Splines (wheel hub) "2"
brake pedal when removing the brake calipers. Wear/damage ~ Replace.
2
EBS30366
REMOVING THE REAR WHEEL HUBS

rear wheel hubs.
1. Remove:
• Wheel axle nut
Refer to "REMOVING THE FRONT WHEEL
HUBS" on page 4-21.
2. Remove:
• Rear brake caliper EBS30369
TIP ~~~~~~~~~~~~~~
INSTALLING THE REAR BRAKE DISCS
Do not operate the brake lever or brake pedal
rear brake discs.
when removing the brake caliper.
1. Install:
EBS30367
Brake disc
CHECKING THE REAR WHEELS
Rear brake disc bolt
The following procedure applies to both of the 30 N,m (3.0 kgf,m, 22 lb,ft)
rear wheels. LOCTITE®
1. Check:
• Tire TIP~~~~~~~~~~~~~~
• Wheel Install the brake disc so that the recessed por-
Refer to "CHECKING THE TIRES" on page
tion of the bolt hole faces away from the hub.
3-14 and "CHECKING THE WHEELS" on
page 3-14.
2. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to "CHECKING THE FRONT
WHEELS" on page 4-21 . ' --
Over the specified limit ~ Replace the wheel
or check the wheel bearing play.
Radial wheel runout limit EBS30370
0.5 mm (0.02 in) INSTALLING THE REAR WHEEL HUBS

Lateral wheel runout limit The following procedure applies to both of the
0.5 mm (0.02 in) rear wheel hubs.
4-24
REAR WHEELS
1. Install:
• Wheel axle nut i~tWJ
Rear wheel axle nut
260 N,m (26 kgf,m, 192 lb,ft)
TIP~~~~~~~~~~~~~~
• Do not apply oil to the threads of the nut.

• After tightening the nut, stake the collar of the
nut into the notch of the shaft. I
EBS30371
INSTALLING THE REAR WHEELS

rear wheels.
1. Install:
• Wheel
TIP ~~~~~~~~~~~~~~
The arrow mark "1" on the tire must point in the

direction of wheel rotation .
2. Tighten:
• Wheel nuts "1"
Rear wheel nut

55 N,m (5.5 kgf,m, 41 lb,ft)
EWB03130
A WARNING
Tapered wheel nuts are used for both the
front and rear wheels. Install each nut with
its tapered side towards the wheel.
4-25
FRONT BRAKE
EBS20097
FRONT BRAKE
Removing the front brake pads
4 ..._,,.--- - 5
·. 5 N•m (0.5 kgf,m, 3.7 lb-ft)

,,, 17 N·m 1.7 k f,m, 13 lb·ft
~. 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)

the front brake calipers.
Front wheel Refer to "FRONT WHEELS" on page 4-20.
1 Front brake caliper bolt 2
2 Brake pad holding bolt plug 1
3 Brake pad holding bolt 1
4 Front brake pad 2
5 Brake pad spring 1
4-26
FRONT BRAKE
Removing the front brake master cylinder

·r,J 1.5 N•m (0.15 kgf·m, 1.1 lb·ft) I
_---::7
·•
'<. 7 N·m (0.7 kgf·m, 5.2 lb·ft) <
1
~::::.
~ :.,
"-r>- 10 - -1. 2
0 _::,, ~
'" ~
'
-
.\ '
-
~~
~ ----
-
=---
I 3
- - ')
r'\
--
~
- - --
\.__, l----'
\
~
'\
~ -
-
,.
~
I -
.
j_p/.
--J:;
-----', ---- 11
n~ 'I
I
I
61~00
- I I I
~
I •,J 6 N·m (0.6 kgf·m, 4.4 lb·ft) I ~I r I
I ~~(~
I & I
s '
"'@
'c.,V" ~~),,
', ::-~1---
_ _ _1
8 ~
5
~~
("
~
'
~ 0-
{~
/J I "
·-- ~
I
4
' 9 7
I ·,, I6 N•m (0.6 kgf·m, 4.4 lb·ft) .

1:... 27 N·m (2.7 kgf·m, 20 lb·ft)
"'
. 1.2 N·m (0.12 kaf·m, 0.88 lb·ft) I
~
Drain.
Brake fluid Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-13.
On-Command four-wheel-drive motor switch
Refer to "HANDLEBAR" on page 4-48.
and differential gear lock switch
1 Brake fluid reservoir cap 1
2 Brake fluid reservoir diaphragm holder 1
3 Brake fluid reservoir diaphragm 1
4 Brake lever 1
5 Union bolt 1
6 Copper washer 2
7 Front brake hose 1 Disconnect.
8 Front brake light switch connector 2 Disconnect.
9 Front brake light switch 1
10 Front brake master cylinder holder 1
11 Front brake master cylinder 1
4-27
FRONT BRAKE
Disassembling the front brake master cylinder
31~f:M
1
2 l~f:M ---------
1 Dust boot 1
2 Circlip 1
3 Brake master cylinder kit 1
4 Brake master cylinder body 1
4-28
FRONT BRAKE
Removing the front brake calipers
•,,, 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
,:, 17 N·m 1.7 k f·m, 13 lb·ft
,,., ----------
, ,
, /
,
, , -
I
, , , I
,
4 I
, ; , ,
3 I
I,
; ,
. , /
) II
II I
.,, 27 N·m 2.7 k f·m, 20 lb·ft

6
>,, 30 N·m (3.0 kgf·m, 22 lb·ft)

21~m
1

Drain.
Front wheel Refer to "FRONT WHEELS" on page 4-20.
1 Union bolt 1
2 Copper washer 2
3 Front brake hose 1 Disconnect.
5 Brake pad holding bolt 1 Loosen.
6 Front brake caliper bolt 2
7 Front brake caliper assembly 1
4-29
FRONT BRAKE
Disassembling the front brake calipers
. 17 N·m (1.7 kgf·m, 13 lb·ft)

4
··• 5 N•m (0.5 kgf-m, 3.7 lb•ft)
10
6
bi
·, 22 N•m (2.2 kgf-m, 16 lb-ft)
1
-:._ 17 N-m (1.7 kgf•m, 13 lb-ft)

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 1
8 Brake caliper dust seal 1
9 Brake caliper piston seal 1
10 Bleed screw 1
4-30
FRONT BRAKE
EBS30372
INTRODUCTION
EWB02930
AwARNING
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
4. Measure:
system must be disassembled, drained,
cleaned, properly filled, and bled after reas- • Brake disc thickness "a"
Measure the brake disc thickness at a few dif-
sembly.
ferent locations.
• Never use solvents on internal brake com-
ponents.
• Use only clean or new brake fluid for clean- Brake disc thickness limit
ing brake components. 3.0 mm (0.12 in)
• Brake fluid may damage painted surfac.es
and plastic parts. Therefore, always clean a
up any spilt brake fluid immediately. • 11 •
• 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.
EBS30373
CHECKING THE FRONT BRAKE DISCS 5. Adjust:

The following procedure applies to both brake
• Brake disc runout
discs.
a. Remove the brake disc.
1. Remove: b. Rotate the brake disc by one bolt hole.
• Front wheel c. Install the brake disc.
2. Check: Front brake disc bolt
• Brake disc 30 N,m (3.0 kgf,m, 22 lb,ft)
Damage/galling ~ Replace. LOCTITE®
3. Measure:
• Brake disc runout TIP ~~~~~~~~~~~~~~~
Out of specification ~ Correct the brake disc Install the brake disc so that the recessed por-
deflection or replace the brake disc. tion of the bolt hole faces away from the hub.
Brake disc runout limit
0.1 O mm (0.0039 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) -' ,,
below the edge of the brake disc.
d. Measure the brake disc deflection.
4-31
FRONT BRAKE
e. If out of specification, repeat the adjust-

ment steps until the brake disc deflection
is within specification.
f. If the brake disc deflection cannot be
brought within specification, replace the
brake disc.
6. Install:
• Front wheels
EBS30374
REPLACING THE FRONT BRAKE PADS b. Loosen the bleed screw and push the
The following procedure applies to both brake brake caliper piston into the brake caliper
calipers. with your finger.
c. Tighten the bleed screw.
TIP ~~~~~~~~~~~~~~
When replacing the brake pads, it is not neces- Brake caliper bleed screw
sary to disconnect the brake hose or disassem- 5 N,m (0.5 kgf,m, 3.7 lb,ft)
ble the brake caliper.
d. Install new brake pads and a new brake
1. Measure: pad spring.
• Brake pad wear limit "a" 3. Install:
Out of specification ~ Replace the brake
• Brake pad holding bolt
pads and brake pad spring as a set. • Brake pad holding bolt plug
Brake pad lining thickness limit • Brake caliper
1.0 mm (0.04 in)
Brake pad holding bolt
17 N,m (1.7 kgf,m, 13 lb,ft)
Brake pad holding bolt plug
2.5 N,m (0.25 kgf,m, 1.8 lb,ft)
Front brake caliper bolt
30 N,m (3.0 kgf,m, 22 lb,ft)
I)
4. Check:
• Brake fluid level
Below the minimum level mark ~ Add the
specified brake fluid to the proper level.
Refer to "CHECKING THE BRAKE FLUID
2. Install: LEVEL" on page 3-12.
• Brake pad spring 5. Check:
• Brake pads • Brake lever operation
TIP ~~~~~~~~~~~~~~~ Soft or spongy feeling~ Bleed the brake sys-
Always install new brake pads and a new brake tem.
pad spring as a set. Refer to "BLEEDING THE HYDRAULIC
a. Connect a clear plastic hose "1" tightly to
the bleed screw "2". Put the other end of EBS30375
the hose into an open container. DISASSEMBLING THE FRONT BRAKE

CALIPERS
brake calipers.
TIP~~~~~~~~~~~~~~
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
4-32
FRONT BRAKE
• Brake caliper piston "1" • Brake caliper piston "1"
• Brake caliper dust seal "2" Rust/scratches/wear ~ Replace the brake
• Brake caliper piston seal "3" caliper piston.
• Brake caliper cylinder "2"
Scratches/wear ~ Replace the brake caliper
assembly.
• Brake caliper body "3"
Cracks/damage ~ Replace the brake caliper
assembly.
• Brake fluid delivery passages
3 (brake caliper body)
Obstruction ~ Blow out with compressed air.
EWB03140
a. Blow compressed air into the brake hose A WARNING

joint opening "a" to force out the piston Whenever a brake caliper is disassembled,
from the brake caliper. replace the brake caliper piston dust seals
EWB02890
and brake caliper piston seals.
& WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
2
EBS30376
ASSEMBLING THE FRONT BRAKE

CALIPERS
brake calipers.
EWB03150
b. Remove the brake caliper dust seal and & WARNING

brake caliper piston seal. • Before installation, all internal brake com-
ponents should be cleaned and lubricated
EBS30380
with clean or new brake fluid.
CHECKING THE FRONT BRAKE CALIPERS
ponents as they will cause the brake caliper
brake calipers.
piston dust seals and brake caliper piston
Recommended brake component replacement seals to swell and distort.
schedule • Whenever a brake caliper is disassembled,
Brake pads If necessary replace the brake caliper piston dust seals
Piston seals, dust seals Every two years and brake caliper piston seals.
Brake hoses Every four years
Every two years and D0T4
Brake fluid whenever the brake is
disassembled
EBS303n
INSTALLING THE FRONT BRAKE CALIPERS

brake calipers.
4-33
FRONT BRAKE
1. Install: • When refilling, be careful that water does

• Brake caliper assembly not enter the brake fluid reservoir. Water
• Brake caliper bolts "1" will significantly lower the boiling point of
• Brake hose "2" the brake fluid and could cause vapor lock.
• Copper washers "3" l~fffi ECB01320
• Brake hose union bolt "4" NOTICE

-------------
Brake fluid may damage painted surfac.es
Front brake caliper bolt and plastic parts. Therefore, always clean up
30 N,m (3.0 kgf,m, 22 lb,ft) any spilt brake fluid immediately.
Brake hose union bolt
27 N,m (2.7 kgf,m, 20 lb,ft) 3. Bleed:
• Brake system
EWB02870
Refer to "BLEEDING THE HYDRAULIC
A WARNING BRAKE SYSTEM" on page 3-13.
Proper brake hose routing is essential to in- 4. Check:
sure safe vehicle operation. • Brake fluid level
Refer to "CABLE ROUTING" on page 2-19. Below the minimum level mark ~ Add the
ECB02330 specified brake fluid to the proper level.
NOTICE Refer to "CHECKING THE BRAKE FLUID
------------- LEVEL" on page 3-12.
When installing the brake hose onto the
brake caliper, make sure the brake pipe 5. Check:
touches the projection "a" on the brake cali- • Brake lever operation
per. Soft or spongy feeling~ Bleed the brake sys-
tem.
EBS30378
CHECKING THE FRONT BRAKE MASTER

CYLINDER
1. Check:
• Brake master cylinder
Damage/scratches/wear ~ Replace.
2. Fill: (brake master cylinder body)
• Brake master cylinder reservoir Obstruction~ Blow out with compressed air.
(with the specified amount of the specified 2. Check:
brake fluid) • Brake master cylinder kit
Specified brake fluid 3. Check:
D0T4 • Brake master cylinder reservoir
EWB02790
A WARNING • Brake master cylinder reservoir diaphragm
• Use only the designated brake fluid. Other 4. Check:
brake fluids may cause the rubber seals to • Brake hoses
deteriorate, causing leakage and poor Cracks/damage/wear ~ Replace.
brake performance.
4-34
FRONT BRAKE
EBS30379 EW B02870
ASSEMBLING THE FRONT BRAKE MASTER & WARNING

CYLINDER Proper brake hose routing is essential to in-
EWB03590
& WARNING sure safe vehicle operation.

• Before installation, all internal brake com- Refer to "CABLE ROUTING" on page 2-19.
ponents should be cleaned and lubricated TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
with clean or new brake fluid. • While holding the brake hose, tighten the union
• Never use solvents on internal brake com- bolt as shown.
ponents. • Turn the handlebar to the left and right to make
• Whenever a master cylinder is disassem- sure the brake hose does not touch other parts
bled, replace the brake master cylinder kit. (e.g., wire harness, cables, leads). Correct if
necessary.
DOT4
EBS30381
INSTALLING THE FRONT BRAKE MASTER

CYLINDER IO l
1. Install:
40-50°
• Brake master cylinder "1"
• Brake master cylinder holder "2"
Front brake master cylinder hold-

er bolt 3. Fill:
7 N-m (0.7 kgf-m, 5.2 lb,ft) • Brake master cylinder reservoir
(with the specified amount of the specified
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
brake fluid)
• Align the end of the brake master cylinder hold-
er with the punch mark "a" on the handlebar. Specified brake fluid
• Install the brake master cylinder holder with the DOT4
"UP" mark "b" facing up. EW B02880
• First, tighten the upper bolt, then the lower bolt. & WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reser-
2. Install: voir. Water will significantly lower the boil-
• Brake hose ing point of the brake fluid and could cause
• Copper washers l~f:M vapor lock.
• Brake hose union bolt EC B01320
NOTICE
Brake hose union bolt - - - - - - - - - - - - -
27 N,m (2.7 kgf,m, 20 lb,ft) and plastic parts. Therefore, always clean up
4-35
FRONT BRAKE
4. Bleed:
• Brake system
5. Check:
6. Check:
• Brake lever operation
Soft or spongy feeling ~ Bleed the brake sys-
tem.
4-36
REAR BRAKE
EBS20098
REAR BRAKE
Removing the brake pedal
.,,_, 7 N·m (0. 7 kgf·m, 5.2 lb-ft)

4-1 .
Front fender inner panel (right)
4-8.
Footrest board (right)
4-11 .
1 Brake pedal cable 1 Disconnect.
2 Brake pedal spring 1
3 Brake pedal 1
4-37
REAR BRAKE
Removing the rear brake pads
·· 5 N·m 0.5 k f·m, 3.7 lb·ft
cr, 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 2

-:. 30 N·m (3.0 kgf·m, 22 lb·ft)
"· 17 N·m (1.7 kgf·m, 13 lb·ft)

the rear brake calipers.
Rear wheel Refer to "REAR WHEELS" on page 4-23.
1 Rear brake caliper bolt 2
4 Rear brake pad 2
4-38
REAR BRAKE
Removing the rear brake master cylinder

•
:;. 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
.-. 7 N·m 0. 7 k f·m, 5.2 lb·ft
1
12
2
·~Mi 8 -----,-
t,,. 6 N·m (0.6 kgf·m, 4.4 lb·ft)
. 1.2 N·m (0.12 kgf·m, 0.88 lb·ft)

•
·; 6 N·m (0.6 kgf·m, 4.4 lb·ft)
·, 27 N·m (2.7 kgf·m, 20 lb·ft)
Drain.
1 Brake fluid reservoir cap 1
2 Brake fluid reservoir diaphragm holder 1
3 Brake fluid reservoir diaphragm 1
4 Rear brake cable 1 Disconnect.
5 Brake lever 1
6 Brake lever bracket 1
7 Union bolt 1
8 Copper washer 2
9 Rear brake hose 1 Disconnect.
10 Rear brake light switch connector 2 Disconnect.
11 Rear brake light switch 1
12 Rear brake master cylinder holder 1
13 Rear brake master cylinder 1
4-39
REAR BRAKE
Disassembling the rear brake master cylinder
31~@
21~@
I 1
1 Dust boot 1
2 Circlip 1
3 Brake master cylinder kit 1
4 Brake master cylinder body 1
4-40
REAR BRAKE
Removing the rear brake calipers
(/) ,. ,, ,,
_4),,,~-\
-< 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
~~,@ v ).
@
'"' 17 N·m 1.7 k f·m, 13 lb·ft
6
' '
' '
'
-;, 27 N·m 2.7 k f·m, 20 lb·ft I

I
' ' I
'
' ' I
' ' I
21~t£i I
'
'' I
'

Drain.
Rear wheel
1 Union bolt 1
2 Copper washer 2
3 Rear brake hose 1 Disconnect.
5 Brake pad holding bolt 1 Loosen.
6 Rear brake caliper bolt 2
7 Rear brake caliper assembly 1
4-41
REAR BRAKE
Disassembling the rear brake calipers

0.5 k f·m, 3.7 lb·ft 2
3 C'
C'
.•,• 17 N•m
·, 17 N·m (1. 7 kgf·m, 13 lb·ft) ~

, ~.~nt4•g•j 9
0 i--- 4
~,, 22 N·m (2.2 kgf·m, 16 lb·ft)

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 1
8 Brake caliper dust seal 1
9 Brake caliper piston seal 1
10 Bleed screw 1
4-42
REAR BRAKE
EBS30382
Refer to "CHECKING THE FRONT BRAKE
INTRODUCTION DISCS" on page 4-31.
EWB02930
AwARNING
Brake disc thickness limit
Disc brake components rarely require disas- 3.0 mm (0.12 in)
sembly. Therefore, always follow these pre-
ventive measures: 5. Adjust:
• Never disassemble brake components un- • Brake disc runout
less absolutely necessary. Refer to "CHECKING THE FRONT BRAKE
• If any connection on the hydraulic brake DISCS" on page 4-31 .
system is disconnected, the entire brake
system must be disassembled, drained, Front brake disc bolt
cleaned, properly filled, and bled after reas- 30 N,m (3.0 kgf,m, 22 lb,ft)
sembly. LOCTITE®
ponents. 6. Install:
• Use only clean or new brake fluid for clean- Rear wheels
ing brake components.
• Brake fluid may damage painted surfac.es EBS30384
and plastic parts. Therefore, always clean REPLACING THE REAR BRAKE PADS
up any spilt brake fluid immediately. The following procedure applies to both brake
• Avoid brake fluid coming into contact with calipers.
the eyes as it can cause serious injury. TIP~~~~~~~~~~~~~~
FIRST AID FOR BRAKE FLUID ENTERING When replacing the brake pads, it is not neces-
THE EYES: sary to disconnect the brake hose or disassem-
• Flush with water for 15 minutes and get im- ble the brake caliper.
mediate medical attention.
1. Measure:
EBS30383
• Brake pad wear limit "a"
CHECKING THE REAR BRAKE DISCS Out of specification ~ Replace the brake
The following procedure applies to both brake pads and brake pad spring as a set.
discs.
1. Remove: Brake pad lining thickness limit
• Rear wheel 1.0 mm (0.04 in)
2. Check:
• Brake disc
Damage/galling ~ Replace.
3. Measure:
• Brake disc runout r u !l - c=3 t
,; a
Out of specification ~ Correct the brake disc
deflection or replace the brake disc.
Refer to "CHECKING THE FRONT BRAKE
DISCS" on page 4-31 .
Brake disc runout limit 2. Install:

0.10 mm (0.0039 in) • Brake pad spring
• Brake pads
4. Measure: TIP ~~~~~~~~~~~~~~
• Brake disc thickness Always install new brake pads and a new brake
Measure the brake disc thickness at a few dif- pad spring as a set.
ferent locations.
Out of specification ~ Replace. a. Connect a clear plastic hose "1" tightly to
the bleed screw "2". Put the other end of
the hose into an open container.
4-43
REAR BRAKE
ECB02880
NOTICE
- - - - - - - - - - - - -
The brake lever pivot bolt and nut have left-
handed threads. To loosen the pivot bolt and
nut, turn them clockwise.
EBS30388
DISASSEMBLING THE REAR BRAKE

CALIPERS
b. Loosen the bleed screw and push the brake calipers.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
brake caliper piston into the brake caliper
with your finger. Before disassembling the brake caliper, drain
c. Tighten the bleed screw. the brake fluid from the entire brake system.
Brake caliper bleed screw 1. Remove:

5 N,m (0.5 kgf,m, 3.7 lb,ft) • Brake caliper piston "1"
• Brake caliper dust seal "2"
d. Install new brake pads and a new brake • Brake caliper piston seal "3"
pad spring.
3. Install:
• Brake pad holding bolt
• Brake pad holding bolt plug
• Brake caliper
Brake pad holding bolt

17 N,m (1. 7 kgf,m, 13 lb,ft) 3
Brake pad holding bolt plug
2.5 N,m (0.25 kgf,m, 1.8 lb,ft)
Rear brake caliper bolt a. Blow compressed air into the brake hose
30 N,m (3.0 kgf,m, 22 lb,ft)
joint opening "a" to force out the piston
4. Check: from the brake caliper.
EWB02890
• Brake fluid level & WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
5. Check:
ton.
• Brake lever and pedal operation
tem.
EBS30385
REMOVING THE REAR BRAKE MASTER

CYLINDER
1. Remove:
• Brake lever
• Brake lever bracket
b. Remove the brake caliper dust seal and
brake caliper piston seal.
4-44
REAR BRAKE
EBS30387
CHECKING THE REAR BRAKE CALIPERS
ponents as they will cause the brake caliper
piston dust seals and brake caliper piston
brake calipers.
seals to swell and distort.
Recommended brake component replacement • Whenever a brake caliper is disassembled,
schedule
replace the brake caliper piston dust seals
Brake pads If necessary and brake caliper piston seals.
Piston seals, dust seals Every two years
Brake hoses Every four years Specified brake fluid
Every two years and
D0T4
Brake fluid whenever the brake is
disassembled EBS30389
INSTALLING THE REAR BRAKE CALIPERS

1. Check: The following procedure applies to both of the
• Brake caliper piston "1" brake calipers.
RusVscratches/wear ~ Replace the brake 1. Install:
caliper piston. • Brake caliper assembly
• Brake caliper cylinder "2" • Brake caliper bolts "1"
Scratches/wear~ Replace the brake caliper • Brake hose "2"
assembly. • Copper washers "3" l~iWJ
• Brake caliper body "3" • Brake hose union bolt "4"
Cracks/damage ~ Replace the brake caliper
assembly. Rear brake caliper bolt
• Brake fluid delivery passages 30 N-m (3.0 kgf-m, 22 lb·ft)
(brake caliper body) Brake hose union bolt
Obstruction ~ Blow out with compressed air. 27 N-m (2.7 kgf-m, 20 lb·ft)
EWB03140
EWB02870
AwARNING
AwARNING
Whenever a brake caliper is disassembled,
Proper brake hose routing is essential to in-
replace the brake caliper piston dust seals
sure safe vehicle operation.
and brake caliper piston seals.
Refer to "CABLE ROUTING" on page 2-19.
ECB02330
NOTICE
-------------
When installing the brake hose onto the
brake caliper, make sure the brake pipe
touches the projection "a" on the brake cali-
per.
2
EBS30388
ASSEMBLING THE REAR BRAKE CALIPERS

brake calipers.
EWB031SO 4
A WARNING
• Before installation, all internal brake com-
ponents should be cleaned and lubricated 2. Fill:
with clean or new brake fluid. • Brake master cylinder reservoir
brake fluid)
4-45
REAR BRAKE
3. Check:
Specified brake fluid • Brake master cylinder reservoir
DOT4 Cracks/damage ~ Replace.
EWB02790
• Brake master cylinder reservoir diaphragm
& WARNING Cracks/damage ~ Replace.
• Use only the designated brake fluid. Other 4. Check:
brake fluids may cause the rubber seals to • Brake hoses
deteriorate, causing leakage and poor Cracks/damage/wear ~ Replace.
brake performance. EBS30391
• Refill with the same type of brake fluid that ASSEMBLING THE REAR BRAKE MASTER
is already in the system. Mixing brake fluids CYLINDER
EWB03590
leading to poor brake performance. & WARNING
• When refilling, be careful that water does • Before installation, all internal brake com-
not enter the brake fluid reservoir. Water ponents should be cleaned and lubricated
will significantly lower the boiling point of with clean or new brake fluid.
the brake fluid and could cause vapor lock. • Never use solvents on internal brake com-
ECB01320
ponents.
NOTICE • Whenever a master cylinder is disassem-
------------- bled, replace the brake master cylinder kit.
Brake fluid may damage painted surfaces
any spilt brake fluid immediately. Specified brake fluid
DOT4
3. Bleed:
• Brake system EBS30392
Refer to "BLEEDING THE HYDRAULIC INSTALLING THE REAR BRAKE MASTER

BRAKE SYSTEM" on page 3-13. CYLINDER
4. Check: 1. Install:
• Brake fluid level • Brake master cylinder "1"
Below the minimum level mark ~ Add the • Brake master cylinder holder "2"
Refer to "CHECKING THE BRAKE FLUID Rear brake master cylinder hold-
LEVEL" on page 3-12. er bolt
7 N-m (0.7 kgf-m, 5.2 lb·ft)
5. Check:
• Brake lever and pedal operation TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
tem. • Align the end of the brake master cylinder hold-
Refer to "BLEEDING THE HYDRAULIC er with the punch mark "a" on the handlebar.
BRAKE SYSTEM" on page 3-13. • Install the brake master cylinder holder with the
"UP" mark "b" facing up.
EBS30390 • First, tighten the upper bolt, then the lower bolt.
CHECKING THE REAR BRAKE MASTER
CYLINDER
1. Check:
• Brake master cylinder
(brake master cylinder body)
Obstruction ~ Blow out with compressed air.
2. Check:
• Brake master cylinder kit
2. Install:
• Brake hose
4-46
REAR BRAKE
• Copper washers l~f:M

EWB02880
• Brake hose union bolt

& WARNING
• Use only the designated brake fluid. Other
Brake hose union bolt brake fluids may cause the rubber seals to
27 N-m (2.7 kgf-m, 20 lb-ft) deteriorate, causing leakage and poor
brake performance.
EWB02870
& WARNING is already in the system. Mixing brake fluids
Proper brake hose routing is essential to in- may result in a harmful chemical reaction,
sure safe vehicle operation. leading to poor brake performance.
Refer to "CABLE ROUTING" on page 2-19. • When refilling, be careful that water does
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
• While holding the brake hose, tighten the union
ing point of the brake fluid and could cause
bolt as shown.
vapor lock.
• Turn the handlebar to the left and right to make
sure the brake hose does not touch other parts EC B01320
NOTICE
(e.g., wire harness, cables, leads). Correct if -------------
necessary.
5. Bleed:
• Brake system
45-50° BRAKE SYSTEM" on page 3-13.
6. Check:
3. Install: Refer to "CHECKING THE BRAKE FLUID
• Brake lever bracket LEVEL" on page 3-12.
• Brake lever 7. Check:
• Brake lever and pedal operation
Rear brake lever pivot bolt Soft or spongy feeling~ Bleed the brake sys-
6 N-m (0.6 kgf-m, 4.4 lb-ft) tem.
Rear brake lever pivot nut Refer to "BLEEDING THE HYDRAULIC
6 N-m (0.6 kgf-m, 4.4 lb-ft) BRAKE SYSTEM" on page 3-13.
ECBD2890
NOTICE
- - - - - - - - - - - - -
The brake lever pivot bolt and nut have left-
handed threads. To tighten the pivot bolt and
nut, turn them counterclockwise.
4. Fill:
• Brake master cylinder reservoir
brake fluid)

D0T4
4-47
HANDLEBAR
EBS20099
HANDLEBAR
Removing the handlebar
1 2 1 . 7 N·m (0. 7 kgf·m, 5.2 lb·ft)

5
.,. 1.5 N•m 0.15 k f-m, 1.1 lb·ft
•
4 l 9
~~ I '--
6
I ~'\) '\)-
~ s
.•,. 4.0 N·m (0.40 kgf·m, 3.0 lb-ft)
,, 7 N·m 0.7 k f·m, 5.2 lb·ft
\ . 3.5 N·m (0.35 kgf·m, 2.6 lb-ft) ~;, 20 N·m (2.0 kgf·m, 15 lb·ft)
t., 7 N·m (0. 7 kgf·m, 5.2 lb-ft)
1 Handle mounted light cover 1

2 Multi-function meter 1
3 Multi-function meter coupler 1 Disconnect.
4 Handlebar cover 1
5 Plastic band 2
On-Command four-wheel-drive motor switch
6 and differential gear lock switch 1
7 Throttle cable 1 Disconnect.

8 Throttle lever assembly holder 1
9 Throttle lever assembly 1
4-48
HANDLEBAR
Removing the handlebar
1\ 7 N·m (0.7 kgf·m, 5.2 lb·ft)

18
,. 1.5 N•m 0.15 k f-m, 1.1 lb•ft
•
11
14
16
·· 7 N·m 0.7 k f•m, 5.2 lb·ft

\ . 3.5 N·m (0.35 kgf·m, 2.6 lb-ft) ~;, 20 N•m (2.0 kgf·m, 15 lb·ft)
t.,. 7 N·m (0.7 kgf•m, 5.2 lb-ft)

10 Front brake master cylinder holder 1
11 Front brake master cylinder 1
12 Rear brake master cylinder holder 1
13 Rear brake light switch connector 2 Disconnect.
14 Rear brake master cylinder 1
15 Handlebar switch (left) 1
16 Handlebar grip 2
17 Handle mounted light connector 2 Disconnect.
18 Handle mounted light assembly 1
19 Handlebar holder 2
20 Handlebar 1
4-49
HANDLEBAR
EBS30393
REMOVING THE HANDLEBAR

2. Remove:
• Handlebar grips "1"
TIP ~~~~~~~~~~~~~~~
Blow compressed air between the handlebar

end and the handlebar grip, and gradually push
the grip off the handlebar.
1
a
EBS30394
CHECKING THE HANDLEBAR 2

1. Check:
• Handlebar
Bends/cracks/damage ~ Replace.
EWB03680
& WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
EBS30395
INSTALLING THE HANDLEBAR

2. Install:
• Handlebar
• Handlebar holders
• Handle mounted light assembly
Handlebar holder bolt

20 N-m (2.0 kgf-m, 15 lb-ft)
TIP ~~~~~~~~~~~~~~~ b
• Install the handlebar within 15° from the hori- 3. Install:
zontal line shown in the illustration. • Handlebar grips "1"
• The handlebar holders should be installed with a. Wipe off grease or oil on the handlebar
the punch mark "a" forward "A". surface "a" with a lacquer thinner.
• Align the punch mark "b" on the handlebar with b. Apply a thin coat of rubber adhesive onto
the lower surface of the right handlebar holder. the left and right ends of the handlebar.
• First tighten the bolts "1" on the front side of the c. Install the handlebar grips to the handle-
handlebar holders, and then tighten the bolts bar so that arrow mark "L" faces up on the
"2" on the rear side. left handlebar grip and the arrow mark "R"
faces up on the right handlebar.
d. Wipe off any excess rubber adhesive with
a clean rag.
4-50
HANDLEBAR
EWB03690
• The "UP" mark "b" on the brake master cylinder
AwARNING holder should face up.
Do not touch the handlebar grip until the rub- • First tighten the bolt "3" on the upper side of the
ber adhesive has fully dried. brake master cylinder holder, and then tighten
the bolt "4" on the lower side.
0 " - -- - -
4. Install:
• Handlebar switch (left) 6. Install:
• Rear brake master cylinder "1" • Throttle lever assembly "1"
• Rear brake master cylinder holder "2" • Throttle lever assembly holder
TIP ~~~~~~~~~~~~~~~
Rear brake master cylinder hold-
er bolt Align the projection "a" on the throttle lever as-
7 N,m (0.7 kgf,m, 5.2 lb,ft) sembly with the end of the brake master cylinder
holder "b".
TIP~~~~~~~~~~~~~~~
• Align the end of the brake master cylinder hold- 1

er with the punch mark "a" on the handlebar.
• The "UP" mark "b" on the brake master cylinder =
holder should face up.
• First tighten the bolt on the upper side of the
brake master cylinder holder, and then tighten
the bolt on the lower side.
\
7. Connect:
• Throttle cable
TIP~~~~~~~~~~~~~~~
Lubricate the end of the throttle cable with a thin
coat of lithium-soap-based grease.
Throttle lever assembly cover

bolt
5. Install: 1.5 N,m (0.15 kgf,m, 1.1 lb,ft)
• Brake master cylinder "1"
• Brake master cylinder holder "2" 8. Adjust:
• Rear brake lever free play
Front brake master cylinder hold- Refer to "ADJUSTING THE REAR DISC
er bolt BRAKE" on page 3-10.
7 N,m (0.7 kgf,m, 5.2 lb,ft)
9. Adjust:
• Throttle lever free play
TIP ~~~~~~~~~~~~~~~
Refer to "ADJUSTING THE THROTTLE LE-
• Align the end of the brake master cylinder hold- VER FREE PLAY" on page 3-31 .
er with the punch mark "a" on the handlebar.
4-51
STEERING STEM
EBS20101
STEERING STEM
Removing the steering stem
,;.. 51 N•m
1,, 23 N·m (2.3 kgf·m, 17 lb·ft)
2
·~· 1
'
~, 35 N·m (3.5 kgf·m, 26 lb-ft)
B
(4) .;._ 30 N·m 3.0 k f·m, 22 lb-ft
\\
-., 7 N-m (0.7 kgf·m, 5.2 lb-ft)
.,,, 25 N·m 2.5 k f·m, 18 lb-ft
\ 210 N-m (21 kgf·m, 155 lb-ft)

Side panels 4-1 .
4-6.
Front fender
4-8.
Electrical components tray
4-11 .
Storage compartment 4-17.
Handlebar Refer to "HANDLEBAR" on page 4-48.
1 Lock washer 1
2 Cable guide 1
3 Steering stem bushing holder 2
4 Steering stem bushing 2
5 Collar 2
4-52
STEERING STEM
Removing the steering stem
l,, 23 N·m (2.3 kgf·m, 17 lb·ft) 11

15
•
~, 35 N·m (3.5 kgf·m, 26 lb-ft)
13
\ _ 10
l B
(4) .;.. 30 N·m 3.0 k f·m, 22 lb-ft
\\
14
-., 7 N-m (0. 7 kgf·m, 5.2 lb-ft)
g ~,, 25 N·m 2.5 k f·m, 18 lb-ft

8
·, 210 N-m (21 kgf·m, 155 lb-ft)
6 Tie-rod nut 2
7 Tie-rod 2 Disconnect.
8 Pitman arm nut 1
9 Pitman arm 1
10 Steering stem pinch bolt 1
11 Steering stem 1
12 Plug 1
13 EPS motor cover 1
14 EPS unit 1
15 Steering stem bracket 1
4-53
STEERING STEM
EBS30397
3. Install:
CHECKING THE STEERING STEM
• Steering stem "1 O''
1. Check:
• Steering stem pinch bolt "11"
• Steering stem (temporarily tighten)
Bends ~ Replace.
EWB03780 TIP ~~~~~~~~~~~~~~~
AwARNING Align the punch mark "a" on the EPS unit with
Do not attempt to straighten a bent stem; this the groove "b" in the steering stem.
may dangerously weaken the stem.
2. Check:
• Steering stem bushings
EBS30398
INSTALLING THE STEERING STEM
51~00 4. Install:
4 3 • Steering stem bracket bolts "12"
(temporarily tighten)
5. Tighten:
• EPS unit bolts "9"
• Steering stem pinch bolts "11"
_ .,,,.,11
Steering stem pinch bolt
35 N-m (3.5 kgf-m, 26 lb·ft)
LOCTITE®
6. Tighten:
• Steering stem bolts "7"
8
Steering stem bolt
23 N-m (2.3 kgf-m, 17 lb·ft)
TIP ~~~~~~~~~~~~~~~
1. Install: • Bend the lock washer tabs "c" along a flat side
• Collars "1" of the bolts.
• Steering stem bushings "2" • Pass the brake hoses through the cable guide.
• Steering stem bushing holders "3" Refer to "CABLE ROUTING" on page 2-19.
• Cable guide "4"
• Lock washer "5" ~.~1"11114"'~"1
• Steering stem bracket "6"
• Steering stem bolts "7''
(temporarily tighten)
TIP ~~~~~~~~~~~~~~~
Apply lithium-soap-based grease to the steering

stem bushings.
2. Install:
• EPS unit "8"
7. Tighten
• EPS unit bolts "9"
(temporarily tighten) • Steering stem bracket bolts "12"
4-54
STEERING STEM
Steering stem bracket bolt

51 N,m (5.1 kgf,m, 38 lb,ft)
LOCTITE®
EBS30399
INSTALLING THE PITMAN ARM

1. Install:
• Pitman arm "1"
• Washer
• Pitman arm nut
• Cotter pin l~i:M
'J~~
i7 Pitman arm nut
21 O N,m (21 kgf,m, 155 lb,ft)
TIP~~~~~~~~~~~~~~
Align the punch mark "a" on the EPS unit with

the groove "b" in the pitman arm .
4-55
TIE-RODS AND STEERING KNUCKLES
EBS20100

Removing the tie-rods and steering knuckles
·- 25 N·m (2.5 k f·m, 18 lb·ft)
' •\ 15 N·m (1.5 kgf·m, 11 lb-ft)
~ 6
(', 5
\) 7
·• 25 N•m (2.5 kgf-m, 18 lb·ft)
~;, 7 N-m 0.7 k f·m, 5.2 lb-ft S (
I ·,J30 N•m (3.0 kgf-m, 22 lb·ft) I~ ,
··, 30 N·m (3.0 kgf·m, 22 lb·ft)

,
,,
'
'
'
'... . . . . . . . . . . . .
\ 7 N-m (0.7 kgf·m, 5.2 lb-ft)

the tie-rods and steering knuckles.
Front wheel hub Refer to "FRONT WHEELS" on page 4-20.
1 Screw 3 for YFM70GPAK/YFM70GPHK
2 Bolt 3 for YFM70GPLK
3 Brake disc guard 1
4 Front arm protector 1
5 Tie-rod end locknut 2
6 Tie-rod end 2
7 Tie-rod 1
8 Nut 2
9 Steering knuckle 1
10 Circlip 1
11 Ball joint 1
12 Circlip 1
13 Wheel bearing 1
4-56
EBS304-01
2. Check:
REMOVING THE STEERING KNUCKLES
• Front wheel bearing "1"
The following procedure applies to both of the Rough movemenVexcessive free play ~ Re-
steering knuckles.
place.
1. Remove: a. Clean the surface of the steering knuckle.
• Steering knuckle "1"
b. Remove the circlip "2".
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
c. Drive out the bearing.
Use a general puller to separate the ball joints EWB03790
"2" from the steering knuckle "1" or the front low- & WARNING
er arm "3". Eye protection is recommended when using
striking tools.
2 1
2
EBS304-02
CHECKING THE TIE-RODS d. Apply lithium-soap-based grease to the

The following procedure applies to both of the balls of the new bearing.
tie-rods. e. Install the new bearing.
1. Check: ECB02650
• Tie-rod movement NOTICE

-------------
Rough movement~ Replace the tie-rod end. Do not strike the center race or balls of the
2. Check: bearing. Contact should be made only with
• Tie-rod the outer race.
Bends/damage ~ Replace. f. Install a new circlip.
Rubber boot damage ~ Replace the tie-rod
end. EBS30404
CHECKING THE STEERING KNUCKLE BALL

JOINTS
\,_ / steering knuckle ball joints.
•
1. Check:
~· • Ball joint (steering knuckle)
Damage/pitting ~ Replace the ball joint.
0
Rubber boot damage ~ Replace the ball
joint.
Rough movement ~ Replace the ball joint.
EBS304-03
CHECKING THE STEERING KNUCKLES

AND FRONT WHEEL BEARINGS
steering knuckles and front wheel bearings.
1. Check:
• Steering knuckle
Damage/pitting ~ Replace.
a. Clean the surface of the steering knuckle.
4-57

Ball joint remover
90890-01474
Ball joint remover
YM-01474
Ball joint remover attachment set
90890-01480
YM-01480
Ball joint installer attachment
38mm
90890-01583
c. Remove the ball joint "2". Ball joint installer attachment
TIP~~~~~~~~~~~~~~
38mm
YM-01583
Use a suitable socket "3" to separate the ball Ball joint remover short shaft set
joint "2" from the steering knuckle "4". 90890-01514
Ball joint remover short shaft set
YM-01514
No. Tool name Tool No.

90890-01474
6 Body
YM-01474
7 Installer spacer 90890-01480
8 Base YM-01480
3 2
t Ball joint installer at- 90890-01583
9
tachment 38mm YM-01583
d. Measure the ball joint bore inside diameter
10 Guide bolt 90890-01514
"a".
11 Short bolt YM-01514
Out of specification ~ Replace the steer-
ing knuckle.
11 10
Ball joint bore inside diameter 7
32.45--32.50 mm (1.278--1.280 in)
-
8
6
10 6 9 5 4 8
11
e. Attach the special tools and new ball joint
"5" to the steering knuckle "4". ,. ,.' ..
0 'r-·
TIP~~~~~~~~~~~~~~ .. - -
'
• Always use a new ball joint.
• Do not tap or damage the top of the ball joint. 7
f. Hold the base "8" in place while turning in
the short bolt "11" to install the new ball
joint "5" into the steering knuckle "4".
g. Remove the special tools.
4-58
h. Install a new circlip.

