Manual de Servicio YXZ1000R 2HC-F8197-10 PDF

2016
SERVICE MANUAL
YXZ10YPSG
LIT-11616-29-39 2HC-F8197-10
EBS20002
YXZ10YPSG
SERVICE MANUAL
©2015 by Yamaha Motor Corporation, U.S.A.
First edition, October 2015
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-11616-29-39
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 inju-
ry hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could result

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

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

EBS20004
HOW TO USE THIS MANUAL

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

G
Filling fluid Molybdenum disulfide oil

M
Lubricant Brake fluid

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

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

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

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

VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL.......................................................................................... 1-1
FEATURES...................................................................................................... 1-3
1
OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM...... 1-3
INSTRUMENT FUNCTIONS ..................................................................... 1-5
IMPORTANT INFORMATION ......................................................................... 1-9

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

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

IDENTIFICATION
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 to the frame under
the driver seat. This information will be needed
to order spare parts.
1-1
IDENTIFICATION
1-2
FEATURES
EBS20010
FEATURES
EBS30007
OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM
1 d 3
c e
5
f
7 6 a
5 b
1-3
FEATURES
1. Speed information from speed sensor

2. Engine RPM information from ECU
3. Battery
4. EPS control unit
5. EPS unit
6. EPS motor
7. Torque sensor
a. Operates steering
b. Twists torsion bar
c. Sends the torque sensor signal
d. EPS control unit calculates assist power
e. Electricity output switched by EPS control unit
f. Activates EPS motor
ECB01790
NOTICE
To prevent accidental damage to the EPS unit, it must not be disassembled.
1-4
FEATURES
EBS30008
Speedometer
INSTRUMENT FUNCTIONS
1
Multi-function meter unit
1 2 3 4 5 6
1. Speedometer
10 9 8 7 The speedometer shows the vehicle’s traveling
1. Tachometer speed.
2. Transmission gear display
3. Shift timing indicator light Tachometer
4. Speedometer
1
5. “SELECT” button
6. “MODE” button 2
7. “RESET” button
8. Clock/Hour meter/Voltage display
9. Fuel meter
10. Odometer/Tripmeter A/Tripmeter B
The multi-function meter unit is equipped with
the following:
• speedometer
1. Tachometer
• tachometer
2. Tachometer red zone
• odometer
• two tripmeters The tachometer shows the engine speed in
• clock crankshaft revolutions per minute (r/min).
• hour meter When the vehicle is first powered on, the ta-
• voltage display chometer needle will sweep once across the
• fuel meter r/min range and then return to zero r/min in order
• transmission gear display to test the electrical circuit.
• shift timing indicator control mode ECB03060
• self-diagnosis device NOTICE

TIP Do not operate the engine in the tachometer
To switch the display between “mph” and “km/h”, red zone.
turn the key to “ ” (off), then push and hold the
“SELECT” button while turning the key to “ ” Red zone
(on). 10500 r/min and above
1-5
FEATURES
Odometer and tripmeter modes The clock displays time in 12-hour format.
The hour meter shows the total time the engine
has been running.
The voltage display shows the battery voltage.
Pushing the “MODE” button switches the display
between the clock mode “CLOCK”, the hour me-
ter mode “HOUR”, and the voltage display mode
“VOLTAGE” in the following order:
CLOCK → HOUR → VOLTAGE → CLOCK

1 2 3
1. Odometer/Tripmeter A/Tripmeter B [To set the clock]
2. “SELECT” button 1. Set the display to the clock mode.
3. “RESET” button 2. Push the “SELECT” button and “RESET” but-
ton together for three seconds.
The odometer shows the total distance traveled 3. When the hour digits start flashing, push the
by the vehicle. “RESET” button to set the hours.
The tripmeters show the distance traveled since 4. Push the “SELECT” button, and the minute
they were last reset. digits will start flashing.
TIP 5. Push the “RESET” button to set the minutes.
• The odometer will lock at 99999. 6. Push the “SELECT” button, and then release
• The tripmeters will reset and continue counting it to start the clock.
after 9999.9 is reached. [Voltage display mode]
Pushing the “SELECT” button switches the dis-
play between the odometer mode “ODO” and
the tripmeter modes “TRIP A” and “TRIP B” in
the following order:
ODO → TRIP A → TRIP B → ODO
To reset a tripmeter, select it by pushing the “SE-

LECT” button, and then push the “RESET” but-
ton for three seconds. The tripmeters can be
This display shows “ ” and the battery voltage.
used to estimate the distance that can be trav-
If the battery voltage is less than 10 volts, “LO” is
eled with a full tank of fuel. This information en-
displayed, and if the voltage is above 16 volts,
ables you to plan future fuel stops.
“HI” is displayed.
ECB02020
Clock, hour meter and voltage display NOTICE
modes
If the voltage display indicates “LO” or “HI”,
there may be trouble with the battery
charging circuit or the battery may be faulty.
If this occurs, check or repair the vehicle.
1 2 3 4
1. Clock/Hour meter/Voltage display
2. “SELECT” button
3. “RESET” button
4. “MODE” button
1-6
FEATURES
Fuel meter Self-diagnosis device

1 2
1 2
1. Fuel level warning indicator 1. Fault code display
2. Fuel meter 2. Engine trouble warning light “ ”
The fuel meter indicates the amount of fuel in the This model is equipped with a self-diagnosis de-
fuel tank. The display segments of the fuel meter vice for various electrical circuits.
disappear from “F” (full) towards “E” (empty) as If a problem is detected in any of those circuits,
the fuel level decreases. When the last segment the engine trouble warning light comes on or
on the left disappears and the fuel level warning flashes, and the multi-function display indicates
indicator flashes, refuel as soon as possible. a fault code.
TIP If the multi-function display indicates a fault
This fuel meter is equipped with a self-diagnosis code, note the code number, and then check the
system. If a problem is detected in an electrical fuel injection system.
circuit, all the display segments and fuel level Refer to “FUEL INJECTION SYSTEM” on page
warning indicator start flashing. If this occurs, 9-29.
ECB02030
check the electrical circuit. NOTICE
Refer to “SIGNALING SYSTEM” on page 9-19.
If the display indicates a fault code, the vehi-
cle should be checked as soon as possible
Transmission gear display in order to avoid engine damage.
1 2
Shift timing indicator light
1 2 3
1. Transmission gear display