EBS304-05
INSTALLING THE TIE-RODS
tie-rods.
1. Install:
• Tie-rod
Steering knuckle and tie-rod nut

25 N,m (2.5 kgf,m, 18 lb,ft)
Pitman arm and tie-rod nut
25 N,m (2.5 kgf,m, 18 lb,ft)
TIP ~~~~~~~~~~~~~~
Install the tie-rod so that the groove "1" is on the

wheel side.
,•I
2. Adjust:
• Toe-in
Refer to "ADJUSTING THE TOE-IN" on page
3-20.
EBS304-06
INSTALLING THE FRONT ARM

PROTECTORS
front arm protectors.
1. Install:
• Front arm protector "1"
~ Front arm protector bolt

~~ 7 N,m (0.7 kgf,m, 5.2 lb,ft)
a. Fit the holders "a" on the front arm protec-

tor onto the lower arm.
b. Tighten the bolt "b".
4-59
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES
EBS20031

Removing the front arms and front shock absorber assemblies
"· 45 N·m (4.5 kgf·m, 33 lb·ft)
r r~ J
-......
, 5
7 N•m (0.7 kgf•m, 5.2 lb·ft) I
~"
"'- "' ' ' ' -
~
~ 10
~
00
-o
c·s- 11
11
L--
8
., , 7 N·m (0. 7 kgf·m, 5.2 lb·ft)

the front upper arms, front lower arms, and
Front wheel hub Refer to "FRONT WHEELS" on page 4-20.
Front brake caliper assembly Refer to "FRONT BRAKE" on page 4-26.
4 Front arm protector 1
5 Front brake hose holder 2
6 Nut 2
7 Nut/Bolt 2/2
8 Front shock absorber assembly 1
9 Nut/Washer/Bolt 2/2/2
10 Front upper arm 1
11 Nut/Bolt 2/2
4-60
Removing the front arms and front shock absorber assemblies

,, , 45 N·m (4.5 kgf·m, 33 lb·ft)
r r~ .J 7 N•m (0.7 kgf•m, 5.2 lb·ft) I
, -16
12 Front lower arm 1

13 Dust cover 2
14 Bushing 4
15 Circlip 1
16 Ball joint 1
4-61
ESS30113
• Spring
CHECKING THE FRONT ARMS
Move the spring up and down.
Fatigue ~ Replace the front shock absorber
front upper arms and front lower arms.
assembly.
1. Check:
• Front arm free play EBS30117
a. Check the front arm side play "A" by mov- CHECKING THE FRONT ARM BALL JOINTS
ing it from side to side. The following procedure applies to both of the
If side play is noticeable, check the bush- front arm ball joints.
. 1. Check:
1ngs.
• Ball joint (front upper arm)
Damage/pitting ~ Replace the ball joint.
Rubber boot damage ~ Replace the ball
joint.
Rough movement ~ Replace the ball joint.
b. Check the front arm vertical movement "B"

by moving it up and down.
If the vertical movement is tight or rough,
or if there is binding, check the bushings.
a. Clean the surface of the front upper arm.

b. Remove the circlip "1 ".
2. Check:
1
• Front upper arm
• Front lower arm
Bends/damage ~ Replace. c. Remove the ball joint "2".
3. Check: TIP~~~~~~~~~~~~~~
• Bushings Use the suitable socket "3" to separate the ball
Wear/damage ~ Replace. joint "2" from the front upper arm "4".
ESS30116
CHECKING THE FRONT SHOCK ABSORBER

ASSEMBLIES
The following procedure applies to both of the 4 ---.c I
1. Check:
• Front shock absorber assembly 3- ----< 2
Oil leaks~ Replace the front shock absorber
assembly.
• Front shock absorber rod
Bends/damage ~ Replace the front shock
t
d. Attach the special tools and new ball joint
absorber assembly. "5" to the front upper arm "4".
4-62
EBS301 18
TIP ~~~~~~~~~~~~~~
INSTALLING THE FRONT ARMS AND
• Always use a new ball joint. FRONT SHOCK ABSORBER ASSEMBLIES
• Do not tap or damage the top of the ball joint. The following procedure applies to both of the
front upper arms, front lower arms, and front
Ball joint remover shock absorber assemblies.
90890-01474 1. Install:
Ball joint remover • Front upper arm
YM-01474 • Front lower arm
Ball joint remover attachment set • Front shock absorber assembly
90890-01480 a. Install the front upper arm "1" and front
lower arm "2".
YM-01480
TIP ~~~~~~~~~~~~~~
No. Tool name Tool No. • Lubricate the front upper and lower arm bolts
"3" with lithium-soap-based grease.
6 Long bolt
• Be sure to position the front upper and lower
7 Body 90890-01474 arm bolts "3" so that the bolt heads face for-
8 Guide bolt YM-01474 ward.
9 Remover attachment • Install the washers "4".
10 Installer spacer • Temporarily tighten the front upper and lower
90890-01480 arm nuts "5".
11 Installer washer
YM-01480
12 Base b. Install the front shock absorber assembly
"6", bolts "7'', and nuts "8".
7 8
-~ u 9~
10
Front shock absorber assembly
nut
45 N,m (4.5 kgf,m, 33 lb,ft)
11
c. Install the steering knuckle, upper steering
0
knuckle nut "9", and lower steering knuck-
le nut "1 O".
12 Steering knuckle and front upper
arm nut
30 N,m (3.0 kgf,m, 22 lb,ft)
Steering knuckle and front lower
arm nut
30 N,m (3.0 kgf,m, 22 lb,ft)
d. Install the new cotter pins.

e. Tighten the front upper and lower arm nuts
"5" to specification.
4 12 Front upper arm nut
55 N,m (5.5 kgf,m, 41 lb,ft)
e. Hold the base "12" in place while turning in Front lower arm nut
the long bolt "6" to install the new ball joint 55 N,m (5.5 kgf,m, 41 lb,ft)
"5" into the front upper arm "4".
f. Remove the special tools.
g. Install a new circlip.
4-63
3,4,5
2
l
10
EBS304-07
INSTALLING THE FRONT ARM

PROTECTORS
front arm protectors.
1. Install:
• Front arm protector "1"
~ Front arm protector bolt

~~ 7 N,m (0.7 kgf,m, 5.2 lb,ft)
a. Fit the holders "a" on the front arm protec-

tor onto the lower arm.
b. Tighten the bolt "b".
- - - - - ja
4-64
REAR KNUCKLES AND STABILIZER
EBS20032

Removing the rear knuckles and stabilizer
.,., 56 N·m 5.6 k f·m, 41 lb·ft
r -J 30 N•m (3.0 kgf•m, 22 lb·ft) ~
·, 7 N·m (0.7 kgf·m, 5.2 lb·ft) ~~

\ ~~~
' \ ___..-,._ -
5_ _
'
, • 7 N·m (0.7 kgf·m, 5.2 lb·ft)
-.. 45 N·m (4.5 kgf·m, 33 lb·ft)

.,., 56 N·m 5.6 k f·m, 41 lb·ft

the rear knuckles.
Rear wheel hub Refer to "REAR WHEELS" on page 4-23.
4 Rear arm protector 1
5 Rear brake disc cleaning plate 1
6 Rear knuckle 1
7 Spacer cover 4
8 Spacer 2
9 Circlip 1
10 Wheel bearing 1
4-65
Removing the rear knuckles and stabilizer

.,,, 56 N·m 5.6 k f·m, 41 lb·ft
., 30 N•m (3.0 kgf•m, 22 lb·ft)
~ - - - - - - ~ 12 ~
,, 7 N·m (0.7 kgf•m, 5.2 lb-ft) ~ ,;
\, ~~~
13
'
·., 7 N•m (0.7 kgf•m, 5.2 lb·ft)
> 45 N•m (4.5 kgf-m, 33 lb•ft)

.,,, 56 N·m 5.6 k f·m, 41 lb·ft
11 Stabilizer joint 2
12 Stabilizer holder 2
13 Bushing 2
14 Stabilizer 1
4-66
ESS30119
CHECKING THE REAR KNUCKLES AND Rear arm protector bolt

REAR WHEEL BEARINGS 7 N,m (0.7 kgf,m, 5.2 lb,ft)
The following procedure applies to both of the Rear arm protector nut
rear knuckles and rear wheel bearings. 7 N,m (0.7 kgf,m, 5.2 lb,ft)
1. Check:
• Rear knuckle a. Fit the holders "a" on the rear arm protec-
Damage/pitting ~ Replace. tor onto the lower arm.
2. Check: b. Tighten the bolts "b"
• Rear wheel bearing "1" c. Tighten the nut "c"
Rough movement/excessive free play ~ Re-
place.
a. Clean the surface of the rear knuckle.
c. Drive out the bearing.
EWB03790
AwARNING
Eye protection is recommended when using
striking tools.
d. Apply lithium-soap-based grease to the

bearing.
e. Install the new bearing.
ECB0'.!650
NOTICE
-------------
Do not strike the center race or balls of the
bearing. Contact should be made only with
the outer race.
f. Install the new circlip.
EBS30120
CHECKING THE STABILIZER

1. Check:
• Stabilizer
Bends/cracks/damage ~ Replace.
EBS304-08
INSTALLING THE REAR ARM PROTECTORS

rear arm protectors.
1. Install:
• Rear arm protector "1"
4-67
REAR ARMS AND REAR SHOCK ABSORBER ASSEMBLIES
EBS20033

Removing the rear arms and rear shock absorber assemblies
~;, 55 N·m (5.5 kgf·m, 41 lb·ft) ·•. 45 N·m (4.5 kgf·m, 33 lb-ft)
2
·,. 7 N·m (0.7 kgf·m, 5.2 lb·ft)

g-® 3
·,. 55 N·m 5.5 k f·m, 41 lb·ft
,•,.. 45 N·m 4.5 k f·m, 33 lb·ft

the rear upper arms, rear lower arms, and
Refer to "REAR KNUCKLES AND STABI·
Rear knuckle/Stabilizer
LIZER" on page 4-65.
1 Rear brake hose guide 1
3 Rear shock absorber assembly 1
5 Rear upper arm 1
6 Dust cover 1
7 Nut/Bolt 2/2
8 Rear lower arm 1
9 Dust cover 2
10 Bushing 4
4-68
EBS30122
• Spring
CHECKING THE REAR ARMS
Move the spring up and down.
Fatigue ~ Replace the rear shock absorber
rear upper arms and rear lower arms.
assembly.
1. Check:
• Rear arm free play EBS30126
a. Check the rear arm side play "A" by mov- INSTALLING THE REAR ARMS AND REAR
ing it from side to side. SHOCK ABSORBER ASSEMBLIES
If side play is noticeable, check the bush- The following procedure applies to both of the
. rear upper arms, rear lower arms, and rear
1ngs.
shock absorber assemblies.
1. Install:
• Rear upper arm
• Rear lower arm
a. Install the rear upper arm "1" and rear low-
er arm "2".
TIP ~~~~~~~~~~~~~~
-zi
b. Check the rear arm vertical movement "B"
• Lubricate the rear upper and lower arm bolts
"3" with lithium-soap-based grease.
• Be sure to position the rear upper and lower
by moving it up and down. arm bolts "3" so that the bolt heads face out-
If the vertical movement is tight or rough, ward.
or if there is binding, check the bushings. • Installed the washers "4".
• Temporarily tighten the rear upper and lower
arm nuts "5".
b. Install the rear shock absorber assembly
"6", bolts "7", washer "8",and nuts "9".
Rear shock absorber assembly

nut
45 N,m (4.5 kgf,m, 33 lb,ft)
c. Install the rear knuckle and nuts "1 O".

2. Check:
• Rear upper arm Rear knuckle nut
45 N,m (4.5 kgf,m, 33 lb,ft)
• Rear lower arm
Bends/damage ~ Replace.
d. Tighten the rear upper and lower arm nuts
3. Check:
"5" to specification.
• Bushings
Wear/damage ~ Replace. Rear upper arm nut
EBS30125
55 N,m (5.5 kgf,m, 41 lb,ft)
CHECKING THE REAR SHOCK ABSORBER Rear lower arm nut
ASSEMBLIES 55 N,m (5.5 kgf,m, 41 lb,ft)
1. Check:
Oil leaks ~ Replace the rear shock absorber
assembly.
• Rear shock absorber rod
Bends/damage ~ Replace the rear shock
absorber assembly.
4-69
4-70
4-71
ENGINE
LUBRICATION SYSTEM CHART AND DIAGRAMS ...................................... 5-1

LUBRICATION DIAGRAMS ...................................................................... 5-1
ENGINE INSPECTION .................................................................................... 5-3

MEASURE THE COMPRESSION PRESSURE ........................................ 5-3
ENGINE REMOVAL (1) ................................................................................... 5-4

INSTALLING THE MUFFLER ................................................................... 5-6
INSTALLING THE V-BELT COOLING DUCTS ......................................... 5-6
ENGINE REMOVAL (2) ................................................................................... 5-8

INSTALLING THE DRIVE SELECT LEVER UNIT .................................... 5-9
ENGINE REMOVAL (3) ................................................................................. 5-1 O

INSTALLING THE ENGINE ..................................................................... 5-13
CYLINDER HEAD .......................................................................................... 5-14

REMOVING THE CYLINDER HEAD ....................................................... 5-16
CHECKING THE CYLINDER HEAD ....................................................... 5-16
CHECKING THE CAMSHAFT SPROCKET ............................................ 5-17
CHECKING THE TAPPET COVERS AND CAMSHAFT
SPROCKET COVER .............................................................................. 5-17
CHECKING THE TIMING CHAIN TENSIONER ...................................... 5-17
INSTALLING THE CYLINDER HEAD ..................................................... 5-18
ROCKER ARMS AND CAMSHAFT .............................................................. 5-20

REMOVING THE ROCKER ARMS AND CAMSHAFT ............................ 5-21
CH ECKi NG THE CAMSHAFT ................................................................. 5-21
CHECKING THE DECOMPRESSION SYSTEM ..................................... 5-21
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-21
INSTALLING THE CAMSHAFT AND ROCKER ARMS .......................... 5-22
VALVES AND VALVE SPRINGS .................................................................. 5-24

REMOVING THE VALVES ...................................................................... 5-25
CHECKING THE VALVES AND VALVE GUIDES .................................. 5-25
CH ECKi NG THE VALVE SEATS ............................................................ 5-27
CHECKING THE VALVE SPRINGS ........................................................ 5-28
INSTALLING THE VALVES .................................................................... 5-29
CYLINDER AND PISTON .............................................................................. 5-31

REMOVING THE PISTON ...................................................................... 5-32
CHECKING THE CYLINDER AND PISTON ........................................... 5-32
CHECKING THE PISTON RINGS ........................................................... 5-33
CH ECKi NG THE Pl STON Pl N ................................................................ 5-34
INSTALLING THE PISTON AND CYLINDER ......................................... 5-34
AC MAGNETO AND STARTER CLUTCH .................................................... 5-36
REMOVING THE AC MAGNETO ROTOR .............................................. 5-39
REMOVING THE STARTER CLUTCH ................................................... 5-39
CHECKING THE STATOR COIL AND CRANKSHAFT
POSITION SENSOR .............................................................................. 5-39
CHECKING THE STARTER CLUTCH .................................................... 5-40
CHECKING THE TORQUE LIMITER ...................................................... 5-40
INSTALLING THE STARTER CLUTCH .................................................. 5-40
INSTALLING THE AC MAGNETO .......................................................... 5-40
ELECTRIC STARTER ................................................................................... 5-42

CHECKING THE STARTER MOTOR ..................................................... 5-44
ASSEMBLING THE STARTER MOTOR ................................................. 5-45
BALANCER GEARS AND OIL PUMP GEARS ............................................ 5-46

REMOVING THE BALANCER DRIVEN GEAR AND OIL PUMP
DRIVEN GEAR ....................................................................................... 5-47
CHECKING THE OIL PUMP DRIVE ....................................................... 5-47
CHECKING THE BALANCER DRIVE ..................................................... 5-47
INSTALLING THE BALANCER DRIVE GEAR, BALANCER
DRIVEN GEAR, AND OIL PUMP DRIVEN GEAR ................................. 5-47
PRIMARY AND SECONDARY SHEAVES .................................................... 5-49

REMOVING THE PRIMARY AND SECONDARY SHEAVES ................. 5-52
DISASSEMBLING THE SECONDARY SHEAVE .................................... 5-52
CHECKING THE V-BELT ........................................................................ 5-53
CHECKING THE PRIMARY SHEAVE .................................................... 5-53
CHECKING THE PRIMARY SHEAVE WEIGHTS ................................... 5-53
CHECKING THE PRIMARY SHEAVE SLIDERS .................................... 5-53
CHECKING THE SECONDARY SHEAVE .............................................. 5-53
ASSEMBLING THE PRIMARY SHEAVE ................................................ 5-54
ASSEMBLING THE SECONDARY SHEAVE .......................................... 5-54
INSTALLING THE PRIMARY AND SECONDARY SHEAVES ................ 5-56
CLUTCH ........................................................................................................ 5-58

REMOVING THE CLUTCH ..................................................................... 5-60
CHECKING THE CLUTCH ...................................................................... 5-60
CH ECKi NG THE CLUTCH SHOE ........................................................... 5-60
ASSEMBLING THE CLUTCH HOUSING ................................................ 5-61
INSTALLING THE CLUTCH .................................................................... 5-61
CRANKCASE ................................................................................................ 5-63

SEPARATING THE CRANKCASE .......................................................... 5-67
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE ............. 5-67
CH ECKi NG THE RELi EF VALVE ........................................................... 5-67
CH ECKi NG THE SEARi NGS .................................................................. 5-67
CH ECKi NG THE CRANKCASE .............................................................. 5-68
ASSEMBLING THE CRANKCASE .......................................................... 5-68
INSTALLING THE SH IFT LEVER ........................................................... 5-69
CRANKSHAFT AND OIL PUMP ................................................................... 5-70
REMOVING THE CRANKSHAFT ........................................................... 5-72
CHECKING THE OIL PUMP ................................................................... 5-72
CHECKING THE OIL STRAINER ........................................................... 5-73
CHECKING THE CRANKSHAFT ............................................................ 5-73
ASSEMBLING THE OIL PUMP ............................................................... 5-73
INSTALLING THE CRANKSHAFT .......................................................... 5-74
TRANSMISSION ............................................................................................ 5-75

REMOVING THE TRANSMISSION ........................................................ 5-79
CHECKING THE SHIFT FORKS ............................................................. 5-79
CHECKING THE SHIFT DRUM .............................................................. 5-79
CHECKING THE TRANSMISSION ......................................................... 5-79
CHECKING THE SECONDARY SHAFT ................................................. 5-80
CHECKING THE STOPPER LEVER AND STOPPER WHEEL .............. 5-80
ASSEMBLING THE SHIFT FORK ASSEMBLY ...................................... 5-80
INSTALLING THE SHIFT FORKS AND SHIFT DRUM ........................... 5-80
MIDDLE GEAR .............................................................................................. 5-82

REMOVING THE MIDDLE DRIVE SHAFT ............................................. 5-85
REMOVING THE MIDDLE DRIVEN SHAFT ........................................... 5-85
CHECKING THE PINION GEARS .......................................................... 5-86
INSTALLING THE BEARING AND OIL SEALS ...................................... 5-87
INSTALLING THE MIDDLE DRIVEN SHAFT ......................................... 5-87
INSTALLING THE MIDDLE DRIVE SHAFT ............................................ 5-88
MEASURING THE MIDDLE GEAR BACKLASH ..................................... 5-89
ALIGNING THE MIDDLE GEAR ............................................................. 5-90
LUBRICATION SYSTEM CHART AND DIAGRAMS
EBS20149

EBS30796
LUBRICATION DIAGRAMS
1- -, -i-----3
.. •..
1. Oil delivery pipe 1

2. Oil delivery pipe 2
3. Oil filter cartridge
4. Oil strainer
5. Drive axle
6. Relief valve assembly
7. Reverse idle gear shaft
5-1
- I
1
~
~~. Pn-
u -~
l=-, ..
' - §\
-..,:,
... .,L~
i) / JfaJ '~
p-
_,=;-
v:::: ',/ / ~
r =
' - - J
V
~
~
=-..
-
..oM~ l
.J
>-
"M~J
'
~ - ~
-- u u
l
~
I
I
~
- I
. \\
,r1; ' ~
<I '' .
'
'
D• :mt
I I
'
1-Jf 0 0
!. j ' l
'-, ,-
j - - L
.~ ~~l - 11
1~ ~\~
5 4 3
1. Camshaft
2. Crankshaft
3. Oil strainer
4. Oil pump rotor
5. Oil pump driven gear
5-2
ENGINE INSPECTION
EBS20105
7. Measure:
ENGINE INSPECTION • Compression pressure
EBS30539
Out of specification~ Refer to steps (c) and
MEASURE THE COMPRESSION PRESSURE (d) .
TIP ~~~~~~~~~~~~~~
Compression pressure
Insufficient compression pressure will result in a 435-560 kPa (4.4-5.6 kgf/cm 2 ,
loss of performance. 61.9-79.6 psi)
1. Measure:
a. Set the main switch to "ON".
• Valve clearance
b. With the throttle wide open, crank the en-
gine until the reading on the compression
Refer to "ADJUSTING THE VALVE CLEAR-
gauge stabilizes.
ANCE" on page 3-4. EW B03200
2. Start the engine, warm it up for several min- & WARNING

utes, and then turn it off. To prevent sparking, ground the spark plug
3. Remove: lead before cranking the engine.
Refer to "GENERAL CHASSIS (2)" on page c. If the compression pressure is above the
4-6. maximum specification, check the cylinder
4. Disconnect: head, valve surfaces and piston crown for
• Spark plug cap carbon deposits.
5. Remove: Carbon deposits ~ Eliminate.
• Spark plug d. If the compression pressure is below the
ECB01870 minimum specification, pour a teaspoonful
NOTICE of engine oil into the spark plug bore and
-------------
Before removing the spark plug, use com- measure again.
.
pressed air to blow away any dirt accumulat- Refer to the following table.
ed in the spark plug well to prevent it from Compression pressure (with oil applied into the
falling into the cylinder. cylinder)
6. Attach: Reading Diagnosis

• Extension "1" Higher than without oil
Piston ring(s) wear or
• Compression gauge "2" damage ~ Repair.
Piston, valves, cylinder
Compression gauge head gasket or piston
90890-03081 Same as without oil
ring(s) possibly defec-
Engine compression tester tive ~ Repair.
YU-33223
Compression gauge extension 8. Install:
73mm • Spark plug
90890-04082
Compression gauge extension Spark plug
73mm 13 N-m (1.3 kgf-m, 9.6 lb·ft)
YM-04082
9. Connect:
• Spark plug cap
1O.lnstall:
4-6.
5-3
ENGINE REMOVAL (1)
EBS20034
ENGINE REMOVAL (1)

Removing the V-belt cooling ducts, muffler and exhaust pipe
·. 7 N-m (0. 7 kgf·m, 5.2 lb-ft)
' ' .. 20 N·m (2.0 kgf·m, 15 lb·ft)
, ,, 1.5 N·m (0.15 kgf·m, 1.1 lb-ft)
/ ~
'
4
r , 11.5 N•m (0.15 kgf-m, 1.1 lb·ft) I
'

4-1 .
4-6.
Front fenders/Rear fender
4-8.
Footrest board (left)
4-11 .
Storage compartment 4-17.
1 V-belt cooling exhaust duct 1
2 V-belt cooling exhaust duct joint 1
3 V-belt cooling intake duct joint 1
4 V-belt cooling intake duct 1
5-4
ENGINE REMOVAL (1)
Removing the V-belt cooling ducts, muffler and exhaust pipe
·. 7 N-m (0.7 kgf•m, 5.2 lb-ft)
, , .. 20 N•m (2.0 kgf·m, 15 lb·ft)
,. 1.5 N·m (0.15 kgf•m, 1.1 lb-ft)
/ ~
'
r-,11.5 N•m (0.15 kgf-m, 1.1 lb·ft) I

'
, 1.5 N·m 0.15 k f•m, 1.1 lb·ft
5 Exhaust pipe protector 1

6 Spring 2
7 Muffler 1
8 Gasket 1
9 Muffler bracket 1
10 Exhaust pipe 1
11 Gasket 1
5-5
ENGINE REMOVAL (1)
EBS30889
INSTALLING THE MUFFLER

1. Install:
• Gasket "1" l~f:M
• Exhaust pipe "2"
• Exhaust pipe nuts "3"
Exhaust pipe nut

20 N,m (2.0 kgf,m, 15 lb,ft)
2. Install:
• Muffler bracket "4"
• Muffler bracket bolts "5"
Muffler bracket bolt

20 N,m (2.0 kgf,m, 15 lb,ft)
3. Install:
• Gasket "6" l~f41J
• Muffler "7"
• Washer "8"
• Muffler bolt "9"
TIP ~~~~~~~~~~~~~~ EBS30554
INSTALLING THE V-BELT COOLING DUCTS

Do not fully tighten the muffler bolt.
1. Install:
4. Install: • V-belt cooling intake duct joint "1"
• Springs "1 O'' • V-belt cooling intake duct "2"
TIP ~~~~~~~~~~~~~~ a. Position the V-belt cooling intake duct joint
Install the springs so that the spring ends are with its arrow mark "a" pointing toward the
.
pointing inward as shown in the illustration. engine.
b. Align the projection on the V-belt cooling
intake duct joint with the rib on the crank-
case in the area "b" shown in the illustra-
tion .
c. Align the screw head with the seam on the
© V-belt cooling intake duct joint in the area
"c" shown in the illustration.
d. Align the projection on the V-belt cooling
intake duct with the projection on the V-
belt cooling intake duct joint in the area "d"
shown in the illustration.
5. Tighten: e. Align the bend in the screw clamp with the
• Muffler bolt "9" projection on the V-belt cooling intake duct
joint in the area "e" shown in the illustra-
Muffler bolt tion .
33 N,m (3.3 kgf,m, 24 lb,ft)
5-6
ENGINE REMOVAL (1)
~-
' '' '
' ' ''
'
''
'
..
..
'' .••.• •.••
'
'' ' ' 2
, , ,
ab 1
C
a 1
X 2
---
2. Install:
• V-belt cooling exhaust duct joint "1"
• V-belt cooling exhaust duct "2"
a. Position the V-belt cooling exhaust duct
joint with its arrow mark "a" pointing to-
ward the engine.
b. Align the projection on the V-belt cooling
exhaust duct joint with the projection on
the drive belt case in the area "b" shown in
the illustration.
c. Align the screw head with the arrow mark
"a" on the V-belt cooling exhaust duct joint
in the area "c" shown in the illustration.
d. Align the projection on the V-belt cooling
exhaust duct with the projection on the V-
belt cooling exhaust duct joint in the area
"d" shown in the illustration.
e. Align the screw head with the rib on the V-
belt cooling exhaust duct in the area "e"
5-7
ENGINE REMOVAL (2)
EBS20093
ENGINE REMOVAL (2)

Removing the drive select lever unit
, 7 N·m (0.7 kgf·m, 5.2 lb·ft)
.,.........--------,
l\ 7 N·m (0.7 kgf·m, 5.2 lb·ft) ·, 8 N·m (0.8 kgf-m, 5.9 lb·ft)
. 14N·m 1.4k f·m,101b·ft
1
,
\ -
B
1 Drive select lever shift rod 1

2 Drive select lever unit 1
3 Shift arm 1
5-8
ENGINE REMOVAL (2)
EBS30553
INSTALLING THE DRIVE SELECT LEVER

UNIT
1. Install:
• Shift arm "1"
• Drive select lever unit "2"
• Drive select lever shift rod "3"
Shift arm bolt

14 N,m (1.4 kgf,m, 1O lb,ft)
LOCTITE®
Drive select lever unit bolt
7 N,m (0.7 kgf,m, 5.2 lb,ft)
nut
8 N,m (0.8 kgf,m, 5.9 lb,ft)
TIP ~~~~~~~~~~~~~~
• Make sure that the drive select lever and trans-

mission are in "N" (neutral).
• The installed length "a" of the shift rod is 413
mm (16.3 in).
5-9
ENGINE REMOVAL (3)
EBS20120
ENGINE REMOVAL (3)

Disconnecting the leads, cables and hoses
Drain.
Coolant Refer to "CHANGING THE COOLANT' on
page 3-27.
Drain.
Engine oil Refer to "CHANGING THE ENGINE OIL'.' on
page 3-22.
Footrest board (right)
4-11 .
Air filter case
4-17.
Refer to "AIR INDUCTION SYSTEM" on
Air cut-off valve/Air induction system hose
page 7-9.
Throttle body assembly Refer to "THROTILE BODY" on page 7-4.
Coolant reservoir Refer to "RADIATOR" on page 6-2.
Radiator inlet hose/Radiator outlet hose Disconnect.

Refer to "RADIATOR" on page 6-2.
Refer to "FRONT CONSTANT VELOCITY
SHAFT ASSEMBLIES, DIFFERENTIAL AS-
Differential assembly
SEMBLY AND FRONT DRIVE SHAFT' on
page 8-4.
5-10
ENGINE REMOVAL (3)
Disconnecting the leads, cables and hoses

Refer to "REAR CONSTANT VELOCITY
SHAFT ASSEMBLIES, FINAL DRIVE AS-
Final drive assembly
SEMBLY AND REAR DRIVE SHAFT" on
page 8-15.
Refer to "ELECTRIC STARTER" on page
Starter motor 5-42.
1 Cylinder head breather hose 1
2 Coolant temperature sensor coupler 1 Disconnect.
3 Spark plug cap 1
4 Reverse switch lead 1 Disconnect.
5 Speed sensor coupler 1 Disconnect.
6 Crankshaft position sensor coupler 1 Disconnect.
7 AC magneto lead coupler 1 Disconnect.
8 Gear position switch coupler 1 Disconnect.
5-11
ENGINE REMOVAL (3)
Removing the engine
h, 42 N·m (4.2 kgf·m, 31 lb·ft)
,:.,_ 1O N·m (1.0 kgf·m, 7.4 lb·ft)
'\_r-, 4
1 7
bi 9
.•.• 10 N•m
·. 42 N·m (4.2 kgf·m, 31 lb·ft) 6
8 3
·. 1O N·m 1.0 k f·m , 7.4 lb·ft

"'· 42 N·m (4.2 kgf·m, 31 lb·ft)

1 Rubber damper nut (front side) 2
2 Engine mounting bolt (rear) (M6) 2
3 Engine mounting bolt (rear) (M10) 2
4 Rubber damper nut (rear side) 2
5 Rubber damper (rear side) 2
TIP
6 Engine 1 Remove the engine from the left side of the
vehicle.
7 Engine mounting bolt (front) (M6) 2

8 Engine mounting bolt (front) (M 10) 2
9 Rubber damper (front side) 2
5-12
ENGINE REMOVAL (3)
EBS30351
INSTALLING THE ENGINE Engine mounting bolt (front low-

1. Install: er side)
• Rubber dampers (front side) "1" 42 N-m (4.2 kgf-m, 31 lb·ft)
• Engine mounting bolts (front lower side) "2" Engine mounting bolt (front up-
• Engine mounting bolts (front upper side) "3" per side)
• Rubber dampers (rear side) "4" 1O N-m (1.0 kgf-m, 7.4 lb·ft)
• Rubber damper nuts (rear side) "5" LOCTITE®
• Engine "6" Engine mounting bolt (rear lower
• Engine mounting bolts (rear lower side) "7" side)
42 N-m (4.2 kgf-m, 31 lb·ft)
• Engine mounting bolts (rear upper side) "8"
Engine mounting bolt (rear upper
• Rubber damper nuts (front side) "9" side)
ECB01630
NOTICE 1O N-m (1.0 kgf-m, 7.4 lb·ft)

------------- LOCTITE®
Make sure that the engine does not strike the Rubber damper nut (front side)
brake pipe when installing it. 42 N-m (4.2 kgf-m, 31 lb·ft)
Rubber damper nut (rear side)
TIP ~~~~~~~~~~~~~~
42 N-m (4.2 kgf-m, 31 lb·ft)
Do not fully tighten the bolts and nuts.
9 2
1 6
2. Tighten:
• Engine mounting bolts (front lower side) "2"
• Engine mounting bolts (front upper side) "3"
• Engine mounting bolts (rear lower side) "7"
• Engine mounting bolts (rear upper side) "8"
• Rubber damper nuts (front side) "9"
• Rubber damper nuts (rear side) "5"
5-13
CYLINDER HEAD
EBS20035
CYLINDER HEAD
Removing the cylinder head
o'1o ., . 20 N·m 2.0 k f·m, 15 lb·ft ~;,_ 20 N·m (2.0 kgf·m, 15 lb·ft)
#',, 10 N·m (1.0 kgf·m, 7.4 lb·ft) "'· 1O N·m (1.0 kgf·m, 7.4 lb·ft)
,;, 13 N·m (1.3 kgf·m, 9.6 lb·ft)
,,,. 35 N·m (3.5 kgf·m, 26 lb·ft)

8
'
·', 10 N·m (1.0 kgf·m, 7.4 lb·ft)
·•. 35 N·m 3.5 k f·m, 26 lb·ft

~~. 20 N·m (2.0 kgf·m, 15 lb·ft) .,_ 38 N·m 3.8 k f·m, 28 lb·ft
·· 35 N·m (3.5 kgf·m, 26 lb·ft) ,,, 2.0 N·m 0.20 k f·m, 1.5 lb·ft
•;, 1O N·m 1.0 k f·m, 7.4 lb·ft .,., 1O N·m 1.0 k f·m, 7.4 lb·ft "·,. 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)

Throttle body assembly Refer to "THROTILE BODY" on page 7-4.
Thermostat/Coolant temperature sensor Refer to "THERMOSTAT' on page 6-5.
Refer to "ENGINE REMOVAL (1 )" on page
V-belt cooling ducts/Exhaust pipe
5-4.
Refer to "AIR INDUCTION SYSTEM" on
Reed valve assembly page 7-9.
1 Spark plug cap 1 Disconnect.
2 Spark plug 1
3 Cylinder head breather hose 1
4 Camshaft sprocket cover 1
5 Tappet cover 2
6 Oil delivery pipe 2 1
7 Oil check bolt 1
8 Timing chain tensioner cap bolt 1
9 Timing chain tensioner 1
10 Gasket 1
11 Camshaft sprocket 1
5-14
CYLINDER HEAD
Removing the cylinder head

o'1o ., , 20 N·m 2.0 k f·m, 15 lb-ft ..:, 20 N-m (2.0 k f•m, 15 lb-ft)
'"'-· 10 N·m (1.0 kgf•m, 7.4 lb·ft) ,,,, 1O N•m (1.0 kgf·m, 7.4 lb·ft)
,;, 13 N-m (1.3 kgf•m, 9.6 lb-ft)
,,,. 35 N-m (3.5 kgf•m, 26 lb-ft)
-, 10 N•m (1.0 kgf-m, 7 .4 lb·ft)
~t. 20 N•m (2.0 kgf·m, 15 lb·ft) >,, 38 N·m 3.8 k f·m, 28 lb-ft
,,, 2.0 N•m 0.20 k f•m, 1.5 lb·ft
•;, 1O N·m 1.0 k f•m, 7 .4 lb-ft .,,, 10 N-m 1.0 k f·m, 7.4 lb-ft "·,. 1.5 N•m (0.15 kgf·m, 1.1 lb-ft)

12 Decompressor assembly 1
13 Cylinder head 1
14 Cylinder head gasket 1
15 Dowel pin 2
5-15
CYLINDER HEAD
EBS30438
• Camshaft sprocket
REMOVING THE CYLINDER HEAD
• Timing chain
1. Align:
• "I" mark "a" on the AC magneto rotor TIP - - - - - - - - - - - - - - - ~
(with the stationary pointer "b" on the AC To prevent the timing chain from falling into the
magneto cover) crankcase, fasten it with a wire.
a. Turn the crankshaft counterclockwise. 5. Remove:
• Cylinder head
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~
• Loosen the bolts in the proper sequence as
shown.
b '--..:: • 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 com- 2 ),-.

pression stroke, align the "I" mark "c" on
the camshaft sprocket with the stationary
pointer "d" on the cylinder head.
EBS30439
CHECKING THE CYLINDER HEAD

1. Eliminate:
• Combustion chamber carbon deposits
(with a rounded scraper)
EC.00185 1
NOTICE
-------------
2. Loosen: Do not use a sharp instrument; otherwise,
• Camshaft sprocket bolts "1" the following may be damaged or scratched:
• Decompresser assembly bolts "2" • Spark plug bore threads
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~ • Valve seats
While holding the AC magneto rotor nut with a
wrench , loosen the camshaft sprocket bolts and
decompresser assembly bolts.
2. Check:
• Cylinder head
Damage/scratches ~ Replace.
• Cylinder head water jacket
3. Loosen: Mineral deposits/rust ~ Eliminate.
• Timing chain tensioner cap bolt
4. Remove:
• Timing chain tensioner
5-16
CYLINDER HEAD
3. Measure:
• Cylinder head warpage
Out of specification ~ Resurface the cylinder
head.
•
Warpage limit •
'
0.03 mm (0.0012 in)
2
a. Place a straightedge "1" and a thickness
gauge "2" across the cylinder head.
a. 1/4 tooth
b. Correct
1. Timing chain roller
2. Camshaft sprocket
EBS30132
CHECKING THE TAPPET COVERS AND

CAMSHAFT SPROCKET COVER
tappet covers.
1. Check:
• Tappet cover
• Camshaft sprocket cover
Damage/wear ~ Replace.
EBS30435
CHECKING THE TIMING CHAIN TENSIONER

1. Check:
e Cracks/damage ~ Replace.
2. Check:
b. Measure the warpage. • One-way cam operation
c. If the limit is exceeded, resurface the cylin- Rough movement ~ Replace the timing
der head as follows. chain tensioner.
d. Place a 400-600 grit wet sandpaper on 3. Check:
the surface plate and resurface the cylin- • Timing chain tensioner cap bolt
der head using a figure-eight sanding pat- • Spring
tern . • One-way cam
TIP ~~~~~~~~~~~~~~ • Timing chain tensioner rod
To ensure an even surface, rotate the cylinder Damage/wear ~ Replace the defective
head several times. part(s).
EBS30434
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
set.
5-17
CYLINDER HEAD
EBS30440
d. Align the "I" mark "c" on the camshaft
INSTALLING THE CYLINDER HEAD
sprocket with the stationary pointer "d" on
1. Install: the cylinder head.
• Cylinder head gasket l~c:M e. Install the timing chain "2" onto the cam-
• Dowel pins shaft sprocket "3", and then install the
2. Install: camshaft sprocket onto the camshaft, and
• Cylinder head then finger tighten the camshaft sprocket
• Cylinder head bolts bolts "4".
Cylinder head bolt "1 "
35 N,m (3.5 kgf,m, 26 lb,ft)
Cylinder head bolt "2"
35 N,m (3.5 kgf,m, 26 lb,ft)
38 N,m (3.8 kgf,m, 28 lb,ft)
1O N,m (1.0 kgf,m, 7.4 lb,ft)
Cylinder head bolts "1"

Length: 135 mm (5.31 in)
Cylinder head bolts "2" d -_ 4
Length: 145 mm (5.71 in)
TIP~~~~~~~~~~~~~~~
• Lubricate the cylinder head bolt "1" and "2"

threads and mating surface with molybdenum
disulfide grease.
• Lubricate the cylinder head bolts "3" threads 4
>
3
and mating surface with engine oil.
• Tighten the cylinder head bolts in the proper
tightening sequence as shown and torque TIP~~~~~~~~~~~~~~~
them in two stages. When installing the camshaft sprocket, be sure
to keep the timing chain as tight as possible on
the exhaust side.
4 ECB01860
NOTICE ~~~~~~~~~~~~
),(3
Do not turn the crankshaft when installing
1 the camshaft to avoid damage or improper
valve timing.
f. Remove the wire from the timing chain.
4 4. Install:
3. Install: a. Remove the timing chain tensioner cap
• Decompresser assembly bolt "1 ", copper washer "2" and spring "3".
• Camshaft sprocket b. Release the timing chain tensioner one-
(onto the camshaft) way cam "4" and push the timing chain
a. Install the decompresser assembly onto tensioner rod "5" all the way into the timing
the camshaft, and then finger tighten the chain tensioner housing.
decompresser assembly bolts "1". c. Install the timing chain tensioner and gas-
b. Turn the crankshaft counterclockwise.
c. Align the "I" mark "a" on the AC magneto ket "6" ·~tm onto the cylinder.
rotor with the stationary pointer "b" on the Timing chain tensioner bolt
AC magneto cover. 1O N,m (1.0 kgf,m, 7.4 lb,ft)
5-18
CYLINDER HEAD
TIP ~~~~~~~~~~~~~~
Install the gasket with its beaded side facing the

timing chain tensioner end.
d. Install the spring, copper washer l~fffi

and timing chain tensioner cap bolt.
Timing chain tensioner cap bolt

20 N,m (2.0 kgf,m, 15 lb,ft)
7. Tighten:
61~t£j • Camshaft sprocket bolts "1"
• Decompressor assembly bolts "2"
21~t£j Camshaft sprocket bolt
1 20 N,m (2.0 kgf,m, 15 lb,ft)
Decompressor assembly bolt
0 20 N,m (2.0 kgf,m, 15 lb,ft)
TIP~~~~~~~~~~~~~~
• While holding the AC magneto rotor nut with a

wrench, tighten the camshaft sprocket bolts
and decompressor assembly bolts.
• After tightening the decompressor assembly
bolts, check that decompressor assembly
moves smoothly.
5. Turn :
• Crankshaft
(several turns counterclockwise)
6. Check:
• "I" mark "a"
Align the "I" mark on the AC magneto rotor
with the stationary pointer "b" on the AC mag-
neto cover.
• "I" mark "c"
Align the "I" mark on the camshaft sprocket
with the stationary pointer "d" on the cylinder
head.
Out of alignment ~ Correct.
Refer to the installation steps above.
8. Measure:
• Valve clearance
Refer to "ADJUSTING THE VALVE CLEAR-
ANCE" on page 3-4.
5-19
ROCKER ARMS AND CAMSHAFT
EBS20036
ROCKERARMSANDCAMSHA~
Removing the rocker arms and camshaft
·, 14 N·m 1.4 k f·m, 10 lb·ft
~.,, 14 N·m (1.4 kgf·m, 1O lb-ft) «::!JC-- 5

3
1---_6
5 5
Cylinder head Refer to "CYLINDER HEAD" on page 5-14.

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
7 Camshaft 1
8 Decompressor lever 1
9 Decompressor lever pin 1
10 Bearing 1
5-20
EBS30136
REMOVING THE ROCKER ARMS AND

CAMSHAFT
1. Loosen:
• Locknuts
• Valve clearance adjusting screws
2. Remove:
• Intake rocker arm shaft
• Exhaust rocker arm shaft
• Intake rocker arm
• Exhaust rocker arm 3. Measure:
TIP ~~~~~~~~~~~~~~~
• Camshaft runout
Remove the rocker arm shafts with the slide Out of specification ~ Replace the camshaft.
hammer bolt "1" and weight "2".
Camshaft runout limit
0.015 mm (0.0006 in)
Slide hammer bolt (M6)
90890-01083
YU-01083-1
Weight
I
90890-01084
Weight
YU-01083-3
EBS-10138
CHECKING THE DECOMPRESSION SYSTEM

1. Check:
• Decompression system
a. Check the decompression system with the
camshaft sprocket installed on the decom-
pressor lever and pin installed in the cam-
EBS30433 shaft.
CHECKING THE CAMSHAFT b. Check that the decompressor lever pin "1"
1. Check: projects from the camshaft.
• Camshaft lobes c. Check that the decompressor cam "2"
Blue discoloration/pitting/scratches ~ Re- moves smoothly.
place the camshaft.
2. Measure: e
• Camshaft lobe dimensions "a"
Out of specification ~ Replace the camshaft.
Camshaft lobe dimensions

Lobe height (Intake) limit
42.885 mm (1.6884 in)
Lobe height (Exhaust) limit
43.390 mm (1.7083 in)
EBS-10139
CHECKING THE ROCKER ARMS AND

ROCKER ARM SHAFTS
rocker arms and rocker arm shafts.
5-21
1. Check:
• Rocker arm Installed depth
Damage/wear ~ Replace. O mm (0 in)
2. Check:
• Rocker arm shaft
Blue discoloration/excessive wear/pitting/
scratches~ Replace or check the lubrication
system.
3. Measure:
• Rocker arm inside diameter
a --i--b
Rocker arm inside diameter limit
12.033 mm (0.4737 in)
b. Installed depth
2. Lubricate:
• Camshaft
• Decompressor lever pin
• Decompressor lever
........ Recommended lubricant

~ l Camshaft
Molybdenum disulfide oil
Camshaft bearing, decompressor
lever pin, decompressor lever
4. Measure: Engine oil
• Rocker arm shaft outside diameter
Out of specification ~ Replace. 3. Install:
• Decompressor lever pin "1"
Rocker arm shaft outside diame- • Decompressor lever "2"
ter limit TIP~~~~~~~~~~~~~~
11.950 mm (0.4705 in)
Install the decompressor lever pin "1" and de-
compressor lever "2" in the camshaft "3" as
3
/_,
2./"F
ESS30140
INSTALLING THE CAMSHAFT AND ROCKER

ARMS 4. Install:
1. Install: • Camshaft "1"
• Bearing "1" TIP ~~~~~~~~~~~~~~
(onto the cylinder head)
Install the camshaft so that the pins "a" become
TIP~~~~~~~~~~~~~~
horizontal.
• Apply engine oil to the bearing.
• Install the bearing so that the seal "a" is facing
the camshaft.
5-22
a
5. Lubricate:
• Rocker arms
• Rocker arm shafts
Recommended lubricant
I
Rocker arm inner surface
Molybdenum disulfide grease
Rocker arm shaft
Engine oil
6. Install:
• Exhaust rocker arm "1"
• Exhaust rocker arm shaft "2"
• Intake rocker arm
• Intake rocker arm shaft
TIP~~~~~~~~~~~~~~
• Use a slide hammer bolt "3" to install the rocker

arm shaft.
• Make sure the rocker arm shafts are complete-
ly pushed into the cylinder head.
Slide hammer bolt (M6)

90890-01083
YU-01083-1
5-23
VALVES AND VALVE SPRINGS
EBS20037

Removing the valves and valve springs
2 1
2
3 3 ~
~ 2
/
3 3
7 7

Refer to "ROCKER ARMS AND CAM-
Rocker arms/Rocker arm shafts/Camshaft
SHAFT' on page 5-20.
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
5-24
ESS30141
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 5-27. • Valve "3"
a. Pour a clean solvent "a" into the intake and • Valve stem seal "4"
exhaust ports. • Valve spring seat "5"
b. Check that the valves properly seal. TIP ~~~~~~~~~~~~~~
TIP ~~~~~~~~~~~~~~~ Identify the position of each part very carefully so

There should be no leakage at the valve seat "1 ". that it can be reinstalled in its original place.
i...___- ...___
-...___
' ®--1
5
®--4
3
1
2. Remove: EBS30142
• Valve cotters CHECKING THE VALVES AND VALVE

GUIDES
TIP ~~~~~~~~~~~~~~~
Remove the valve cotters by compressing the valves and valve guides.
valve spring with the valve spring compressor 1. Measure:
"1" and the valve spring compressor attachment • Valve-stem-to-valve-guide clearance
"2". Out of specification ~ Replace the valve
guide.
Valve spring compressor • Valve-stem-to-valve-guide clearance =
90890-04019 Valve guide inside diameter "a" -
Valve spring compressor Valve stem diameter "b"
YM-04019
Valve spring compressor attach-
ment (026) Valve-stem-to-valve-guide clear-
90890-01243 ance (intake) limit
Valve spring compressor adapt- 0.080 mm (0.0032 in)
er (26 mm) Valve-stem-to-valve-guide clear-
YM-01253-1 ance (exhaust) limit
0.100 mm (0.0039 in)
5-25
c
a. Valve guide position
c. After installing the valve guide, bore the
valve guide with the valve guide reamer
"3" to obtain the proper valve-stem-to-
valve-guide clearance.
2. Replace:
• Valve guide
TIP~~~~~~~~~~~~~~
To ease valve guide removal and installation,

and to maintain the correct fit, heat the cylinder
head to 100 °C (212 °F) in an oven. TIP~~~~~~~~~~~~~~
a. Remove the valve guide with the valve After replacing the valve guide, reface the valve
guide remover "1". seat.
Valve guide remover (06)

90890-04064
Valve guide remover (6.0 mm)
YM-04064-A
Valve guide installer (06)
90890-04065
Valve guide installer (6.0 mm)
YM-04065-A
Valve guide reamer (06)
90890-04066
b. Install the new valve guide with the valve Valve guide reamer (6.0 mm)
guide installer "2" and valve guide remov- YM-04066
er "1".
3. Eliminate:
Valve guide position
• Carbon deposits
12.7-13.1 mm (0.50-0.52 in)
(from the valve face and valve seat)
4. Check:
• Valve face
Pitting/wear ~ Grind the valve face.
• Valve stem end
Mushroom shape or diameter larger than the
body of the valve stem ~ Replace the valve.
5-26
5. Measure:
• Valve stem runout
Out of specification ~ Replace the valve.
TIP ~~~~~~~~~~~~~~
• When installing a new valve, always replace

the valve guide. a
• If the valve is removed or replaced, always re-
place the valve stem seal.
Valve stem runout

a. Apply blue layout fluid "b" onto the valve
0.040 mm (0.0016 in)
face.
//
EBS30143
b. Install the valve into the cylinder head.
CHECKING THE VALVE SEATS c. Press the valve through the valve guide
The following procedure applies to all of the and onto the valve seat to make a clear
. .
valves and valve seats. 1mpress1on.
1. Eliminate: d. Measure the valve seat width .
• Carbon deposits TIP~~~~~~~~~~~~~~
(fram the valve face and valve seat) Where the valve seat and valve face contacted
2. Check: one another, the blue layout fluid will have been
• Valve seat removed.
Pitting/wear ~ Replace the cylinder head.
4. Lap:
3. Measure:
• Valve face
• Valve seat width C "a"
• Valve seat
Out of specification ~ Replace the cylinder
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
head.
After replacing the cylinder head or replacing the
Valve seat contact width (intake) valve and valve guide, the valve seat and valve
1.00-1.20 mm (0.0394-0.0472 in) face should be lapped.
Valve seat contact width (intake)
limit a. Apply a coarse lapping compound "a" to
1.6 mm (0.06 in) the valve face.
Valve seat contact width (ex- EC B01360
haust) NOTICE
-------------
1.00-1.20 mm (0.0394-0.0472 in) Do not let the lapping compound enter the
Valve seat contact width (ex- gap between the valve stem and the valve
haust) limit guide.
1.6 mm (0.06 in)
5-27
a b
b. Apply molybdenum disulfide oil onto the h. Install the valve into the cylinder head.
valve stem. i. Press the valve through the valve guide
and onto the valve seat to make a clear
. .
1mpress1on.
j. Measure the valve seat width "c" again. If
the valve seat width is out of specification,
reface and lap the valve seat.
c. Install the valve into the cylinder head.

d. Turn the valve until the valve face and
valve seat are evenly polished, then clean
off all of the lapping compound.
TIP~~~~~~~~~~~~~~
For the best lapping results, lightly tap the valve EBS30144
CHECKING THE VALVE SPRINGS

seat while rotating the valve back and forth be-
tween your hands.
valve springs.
1. Measure:
• Valve spring free length "a"
Out of specification ~ Replace the valve
.
spring.
Free length (intake)

40.38 mm (1.59 in)
Limit
\\ 0 ~ 35.00 mm (1.38 in)
~\....: Free length (exhaust)
40.38 mm (1.59 in)
e. Apply a fine lapping compound to the Limit
valve face and repeat the above steps. 35.00 mm (1.38 in)
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply blue layout fluid "b" onto the valve
face.
5-28
I'\ TIP ~~~~~~~~~~~~~~

I
• Make sure each valve is installed in its original
place.
I , I , I , , I , I , I , I
I I I
'/ • Install the valve springs with the larger pitch "a"
r facing up.
~r -I - r,
,\
-
~
- ·----
I - ---.._
\ ., ----- '
' ..
~ ~ u u
-.. I'
EBS30145
INSTALLING THE VALVES I'

valves and related components.
I.__
'
4
3
1. Deburr: -----
• Valve stem end
(with an oil stone)
b. Smaller pitch
2. Lubricate:
• Valve stem "1" 4. Install:
• Valve cotters
• Valve stem seal "2" l~fffi
TIP ~~~~~~~~~~~~~~~~
(with the recommended lubricant)
Install the valve cotters by compressing the
I Recommended lubricant valve spring with the valve spring compressor
Molybdenum disulfide oil "1" and the valve spring compressor attachment
"2".

90890-04019
YM-04019
Valve spring compressor attach-
ment (026)
90890-01243
Valve spring compressor adapt-
er (26 mm)
3. Install: YM-01253-1
• Valve spring seat "1"
• Valve stem seal "2" l~~ll !fij"'Q"J
• Valve "3"
• Valve spring "4"
• Valve spring retainer "5"
(into the cylinder head)
5-29
5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
ECB01370
NOTICE
- - - - - - - - - - - -
Hitting the valve tip with excessive forc.e
could damage the valve.
5-30
CYLINDER AND PISTON
EBS20038
CYLINDER AND PISTON

Removing the cylinder and piston
1
,. 10 N·m (1.0 kgf·m, 7.4 lb·ft)
8 7
9
10 31~f:M
·~· 5
m·~ms

Water jacket joint Refer to "WATER PUMP" on page 6-8.
1 Timing chain guide (exhaust side) 1
2 Cylinder 1
3 Cylinder gasket 1
4 Dowel pin 2
5 Piston pin clip 2
6 Piston pin 1
7 Piston 1
8 Top ring 1
9 2nd ring 1
10 Oil ring 1
5-31
CYLINDER AND PISTON
EBS30146
TIP -~~~~~~~~~~~~~
REMOVING THE PISTON
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"
ECB01380
NOTICE
-------------
Do not use a hammer to drive the piston pin
out.
I
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- EBS30147
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
YU-01304 • Piston-to-cylinder clearance
a. Measure cylinder bore with the cylinder
bore gauge.
,,
' ------ --
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
------x3 2 Measure cylinder bore "C" by taking side-to-side
"' .. and front-to-back measurements of the cylinder.
Bore
102.000-102.010 mm (4.0157-
4.0161 in)
Wear limit
4 102.060 mm (4.0181 in)
2. Remove:
• Top ring
• 2nd ring
b. If out of specification, replace the cylinder,
• Oil ring
and replace the piston and piston rings as
a set.
5-32
CYLINDER AND PISTON
c. Measure piston skirt diameter "P" with the

micrometer. Top ring
Ring side clearance
Piston skirt diameter 0.030-0.070 mm (0.0012-0.0028
101.955-101.970 mm (4.0140- in)
4.0146 in) Ring side clearance limit
0.120 mm (0.0047 in)
2nd ring
Ring side clearance
a 0.030-0.070 mm (0.0012-0.0028
in)
Ring side clearance limit
.. 1 0.130 mm (0.0051 in)
p
a. 10 mm (0.39 in) from the bottom edge of the

piston
d. If out of specification, replace the piston

and piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
• Piston-to-cylinder clearance = 2. Install:
Cylinder bore "C" - Piston skirt diameter "P" • Piston ring
(into the cylinder)
TIP~~~~~~~~~~~~~~~
Piston-to-cylinder clearance
0.030-0.055 mm (0.0012-0.0022 Use the piston crown to level the piston ring near
in) bottom of cylinder "a" where cylinder wear is low-
est.
f. If out of specification, replace the cylinder,
and replace the piston and piston rings as
a set. .,,,..,---- -., a
/ '
EBS30148
CHECKING THE PISTON RINGS

1. Measure:
• Piston ring side clearance
Out of specification ~ Replace the piston I
I
and piston rings as a set.
TIP~~~~~~~~~~~~~~~
Before measuring the piston ring side clearance, 3. Measure:
~---- b
eliminate any carbon deposits from the piston • Piston ring end gap
ring grooves and piston rings. Out of specification ~ Replace the piston
.
nng.
TIP ~~~~~~~~~~~~~~~
The oil ring expander spacer end gap cannot be

measured. If the oil ring rail gap is excessive, re-
place all three piston rings.
5-33
CYLINDER AND PISTON
EBS30150
Top ring INSTALLING THE PISTON AND CYLINDER

End gap (installed) 1. Install:
0.20-0.35 mm (0.008-0.014 in) • Lower oil ring rail "1"
End gap (installed) limit • Oil ring expander "2"
0.60 mm (0.0236 in) • Upper oil ring rail "3"
2nd ring • 2nd ring "4"
End gap (installed) • Top ring "5"
0.75-0.90 mm (0.03-0.04 in)
TIP ~~~~~~~~~~~~~~
End gap (installed) limit
1.25 mm (0.0492 in) Be sure to install the piston rings so that the
manufacturer's marks "a" face up.
ESS30149
CHECKING THE PISTON PIN a

1. Check:
• Piston pin
Blue discoloration/grooves ~ Replace the
piston pin and then check the lubrication sys-
tem.
2. Measure: 4
• Piston pin outside diameter "a"
Out of specification ~ Replace the piston pin.
Piston pin outside diameter limit 2. Install:

22.971 mm (0.9044 in) • Piston "1"
• Piston pin "2"
• Piston pin clips "3" l~fffi
TIP ~~~~~~~~~~~~~~~
• Apply engine oil to the piston pin.

/ • Make sure the punch mark "a" on the piston
points towards the exhaust side of the cylinder.
• Before installing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
the clips from falling into the crankcase.
a
3. Measure:
• Piston pin bore diameter "b" 1
Out of specification ~ Replace the piston.
Piston pin bore inside diameter

limit
23.045 mm (0.9073 in) 2
0--3 ,~m
3. Install:
• Cylinder gasket l~fffi
J • Dowel pins
4. Lubricate:
• Piston
• Piston rings
• Cylinder
5-34
CYLINDER AND PISTON
Recommended lubricant Cylinder bolt

I
Engine oil 1st
15 N,m (1.5 kgf,m, 11 lb,ft)
5. Offset: 2nd
• Piston ring end gaps 50 N,m (5.0 kgf,m, 37 lb,ft)
Cylinder bolt (timing chain side)
1O N,m (1.0 kgf,m, 7.4 lb,ft)
e 120° a
-1
d~ 45°
1 Gl
A
a. Top ring
b. Oil ring expander 2
c. Upper oil ring rail
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.
• Pass the timing chain and timing chain guide
(exhaust side) through the timing chain cavity.
7. Install:
• Cylinder bolts "1"
TIP ~~~~~~~~~~~~~~~
Lubricate the cylinder bolt "1" threads and mat-
ing surface with engine oil.
8. Tighten:
• Cylinder bolts "1"
• Cylinder bolts (timing chain side) "2"
5-35
AC MAGNETO AND STARTER CLUTCH
EBS20039
-
B '
;,;_ 30 N·m (3.0 kgf·m, 22 lb·ft)

,.. 60 N-m (6.0 kgf·m, 44 lb-ft)
Drain.
Engine oil Refer to "CHANGING THE ENGINE Oil.'.' on
page 3-22.
Drain.
Coolant Refer to "CHANGING THE COOLANT' on
page 3-27.
4-11 .
Refer to "ENGINE REMOVAL (2)" on page
Drive select lever unit
5-8.
Water pump cover Refer to "WATER PUMP" on page 6-8.
1 Oil delivery pipe 1 1
2 AC magneto coupler 1 Disconnect.
3 Crankshaft position sensor coupler 1 Disconnect.
4 Lead holder bracket 1
5-36
11
12
-
B '
t:._ 30 N•m (3.0 kgf·m, 22 lb·ft)

,,, 60 N-m (6.0 kgf·m, 44 lb-ft)
5 AC magneto cover 1
6 AC magneto cover gasket 1
7 Dowel pin 2
8 Lead holder 1
9 Crankshaft position sensor 1
10 Stator coil 1
11 Torque limiter 1
12 Starter idle gear 1
13 Starter idle gear shaft 1
5-37
bi , -
m 17
•
,
t(J
/ ~ "
'-
~
-
B '
t:._ 30 N•m (3.0 kgf·m, 22 lb·ft)

,,, 60 N-m (6.0 kgf·m, 44 lb-ft)
14 AC magneto rotor 1
15 Starter clutch 1
16 Woodruff key 1
17 Starter wheel gear 1
18 Washer 1
5-38
EBS30151
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
REMOVING THE AC MAGNETO ROTOR
1. Remove: • Use the flywheel puller "2".
• Lead holder bracket "1" • Install the flywheel puller bolts to the threaded
• AC magneto cover holes of the starter clutch .
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ • Make sure the flywheel puller is centered over
the AC magneto rotor.
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. Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B
2. Remove:
• AC magneto rotor nut "1"
• Washer
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ EBS30152
REMOVING THE STARTER CLUTCH

Hold the AC magneto rotor "2" with the rotor
1. Remove:
holding tool "3" while loosening the AC magneto
• Starter clutch bolts "1"
rotor nut.
TIP ~ - - - - - - - - - - - - ~
Rotor holding tool
90890-04166 holding tool "3" while removing the starter clutch
Rotor holding tool bolts.
YM-04166
Rotor holding tool
90890-04166
Rotor holding tool
YM-04166
~
3. Remove:
• AC magneto rotor "1"
(with the starter clutch)
• Woodruff key
ECB01390 EBS30890
NOTICE CHECKING THE STATOR COIL AND

------------ CRANKSHAFT POSITION SENSOR
To protect the end of the crankshaft, place an
appropriate sized socket between the fly- 1. Check:
wheel puller set center bolt and the crank- • Stator coil "1"
shaft.
5-39
• Crankshaft position sensor "2" EBS30154
CHECKING THE TORQUE LIMITER

Damage ~ Replace the crankshaft position
sensor/stator assembly. 1. Check:
• Torque limiter
TIP ~~~~~~~~~~~~~~
Do not disassemble the torque limiter.

1
EBS30155
INSTALLING THE STARTER CLUTCH

1. Install:
• Starter clutch
• Starter clutch bolts "1"
EBS30153
Starter clutch bolt
CHECKING THE STARTER CLUTCH 30 N,m (3.0 kgf,m, 22 lb,ft)
1. Check: LOCTITE®
• Starter clutch rollers
Damage/wear ~ Replace. TIP ~~~~~~~~~~~~~~~
2. Check:
While holding the AC magneto rotor "2" with the
• Starter idle gear
rotor holding tool "3", tighten the starter clutch
• Starter wheel gear
bolts.
Burrs/chips/roughness/wear ~ Replace the
defective part(s).
3. Check: Rotor holding tool
• Starter clutch gear contact surfaces 90890-04166
Damage/pitting/wear ~ Replace the defec- Rotor holding tool
YM-04166
tive part(s).
4. Check:
• Starter clutch operation
a. Install the starter wheel gear onto the
starter clutch , and then hold the starter
clutch .
b. When turning the starter wheel gear coun-
terclockwise "A", the starter clutch and the
starter wheel gear should engage; other-
wise, the starter clutch is faulty and must
be replaced.
c. When turning the starter wheel gear clock- EBS30891
wise "B", it should turn freely; otherwise, INSTALLING THE AC MAGNETO
the starter clutch is faulty and must be re- 1. Install:
placed. • Stator coil "1"
Stator coil assembly bolt

7 N,m (0.7 kgf,m, 5.2 lb,ft)
LOCTITE®
TIP~~~~~~~~~~~~~~~
A
Align the projection "a" on the stator coil with the
slot "b" in the AC magneto cover.
5-40
Rotor holding tool

90890-04166
(/ Rotor holding tool
YM-04166
2. Apply:
• Sealant "1"
(onto the crankshaft position sensor/stator
assembly lead grommet)
Yamaha bond No. 1215

90890-85505 5. Install:
(Three bond No.1215®) • AC magneto cover
• Lead holder bracket "1"
• AC magneto cover bolts
AC magneto cover bolt

10 N,m (1.0 kgf,m, 7.4 lb,ft)
TIP~~~~~~~~~~~~~~
• Align the projection "a" on the oil pump with the

slot "b" in the impeller shaft.
• Tighten the AC magneto cover bolts in stages,
using a crisscross pattern.
3. Install:
• Woodruff key
• AC magneto rotor
• Washer
• AC magneto rotor nut
TIP ~~~~~~~~~~~~~~
• Clean the tapered portion of the crankshaft and

the AC magneto rotor hub.
• When installing the AC magneto rotor, make b
sure the woodruff key is properly seated in the
keyway of the crankshaft.
4. Tighten:
• AC magneto rotor nut "1"
AC magneto rotor nut

60 N,m (6.0 kgf,m, 44 lb,ft)
TIP~~~~~~~~~~~~~~

holding tool "3" while tightening the AC magneto
rotor nut.
5-41
ELECTRIC STARTER
EBS20040
ELECTRIC STARTER
Removing the starter motor
.,. 10 N•m 1.0 k f-m, 7.4 lb·ft
, ..· 11 N·m (1.1 kgf·m, 8.1 lb·ft)
~------- 2
',
•'
'
'
,,
•' '
''
' '
' ' ••'
' '
' ' '
' '•

Muffler
5-4.
1 Starter motor lead 1 Disconnect.
2 Ground lead 1 Disconnect.
3 Starter motor 1
5-42
ELECTRIC STARTER
Disassembling the starter motor
~ r~.1 11 N•m (1.1 kgf•m, 8.1 lb·ft) I

@_@ 0
~ 2
,
,
,'
,', ,
''
',,
',
j
3
,
,'
''
.. .. .. 0
'
'
' '
' '
' ',,,'',,, ,
' ,
'
','
4
1~ --J
'
, 5 N·m (0.5 kgf·m, 3.7 lb·ft)
1 Starter motor front cover 1

2 Starter motor rear cover 1
3 Brush holder set 1
4 Armature assembly 1
5 Starter motor yoke 1
5-43
ELECTRIC STARTER
EBS30157
CHECKING THE STARTER MOTOR

1. Check: rm-11
~
• Commutator <== o>
Dirt ~ Clean with 600 grit sandpaper.
2. 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.
Mica undercut (depth) 4. Measure:

0.70 mm (0.03 in) • Brush length "a"
Out of specification ~ Replace the brushes
TIP ~~~~~~~~~~~~~~ as a set.
The mica of the commutator must be undercut to Brush overall length limit
ensure proper operation of the commutator. 6.50 mm (0.26 in)
I
• • • •
3. Measure:
• Armature assembly resistance (commutator) 5. Measure:
Out of specification ~ Replace the starter • Brush spring force
motor. Out of specification ~ Replace the brush
a. Measure the armature assembly resis- springs as a set.
tance with the digital circuit tester. Brush spring force
6.03-6.52 N (615-665 gf, 21.71-
90890-03243 23.47 oz)
Model 88 Multimeter with ta-
chometer
YU-A1927
Armature coil
Commutator resistance "1"
0.0050-0.0150 Q at 20 °c (68 °F)
b. If any resistance is out of specification, re-

place the starter motor.
6. Check:
• Gear teeth
Damage/wear ~ Replace the gear.
7. Check:
• Bearing
5-44
ELECTRIC STARTER
• Oil seal
Damage/wear ~ Replace the defective
part(s).
EBS30158
ASSEMBLING THE STARTER MOTOR

1. Install:
• Starter motor yoke "1"
• Starter motor front cover "2"
• Starter motor rear cover "3"
TIP ~~~~~~~~~~~~~~~
Align the alignment marks "a" on the starter mo-

tor yoke with the match marks "b" on the front
and starter motor rear covers.
b-\ b -
A 1
0
~
\
/ ~ I )
!O
' ~
2
7 1
\3
5-45
BALANCER GEARS AND OIL PUMP GEARS
EBS20041

Removing the balancer gears and oil pump gears
'< 85 N•m (8.5 kgf-m, 63 lb·ft)
5
4
2
1
~
~ •-, 22 N•m (2.2 kgf-m, 16 lb·ft)
Gl
12
)
10
11 9

Refer to "AC MAGNETO AND STARTER
Starter wheel gear
CLUTCH" on page 5-36.
1 Lock washer 1
2 Balancer driven gear 1
3 Oil pump drive gear 1
4 Collar 1
5 Chain 1
6 Straight key 1
7 Lock washer 1
8 Oil pump driven gear 1
9 Plate 1
10 Spring 8
11 Pin 4
12 Balancer drive gear 1
5-46
EBS30892
REMOVING THE BALANCER DRIVEN GEAR

AND OIL PUMP DRIVEN GEAR
1. Straighten the lock washer tabs.
2. Loosen:
• Balancer driven gear nut "1"
• Oil pump driven gear nut "2"
TIP ~~~~~~~~~~~~~~~
Place an aluminum plate "3" between the teeth

of the balancer drive gear "4" and balancer driv-
en gear "5", then loosen the nuts. 2. Install:
• Balancer drive gear "1"
• Balancer driven gear "2"
• Oil pump driven gear "3"
TIP ~~~~~~~~~~~~~~
• Align the punch mark "a" on the balancer drive

gear with the punch mark "b" on the balancer
driven gear.
• Install the oil pump driven gear with the "384"
mark "c" facing out.
EBS30893
CHECKING THE OIL PUMP DRIVE

1. Check:
• Oil pump drive gear
• Oil pump driven gear
Cracks/wear/damage ~ Replace.
EBS30894
CHECKING THE BALANCER DRIVE

1. Check:
• Balancer drive gear 3. Install:
• Balancer driven gear
• Lock washers l~f:M
Damage/wear ~ Replace the balancer drive
• Oil pump driven gear nut "1"
gear and balancer driven gear as a set.
• Balancer driven gear nut "2"
Excessive noise during operation ~ Replace
the balancer drive gear and balancer driven Oil pump driven gear nut
gear as a set. 22 N,m (2.2 kgf,m, 16 lb,ft)
Balancer driven gear nut
EBS30895
85 N,m (8.5 kgf,m, 63 lb,ft)
INSTALLING THE BALANCER DRIVE GEAR,
BALANCER DRIVEN GEAR, AND OIL PUMP
TIP ~~~~~~~~~~~~~~
DRIVEN GEAR
1. Install: • Place an aluminum plate "3" between the teeth
• Pin of the balancer drive gear "4" and balancer
• Spring driven gear "5", then tighten the nuts.
• Balancer drive gear • Apply the engine oil to the thread of axles and
(onto the buffer boss) nuts.
TIP ~~~~~~~~~~~~~~~
Align the punch mark "a" on the balancer drive

gear with the hole "b" to the buffer boss.
5-47
4. Bend the lock washer tabs along the balancer

driven gear nut and oil pump driven gear nut.
5-48
PRIMARY AND SECONDARY SHEAVES
EBS20043

Removing the primary and secondary sheaves
"'-. 10 N•m (1.0 kgf-m, 7 .4 lb-ft)
'
11 1~m \\
- 21~m '
101~m
, /J 6
'
'
, 140 N·m 14 k f·m, 103 lb·ft

3
100 N·m 10 k f·m, 74 lb·ft
,.-, 1O N·m (1.0 kgf·m, 7.4 lb-ft) •,

0
10 N•m (1.0 kgf•m, 7.4 lb-ft)
Front fender (right)/Rear fender Refer to "GENERAL CHASSIS (3)" on page

4-8.
Footrest board (right) Refer to "GENERAL CHASSIS (4)" on page

4-11 .
V-belt cooling ducts Refer to "ENGINE REMOVAL (1 )" on page

5-4.
1 Drive belt cover 1
2 Rubber gasket 1
3 Bearing housing 1
4 Dowel pin 2
5 Primary sheave assembly 1
6 V-belt 1
7 Primary fixed sheave 1
8 Secondary sheave assembly 1
9 Drive belt case 1
10 Rubber gasket 1
11 Rubber gasket 1
5-49
Disassembling the primary sheave
s i~M 7
Bl~fii
s•~tu
2~
1 J'· 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
* Apply Yamaha Grizzly grease.
1 Primary sheave cap 1

2 Primary sheave slider 4
3 Primary sheave cam 1
4 Primary sheave weight 8
5 Collar 1
6 Oil seal 2
7 Primary sliding sheave 1
8 0-ring 1
5-50
Disassembling the secondary sheave
8- -J
'
5
11~m
91~t£i 4
2
, 90 N·m (9.0 kgf·m, 66 lb·ft)
1
* Apply BEL-RAY assembly lube®.
1 Nut 1
2 Spring seat 1
3 Compression spring 1
4 Spring seat 1
5 Guide pin 4
6 Secondary sliding sheave 1
7 0-ring 2
8 Secondary fixed sheave 1
9 Oil seal 2
5-51
ESS301 67 EBS30168
REMOVING THE PRIMARY AND DISASSEMBLING THE SECONDARY

SECONDARY SHEAVES SHEAVE
1. Loosen: 1. Remove:
• Primary sheave assembly nut "1" • Nut "1"
TIP ~~~~~~~~~~~~~~ a. Attach the sheave fixed block "2", locknut
Use the rotor holding tool "2" to hold the primary wrench "3" and sheave spring compressor
sheave. "4" to the secondary sheave assembly.
Sheave fixed block

Rotor holding tool 90890-04135
90890-04166 Sheave fixed bracket
Rotor holding tool YM-04135
YM-04166 Locknut wrench
90890-01348
Locknut wrench
YM-01348
90890-04134
YM-04134
b. Place the sheave fixed block in a vise and

secure it.
c. Tighten the sheave spring compressor nut
2. Loosen: "5" and compress the spring.
d. Loosen the nut "1" with the locknut wrench
• Secondary sheave assembly nut "1"
"3".
TIP ~~~~~~~~~~~~~~
e. Remove the nut "1 ".
Use the extension handle "2" and secondary f. Remove the sheave spring compressor
sheave holding tool "3" to hold the secondary and locknut wrench.
sheave.
~
Secondary sheave holding tool
(53mm) 4 5
1
90890-04186
Secondary sheave holding tool 3
(53mm)
YM-04186
Extension handle : :
90890-04187 II I. I.
Extension handle .I i' !i
YM-04187
5-52
EBS30171
EBS30169
CHECKING THE V-BELT CHECKING THE PRIMARY SHEAVE

1. Check: WEIGHTS
• V-belt "1" The following procedure applies to all of the pri-
Cracks/damage/wear ~ Replace. mary sheave weights.
Grease/oil ~ Clean the primary and second- 1. Check:
ary sheave. • Primary sheave weight
2. Measure: Cracks/damage/wear ~ Replace.
• V-belt width "a" 2. Measure:
Out of specification ~ Replace. • Primary sheave weight outside diameter "a"
V-belt width limit
31.3 mm (1.23 in) Primary sheave weight outside
diameter
30 mm (1.16 in)
2 Limit
a 29.5 mm (1.16 in)
2. Plastic board
3. Ruler
EBS30170
CHECKING THE PRIMARY SHEAVE EBS30172
1. Check: CHECKING THE PRIMARY SHEAVE

• Primary sliding sheave splines SLIDERS
Wear/cracks/damage ~ Replace. The following procedure applies to all of the pri-
• Primary sheave cam mary sheave sliders.
Cracks/damage ~ Replace. 1. Check:
2. Check: • Primary sheave slider
• Primary sliding sheave Cracks/damage/wear ~ Replace.
• Primary fixed sheave
EBS30173
Cracks/damage ~ Replace. CHECKING THE SECONDARY SHEAVE
1. Check:
• Secondary fixed sheave
• Secondary sliding sheave
Cracks/damage/wear ~ Replace the sec-
ondary fixed and sliding sheaves as a set.
5-53
2. Check:
• Torque cam grooves "1"
Damage/wear ~ Replace the secondary
1 4
fixed and sliding sheaves as a set. 3
3. Check:
• Guide pins "2"
•
Damage/wear ~ Replace the secondary
fixed and sliding sheaves as a set.
2. Install:
• Oil seals "1" l~Um
Installed depth "a"
O mm (0 in)
2
4. Check:
• Secondary sheave spring
Damage ~ Replace. a -i-.--,
5. Measure:
• Secondary sheave spring free length "a"
Out of specification ~ Replace the second-
ary sheave spring. 11~00 11~m
Free length 2. Primary sliding sheave
130.6 mm (5.14 in)
Limit 3. Install:
128.0 mm (5.04 in) • Primary sheave weights "1"
TIP ~~~~~~~~~~~~~~
• Apply Yamaha Grizzly grease (90 g) to the

whole outer surface of the weights and install.
• Apply Yamaha Grizzly grease (2.5 g) to the in-
ner surface of the collar.
• Apply Yamaha Grizzly grease (2.5 g) to the in-
ner surface of the primary sliding sheave.
ESS30174
ASSEMBLING THE PRIMARY SHEAVE

1. Clean :
• Primary sliding sheave "1"
• Primary fixed sheave "2"
• Collar "3"
• Primary sheave weights "4"
• Primary sliding sheave cam face EBS30175
TIP~~~~~~~~~~~~~~
ASSEMBLING THE SECONDARY SHEAVE
1. Install:
Remove any excess grease.
• Oil seals "1" l~Um
5-54
Installed depth "a" Recommended lubricant

I BEL-RAY assembly lube®
O mm (0 in)
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
11~m _ 1_1:~t
,. _._,:wJ - ~ -1::F"'~~~ Apply BEL-RAY assembly lube® (5.0 g) to the
r··-1
'"=. - - - - - - -"""- 'a guide pin grooves.
- - -8 - --
2
I \
2. Secondary sliding sheave
--
2. Lubricate:
• Secondary sliding sheave "1"
• Secondary fixed sheave "2" 6. Install:
(with the recommended lubricant) • Spring seat
• Compression spring
I Recommended lubricant • Spring seat
BEL-RAY assembly lube®
• Nut
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ a. Attach the sheave fixed block, locknut
wrench and sheave spring compressor to
Apply BEL-RAY assembly lube® (15 g) to the in- the secondary sheave.
ner surface of the secondary fixed sheave.
Sheave fixed block
90890-04135
1 2 Sheave fixed bracket
YM-04135
Locknut wrench
0
90890-01348
Locknut wrench
0
' YM-01348
90890-04134
3. Install: YM-04134
• Secondary sliding sheave
4. Install: b. Place the sheave fixed block in a vise and
• Guide pins "1" secure it.
c. Tighten the sheave spring compressor nut
"1" and compress the spring.
1
d. Install the nut "2" and tighten it to the spec-
ified torque using the locknut wrench .
Nut
90 N,m (9.0 kgf,m, 66 lb,ft)
5. Lubricate:
• Guide pin grooves "1"
5-55
; ~ 1.0 mm (0.04 in)

~
I..
Illl!\MmW~~(
..
fo~~ in)
:1 45 mm 1.77 in
•• 1 .. .. 3
11' II
I• •iM-<!'\ I.
t>-n , I
2. Check:
e. Remove the sheave spring compressor,
locknut wrench, and sheave fixed block. • Primary sheave weights position
Out of specification ~ Repeat step (1 ).
EBS30176
TIP~~~~~~~~~~~~~~
INSTALLING THE PRIMARY AND
To check that the primary sheave weights "1"
SECONDARY SHEAVES
are installed correctly, make sure that the sec-
1. Install:
ondary sheave "2", primary sheave "3", and V-
• Secondary sheave
belt "4" are positioned as shown in the illustra-
• V-belt
tion.
• Primary sheave
TIP ~~~~~~~~~~~~~~
• Be sure to push in the primary sheave cam "1"

when installing the primary sheave so that the
primary sheave weights "2" will be properly po- 2
sition "a".
• Tightening the bolts "3" will push the secondary
sliding sheave away, causing the gap between ~ 4
the secondary fixed and sliding sheaves to
widen . 3
1
• Install the V-belt so that its arrow points in the
direction of rotation as shown in the illustration.
2
1
1
2 A. Correct position
a B. Incorrect position
5-56
3. Tighten:
• Secondary sheave assembly nut "1"
~ Secondary sheave assembly nut

e-'~ 140 N,m (14 kgf,m, 103 lb,ft)
TIP ~~~~~~~~~~~~~~
Use the extension handle "2" and secondary

sheave holding tool "3" to hold the secondary
sheave, and then tighten the secondary sheave
assembly nut.