2. Neutral indicator light “N”
This display shows the selected gear. The neu- 1. Shift timing indicator light
tral position is indicated by “N” and by the neutral 2. “RESET” button
indicator light “N”. 3. “MODE” button
The shift timing indicator light has three settings
which can be adjusted.
• Flashing pattern: this function allows you to
choose whether or not the indicator light will
come on and whether it should flash or stay on
when activated.
1-7
FEATURES
• Activation point: this function allows you to se- 1. Push the “RESET” button to select the de-
lect the engine speed at which the indicator sired engine speed for activating the indicator
light is activated. light.
• Deactivation point: this function allows you to 2. Push the “MODE” button to confirm the se-
select the engine speed at which the indicator lected engine speed. The shift timing indica-
light is deactivated. tor light flashes and the tachometer shows
the current setting r/min for the deactivation
[To adjust the shift timing indicator light] point.
1. Turn the key to “ ” (off).
2. Push and hold the “MODE” button. [To set the deactivation point]
3. Turn the key to “ ” (on), and then release TIP
the “MODE” button after five seconds. After • The shift timing indicator light deactivation
all segments of the display disappear and the point can be set between 7000 r/min and
shift timing indicator light comes on, the shift 12000 r/min. The deactivation point can be set
timing indicator light can be adjusted. in increments of 500 r/min.
• Be sure to set the deactivation point to a higher
[To set the flashing pattern] engine speed than for the activation point, oth-
1. Push the “RESET” button to select one of the erwise the shift timing indicator light will not
following flashing pattern settings: come on.
• On: the indicator light stays on when activat- • The tachometer needle will start over at 7000
ed. (The indicator light will confirm this setting r/min after 12000 r/min.
by staying on.)
• Flash: the indicator light flashes when activat- 1. Push the “RESET” button to select the de-
ed. (The indicator light will confirm this setting sired engine speed for deactivating the indi-
by flashing four times per second.) cator light.
• Off: the indicator light is deactivated; in other 2. Push the “MODE” button to confirm the se-
words, it does not come on or flash. (The in- lected engine speed. The display exits the
dicator light will confirm this setting by flash- shift timing light control mode and returns to
ing once every two seconds.) the standard multi-function display mode.
2. Push the “MODE” button to confirm the se-
lected flashing pattern. The control mode
changes to the activation point setting mode.
The shift timing indicator light remains on and
the tachometer shows the current setting
r/min for the activation point.
[To set the shift activation point]

TIP
• The shift timing indicator light activation point
can be set between 7000 r/min and 12000
r/min. The activation point can be set in incre-
ments of 500 r/min.
• The tachometer needle will start over at 7000
r/min after 12000 r/min.
1-8
IMPORTANT INFORMATION
EBS20011
EBS30009
PREPARATION FOR REMOVAL AND

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

1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
2. Use only the proper tools and cleaning equip- lips with grease.
ment.
Refer to “SPECIAL TOOLS” on page 1-16.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mat-
ed” through normal wear. Mated parts must
always be reused or replaced as an assem-
bly.
1. Oil
2. Lip
3. Spring
4. Grease
EBS30012
LOCK WASHERS/PLATES AND COTTER

PINS
After removal, replace all lock washers/plates
4. During disassembly, clean all of the parts and “1” and cotter pins. After the bolt or nut has been
place them in trays in the order of disassem- tightened to specification, bend the lock tabs
bly. This will speed up assembly and allow for along a flat of the bolt or nut.
the correct installation of all parts.
5. Keep all parts away from any source of fire.
EBS30010
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
1-9
EBS30013 EBS30015
BEARINGS AND OIL SEALS RUBBER PARTS

Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in-
manufacturer’s marks or numbers are visible. spection. Some of the rubber parts are sensitive
When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc. Do not al-
lips with a light coat of lithium-soap-based low any items other than the specified one to
grease. Oil bearings liberally when installing, if contact the parts.
appropriate.
ECB01260
NOTICE
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
EBS30014
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
1-10
BASIC SERVICE INFORMATION
EBS20012

EBS30016
QUICK FASTENERS
Rivet type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, push its pin with a
screwdriver, then pull the fastener out. Screw type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, loosen the screw
with a screwdriver, then pull the fastener out.
2. Install:
• Quick fastener
TIP
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the part to be secured and push 2. Install:
the pin in with a screwdriver. Make sure that the • Quick fastener
pin is flush with the fastener’s head.
TIP
To install the quick fastener, insert the fastener
into the part to be secured and tighten the screw.
1-11
ECB01520
EBS30017
NOTICE
ELECTRICAL SYSTEM
Be sure to connect the battery leads to the
Electrical parts handling correct battery terminals. Reversing the bat-
ECB01460 tery lead connections could damage the
NOTICE electrical components.
Never disconnect a battery lead while the en-
gine is running; otherwise, the electrical
components could be damaged.
ECB01530
NOTICE
When connecting the battery leads to the
ECB01510 battery, be sure to connect the positive bat-
NOTICE tery lead first, then the negative battery lead.
When disconnecting the battery leads from If the negative battery lead is connected first
the battery, be sure to disconnect the nega- and a tool or similar item contacts the vehi-
tive battery lead first, then the positive bat- cle while the positive battery lead is being
tery lead. If the positive battery lead is connected, a spark could be generated,
disconnected first and a tool or similar item which is extremely dangerous.
contacts the vehicle, a spark could be gener-
ated, which is extremely dangerous.
ECB01470
NOTICE
TIP Turn the main switch to “OFF” before dis-

connecting or connecting an electrical com-
If a battery lead is difficult to disconnect due to
ponent.
rust on the battery terminal, remove the rust us-
ing hot water.
1-12
ECB01480
NOTICE Checking the electrical system

Handle electrical components with special TIP
care, and do not subject them to strong Before checking the electrical system, make
shocks. sure that the battery voltage is at least 12 V.
ECB01490 ECB01440
NOTICE NOTICE
Electrical components are very sensitive to Never insert the tester probes into the cou-
and can be damaged by static electricity. pler terminal slots. Always insert the probes
Therefore, never touch the terminals and be from the opposite end “a” of the coupler, tak-
sure to keep the contacts clean. ing care not to loosen or damage the leads.
ECB01500
TIP
NOTICE
When resetting the ECU by turning the main
switch to “OFF”, be sure to wait approximately 5 For waterproof couplers, never insert the
seconds before turning the main switch back to tester probes directly into the coupler. When
“ON”. performing any checks using a waterproof
coupler, use the specified test harness or a
suitable commercially available test har-
ness.
1-13
2. Check:
Checking the connections
• Lead
Check the leads, couplers, and connectors for
• Coupler
stains, rust, moisture, etc.
• Connector
1. Disconnect:
Moisture → Dry with an air blower.
• Lead
Rust/stains → Connect and disconnect sev-
• Coupler
eral times.
• Connector
ECB01540
NOTICE
• When disconnecting a coupler, release the
coupler lock, hold both sections of the cou-
pler securely, and then disconnect the cou-
pler.
• There are many types of coupler locks;
therefore, be sure to check the type of cou-
pler lock before disconnecting the coupler.
3. Check:
• All connections
Loose connection → Connect properly.
TIP
• If the pin “1” on the terminal is flattened, bend
it up.
• After disassembling and assembling a coupler,
pull on the leads to make sure that they are in-
stalled securely.
ECB01550
NOTICE
When disconnecting a connector, do not pull
the leads. Hold both sections of the connec-
tor securely, and then disconnect the con-
nector.
4. Connect:
• Lead
• Coupler
• Connector
1-14
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.
6. Check:
• Resistance
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
TIP
The resistance values shown were obtained at
the standard measuring temperature of 20 °C
(68 °F). If the measuring temperature is not 20
°C (68 °F), the specified measuring conditions
will be shown.
Intake air temperature sensor re-