(53mm)
90890-04186
(53mm)
YM-04186
Extension handle
90890-04187
Extension handle
YM-04187
4. Tighten:
• Primary sheave assembly nut "1"
~ Primary sheave assembly nut

e-'~ 100 N,m (10 kgf,m, 74 lb,ft)
TIP ~~~~~~~~~~~~~~
Use the rotor holding tool "2" to hold the primary

sheave.
Rotor holding tool

90890-04166
Rotor holding tool
YM-04166
5-57
CLUTCH
EBS20044
CLUTCH
Removing the clutch
1;, 1O N·m 1.0 k f·m, 7.4 lb·ft
.,;, 190 N·m (19 kgf·m, 140 lb·ft)
-. 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Primary sheave/Secondary sheave
1 Clutch housing assembly 1
2 Gasket 1
3 Dowel pin 2
4 Nut 1
5 Clutch carrier assembly 1
5-58
CLUTCH
Disassembling the clutch housing assembly
s i~twJ
7
i~t¥1 4
5
3
21~-
11
1 r.1~"fl!!lij"ful
1 Oil seal 1
2 Circlip 1
3 Bearing housing 1
4 Circlip 1
5 Bearing 1
6 Seal ring 1
7 One-way clutch bearing 1
8 Bearing 1
9 Clutch housing 1
5-59
CLUTCH
EBS301n EBS30178
REMOVING THE CLUTCH CHECKING THE CLUTCH

• Clutch housing assembly • Clutch housing
• Gasket Damage/wear ~ Replace.
• Dowel pins • One-way clutch bearing
TIP ~~~~~~~~~~~~~~ Chafing/wear/damage ~ Replace.
Working in crisscross pattern, loosen each bolt TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
1/4 of a turn . Remove them after all of them are • Replace the one-way clutch assembly and
loosened. clutch housing as a set.
• The one-way clutch bearing must be installed
1 0 /
with the flange side facing in.
2. Check:
~ @<=~~c • One-way clutch operation
'v O) ;/; ~ --
a. Install the one-way clutch bearing and
clutch carrier assembly to the clutch hous-
0@ 1~ ing and hold the clutch carrier assembly.
@2@ @~ b. When turning the clutch housing clock-
~:::::::::o~~~ao-- wise "A", it should turn freely; otherwise,
the one-way clutch assembly is faulty and
2. Straighten: must be replaced.
• Punched portion "a" of the nut "1" c. When turning the clutch housing counter-
3. Remove: clockwise "B", the clutch housing and
• Nut "1" crankshaft should engage; otherwise, the
ECB01710
one-way clutch assembly is faulty and
NOTICE
------------- must be replaced.
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.
\
90890-04086
Universal clutch holder EBS30179
YM-91042 CHEC~NGTHECLUTCHSHOE
1. Check:
• Clutch shoe
Glazed areas ~ Sand with coarse sandpa-
per.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
After sanding the glazed areas, clean the clutch
with a cloth .
2. Measure:
• Clutch shoe thickness
5-60
CLUTCH
3. Install:
Clutch shoe thickness • One-way clutch bearing
1.5 mm (0.06 in) TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Clutch shoe thickness limit
1.0 mm (0.04 in) The one-way clutch bearing should be installed
in the clutch carrier assembly with the "OUT
SIDE" mark "a" facing toward the clutch housing.
EBS30180
ASSEMBLING THE CLUTCH HOUSING

4. Install:
1. Install:
• Bearing "1" • Seal ring "1" l~f®
Installed depth "a"

2.5-2.7 mm (0.10-0.11 in)
2
2. One-way clutch bearing
= EBS30181
INSTALLING THE CLUTCH

2. Clutch housing
1. Install:
• Clutch carrier assembly
2. Install: • Nut "1" l~fWJ
• Oil seal "1" l~f4ii
Clutch carrier assembly nut
Installed depth "a" 190 N,m (19 kgf,m, 140 lb,ft)
O mm (0 in)
ECB01720
NOTICE
- - - - - - - - - - - - -
,K 2
a
The clutch carrier assembly nut has left-
J) -
hand threads. To tighten the clutch carrier
assembly nut, turn it counterclockwise.
-~ f l
11~~I TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
- \
:h ~
V
Use a clutch holding tool "2" to hold the clutch
carrier assembly.
' " Universal clutch holder

2. Bearing housing 90890-04086
YM-91042
5-61
CLUTCH
2. Lock the threads with a drift punch.

3. Install:
• Dowel pins
• Gasket i~f:M
• Clutch housing assembly
Clutch housing assembly bolt

1O N,m (1.0 kgf,m, 7.4 lb,ft)
TIP~~~~~~~~~~~~~~
• Tighten the bolts in stages, using a crisscross

pattern.
• After tightening the bolts, check that the clutch
housing assembly rotates smoothly.
5-62
CRANKCASE
EBS20045
CRANKCASE
Removing the timing chain and oil filter cartridge
, 7 N·m (0.7 kgf·m, 5.2 lb·ft)
{" 10 N·m 1.0 k f·m, 7.4 lb·ft
,"- ~ 10 N·m (1.0 kgf·m, 7.4 lb·ft)
~
~
',,,~ ',,, 3 I~
," I} '
... ........ <:z, ',
ILiJal 2
(Q'r, ' ' "' ~ lfll
~
,:,i, ' '
ILl.l,;;iLI,, ' ' ' '(((q ' ';5<
", 33 N·m 3.3 k f·m, 24 lb·ft 1--

:,_ 17N·m 1.7k f·m,131b·ft
,,, 10 N·m 1.0 k f·m, 7.4 lb·ft

Engine 5-4,
Cylinder head Refer to "CYLINDER HEAD" on page 5-14,
Refer to "CYLINDER AND PISTON" on page
Cylinder/Piston
5-31 ,
AC magneto rotor/Starter wheel gear
CLUTCH" on page 5-36,
Refer to "BALANCER GEARS AND OIL
Balancer driven gear/Oil pump driven gear
PUMP GEARS" on page 5-46,
Primary sheave assembly/Secondary sheave Refer to "PRIMARY AND SECONDARY
assembly SHEAVES" on page 5-49,
Clutch carrier assembly Refer to "CLUTCH" on page 5-58,
1 Timing chain guide (intake side) 1
2 Timing chain guide (lower) 1
3 Timing chain 1
5-63
CRANKCASE
Removing the timing chain and oil filter cartridge

". 7 N-m (0. 7 kgf·m, 5.2 lb-ft)
~. 10 N·m 1.0 k f·m, 7.4 lb·ft
5
~ 10 N·m (1.0 kgf·m, 7.4 lb-ft)
',. 33 N-m 3.3 k f·m, 24 lb-ft

'.,_ 17 N•m
"{, 10 N•m 1.0 k f-m, 7.4 lb·ft

4 Oil filter cartridge 1
5 Speed sensor 1
6 Dipstick 1
7 Relief valve assembly 1
8 Reverse switch 1
9 Gear position switch 1
5-64
CRANKCASE
Separating the crankcase

-._ 10 N·m (1.0 kgf·m, 7.4 lb·ft)
,, ,. 20 N·m (2.0 kgf·m, 15 lb·ft)
~;._ 1O N·m (1.0 kgf·m, 7.4 lb-ft)
2 l~tMJ
8
'
9 > •
10
'
.,., 1O N·m (1.0 kgf·m, 7.4 lb-ft)
? ·, . 26 N-m (2.6 kgf·m, 19 lb-ft) ,. .. 14 N·m (1.4 kgf·m, 1O lb·ft)
1 Shift lever cover 1

2 Gasket 1
3 Dowel pin 1
4 Shift lever 1 1
5 Shift lever 2 assembly 1
6 Shift drum stopper 1 Spring identification color: white
7 Stopper lever stopper 1 Spring identification color: red
8 Crankcase (right) 1
9 Dowel pin 2
10 Crankcase (left) 1
5-65
CRANKCASE
Removing the crankcase bearings
1~
2
~,,..at'=-·=·
. ---
i~fMJ 3
. 1O N·m (1.0 kgf·m, 7.4 lb·ft)
7
7
-
@
m

Refer to "CRANKSHAFT AND OIL PUMP"
Crankshaft/Oil pump on page 5-70.
Transmission Refer to "TRANSMISSION" on page 5-75.
Middle drive shaft/Middle driven shaft Refer to "MIDDLE GEAR" on page 5-82.
1 Collar 1
2 0-ring 1
3 Oil seal 1
5 Spacer 1
6 Crank seal 2
7 Bearing 9
5-66
CRANKCASE
EBS30182
SEPARATING THE CRANKCASE

1. Remove:
• Crankcase bolts
• Lead holders •
•
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)
EBS30184
CHECKING THE RELIEF VALVE

1. Check:
• Spring seat "1"
• Spring "2"
• Relief valve body "3"
• Relief valve "4"
Damage/wear ~ Replace the defective
part(s).
0
4
__,
( )
,-.._ •
I ®
00
A. Crankcase (left)
B. Crankcase (right)
2. Remove:
• Crankcase (right) EBS30185
• Dowel pins CHECKING THE BEARINGS

ECB03210
1. Check:
NOTICE • Bearings
- - - - - - - - - - - - -
Tap on one side of the crankcase with a soft- Clean and lubricate, then rotate the inner
fac.e hammer. Tap only on reinforced por- race with a finger.
tions of the crankcase, not on the crankcase Roughness ~ Replace.
mating surfac.es. Work slowly and carefully
!
and make sure that the crankcase halves
separate evenly. /
EBS30183
CHECKING THE TIMING CHAIN AND TIMING

CHAIN GUIDE
1. Check:
• Timing chain
Damage/stiffness ~ Replace the timing
chain and camshaft sprocket as a set.
5-67
CRANKCASE
EBS30186
CHECKING THE CRANKCASE

1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and - 2
crankcase mating surfaces.
3. Check:
• Crankcase
• Oil delivery passages
Obstruction ~ Blow out with compressed air. 5. Fit the right crankcase onto the left crank-
EBS30187 case. Tap lightly on the case with a soft ham-
ASSEMBLING THE CRANKCASE mer.
1. Install: EC B01730
NOTICE
• Oil seal "1" i~i@ -------------
Before tightening the crankcase bolts, make
Installed depth "a" sure the transmission gears shift correctly
1.0-1.5 mm (0.04-0.06 in) when the shift drum assembly is turned by
hand.
11~m 6. Install:
• Lead holders
• Crankcase bolts
2 7. Tighten:
• Crankcase bolts
Crankcase bolt "1 "

26 N-m (2.6 kgf-m, 19 lb·ft)
Crankcase bolt (I = 60 mm (2.36
r ' in)) "2"
2. Crankcase 1O N-m (1.0 kgf-m, 7.4 lb·ft)
2. Thoroughly clean the crankcase mating sur- Crankcase bolt (I = 30 mm (6.68
faces. in)) "3"
10 N-m (1.0 kgf-m, 7.4 lb·ft)
3. Apply:
• Sealant "1" M8 x 40 mm "1"
(onto the crankcase mating surfaces) M6 x 60 mm "2"
M6 x 30 mm "3"
Yamaha bond No. 1215
90890-85505 TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
(Three bond No.1215®) Tighten the bolts in stages, using a crisscross
pattern.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Apply two coats of sealant to the area "a"
• Do not allow any sealant to come into contact
with the oil gallery.
4. Install:
• Dowel pins "2"
5-68
CRANKCASE
A. Crankcase (right)
B. Crankcase (left)
8. Apply:
• 4-stroke engine oil
(to the crankshaft pin, bearings and oil deliv-
ery hole)
9. Check:
• Crankshaft and transmission operation
Rough operation ~ Repair.
EBS30165
INSTALLING THE SHIFT LEVER

1. Install:
• Shift lever 2 assembly "1"
• Shift lever 1 "2"
Shift lever 2 assembly bolt

14 N,m (1.4 kgf,m, 1O lb,ft)
TIP ~~~~~~~~~~~~~~~
When installing the shift lever 1, align the align-
ment mark "a" on the shift lever 1 with the punch
marks "b" on the shift lever 2.
5-69
CRANKSHAFT AND OIL PUMP
EBS20046

Removing the crankshaft and oil pump
2 l~f:M
.............. •'
,. 10 N·m (1.0 kgf·m, 7.4 lb·ft)
,, 1O N·m (1.0 kgf·m, 7.4 lb·ft)

Separate.
Crankcase Refer to "CRANKCASE" on page 5-63.
1 Oil pump 1
2 Gasket 1
3 Balancer 1
4 Crankshaft 1
5-70
Disassembling the oil pump
5
,
4 /
/
1
··. 5 N•m 0.5 k f-m, 3. 7 lb·ft
1 Oil pump housing cover 1

2 Pin 1
3 Oil pump shaft 1
4 Inner rotor 1
5 Outer rotor 1
6 Oil pump housing 1
5-71
EBS30188
REMOVING THE CRANKSHAFT Outer-rotor-to-inner-rotor-tip

1. Remove: clearance
• Crankshaft "1" 0-0.12 mm (0-0.0047 in)
TIP ~~~~~~~~~~~~~~ Outer-rotor-to-inner-rotor-tip
• Remove the crankshaft with the crankcase clearance limit
0.20 mm (0.0079 in)
separating tool "2". Outer-rotor-to-oil-pump-housing
• Make sure the crankcase separating tool is clearance
centered over the crankshaft. 0.09-0.17 mm (0.0035-0.0067 in)
ECB01880 Outer-rotor-to-oil-pump-housing
NOTICE~~~~~~~~~~~~ clearance limit
• To protect the end of the crankshaft, place 0.24 mm (0.0094 in)
Oil-pump-housing-to-inner-and-
an appropriate sized socket between the
outer-rotor clearance
crankcase separating tool bolt and the
0.03-0.1 o mm (0.0012-0.0039 in)
crankshaft. Oil-pump-housing-to-inner-and-
• Do not tap on the crankshaft. outer-rotor clearance limit
0.17 mm (0.0067 in)
Crankcase separating tool
90890-01135
Crankcase separator
YU-01135-B
C
EBS30189
CHECKING THE OIL PUMP

1. Check:
• Oil pump housing
• Oil pump housing cover
Cracks/damage/wear ~ Replace the oil
pump.
2. Measure: 1. Inner rotor
• Inner-rotor-to-outer-rotor-tip clearance "a" 2. Outer rotor
• Outer-rotor-to-oil-pump-housing clearance 3. Oil pump housing
"b"
• Oil-pump-housing-to-inner-rotor-and-outer- 3. Check:
rotor clearance "d' • Oil pump operation
Out of specification ~ Replace the oil pump. Rough movement~ Repeat steps (1) and
(2) or replace the oil pump.
5-72
b b
EBS30190
!
CHECKING THE OIL STRAINER
1. Check:
• Oil strainer
Damage ~ Replace.
Contaminants ~ Clean with solvent.
ESS30191
I.. ..I
CHECKING THE CRANKSHAFT a
1. Measure:
• Crankshaft width "a"
Out of specification ~ Replace the crank-
shaft. 4. Check:
• Crankshaft sprocket
Crank assembly width 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 "b" 5. Check:
Out of specification ~ Replace the crank- • Crankshaft journal
shaft. Scratches/wear ~ Replace the crankshaft.
• Crankshaft journal oil passage
Runout limit Obstruction~ Blow out with compressed air.
0.030 mm (0.0012 in)
EBS30192
3. Measure: ASSEMBLING THE OIL PUMP

• Big end side clearance "c" 1. Lubricate:
Out of specification ~ Replace the crank- • Inner rotor
shaft. • Outer rotor
• Oil pump shaft
Big end side clearance (with the recommended lubricant)
0.350-0.650 mm (0.013&-0.0256
in) Recommended lubricant
Engine oil
2. Install:
• Oil pump housing "1"
• Outer rotor "2"
• 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".
5-73
a '
4
5
3. Check: EC B01890
• Oil pump operation NOTICE

- - - - - - - - - - - -
Refer to "CHECKING THE OIL PUMP" on App Iy engine oil to each bearing to protect
page 5-72. the crankshaft against scratches and to
make installation easier.
EBS30193
INSTALLING THE CRANKSHAFT TIP _ _ _ _ _ _ _ _ _ _ _ _ __

1. Install: Hold the connecting rod at top dead center
• Crankshaft "1" (TDC) with one hand while turning the nut of the
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ crankshaft installer bolt with the other. Turn the
Install the crankshaft assembly with the crank- crankshaft installer bolt until the crankshaft as-
shaft installer pot "2", crankshaft installer bolt "3", sembly bottoms against the bearing.
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
90890-01309
Pot spacer
YU-90059
5-74
TRANSMISSION
EBS20047
TRANSMISSION
Removing the transmission, shift drum and shift forks
01"'"'",- -.
13~
/
/
12 /
/
/
/ \
\
'
/
/ /
/ /
\
/ /
/ /
11 /
/
/
/
/
/
/
/
6
~ ', \
9 /
/
/
\
\
10 /
/
/
/
\
/ /
/ /
/ /
,,,,.,,."" 4 /
/
/
/ /
/ /
/ /
/ /
,
/
,," 3 , /
/ /
/ /'
\ /
/
\ /

Separate.
Middle driven gear Refer to "MIDDLE GEAR" on page 5-82.
1 Shift drum 1
2 Shift fork assembly 1
3 Shift fork "R" 1
4 Spring 1
5 Shift fork "L" 1
6 Shift fork guide bar 1
7 Secondary shaft 1
8 Drive axle assembly 1
9 Reverse idle gear 1
10 Bearing 1
11 Collar 1
12 Reverse idle gear shaft 1
13 Stopper lever 1
5-75
TRANSMISSION
Removing the transmission, shift drum and shift forks
01"'"'",- -.
14
'
New
I

14 Stopper lever shaft 1
5-76
TRANSMISSION
Disassembling the drive axle assembly
7
·~· 6
5
4
3
1
17
('
~I
/
16
15
14
12
131~f:M
10
11 l~f:M
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
17 Stopper wheel 1
5-77
TRANSMISSION
Disassembling the drive axle assembly
-
Q
18

18 Drive axle 1
5-78
TRANSMISSION
EBS30194
REMOVING THE TRANSMISSION

1. Remove:
• Shift drum "1"
• Shift fork assembly "2"
a. Pull out the guide bar from the left crank-
case.
b. Push down on the drive shaft, and then
slide the shift fork assembly to remove the
shift fork cam followers.
c. Remove the shift drum. 3. Check:
d. Remove the shift fork assembly. • Shift fork movement
(along the shift fork guide bar)
~~@ Rough movement ~ Replace the shift forks
and shift fork guide bar as a set.
EBS30196
CHECKING THE SHIFT FORKS 4. Check:

The following procedure applies to all of the shift • Spring
forks. Cracks/damage ~ Replace.
1. Check:
• Shift fork cam follower "1" EBS30197
• Shift fork pawl "2" CHECKING THE SHIFT DRUM

Bends/damage/scoring/wear ~ Replace the 1. Check:
shift fork. • Shift drum grooves
Damage/scratches/wear~ Replace the shift
drum.
2. Check:
• Shift fork guide bar
Roll the shift fork guide bar on a flat surface. EBS30198
Bends ~ Replace. CHECKING THE TRANSMISSION

EWB027SO 1. Measure:
A WARNING • Drive axle runout
Do not attempt to straighten a bent shift fork (with a centering device and dial gauge "1 ")
guide bar. Out of specification ~ Replace the drive axle.
Drive axle runout limit

0.05 mm (0.0020 in)
5-79
TRANSMISSION
• Stopper wheel "2"

- Damage/wear ~ Replace the stopper wheel
I'-.. l
1 and stopper lever as a set.
• Stopper lever shaft "3"
• Bends/damage/wear ~ Replace .
• •
• •
• •
b. !:::,.
1
2
2. Check:
• Transmission gears
Blue discoloration/pitting/wear ~ Replace 3
the defective gear(s).
• Transmission gear dogs
Cracks/damage/rounded edges ~ Replace EBS30896
the defective gear(s). ASSEMBLING THE SHIFT FORK ASSEMBLY

1. Install:
0 X ox 0 X • Shift fork guide bar "1"
u 'J • Shift fork "L" "2"
~ ? nn j"\_ Jl
• Spring "3"
• Shift fork "R" "4"
• Circlip "5" l~fffi
TIP~~~~~~~~~~~~~~
Install the shift forks with "28P" mark "a" and

"384" mark "b" facing each other.
3. Check:
• Transmission gear engagement
(each pinion gear to its respective wheel 2
gear)
Incorrect~ Reassemble the transmission
axle assemblies.
4. Check:
• Transmission gear movement
Rough movement ~ Replace the defective
part(s).
5. Check: EBS30202
• Circlips INSTALLING THE SHIFT FORKS AND SHIFT

Bends/damage/looseness ~ Replace. DRUM
1. Install:
EBS30199
• Stopper lever shaft
CHECKING THE SECONDARY SHAFT
• Stopper lever
1. Check:
• Reverse idle gear "1"
• Gear teeth
Blue discoloration/pitting/wear ~ Replace. • Drive axle assembly "2"
• Secondary shaft "3"
EBS30555 • Shift fork assembly "4"
CHECKING THE STOPPER LEVER AND • Shift drum "5"
STOPPER WHEEL
1. Check:
• Stopper lever pawl "1"
Bends/damage/wear ~ Replace the stopper
lever and stopper wheel as a set.
5-80
TRANSMISSION
TIP~~~~~~~~~~~~~~
Install the shift forks "6" with the "L" mark "a" and
"R" mark "b" facing towards the left and right
sides of the crankcase respectively.
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.
5-81
MIDDLE GEAR
EBS20048
MIDDLE GEAR
Removing the middle drive shaft
.,., 190 N·m 19 k f·m, 140 lb·ft
4 ~,. 32 N·m (3.2 kgf·m, 24 lb·ft)

2
9
5 81~tM
,a 6
·• 29 N·m 2.9 k f·m, 21 lb·ft

Separate.
1 Bearing housing 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 5-90.
5 Middle drive shaft 1
7 Bearing 1
8 Circlip 1
9 Middle driven gear 1
5-82
MIDDLE GEAR
Removing the middle driven shaft
14
'-----110
,; 80 N•m 8.0 k f·m, 59 lb·ft la
,,. 130 N·m 13 k f·m, 96 lb·ft
~
12 /
/
11 /
.,, " 150 N·m (15 kgf·m, 111 lb·ft)
\
///\
/ /
/ \
/ \ ,
'
/
'
l_\
\ /
/
\ ,, /
/
3
\ / /
-
m
/ /
\
8 ,,,..,,,""'
\ 9
------- /
/
/

Separate.
1 Front drive shaft yoke nut (middle gear side) 1
2 Front drive shaft yoke (middle gear side) 1
3 Middle driven pinion gear assembly 1
4 Rear drive shaft yoke nut (middle gear side) 1
5 Rear drive shaft yoke (middle gear side) 1
6 Bearing housing 1
7 0-ring 1
Refer to "ALIGNING THE MIDDLE GEAR"
8 Middle driven pinion gear shim
on page 5-90.
9 Middle driven pinion gear 1
10 Bearing 1
11 Middle driven pinion gear bearing retainer 1
12 Bearing 1
13 Middle driven shaft bearing retainer 1
14 Bearing 1
5-83
MIDDLE GEAR
Removing the middle driven shaft
~
15
)-
Gl _ ! .J25 N•m (2.5 kgf•m, 18 lb·ft) I
1€)
,; 80 N·m 8.0 k f·m, 59 lb-ft ,a <~ /-----,
)
//; ) : / @ :
,,. 130 N-m 13 k f·m, 96 lb-ft
/
/
/
/
/
-
B:
/
/
/ I
.,, , 150 N·m (15 kgf·m, 111 lb-ft)

15 Middle driven shaft 1
5-84
MIDDLE GEAR
EBS30203
REMOVING THE MIDDLE DRIVE SHAFT Coupling gear/middle shaft tool

1. Straighten: 90890-01229
• Punched portion of the middle drive pinion Gear holder
gear nut YM-01229
2. Loosen:
• Middle drive pinion gear nut "1"
TIP ~~~~~~~~~~~~~~~
Wrap the middle drive shaft in a folded rag, and

then secure it in a vise.
2. Remove:
• Rear drive shaft yoke nut (middle gear side)
"1 "
// • Washer
• Rear drive shaft yoke (middle gear side) "2"
3. Remove: TIP~~~~~~~~~~~~~~~
• Middle drive pinion gear nut Use the coupling gear/middle shaft tool "3" to
• Middle drive pinion gear hold the rear drive shaft coupling sleeve.
• Shim(s)
4. Remove:
• Middle driven gear "1" Coupling gear/middle shaft tool
90890-01229
• Circlip Gear holder
• Middle drive shaft "2" YM-01229
TIP ~~~~~~~~~~~~~~~
Press the middle drive shaft end and remove the

middle driven gear.
• 1
• L---2•
3. Remove:
• Bearing housing assembly "1"
a. Clean the surface of the bearing housing
EBS30204
assembly.
REMOVING THE MIDDLE DRIVEN SHAFT
b. Place the bearing housing assembly onto
1. Remove:
a hydraulic press.
• Front drive shaft yoke nut (middle gear side) EC B01900
"1 " NOTICE~~~~~~~~~~~~~

• Washer • Never directly press the middle driven pin-
• Front drive shaft yoke (middle gear side) "2" ion gear end with a hydraulic press, this will
TIP~~~~~~~~~~~~~~ result in damage to the middle driven pin-
Use the coupling gear/middle shaft tool "3" to ion gear thread.
hold the front drive shaft coupling sleeve.
5-85
MIDDLE GEAR
• Install a suitable socket "2" on the middle

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

90890-04128
YM-04128
ECB0174-0
NOTICE 3
-------------
The middle driven pinion gear bearing retain-
er has left-hand threads. To loosen the re- 6. Remove:
tainer, turn it clockwise. • Middle driven shaft "1"
(with bearing)
c. Remove the bearing retainer and bearing.

5. Remove: EBS30205
• Oil seal "1" CHECKING THE PINION GEARS

• Middle driven shaft bearing retainer "2" 1. Check:
TIP __________________________________________ • Drive pinion gear teeth
• Driven pinion gear teeth
Attach the ring nut wrench "3".
Pitting/galling/wear ~ Replace.
2. Check:
• 0-ring
Damage ~ Replace.
5-86
MIDDLE GEAR
• Bearings
Pitting/damage ~ Replace. Ring nut wrench
90890-01430
EBS30206 Ring nut wrench
INSTALLING THE BEARING AND OIL SEALS YM-38404
1. Install:
• Bearing "1" EC B01760
NOTICE
• Oil seal "2" i"~~i:f"'.j -------------
The middle driven shaft bearing retainer has
• Oil seal "3" l~cfi left-hand threads. To tighten the retainer turn
Installed depth of bearing "a" it counterclockwise.
0.9-1.4 mm (0.035-0.055 in)
Installed depth of oil seal "b"
1.0-1.5 mm (0.039-0.059 in)
Installed depth of oil seal "c" 0
1.0-1.5 mm (0.039-0.059 in)
2
2. Install:
• Middle driven pinion gear bearing retainer "1"
a. Wrap the bearing housing in a folded rag,
and then secure the bearing housing edge
. .
1n a vise.
4. Middle drive pinion gear bearing retainer
b. Attach the bearing retainer wrench "2".
5. Bearing housing
6. Middle driven shaft bearing retainer Bearing retainer wrench
7. Crankcase 90890-04128
EBS30207
YM-04128
INSTALLING THE MIDDLE DRIVEN SHAFT
1. Install: c. Tighten the bearing retainer.
• Middle driven shaft bearing retainer "1"
Middle driven pinion gear bearing
Middle driven shaft bearing re- retainer
tainer 130 N-m (13 kgf-m, 96 lb·ft)
80 N-m (8.0 kgf-m, 59 lb-ft) LOCTITE®
LOCTITE®
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Attach the ring nut wrench "2".
5-87
MIDDLE GEAR
ECB01770
NOTICE
- - - - - - - - - - - -
The middle driven pinion gear bearing retain-
er has left-hand threads. To tighten the re-
tainer turn it counterclockwise.
5. Install:
• Front drive shaft yoke (middle gear side) "1"
• Washer
2 • Front drive shaft yoke nut (middle gear side)
"2''
3. Install: Front drive shaft yoke nut (mid-
• Middle driven pinion gear shim(s) "1" dle gear side)
• Bearing housing 115 N-m (11.5 kgf-m, 85 lb-ft)
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Install the shim(s) so that the tabs are positioned TIP _ _ _ _ _ _ _ _ _ _ _ _ __
as shown in the illustration. Use the coupling gear/middle shaft tool "3" to
hold the coupling yoke.
1
Coupling gear/middle shaft tool
90890-01229
Gear holder
YM-01229
4. Install:
• Rear drive shaft yoke (middle gear side) "1"
• Washer
• Rear drive shaft yoke nut (middle gear side)
"2"
Rear drive shaft yoke nut (middle

gear side) EBS30208
150 N-m (15 kgf-m, 111 lb·ft) INSTALLING THE MIDDLE DRIVE SHAFT
LOCTITE® 1. Install:
• Circlip
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ • Middle driven gear "1"
Use the coupling gear/middle shaft tool "3" to (to the middle drive shaft "2")
hold the coupling yoke.
Installed depth of middle driven
gear "a"
Coupling gear/middle shaft tool 24.7-24.9 mm (0.97-0.98 in)
90890-01229
Gear holder
YM-01229
5-88
MIDDLE GEAR
EBS30209
MEASURING THE MIDDLE GEAR

BACKLASH
1. Measure:
• Middle gear backlash
Out of specification~ Refer to "ALIGNING
THE MIDDLE GEAR" on page 5-90.
\2 Middle gear backlash
0.10-0.30 mm (0.004-0.012 in)
2. Tighten: a. Temporarily install the left crankcase.

• Bearing retainer bolts "1" l~c:M b. Wrap a rag "1" around a screwdriver "2",
• Middle drive pinion gear nut "2" l~~lll!fij"§"i and then insert it into the installation hole
"a" of the left crankcase speed sensor to
Middle drive shaft bearing retain- hold the middle driven gear.
er bolt
29 N,m (2.9 kgf,m, 21 lb,ft)
LOCTITE®
Middle drive pinion gear nut 1
®
D~ / ~ a
190 N,m (19 kgf,m, 140 lb,ft)
TIP ~~~~~~~~~~~~~~
_____,.,...- ~~ 2 0
Wrap the middle drive shaft in a folded rag, and () 0

then secure it in a vise.
...__ J/.
3. Lock the threads with a drift punch.
c. Attach the final gear backlash band "3"
TIP ~~~~~~~~~~~~~~
and dial gauge "4".
Stake the bearing retainer bolts at the cutouts "a"
in the bearing retainers "3". Final gear backlash band
90890-01511
YM-01230
11~@}1
4
-
//
0
b
b. 45 mm (1.8 in)
d. Measure the gear lash while rotating the
middle driven shaft back and forth.
TIP ~~~~~~~~~~~~~~
a O Measure the gear lash at 4 positions. Rotate the

0.,,-------J
middle driven gear 90° each time.
e. If the gear lash is incorrect, adjust the gear
lash by middle driven pinion gear shims
and/or middle drive pinion gear shim(s).
5-89
MIDDLE GEAR
EBS30210
Middle drive pinion gear shim thickness
ALIGNING THE MIDDLE GEAR
"A" = "e" + "d" - "b" - "c" - "a"
TIP ~~~~~~~~~~~~~~~~
Aligning the middle gear is necessary when any "a" = a numeral (usually a decimal num-
of the following parts are replaced: ber) on the bearing housing is either add-
• Crankcase ed to or subtracted from "0.6"
• Middle drive gear "b" = 17.0
• Middle driven gear "c" = 55.0
• Middle driven shaft bearing housing "d" = a numeral (usually a decimal num-
ber) on the right crankcase specifies a
1. Select: thickness of "65.0"
• Middle drive pinion gear shim(s) "1" "e" = a numeral (usually a decimal num-
• Middle driven pinion gear shim(s) "2" ber) on the left crankcase specifies a thick-
ness of "9.0''
Example:
If the bearing housing is marked "-02",
"a" is O. 58
1
- ~
"A"
i-
I
'- -
_,J
1 " '-- "b" is 17.0
'-'-,.
---
(
l~ "c" is 55.0
If the right crankcase is marked "64.97",
"d" is 64.97
1 - '
~
_ ,.,. 1
~ -- ~-. -(
...
~'
'
l
) 'n
~
~~ .
,-...
,
f 2 d
'
'\
~~- ·· ,
'
I:n,,-',...,
U:b.._j· I
", ' Ir""'
:
L,. r.....
... 's::7
--
'
'- "'" \
I:
~
'--..=r'. =.·
lo,: ii
' '11 ~ f- t"B"
i...J-' - ~ - ----- I
l'I
If the left crankcase is marked "9.01",
"e" is 9.01
A. Middle drive pinion gear shim thickness
B. Middle driven pinion gear shim thickness
a. Position the middle gears with the appro-

priate shim(s) that has had its respective
thickness calculated from information
marked on the crankcase, middle driven
shaft bearing housing and middle driven
. .
p1n1on gear.
b. To find middle drive pinion gear shim
thickness "A", use the following formula.
5-90
MIDDLE GEAR
Therefore, "A" is 1.40. "i" = a numeral (usually a decimal number)

"A" = 9.01 + 64.97 - 17.0 - 55.0 - 0.58 = on the left crankcase specifies a thickness
1.40 of "99.98"
Round off hundredths digit and select ap- "j" = a numeral (usually a decimal number)
propriate shim(s). on the right crankcase specifies a thick-
In the above example, the calculated shim ness of "8.12"
thickness is 1.40 mm. The following chart Example:
instructs you, however, to round off Oto 0. If the bearing housing is marked "+03",
Hundredth Rounded value
''f' is 77.53
0, 1, 2 0
3,4,5, 6, 7 5 f
8, 9 10
Shims are supplied in the following thick-

nesses.
Middle drive pinion gear shim

Thickness (mm)
0.50 0.55 0.60 0.70 0.80 0.90 1.00
If the driven pinion gear is marked "+O",
c. To find middle driven pinion gear shim "g" is 49. O
thickness "B", use the following formula.
Middle driven pinion gear shim thickness
"B" = "f" - "g" + "h" - "i" - "j" - 0.05
''f" = a numeral (usually a decimal number)

on the bearing housing is either added to
or subtracted from "77.5"
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 If the driven pinion gear is marked "-1 O'',
measure distance ''f' to select the correct middle "h" is 80. 40
driven pinion gear shim thickness.
If the left crankcase is marked "99.99",

"i" is 99. 99
"g" = a numeral (usually a decimal num-
ber) on the middle driven pinion gear is ei-
ther added to or subtracted from "49.0"
"h" = a numeral (usually a decimal num-
ber) on the middle driven pinion gear is ei-
ther added to or subtracted from "80.5"
5-91
MIDDLE GEAR
If the right crankcase is marked "8.17",

"j" is 8.17
Therefore, "B" is O.72.

"B" = 77.53 - 49.0 + 80.40 - 99.99 - 8.17 -
0.05 = 0.72
Round off hundredth digit and select ap-
propriate shim(s).
In the example above, the calculated shim
thickness is 0.72 mm. The chart instructs
you , however, to round off 2 to 0.
0, 1, 2 0
3,4,5, 6, 7 5
8, 9 10

nesses.
Middle driven pinion gear shim

Thickness (mm)
0.10 0.15 0.20 0.30 0.40 0.50 0.60
5-92
MIDDLE GEAR
5-93
COOLING SYSTEM
COOLING SYSTEM DIAGRAMS .................................................................... 6-1
RADIATOR ...................................................................................................... 6-2

CHECKING THE RADIATOR .................................................................... 6-4
INSTALLING THE RADIATOR .................................................................. 6-4
TH ER MOSTAT ................................................................................................ 6-5

CHECKING THE THERMOSTAT .............................................................. 6-6
INSTALLING THE THERMOSTAT ............................................................ 6-6
WATER PUMP ................................................................................................. 6-8

DISASSEMBLING THE WATER PUMP .................................................. 6-10
CHECKING THE WATER PUMP ............................................................ 6-10
ASSEMBLING THE WATER PUMP ........................................................ 6-10
COOLING SYSTEM DIAGRAMS
ESS20147
COOLING SYSTEM DIAGRAMS
1 2 3
8 ----+- 0
0
BM
.. 0
0 0 0
7 6 5 4

2. Radiator inlet hose
3. Coolant reservoir
4. Water pump
5. Water pump outlet pipe
6. Water pump outlet hose
7. Radiator outlet hose
8. Radiator
6-1
RADIATOR
EBS20051
RADIATOR
Removing the radiator
1
(4)
--~
' (D '
l lj l l
! I
4
·, 7 N·m (0. 7 kgf·m, 5.2 lb·ft)

Front skid plate/Center skid plate/Top cover/ Refer to "GENERAL CHASSIS (1)" on page
Side panels 4-1 .
Front guard
4-6.
Front fenders
4-8.
4-11 .
Drain.
Coolant Refer to "CHANGING THE COOLANT" on
page 3-27.
1 Radiator fan motor coupler 1 Disconnect.
2 Radiator fan motor breather hose 1
3 Coolant reservoir hose 1
4 Coolant reservoir breather hose 1
6-2
RADIATOR
Removing the radiator
'
(D .
lflj
I 41
. I
-, 7 N·m (0. 7 k f·m, 5.2 lb·ft)
5 Coolant reservoir cap 1

6 Coolant reservoir 1
7 Radiator outlet hose 1
8 Radiator inlet hose 1
9 Radiator 1
10 Radiator fan 1
6-3
RADIATOR
EBS30213
CHECKING THE RADIATOR

1. Check:
• Radiator fins
Obstruction~ Clean.
Apply compressed air to the rear of the radia-
tor.
Damage ~ Repair or replace.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Straighten any flattened fins with a thin , flat-head
screwdriver. b. Apply the specified pressure for ten sec-
onds 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 9-25.
-
-
- - EBS30214
INSTALLING THE RADIATOR

•
1. Fill:
2. Check: • Cooling system
• Radiator hoses (with the specified amount of the recom-
Cracks/damage ~ Replace. mended coolant)
3. Measure: Refer to "CHANGING THE COOLANT' on
• Radiator cap opening pressure page 3-27.
Below the specified pressure ~ Replace the 2. Check:
radiator cap. • Cooling system
Leaks ~ Repair or replace any faulty part.
Radiator cap opening pressure 3. Measure:
107.9-137.3 kPa (1.1-1.4 kgf/ • Radiator cap opening pressure
cm 2 , 15.6-19.9 psi) Below the specified pressure ~ Replace the
radiator cap.
a. Install the radiator cap tester "1" and radi-
Refer to "CHECKING THE RADIATOR" on
ator cap tester adapter "2" to the radiator
page 6-4.
cap "3".
Radiator cap tester

90890-01325
Mityvac cooling system tester kit
YU-24460-A
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984
6-4
THERMOSTAT
EBS20052
THERMOSTAT
Removing the thermostat
4 1
5
r.:, 18 N·m 1.8 k f·m, 13 lb-ft
,. 10 N•m 1.0 k f-m, 7.4 lb·ft
•
3
r- . 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Air filter case
4-17.
V-belt cooling exhaust ducW-belt cooling intake Refer to "ENGINE REMOVAL (1 )" on page
duct 5-4.
Drain.
page 3-27.
1 Radiator inlet hose 1 Disconnect.
2 Thermostat cover 1
3 Thermostat 1
4 Coolant temperature sensor coupler 1 Disconnect.
5 Coolant temperature sensor 1
6-5
THERMOSTAT
EBS30215
• Thermostat housing (cylinder head)
CHECKING THE THERMOSTAT
1. Check:
• Thermostat EBS30216
Does not open at 69-73 °C (156.2-163.4 °F) INSTALLING THE THERMOSTAT

~ Replace. 1. Install:
• Copper washer l~fffi
• Coolant temperature sensor
Coolant temperature sensor

18 N,m (1.8 kgf,m, 13 lb,ft)
ECB01910
NOTICE
-------------
Use extreme care when handling the coolant
temperature sensor. Replace any part that
was dropped or subjected to a strong im-
a. Suspend the thermostat "1" in a container pact.
"2" filled with water.
b. Slowly heat the water "3". 2. Install:
c. Place a thermometer "4" in the water. • Thermostat "1"
d. While stirring the water, observe the ther- • 0-ring "2" i~tWJ
mostat and the temperature indicated on • Thermostat cover "3"
the thermometer.
Thermostat cover bolt
1O N,m (1.0 kgf,m, 7.4 lb,ft)
~ 4
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~
Install the thermostat with its breather hole "a"
\ \-=_---1 r--====-::--=====:f..)'...._ 3 facing up.
- - =_:- II
1
11-- 2 3
2
a
1
B
8mm
(0.31 in)
3. Fill:
0 1......-~- - - - - - 1 - - - -
69-73 °C 85 •c • Cooling system
(156.2 - 163.4 °F) (185 °F) (with the specified amount of the recom-
mended coolant)
A. Fully closed Refer to "CHANGING THE COOLANT' on
B. Fully open page 3-27.
4. Check:
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Cooling system
If the accuracy of the thermostat is in doubt, re- Leaks ~ Repair or replace any faulty part.
place it. A faulty thermostat could cause serious 5. Measure:
overheating or overcooling. • Radiator cap opening pressure
2. Check: Below the specified pressure ~ Replace the
• Thermostat housing cover radiator cap.
6-6
THERMOSTAT
Refer to "CHECKING THE RADIATOR" on

page 6-4.
6-7
WATER PUMP
EBS20053
WATER PUMP
Removing the water pump
""'- - .J
' 0
'--, 10 N•m (1.0 kgf-m, 7.4 lb·ft)
,. 10 N·m (1.0 kgf·m, 7.4 lb·ft) -,. 10 N•m (1.0 kgf-m, 7.4 lb·ft)

Front fender (left)
4-8.
4-11 .
AC magneto cover CLUTCH" on page 5-36.
Drain.
page 3-27.
1 Radiator outlet hose 1 Disconnect.
2 Water jacket joint 1
3 Water pump outlet hose 1
4 Water pump outlet pipe 1
6-8
WATER PUMP
Removing the water pump
""'- - .J
' 0
12 l~tMJ
'
·, 10 N•m (1.0 kgf,m, 7 .4 lb•ft)
, 1O N·m (1.0 kgf,m, 7 .4 lb·ft) ·,. 10 N•m (1.0 kgf,m, 7 .4 lb·ft)
5 Water pump breather hose 1

6 Water pump cover 1
7 Gasket 1
8 Circlip 1
9 Impeller shaft 1
10 Mechanical seal 1
11 Bearing 1
12 Oil seal 1
6-9
WATER PUMP
EBS30217 EBS30218
DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP

• Mechanical seal (impeller side) "1" • Water pump cover
(from the impeller, with a thin, flathead screw- • AC magneto cover
driver) • Impeller
TIP ~~~~~~~~~~~~~~ Cracks/damage/wear ~ Replace.
Do not scratch the impeller shaft. 2. Check:
• Water pump outlet pipe
3. Measure:
• Impeller shaft tilt
TIP ~~~~~~~~~~~~~~~
Place a straightedge "1" and measure the impel-

ler shaft tilt.
Impeller shaft tilt limit

2. Remove: 0.15 mm (0.006 in)
• Mechanical seal (AC magneto cover side) "1"
TIP ~~~~~~~~~~~~~~~
Tap out the mechanical seal from the inside of
the AC magneto cover "2".
1~
1---/--
EBS30219
ASSEMBLING THE WATER PUMP

1. Install:
• Oil seal "1" l~fffi
3. Remove: (into the AC magneto cover "2")
• Oil seal "1" TIP ~~~~~~~~~~~~~~~
• Bearing "2" Install the oil seal with a socket "3" that matches
TIP~~~~~~~~~~~~~~~ its outside diameter.
Tap out the bearing and oil seal from the outside
of the AC magneto cover "3".
(
a
11~m
Installed depth of oil seal "a"

8.1-8.7 mm (0.32-0.34 in)
6-10
WATER PUMP
2. Install:
• Mechanical seal (AC magneto cover side) "1"
•~tu
(into the AC magneto cover "2")
EC802410
NOTICE
- - - - - - - - - - - - -
Never lubricate the mechanical seal surfac.e
with oil or grease.
11~m
TIP - - - - - - - - - - - - - - - ~
• Use the special tools and a press to press the
mechanical seal (AC magneto cover side)
straight in until it touches the AC magneto cov-
er.
• Before installing the mechanical seal, apply tap
water or coolant onto its outer surface.
Mechanical seal installer (033)

90890-04132
Water pump seal installer (033)
YM-33221-A
Middle driven shaft bearing driv-
er
90890-04058
Middle drive bearing installer 40
&SO mm
YM-04058
3-
A. Push down
3. Mechanical seal installer
4. Middle driven shaft bearing driver "4"
3. Install:
• Mechanical seal (impeller side) "1"
EC801420
i~tMJ
NOTICE
-------------
Make sure the mechanical seal (impeller
side) is flush with the impeller.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~
If the surface of the mechanical seal (impeller
side) that contacts the mechanical seal (AC
magneto cover side) is dirty, clean it.
6-11
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 ................................................................ 7-2
INSTALLING THE FU EL TANK ................................................................. 7-3
THROTTLE BO DY ........................................................................................... 7-4

REMOVING THE THROTTLE BODY ASSEMBLY ................................... 7-6
CH ECKi NG THE INJECTOR .................................................................... 7-6
CHECKING THE THROTTLE BODY ........................................................ 7-6
INSTALLING THE THROTTLE BODY ASSEMBLY .................................. 7-6
CHECKING THE FUEL PRESSURE ........................................................ 7-7
ADJUSTING THE THROTTLE POSITION SENSOR ................................ 7-7
AIR INDUCTION SYSTEM .............................................................................. 7-9

CHECKING THE AIR INDUCTION SYSTEM .......................................... 7-12
INSTALLING THE AIR INDUCTION SYSTEM ........................................ 7-12
FUEL TANK
EBS20054
FUEL TANK
Removing the fuel tank
~ - 5
............... ,., 7 N·m (0. 7 kgf·m, 5.2 lb·ft)
6
·. 7 N•m (0. 7 kgf-m, 5.2 lb-ft)

·~ :=:::=~7
I ''
'
'
--·I ·:
:~
' ,
, ................... ,......, ~ - - -,.,,.,,,,,,,,,,
/
,,
''
'

Seat/Side panels 4-1 .
Rear fender
4-8.
1 Fuel tank breather hose 2
2 Fuel tank breather hose joint 1
3 Fuel tank shield 1
4 Fuel pump coupler 1 Disconnect.
5 Fuel hose connector holder 1
6 Fuel hose 1
7 Fuel tank 1
8 Fuel pump assembly 1
9 Damper 1
7-1
FUEL TANK
EBS30221
REMOVING THE FUEL TANK

1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump. t
2. Remove:
• Fuel hose connector holder
• Fuel hose
EWBOOOSO
AwARNING
2 3
Cover fuel hose connections with a cloth
when disconnecting them. Residual pres-
sure in the fuel lines could cause fuel to 3. Remove:
spurt out when removing the hose. • Fuel tank
ECB01700 TIP - - - - - - - - - - - - - - - ~
NOTICE Do not set the fuel tank down on the installation
- - - - - - - - - - - - - surface of the fuel pump. Be sure to lean the fuel
• Be sure to disconnect the fuel hose by
hand. Do not forcefully disconnect the tank in an upright position.
hose with tools.
• Although the fuel has been removed from EBS30222
the fuel tank, be careful when removing the REMOVING THE FUEL PUMP
fuel hose, since there may be fuel remain- 1. Remove:
ing in it. • Fuel pump bracket
• Fuel pump
TIP ~~~~~~~~~~~~~~- • Fuel pump gasket
EC B01450
• When removing the fuel hose fram the fuel
NOTICE
pump, remove the fuel hose connector holder -------------
first, and next, insert a slotted head screwdriver • Do not drop the fuel pump or give it a
etc. in the slot part "a" of the fuel hose connec- strong shock.
tor cover "1 ", then slide it in the direction of the • Do not touch the base section of the fuel
arrow, and remove the fuel hose. sender.
• To remove the fuel hose from the throttle body,
slide the fuel hose connector cover "2" on the EBS30223
CHECKING THE FUEL PUMP BODY

end of the hose in direction of the arrow shown,
1. Check:
press the two buttons "3" on the sides of the
• Fuel pump body
connector, and then remove the hose.
Obstruction ~ Clean.
• Before removing the hose, place a few rags in
Cracks/damage ~ Replace the fuel pump
the area under where it will be removed.
assembly.
EBS30224
CHECKING THE FUEL TANK BREATHER

HOSE JOINT
1. Check:
• Fuel tank breather hose joint
Damage/faulty ~ Replace.
EBS30225
INSTALLING THE FUEL PUMP

1. Install:
• Fuel pump gasket l~f:M
• Fuel pump
• Fuel pump bracket
Fuel pump nut

7 N-m (0.7 kgf-m, 5.2 lb·ft)
7-2
FUEL TANK
ECB02010
TIP ~~~~~~~~~~~~~~~
NOTICE~~~~~~~~~~~~
• Do not damage the installation surfaces of the
fuel tank when installing the fuel pump. When installing the fuel hose, make sure that
it is securely connected, and that the fuel
• Always use a new fuel pump gasket.
hose holder is in the correct position, other-
• Install the fuel pump in the direction shown in
the illustration. wise the fuel hose will not be properly in-
stalled.
• Install the fuel pump bracket by aligning the
projections "a" on the fuel pump with the pro- TIP ~~~~~~~~~~~~~~~
jections on the fuel tank. • Install the fuel hose connector holder "1" se-
• Tighten the fuel pump nuts in the proper tight- curely onto the fuel pump until a distinct "click"
ening sequence as shown. is heard, and then make sure that it does not
come loose.
• To install the fuel hose onto the throttle body,
slide the fuel hose connector cover "2" on the
end of the hose in direction of the arrow shown.
FWD ¢::J 10 s
I a
EBS30226
INSTALLING THE FUEL TANK

1. Install:
• Damper "1"
TIP ~~~~~~~~~~~~~~
• Fit the projections "a" on the damper into the

1st and 2nd holes on the right side of the
frame.
• Make sure that the shorter end of the damper
is facing outward as shown in the illustration.
D
2
00 00 000 00
2. Install:
• Fuel hose
• Fuel hose connector holder "1"
• Fuel pump coupler
7-3
THROTTLE BODY
EBS20056
THROTTLE BODY
Removing the throttle body
,, . 0.8 N·m (0.08 kgf·m, 0.59 lb·ft)

4
,., 2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
10 •. 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)

•, 2.8 N·m (0.28 kgf·m, 2.1 lb·ft)

Storage compartment/Air filter case/Air filter Refer to "GENERAL CHASSIS (5)" on page
case joint 4-17.
1 Intake air pressure sensor coupler 1 Disconnect.
2 Throttle position sensor coupler 1 Disconnect.
3 ISC (Idle Speed Control) unit coupler 1 Disconnect.
4 Fuel hose 1 Disconnect.
5 Throttle cable housing cover 1
6 Throttle cable 1 Disconnect.
7 Fuel injector coupler 1 Disconnect.
8 Throttle body joint clamp screw 2 Loosen.
9 Throttle body assembly 1
10 Throttle body breather hose 1
11 Throttle body joint 1
7-4
THROTTLE BODY
Disassembling the throttle body assembly
1'.,, 3.6 N·m (0.36 kgf·m, 2.7 lb-ft)
'
'
\ 5 N·m 0.5 k f•m, 3.7 lb-ft
3
,,,, 3.5 N·m 0.35 k f·m, 2.6 lb·ft

1 Intake air pressure sensor 1
2 Intake air pressure sensor hose 1
3 Throttle position sensor 1
4 Fuel rail 1
5 Fuel injector 1
6 Throttle body 1
7-5
THROTTLE BODY
EBS30229
2. Check:
REMOVING THE THROTTLE BODY
• Fuel passages
ASSEMBLY
Obstructions~ Clean.
1. Disconnect: a. Wash the throttle body in a petroleum-
• Fuel hose
EWB03050
based solvent.
AwARNING Do not use any caustic carburetor clean-
Cover fuel hose connections with a cloth
ing solution.
when disconnecting them. Residual pres- b. Blow out all of the passages with com-
sure in the fuel lines could cause fuel to
pressed air.
spurt out when removing the hose. EBS30233
ECB02360 INSTALLING THE THROTTLE BODY

NOTICE ASSEMBLY
-------------
• Be sure to disconnect the fuel hose by 1. Install:
hand. Do not forcefully disconnect the • Throttle body joint "1"
hose with tools. TIP - - - - - - - - - - - - - - - ~
• Although the fuel has been removed from Fit the ribs "a" on the throttle body joint between
the fuel tank, be careful when disconnect- the projections "b" on the cylinder head.
ing the fuel hose, since there may be fuel
remaining in it.
TIP - - - - - - - - - - - - - - - ~
• To disconnect the fuel hose from the throttle
body, 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- 2. Install:
nected. • Throttle body assembly "1"
TIP - - - - - - - - - - - - - - - ~
Fit the rib "a" on the throttle body assembly with
t the projections "b" on the throttle body joint.
EBS30230
CHECKING THE INJECTOR

1. Check:
• Injector 3. Connect:
Damage ~ Replace. • Fuel hose
EC B02370
EBS30231
NOTICE
CHECKING THE THROTTLE BODY -------------
When connecting the fuel hose, make sure
1. Check:
• Throttle body that it is securely connected, and that the
Cracks/damage~ Replace the throttle body. fuel hose connector cover is in the correct
position, otherwise the fuel hose will not be
properly connected.
7-6
THROTTLE BODY
TIP ~~~~~~~~~~~~~~~
Pressure gauge
To connect the fuel hose onto the throttle body, 90890-03153
slide the fuel hose connector cover "1" on the Pressure gauge
end of the hose in direction of the arrow shown. YU-03153
90890-03176
YM-03176
EBS304-09
CHECKING THE FUEL PRESSURE

1. Check:
• Fuel pressure
a. Remove the rear fender. e. Start the engine.
Refer to "GENERAL CHASSIS (3)" on f. Measure the fuel pressure.
page 4-8. Out of specification ~ Replace the fuel
b. Remove the fuel hose connector holder. pump.
c. Disconnect the fuel hose "1" from the fuel
pump. Fuel pressure
TIP ~~~~~~~~~~~~~~~ 300.0-390.0 kPa (3.00-3.90 kgf/
• When removing the fuel hose from the fuel cm 2 , 43.5-56.6 psi)
pump, remove the fuel hose connector holder
EBS-10234
first, and next, insert a slotted head screwdriver ADJUSTING THE THROTTLE POSITION
etc. in the slot part "a" of the fuel hose connec- SENSOR
tor cover "2", then slide it in the direction of the EWB03070
arrow, and remove the fuel hose. & WARNING

• Before removing the hose, place a few rags in • Handle the throttle position sensor with
the area under where it will be removed. special care.
• Never subject the throttle position sensor
to strong shocks. If the throttle position
sensor is dropped, replace it.
1. Adjust:
• Throttle position sensor angle
\ a. Remove the seat, top cover and side pan-
1 el (left).
Refer to "GENERAL CHASSIS (1 )" on
page 4-1.
b. Remove the protective cap, and then con-
d. Connect the pressure gauge "3" and nect the Yamaha diagnostic tool to cou-
adapter "4" to the fuel pump and fuel hose. pler "1".
TIP~~~~~~~~~~~~~~~
For information about using the Yamaha diag-
nostic tool, refer to the operation manual that is
included with the tool.
7-7
THROTTLE BODY
Yamaha diagnostic tool USB (US)

90890-03257
Yamaha diagnostic tool (A/1)
90890-03262
c. Diagnostic code number "01" is selected.

d. Turn the throttle grip to the fully closed po-
sition.
e. Adjust the position of the accelerator posi-
tion sensor angle so that 14-20 can ap-
pear in the Yamaha diagnostic tool
screen.
f. After adjusting the throttle position sensor
angle, tighten the throttle position sensor
screws "1" to specification.
Throttle position sensor screw

3.5 N-m (0.35 kgf-m, 2.6 lb·ft)
g. Install the seat, top cover and side panel

(left).
page 4-1 .
7-8
AIR INDUCTION SYSTEM
EBS20057
3
1. Air induction system hose (air filter case to air
cut-off valve)
2. Air cut-off valve
3. Air induction system hose (air cut-off valve to
reed valve assembly)
4. Reed valve assembly
7-9
Removing the air cut-off valve
(
'
)
'
'
4
5
I!.J1O N·m (1.0 kgf·m, 7.4 lb·ft) I
3

1 Air cut-off valve coupler 1 Disconnect.
Air induction system hose (air filter case to air
2 cut-off valve) 1
Air induction system hose (air cut-off valve to

3 reed valve assembly) 1
4 Air cut-off valve 1

5 Air cut-off valve bracket 1
7-10
Removing the reed valve
'
3
~ ___ 2
J'.'.: '
u--,,~~ >-·1d
~, 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Side panels
4-1 .
Air induction system hoses Refer to " Removing the air cut-off valve".
1 Reed valve cover 1
2 Reed valve assembly 1
3 Reed valve plate 1
7-11
EBS30235
2. Check:
CHECKING THE AIR INDUCTION SYSTEM
• Reed valve
• Reed valve stopper
Air injection
• Reed valve seat
The air induction system burns unburned ex-
Cracks/damage ~ Replace the reed valve
haust gases by injecting fresh air (secondary air)
assembly.
into the exhaust port, reducing the emission of
3. Check:
hydrocarbons. When there is negative pressure
• Air cut-off valve
at the exhaust port, the reed valve opens, allow-
ing secondary air to flow into the exhaust port.
4. Check:
The required temperature for burning the un-
• Air induction system solenoid
burned exhaust gases is approximately 600 to
Refer to "CHECKING THE AIR INDUCTION
700 °C (1112 to 1292 °F).
SYSTEM SOLENOID" on page 9-90.
Air cut-off valve EBS30236
The air cut-off valve is controlled by the signals INSTALLING THE AIR INDUCTION SYSTEM
from the ECU in accordance with the combus- 1. Install:
tion conditions. Ordinarily, the air cut-off valve • Reed valve plate "1"
opens to allow the air to flow during idle and TIP _ _ _ _ _ _ _ _ _ _ _ _ __
closes to cut-off the flow when the vehicle is be- Align the notch "a" in the reed valve plate with
ing driven. However, if the coolant temperature the projection "b" of the reed valve seat on the
is below the specified value, the air cut-off valve cylinder head.
remains open and allows the air to flow into the
exhaust pipe until the temperature becomes a
higher than the specified value. 0
b--++--
0 0 0 0
~-:lrl o o o o
lJ 0000 bJ
a° ~
~..W..~+:---1
00000
[Al -.--1Hl--+<-l-l---H--+-.- 0
A. From the air filter case

B. To the reed valve
1. Check:
• Hoses
Loose connections ~ Connect properly.
7-12
7-13
DRIVE TRAIN
TROUBLESHOOTING ..................................................................................... 8-1

CH ECKi NG NOISES ................................................................................. 8-2
TROUBLESHOOTING CHART ................................................................. 8-3
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL

ASSEMBLY AND FRONT DRIVE SHAFT ..................................................... 8-4
DISASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT
ASS EM BLI ES ........................................................................................... 8-9
CHECKING THE FRONT CONSTANT VELOCITY SHAFT
ASS EM BLI ES ......................................................................................... 8-1 O
ASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT
ASS EM BLI ES ......................................................................................... 8-1 O
REMOVING THE DIFFERENTIAL GEAR ASSEMBLY ........................... 8-11
CHECKING THE DIFFERENTIAL ASSEMBLY ...................................... 8-12
CHECKING THE DIFFERENTIAL MOTOR OPERATION ...................... 8-12
ASSEMBLING THE DIFFERENTIAL ASS EMBLY .................................. 8-12
MEASURING THE DIFFERENTIAL GEAR BACKLASH ......................... 8-13
ADJUSTING THE DIFFERENTIAL GEAR BACKLASH .......................... 8-14
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE

ASS EMBLY AND REAR DRIVE SHAFT ..................................................... 8-15
DISASSEMBLING THE REAR CONSTANT VELOCITY SHAFT
ASS EM BLI ES ......................................................................................... 8-21
CHECKING THE REAR CONSTANT VELOCITY SHAFT
ASS EM BLI ES ......................................................................................... 8-22
ASSEMBLING THE REAR CONSTANT VELOCITY SHAFT
ASS EM BLI ES ......................................................................................... 8-22
DISASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY ....... 8-23
CHECKING THE REAR DRIVE SHAFT .................................................. 8-23
CHECKING THE FINAL DRIVE ASS EMBLY .......................................... 8-24
ASSEMBLING THE FINAL DRIVE CASE ............................................... 8-24
ASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY ............. 8-24
SELECTING THE FINAL DRIVE PINION GEAR SHIM(S) ..................... 8-25
SELECTING THE FINAL DRIVEN PINION GEAR SHIM
(FINAL DRIVE CASE SIDE) AND THRUST WASHER .......................... 8-26
SELECTING THE FINAL DRIVEN PINION GEAR SHIM
(FINAL DRIVE CASE COVER SIDE) ..................................................... 8-27
SELECTING THE WHEEL GEAR SHIM(S) ............................................ 8-28
MEASURING THE FINAL GEAR BACKLASH ........................................ 8-29
ADJUSTING THE FINAL GEAR BACKLASH ......................................... 8-29
TROUBLESHOOTING
EBS20058
TROUBLESHOOTING
The following conditions may indicate damaged shaft drive components:
Symptoms Possible Causes
1 . A pronounced hesitation or "jerky'' movement A. Bearing damage.
during acceleration, deceleration, or sustained B. Improper gear backlash.
speed. (This must not be confused with engine C. Gear tooth damage.
surging or transmission characteristics.) D. Broken drive shaft.
2. A "rolling rumble" noticeable at low speed; a high- E. Broken gear teeth.
pitched whine; a "clunk" from a shaft drive com- F. Seizure due to lack of lubrication.
ponent or area. G. Small foreign objects lodged between the moving
3. A locked-up condition of the shaft drive train parts.
mechanism, no power transmitted from the en-
gine to the front and/or rear wheels.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite subtle and
difficult to distinguish from normal vehicle operating noise. If there is reason to believe these compo-
nents are damaged, remove the components and check them.
8-1
TROUBLESHOOTING
EBS30237
c. Road test the vehicle for the distance nec-
CHECKING NOISES
essary to locate the leak.
1. Investigate any unusual noises. Leakage ~ Check the component hous-
ing, gasket, and/or seal for damage.
The following "noises" may indicate a me-
Damage ~ Replace the component.
chanical defect:
TIP ~~~~~~~~~~~~~~~~
a. A "rolling rumble" noise during coasting,
acceleration, or deceleration. The noise • An apparent oil leak on a new or nearly new ve-
increases with front and/or rear wheel hicle may be the result of a rust-preventative
speed, but it does not increase with higher coating or excessive seal lubrication.
engine or transmission speeds. • Always clean the vehicle and recheck the sus-
Diagnosis: Possible wheel bearing dam- pected location of an apparent leakage.
age.
Refer to ''TROUBLESHOOTING CHART"
on page 8-3.
b. A "whining" noise that varies with acceler-
ation and deceleration.
Diagnosis: Possible incorrect reassembly,
too little gear backlash.
Refer to ''TROUBLESHOOTING CHART"
on page 8-3.
EWB02900
A WARNING
Insufficient gear backlash is extremely de-
structive to the gear teeth. If a test ride, fol-
lowing reassembly, indicates these
symptoms, stop riding immediately to mini-
mize gear damage.
c. A slight ''thunk" evident at low speed oper-
ation. This noise must be distinguished
from normal vehicle operation.
Diagnosis: Possible broken gear teeth .
EWB02910
A WARNING
Stop riding immediately if broken gear teeth
are suspected. This condition could result in
the shaft drive assembly locking up, causing
a loss of control and possible injury to the
rider.
2. Check:
• Drained oil
Drained oil shows large amounts of metal
particles ~ Check the bearing for seizure.
TIP ~~~~~~~~~~~~~~~~
A small amount of metal particles in the oil is nor-

mal.
3. Check:
• Oil leakage
a. Clean the entire vehicle thoroughly, then
dry it.
b. Apply a leak-localizing compound or dry
powder spray to the shaft drive.
8-2
TROUBLESHOOTING
EBS30238
TROUBLESHOOTING CHART
When basic conditions (a) and (b) exist, check the following points:
--------------~
YES~ Replace the wheel bearing. (Refer to ''TIE-
1. Elevate and spin both wheels. Feel RODS AND STEERING KNUCKLES" on
for wheel bearing damage. page 4-56 and "REAR KNUCKLES AND
STABILIZER" on page 4-65.)
NO J,
Torque to specification . (Refer to "FRONT

2. Check the wheel nuts and axle nuts
WHEELS" on page 4-20 and "REAR
for tightness.
WHEELS" on page 4-23.)
YES J,
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 J,
NO~ Adjust per instructions. (Refer to "AD-

4. Check the rear brake adjustment. JUSTING THE REAR DISC BRAKE" on
page 3-10.)
YES J,
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 J,
Remove the shaft drive components.
8-3
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN-
TIAL ASSEMBLY AND FRONT DRIVE SHAFT
EBS20059
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL

ASSEMBLY AND FRONT DRIVE SHAFT
Removing the front constant velocity shaft assemblies, differential assembly and front drive shaft
.•. 55 N·m (5.5 kgf·m, 41 lb·ft) , 55 N·m (5.5 kgf·m, 41 lb·ft)
'
''•
·~ t;.t
'''
'
____ l___ ·-------·

4 6
:il-~ 3
·• 66 N·m (6.6 kgf·m, 49 lb·ft)
Front skid plate Refer to "GENERAL CHASSIS (1)" on page

4-1 .
Steering knuckles Refer to "TIE-RODS AND STEERING

KNUCKLES" on page 4-56.
Refer to "FRONT ARMS AND FRONT
Front arms SHOCK ABSORBER ASSEMBLIES" on
page 4-60.
Drain.
Differential gear oil Refer to "CHANGING THE DIFFERENTIAL
GEAR OIL'.' on page 3-24.
1 Front constant velocity shaft assembly 2
2 Differential motor coupler 1 Disconnect.
4 Differential assembly 1
5 Front drive shaft 1
8-4
Removing the front constant velocity shaft assemblies, differential assembly and front drive shaft
.•• 55 N·m (5.5 kgf·m, 41 lb·ft) , 55 N·m (5.5 kgf·m, 41 lb·ft)
'
''•
·~ t ;>
'''
'
-------- ·------- '
·. 66 N•m (6.6 kgf-m, 49 lb·ft)
6 Spring 1
7 Damper 1
8 Front drive shaft coupling sleeve 1
9 Dust seal 1
10 Dust seal 1
8-5
11~m
6
71~fMJ
8
Sl~fMJ
1~tMJ3
4
. 11
14
101~fMj
131~fMJ
d 12
A: Wheel side
B: Differential side

the front constant velocity shaft assemblies.
1 Clip 1
2 Boot band 1
3 Boot band 1
4 Dust boot 1
5 Clip 1
6 Double offset joint 1
7 Circlip 1
8 Ball bearing 1
9 Boot band 1
10 Boot band 1
11 Dust boot 1
12 Constant velocity joint 1
13 Clip 1
14 Constant velocity shaft 1
8-6
Disassembling the differential assembly
3
·• 24 N·m (2.4 kgf·m, 18 lb·ft) 4
., 23 N·m (2.3 kgf·m, 17 lb·ft)
•
B
,;, 62 N·m (6.2 kgf·m, 46 lb·ft)
'
,\ 11 N·m (1.1 kgf·m, 8.1 lb·ft)
'\ 1O N·m (1.0 kgf·m, 7.4 lb·ft)

'
5 2
9
8
TIP
Do not disassemble the differential motor or
remove the differential motor pinion gear.
1 Differential motor 1
2 0-ring 1
3 Front drive shaft yoke nut (differential case side) 1
4 Front drive shaft yoke (differential case side) 1
5 Differential case cover 1
6 0-ring 1
7 Differential gear assembly 1
Refer to "ADJUSTING THE DIFFEREN-
8 Differential gear assembly shim
TIAL GEAR BACKLASH'' on page 8-14.
9 Bearing 1
8-7
Disassembling the differential assembly
·• 24 N•m (2.4 kgf,m, 18 lb-ft)

11
,, 23 N•m (2.3 kgf,m, 17 lb·ft)
12
14
• 15
B
,;, 62 N•m (6.2 kgf·m, 46 lb·ft)
' 7
10
,\ 11 N·m (1.1 kgf·m, 8.1 lb·ft)
··, 10 N•m (1.0 k f,m, 7.4 lb·ft)

'
16
10 Bearing 1
11 Oil seal 1
12 Clip 1
13 Differential pinion gear 1
14 Bearing 1
15 Bearing 1
16 Oil seal 2
17 Differential case 1
8-8
EBS30240
DISASSEMBLING THE FRONT CONSTANT

VELOCITY SHAFT ASSEMBLIES 4
front constant velocity shaft assemblies.
3
1. Remove:
• Boot band "1"
Use the boot band installation tool "2".

90890-01526
Boots band installation tool A. Differential side
YM-01526
3. Remove:
• Boot band "1"

2 90890-01526
1 Boots band installation tool
YM-01526
A. Final drive side

2
2. Remove: 1
• Clip "1"
• Double offset joint "2"
• Circlip "3"
• Ball bearing "4"
• Dust boot "5"
B. Wheel side
TIP~~~~~~~~~~~~~~
Before removing the clip, slide the dust boot 4. Remove:

away from the double offset joint. • Dust boot
• Constant velocity joint
• Clip
TIP~~~~~~~~~~~~~~
Secure the constant velocity shaft in a vise, and
then remove the constant velocity joint using
hammers.
B. Wheel side
8-9
ESS30241
CHECKING THE FRONT CONSTANT

front constant velocity shaft assemblies.
1. Check:
• Double offset joint splines
• Constant velocity joint splines
• Constant velocity shaft splines
2. Check:
• Dust boots
EC801590
NOTICE
-------------
A Iways use a new boot band.
3. Check:
• Balls and ball races (
• Inner surface of double offset joint
Pitting/wear/damage ~ Replace.
EBS30242
A. Wheel side
ASSEMBLING THE FRONT CONSTANT
VELOCITY SHAFT ASSEMBLIES 2. Install:
The following procedure applies to both of the • Dust boot
front constant velocity shaft assemblies. • Ball bearing "1"
1. Install: • Circlip "2" l~fffi
• Clip "1" l~iU • Double offset joint "3"
• Constant velocity joint "2" • Clip "4" l~fU
• Constant velocity shaft "3" TIP _~~~~~~~~~~~~~
• Dust boot
• Securely install the circlip into the groove in the
a. Install the clip.
constant velocity shaft.
b. Install the constant velocity joint.
• Securely install the clip into the groove in the
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ double offset joint.
• Install the clip into the groove in the constant
velocity shaft as shown.
• Secure the constant velocity joint in a vise, and 1
then fit the constant velocity shaft into the con-
stant velocity joint using a hammer. 21~f:M
< 3
8-10

90890-01526
YM-01526
41~tMJ
6
B. Differential side
3. Apply:
• Molybdenum disulfide grease
(into the double offset joint, constant velocity
joint, and dust boots)
5. Check:
Molybdenum disulfide grease • Thrust movement free play
I 70 g (2.5 oz) per dust boot Excessive play ~ Replace the constant ve-
(wheel side) locity shaft assembly.
55 g (1.9 oz) per dust boot (dif-
ferential side)
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Molybdenum disulfide grease is included in the
repair kit. -
4. Install:
• Dust boots "1"
• Boot bands "2", "3", "4", "5" l~fffi
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ EBS30244
• The new boot bands may differ from the origi- REMOVING THE DIFFERENTIAL GEAR
nal ones. ASSEMBLY
• The dust boots should be fastened with the 1. Remove:
boot bands "3" and "5" at the grooves in the • Differential gear assembly "1"
EC B01570
NOTICE
------------
The ring gear and differential gear are as-
sembled into a proper unit at the factory by
means of specialized equipment. Do not at-
tempt to disassemble this unit. Disassembly
will result in the malfunction of the unit.
a. Install the dust boots.

b. Install the dust boot bands.
8-11
EBS30246
CHECKING THE DIFFERENTIAL ASSEMBLY 3V

1. Check: I +
• Gear teeth
Pitting/galling/wear ~ Replace differential
pinion gear and differential gear assembly as 1
a set.
• Bearings
Pitting/damage ~ Replace.
• Oil seals
• 0-rings
Damage ~ Replace.
3V
2. Check:
...--,,+ I +
• Drive shaft splines
• Pinion gear splines
• Spring
Fatigue ~ Replace.
3. Check:
• Front drive shaft
Bends ~ Replace.
EWB0304-0 A. Check that the differential motor pinion gear
A WARNING "2" turns counterclockwise.
Do not attempt to straighten a bent shaft; B. Check that the differential motor pinion gear
"2" turns clockwise.
this may dangerously weaken it.
EBS30249
EBS30247 ASSEMBLING THE DIFFERENTIAL
CHECKING THE DIFFERENTIAL MOTOR ASSEMBLY
OPERATION 1. Measure:
1. Check: • Gear backlash
• Differential motor Refer to "MEASURING THE DIFFERENTIAL
Does not operate ~ Replace. GEAR BACKLASH" on page 8-13.
ECB01930
NOTICE
2. Install:
-------------
Do not disassemble the differential motor or
• Differential motor
a. Slide the shift fork sliding gear "1 ", which is
remove the differential motor pinion gear. installed to the differential case cover, to
a. Connect two C-size batteries to the differ- the left as shown in the illustration to put it
ential motor terminals "1" (as shown in the into the 2WD mode.
illustrations).
ECB01940
NOTICE
-------------
• Do not use a 12 V battery to operate the dif-
ferential motor pinion gear.
• Do not connect the batteries to the differen-
tial motor when it is installed in the differen-
tial case. The differential motor should be
checked when it is removed from the differ-
ential case.
b. Connect two C-size batteries to the differ-
ential motor terminal "2" to operate the dif-
ferential motor pinion gear "3". Operate
the differential motor pinion gear until the
8-12
mark "4" on the differential motor pinion
gear is aligned with the mark "5" on the dif-
ferential motor case.
EC8016SO
NOTICE
- - - - - - - - - - - -
Do not use a 12 V battery to operate the dif-
ferential motor pinion gear.
3V
r---11+ I +
EBS30251
MEASURING THE DIFFERENTIAL GEAR

BACKLASH
1. Secure the differential case in a vise or anoth-
er supporting device.
2. Remove:
• Drain plug
c. Insert 6 mm bolts "6" into the differential • Gasket
motor "7" and use them as a guide to set 3. Install:
the motor on the differential case cover "8" • Ring gear fix bolt (M10) "1"
so that the shift fork sliding gear "9" does (into the drain plug hole)
not move. Ring gear fix bolt (M1 O)
ECB019SO
NOTICE 90890-01527
------------ Ring gear fix bolt (M1 O)
1f the position of the shift fork sliding gear is YM-01527
moved, the position of the differential gear
assembly and the indicator light display may ECB01250
differ, and the 2WD or differential lock mode NOTICE

------------
may not be activated. Finger tighten the bolt until it holds the ring
gear. Otherwise, the ring gear will be dam-
6 aged.
4. Attach :
7 • Gear lash measurement tool "2"
• Dial gauge "3"
Gear lash measurement tool

90890-01475
YM-01475
d. Remove the 6 mm bolts, and then install
the motor with the differential motor bolts.
Differential motor bolt

11 N,m (1.1 kgf,m, 8.1 lb,ft)
3. Check:
• Differential assembly operation 0
Unsmooth operation ~ Replace the differen-

tial assembly.
Insert the double offset joint into the differen-
tial assembly, and turn the gears back and a. Measuring point is 22.5 mm (0.86 in)
forth. b. Measuring point is 28 mm (1.10 in)
8-13
5. Measure:
• Gear backlash
Gently rotate the differential pinion gear from
engagement to engagement.
Differential gear backlash

0.05-0.25 mm (0.002-0.01 O in)
TIP ~~~~~~~~~~~~~~
Measure the gear backlash at four positions. Ro-

tate the differential pinion gear 90° each time.
EBS30252
ADJUSTING THE DIFFERENTIAL GEAR

BACKLASH
1. Remove:
• Differential gear assembly shim(s) "1"
• Differential gear assembly "2"
2
2. Adjust:
• Gear backlash
a. Select the suitable shims using the follow-
ing chart.
Differential gear backlash is
Thinner shim
increased.
Differential gear backlash is
Thicker shim
decreased.
Differential gear assembly shims

Thickness (mm)
0.10.20.3 0.4
b. Measure the differential gear backlash

.
again.
8-14
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
EBS20060
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE

ASSEMBLY AND REAR DRIVE SHAFT
Removing the rear constant velocity shaft assemblies, final drive assembly and rear drive shaft
3
2
1
el
J§Y~/
· ~ '
/
ts. 66 N·m (6.6 kgf·m, 49 lb·ft)

I
·---------------

Rear skid plate 4-1 .
Rear fender Refer to "GENERAL CHASSIS (3)" on page

4-8.
Refer to "REAR ARMS AND REAR SHOCK
Rear arms ABSORBER ASSEMBLIES" on page 4-68.
Drain.
Final gear oil Refer to "CHANGING THE FINAL GEAR
OIL'.' on page 3-25.
1 Rear constant velocity shaft assembly 2
2 Final drive case breather hose 1 Disconnect.
3 Trailer hitch 1
8-15
Removing the rear constant velocity shaft assemblies, final drive assembly and rear drive shaft
t,". 66 N·m (6.6 kgf·m, 49 lb-ft)

:__________ r___ I

4 Final drive assembly 1
5 Rear drive shaft 1
6 Spring 1
7 Damper 1
8 Rear drive shaft coupling sleeve 1
9 Dust seal 1
10 Dust seal 1
8-16
11~f:Mj
6
71~f:Mj
8
I
·~·3
2 l~fMJ
· 11
101~f:Mj
14
131~f:Mj
d 12
A: Wheel side
B: Final drive side

the rear constant velocity shaft assemblies.
1 Clip 1
2 Boot band 1
3 Boot band 1
4 Dust boot 1
5 Clip 1
6 Double offset joint 1
7 Circlip 1
8 Ball bearing 1
9 Boot band 1
10 Boot band 1
11 Dust boot 1
12 Constant velocity joint 1
13 Clip 1
14 Constant velocity shaft 1
8-17
Disassembling the final drive assembly
•
,
, ,,
, , '
,, ,'/~ - - - - - - - - ~
, ,
, ··• 23 N·m (2.3 kgf·m, 17 lb·ft)
,
,, , ,
, , <,. 1O N·m (1.0 kgf·m, 7.4 lb·ft)
, -. 23 N·m (2.3 kgf·m, 17 lb·ft)

, ,
,
,,
,
,,
·, 23 N·m (2.3 kgf·m, 17 lb·ft)
:\_ 23 N·m (2.3 kgf·m, 17 lb·ft)
1 Final drive pinion gear assembly 1

Refer to "SELECTING THE FINAL DRIVE
2 Final drive pinion gear shim
PINION GEAR SHIM(S)" on page 8-25.
TIP
3 Final drive case cover 1 Working in a crisscross pattern, loosen each
bolt 1/4 of a turn. After all the bolts are loos-
ened, remove them.
4 Dowel pin 2
5 Gasket 1
6 Oil seal 1
7 Bearing 1
8 Bearing 1
Refer to "SELECTING THE WHEEL GEAR
9 Wheel gear shim SHIM(S)" on page 8-28.
8-18
• ,
,
, , ··• 23 N·m (2.3 kgf·m, 17 lb-ft)
,
,
, <,, 10 N-m (1.0 kgf·m, 7.4 lb-ft)
-. 23 N·m (2.3 kgf·m, 17 lb·ft)
13
·, 23 N·m (2.3 kgf·m, 17 lb-ft)
:\_ 23 N-m (2.3 kgf·m, 17 lb-ft)
10 Wheel gear 1
Refer to "SELECTING THE FINAL DRIVEN
Final driven pinion gear shim (final drive case
11 PINION GEAR SHIM (FINAL DRIVE CASE
cover side)
COVER SIDE)" on page 8-27.
12 Pinion gear 1
13 Final driven pinion gear 1
PINION GEAR SHIM (FINAL DRIVE CASE
14 Thrust washer
SIDE) AND THRUST WASHER" on page
8-26.
Final driven pinion gear shim (final drive case PINION GEAR SHIM (FINAL DRIVE CASE
15 SIDE) AND THRUST WASHER" on page
side)
8-26.
16 Oil seal 1
17 Bearing 1
18 Bearing 1
19 Final drive case 1
8-19
• ,
,
, , ··• 23 N·m (2.3 kgf·m, 17 lb-ft)
,
, <,, 10 N-m (1.0 kgf·m, 7.4 lb-ft)
-. 23 N·m (2.3 kgf·m, 17 lb·ft)
·, 23 N·m (2.3 kgf·m, 17 lb-ft)
:\_ 23 N-m (2.3 kgf·m, 17 lb-ft)
20 Rear drive shaft yoke nut 1

21 Washer 1
22 Rear drive shaft yoke (final drive case side) 1
23 Final drive pinion gear 1
24 Oil seal 1
25 Bearing 1
26 Expander 1
27 Washer 1
28 Bearing 1
29 Final drive pinion gear bearing housing 1
8-20
EBS30253
DISASSEMBLING THE REAR CONSTANT

rear constant velocity shaft assemblies.
3
1. Remove:
• Boot band "1"

90890-01526
Boots band installation tool A. Final drive side
YM-01526
3. Remove:
• Boot band "1"

2 90890-01526
1 Boots band installation tool
YM-01526
A. Final drive side

2
2. Remove: 1
• Clip "1"
• Double offset joint "2"
• Circlip "3"
• Ball bearing "4"
• Dust boot "5"
B. Wheel side
TIP~~~~~~~~~~~~~~
Before removing the clip, slide the dust boot 4. Remove:

away from the double offset joint. • Dust boot
• Constant velocity joint
• Clip
TIP ~~~~~~~~~~~~~~
Secure the constant velocity shaft in a vise, and
then remove the constant velocity joint using
hammers.
B. Wheel side
8-21
EBS30254
CHECKING THE REAR CONSTANT

rear constant velocity shaft assemblies.
1. Check:
• Double offset joint splines
• Constant velocity joint splines
• Constant velocity shaft splines
2. Check:
• Dust boots
EC801590
NOTICE
-------------
AIways use a new boot band.
3. Check:
• Balls and ball races (
• Inner surface of double offset joint
Pitting/wear/damage ~ Replace.
EBS30255
A. Wheel side
ASSEMBLING THE REAR CONSTANT
VELOCITY SHAFT ASSEMBLIES 2. Install:
The following procedure applies to both of the • Dust boot
rear constant velocity shaft assemblies. • Ball bearing "1"
1. Install: • Circlip "2" l~fffi
• Clip "1" l~iU • Double offset joint "3"
• Constant velocity joint "2" • Clip "4" l~fU
• Constant velocity shaft "3" TIP _~~~~~~~~~~~~~
• Dust boot
• Securely install the circlip into the groove in the
a. Install the clip.
b. Install the constant velocity joint.
• Securely install the clip into the groove in the
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ double offset joint.
• Install the clip into the groove in the constant
velocity shaft as shown.
• Secure the constant velocity joint in a vise, and 1
then fit the constant velocity shaft into the con-
stant velocity joint using a hammer. 21~f:M
< 3
8-22

90890-01526
YM-01526
41~tMJ
6
B. Final drive side
3. Apply:
• Molybdenum disulfide grease
(into the double offset joint, constant velocity
joint, and dust boots)
5. Check:
Molybdenum disulfide grease • Thrust movement free play
I 60 g (2.1 oz) per dust boot Excessive play ~ Replace the constant ve-
(wheel side) locity shaft assembly.
70 g (2.5 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" l~fffi
TIP ~~~~~~~~~~~~~~ EBS30256
• The new boot bands may differ from the origi- DISASSEMBLING THE FINAL DRIVE PINION
nal ones. GEAR ASSEMBLY
• The dust boots should be fastened with the 1. Remove:
boot bands "3" and "5" at the grooves in the • Rear drive shaft yoke nut "1"
constant velocity shaft. a. Place a folded rag as shown.
b. Secure the final drive pinion gear in the
.
vise.
a. Install the dust boots.

b. Install the dust boot bands. c. Remove the rear drive shaft yoke nut.
EBS30257
CHECKING THE REAR DRIVE SHAFT

1. Check:
• Drive shaft splines
8-23
• Coupling sleeve splines EBS30262
ASSEMBLING THE FINAL DRIVE PINION

GEAR ASSEMBLY
EBS30258 1. Install:
CHECKING THE FINAL DRIVE ASSEMBLY • Rear drive shaft yoke nut "1"
1. Check: a. Place a folded rag as shown.
• Final drive case b. Secure the final drive pinion gear in the
• Final drive case cover .
vise.
TIP ~~~~~~~~~~~~~~
When the final drive case and/or the final drive

case cover are replaced, be sure to adjust the
shim of the final drive pinion gear and/or final
driven pinion gear.
2. Check:
• Gear teeth
Pitting/galling/wear~ Replace the final drive
pinion gear and final driven pinion gear as a
c. Tighten the rear drive shaft yoke nut.
set. (temporarily)
TIP~~~~~~~~~~~~~~~
When the final drive pinion gear, final driven pin- Rear drive shaft yoke nut (tempo-
ion gear and/or wheel gear are replaced, be sure rarily)
to adjust the shim of the final drive pinion gear, 82 N,m (8.2 kgf,m, 60 lb,ft)
final driven pinion gear and/or wheel gear. LOCTITE®
• Oil seals d. Secure the final drive pinion gear bearing

• 0-ring housing in a vice, and then turn the nut
Damage ~ Replace. with a torque wrench to check the starting
3. Check: torque.
• Bearings
Damage ~ Replace. Final drive pinion gear starting
torque (final drive pinion gear
ESS30410
preload)
ASSEMBLING THE FINAL DRIVE CASE 0.8-1.3 N,m (0.08-0.13 kgf,m,
1. Install: 0.59-0.95 lb,ft)
• Oil seals "1"
e. Out of specification ~ Tighten the nut fur-
Installed depth of oil seal "a" ther.
5.5 mm (0.22 in) f. Repeat steps (d) and (e) until the starting
torque is within specification.
TIP~~~~~~~~~~~~~~
• Be careful not to exceed the specified starting

torque.
1- 1--1
• If the specified starting torque is exceeded, re-
place the expander with a new one and reas-
semble the final drive pinion gear assembly.
--
a -·-
a
• Make sure that the distance "a" is 67.5-68.1
mm (2.66-2.68 in) as shown.
8-24
a
0 A
C
2. Check: d
• Final drive assembly operation
a
Unsmooth operation~ Replace the final
drive assembly.
Insert the double offset joint into the final
drive assembly, and turn the gears back and
forth.
ESS30413
,_,
SELECTING THE FINAL DRIVE PINION
GEAR SHIM(S)
1. Select:
Example:
• Final drive pinion gear shim(s) "1"
a. To find the final drive pinion gear shim "a"= 55
If "-02" is stamped on the final drive pinion
thickness "A", use the following formula.
gear,
Final drive pinion gear shim thickness
"A" = "a" + ("c" - "b") - "d"
"b" = 22.2 - 0.02
= 22.18
"a"= 55 mm
b
"b" = a numeral (usually a decimal num-
ber) on the final drive pinion gear either
added to or subtracted from "22.2"
"c" = a numeral (usually a decimal num-
ber) on the final drive pinion gear bearing
housing either added to or subtracted from
"67.8"
"d" = a numeral (usually a decimal num-
ber) on the final drive case either added to
or subtracted from "100" If "-05" is stamped on the final drive pinion
gear bearing housing,
"c" = 67.8 - 0.05
= 67.75
8-25
If "-01" is stamped on the final drive case, ''f' = a numeral (usually a decimal number)
"d" = 100 - 0.01 on the final driven pinion gear either added
= 99.99 to or subtracted from "51.0"
"g" = a numeral (usually a decimal num-
ber) on the final driven pinion gear either
added to or subtracted from "24.0''
"h" = 49.8
e
d f
g j I
J - ~
>-1
-
Therefore, "A" is 0.58.
_Al~
- r~
~ -=
""" l
l I
"A"= 55 + (67.75 - 22.18) - 99.99 -
= 0.58
Round off the hundredth digit and select }' II
D I
~
-' (
the appropriate shim(s). I'\ ~
In the example above, the calculated num-

ber is 0.58. The chart instructs you to
( ~ "' /r ~;;
round off 8 to 1O at the hundredth place. -
-
1
n
C
>- ll D
Thus, the shim thickness is 0.60 mm I
(0.024 in).
~ [ J
- II
>- ~'lil.J ~ 1
0, 1, 2
3,4,5, 6, 7
0
5 )
----. ,..-
/~0-~2
8, 9 10 .i 1 ( -
-
nesses. [
-
Final drive pinion gear shims ~ 1 1 -
(
-
Thickness (mm)
0.25 0.30 0.35 0.40 0.45 0.50 \1 .---- - '----
'--.,
ESS30412
SELECTING THE FINAL DRIVEN PINION