5. Check: sistance
• Continuity 5.40–6.60 kΩ at 0 °C (32 °F)
(with the pocket tester) 290–390 Ω at 80 °C (176 °F)
Pocket tester
90890-03112
YU-03112-C
TIP
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
1-15
SPECIAL TOOLS
EBS20013
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
TIP
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, “YS-”, “YK-”, or “ACC-”.
• For others, use part number starting with “90890-”.
Reference
Tool name/Tool No. Illustration
pages
Pocket tester 1-15, 1-15, 9-93,
90890-03112 9-94, 9-97,
Analog pocket tester 9-100, 9-100,
YU-03112-C 9-101, 9-101,
9-103, 9-103,
9-104, 9-105,
9-106, 9-107,
9-108, 9-108,
9-109, 9-109,
9-110, 9-110
Thickness gauge 3-5, 5-55
90890-03180
Feeler gauge set
YU-26900-9
Valve lapper 90890-04101

3-5
90890-04101
Valve lapping tool
YM-A8998
YM-A8998
Vacuum gauge 3-10

90890-03094
Vacuummate
YU-44456
YU-44456
1-16
SPECIAL TOOLS
Reference
pages
Oil filter wrench 3-18
90890-01426
Oil filter wrench
YU-38411
Ring nut wrench 1 3-35, 3-37

90890-01584 R60
YM-01584
Ring nut wrench 2 3-35, 3-38

90890-01585 R60
YM-01585
Boots band installation tool 4-62, 8-11, 8-13,

90890-01526 8-25, 8-27
Boots band installation tool
YM-01526
Ball joint installer 4-67, 4-72

90890-01586
YM-01586
Extension 5-1
90890-04136
Compression gauge 90890-03081 5-1

90890-03081
Engine compression tester
YU-33223
YU-33223
Rotor holding tool 5-13, 5-15, 5-41,

90890-01235 5-42, 5-68, 5-71
Universal magneto and rotor holder
YU-01235
1-17
SPECIAL TOOLS
Reference
pages
Yamaha bond No. 1215 5-18, 5-33, 5-69,
90890-85505 5-95
(Three bond No.1215®)
Valve spring compressor 5-23, 5-27

90890-04019
Valve spring compressor
YM-04019
Valve spring compressor attachment 5-23, 5-27

90890-04114
Valve spring compressor adapter 19.5 mm
YM-04114
Valve guide remover (ø4.5) 5-25

90890-04116
Valve guide remover (4.5 mm)
YM-04116
Valve guide installer (ø4.5) 5-25

90890-04117
Valve guide installer (4.5 mm)
YM-04117
Valve guide reamer (ø4.5) 5-25

90890-04118
Valve guide reamer (4.5 mm)
YM-04118
Rotor holding tool 5-31, 5-31, 5-32,

90890-04166 5-32
YM-04166
Flywheel puller 5-31

90890-01362
Heavy duty puller
YU-33270-B
1-18
SPECIAL TOOLS
Reference
pages
Digital circuit tester 5-36, 7-14,
90890-03174 9-102, 9-106,
Model 88 Multimeter with tachometer 9-107
YU-A1927
Universal clutch holder 5-54, 5-57

90890-04086
Universal clutch holder
YM-91042
Piston pin puller set 5-73

90890-01304
Piston pin puller
YU-01304
YU-01304
Piston ring compressor 5-78

90890-05158
Piston ring compressor
YM-08037
1-19
SPECIAL TOOLS
Reference
pages
Universal joint holder 5-94, 5-98,
90890-04062 5-115, 5-116,
Universal joint holder 8-13, 8-16
YM-04062
Coupling gear/middle shaft tool 5-94, 5-97

90890-01229
Gear holder
YM-01229
Damper spring compressor (120 mm) 5-102, 5-103,

90890-01588 5-115, 5-116
YM-01588
Radiator cap tester 6-5

90890-01325
Mityvac cooling system tester kit
YU-24460-A
YU-24460-A
Radiator cap tester adapter 6-5

90890-01352
Pressure tester adapter
YU-33984
YU-33984
1-20
SPECIAL TOOLS
Reference
pages
Mechanical seal installer 6-12
90890-01587
ø30
YM-01587
ø10
ø24.5
Middle driven shaft bearing driver 6-12

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

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

90890-03176
Fuel pressure adapter
YM-03176
Test harness– TPS (3P) 7-14

90890-03204
Test harness– TPS (3P)
YU-03204
Boots band installation tool screw type 8-13, 8-27

90890-01554
Boots band installation tool screw type
YM-01554
Ring gear fix bolt (M10) 8-17

90890-01527
Ring gear fix bolt (M10)
YM-01527
M10×P1.25
Gear lash measurement tool 8-17, 8-30

90890-01475
Middle drive gear lash tool
YM-01475
Coupling gear holding tool (35) 8-28, 8-31

90890-01571
Coupling gear holding tool (35)
YM-01571
1-21
SPECIAL TOOLS
Reference
pages
Bearing retainer wrench 8-29, 8-31
90890-04128
Middle gear bearing retainer
YM-04128
Ring gear fix bolt (M10 x 1.5) 8-30

90890-01572
Ring gear fix bolt (M10 x 1.5)
YM-01572
M10×P1.50
Yamaha diagnostic tool (US) 9-33

90890-03234
Ignition checker 9-101

90890-06754
Oppama pet–4000 spark checker
YM-34487
Test harness– lean angle sensor (3P) 9-101

90890-03213
Test harness– lean angle sensor (3P)
YU-03213
Vacuum/pressure pump gauge set 9-103

90890-06756
Mityvac brake bleeding tool
YS-42423
Test harness S– pressure sensor (3P) 9-105, 9-107

90890-03207
Test harness S– pressure sensor (3P)
YU-03207
1-22
SPECIAL TOOLS
1-23
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................2-2
CHASSIS SPECIFICATIONS ..........................................................................2-7
ELECTRICAL SPECIFICATIONS .................................................................2-10

2
TIGHTENING TORQUES .............................................................................. 2-12
GENERAL TIGHTENING TORQUE SPECIFICATIONS......................... 2-12
ENGINE TIGHTENING TORQUES......................................................... 2-13
CHASSIS TIGHTENING TORQUES.......................................................2-20
LUBRICATION AND SEALING POINTS ......................................................2-28

ENGINE................................................................................................... 2-28
LUBRICATION SYSTEM CHART AND DIAGRAMS.................................... 2-30

ENGINE OIL LUBRICATION CHART .....................................................2-30
TRANSMISSION OIL LUBRICATION CHART........................................ 2-31
LUBRICATION DIAGRAMS .................................................................... 2-33
COOLING SYSTEM DIAGRAMS .................................................................. 2-45
CABLE ROUTING ......................................................................................... 2-51