GEAR SHIM (FINAL DRIVE CASE SIDE) AND h -e
THRUST WASHER
1. Select: Example:
• Final driven pinion gear shim (final drive case If "-03" is stamped on the final drive case,
side) "1" "e" = 71 .6 - 0.03
• Thrust washer "2" = 71 .57
a. To find the final driven pinion gear shim (fi-
nal drive case side) and thrust washer
thickness "B", use the following formula.
Final driven pinion gear shim (final drive case
side) and thrust washer thickness
"B" = "h" - ("e" - "f" + "g") e
"e" = a numeral (usually a decimal num-
ber) on the final drive case either added to
or subtracted from "71.6"
8-26
If "-12" is stamped on the outside of the fi-
nal driven pinion gear, Thrust washer "2"
''f" = 51.0 - 0.12 Thickness (mm)
= 50.88 4.50 4.80 5.10 5.40
TIP ~~~~~~~~~~~~~~
Be sure to use one of each of the final driven pin-

f
ion gear shim (final drive case side) "1" and
thrust washer "2" to obtain the shim and thrust
washer thickness.
EBS30411
SELECTING THE FINAL DRIVEN PINION

GEAR SHIM (FINAL DRIVE CASE COVER
If "-05" is stamped on the outside of the fi- SIDE)
nal driven pinion gear, 1. Measure:
"g" = 24.0 - 0.05 • Final driven pinion gear thrust clearance "C"
= 23.95
"h" = 49.8
Therefore, shim and thrust washer thick-
ness "B" is 5.16.
"B" = 49.8 - (71 .57 - 50.88 + 23.95)
= 5.16
Round off the hundredth digit and select
the appropriate shim(s).
In the example above, the calculated num-
ber is 5.16. The chart instructs you to
round off 6 to 5 at the hundredth place. a. Place four pieces of Plastigauge® be-
Thus, the shim and thrust washer thick-
tween the originally fitted shim(s) and the
ness is 5.15 mm.
final driven pinion gear assembly.
Hundredth Rounded value b. Install the final driven pinion gear assem-
0, 1, 2 0 bly, final driven pinion gear shim (final
drive case side) and thrust washer, and
3,4,5, 6, 7 5
tighten the bolts to specification.
8, 9 10
Final drive case cover bolt
Shim and thrust washer are supplied in 23 N-m (2.3 kgf-m, 17 lb·ft)
the following thicknesses.
TIP~~~~~~~~~~~~~~
Final driven pinion gear shims (fi-
nal drive case side) "1" Do not turn the final drive pinion gear, wheel
Thickness (mm) gear, and driven pinion gear when measuring
0.25 0.30 0.35 0.40 0.45 0.50 the clearance with Plastigauge®.
8-27
c. Remove the final driven pinion gear as- I
sembly.
d. Measure the thrust clearance. Calculate -
the width of the flattened Plastigauge® ITT' __)
r
L (( ~
-
~
"1".
Final driven pinion gear thrust

)
-
----
k2 ·-
clearance
0.08-0.12 mm (0.0031-0.0047 in)
J-
'
u 1
- 111
-
- rTJ >---
l ,-
~
>---
~ ~
1 \ I
e. If out of specification, remove the originally

o- i-
fitted shim(s), and then select the correct
a. Place four pieces of Plastigauge® be-
shim(s). tween the originally fitted wheel gear
2. Select:
shim(s) and the wheel gear.
• Final driven pinion gear shim (final drive case b. Install the wheel gear and tighten the bolts
cover side) to specification.
a. Select suitable final driven pinion gear
shims (final drive case cover side) using Final drive case cover bolt
the following chart. 23 N-m (2.3 kgf-m, 17 lb·ft)
Final driven pinion gear shims (fi- TIP ~~~~~~~~~~~~~~
nal drive case cover side)
Thickness (mm) Do not turn the drive pinion gear, wheel gear, or
0.25 0.30 0.35 0.40 0.45 0.50 driven pinion gear when measuring the clear-
ance with Plastigauge®.
TIP~~~~~~~~~~~~~~ c. Remove the wheel gear.
Measure the thickness of the originally fitted d. Measure the thrust clearance. Calculate
shim(s), and then calculate the required new the width of the flattened Plastigauge®
shim thickness to bring the final driven pinion "1".
gear thrust clearance within the specified limits.
Wheel gear thrust clearance
b. Repeat the measurement steps until the fi- 0.03-0.07 mm (0.0012-0.0028 in)
nal driven pinion gear thrust clearance is
within the specified limits.
1
EBS30414
\
SELECTING THE WHEEL GEAR SHIM(S)
1. Measure:
• Wheel gear thrust clearance "D"
8-28
e. If out of specification, remove the originally
fitted shim(s), and then select the correct
shim(s). 3
2. Select:
• Wheel gear shim(s)
a. Select suitable wheel gear shims using
the following chart.
Wheel gear shims

Thickness (mm) b
0.25 0.30 0.35 0.40 0.45 0.50
a. Measuring point is 31.5 mm (1.24 in)
b. Measuring point is 32.1 mm (1.26 in)
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Measure the thickness of the originally fitted 5. Measure:
shim(s), and then calculate the required new • Gear backlash
shim thickness to bring the wheel gear thrust Gently rotate the final drive pinion gear from
clearance within the specified limits. engagement to engagement.
b. Repeat the measurement steps until the Final gear backlash
wheel gear thrust clearance is within the 0.10-0.20 mm (0.004-0.008 in)
specified limits.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
EBS30260
MEASURING THE FINAL GEAR BACKLASH • When measuring the gear backlash, be sure
1. Secure the final drive case in a vise or anoth- the right side (gear oil level check bolt side) of
er supporting device. the final drive case assembly is facing down-
2. Remove: ward.
• Drain plug • Measure the gear backlash at four positions.
• Gasket Rotate the final drive pinion gear 90° each
3. Install: time.
• Ring gear fix bolt (M 14) "1"
(into the drain plug hole) EBS30261
ADJUSTING THE FINAL GEAR BACKLASH

Ring gear fix bolt (M14) 1. Remove:
90890-01524 • Final driven pinion gear assembly "1"
Ring gear fix bolt (M14) • Final driven pinion gear shim (final drive case
YM-01524 side) "2"
ECB01250
• Thrust washer "3"
NOTICE • Final driven pinion gear shim (final drive case
------------- cover side) "4"
Finger tighten the bolt until it holds the ring
gear. Otherwise, the ring gear will be dam-
aged.
1
4. Attach:
• Final gear backlash band "2" 2 4
• Dial gauge "3"
Final gear backlash band

90890-01511
YM-01230
2. Adjust:
• Gear backlash
a. Select a suitable shim(s) and thrust wash-
er(s) using the following chart.
8-29
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):
Reduce the final driven pinion gear shim
(final drive case cover side) "4" thickness
by 0.2 mm (0.008 in) for every 0.2 mm
(0.008 in) that the final driven pinion gear
shim (final drive case side) "2" and thrust
washer "3" are increased.
c. If reduced by more than 0.2 mm (0.008 in):
Increase the final driven pinion gear shim
(final drive case cover side) "4" thickness
by 0.2 mm (0.008 in) for every 0.2 mm
(0.008 in) that the final driven pinion gear
shim (final drive case side) "2" and thrust
washer "3" are decreased.
nal drive case side) "2"
Thickness (mm)
0.25 0.30 0.35 0.40 0.45 0.50
Thrust washers "3"

Thickness (mm)
4.50 4.80 5.10 5.40
TIP~~~~~~~~~~~~~~
Be sure to use one of each of the final driven pin-
ion gear shim (final drive case side) "2" and
thrust washer "3" to obtain the shim and thrust
washer thickness.

nal drive case cover side) "4"
Thickness (mm)
0.25 0.30 0.35 0.40 0.45 0.50
8-30
8-31
ELECTRICAL SYSTEM
IGNITION SYSTEM ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9-1

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

CIRCUIT DIAGRAM •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........................ .. 9-7
TROUBLESHOOTING •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9-8
CHARGING SYSTEM .................................................................................... 9-10

CIRCUIT DIAGRAM ................................................................................ 9-10
TROUBLESHOOTING •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9-11
LIGHTING SYSTEM ...................................................................................... 9-13

CIRCUIT DIAGRAM ................................................................................ 9-13
SIGNALING SYSTEM ................................................................................... 9-17

CIRCUIT DIAGRAM ................................................................................ 9-17
COOLING SYSTEM ....................................................................................... 9-25

CIRCUIT DIAGRAM •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9-25
FU EL INJECTION SYSTEM .......................................................................... 9-29

CIRCUIT DIAGRAM •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9-29
ECU SELF-DIAGNOSTIC FUNCTION ................................................... . 9-31
TROUBLESHOOTING METHOD ........................................................... . 9-32
YAM AHA DIAGNOSTIC TOOL .............................................................. . 9-32
TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM) .......... .. 9-33
FUEL PUMP SYSTEM ...... ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9-55

CIRCUIT DIAGRAM •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9-55
2WD/4WD SELECTING SYSTEM ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9-59

CIRCUIT DIAGRAM •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9-59
EPS (ELECTRIC POWER STEERING) SYSTEM ......................................... 9-63
CIRCUIT DIAGRAM ................................................................................ 9-6.3
EPS CONTROL UNIT'S SELF-DIAGNOSTIC FUNCTION ..................... 9-65
EPS WARNING LIGHT DURING NORMAL OPERATION ...................... 9-65
DIAGNOSTIC MODE .............................................................................. 9-66
SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM) ...................... 9-68
TROUBLESHOOTING DETAILS (EPS SYSTEM) .................................. 9-69
ELECTRICAL COMPONENTS ...................................................................... 9-73

CH ECKi NG THE SWITCHES ................................................................. 9-75
CHECKING THE BULBS AND BULB SOCKETS ................................... 9-77
CHECKING THE FUSES ........................................................................ 9-78
CHECKING AND CHARGING THE BATTERY ....................................... 9-79
CHECKING THE RELA VS ...................................................................... 9-82
CHECKING THE DIODE ......................................................................... 9-84
CHECKING THE SPARK PLUG CAP ..................................................... 9-84
CHECKING THE IGNITION COIL ........................................................... 9-84
CHECKING THE IGNITION SPARK GAP ............................................... 9-85
CHECKING THE CRANKSHAFT POSITION SENSOR .......................... 9-86
CHECKING THE LEAN ANGLE SENSOR .............................................. 9-86
CHECKING THE STARTER MOTOR OPERATION ............................... 9-86
CHECKING THE STATOR COIL ............................................................ 9-87
CHECKING THE RECTIFIER/REGULATOR .......................................... 9-87
CHECKING THE FUEL SENDER ........................................................... 9-88
CHECKING THE SPEED SENSOR ........................................................ 9-88
CHECKING THE RADIATOR FAN MOTOR ........................................... 9-89
CHECKING THE RADIATOR FAN MOTOR CIRCUIT BREAKER ......... 9-89
CHECKING THE COOLANT TEMPERATURE SENSOR ....................... 9-89
CHECKING THE FUEL INJECTOR ........................................................ 9-90
CHECKING THE AIR INDUCTION SYSTEM SOLENOID ...................... 9-90
CHECKING THE INTAKE AIR TEMPERATURE SENSOR .................... 9-91
CHECKING THE EPS MOTOR ............................................................... 9-91
CHECKING THE EPS TORQUE SENSOR ............................................. 9-91
IGNITION SYSTEM
EBS20074
IGNITION SYSTEM
EBS30264
CIRCUIT DIAGRAM
e a,
~ <(
. -~-......-...
'r'--~~~-~-~-~~~~
'
•
...--,
' ®
·-···• ··------
'',-,-~ - - ~ ~ ~ ~ ~ ~ ~ ~ ~ - - '
• ----- ·
'
t
• s '', .'
tiF-'
'
ii - ,
'°''-----·
m.:m
l!J=:w
: ~J
r·---~--:'------,·:@i :
I
~ :
'------ i
!:Pe : I. - - - -·
ffl:t'' .- :''
I. - - - - - - - -· ~-_ q@p I IJ
'-1---·-_J•
9-1
IGNITION SYSTEM
1. Crankshaft position sensor

4. Main switch
6. Main fuse
7. Battery
1a.Engine ground
12.Joint coupler
20. ECU (Engine Control Unit)
21. Ignition coil
22.Spark plug
30.Lean angle sensor
53.Handlebar switch (left)
56. Engine stop switch
71. Ignition fuse
76. Frame ground 1
A. Wire harness
B. Negative battery sub-wire harness
9-2
IGNITION SYSTEM
EBS30265
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• Before troubleshooting, remove the following part(s):

1. Seat
2. Battery cover
3. Top cover
4. Side panels (left and right)
5. Storage compartment
6. V-belt cooling exhaust duct
1. Check the fuses.

(Main and ignition)
Refer to "CHECKING THE FUS- Replace the fuse(s).
ES" on page 9-78.
OKJ-
2. Check the battery. NG~
Refer to "CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY" on • Recharge or replace the battery.
page 9-79.
OKJ-
3. Check the spark plug. NG~
Refer to "CHECKING THE SPARK Re-gap, clean, or replace the spark plug.
PLUG" on page 3-4.
OKJ-
4. Check the ignition spark gap. OK~
Refer to "CHECKING THE IGNI- Ignition system is OK.
TION SPARK GAP" on page 9-85.
NG J,
5. Check the spark plug cap. NG~
Refer to "CHECKING THE SPARK Replace the spark plug cap.
PLUG CAP" on page 9-84.
OKJ-
6. Check the ignition coil. NG~
Refer to "CHECKING THE IGNI- Replace the ignition coil.
TION COIL'.' on page 9-84.
OKJ-
7. Check the crankshaft position sen- NG~
sor. The crankshaft position sensor is faulty.
Refer to "CHECKING THE CRANK- Replace the crankshaft position sensor/
SHAFT POSITION SENSOR" on stator assembly.
page 9-86.
OKJ-
9-3
IGNITION SYSTEM
8. Check the main switch.

Refer to "CHECKING THE Replace the main switch.
SWITCHES" on page 9-75.
QKJ,
9. Check the engine stop switch. NG~
Refer to "CHECKING THE The engine stop switch is faulty. Replace
the handlebar switch (left).
QKJ,
1a.Check the lean angle sensor. NG~
Refer to "CHECKING THE LEAN Replace the lean angle sensor.
ANGLE SENSOR" on page 9-86.
QKJ,
11 .Check
..
the entire ignition system NG~
w1nng. Properly connect or replace the wire har-
Refer to "CIRCUIT DIAGRAM" on ness.
page 9-1.
QKJ,
Replace the ECU.
9-4
ELECTRIC STARTING SYSTEM
EBS20075

EBS30266
CIRCUIT DIAGRAM
e -a!
~ -
~
1:1
....... -.
-11
. .m,
•®'EW'
.----. ~
~·
·
'--~~-~~-~~~
'
....--,
' ®
·-····------ .
' ',-,-,~- ~ ~~ ~ ~ ~ ~ ~ _ , '
; ----- ·
.-- - - - -
t
<
m .:m
l!J=:w
: I
'--- - -,·~:@i ::
~ ...... -·
•
, - ......i~...........
' ®@ :
'' '
:--c., ...i-,;;.....1.,.1, '
L ••
},._, 1 - - - - - - - - - - - '
~~: 1-·---~·1
9-5
4. Main switch
6. Main fuse
7. Battery
9. Starter relay
1a.Engine ground
11.Starter motor
12.Joint coupler
20.ECU (Engine Control Unit)
32.Gear position switch
55.Start switch
64. Rear brake light switch
70.Signaling system fuse
71. Ignition fuse
76. Frame ground 1
A. Wire harness
9-6
EBS30267
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the engine stop switch is set to "o " and the main switch is set to" a "(on) (both switch circuits are
closed), the starter motor can only operate if at least one of the following conditions is met:
• The transmission is in neutral (the neutral switch circuit of the gear position switch is closed).
• The transmission is in park (the park switch circuit of the gear position switch is closed) .
• The rear brake lever is pulled to the handlebar or the brake pedal is pushed down (the rear brake light
switch circuit is closed).
-
/
'
...L 13
-
- '-.
I
- ~
-
12
e (£)
---~ 1
' )
7 J
4
'
'
8 5
'
6
10
--
9
/"
11
-.... - .... -=-=-

-
1 . Battery
2. Main fuse
3. Main switch
4. Ignition fuse
6. Start switch
7. Signaling system fuse
10. Park switch (gear position switch)
11. Neutral switch (gear position switch)
12. Starter relay
13. Starter motor
9-7
EBS30268
TROUBLESHOOTING
The starter motor fails to turn.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

1. Seat
2. Battery cover
3. Top cover
1. Check the fuses.

(Main, ignition and signaling sys-
tem) Replace the fuse(s).
Refer to "CHECKING THE FUS-
ES" on page 9-78 .
OKJ-
CHARGING THE BATIERY" on • Recharge or replace the battery.
page 9-79.
OKJ-
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.
9-86.
NG J,
4. Check the starter motor. NG~

Refer to "CHECKING THE START- Repair or replace the starter motor.
ER MOTOR" on page 5-44.
OKJ-
5. Check the starter relay. NG~
Refer to "CHECKING THE RE- Replace the starter relay.
LAYS" on page 9-82.
OKJ-
6. Check the main switch. NG~

Refer to "CHECKING THE Replace the main switch .
OKJ-
7. Check the engine stop switch. NG~
The engine stop switch is faulty. Replace
Refer to "CHECKING THE
the handlebar switch (left).
OKJ-
9-8
8. Check the start switch. The start switch is faulty. Replace the han-
SWITCHES" on page 9-75. dlebar switch (left).
QKJ,
9. Check the rear brake light switch. NG~
Refer to "CHECKING THE Replace the rear brake light switch.
QKJ,
1a.Check the gear position switch. NG~
Refer to "CHECKING THE Replace the gear position switch.
QKJ,
11 .Check
..
the entire starting system NG~
page 9-5.
QKJ,
Replace the ECU.
9-9
CHARGING SYSTEM
EBS20076
CHARGING SYSTEM
EBS30269
CIRCUIT DIAGRAM
~ - - - - - - - - - ~ ~:
2. AC magneto
3. Rectifier/regulator
6. Main fuse
7. Battery
10. Engine ground
77.Frame ground 2
9-10
CHARGING SYSTEM
EBS30270
TROUBLESHOOTING
The battery is not being charged.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

1. Seat
2. Battery cover
3. Top cover
4. Side panel (right)
1. Check the fuse.

(Main) Replace the fuse.
ES" on page 9-78 .
OKJ-
page 9-79.
OKJ-
3. Check the stator coil. NG~ The stator coil is faulty. Replace the crank-
Refer to "CHECKING THE STATOR shaft position sensor/stator assembly.
COIL:' on page 9-87.
OKJ-
4. Check the rectifier/regulator. NG~
Refer to "CHECKING THE RECTI- Replace the rectifier/regulator.
FIER/REGULATOR" on page 9-87.
OKJ-
5. Check the entire charging system NG~
wiring. Properly connect or replace the wire har-
page 9-10.
OKJ-
The charging system circuit is OK.
9-11
CHARGING SYSTEM
9-12
LIGHTING SYSTEM
EBS20on
LIGHTING SYSTEM
EBS30271
CIRCUIT DIAGRAM
- - - - - - - - - - - - - - - - - - - - - a- - - - -
' '
:
l"Z
J I .J
I _ : I
: ®,, ~ _:
I.. - - - - - - - - - - - - - - - - - - - -
®
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9-13
LIGHTING SYSTEM
4. Main switch
6. Main fuse
7. Battery
1a.Engine ground
12.Joint coupler
34.Meter assembly
36.High beam indicator light
57.Light switch
58.Handle mounted light
59.Headlight
60.Headlight relay 2
61.Headlight relay 1
62. Tail/brake light
69.Headlight fuse
71. Ignition fuse
76.Frame ground 1
A. Wire harness
9-14
LIGHTING SYSTEM
EBS30272
TROUBLESHOOTING
Any of the following fail to light: Handle mounted light, headlight or taillight.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

1. Seat
2. Battery cover
3. Handle mounted light cover
1. Check the condition of handle

mounted light bulb and bulb socket.
Refer to "CHECKING THE BULBS Replace the bulb and bulb socket.
AND BULB SOCKETS" on page
9-77.
QKJ,
2. Check the fuses. NG~
(Main, headlight and ignition)
Replace the fuse(s).
ES" on page 9-78 .
QKJ,
page 9-79.
QKJ,
QKJ,
5. Check the light switch . NG~
The light switch is faulty. Replace the han-
dlebar switch (left).
QKJ,
6. Check the headlight relay 1. NG~
Refer to "CHECKING THE RE- Replace the headlight relay 1.
LAYS" on page 9-82.
QKJ,
7. Check the headlight relay 2 . NG~
Refer to "CHECKING THE RE- Replace the headlight relay 2.
LAYS" on page 9-82.
QKJ,
9-15
LIGHTING SYSTEM
8. Check
..
the entire lighting system
page 9-13.
QKJ,
Replace the headlight unit, tail/brake
light unit or meter assembly.
9-16
SIGNALING SYSTEM
EBS20078
SIGNALING SYSTEM
EBS30352
CIRCUIT DIAGRAM
; ---@---~
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9-17
SIGNALING SYSTEM
4. Main switch
6. Main fuse
7. Battery
1a.Engine ground
12.Joint coupler
18. Reverse switch
25.Coolant temperature sensor
27.Speed sensor
34.Meter assembly
37.High-range indicator light
38.Low battery voltage indicator light
39.Low-range indicator light
40.0n-Command differential gear lock indicator
light
41. Reverse indicator light
43.Coolant temperature warning light
44. Park indicator light
45.Neutral indicator light
46.Multi-function meter
48. Differential motor
50.Fuel sender
54.0verride switch
62. Tail/brake light
63.Diode
65. Front brake light switch
70.Signaling system fuse
71. Ignition fuse
76. Frame ground 1
A. Wire harness
9-18
SIGNALING SYSTEM
EBS30274
TROUBLESHOOTING
• Any of the following fail to light: warning light, brake light or an indicator light.
• The fuel meter fails to come on.
• The speedometer fails to operate.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

1. Seat
2. Battery cover
3. Top cover
6. Rear fender
1. Check the fuses.

(Main, ignition and signaling sys-
tem) Replace the fuse(s).
ES" on page 9-78 .
QKJ,
page 9-79.
QKJ,
QKJ,
4. Check the entire signaling system NG~
page 9-17.
QKJ,
Check the condition of each of the sig-
naling system circuits. Refer to
"Checking the signaling system" on
page 9-19.
Checking the signaling system

The tail/brake light fails to come on.
1. Check the front brake light switch. NG~
Refer to "CHECKING THE Replace the front brake light switch.
QKJ,
9-19
SIGNALING SYSTEM
2. Check the rear brake light switch.

Refer to "CHECKING THE Replace the rear brake light switch.
QKJ,
3. Check the diode. NG~
Refer to "CHECKING THE DIODE" Replace the diode.
on page 9-84.
QKJ,
page 9-17.
QKJ,
Replace the tail/brake light unit.
The neutral, park, hioh-ranoe, and/or low-ranoe indicator lioht fails to come on.
1. Check the gear position switch. NG~
Refer to "CHECKING THE Replace the gear position switch.
QKJ,
2. Check
..
the entire signaling system NG~
page 9-17.
QKJ,
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.
QKJ,
2. Check
..
page 9-17.
QKJ,
9-20
SIGNALING SYSTEM
The differential qear lock indicator lioht and /or four-wheel-drive indicator liqht fails to come on.
1. Check the four-wheel-drive motor NG~
switch (differential motor).
Refer to "CHECKING AND Replace the differential motor.
CHARGING THE BATTERY" on
page 9-79.
OKJ-
2. Check
..
the entire signaling system
page 9-17.
OKJ-
While the override switch is pushed, the segments of the speedometer digits will not appear as shown
in the illustration.
----- , i)
!i! /,l-/J-J,: mph 1

88888 8B'98B'!•
ODOTRIP AB CLOC :'lUR ID
"c~----~
1. Check the override switch. NG~ The override switch is faulty. Replace the
handlebar switch (left).
OKJ-
2. Check
..
page 9-17.
OKJ-
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 9-89.
OKJ-
9-21
SIGNALING SYSTEM
2. Check
..
page 9-17.
QKJ,
The fuel level indicator fails to come on.

1. Check the fuel sender. NG~
Refer to "CHECKING THE FUEL Replace the fuel pump assembly.
SENDER" on page 9-88.
QKJ,
page 9-17.
QKJ,
Replace the meter assembly.
The speedometer fails to operate.

1. Check the speed sensor. NG~
Refer to "CHECKING THE SPEED Replace the speed sensor.
SENSOR" on page 9-88.
QKJ,
page 9-17.
QKJ,
The low battery voltage indicator light fails to come on.

page 9-79.
QKJ,
9-22
SIGNALING SYSTEM
2. Check
..
page 9-17.
QKJ,
9-23
SIGNALING SYSTEM
9-24
COOLING SYSTEM
EBS20079
COOLING SYSTEM
EBS30275
CIRCUIT DIAGRAM
e -.!!!
~ -
~
'---"I' •-* • --'

'r'--~~~-~-~-~~~~ ...
'
' ®
·-·····------
''r,-~ - - ~ ~ ~ ~ ~ ~ ~ ~ ~ - - ' '
• ----- ·
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•
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~~: 1~·- ----·1
9-25
COOLING SYSTEM
4. Main switch
6. Main fuse
7. Battery
1a.Engine ground
12.Joint coupler
66. Radiator fan motor
67. Radiator fan motor circuit breaker
71. Ignition fuse
74.Radiator fan motor fuse
76.Frame ground 1
A. Wire harness
9-26
COOLING SYSTEM
EBS30276
TROUBLESHOOTING
The radiator fan motor fails to turn.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

1. Seat
2. Battery cover
3. Top cover
5. Front fenders
1. Check the fuses.

(Main, ignition and radiator fan mo-
tor) Replace the fuse(s).
ES" on page 9-78 .
OKJ-
page 9-79.
OKJ-
OKJ-
4. Check the radiator fan motor. NG~ The radiator fan motor is faulty and must
Refer to "CHECKING THE RADIA-
be replaced.
TOR FAN MOTOR" on page 9-89.
OKJ-
5. Check the radiator fan motor relay. NG~
Refer to "CHECKING THE RE- Replace the radiator fan motor relay.
LAYS" on page 9-82.
OKJ-
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 9-89.
OKJ-
7. Check the coolant temperature sen- NG~
sor.
Refer to "CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR"
on page 9-89.
OKJ-
9-27
COOLING SYSTEM
8. Check
..
the entire cooling system
page 9-25.
QKJ,
Replace the ECU.
9-28
FUEL INJECTION SYSTEM
EBS20080

EBS30353
CIRCUIT DIAGRAM
~~
LI.--'-' •
''
~
iElil
'''
1filJ
~:'f~fi': .........I·,~.......
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9-29

4. Main switch
6. Main fuse
7. Battery
8. Fuel injection system fuse
10. Engine ground
12.Joint coupler
17.Fuel injection system relay
19.ISC (Idle Speed Control) unit
21. Ignition coil
22.Spark plug
23. Fuel injector
24. Intake air temperature sensor
26. Yamaha diagnostic tool coupler
27.Speed sensor
28.TPS (throttle position sensor)
29. Intake air pressure sensor
30.Lean angle sensor
31.Air induction system solenoid
34.Meter assembly
42.Engine trouble warning light
46.Multi-function meter
49.Fuel pump
71. Ignition fuse
76. Frame ground 1
A. Wire harness
9-30
EBS30278
ECU SELF-DIAGNOSTIC FUNCTION

The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is
operating normally. If this function detects a malfunction in the system, it immediately operates the en-
gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider
that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is
stored in the memory of the ECU.
• To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
comes on or flashes when the start switch is being pushed 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.
,
":::: 7 '
-~-.....
.,. ,'HH
__,__,,t% . I
l
H
I'"'!
N
fl
q
l noon
nnnn9 ~
p
1. Engine trouble warning light
Engine trouble warning light indication and fuel injection system operation
Warning light indication ECU operation Fl operation Vehicle operation
Warning provided when
Flashing* Operation stopped Cannot be operated
unable to start engine
Operated with substitute
Can or cannot be operat-
characteristics in accor-
Remains on Malfunction detected ed depending on the fault
dance with the descrip-
code
tion of the malfunction
* The warning light flashes when any one of the conditions listed below is present and the start switch
"~ " is pushed:
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" O "(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.
9-31
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.
EBS30279
TROUBLESHOOTING METHOD
The engine operation is not normal and the engine trouble warning light comes on.
1. Check:
• Fault code number
a. Check the fault code number displayed on the meter or Yamaha diagnostic tool.
b. Identify the faulty system with the fault code.
c. Identify the probable cause of the malfunction.
2. Check and repair the probable cause of malfunction.
Fault code No. No fault code No.
Check and repair. Refer to "TROUBLESHOOTING Check and repair.
DETAILS (FUEL INJECTION SYSTEM)" on page
9-33.
Monitor the operation of the sensors and actuators in
the diagnostic mode. Refer to "TROUBLESHOOT-
ING DETAILS (FUEL INJECTION SYSTEM)" on
page 9-33 and "SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE" on page 10-7.
3. Perform the reinstatement action for the fuel injection system.

Refer to "Confirmation of service completion" of table in ''TROUBLESHOOTING DETAILS (FUEL
INJECTION SYSTEM)" on page 9-33.
4. Turn the main switch to " o " (off) and back to" O "(on), then check that no fault code number is dis-
played.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
If another fault code are displayed, repeat steps (1) to (4) until no fault code number is displayed.
5. Erase the malfunction history in the diagnostic mode (code No. 62). Refer to "SELF-DIAGNOSTIC
FUNCTION AND DIAGNOSTIC CODE TABLE" on page 10-7.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Turning the main switch to" o " (off) will not erase the malfunction history.
The engine operation is not normal, but the engine trouble warning light does not come on.
1. Check the operation of the following sensors and actuators in the diagnostic mode.
Refer to ''TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM)" on page 9-33 and "SELF-
DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE'' on page 10-7.
01: Throttle position sensor signal (throttle angle)
30: Ignition coil
36: Fuel injector
48: Air induction system solenoid
If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and actuators, check and repair inner parts of the engine.
EBS30280
YAMAHA DIAGNOSTIC TOOL

This model uses the Yamaha diagnostic tool to identify malfunctions.
For information about using the Yamaha diagnostic tool, refer to the operation manual that is included
with the tool.
9-32
Yamaha diagnostic tool USB (US)

90890-03257
Yamaha diagnostic tool (A/1)
90890-03262
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.
EBS30281
TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM)

This section describes the measures per fault code number displayed on the Yamaha diagnostic tool
or multi-function meter display. Check and service the items or components that are the probable cause
of the malfunction following the order given.
After the check and service of the malfunctioning part has been completed, reset the Yamaha diagnos-
tic tool or multi-function meter display according to the "Confirmation of service completion".
Fault code No.:
Fault code number displayed on the Yamaha diagnostic tool or 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-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE" on page 10-7.
Fault code No. 12

Fault code No. 12
Crankshaft position sensor: no normal signals are received from the

Item
crankshaft position sensor.
Unable to start engine
Fail-safe system
Unable to drive vehicle
Diagnostic code No. -
Indicated -
Procedure -
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
9-33
Fault code No. 12
Crankshaft position sensor: no normal signals are received from the

Item
crankshaft position sensor.
1 Connection of crankshaft posi- Improperly connected -t Con- Crank the engine.
tion sensor coupler. nect the coupler securely or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played -t Service is finished.
the coupler. Fault code number is displayed
Disconnect the coupler and - t Go to item 2.
check the pins (bent or broken
terminals and locking condition
of the pins).
2 Connection of ECU coupler. Improperly connected -t Con- Crank the engine.
Check the locking condition of nect the coupler securely or re- Fault code number is not dis-
the coupler. place the wire harness. played -t Service is finished.
Disconnect the coupler and Fault code number is displayed
check the pins (bent or broken - t Go to item 3.
of the pins).
3 Wire harness continuity. Open or short circuit -t Replace Crank the engine.
the wire harness. Fault code number is not dis-
Between crankshaft position played -t Service is finished.
sensor coupler and ECU cou- Fault code number is displayed
pier. - t Go to item 4.
gray-gray
Between crankshaft position
sensor coupler and joint cou-
pier.
black/blue-black/blue
Between joint coupler and ECU
coupler.
4 Installed condition of crank- Improperly installed sensor - t Crank the engine.
shaft position sensor. Reinstall or replace the sensor. Fault code number is not dis-
Check for looseness or pinch- played -t Service is finished.
ing. Fault code number is displayed
- t Go to item 5.
5 Defective crankshaft position Check the crankshaft position Crank the engine.
sensor. sensor. Fault code number is not dis-
Refer to "CHECKING THE played -t Service is finished.
CRANKSHAFT POSITION Fault code number is displayed
SENSOR" on page 9-86. - t Go to item 6.
Replace if defective.
6 Malfunction in ECU. Replace the ECU.
Fault code No. 13

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
If fault code numbers "13" and "14" are both indicated, take the actions specified for fault code number
"13" first.
Fault code No. 13
Item Intake air pressure sensor: open or short circuit detected.

Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 03
9-34
Fault code No. 13

Indicated Displays the intake air pressure.
Set the engine stop switch to "()", and then operate the throttle while
Procedure pushing the start switch " ~ ". (If the display value changes, the perfor-
mance is OK.)
1 Connection of intake air pres- Improperly connected ~ Con- Turn the main switch to " ~ "
sure sensor coupler. nect the coupler securely or re- (on).
Check the locking condition of place the wire harness. Fault code number is not dis-
the coupler. played ~ Service is finished.
check the pins (bent or broken ~ Go to item 2.
of the pins).
2 Connection of ECU coupler. Improperly connected ~ Con- Turn the main switch to " ~ "
Check the locking condition of nect the coupler securely or re- (on).
the coupler. place the wire harness. Fault code number is not dis-
Disconnect the coupler and played ~ Service is finished.
check the pins (bent or broken Fault code number is displayed
terminals and locking condition ~ Go to item 3.
of the pins).
3 Wire harness continuity. Open or short circuit ~ Replace Turn the main switch to " ~ "
the wire harness. (on).
Between intake air pressure Fault code number is not dis-
sensor coupler and ECU cou- played ~ Service is finished.
pier. Fault code number is displayed
pink-pink ~ Go to item 4.
Between intake air pressure
pier.
blue-blue
coupler.
blue-blue
4 Installed condition of intake air Improperly installed sensor ~ Turn the main switch to " ~ "
pressure sensor. Reinstall or replace the sensor. (on).
Check for looseness or pinch- Fault code number is not dis-
ing. played ~ Service is finished.
Fault code number is displayed
~ Go to item 5.
9-35
Fault code No. 13

5 Defective intake air pressure Execute the diagnostic mode. Turn the main switch to " ~ "
sensor. (Code No. 03) (on).
When engine is stopped: Fault code number is not dis-
Atmospheric pressure at the played ~ Service is finished.
current altitude and weather Fault code number is displayed
conditions is indicated. ~ Go to item 6.
At sea level: Approx. 101 kPa
(757.6 mmHg, 29.8 inHg)
1000 m (3300 ft) above sea lev-
el: Approx. 90 kPa (675.1
mmHg, 26.6 inHg)
mmHg, 23.6 inHg)
mmHg, 20.7 inHg)
When engine is cranking: Make
sure that the indication value
changes.
The value does not change
when engine is cranking. ~
Check the intake air pressure
sensor.
Fault code No. 14

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
"13" first.
Fault code No. 14
Intake air pressure sensor: hose system malfunction (clogged or de-

Item
tached hose).
Fail-safe system
Indicated Displays the intake air pressure.
Set the engine stop switch to "()", and then operate the throttle while
Procedure pushing the start switch "(j)". (If the display value changes, the perfor-
mance is OK.)
1 Condition of intake air pressure Clogged or detached hose ~ Start the engine and let it idle
sensor hose. Repair or replace the sensor for approximately 5 seconds.
Check the intake air pressure hose. Fault code number is not dis-
sensor hose condition. played ~ Service is finished.
~ Go to item 2.
9-36
Fault code No. 14
Intake air pressure sensor: hose system malfunction (clogged or de-

Item
tached hose).
2 Defective intake air pressure Execute the diagnostic mode.
sensor. (Code No. 03)
When engine is stopped:
Atmospheric pressure at the
current altitude and weather
conditions is indicated.
At sea level: Approx. 101 kPa
(757.6 mmHg, 29.8 inHg)
mmHg, 26.6 inHg)
mmHg, 23.6 inHg)
mmHg, 20.7 inHg)
When engine is cranking: Make
sure that the indication value
changes.
The value does not change
when engine is cranking. -t
Check the intake air pressure
sensor.
Fault code No. 15

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• If fault code numbers "15" and "16" are both indicated, take the actions specified for fault code number
"15" first.
• If fault code numbers "15" and "37'' are both indicated, take the actions specified for fault code number
"15" first.
Fault code No. 15
Item Throttle position sensor: open or short circuit detected.

Fail-safe system
Throttle position sensor signal
Indicated
• 14-20 (fully closed position)
Procedure Check with throttle valve fully closed.
1 Connection of throttle position Improperly connected -t Con- Turn the main switch to " 0 "
sensor coupler. nect the coupler securely or re- (on).
the coupler. played -t Service is finished.
check the pins (bent or broken -t Go to item 2.
of the pins).
9-37
Fault code No. 15
Item Throttle position sensor: open or short circuit detected.

2 Connection of ECU coupler. Improperly connected -t Con- Turn the main switch to " ~ "
Disconnect the coupler and played -t Service is finished.
terminals and locking condition -t Go to item 3.
of the pins).
3 Wire harness continuity. Open or short circuit -t Replace Turn the main switch to " ~ "
Between throttle position sensor Fault code number is not dis-
coupler and ECU coupler. played -t Service is finished.
yellow-yellow Fault code number is displayed
Between throttle position sensor -t Go to item 4.
coupler and joint coupler.
blue-blue
coupler.
blue-blue
4 Defective throttle position sen- Check throttle position sensor Turn the main switch to " ~ "
sor. signal. (on).
Execute the diagnostic mode. Fault code number is not dis-
(Code No. 01) played -t Service is finished.
When the throttle valve is fully Fault code number is displayed
closed: -t Go to item 5.
A value of 14-20 is indicated.
An indicated value is out of the
specified range -t Replace the
throttle position sensor.
Fault code No. 16

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
"15" first.
"16" first.
Fault code No. 16
Item Throttle position sensor: stuck throttle position sensor is detected.

Fail-safe system
Throttle position sensor signal
Indicated
• 14-20 (fully closed position)
Procedure Check with throttle valve fully closed.
9-38
Fault code No. 16
Item Throttle position sensor: stuck throttle position sensor is detected.

1 Installed condition of throttle po- Improperly installed sensor ~ Turn the main switch to " ~ "
sition sensor. Reinstall or adjust the sensor. (on), then push the throttle le-
Check
.1ng. for looseness or pinch- Refer to "ADJUSTING THE ver.
THROTILE POSITION SEN- Fault code number is not dis-
SOR" on page 7-7. played ~ Service is finished.
~ Go to item 2.
2 Defective throttle position sen- Check throttle position sensor Turn the main switch to " 0 "
sor. signal. (on), then operate the throttle.
Execute the diagnostic mode. Fault code number is not dis-
(Code No. 01) played ~ Service is finished.
When the throttle valve is fully Fault code number is displayed
closed: ~ Go to item 3.
A value of 14-20 is indicated.
An indicated value is out of the
specified range ~ Replace the
throttle position sensor.
Fault code No. 21

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Make sure that the engine is completely cool before checking the coolant temperature sensor.
Fault code No. 21
Item Coolant temperature sensor: open or short circuit detected.

Fail-safe system
Indicated Displays the coolant temperature.
Compare the actually measured coolant temperature with the indicated
Procedure
value.
1 Connection of coolant tempera- Improperly connected ~ Con- Turn the main switch to " ~ "
ture sensor coupler. nect the coupler securely or re- (on).
of the pins).
of the pins).
9-39
Fault code No. 21
Item Coolant temperature sensor: open or short circuit detected.

Between coolant temperature Fault code number is not dis-
sensor coupler and ECU cou- played -t Service is finished.
green/yellow-green/yellow -t Go to item 4.
Between coolant temperature
pier.
coupler.
4 Defective coolant temperature Execute the diagnostic mode. Turn the main switch to " ~ "
When engine is cold: Fault code number is not dis-
Displayed temperature is close played -t Service is finished.
to the ambient temperature. Fault code number is displayed
The displayed temperature is -t Go to item 5.
not close to the ambient tern-
perature -t Check the coolant
temperature sensor.
COOLANT TEMPERATURE
Fault code No. 22

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Make sure that the engine is completely cool before checking the intake air temperature sensor.
Fault code No. 22
Item Intake air temperature sensor: open or short circuit detected.

Fail-safe system
Indicated Displays the intake air temperature.
Compare the actually measured intake air temperature with the indicated
Procedure
value.
1 Connection of intake air tern- Improperly connected -t Con- Turn the main switch to " 0 "
perature sensor coupler. nect the coupler securely or re- (on).
check the pins (bent or broken -t Go to item 2.
of the pins).
9-40
Fault code No. 22

Item Intake air temperature sensor: open or short circuit detected.
2 Connection of ECU coupler. Improperly connected -t Con- Turn the main switch to " ~ "
of the pins).
Between intake air temperature Fault code number is not dis-
sensor coupler and ECU cou- played -t Service is finished.
brown/white-brown/white -t Go to item 4.
Between intake air temperature
pier.
coupler.
4 Defective intake air temperature Execute the diagnostic mode. Turn the main switch to " ~ "
When engine is cold: Fault code number is not dis-
Displayed temperature is close played -t Service is finished.
to the ambient temperature. Fault code number is displayed
The displayed temperature is -t Go to item 5.
not close to the ambient tern-
perature. -t Check the intake
air temperature sensor.
Refer to "CHECKING THE IN-
TAKE AIR TEMPERATURE
SENSOR" on page 9-91 .
Fault code No. 30

Fault code No. 30
Item Latch up detected.
Fail-safe system
Indicated • 3.6--4.4 (upright)
• 0.7-1.3 (overturned)
Procedure Remove the lean angle sensor and incline it more than 65 degrees.
9-41
Fault code No. 30

Item Latch up detected.
1 The vehicle has overturned. Raise the vehicle upright. Turn the main switch to " ~ "
(on), then to " O " (off) , and then
back to " a .. (on).
Fault code number is not dis-
played ~ Service is finished.
~ Go to item 2.
2 Installed condition of lean an- Check the installed direction Turn the main switch to " ~ "
gle sensor. and condition of the sensor. (on), then to "O " (off) , and then
back to " a " (on).
~ Go to item 3.
3 Defective lean angle sensor. Execute the diagnostic mode. Turn the main switch to " ~ "
(Code No. 08) (on) then to "O " (off), and then
An indicated value is out of the back to " a " (on).
specified range ~ Check the Fault code number is not dis-
lean angle sensor. played ~ Service is finished.
Replace if defective. Fault code number is displayed
Refer to "CHECKING THE ~ Go to item 4.
LEAN ANGLE SENSOR" on
page 9-86.
Fault code No. 33

Fault code No. 33
Ignition coil: open or short circuit detected in the primary lead of the
Item
ignition coil.
Fail-safe system
Actuates the ignition coil five times at one-second intervals.
Actuation The "CHECK" indicator and " 0 " on the Yamaha diagnostic tool screen
come on each time the ignition coil is actuated.
Check that a spark is generated five times.
Procedure • Connect an ignition checker.
1 Connection of ignition coil con- Improperly connected ~ Con- Start the engine and let it idle
nector. nect the connector securely or for approximately 5 seconds.
Check the locking condition of replace the wire harness. Fault code number is not dis-
the connector. played ~ Service is finished.
Disconnect the connector and Fault code number is displayed
of the pins).
9-42
Fault code No. 33

Ignition coil: open or short circuit detected in the primary lead of the
Item
ignition coil.
2 Connection of ECU coupler. Improperly connected -t Con- Start the engine and let it idle
Check the locking condition of nect the coupler securely or re- for approximately 5 seconds.
of the pins).
3 Wire harness continuity. Open or short circuit -t Replace Start the engine and let it idle
the wire harness. for approximately 5 seconds.
Between ignition coil connector Fault code number is not dis-
and ECU coupler. played -t Service is finished.
orange-orange Fault code number is displayed
-t Go to item 4.
4 Installed condition of ignition Improperly installed ignition coil Start the engine and let it idle
coil. -t Reinstall or replace the igni- for approximately 5 seconds.
Check
.1ng. for looseness or pinch- tion coil. Fault code number is not dis-
played -t Service is finished .
-t Go to item 5.
5 Defective ignition coil. Measure the primary coil resis- Start the engine and let it idle
tance of the ignition coil. for approximately 5 seconds.
Replace if out of specification. Fault code number is not dis-
Refer to "CHECKING THE IG- played -t Service is finished.
NITION COIL:' on page 9-84. Fault code number is displayed
-t Go to item 6.
6 Malfunction in ECU. Execute the diagnostic mode.
(Code No. 30)
No spark -t Replace the ECU.
Fault code No. 37

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• Do not remove the ISC (ldel Speed Control) valve.

"15" first.
"16" first.
• If fault code numbers "37'' and "46" are both indicated, take the actions specified for fault code number
"46" first.
• If fault code numbers "37'' and "42" are both indicated, take the actions specified for fault code number
"42" first.
Fault code No. 37

Component other than ISC (Idle Speed Control) unit is defective
A
(ISC operating sound is heard).
Item
Defective ISC (Idle Speed Control) unit (ISC operating sound is
B
not heard).
Fail-safe system
9-43
Fault code No. 37

A
Item
B
not heard).
Fully closes the ISC valve, and then opens the valve.
This operation takes approximately 3 seconds.
come on during the operation.
Procedure The operating sound can be heard when ISC valve operates.
A-1 Locate the malfunction. Execute the diagnostic mode. ISC operating sound is heard ~
(Code No. 54) Go to item A-2.
Fully closes the ISC (Idle Speed ISC operating sound is not
Control) valve, and then fully heard ~ Go to item B-2 for the
opens the valve. defective ISC (Idle Speed Con-
trol) unit.
A-2 Incorrect speed sensor signal. Check the speed sensor. Start the engine and let it idle
Execute the diagnostic mode. for approximately 10 seconds.
(Code No. 07) Fault code number is not dis-
Rotate the rear wheel by hand played ~ Service is finished.
and check that the indicated Fault code number is displayed
value increases. ~ Go to item A-3.
Value does not increase ~ Go
to fault code No. 42.
A-3 Throttle valve does not fully Check the throttle body. Start the engine and let it idle
close. Refer to "THROTTLE BODY" on for approximately 10 seconds.
page 7-4. Fault code number is not dis-
Check the throttle cable. played ~ Service is finished.
Refer to "ADJUSTING THE Fault code number is displayed
THROTILE LEVER FREE ~ Go to item A-4.
PLAY" on page 3-31.
A-4 ISC valve is not moving correct- Replace the throttle body as- Start the engine and let it idle
ly. sembly. for approximately 10 seconds.
~ Go to item A-5.
A-5 Malfunction in ECU. Replace the ECU.
Fault code No. 37
A Component other than ISC (Idle Speed Control) unit is defective

Item
B
not heard).
Fail-safe system
Fully closes the ISC valve, and then opens the valve.
This operation takes approximately 3 seconds.
come on during the operation.
9-44
Fault code No. 37

A
Item
B
not heard).
Procedure The operating sound can be heard when ISC valve operates.
B-1 Locate the malfunction. Execute the diagnostic mode. ISC operating sound is heard -t
(Code No. 54) Go to item A-2 for the compo-
Fully closes the ISC (Idle Speed nent other than ISC (Idle Speed
Control) valve, and then fully Control) unit is defective.
opens the valve. ISC operating sound is not
heard -t Go to item B-2.
B-2 Connection of ISC (Idle Speed Improperly connected -t Con- Execute the diagnostic mode.
Control) unit coupler. nect the coupler securely or re- (Code No. 54)
Check the locking condition of place the wire harness. ISC operating sound is heard -t
the coupler. Go to item B-8.
Disconnect the coupler and ISC operating sound is not
check the pins (bent or broken heard -t Go to item B-3.
of the pins).
B-3 Connection of ECU coupler. Improperly connected -t Con- Execute the diagnostic mode.
Check the locking condition of nect the coupler securely or re- (Code No. 54)
the coupler. place the wire harness. ISC operating sound is heard -t
Disconnect the coupler and Go to item B-8.
check the pins (bent or broken ISC operating sound is not
terminals and locking condition heard -t Go to item B-4.
of the pins).
B-4 Wire harness continuity. Open or short circuit -t Replace Execute the diagnostic mode.
the wire harness. (Code No. 54)
Between ISC (Idle Speed Con- ISC operating sound is heard -t
trol) unit coupler and ECU cou- Go to item B-8.
pier. ISC operating sound is not
red/green-red/green heard -t Go to item B-5.
pink/blue-pink/blue
white/green-white/green
brown/blue-brown/blue
Between ISC (Idle Speed Con-
trol) unit coupler and joint cou-
pier.
red/white-red/white
red/white-red/white
B-5 Installed condition of ISC (Idle Improperly installed ISC (Idle Execute the diagnostic mode.
Speed Control) unit. Speed Control) unit -t Reinstall (Code No. 54)
Check for looseness or pinch- the ISC (Idle Speed Control) ISC operating sound is heard -t
ing. unit. Go to item B-8.
ISC operating sound is not
B-6 ISC valve is not moving correct- Replace the throttle body as- Execute the diagnostic mode.
ly. sembly. (Code No. 54)
ISC operating sound is heard -t
Go to item B-8.
ISC operating sound is not
B-7 Malfunction in ECU. Replace the ECU.
9-45
Fault code No. 37

A
Item
B
not heard).
B-8 Delete the fault code. Start the engine and let it idle
for approximately 10 seconds.
Check that the fault code num-
ber is not displayed.
Fault code No. 39

Fault code No. 39
Item Fuel injector: open or short circuit detected.
Fail-safe system
Actuates fuel injector five times at one-second intervals.
come on each time the fuel injector is actuated.
Disconnect the fuel pump coupler, and then check that fuel injector is ac-
Procedure tuated five times by listening for the operating sound.
Item tion and check Maintenance job pletion
1 Connection of fuel injector cou- Improperly connected ~ Con- Execute the diagnostic mode.
pier. nect the coupler securely or re- (Code No. 36)
Check the locking condition of place the wire harness. Operating sound ~ Go to item
the coupler. 6.
Disconnect the coupler and No operating sound ~ Go to
check the pins (bent or broken item 2.
of the pins).
2 Defective fuel injector. Measure the fuel injector resis- Execute the diagnostic mode.
tance. (Code No. 36)
Replace if out of specification. Operating sound ~ Go to item
Refer to "CHECKING THE 6.
FUEL INJECTOR" on page No operating sound ~ Go to
9-90. item 3.
3 Connection of ECU coupler. Improperly connected ~ Con- Execute the diagnostic mode.
Check the locking condition of nect the coupler securely or re- (Code No. 36)
the coupler. place the wire harness. Operating sound ~ Go to item
Disconnect the coupler and 6.
check the pins (bent or broken No operating sound ~ Go to
terminals and locking condition item 4.
of the pins).
4 Wire harness continuity. Open or short circuit~ Replace Execute the diagnostic mode.
the wire harness. (Code No. 36)
Between fuel injector coupler Operating sound ~ Go to item
and ECU coupler. 6.
red/black-red/black No operating sound ~ Go to
Between fuel injector coupler item 5.
and joint coupler.
red/blue-red/blue
9-46
Fault code No. 39

Item Fuel injector: open or short circuit detected.
6 Delete the fault code. Start the engine and let it idle
for approximately 5 seconds.
Fault code No. 41

Fault code No. 41
Item Lean angle sensor: open or short circuit detected.

Fail-safe system
Indicated • 3.6--4.4 (upright)
• 0.7-1.3 (overturned)
Procedure Remove the lean angle sensor and incline it more than 65 degrees.
1 Connection of lean angle sen- Improperly connected ~ Con- Turn the main switch to " ~ "
sor coupler. nect the coupler securely or re- (on), then to " O " (off) , an then
Check the locking condition of place the wire harness. back to " a " (on).
the coupler. Fault code number is not dis-
of the pins).
Check the locking condition of nect the coupler securely or re- (on), then to " O " (off) , an then
the coupler. place the wire harness. back to " a " (on).
Disconnect the coupler and Fault code number is not dis-
check the pins (bent or broken played ~ Service is finished.
terminals and locking condition Fault code number is displayed
of the pins). ~ Go to item 3.
3 Wire harness continuity. Open or short circuit ~ Replace Turn the main switch to " ~ "
the wire harness. (on), then to " O " (off) , an then
Between lean angle sensor back to " a " (on).
coupler and ECU coupler. Fault code number is not dis-
yellow/green-yellow/green played ~ Service is finished.
Between lean angle sensor Fault code number is displayed
coupler and joint coupler. ~ Go to item 4.
blue-blue
coupler.
blue-blue
9-47
Fault code No. 41
Item Lean angle sensor: open or short circuit detected.

4 Defective lean angle sensor. Execute the diagnostic mode. Turn the main switch to " ~ "
(Code No. 08) (on), then to " O" (off) , and then
An indicated value is out of the back to " a .. (on).
specified range ~ Check the Fault code number is not dis-
lean angle sensor. played ~ Service is finished.
Replace if defective. Fault code number is displayed
Refer to "CHECKING THE ~ Go to item 5.
LEAN ANGLE SENSOR" on
page 9-86.
Fault code No. 42

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
"42" first.
Fault code No. 42

Speed sensor: no normal signals are received from the speed sen-
Item
sor.
Fail-safe system
Vehicle speed pulse
Indicated
0-999
Check that the number increases when the rear wheels are rotated. The
Procedure
number is cumulative and does not reset each time the wheel is stopped.
1 Connection of speed sensor Improperly connected ~ Con- Turn the main switch to " 0 "
coupler. nect the coupler securely or re- (on), and then rotate the rear
Check the locking condition of place the wire harness. wheel by hand.
the coupler. Fault code number is not dis-
Disconnect the coupler and played ~ Go to item 6.
of the pins).
2 Connection of ECU coupler. Improperly connected ~ Con- Turn the main switch to " 0 "
Check the locking condition of nect the coupler securely or re- (on), and then rotate the rear
the coupler. place the wire harness. wheel by hand.
Disconnect the coupler and Fault code number is not dis-
check the pins (bent or broken played ~ Go to item 6.
terminals and locking condition Fault code number is displayed
of the pins). ~ Go to item 3.
9-48
Fault code No. 42

Speed sensor: no normal signals are received from the speed sen-
Item
sor.
3 Wire harness continuity. Open or short circuit -t Replace Turn the main switch to " U "
the wire harness. (on), and then rotate the rear
Between speed sensor coupler wheel by hand.
and joint coupler. Fault code number is not dis-
white-white played -t Go to item 6.
Between joint coupler and ECU Fault code number is displayed
coupler. -t Go to item 4.
white-white
Between speed sensor coupler
and joint coupler.
blue-blue
coupler.
blue-blue
4 Defective speed sensor. Execute the diagnostic mode. Turn the main switch to " ~ "
(Code No. 07) (on), and then rotate the rear
While the rear wheels and wheel by hand.
stopped, check that the indicat- Fault code number is not dis-
ed value does not change. played -t Service is finished.
Rotate the rear wheel by hand Fault code number is displayed
and check that the indicated -t Go to item 5.
value increases.
Malfunction -t Replace the
speed sensor.
Fault code No. 43

Fault code No. 43
Fuel system voltage: incorrect voltage supplied to the fuel injector

Item
and fuel pump.
Fail-safe system
Diagnostic code No. 09,50
Fuel system voltage (battery voltage)
Indicated Approximately 12.0
09 Turn the main switch to " ~ " (on), and then compare the actually mea-
Procedure sured battery voltage with the display value. (If the actually measured
battery voltage is low, recharge the battery.)
Actuates the fuel injection system relay five times at one-second inter-
vals.
The "CHECK" indicator and " 0 " on the Yamaha diagnostic tool screen
Actuation come on each time the relay is actuated.
50 (When the relay is on, the "CHECK" indicator and " a " on the Yamaha di-
agnostic tool screen go off. When the relay is off, the "CHECK" indicator
and "a" on the Yamaha diagnostic tool screen come on.)
Check that the fuel injection system relay is actuated five times by listen-
Procedure ing for the operating sound.
9-49
Fault code No. 43
Fuel system voltage: incorrect voltage supplied to the fuel injector

Item
and fuel pump.
1 Connection of fuel injection sys- Improperly connected -t Con- Start the engine and let it idle
tem relay coupler. nect the coupler securely or re- for approximately 5 seconds.
check the pins (bent or broken - t Go to item 2.
of the pins).
2 Connection of ECU coupler. Improperly connected -t Con- Start the engine and let it idle
Check the locking condition of nect the coupler securely or re- for approximately 5 seconds.
terminals and locking condition - t Go to item 3.
of the pins).
3 Wire harness continuity. Open or short circuit -t Replace Start the engine and let it idle
the wire harness. for approximately 5 seconds.
Between fuel injection system Fault code number is not dis-
relay coupler and ECU coupler. played -t Service is finished.
blue/red-blue/red Fault code number is displayed
Between fuel injection system - t Go to item 4.
relay coupler and joint coupler.
red/blue-red/blue
coupler.
red/blue-red/blue
Between fuel injection system
relay coupler and starter relay
coupler.
brown/black-brown/black
Between fuel injection system
relay coupler and joint coupler.
red/black-red/black
Between joint coupler and han-
dlebar switch (left).
red/black-red/black
4 Defective fuel injection system Execute the diagnostic mode. Start the engine and let it idle
relay. (Code No. 50) for approximately 5 seconds.
No operating sound -t Replace Fault code number is not dis-
the fuel injection system relay. played -t Service is finished.
- t Go to item 5.
5 Defective fuel injection system Execute the diagnostic mode. Start the engine and let it idle
relay. (Code No. 09) for approximately 5 seconds.
Fuel system voltage is below Fault code number is not dis-
3 V - t Replace the fuel injection played -t Service is finished.
system relay. Fault code number is displayed
- t Go to item 6.
9-50
Fault code No. 44

Fault code No. 44
EEPROM fault code number: an error is detected while reading or

Item
writing on EEPROM.
Fail-safe system
The fault code No. 44 detected EEPROM errors are indicated.
Indicated
00 indication: Normal status
Procedure -
1 Locate the malfunction. Execute the diagnostic mode. -
(Code No. 60)
Fault code No. 46

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
"46" first.
Fault code No. 46
Item Charging voltage is abnormal.

Fail-safe system
Indicated -
Procedure -
1 Malfunction in charging system. Check the charging system. Start the engine and let it idle
Refer to "CHARGING SYS- for approximately 5 seconds.
TEM" on page 9-10. Fault code number is not dis-
Defective rectifier/regulator or played ~ Service is finished.
AC magneto ~ Replace. Fault code number is displayed
Defective connection in the ~ Repeat the maintenance job.
charging system circuit ~ Prop-
erly connect or replace the wire
harness.
Fault code No. 50

Fault code No. 50
Faulty ECU (Engine Control Unit) memory. (When this malfunction is
Item
detected in the ECU, the fault code number might not appear.)
Fail-safe system
Indicated -
9-51
Fault code No. 50

Faulty ECU (Engine Control Unit) memory. (When this malfunction is
Item
detected in the ECU, the fault code number might not appear.)
Procedure -
1 Malfunction in ECU. Replace the ECU. Turn the main switch to " ~ "
(on).
Fault code No. Err

Fault code No. Err
Multi-function meter: signals cannot be transmitted between the

Item
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 assembly Improperly connected ~ Con- Turn the main switch to " 0 "
coupler. nect the coupler securely or re- (on).
of the pins).
2 Connection of ECU coupler. Improperly connected ~ Con- Turn the main switch to " 0 "
of the pins).
3 Wire harness continuity. Open or short circuit ~ Replace Turn the main switch to " 0 "
Between meter assembly cou- Fault code number is not dis-
pier and joint coupler. played ~ Service is finished.
light green/red-light green/red Fault code number is displayed
light green/black-light green/ ~ Go to item 4.
black
coupler.
light green/red-light green/red
light green/black-light green/
black
9-52
Fault code No. Err
Multi-function meter: signals cannot be transmitted between the

Item
ECU and the multi-function meter.
4 Defective meter assembly. Replace the meter assembly. Turn the main switch to " U "
(on).
~ Go to item 5.
9-53
9-54
FUEL PUMP SYSTEM
EBS20081
FUEL PUMP SYSTEM

EBS30282
CIRCUIT DIAGRAM
e a,
~ <(
.----.
'--~'--~~~~-~~~
'
' ®
...........--,
·-·····------
' 'r-r~- -~ ~ ~ ~ ~ ~ ~ ~ _ _ , '
• ----- ·
.'----,,\fW
f·
.----.J:il..
'- - -.
~
~al
. """ •- - '
- - ''
' 'cl
,_
t
• s '', .'
tiF-'
'
ii - ,
'°''----- ·
m .:m
l!J=:w
: I
~I
'--- - -··~:@i ::
~ --- -·
~-_q@p I IJ
'--1---·-_J•
9-55
FUEL PUMP SYSTEM
4. Main switch
6. Main fuse
7. Battery
1a.Engine ground
12.Joint coupler
20.ECU (Engine Control Unit)
49.Fuel pump
71. Ignition fuse
76.Frame ground 1
A. Wire harness
9-56
FUEL PUMP SYSTEM
EBS30283
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

1. Seat
2. Battery cover
3. Top cover
5. Rear fender
1. Check the fuses.

(Main, ignition and fuel injection
system) Replace the fuse(s).
ES" on page 9-78.
QKJ,
page 9-79.
QKJ,
QKJ,
4. Check the engine stop switch. NG~ The engine stop switch is faulty. Replace
Refer to "CHECKING THE the handlebar switch (left).
QKJ,
5. Check the fuel injection system re- NG~
lay. Replace the fuel injection system relay.
Refer to "CHECKING THE RE-
LAYS" on page 9-82.
QKJ,
6. Check the fuel pump. NG~
Refer to "CHECKING THE FUEL Replace the fuel pump.
PUMP BODY'' on page 7-2.
QKJ,
7. Check
..
the entire fuel pump system NG~
page 9-55.
QKJ,
Replace the ECU.
9-57
FUEL PUMP SYSTEM
9-58
2WD/4WD SELECTING SYSTEM
EBS20082

EBS30448
CIRCUIT DIAGRAM
e -.!!!
~ -
~
.- --~
'--~~-~~-~~~
'
' ®
....--,
·-····------
' ',-,-,~- ~ ~~ ~ ~ ~ ~ ~ _ , '
! 1Si----- ·
--------,
•-H- - - - - - '
'
:@ ~:~
·--------·
i,
t
•
m.:m
l!J=:w
: I
'--- - -,·~:@i :»
~ --- -·
~-_ q@~• I IJ
---·-_J ~~
i._,1----------'
1-·---~·r·~ ----~
9-59
4. Main switch
6. Main fuse
7. Battery
1a.Engine ground
12.Joint coupler
47.0n-Command four-wheel-drive motor switch
and differential lock switch
48.Differential motor
51.Four-wheel-drive motor relay 1
52. Four-wheel-drive motor relay 2
71. Ignition fuse
72. Four-wheel-drive motor fuse
76. Frame ground 1
A. Wire harness
9-60
EBS30285
TROUBLESHOOTING
The four-wheel-drive motor fails to operate.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

1. Battery cover
1. Check the fuses.

(Main, Ignition and four-wheel-drive
motor) Replace the fuse(s).
ES" on page 9-78 .
OKJ-
page 9-79.
OKJ-
OKJ-
4. Check the On-Command four- NG~
wheel-drive motor switch and differ- Replace the On-Command four-wheel-
ential lock switch. drive motor switch and differential lock
Refer to "CHECKING THE switch .
OKJ-
relay 1. Replace the four-wheel-drive motor relay
Refer to "CHECKING THE RE- 1.
LAYS" on page 9-82.
OKJ-
relay 2. Replace the four-wheel-drive motor relay
Refer to "CHECKING THE RE- 2.
LAYS" on page 9-82.
OKJ-
7. Check the differential motor. NG~
Refer to "CHECKING THE DIF-
Replace the differential motor.
FERENTIAL MOTOR OPERATION"
on page 8-12.
OKJ-
9-61
8. Check the entire 2WD/4WD select-

ing system wiring. Properly connect or replace the wire har-
page 9-59.
QKJ,
Replace the ECU.
9-62
EPS {ELECTRIC POWER STEERING) SYSTEM
EBS20083
EPS (ELECTRIC POWER STEERING) SYSTEM

EBS30286
CIRCUIT DIAGRAM
-
i@t 2
-
8' a!
e- a!
~ -
~
~:~:
(~ )
·W.·
,--------------_,-.'
---~
.•
•
--~'--~~~~-~~~
®
• -- .
.........
. ',-,--~- -~ ~ ~ ~ ~ ~ ~ ~ _ _ , .
·-·····------ • ----- ·
•
®-.---_--_--_--_-_--_--_--_-_--_-_, -,~
~ - -l
·n··-.
•
•
•
•
•
' •
.
-
{I
i - - ..,-
··1··--. .-;,i.w...
1 :.0C I ~
a ~ i ' '---------,
.
I I ~
' •• ••
t
•
m .:m
l!J=:w
: I
'--- - -,·~:@i ::
~ --- -·
~-_q@p I IJ
'-1---·-_J• ks - - - - - - - - - '
~~: 1~·-----·1
9-63
4. Main switch
5. EPS fuse
6. Main fuse
7. Battery
1a.Engine ground
12.Joint coupler
13. EPS torque sensor
14.EPS motor
15.EPS (electric power steering) control unit
16. EPS self-diagnosis signal connector
27.Speed sensor
34.Meter assembly
35. EPS warning light
71. Ignition fuse
76. Frame ground 1
A. Wire harness
C. EPS (electric power steering) control unit
9-64
EBS30287
EPS CONTROL UNIT'S SELF-DIAGNOSTIC FUNCTION

The EPS control unit is equipped with a self-diagnostic function . If this function detects a malfunction in
the EPS system, it lights the EPS warning light to alert the rider that a malfunction has occurred in the
system. Once a malfunction has been detected, it becomes stored in the EPS control unit memory in
the form of a fault code.
• The EPS warning light comes on when the main switch is turned to" O "(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" O "(on). If the
warning light does not come on, the electrical circuit may be defective.
,·~-~
1. EPS warning light

-
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• If the engine is stopped using the engine stop switch and the main switch is in the " O " (on) position,
the EPS warning light comes on to indicate that the power assistance for the steering is not function-
.
1ng.
• If the steering usage is too heavy (i.e., excessive steering use when the vehicle is traveling at a slow
speed), the power assist is reduced to protect the EPS motor from overheating.
EBS30288
EPS WARNING LIGHT DURING NORMAL OPERATION

The EPS warning light comes on initially for 2 seconds after the main switch is turned to" O "(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.
9-65
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. "O " (off) i. Goes off.
e. " O "(on)
EBS30289
DIAGNOSTIC MODE
Setting the diagnostic mode (present and past malfunctions)

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

Ground the connector "1" quickly* to the EPS control unit "2" over 2 times.
* Quickly = from 20 to 76 ms inteNal
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• Because the "quickly'' inteNals are approximately the same as the inteNals when sliding the connec-
tor "1" across the area "a" of the EPS control unit "2", this method can also be used to set the diag-
nostic mode.
• To set the diagnostic mode, this step should be started within 5 seconds and completed within 1Osec-
onds after the main switch is turned to " O " (on).
The EPS warning light starts to show present fault codes.
• Past malfunction signaling mode
While the present malfunction mode is activated, briefly disconnect the connector "1", ground it
again, and leave it grounded. The signaling mode is activated after 5 seconds.
The EPS warning light starts to show past fault codes.
9-66
4. Turn the main switch to "o " (off) to cancel the diagnostic mode.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• The diagnostic mode can also be canceled by riding the vehicle at speeds above 2 km/h (1 .2 mi/h).
• When the diagnostic mode is selected and during the initial lighting of the EPS warning light, the EPS
control unit does not receive input from the EPS self-diagnosis signal connector.
5. Connect the EPS self-diagnosis signal connector.
Identifying fault codes

When the diagnostic mode is activated, the fault codes determined by the fail-safe specifications are
signaled by the EPS warning light as follows.
• Present malfunction signaling mode: Currently detected fault codes are signaled.
• Past malfunction signaling mode: Both previously detected fault codes and currently detected fault
codes are signaled.
Signaling method
Example 1: Fault code No. 23
5
d d •
a g I
I g
• k
J
b h
e A
- - - - - - ~
V B- -
C
f
- - - - - -
5
•
I
2
0.5 X 3
1
0.5 X 5
3
4
a. EPS self-diagnosis signal connector A. The EPS warning light comes on for 5
b. Diagnostic mode seconds during the diagnostic mode selection
c. EPS warning light judgment.
d. Disconnected B. Display of the present malfunctions stops
when the past malfunction display mode is
e. On
selected.
f. Off
g. Grounded
h. Normal mode (diagnostic mode not activated)
i. Mode selection judgment
j. Present malfunction signaling mode
k. Past malfunction signaling mode
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 1Oand
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
9-67
a C
f
d A
b e
5 1.5 1.5 1.5 1) -~ 1) .5, 1) . 5 . ~

g
a. EPS self-diagnosis signal connector A. The EPS warning light comes on for 5
b. EPS warning light seconds during the diagnostic mode selection
c. Disconnected judgment.
d. Comes on.
e. Goes off.
f. Grounded
g. Mode selection judgment
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
n1 . I· I· I· I·
T1 · T1 · T1 · T1 · T2 ·I
a. EPS self-diagnosis signal connector c. Grounded

b. Disconnected
T1: Connector grounded - - - - 0.1 < T1 < 1.6 seconds

T2: Fault codes deleted - - - - - Maximum 1.5 seconds required
EBS30290
SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)

Fault code Probable cause of mal-
Item Symptom
No. function
• Open or short circuit in
11 wire harness.
13 No normal signals are received from • Malfunction in torque sen-
EPS torque sensor
15 the torque sensor. sor.
16 • Malfunction in EPS control
unit.
9-68
Fault code Probable cause of mal-

Item Symptom
No. function
wire harness.
No normal signals are received from • Malfunction in speed sen-
21 Speed sensor
the speed sensor. sor.
• Malfunction in EPS control
unit.
wire harness.
No normal signals are received from
22 Engine speed signal • Malfunction in ECU.
the ECU.
unit.
41
wire harness.
42 No normal signals are received from
EPS motor • Malfunction in EPS motor.
43 the EPS motor.
45
unit.
Relay contacts in the EPS control unit Malfunction in EPS control
52 EPS control unit
are welded together. unit.
• Faulty battery.
• Malfunction in the
charging system.
53 EPS control unit Battery voltage has dropped. Refer to "CHARGING
unit.
Relay contacts in the EPS control unit Malfunction in EPS control
54 EPS control unit
are welded together. unit.
• Malfunction in the
charging system.
Battery voltage has increased.
Refer to "CHARGING
55 EPS control unit Abnormality exists between the EPS
and the ECU.
unit.
EBS30291
TROUBLESHOOTING DETAILS (EPS SYSTEM)

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
The malfunction history is stored even if the main switch is turned to" O " (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 9-66.
9-69
Fault code No. 11, 13, 15, 16

Fault code No. 11, 13, Symptom EPS torque sensor: no normal signals are received from the
15,16 EPS torque sensor.
Order Item/components and probable cause Check or maintenance job Reinstatement
method
1 Connections • Check the locking condition of the Turning the main
• EPS torque sensor coupler coupler. switch to "0 "
• Disconnect the coupler and check (off).
the pins (bent or broken terminals
and locking condition of the pins).
• If there is a malfunction, connect
the coupler securely or replace the
wire harness.
2 Open or short circuit in EPS torque sen- • Replace if there is an open or short
sor lead. circuit.
• Between EPS torque sensor cou-
pier and EPS control unit coupler.
white-white
red-red
green-green
black-black
3 Defective EPS torque sensor. • Replace if defective.
Refer to "CHECKING THE EPS
TORQUE SENSOR" on page 9-91.
4 Malfunction in EPS control unit. Replace the EPS control unit.
Fault code No. 21

Fault code No. 21 Symptom Speed sensor: no normal signals are received from the speed
sensor.
method
1 Connections • Check the locking condition of the Starting the en-
• Speed sensor coupler coupler. gine and activat-
• EPS control unit coupler at the wire • Disconnect the coupler and check ing the vehicle
harness the pins (bent or broken terminals speed sensor by
and locking condition of the pins). operating the ve-
• If there is a malfunction, connect hicle above 5 km/
the coupler securely or replace the h (3 mi/h), or
wire harness. turning the main
Open or short circuit in wire harness. • Replace if there is an open or short switch to "0 "
2
circuit. (off), then to " O "
• Between speed sensor coupler (on), and then
and joint coupler. deleting the fault
white-white codes. Refer to
• Between joint coupler and EPS "DIAGNOSTIC
control unit coupler. MODE" on page
white-white 9-66.
3 Defective speed sensor. • Replace if defective.

Refer to "CHECKING THE SPEED
9-70
Fault code No. 22

Fault code No. 22 Symptom No normal signals are received from the ECU.

method
• EPS control unit coupler at the wire coupler. switch to "0 "
harness • Disconnect the coupler and check (off).
• ECU coupler at the wire harness the pins (bent or broken terminals
wire harness.
2 Open or short circuit in wire harness. • Replace if there is an open or short
circuit.
• Between ECU coupler and EPS
control unit coupler.
orange/white-orange/white
Fault code No. 41, 42, 43, 45

Fault code No. 41, 42, Symptom EPS motor: no normal signals are received from the EPS motor.
43,45
method
• EPS motor coupler coupler. switch to "0 "
• Disconnect the coupler and check (off).
the pins (bent or broken terminals
wire harness.
2 Open or short circuit in EPS motor lead. • Replace if there is an open or short
circuit.
• Between EPS motor and EPS con-
trol unit coupler.
red-red
black-black
3 Defective EPS motor. Replace if defective.
Refer to "CHECKING THE EPS MO-
TOR" on page 9-91.
Fault code No. 52

Fault code No. 52 Symptom Relay contacts in the EPS control unit are welded together.

method
1 Malfunction in EPS control unit. Replace the EPS control unit. Turning the main
switch to "0 "
(off).
9-71
Fault code No. 53

Fault code No. 53 Symptom Battery voltage has dropped.

method
1 Faulty battery. Replace or charge the battery. Turning the main
Refer to "CHECKI NG AND switch to "0 "
CHARGING THE BATTERY" on (off).
page 9-79.
2 Malfunction in rectifier/regulator or Replace if defective.
charging system. Refer to "CHECKING THE RECTIFI-
ER/REGULATOR" on page 9-87.
Fault code No. 54

Fault code No. 54 Symptom Relay contacts in the EPS control unit are welded together.

method
1 Malfunction in EPS control unit. Replace the EPS control unit. Turning the main
switch to "0 "
(off).
Fault code No. 55

Fault code No. 55 Symptom Battery voltage has increased.
Abnormality exists between the EPS and the ECU.

method
1 Faulty battery. Replace the battery. Turning the main
Refer to "CHECKI NG AND switch to "0 "
CHARGING THE BATTERY" on (off).
page 9-79.
2 Malfunction in rectifier/regulator. Replace if defective.
Refer to "CHECKING THE RECTIFI-
ER/REGULATOR" on page 9-87.
9-72
ELECTRICAL COMPONENTS
EBS20084
3 8
1 2 6 7
18
:-,:::--\,\1~
17
{!, ,.,,_'-.>
. :;..;;.. s ,
10
16
12
15
13
1. Four-wheel-drive motor relay 1 17.EPS motor
2. Four-wheel-drive motor relay 2 18. Radiator fan motor
5. Starter relay
6. EPS fuse
7. Main fuse
8. Fuse box (ignition, headlights, four-wheel-
drive motor, radiator fan motor, signaling
system, auxiliary DC jack)
9. Radiator fan motor circuit breaker
11. Reverse switch
12. Gear position switch
13. Auxiliary DC jack
14. Main switch
16. EPS torque sensor
9-73
1 2 3 5
0
19
1 10
17
16
11
15
12
14
13
1. Lean angle sensor
5. Front brake light switch
7. Intake air temperature sensor
8. Intake air pressure sensor
9. TPS (throttle position sensor)
1O. ISC (Idle Speed Control) unit
11. Fuel pump
12. Speed sensor
14. Coolant temperature sensor
15. Ignition coil
16. Air induction system solenoid
17. Battery
19. EPS control unit
9-74
EBS30292
CHECKING THE SWITCHES

I
- - - - - - - - - - - - - - - - - - - - - - - - - - -I ,--------- ,---------
10 .-
,1 11 B;/Y Br/Y
I
-----
ON
R Br/L Br
J '--'
-
I 0
-
I 0
OFF
I
- - - - - - - - - - - - - - - - - - - - - - - - - - -I
~ ------------------------
2
R/Y L y I I
L 0 L 0
OFF
LO
y Y/W
HI
l l
3 A
Br RIB
------
OFF
vT y L
ON \..J ,J UY Lg B
4 A
RIB UY
OFF
I
[ RIB Br J
PUSH (Gy) ID OJ
5
Lg B =
OFF
PUSH
- - - - - - - - - - - - - - - - - - - - - - - _,
-------------------------,
6 ------- ·------ r----------- ----------- ,-
9
LIN B G/R
2WD -LOCK C}- K)
7
r----r-r-r-r----
8
-A - - - - -
G/W
4WD -DIFF
I L p r-
4WD -LOCK 0- f-0 1
:1:
I
Gy W I
- - - - - - - - - - - - - - - - - - - - - - - - J
I I
I I
- - - - - - - - - - - - - - - - - - - - - - - _J
I
I - =- .,
- I
1. Main switch
2. Light switch
4. Start switch
5. Override switch
6. On-Command four-wheel-drive motor switch
and differential gear lock switch
7. Four-wheel-drive motor switch (differential
motor)
8. Gear position switch
9. Reverse switch
11 . Front brake light switch
9-75
Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check
the wiring connections and if necessary, replace the switch.
ECB02380
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.

90890-03243
chometer
YU-A1927
TIP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~
When checking for continuity, switch back and forth between the switch positions a few times.
D
<==~
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
"0 - 0 ". There is continuity between red, brown/blue, and brown when the switch is set to "ON".
b
R Br/L Br
---------
ON 0 -0 0
OFF
[R lsrtll Br ]
9-76
EBS30293
• Avoid touching the glass part of a handle
CHECKINGTHEBULBSANDBULB
mount~d light bulb to keep it free from oil,
SOCKETS
otherwise the transparency of the glass,
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
the life of the bulb, and the luminous flux
Do not check any of the lights that use LEDs. will be adversely affected. If the handle
Check each bulb and bulb socket for damage or mounted light bulb gets soiled, thoroughly
wear, proper connections, and also for continuity clean it with a cloth moistened with alcohol
between the terminals. or lacquer thinner.
Damage/wear~ Repair or replace the bulb, 2. Check:
bulb socket or both. • Bulb (for continuity)
Improperly connected ~ Properly connect. (with the pocket tester)
No continuity ~ Repair or replace the bulb, bulb No continuity ~ Replace.
socket or both.
Types of bulbs 90890-03243
The bulbs used on this vehicle are shown in the Model 88 Multimeter with ta-
illustration. chometer
• Bulb "a" is used for the handle mounted light YU-A1927
and usually use a bulb holder that must be de-
a. Connect the positive tester probe to termi-
tached before removing the bulb. The majority
nal "1" and the negative tester probe toter-
of these types of bulbs can be removed from
minal "2", and check the continuity.
their respective sockets by turning them coun-
b. Connect the positive tester probe to termi-
terclockwise. nal "1" and the negative tester probe toter-
minal "3", and check the continuity.
c. If either of the readings indicate no conti-
a nuity, replace the bulb.
If'
I I
'~
'
\ "~
'
\J
Checking the condition of the bulbs

bulbs.
1. Remove:
Checking the condition of the bulb sockets
• Bulb The following procedure applies to all of the bulb
EWB03950
A WARNING sockets.
Since the handle mounted light bulb gets ex- 1. Check:
tremely hot, keep flammable products and • Bulb socket (for continuity)
your hands away from it until it has cooled (with the pocket tester)
down. No continuity ~ Replace.
ECB03000
NOTICE 90890-03243
-------------
• Be sure to hold the socket firmly when re- Model 88 Multimeter with ta-
moving the bulb. Never pull the lead, other- chometer
wise it may be pulled out of the terminal in YU-A1927
the coupler.
9-77
TIP ~~~~~~~~~~~~~~
11 1•··, - - , r--, .,dll
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
a. Install a good bulb into the bulb socket.
-® +
b. Connect the pocket tester probes to the

respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any
of the readings indicate no continuity, re-
place the bulb socket. b. If the pocket tester indicates "oo", replace
EBS30296
the fuse.
CHECKING THE FUSES 3. Replace:
The following procedure applies to all of the fus- • Blown fuse
es. a. Set the main switch to" o " (off).
ECB02590 b. Install a new fuse of the correct amperage
NOTICE rating.
-------------
To avoid a short circuit, always set the main c. Set the switch(es) to on to verify if the elec-
switch to "OFF" when checking or replacing trical circuit is operational.
a fuse. d. If the fuse immediately blows again, check
1. Remove: the electrical circuit.
• Battery cover Fuses
Amperage
Q'ty
Refer to "GENERAL CHASSIS (1 )" on page rating
4-1. Main 40A 1
2. Check: EPS 40A 1
• Fuse
Radiator fan motor 20A 1
Headlight 10 A 1
Ignition 10 A 1
Fuel injection system 15 A 1
Four-wheel-drive motor 10 A 1
I
; Auxiliary DC jack
Signaling system
10 A
10 A
1
1
Spare 20A 1
/ l / II rr-r-._
Spare 15 A 1
a. Connect the digital circuit tester to the fuse
and check the continuity. Spare 10 A 1
EWB03660
Digital circuit tester (CD732) & WARNING
90890-03243
Model 88 Multimeter with ta- Never use a fuse with an amperage rating
chometer other than that specified. Improvising or us-
YU-A1927 ing a fuse with the wrong amperage rating
may cause extensive damage to the electri-
cal system, cause the lighting and ignition
systems to malfunction and could possibly
cause a fire.
4. Install:
• Battery cover
4-1 .
9-78
EBS30297
specific gravity of the electrolyte. Therefore, the
CHECKING AND CHARGING THE BATTERY charge of the battery has to be checked by mea-
EWB0364-0
AwARNING suring the voltage at the battery terminals.