GENERAL SPECIFICATIONS
EBS20014
GENERAL SPECIFICATIONS
Model
Model 2HC1
Dimensions
Overall length 3121 mm (122.9 in)
Overall width 1626 mm (64.0 in)
Overall height 1834 mm (72.2 in)
Wheelbase 2300 mm (90.6 in)
Ground clearance 330 mm (13.0 in)
Minimum turning radius 6000 mm (236 in)
Maximum water depth 39 cm (15 in)
Weight
Curb weight 699.0 kg (1541 lb)
Maximum loading limit 326.0 kg (719 lb)
(Total weight of operator, passenger, cargo, and
accessories)
Loading
Rear carrier load limit 136.0 kg (300 lb)
Storage compartment load limit 4.5 kg (10 lb)
2-1
ENGINE SPECIFICATIONS
EBS20015
Engine
Engine type Liquid cooled 4-stroke, DOHC
Cylinder arrangement Inline 3-cylinder
Displacement 998 cm³
Bore × stroke 80.0 × 66.2 mm (3.15 × 2.61 in)
Compression ratio 11.3 : 1
Standard compression pressure (at sea level) 1500–1800 kPa (15.0–18.0 kgf/cm², 213.3–
256.0 psi)
Starting system Electric starter
Fuel
Recommended fuel Regular unleaded gasoline only
Fuel tank capacity 34.0 L (8.98 US gal, 7.48 Imp.gal)
Engine oil
Lubrication system Dry sump
Recommended brand YAMALUBE
Type SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-
40 or 20W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Engine oil quantity
Without oil filter cartridge replacement 2.50 L (2.64 US qt, 2.20 Imp.qt)
With oil filter cartridge replacement 2.70 L (2.85 US qt, 2.38 Imp.qt)
Quantity (disassembled) 3.40 L (3.59 US qt, 2.99 Imp.qt)
Transmission oil
Type SAE 5W-30, 10W-30, 10W-40, 15W-40, 20W-
40 or 20W-50
Recommended transmission oil grade YAMALUBE
Quantity 1.50 L (1.59 US qt, 1.32 Imp.qt)
Differential gear oil

Type SAE 80 API GL-4 Hypoid gear oil
Final gear oil

Type SAE 80 API GL-4 Hypoid gear oil
Oil filter
Oil filter type Cartridge
Oil pump
Inner-rotor-to-outer-rotor-tip clearance 0.09–0.15 mm (0.0035–0.0059 in)
Limit 0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing clearance 0.03–0.08 mm (0.0012–0.0032 in)
Limit 0.15 mm (0.0059 in)
2-2
Cooling system
Coolant quantity
Radiator (including all routes) 3.75 L (3.96 US qt, 3.30 Imp.qt)
Coolant reservoir (up to the maximum level
mark) 0.31 L (0.33 US qt, 0.28 Imp.qt)
Radiator cap opening pressure 107.9–137.3 kPa (1.1–1.4 kgf/cm², 15.6–19.9
psi)
Thermostat
Valve opening temperature 69–73 °C (156–163 °F)
Valve full open temperature 85 °C (185 °F)
Valve lift (full open) 8.0 mm (0.31 in)
Water pump
Water pump type Single suction centrifugal pump
Impeller shaft tilt limit 0.15 mm (0.006 in)
Spark plug (s)

Manufacturer/model NGK/CR9EB
Spark plug gap 0.7–0.8 mm (0.028–0.031 in)
Cylinder head
Warpage limit 0.10 mm (0.0039 in)
Camshaft
Camshaft cap inside diameter 23.800–24.000 mm (0.9370–0.9449 in)
Camshaft journal diameter 22.800–23.000 mm (0.8976–0.9055 in)
Camshaft-journal-to-camshaft-cap clearance
limit 1.200 mm (0.0472 in)
Camshaft lobe dimensions
Lobe height (Intake) limit 32.750 mm (1.2894 in)
Base circle diameter (Intake) limit 24.850 mm (0.9783 in)
Lobe height (Exhaust) limit 33.250 mm (1.3091 in)
Base circle diameter (Exhaust) limit 24.850 mm (0.9783 in)
Camshaft runout limit 0.030 mm (0.0012 in)
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.15–0.22 mm (0.0059–0.0087 in)
Exhaust 0.21–0.27 mm (0.0083–0.0106 in)
Valve dimensions
Valve seat contact width (intake) 0.90–1.10 mm (0.0354–0.0433 in)
Valve seat contact width (intake) limit 1.6 mm (0.06 in)
Valve seat contact width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
Valve seat contact width (exhaust) limit 1.6 mm (0.06 in)
Valve stem diameter (intake) limit 4.445 mm (0.1750 in)
Valve stem diameter (exhaust) limit 4.430 mm (0.1744 in)
Valve guide inside diameter (intake) limit 4.550 mm (0.1791 in)
Valve guide inside diameter (exhaust) limit 4.550 mm (0.1791 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 0.010 mm (0.0004 in)
2-3
Valve spring
Spring tilt (intake) 1.8 mm (0.07 in)
Spring tilt (exhaust) 1.8 mm (0.07 in)
Cylinder
Bore 80.000–80.010 mm (3.1496–3.1500 in)
Wear limit 80.080 mm (3.1528 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.050 mm (0.0020 in)
Piston
Piston-to-cylinder clearance 0.035–0.060 mm (0.0014–0.0024 in)
Diameter 79.950–79.965 mm (3.1476–3.1482 in)
Measuring point (from piston skirt bottom) 8.0 mm (0.31 in)
Piston pin bore inside diameter limit 19.045 mm (0.7498 in)
Piston pin outside diameter limit 18.971 mm (0.7469 in)
Piston ring
Top ring
Ring type Barrel
End gap (installed) limit 0.50 mm (0.0197 in)
Ring side clearance limit 0.12 mm (0.0047 in)
2nd ring
Ring type Taper
End gap (installed) limit 0.70 mm (0.0276 in)
Ring side clearance limit 0.12 mm (0.0047 in)
Connecting rod
Oil clearance (using plastigauge®) 0.032–0.050 mm (0.0013–0.0020 in)
Bearing color code 1. Blue 2. Black 3. Brown 4. Green 5. Yellow 6.
Pink
Crankshaft
Runout limit 0.030 mm (0.0012 in)
Big end side clearance 0.160–0.262 mm (0.0063–0.0103 in)
Journal oil clearance (using plastigauge®) 0.027–0.045 mm (0.0011–0.0018 in)
Bearing color code 2. Black 3. Brown 4. Green 5. Yellow 6. Pink 7.
Red 8. White
Balancer
Balancer shaft runout limit 0.200 mm (0.0079 in)
Clutch
Clutch type Wet, multiple-disc
Specified brake and clutch fluid DOT 4
Clutch pedal free play 0.0 mm (0.00 in)
Friction plate thickness 1 2.92–3.08 mm (0.11–0.12 in)
Plate quantity 8 pcs
Friction plate thickness 2 2.92–3.08 mm (0.11–0.12 in)
2-4
Clutch plate thickness 1.90–2.10 mm (0.07–0.08 in)

Warpage limit 0.20 mm (0.0079 in)
Clutch spring height 6.50 mm (0.26 in)
Minimum height 6.1 mm (0.24 in)
Push rod bending limit 0.3 mm (0.01 in)
Drivetrain
Primary reduction ratio 88/53 (1.660)
Transmission type Constant mesh 5-speed forward, 1-speed
reverse
Operation Right hand operation
Gear ratio
1st 35/17 (2.059)
2nd 34/22 (1.545)
3rd 31/26 (1.192)
4th 25/26 (0.962)
5th 25/31 (0.806)
Reverse gear 37/15 (2.467)
Main axle runout limit 0.06 mm (0.0024 in)
Drive axle runout limit 0.06 mm (0.0024 in)
Secondary reduction ratio 41/22 × 33/9 (6.833)
Secondary reduction system Shaft drive
Transmission oil pump