Batteries generate explosive hydrogen gas 1. Remove:
and contain electrolyte which is made of poi- • Battery cover
sonous and highly caustic sulfuric acid. Refer to "GENERAL CHASSIS (1)" on page
Therefore, always follow these preventive 4-1 .
measures: • Front carrier
• Wear protective eye gear when handling or • Battery holding bracket
working near batteries. Refer to "GENERAL CHASSIS (2)" on page
• Charge batteries in a well-ventilated area. 4-6.
• Keep batteries away from fire, sparks or 2. Disconnect:
open flames (e.g., welding equipment, • Battery leads
lighted cigarettes). (from the battery terminals)
• DO NOT SMOKE when charging or han- EC B02570
dling batteries. NOTICE

-------------
• KEEP BATTERIES AND ELECTROLYTE First, disconnect the negative battery lead
OUT OF REACH OF CHILDREN. "1 ", and then positive battery lead "2".
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin - Wash with water.
• Eyes- Flush with water for 15 minutes and
0
get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or 3. Remove:
vegetable oil. Get immediate medical atten- • Battery
tion. 4. Check:
ECB02390
• Battery charge
NOTICE
-------------
• This is a VALA (Valve Regulated Lead Acid)
a. Connect a pocket tester to the battery ter-
minals.
battery. Never remove the sealing caps be- • Positive tester probe -t
cause the balance between cells will not be positive battery terminal
maintained and battery performance will • Negative tester probe -t
deteriorate. negative battery terminal
• Charging time, charging amperage and
TIP_~~~~~~~~~~~~~
charging voltage for a VALA (Valve Regu-
lated Lead Acid) battery are different from • The charge state of a VRLA (Valve Regulated
those of conventional batteries. The VALA Lead Acid) battery can be checked by measur-
(Valve Regulated Lead Acid) battery should ing its open-circuit voltage (i.e., the voltage
be charged as explained in the charging when the positive battery terminal is discon-
method. If the battery is overcharged, the nected).
electrolyte level will drop considerably. • No charging is necessary when the open-cir-
Therefore, take special care when charging cuit voltage equals or exceeds 12.8 V.
the battery. b. Check the charge of the battery, as shown
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ in the charts and the following example.
Since VRLA (Valve Regulated Lead Acid) bat-
teries are sealed, it is not possible to check the
charge state of the battery by measuring the
9-79
Example • When charging a battery, be sure to remove

Open-circuit voltage = 12.0 V it from the vehicle. (If charging has to be
Charging time = 6.5 hours done with the battery mounted on the vehi-
Charge of the battery = 20-30°/o cle, disconnect the negative battery lead
from the battery terminal.)
A • To reduce the chance of sparks, do not
13.0
plug in the battery charger until the battery
12.5 charger leads are connected to the battery.
12.0
• Before removing the battery charger lead
clips from the battery terminals, be sure to
11.5 turn off the battery charger.
• Make sure the battery charger lead clips are
5 6.5 10 B in full contact with the battery terminal and
D that they are not shorted. A corroded bat-
tery charger lead clip may generate heat in
A. Open-circuit voltage (V)
the contact area and a weak clip spring may
B. Charging time (hours)
C. Relationship between the open-circuit voltage
cause sparks.
and the charging time at 20 °c (68 °F) • If the battery becomes hot to the touch at
D. These values vary with the temperature, the any time during the charging process, dis-
condition of the battery plates, and the connect the battery charger and let the bat-
electrolyte level. tery cool before reconnecting it. Hot
batteries can explode!
• As shown in the following illustration, the
open-circuit voltage of a VALA (Valve Reg-
ulated Lead Acid) battery stabilizes about
30 minutes after charging has been com-
pleted. Therefore, wait 30 minutes after
charging is completed before measuring
the open-circuit voltage.
~ -~----,-~-~~~•- ~- B A ---·
C
100 75 50 30 2520 0
18
D
17
A. Open-circuit voltage (V)
16
B. Charging condition of the battery (o/o) 15
\
\
C. Ambient temperature 20 °c (68 °F) 14 ......
13
5. Charge: 12
11
• Battery
10
(refer to the appropriate charging method) o ,o 20 30 40 so so B
EWB03650 4E
A WARNING A. Open-circuit voltage (V)
Do not quick charge a battery. B. Time (minutes)
ECB02580 C. Charging
NOTICE
-------------
• Do not use a high-rate battery charger
D.
E.
Ambient temperature 20 °c (68 °F)
Check the open-circuit voltage.
since it forces a high-amperage current
into the battery quickly and can cause bat- Charging method using a variable-current
tery overheating and battery plate damage. (voltage) charger
• If it is impossible to regulate the charging a. Measure the open-circuit voltage prior to
current on the battery charger, be careful charging.
not to overcharge the battery. TIP - - - - - - - - - - - - - - - ~
Voltage should be measured 30 minutes after
the engine is stopped.
9-80
b. Connect a charger and ammeter to the TIP ~~~~~~~~~~~~~~

battery and start charging. If the current is lower than the standard charging
TIP ~~~~~~~~~~~~~~ current written on the battery, this type of battery
Set the charging voltage at 16-17 V. If the set- charger cannot charge the VRLA (Valve Regu-
ting is lower, charging will be insufficient. If too lated Lead Acid) battery. A variable voltage
high, the battery will be over-charged. charger is recommended.
c. Make sure that the current is higher than d. Charge the battery until its charging volt-
the standard charging current written on age is 15 V.
the battery. TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~ Set the charging time at 20 hours (maximum).
If the current is lower than the standard charging
e. Measure the battery open-circuit voltage
current written on the battery, set the charging
after leaving the battery unused for more
voltage adjust dial at 20-24 V and monitor the
than 30 minutes.
amperage for 3-5 minutes to check the battery.
12.8 V or more --- Charging is complete.
• Reaches the standard charging current ~ 12.7 V-12.0 V --- Recharging is required.
Battery is good. Under 12.0 V --- Replace the battery.
• Does not reach the standard charging current
~ 6. Install:
Replace the battery. • Battery
7. Connect:
d. Adjust the voltage so that the current is at • Battery leads
the standard charging level. (to the battery terminals)
e. Set the time according to the charging EC B02560
time suitable for the open-circuit voltage. NOTICE

f. If charging requires more than 5 hours, it is -------------
First, connect the positive battery lead "1 ",
advisable to check the charging current af- and then the negative battery lead "2".
ter a lapse of 5 hours. If there is any
change in the amperage, readjust the volt-
age to obtain the standard charging cur-
rent.
g. Measure the battery open-circuit voltage
after leaving the battery unused for more
than 30 minutes.
0
12.8 V or more --- Charging is complete.
12. 7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
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.
9. Lubricate:
TIP - - - - - - - - - - - - - - - ~ • Battery terminals
Voltage should be measured 30 minutes after
the engine is stopped. Recommended lubricant
l
Dielectric grease
b. Connect a charger and ammeter to the
battery and start charging. 1O.lnstall:
c. Make sure that the current is higher than • Battery holding bracket
the standard charging current written on • Front carrier
the battery. Refer to "GENERAL CHASSIS (2)" on page
4-6.
9-81
• Battery cover 2. Negative battery terminal

Refer to "GENERAL CHASSIS (1 )" on page 3. Positive tester probe
4-1. 4. Negative tester probe
EBS30298
CHECKING THE RELAYS Result

Check each switch for continuity with the pocket Continuity
tester. If the continuity reading is incorrect, re- (between "3" and "4")
place the relay.
Headlight relay 2
90890-03243 I
=
chometer
I -
l
+ I
(
I-
>-
YU-A1927
~~
I
1
1. Disconnect the relay from the wire harness.
2. Connect the digital circuit tester and battery
(12 V) to the relay terminal as shown.
Check the relay operation.
1. Positive battery terminal
Starter relay 2. Negative battery terminal
3. Positive tester probe
3
--- -~ -------------- ; 4. Negative tester probe
'
R '
'
'
/
' Result
>C> Continuity
>= (between "3" and "4")
"-
'
'
B '
'
h. 2 1 ,' Radiator fan motor relay
---"\ S ~~-------------'
I
=
1. Positive battery terminal I I' l
+ I
(
I-
2. Negative battery terminal
>-
3. Positive tester probe I
~~
4. Negative tester probe 1
Result
Continuity
(between "3" and "4")
Headlight relay 1 2. Negative battery terminal
I
= 4. Negative tester probe
I -
l
+ I
(
I-
>- Result
~~
I
Continuity
1
L
G
y
9-82
Fuel injection system relay Second step:

I
3 3 1---E
I - l (
I I' 1 (
2
lb '.- \ - + I I- 5 r--!L
4 ~I r.===!'
2~
...,, [
~-
.....
1
+ I I-
1
G/R B Br
Br
Br/8
1 . Positive battery terminal

1 . Positive battery terminal
2. Negative battery terminal 2. Negative battery terminal
3. Positive tester probe 3. Positive tester probe
4. Negative tester probe 4. Negative tester probe
5 . Negative tester probe
• Jjj
, Result
Continuity Result
No continuity
Continuity
Four-wheel-drive motor relay 1 (between "3" and "5")
First step:
Four-wheel-drive motor relay 2
1
~
3 I I' - First step:
2 ~
,-
I'
G/R B Br
Br
Br/B
Y/B B Br
Br
1 . Positive tester probe BN
2. Negative tester probe
Result 3. Negative tester probe
Continuity
No continuity Result
(between "1" and "3") Continuity
No continuity
9-83
Second step:
I
3~ l (
5 ~I p + I 1-
4 ~ I'-41
r.===!'
i
,-
2~ \ ...
1 y
Y/8 B Br B/Y
Br
~<<
BN
a. Disconnect the diode from the wire har-

1. Positive battery terminal ness.
2. Negative battery terminal b. Connect the digital circuit tester to the di-
3. Positive tester probe ode coupler as shown.
4. Negative tester probe c. Check the diode for continuity.
5. Negative tester probe d. Check the diode for no continuity.
EBS30299
Result CHECKING THE SPARK PLUG CAP
No continuity 1. Check:
• Spark plug cap resistance
Continuity
Resistance
ESS30416
10.0 k.Q
CHECKING THE DIODE
1. Check:
a. Remove the spark plug cap from the spark
• Diode
plug lead.
b. Connect the digital circuit tester to the
Digital circuit tester (CD732) spark plug cap as shown.
90890-03243
Model 88 Multimeter with ta- Digital circuit tester (CD732)
90890-03243
chometer
YU-A1927 Model 88 Multimeter with ta-
chometer
YU-A1927
Continuity
Positive tester probe ~ black/
yellow "1"
Negative tester probe ~ yellow D
<== Q)
"2"
No continuity
Positive tester probe ~ yellow
"2"
Negative tester probe ~ black/
yellow "1"
c. Measure the spark plug cap resistance.

EBS30300
CHECKING THE IGNITION COIL

1. Check:
• Primary coil resistance
9-84
Primary coil resistance

2.16-2.64 Q 2
D
<==Ql
a. Disconnect the ignition coil connectors
fram the ignition coil terminals.
b. Connect the digital circuit tester to the igni- 0
tion coil as shown.

90890-03243
Model 88 Multimeter with ta- c. Measure the secondary coil resistance.
chometer EBS30301
YU-A1927 CHECKING THE IGNITION SPARK GAP
1. Check:
• Positive tester probe • Ignition spark gap
orange "1"
Out of specification ~ Perform the ignition
• Negative tester probe
red/black "2" system troubleshooting, starting with step 5.
4-1 .
D
<==Q)
Minimum ignition spark gap
6.0 mm (0.24 in)
2
TIP~~~~~~~~~~~~~~
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
1 a. Disconnect the spark plug cap from the

spark plug.
c. Measure the primary coil resistance. b. Connect the ignition checker "1" as
2. Check: shown.
• Secondary coil resistance
Out of specification ~ Replace. Ignition checker
90890-06754
Secondary coil resistance Oppama pet-4000 spark checker
8.64-12.96 k.Q YM-34487
a. Disconnect the spark plug cap from the ig-

nition coil.
b. Connect the digital circuit tester to the igni-
tion coil as shown. r=====I ~

90890-03243
chometer
YU-A1927 2
1
• Positive tester probe 2. Spark plug cap

red/black "1"
• Negative tester probe c. Set the main switch to " O "(on) and en-
Spark plug lead "2" gine stop switch to "o".
d. Measure the ignition spark gap "a".
9-85
e. Crank the engine by pushing the start

switch "~" and gradually increase the Lean angle sensor output voltage
spark gap until a misfire occurs. Less than 65°: 3.55-4.45 V
More than 65°: 0.65-1.35 V
EBS30302
CHECKING THE CRANKSHAFT POSITION a. Connect the lean angle sensor coupler to
SENSOR the wire harness.
1. Disconnect: b. Connect the digital circuit tester to the lean
• Crankshaft position sensor coupler angle sensor coupler as shown.
(from the wire harness)
2. Check: Digital circuit tester (CD732)
• Crankshaft position sensor resistance 90890-03243
Out of specification ~ Replace the crank- Model 88 Multimeter with ta-
shaft position sensor/stator assembly. chometer
YU-A1927
Crankshaft position sensor resis-
tance • Positive tester probe
459-561 Q yellow/green "1"
a. Connect the digital circuit tester to the black/blue "2"
crankshaft position sensor coupler as
shown.

90890-03243
chometer
YU-A1927
• Positive tester probe

gray "1"
• Negative tester probe c. Set the main switch to " O " (on).
black "2"
d. Tilt the lean angle sensor to 65°.
e. Measure the lean angle sensor output
voltage.
EBS30304
CHECKING THE STARTER MOTOR

OPERATION
1. Check:
Gy B • Starter motor operation
7 '----'--~ Does not operate ~ Perform the electric
starting system troubleshooting, starting with
1 2
step 4.
b. Measure the crankshaft position sensor Refer to "TROUBLESHOOTING" on page
resistance. 10-1 .
a. Connect the positive battery terminal "1"
EBS30303
CHECKING THE LEAN ANGLE SENSOR and starter motor lead "2" with a jumper
1. Remove: lead "3".
EWB03700
• Lean angle sensor & WARNING
2. Check:
• A wire that is used as a jumper lead must
• Lean angle sensor output voltage
have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may
burn.
9-86
• This check is likely to produce sparks,

therefore, make sure no flammable gas or
fluid is in the vicinity.
3
2
'
\:::::=I= =
}t--------,1;------i f '
1 2 3
M
(±) e b. Measure the stator coil resistance.
- - EBS30306
CHECKING THE RECTIFIER/REGULATOR

b. Check the starter motor operation . 1. Check:
• Charging voltage
EBS30305
Out of specification ~ Replace the rectifier/
CHECKING THE STATOR COIL
regulator.
1. Disconnect:
• AC magneto coupler Charging voltage
(from the wire harness) above 14 Vat 5000 r/min
2. Check:
• Stator coil resistance a. Connect the engine tachometer to the
Out of specification ~ Replace the crank- spark plug lead.
shaft position sensor/stator assembly. b. Connect the digital circuit tester to the rec-
tifier/regulator coupler as shown.
Stator coil resistance
0.12-0.14 Q Digital circuit tester (CD732)
90890-03243
a. Connect the digital circuit tester to the AC Model 88 Multimeter with ta-
magneto coupler as shown. chometer
YU-A1927
90890-03243
Model 88 Multimeter with ta- red "1"
chometer • Negative tester probe
YU-A1927 black "2"

white "1"
white "2"

white "1"
white "3"

white "2" c. Start the engine and let it run at approxi-
• Negative tester probe mately 5000 r/min .
white "3"
d. Measure the charging voltage.
9-87
EBS30307
CHECKING THE FUEL SENDER

1. Disconnect:
• Fuel pump coupler
(from the wire harness) lil iii il
2. Remove:
4
• Fuel pump assembly
(from the fuel tank)
3. Check:
• Fuel sender resistance
Out of specification ~ Replace the fuel pump
assembly.
Sender unit resistance (full)

19.0-21.0 Q
Sender unit resistance (empty)
138.5-141.5 Q ,-------,
L--~,~--j---------
r--~r--~---------
3 ___.-t-------'
a. Connect the digital circuit tester to the fuel
sender terminal as shown.

90890-03243 c. Measure the fuel sender resistance.
chometer EBS30309
YU-A1927 CHEC~NGTHESPEEDSENSOR
1. Check:
• Positive tester probe • Speed sensor output voltage
green/yellow "1" Out of specification ~ Replace.
black/white "2" Output voltage reading cycle
0.6 V-4.8 V-0.6 V-4.8 V-0.6 V
a. Connect the digital circuit tester to the

speed sensor coupler as shown.

90890-03243
chometer
YU-A1927

b. Move the fuel sender float to the minimum
white "1"
"3" and maximum "4" level positions. • Negative tester probe
black/blue "2"
L W
B/L
\2
9-88
b. Set the main switch to" 0 "(on) . 2. Check:

c. Elevate the rear wheels and slowly rotate • Radiator fan motor circuit breaker resistance
them. Out of specification ~ Replace the radiator
d. Measure the voltage of white and black/ fan motor circuit breaker.
blue. With each full rotation of the rear
wheel, the voltage reading should cycle Radiator fan motor circuit break-
from 0.6 V to 4.8 V to 0.6 V to 4.8 V. er resistance
Zero n at 20 °c (68 °F)
EBS30310
CHECKING THE RADIATOR FAN MOTOR a. Connect the digital circuit tester to the ra-
1. Check: diator fan motor circuit breaker as shown.
• Radiator fan motor
Faulty/rough movement~ Replace. Digital circuit tester (CD732)
a. Disconnect the radiator fan motor coupler 90890-03243
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" ,. '
' .
" 'I
r=m==i
~
<==a>
2
L
B
7
1
12V
b. Measure the radiator fan motor circuit
breaker resistance.
EBS30312
c. Measure the radiator fan motor move-
CHECKING THE COOLANT TEMPERATURE
ment. SENSOR
EBS30311 1. Remove:
CHECKING THE RADIATOR FAN MOTOR • Coolant temperature sensor
CIRCUIT BREAKER EWB03710
1. Remove: & WARNING

• Radiator fan motor circuit breaker • Handle the coolant temperature sensor
(from the wire harness) with special care.
TIP ~~~~~~~~~~~~~~ • Never subject the coolant temperature sen-
The radiator fan motor circuit breaker "1" is at- sor to strong shocks. If the coolant tem-
tached to the wire harness with black tape as perature sensor is dropped, replace it.
shown in the illustration. 2. Check:
• Coolant temperature sensor resistance
Coolant temperature sensor re-

sistance
2320-2590 n at 20 °C (2320-
2590 Q at 68 °F)

coolant temperature sensor terminals as
shown.
9-89

90890-03243 1 2
~
Model 88 Multimeter with ta- / CJ \
chometer ~ .t:2z'!:t!
YU-A1927
3
--- C]
(== l;))
,
- I
t~J~ ,n
,,
c. Measure the fuel injector resistance.
- EBS30317
-- . 1,F,. 0 CHECKING THE AIR INDUCTION SYSTEM
. ) J
.,,
·J;-2 SOLENOID
1. Check:
• Air induction system solenoid resistance
b. Immerse the coolant temperature sensor Out of specification ~ Replace.
"1" in a container filled with coolant "2".
TIP~~~~~~~~~~~~~~
Solenoid resistance
18-22 Q
Make sure the coolant temperature sensor ter-
minals do not get wet. a. Disconnect the air induction system sole-
c. Place a thermometer "3" in the coolant. noid coupler from the wire harness.
d. Slowly heat the coolant, and then let it cool b. Connect the digital circuit tester to the air
down to the specified temperature. induction system solenoid terminals as
e. Measure the coolant temperature sensor shown.
resistance.
EBS30316 90890-03243
CHECKING THE FUEL INJECTOR Model 88 Multimeter with ta-
1. Check: chometer
• Fuel injector resistance YU-A1927
Out of specification ~ Replace the fuel injec-
tor. • Positive tester probe -t
Air induction system solenoid terminal "1"
Resistance • Negative tester probe -t
12.0 Q Air induction system solenoid terminal "2"
a. Disconnect the fuel injector coupler from

wire harness. 2
b. Connect the digital circuit tester to the fuel
injector terminals as shown.

90890-03243
chometer
YU-A1927
a
c. Measure the air induction system solenoid
• Positive tester probe resistance.
Fuel injector terminal "1"
Fuel injector terminal "2"
9-90
EBS30315
e. Measure the intake air temperature sen-
CHECKING THE INTAKE AIR sor resistance.
TEMPERATURE SENSOR
1. Remove: EBS30319
• Intake air temperature sensor CHECKING THE EPS MOTOR

(from the air filter case.) 1. Remove:
EWB03820 • EPS unit
A WARNING 2. Check:
• Handle the intake air temperature sensor • EPS motor
with special care. Out of specification ~ Replace the EPS unit.
• Never subject the intake air temperature
sensor to strong shocks. If the intake air Continuity
temperature sensor is dropped, replace it. Positive tester probe ~ red "1"
Negative tester probe ~ black
2. Check: "2"
• Intake air temperature sensor resistance No continuity
Out of specification ~ Replace. Positive tester probe ~ red "1"
Negative tester probe ~ EPS
Intake air temperature sensor re- motor body "3"
sistance No continuity
2210-2690 Q at 20 °c (2210- Positive tester probe ~ black
2690 Q at 68 °F) "2"
Intake air temperature sensor re- Negative tester probe ~ EPS
sistance motor body "3"
290-354 Q at 80 °C (290-354 Q
at 176 OF)
a. Connect the digital circuit tester to the in-

take air temperature sensor terminal as
shown.

90890-03243
chometer
YU-A1927
EPS motor coupler terminal and EPS mo-
tor body.
3
1 Digital circuit tester (CD732)
90890-03243
chometer
YU-A1927
b. Check the EPS motor for continuity.

c. Check the EPS motor for no continuity.
b. Immerse the intake air temperature sen-
EBS30320
sor "1" in a container filled with water "2". CHECKING THE EPS TORQUE SENSOR
TIP~~~~~~~~~~~~~~~ 1. Remove:
Make sure that the air temperature sensor termi- • EPS unit
nals do not get wet. 2. Check:
c. Place a thermometer "3" in the water. • EPS torque sensor resistance
d. Slowly heat the water, then let it cool down Out of specification ~ Replace the EPS unit.
to the specified temperature.
9-91
Coil resistance
1.00-1.50 k.Q

EPS torque sensor coupler terminal as
shown.

90890-03243
chometer
YU-A1927
• Positive tester probe ~

red "1"
• Negative tester probe ~
black "2"
2
~ GR
B W
b. Measure the EPS torque sensor resis-

tance.
9-92
9-93
TROUBLESHOOTING
TROUBLESHOOTING ................................................................................... 10-1

GENERAL INFORMATION ..................................................................... 10-1
STARTING FAILURES ............................................................................ 10-1
INCORRECT ENGINE IDLING SPEED .................................................. 10-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......................... 10-2
FAULTY DRIVE TRAIN ........................................................................... 10-3
FAULTY GEAR SHIFTING ...................................................................... 10-4
SH IFT LEVER DOES NOT MOVE .......................................................... 10-4
JUMPS OUT OF GEAR ........................................................................... 10-4
FAULTY CLUTCH ................................................................................... 10-4
OVERHEATING ...................................................................................... 10-4
OVERCOOLING ...................................................................................... 10-5
POOR BRAKING PERFORMANCE ........................................................ 10-5
FAULTY SHOCK ABSORBER ASSEMBLY ............................................ 10-5
UNSTABLE HANDLING .......................................................................... 10-5
FAULTY LIGHTING OR SIGNALING SYSTEM ...................................... 10-5
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE .......... 10-7

SELF-DIAGNOSTIC FUNCTION TABLE ................................................ 10-7
COMMUNICATION ERROR WITH THE METER ................................... 10-7
DIAGNOSTIC CODE: SENSOR OPERATION TABLE ........................... 10-7
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ...................... 10-9
TROUBLESHOOTING
EBS20085
• Sucked-in air
TROUBLESHOOTING
EBS30321
Electrical system
GENERAL INFORMATION 1. Battery
TIP ~~~~~~~~~~~~~~~~
• Discharged battery
• Faulty battery
The following guide for troubleshooting does not
2. Fuse(s)
cover all the possible causes of trouble. It should
• Blown, damaged or incorrect fuse
be helpful, however, as a guide to basic trouble-
• Improperly installed fuse
shooting. Refer to the relative procedure in this
3. Spark plug
manual for checks, adjustments, and replace-
• Incorrect spark plug gap
ment of parts.
• Incorrect spark plug heat range
• Fouled spark plug
EBS30322
STARTING FAILURES • Worn or damaged electrode

• Worn or damaged insulator
Engine • Faulty spark plug cap
1. Cylinder and cylinder head 4. Ignition coil
• Loose spark plug • Cracked or broken ignition coil body
• Loose cylinder head or cylinder • Broken or shorted primary or secondary coils
• Damaged cylinder head gasket • Faulty spark plug lead
• Damaged cylinder gasket 5. Ignition system
• Worn or damaged cylinder • Faulty ECU
• Incorrect valve clearance • Faulty crankshaft position sensor
• Improperly sealed valve • Broken AC magneto rotor woodruff key
• Incorrect valve-to-valve-seat contact 6. Switches and wiring
• Incorrect valve timing • Faulty main switch
• Faulty valve spring • Faulty engine stop switch
• Seized valve • Broken or shorted wiring
2. Piston and piston ring(s) • Faulty gear position switch
• Improperly installed piston ring • Faulty start switch
• Damaged, worn or fatigued piston ring • Faulty brake light switch
• Seized piston ring • Improperly grounded circuit
• Seized or damaged piston • Loose connections
3. Air filter 7. Starting system
• Improperly installed air filter • Faulty starter motor
• Clogged air filter element • Faulty starter relay
4. Crankcase and crankshaft • Faulty starter clutch
• Improperly assembled crankcase EBS-10323
• Seized crankshaft INCORRECT ENGINE IDLING SPEED
Fuel system Engine

1. Fuel tank 1. Cylinder and cylinder head
• Empty fuel tank • Incorrect valve clearance
• Clogged fuel tank drain hose • Damaged valve train components
• Clogged rollover valve 2. Air filter
• Clogged rollover valve hose • Clogged air filter element
• Deteriorated or contaminated fuel
2. Fuel pump Fuel system
• Faulty fuel pump 1. Throttle body
• Faulty fuel injection system relay • Damaged or loose throttle body joint
• Clogged or damaged fuel hose • Improper throttle cable free play
3. Throttle body • Flooded throttle body
• Deteriorated or contaminated fuel
10-1
TROUBLESHOOTING
Electrical system
1. Battery
• Discharged battery
• Faulty battery
2. Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
3. Ignition coil
• Broken or shorted primary or secondary coils
• Faulty spark plug lead
• Cracked or broken ignition coil
4. Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
• Broken AC magneto rotor woodruff key
EBS30324
POOR MEDIUM-AND-HIGH-SPEED
PERFORMANCE
Referto"STARTING FAILURES"on page 10-1 .
Engine
1. Air filter
• Clogged air filter element
Fuel system
1. Fuel pump
• Faulty fuel pump
10-2
TROUBLESHOOTING
EBS30325
FAULTY DRIVE TRAIN

The following conditions may indicate damaged shaft drive components:
Symptoms Possible Causes
1 . A pronounced hesitation or "jerky'' movement A. Bearing damage.
during acceleration, deceleration, or sustained B. Improper gear backlash.
speed. (This must not be confused with engine C. Gear tooth damage.
surging or transmission characteristics.) D. Broken drive shaft.
2. A "rolling rumble" noticeable at low speed; a high- E. Broken gear teeth.
pitched whine; a "clunk" from a shaft drive com- F. Seizure due to lack of lubrication.
ponent or area. G. Small foreign objects lodged between the moving
3. A locked-up condition of the shaft drive mecha- parts.
nism, no power transmitted from the engine to the
front and/or rear wheels.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite subtle and
difficult to distinguish from normal vehicle operating noise. If there is reason to believe these compo-
nents are damaged, remove the components and check them.
10-3
TROUBLESHOOTING
EBS30326
Poor starting performance
FAULTY GEAR SHIFTING 1. V-belt
• V-belt slips
Shifting is difficult
Refer to "FAULTY CLUTCH" on page 10-4. • Oil or grease on the V-belt
2. Primary sliding sheave
EBS30327 • Faulty operation
SHIFT LEVER DOES NOT MOVE • Worn pin groove
• Worn pin
Shift drum and shift forks 3. Clutch shoe
• Foreign object in a shift drum groove • Bent, damaged or worn clutch shoe
• Seized shift fork
• Bent shift fork guide bar Poor speed performance
1. V-belt
Transmission • Oil or grease on the V-belt
• Seized transmission gear 2. Primary pulley weight(s)
• Foreign object between transmission gears • Faulty operation
• Improperly assembled transmission • Worn primary pulley weight
EBS30328 3. Primary fixed sheave
JUMPS OUT OF GEAR • Worn primary fixed sheave
4. Primary sliding sheave
Shift forks • Worn primary sliding sheave
• Worn shift fork 5. Secondary fixed sheave
• Worn secondary fixed sheave
Shift drum 6. Secondary sliding sheave
• Incorrect axial play • Worn secondary sliding sheave
• Worn shift drum groove
EBS-10330
OVERHEATING
Transmission
• Worn gear dog
Engine
EBS30329 1. Clogged coolant passages
FAULTY CLUTCH 2. Cylinder head and piston
• Heavy carbon buildup
Engine operates but vehicle will not move 3. Engine oil
1. V-belt • Incorrect oil level
• Damaged or worn V-belt • Incorrect oil viscosity
• Slipping V-belt • Inferior oil quality
2. Primary pulley cam and primary pulley slider
• Damaged or worn primary pulley cam Cooling system
• Damaged or worn primary pulley slider 1. Coolant
3. Clutch spring(s) • Low coolant level
• Damaged clutch spring 2. Radiator
4. Transmission gear(s) • Damaged or leaking radiator
• Damaged transmission gear • Faulty radiator cap
• Bent or damaged radiator fin
Clutch slips 3. Water pump
1. Clutch spring • Damaged or faulty water pump
• Damaged, loose or worn clutch spring 4. Thermostat
2. Clutch shoe • Thermostat stays closed
• Damaged or worn clutch shoe 5. Hose(s) and pipe(s)
3. Primary sliding sheave • Damaged hose
• Seized primary sliding sheave • Improperly connected hose
• Damaged pipe
• Improperly connected pipe
10-4
TROUBLESHOOTING
Fuel system EBS30334
1. Throttle body
UNSTABLE HANDLING
1. Handlebar
• Damaged or loose throttle body joint
• Bent or improperly installed handlebar
2. Air filter
2. Steering
• Clogged air filter element
• Incorrect toe-in
Chassis • Bent steering stem
1. Brake(s) • Improperly installed steering stem
• Damaged bearing or bearing race
• Dragging brake
• Bent tie-rods
Electrical system • Deformed steering knuckles
1. Spark plug 3. Shock absorber
• Incorrect spark plug gap • Faulty shock absorber spring
• Incorrect spark plug heat range • Leaking oil
2. Ignition system 4. Tire(s)
• Faulty ECU • Uneven tire pressures (left and right)
• Incorrect tire pressure
EBS30331
• Uneven tire wear
OVERCOOLING 5. Wheel(s)
• Incorrect wheel balance
Cooling system
• Deformed wheel
1. Thermostat
• Damaged or loose wheel bearing
• Thermostat stays open
• Bent or loose wheel axle
EBS30332 • Excessive wheel runout
POOR BRAKING PERFORMANCE 6. Frame
• Worn brake pad • Bent frame
• Worn brake disc • Damaged frame
• Air in hydraulic brake system
EBS30335
• Leaking brake fluid
FAULTY LIGHTING OR SIGNALING SYSTEM
• Faulty brake caliper kit
• Faulty brake caliper piston seal Headlight or handle mounted light does not
• Loose union bolt come on
• Damaged brake hose
• Wrong handle mounted light bulb
• Oil or grease on the brake disc • Too many electrical accessories
• Oil or grease on the brake pad • Hard charging
• Incorrect brake fluid level
• Incorrect connection
• Faulty brake caliper kit • Improperly grounded circuit
• Faulty brake caliper seal • Poor contacts (main or light switch)
• Loose union bolt
• Burnt-out handle mounted light bulb
• Damaged brake hose • Faulty headlight or handle mounted light as-
• Oil or grease on the brake disc sembly
• Oil or grease on the brake pad
• Incorrect brake fluid level Handle mounted light bulb burnt out
EBS30333
• Wrong handle mounted light bulb
FAULTY SHOCK ABSORBER ASSEMBLY • Faulty battery
• Faulty rectifier/regulator
Leaking oil • Improperly grounded circuit
• Bent, damaged or rusty damper rod • Faulty main switch
• Cracked or damaged shock absorber • Faulty light switch
• Damaged oil seal lip • Handle mounted light bulb life expired
Malfunction Tail/brake light does not come on

• Fatigued or damaged shock absorber spring • Faulty brake light switch
• Bent or damaged damper rod
10-5
TROUBLESHOOTING
• Too many electrical accessories

• Incorrect connection
• Faulty tail/brake light assembly
10-6
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EBS20086

EBS30336
SELF-DIAGNOSTIC FUNCTION TABLE

Fault code Item
No.
Crankshaft position sensor: no normal signals are received from the crankshaft position sen-
12
sor.
13 Intake air pressure sensor: open or short circuit detected.
14 Intake air pressure sensor: hose system malfunction (clogged or detached hose).
15 Throttle position sensor: open or short circuit detected.
16 Throttle position sensor: stuck throttle position sensor is detected.
21 Coolant temperature sensor: open or short circuit detected.
22 Intake air temperature sensor: open or short circuit detected.
30 Latch up detected.
33 Ignition coil: open or short circuit detected in the primary lead of the ignition coil.
Component other than ISC (Idle Speed Control) unit is defective (ISC operating sound is
37 heard).
Defective ISC (Idle Speed Control) unit (ISC operating sound is not heard).
39 Fuel injector: open or short circuit detected.
41 Lean angle sensor: open or short circuit detected.
42 Speed sensor: no normal signals are received from the speed sensor.
43 Fuel system voltage: incorrect voltage supplied to the fuel injector and fuel pump.
44 EE PROM fault code number: an error is detected while reading or writing on EEPROM.
46 Charging voltage is abnormal.
Faulty ECU (Engine Control Unit) memory. (When this malfunction is detected in the ECU, the
50 fault code number might not appear.)
EBS30337
COMMUNICATION ERROR WITH THE METER

TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
For details of the fault code, refer to ''TROUBLESHOOTING METHOD" on page 9-32.
Fault code Item

No.
Multi-function meter: signals cannot be transmitted between the ECU and the multi-function
Err
meter.
EBS30338
DIAGNOSTIC CODE: SENSOR OPERATION TABLE

TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
The diagnostic code numbers cannot be displayed on the multi-function meter. To display the diagnos-
tic code numbers, use the Yamaha diagnostic tool.
Diagnostic Display
code No. Item Procedure
01 Throttle angle Check with throttle valve fully

closed.
• Fully closed position 14-20
10-7
Diagnostic
Item Display Procedure
code No.
03 Pressure difference Displays the intake air pres- Set the engine stop switch to
(atmospheric pressure and sure. "o", and then operate the
intake air pressure) throttle while pushing the
start switch"~". (If the dis-
play value changes, the per-
formance is OK.)
05 Intake air temperature Displays the intake air tern- Compare the actually mea-
perature. sured intake air temperature
with the indicated value.
06 Coolant temperature Displays the coolant tern- Compare the actually mea-
perature. sured coolant temperature
with the indicated value.
07 Vehicle speed pulse 0-999 Check that the number in-
creases when the rear
wheels are rotated.
The number is cumulative
and does not reset each time
the wheel is stopped.
08 Lean angle sensor output Remove the lean angle sen-
voltage sor and incline it more than
• Upright 3.6-4.4
65 degrees.
• Overturned 0.7-1.3
09 Fuel system voltage Approximately 12.0 Turn the main switch to " O "
(battery voltage) (on), and then compare the
actually measured battery
voltage with the display val-
ue. (If the actually measured
battery voltage is low, re-
charge the battery.)
21 Neutral switch Shift the transmission.
• Neutral ON
• In gear OFF
60 EEPROM fault code display The fault code No. 44 detect- -
ed EEPROM errors are indi-
cated.
00 indication: Normal status
61 Malfunction history code dis-
play
• No history 00 -
• History exists Fault codes 12-50 -
• (If more than one code
number is detected, the
display alternates every
two seconds to show all the
detected code numbers.
When all code numbers are
shown, the display repeats
the same process.)
10-8
Diagnostic
Item Display Procedure
code No.
62 Malfunction history code era-
sure
• No history 0 -
• History exists Displays the total number of Save the malfunction history
malfunctions, including the to the computer, and then
current malfunction, that delete the fault codes.
have occurred since the his-
tory was last erased. (For ex-
ample, if there have been
three malfunctions, "03" is
displayed.)
70 Control number 0-254 [-] -
EBS30339
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diagnostic
Item Actuation Procedure
code No.
30 Ignition coil Actuates the ignition coil five Check that a spark is gener-
times at one-second inter- ated five times.
vals. • Connect an ignition check-
The "CHECK'' indicator and er.
" 0 " on the Yamaha diag-
nostic tool screen come on
each time the ignition coil is
actuated.
36 Fuel injector Actuates the fuel injector five Disconnect the fuel pump
times at one-second inter- coupler, and then check that
vals. fuel injector is actuated five
The "CHECK'' indicator and times by listening for the op-
" 0 " on the Yamaha diag- erating sound.
each time the fuel injector is
actuated.
48 Air induction system solenoid Actuates the air induction Check that the air induction
system solenoid five times at system solenoid is actuated
one-second intervals. five times by listening for the
The "CHECK'' indicator and operating sound.
each time the air induction
system solenoid is actuated.
10-9
Diagnostic
Item Actuation Procedure
code No.
50 Fuel injection system relay Actuates the fuel injection Check that the fuel injection
system relay five times at system relay is actuated five
one-second intervals. times by listening for the op-
The "CHECK'' indicator and erating sound.
each time the relay is actuat-
ed.
(When the relay is on, the
"CHECK'' indicator and" 0 "
on the Yamaha diagnostic
tool screen go off. When the
relay is off, the "CHECK" in-
dicator and " 0 " on the
Yamaha diagnostic tool
screen come on.)
51 Radiator fan motor relay Actuates the radiator fan mo- Check that the radiator fan
tor relay five times at five- motor relay is actuated five
second intervals. (2 seconds times by listening for the op-
on, 3 seconds off) erating sound.
The "CHECK'' indicator and
each time the relay is actuat-
ed.
(When the relay is on, the
"CHECK'' indicator and" a"
on the Yamaha diagnostic
tool screen go off. When the
relay is off, the "CHECK'' in-
dicator and " 0 " on the
Yamaha diagnostic tool
screen come on.)
54 ISC valve Fully closes the ISC valve, Check that the ISC is actuat-
and then opens the valve. ed three times by listening for
This operation takes approxi- the operating sound.
mately 4 seconds.
The "CHECK'' indicator and
during the operation.
10-10
EBS20008 50. Fuel pump EBS30002
WIRING DIAGRAM 51. Four-wheel-drive motor relay 1 COLOR CODE

YFM70GPAK/YFM70GPHK/ 52. Four-wheel-drive motor relay 2 B Black
YFM70GPLK 2019 53. Handlebar switch (left) Br Brown
1. Crankshaft position sensor 54. Override switch G Green
2. AC magneto 55. Start switch Gy Gray
56. Engine stop switch L Blue
57. Light switch Lg Light green
4. Main switch
58. Handle mounted light 0 Orange
5. EPS fuse
P Pink
6. Main fuse 59. Headlight
R Red
7. Battery 60. Headlight relay 2
Sb Sky blue
8. Fuel injection system fuse 61. Headlight relay 1
W White
9. Starter relay 62. Tail/brake light
Y Yellow
10. Engine ground 63. Diode B/G Black/Green
11. Starter motor 64. Rear brake light switch B/L Black/Blue
12. Joint coupler 65. Front brake light switch B/R Black/Red
13. EPS torque sensor 66. Radiator fan motor B/W Black/White
14. EPS motor 67. Radiator fan motor circuit B/Y Black/Yellow
15. EPS (electric power steering) breaker Br/B Brown/Black
control unit 68. Radiator fan motor relay Br/L Brown/Blue
16. EPS self-diagnosis signal con- 69. Headlight fuse Br/W Brown/White
nector 70. Signaling system fuse Br/Y Brown/Yellow
17. Fuel injection system relay 71. Ignition fuse G/R Green/Red
18. Reverse switch 72. Four-wheel-drive motor fuse G/W Green/White
19. ISC (Idle Speed Control} unit 73. Auxiliary DC jack fuse G/Y Green/Yellow
20. ECU (Engine Control Unit) 74. Radiator fan motor fuse Gy/G Gray/Green
21. Ignition coil 75. Auxiliary DC jack UB Blue/Black
22. Spark plug 76. Frame ground 1 UR Blue/Red
23. Fuel injector 77. Frame ground 2 UW Blue/White
24. Intake air temperature sensor A. Wire harness L/Y Blue/Yellow
Lg/B Light green/Black
25. Coolant temperature sensor B. Negative battery sub-wire har-
Lg/R Light green/Red
26. Yamaha diagnostic tool coupler ness
0/L Orange/Blue
27. Speed sensor C. EPS (electric power steering)
0/W Orange/White
28. TPS (throttle position sensor) control unit
P/L Pink/Blue
29. Intake air pressure sensor P/W Pink/White
30. Lean angle sensor RIB Red/Black
31. Air induction system solenoid RIG Red/Green
32. Gear position switch RIL Red/Blue
33. GPS coupler R/W Red/White
34. Meter assembly R/Y Red/Yellow
35. EPS warning light W/B White/Black
36. High beam indicator light WIG White/Green
37. High-range indicator light W/L White/Blue
38. Low battery voltage indicator W/R White/Red
light Y/B Yellow/Black
39. Low-range indicator light Y/G Yellow/Green
40. On-Command differential gear Y/L Yellow/Blue
lock indicator light Y /R Yellow/Red
41. Reverse indicator light Y/W Yellow/White
42. Engine trouble warning light
43. Coolant temperature warning
light
44. Park indicator light
45. Neutral indicator light
46. Multi-function meter
47. On-Command four-wheel-drive
motor switch and differential
lock switch
49. Fuel sender
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Yamaha 2019-2020 Grizzly Service Manual

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Yamaha 2019-2020 Grizzly Service Manual

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EBS20003

IMPORTANT MANUAL INFORMATION

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

A NOTICE indicates special precautions that must be taken to avoid dam-

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

HOW TO USE THIS MANUAL

1.0 mm (0.04 In) The on.way 411th bearing should be instal«I

[~,=, ~,~~~,~ ...-

s- ---- ---.• ~ .;i.. ...,...,...,.....,i

' ...... '

U N • ~ ~ IOOl 'T k>nold h WICfl

The following symbols are not relevant to every vehicle.

SYMBOL DEFINITION SYMBOL DEFINITION

A Serviceable with engine mounted -1 Gear oil

I Lubricant 1- Brake fluid

Wear limit, clearance

PERIODIC CHECKS AND

IDENTIFICATION ............................................................................................ 1-1

FEATURES ...................................................................................................... 1-2

IM PORTA NT INFORMATION ......................................................................... 1-5

BASIC SERVICE INFORMATION ................................................................... 1-7

SPECIAL TOOLS .......................................................................................... 1-12

VEHICLE IDENTIFICATION NUMBER

1. Odometer/Tripmeter A/Tripmeter 8/Service

The odometer shows the total distance traveled

Clock, hour meter, voltage display and cool- Voltage display

The clock displays time in 12-hour format. The NOTICE

SET' button for 2 seconds. The hour digits 1-~---& 7C °F

Fuel gauge To adjust the brightness

11..II..I 1: 3. Push the "SELECT' button to confirm the se-

This mode allows you to adjust the brightness of

PREPARATION FOR REMOVAL AND

GASKETS, OIL SEALS AND 0-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS RUBBER PARTS

BASIC SERVICE INFORMATION

To remove the quick fastener, push its pin with a

To remove the quick fastener, loosen the screw

To install the quick fastener, insert the fastener

NOTICE Checking the electrical system

Digital circuit tester (CD732)

The resistance values shown were obtained at

Digital circuit tester (CD732) Intake air temperature sensor re-

• If there is no continuity, clean the terminals. ~

available at most part stores. ·1 ) -- iiY,;.o

Thickness gauge 3-6

Tappet adjusting tool 90890-01311 3-6

Ring nut wrench 3-17 3-18

Belt tension gauge 3-19

Ball joint remover 4-58, 4-63

Ball joint remover attachment set 4-58, 4-63

Ball joint remover short shaft set 4-58

Compression gauge 90890-03081

Compression gauge extension 73mm 5-3

Slide hammer bolt (M6) 5-21 , 5-23

Valve spring compressor 5-25 5-29

Valve spring compressor attachment (026) 5-25 5-29

Valve guide remover (06) 5-26

Valve guide installer (06) 5-26

Valve guide reamer (06) 5-26

Piston pin puller set 90890-01304 5-32

Flywheel puller 5-39

Yamaha bond No. 1215 5-41 , 5-68

Secondary sheave holding tool (53mm) 5-52, 5-57