Inner-rotor-to-outer-rotor-tip clearance 0.15 mm (0.0059 in)
Limit 0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing clearance 0.10–0.15 mm (0.0039–0.0059 in)
Limit 0.22 mm (0.0087 in)
Shaft drive
Final gear backlash 0.15–0.25 mm (0.006–0.010 in)
Differential gear backlash 0.05–0.25 mm (0.002–0.010 in)
Shifting mechanism
Shift fork thickness 6.26–6.39 mm (0.2465–0.2516 in)
Air filter
Primary air filter element Wet element
Secondary air filter element Oil-coated paper element
Air filter oil grade Foam air-filter oil
Fuel pump
Pump type Electrical
Throttle body
Type/quantity 41EIDW-B23/1
ID mark 2HC1 00
Fuel injector
Model/quantity EAT819/3
Resistance 11.5–12.5 Ω
2-5
Throttle position sensor

Resistance 2.64–6.16 kΩ
Idling condition
Engine idling speed 1400–1500 r/min
Intake vacuum 33.3 kPa (250 mmHg, 9.8 inHg)
Difference in vacuum pressure between the
cylinders 1.3 kPa (10 mmHg, 0.4 inHg)
Water temperature 75–85 °C (167–185 °F)
Oil temperature 55–65 °C (131–149 °F)
Accelerator pedal free play 10.0–25.0 mm (0.39–0.98 in)
Air induction system

Solenoid resistance 20–24 Ω
2-6
CHASSIS SPECIFICATIONS
EBS20016
Chassis
Frame type Steel tube frame
Caster angle 6.80°
Camber angle -1.5°
Kingpin angle 11.3°
Kingpin offset 16.0 mm (0.63 in)
Trail 33.7 mm (1.33 in)
Toe-in (with tires touching the ground) -5.0–5.0 mm (-0.20–0.20 in)
Tread rear (STD) 1346.0 mm (52.99 in)
Tread front (STD) 1397.0 mm (55.00 in)
Front wheel
Wheel type Cast wheel
Rim size 14 × 6.5AT
Wheel material Aluminum
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Rear wheel
Wheel type Cast wheel
Rim size 14 × 8.0AT
Wheel material Aluminum
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Front tire
Type Tubeless
Size 27 × 9.00R-14NHS
Manufacturer/model MAXXIS/MU09
Wear limit (front) 3.0 mm (0.12 in)
Rear tire
Type Tubeless
Size 27 × 11.00R-14NHS
Manufacturer/model MAXXIS/MU10
Wear limit (rear) 3.0 mm (0.12 in)
Tire air pressure (measured on cold tires)

Recommended
Vehicle load 0 – 195 kg (0 – 430 lb)
Front 114.0 kPa (1.140 kgf/cm², 16.5 psi)
Rear 128.0 kPa (1.280 kgf/cm², 18.5 psi)
Vehicle load 195 kg - maximum (430 lb - maximum)
Minimum
Vehicle load 0 – 195 kg (0 – 430 lb)
Vehicle load 195 kg - maximum (430 lb - maximum)
2-7

Front brake
Type Hydraulic disc brake
Operation Unified brake
Disc outside diameter × thickness 244.5 × 5.5 mm (9.63 × 0.22 in)
Brake disc thickness limit 5.0 mm (0.20 in)
Brake disc deflection limit 0.10 mm (0.0039 in)
Brake pad lining thickness limit 1.0 mm (0.04 in)
Master cylinder inside diameter 17.46 mm (0.69 in)
Caliper cylinder inside diameter 32.03 mm × 2 (1.26 in × 2)
Rear brake
Type Hydraulic disc brake
Operation Unified brake
Brake disc deflection limit 0.10 mm (0.0039 in)
Master cylinder inside diameter 17.46 mm (0.69 in)
Caliper cylinder inside diameter 27.00 mm × 2
Brake pedal free play 0 mm (0 in)
Parking brake
Type Disc
Front suspension
Type Double wishbone
Spring/shock absorber type Coil spring/gas-oil damper
Shock absorber travel 237.4 mm (9.35 in)
Installed length 415.5 mm (16.36 in)
Wheel travel 410 mm (16.2 in)
Spring preload adjusting positions
Minimum 428.2 mm (16.86 in)
Standard 415.5 mm (16.36 in)
Maximum 402.8 mm (15.86 in)
Rebound damping adjusting positions
Minimum 26 click(s) out from the fully turned in position
Standard 12 click(s) out from the fully turned in position
Maximum 1 click out from the fully turned in position
Compression damping setting (for fast compression damping)
Minimum 4 turn(s) out from the fully turned in position
Standard 2 turn(s) out from the fully turned in position
Maximum Adjusting bolt fully turned in
Compression damping setting (for slow compression damping)
Standard 1 1/2 turn(s) out from the fully turned in position
2-8
Maximum Adjusting screw fully turned in
Rear suspension
Type Double wishbone
Spring/shock absorber type Coil spring/gas-oil damper
Wheel travel 432 mm (17.0 in)
Rear shock absorber assembly travel 272.9 mm (10.74 in)
Installed length 484.1 mm (19.06 in)
Minimum 496.8 mm (19.56 in)
Standard 484.1 mm (19.06 in)
Maximum 471.4 mm (18.56 in)
Rebound damping adjusting positions
Minimum 26 click(s) out from the fully turned in position
Standard 8 click(s) out from the fully turned in position
Maximum 1 click out from the fully turned in position
Compression damping setting (for fast compression damping)
Maximum Adjusting bolt fully turned in
Compression damping setting (for slow compression damping)
Maximum Adjusting screw fully turned in
2-9
ELECTRICAL SPECIFICATIONS
EBS20017
Voltage
System voltage 12 V
Engine control unit

Model/manufacturer F8T86171/MITSUBISHI
Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 5.0°/1450 r/min
Ignition coil
Primary coil resistance 1.19–1.61 Ω
Secondary coil resistance 8.50–11.50 kΩ
Charging system
Charging system AC magneto
Standard output 14.0 V, 33.7 A at 5000 r/min
Stator coil resistance 0.15–0.23 Ω
Rectifier/regulator
Regulator type Semi conductor-short circuit
Regulated voltage (DC) 14.3–14.7 V
Rectifier capacity (DC) 50.0 A
Battery
Model U1-H11L
Voltage, capacity 12 V, 28.0 Ah
Bulb voltage, wattage × quantity

Headlight LED
Tail/brake light LED
Indicator and warning lights

Neutral indicator light LED
Reverse indicator light LED
Coolant temperature warning light LED
Parking brake indicator light LED
Engine trouble warning light LED
Differential gear lock indicator light LED
Helmet/Seat belt indicator light 14 V, 0.85 W × 2
EPS warning light LED
Shift timing indicator light LED
Starter motor
Power output 0.80 kW
Armature coil resistance 0.005–0.015 Ω
Brush overall length limit 6.50 mm (0.26 in)
Mica undercut (depth) 0.70 mm (0.03 in)
2-10
Fuel sender unit

Sender unit resistance (full) 19.00–21.00 Ω
Sender unit resistance (empty) 138.50–141.50 Ω
Oil pressure switch

Working pressure 14–24 kPa (0.15–0.25 kgf/cm², 2–4 psi)
EPS torque sensor

Coil resistance 1.00–1.50 kΩ
Auxiliary DC output
Jack capacity 12 V, 10.0 A (120 W)
Fuel injection sensor

Crankshaft position sensor resistance 445–544 Ω
Intake air pressure sensor output voltage 3.51–3.77 V
Intake air temperature sensor resistance 5.40–6.60 kΩ at 0 °C (32 °F)
290–390 Ω at 80 °C (176 °F)
Coolant temperature sensor resistance 2.32–2.59 kΩ at 20 °C (68 °F)
310–326 Ω at 80 °C (176 °F)
Fuses
Main fuse 40.0 A
Headlight fuse 15.0 A
Signaling system fuse 10.0 A
Ignition fuse 15.0 A
Radiator fan motor fuse 30.0 A
Auxiliary DC jack fuse 10.0 A
Fuel injection system fuse 15.0 A
Backup fuse 10.0 A
Four-wheel-drive motor fuse 10.0 A
EPS fuse 40.0 A
2-11
TIGHTENING TORQUES
EBS20018
TIGHTENING TORQUES
EBS30018
GENERAL TIGHTENING TORQUE

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

B. Outside thread diameter
General tightening torques

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

Thread
Item Q’ty Tightening torque Remarks
size
Exhaust pipe nut M8 6 20 Nm (2.0 m·kgf, 14 ft·lbf)
Muffler bolt M10 4 90 Nm (9.0 m·kgf, 65 ft·lbf)
Exhaust pipe joint clamp bolt M8 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Muffler bracket bolt M10 2 55 Nm (5.5 m·kgf, 40 ft·lbf)
Tailpipe bolt M6 6 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tailpipe cover bolt M6 3 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Cylinder head cover bolt M6 4 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Camshaft cap bolt M6 16 10 Nm (1.0 m·kgf, 7.2 ft·lbf) E
Cylinder head bolt (M10) M10 8 See TIP. E
Cylinder head bolt (M6) M6 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)

Reed valve cover bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing chain bolt (rear side of cylin-
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
der head)
Oil check bolt (M8) M8 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Cylinder head plug M27 2 80 Nm (8.0 m·kgf, 58 ft·lbf) LT
Cylinder head stud bolt (exhaust

M8 6 15 Nm (1.5 m·kgf, 11 ft·lbf)
pipe)
Timing chain tensioner bolt M6 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Timing chain guide bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Camshaft sprocket bolt M7 4 24 Nm (2.4 m·kgf, 17 ft·lbf)

AC magneto cover bolt M6 8 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
AC magneto cover bolt M6 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf) LT
Stator coil assembly lead holder 3

M6 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf) LT
bolt
M6 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
bolt
Crankshaft end accessing screw M36 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Timing mark accessing screw M14 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
AC magneto rotor bolt M12 1 130 Nm (13 m·kgf, 94 ft·lbf) E
Starter clutch bolt M6 6 16 Nm (1.6 m·kgf, 12 ft·lbf) LT
Thermostat inlet hose clamp screw — 2 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Thermostat outlet hose clamp screw — 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Water pump housing bolt (M6 × 40) M6 4 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Water pump housing bolt (M6 × 25) M6 3 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Water pump housing cover screw M6 3 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Thermostat cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Water jacket joint bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Water jacket joint air bleed bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Water pump air bleed hose clamp
— 2 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
screw
Oil filter cartridge M20 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
2-13
TIGHTENING TORQUES
Thread
size
Oil filter cartridge union bolt M20 1 80 Nm (8.0 m·kgf, 58 ft·lbf)
Oil cooler bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Water pump outlet hose clamp

— 2 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
screw
Oil cooler outlet hose clamp screw — 2 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Oil separator bracket bolt M8 1 23 Nm (2.3 m·kgf, 17 ft·lbf)
Oil pan bolt (M6 × 25) M6 15 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pan bolt (M6 × 35) M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Engine oil drain bolt (crankcase) M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Relief valve cover screw M5 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Oil pump drive chain guide bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pump driven sprocket bolt M6 1 15 Nm (1.5 m·kgf, 11 ft·lbf)
Oil pump assembly bolt M6 5 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Oil pump housing cover 1 screw M5 5 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Oil pump housing cover 2 screw (M5
M5 4 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
× 25)
Oil pump housing cover 2 screw (M5
M5 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
× 35)
Oil strainer screw M3 4 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Oil pan divider screw M5 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Oil tank inlet pipe 1 bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil tank outlet pipe 3 bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle body joint clamp screw
M5 3 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
(throttle body side)
Throttle body joint clamp screw (cyl-
M5 3 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
inder head side)
Throttle cable housing cover bolt M4 3 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Fuel rail bolt M5 2 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) LT
Throttle cable locknut (throttle cable) M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Throttle cable locknut (throttle bod-
M6 1 1.0 Nm (0.10 m·kgf, 0.72 ft·lbf)
ies)
Crankcase bolt (M9 × 164) M9 4 See TIP. E
Crankcase bolt (M9 × 105) M9 4 See TIP. E
Crankcase bolt (M8 × 70) M8 3 24 Nm (2.4 m·kgf, 17 ft·lbf) E
Crankcase bolt (M8 × 55) M8 1 24 Nm (2.4 m·kgf, 17 ft·lbf) E
Crankcase bolt (M6 × 80) M6 3 12 Nm (1.2 m·kgf, 8.7 ft·lbf) E
Crankcase bolt (M6 × 80) M6 3 12 Nm (1.2 m·kgf, 8.7 ft·lbf) LT
Crankcase plug M27 1 80 Nm (8.0 m·kgf, 58 ft·lbf) LT
Connecting rod bolt M8 6 See TIP. M
Main gallery bolt PT 3/8 3 45 Nm (4.5 m·kgf, 33 ft·lbf) LT
2-14
TIGHTENING TORQUES
Thread
size
Balancer shaft bearing retainer bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Balancer weight bolt M10 2 35 Nm (3.5 m·kgf, 25 ft·lbf)

Primary drive shaft assembly bolt M12 1 120 Nm (12 m·kgf, 87 ft·lbf) E
Flywheel bolt M8 6 37 Nm (3.7 m·kgf, 27 ft·lbf)

Primary drive shaft yoke bolt M8 6 37 Nm (3.7 m·kgf, 27 ft·lbf)
LT
Primary driven shaft yoke bolt M12 1 115 Nm (11.5 m·kgf, 83 ft·lbf)
See TIP.
Front drive shaft yoke nut (middle
M16 1 190 Nm (19 m·kgf, 137 ft·lbf) See TIP.
driven gear side)
Rear drive shaft coupling gear nut
M16 1 190 Nm (19 m·kgf, 137 ft·lbf) See TIP.
(middle driven gear side)
Transmission case bolt (M6 × 45) M6 16 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Transmission case bolt (M6 × 60) M6 5 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Primary drive shaft bearing housing
M6 4 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
bolt
Torque limiter housing bolt (M6 × 30) M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Torque limiter housing bolt (M6 × 30) M6 5 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Transmission oil gallery bolt (M10 ×
M10 5 20 Nm (2.0 m·kgf, 14 ft·lbf)
12)
Transmission oil check bolt (M6 ×
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
10)
Transmission oil gallery bolt (M6 ×
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
10)
Reverse gear lock cable bracket bolt M8 2 24 Nm (2.4 m·kgf, 17 ft·lbf) LT
Transmission oil drain bolt M12 1 20 Nm (2.0 m·kgf, 14 ft·lbf)

Transmission oil strainer bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Clutch boss nut M22 1 105 Nm (10.5 m·kgf, 76 ft·lbf) Stake.
Clutch cover bolt M6 12 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Clutch release cylinder bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Clutch spring plate retainer bolt M6 6 8 Nm (0.8 m·kgf, 5.8 ft·lbf)

Clutch release cylinder bleed screw M8 1 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Shift arm bolt M6 1 15 Nm (1.5 m·kgf, 11 ft·lbf)
Shift lever nut M8 1 27 Nm (2.7 m·kgf, 20 ft·lbf)
Shift lever rod locknut M8 2 15 Nm (1.5 m·kgf, 11 ft·lbf)
Shift shaft spring stopper M8 1 22 Nm (2.2 m·kgf, 16 ft·lbf) LT
Reverse gear lock arm bolt M6 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf)

Stopper lever bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Main axle bearing retainer bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Transmission oil pump housing cov-

M6 3 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
er screw (M6 × 30)
Transmission oil pump housing cov-
M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
er screw (M6 × 20)
Secondary air filter cover screw M5 11 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
2-15
TIGHTENING TORQUES
Thread
size
Air filter case bracket bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Air filter case bolt M6 2 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Air filter case joint clamp screw M5 3 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Primary air filter cover lock screw M5 2 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
Radiator bolt M6 2 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Radiator fan bolt M6 4 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Radiator inlet pipe holder bolt M6 3 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Radiator outlet pipe holder bolt M6 2 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Coolant drain bolt (radiator outlet
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
pipe)
Starter motor bolt M8 2 27 Nm (2.7 m·kgf, 20 ft·lbf)
Spark plug M10 3 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Ignition coil bolt M6 6 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Stator coil bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT

M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
bolt
Throttle position sensor screw M5 2 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Intake air pressure sensor #1 screw M5 2 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Intake air pressure sensor #2 screw M5 2 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Intake air temperature sensor screw M5 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Crankshaft position sensor bolt M5 2 6 Nm (0.6 m·kgf, 4.3 ft·lbf) LT
Oil pressure switch PT 1/8 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf) LT
Coolant temperature sensor M12 1 23 Nm (2.3 m·kgf, 17 ft·lbf)

Gear position sensor bolt M5 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) LT
Neutral switch M10 1 17 Nm (1.7 m·kgf, 12 ft·lbf)

Speed sensor bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
TIP
Cylinder head bolt
1. Tighten the cylinder head bolts (M10) to 25 Nm (2.5 m·kgf, 18 ft·lbf) in the proper tightening se-
quence.
2. Loosen and retighten the cylinder head bolts (M10) to 25 Nm (2.5m·kgf, 18 ft·lbf) in the proper tight-
ening sequence.
3. Tighten the cylinder head bolts (M10) to the specified angle 175–185° in the proper tightening se-
quence.
6 2 4 8
7 3 1 5
2-16
TIGHTENING TORQUES
TIP
Crankcase bolt
1. Finger tighten the crankcase bolts.
2. Tighten the crankcase bolts “1”–“8” to 15 Nm (1.5 m·kgf, 11 ft·lbf) in the proper tightening sequence.
3. Loosen and retighten the crankcase bolts “1”–“8” to 15 Nm (1.5 m·kgf, 11 ft·lbf) in the proper tight-
ening sequence.
4. Tighten the crankcase bolts “1”–“4” to the specified angle 95–100° in the proper tightening se-
quence.
5. Tighten the crankcase bolts “5”–“8” to the specified angle 75–80° in the proper tightening sequence.
6. Tighten the crankcase bolts “9”–“12” to 24 Nm (2.4 m·kgf, 17 ft·lbf) in the proper tightening se-
quence.
7. Tighten the crankcase bolts “13”–“24” to 12 Nm (1.2 m·kgf, 8.7 ft·lbf) in the proper tightening se-
quence.
×4 ×4
1 3 7
5
6 2 4 8
2-17
TIGHTENING TORQUES
×3 ×1 ×5 ×3 ×3 ×1
23
24 22 20 19 21
11
9
10
12
18 17
16 14 13 15
TIP
Connecting rod bolt
1. Tighten the bolts to 20 Nm (2.0 m·kgf, 14 ft·lbf).
2. Tighten the bolts further to reach the specified angle 115–125°.
TIP
Primary driven shaft yoke bolt
1. Apply LOCTITE® to the primary driven shaft yoke bolt in the 2.0 mm (0.08 in) wide “a” and 10.0 mm
(0.39 in) long “b” area shown in the illustration.
2. Tighten the bolt to 115 Nm (11.5 m·kgf, 83 ft·lbf).
TIP
Front drive shaft yoke nut (middle driven gear side)
1. Apply LOCTITE® to the threads of the torque limiter assembly shaft in the 2.0 mm (0.08 in) wide “a”
area shown in the illustration.
2. Tighten the nut to 190 Nm (19 m·kgf, 137 ft·lbf).
2-18
TIGHTENING TORQUES
TIP
Rear drive shaft coupling gear nut (middle driven gear side)
1. Apply LOCTITE® to the threads of the middle driven shaft in the 2.0 mm (0.08 in) wide “a” area
shown in the illustration.
2. Tighten the nut to 190 Nm (19 m·kgf, 137 ft·lbf).
2-19
TIGHTENING TORQUES
EBS30020
CHASSIS TIGHTENING TORQUES

Thread
size
Engine mounting nut M12 2 60 Nm (6.0 m·kgf, 43 ft·lbf)
Engine mounting bolt (rear lower) M8 2 25 Nm (2.5 m·kgf, 18 ft·lbf)
Engine mounting bolt (rear upper) M8 2 25 Nm (2.5 m·kgf, 18 ft·lbf)
Engine bracket bolt M10 2 55 Nm (5.5 m·kgf, 40 ft·lbf)
Transmission case nut M10 3 60 Nm (6.0 m·kgf, 43 ft·lbf)
Flywheel housing bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Drive shaft cover bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Drive shaft universal joint cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant reservoir bolt M6 2 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Engine oil drain bolt (oil tank) M8 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
Engine oil tank bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Engine oil tank cover bolt M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Oil tank outlet pipe 1 bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Oil pipe guide 2 bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pipe guide 1 bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle cable locknut (accelerator
M6 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
pedal)
Fuel tank bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel pump nut M6 6 See TIP.
Fuel tank breather hose joint bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank retainer bolt M8 2 32 Nm (3.2 m·kgf, 23 ft·lbf)
Side panel bolt (left) M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Side panel bolt (right) M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Door hinge plate bolt M8 8 17 Nm (1.7 m·kgf, 12 ft·lbf)
Door hinge bolt M6 4 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Door panel bolt M6 12 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Door handle latch bolt M6 8 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Door latch striker bolt M8 4 23 Nm (2.3 m·kgf, 17 ft·lbf)
Center console bolt M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Center console cover bolt M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Center console side panel bolt (left) M6 3 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Center console side panel bolt
M6 3 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
(right)
Seat back bolt M6 6 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Driver seat frame bolt M8 4 32 Nm (3.2 m·kgf, 23 ft·lbf)
Driver seat position adjuster assem-
M8 4 32 Nm (3.2 m·kgf, 23 ft·lbf)
bly bolt
Driver seat frame nut M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
Passenger seat frame bolt M8 4 32 Nm (3.2 m·kgf, 23 ft·lbf)
Rear panel bolt (left) M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear panel bolt (right) M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
2-20
TIGHTENING TORQUES
Thread
size
Floor board bolt (left) M6 5 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Floor board bolt (right) M6 6 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Seat belt guide bolt M11 2 59 Nm (5.9 m·kgf, 43 ft·lbf)
Seat belt bolt (M12 × 20) M12 4 59 Nm (5.9 m·kgf, 43 ft·lbf)
Seat belt bolt (M12 × 18) M12 2 59 Nm (5.9 m·kgf, 43 ft·lbf)
Seat belt buckle bolt M12 2 59 Nm (5.9 m·kgf, 43 ft·lbf)
Sun top holder screw M6 10 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Sun top bracket screw M6 2 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Sun top rear side bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Top frame bolt M10 8 70 Nm (7.0 m·kgf, 51 ft·lbf)
Side frame nut (front left) M10 2 70 Nm (7.0 m·kgf, 51 ft·lbf)
Rear frame bolt (left) M10 2 70 Nm (7.0 m·kgf, 51 ft·lbf)
Side frame nut (center left) M10 1 48 Nm (4.8 m·kgf, 35 ft·lbf)
Side frame nut (rear left) M10 2 70 Nm (7.0 m·kgf, 51 ft·lbf)
Side frame nut (front right) M10 2 70 Nm (7.0 m·kgf, 51 ft·lbf)
Rear frame bolt (right) M10 2 70 Nm (7.0 m·kgf, 51 ft·lbf)
Side frame nut (center right) M10 1 48 Nm (4.8 m·kgf, 35 ft·lbf)
Side frame nut (rear right) M10 2 70 Nm (7.0 m·kgf, 51 ft·lbf)
Sun top bracket bolt M10 2 70 Nm (7.0 m·kgf, 51 ft·lbf)
Skid plate bolt (center) M6 5 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Skid plate bolt (front) M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Skid plate (front) and skid plate (cen-
M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
ter) bolt
Skid plate bolt (rear) M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Skid plate (rear) and skid plate (cen-
M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
ter) bolt
Skid plate bolt (left) (M6 × 8) M6 5 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Skid plate bolt (left) (M6 × 20) M6 6 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Skid plate bolt (right) (M6 × 8) M6 5 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Skid plate bolt (right) (M6 × 20) M6 8 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Air scoop bolt (upper) M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Air scoop bolt (right) M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Pedal assembly cover bolt M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Mudguard bolt (left) (M6 × 20) M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Mudguard bolt (left) (M6 × 8) M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Mudguard bolt (right) (M6 × 20) M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Mudguard bolt (right) (M6 × 8) M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Upper cover bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Hood bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front fender and frame bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front fender and front grill bolt M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Side fender bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
2-21
TIGHTENING TORQUES
Thread
size
Front grill and headlight bracket bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front grill and front fender bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front grill and frame bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Headlight screw M5 8 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Headlight bracket bolt (M6) M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Headlight bracket bolt (M8) M8 4 16 Nm (1.6 m·kgf, 12 ft·lbf)
Front guard bolt M10 4 48 Nm (4.8 m·kgf, 35 ft·lbf)
Sub-frame bolt (front) M8 2 17 Nm (1.7 m·kgf, 12 ft·lbf)
Sub-frame bolt (rear) M8 2 32 Nm (3.2 m·kgf, 23 ft·lbf)
Instrument panel bolt M6 11 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Glove compartment latch plate
M4 2 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
screw
Passenger handhold nut M6 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Electrical components tray bolt (M6
M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
× 16)
Electrical components tray bolt (M6
M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
× 20)
Cargo bed bolt M6 9 See TIP.
Heat protector bolt M8 5 11 Nm (1.1 m·kgf, 8.0 ft·lbf)
Rear fender bolt (M6 × 16) M6 6 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear fender bolt (M6 × 12.5) M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear fender bolt (M6 × 20) M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear fender bracket bolt M6 4 11 Nm (1.1 m·kgf, 8.0 ft·lbf)
Front wheel nut M12 8 75 Nm (7.5 m·kgf, 54 ft·lbf)
Rear wheel nut M12 8 75 Nm (7.5 m·kgf, 54 ft·lbf)
Bead lock bolt M6 60 See TIP.
Front wheel axle nut M24 2 370 Nm (37 m·kgf, 268 ft·lbf) Stake.
Rear wheel axle nut M24 2 370 Nm (37 m·kgf, 268 ft·lbf) Stake.
Steering knuckle nut (upper side) M14 2 70 Nm (7.0 m·kgf, 51 ft·lbf)
Steering knuckle nut (lower side) M14 2 70 Nm (7.0 m·kgf, 51 ft·lbf)
Front upper arm bolt M12 4 90 Nm (9.0 m·kgf, 65 ft·lbf)
Front upper arm grease nipple M6 4 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Front lower arm bolt M12 4 90 Nm (9.0 m·kgf, 65 ft·lbf)
Front lower arm grease nipple M6 4 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Front stabilizer holder bolt M8 4 30 Nm (3.0 m·kgf, 22 ft·lbf)
Front stabilizer joint nut M10 4 60 Nm (6.0 m·kgf, 43 ft·lbf)
Front shock absorber assembly nut M10 4 65 Nm (6.5 m·kgf, 47 ft·lbf)
Front constant velocity shaft dust
M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
boot guard bolt
Spring preload adjusting ring locknut — 4 41 Nm (4.1 m·kgf, 30 ft·lbf)
Rear upper arm bolt M12 2 90 Nm (9.0 m·kgf, 65 ft·lbf)
Rear upper arm grease nipple M6 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
2-22
TIGHTENING TORQUES
Thread
size
Rear knuckle bolt M12 4 85 Nm (8.5 m·kgf, 61 ft·lbf)
Rear lower arm bolt M12 4 120 Nm (12 m·kgf, 87 ft·lbf)
Rear knuckle grease nipple M6 4 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Rear stabilizer joint nut M12 4 100 Nm (10 m·kgf, 72 ft·lbf)
Rear stabilizer holder bolt M10 4 65 Nm (6.5 m·kgf, 47 ft·lbf)
Rear shock absorber assembly bolt M12 4 82 Nm (8.2 m·kgf, 59 ft·lbf)
Steering wheel nut M12 1 35 Nm (3.5 m·kgf, 25 ft·lbf)
Steering assembly bolt M10 4 See TIP.
Steering joint bolt M8 2 33 Nm (3.3 m·kgf, 24 ft·lbf)
Tie-rod M12 2 55 Nm (5.5 m·kgf, 40 ft·lbf)
Tie-rod end locknut M14 2 50 Nm (5.0 m·kgf, 36 ft·lbf)
Tie-rod end nut M12 2 40 Nm (4.0 m·kgf, 29 ft·lbf)
EPS unit bracket nut M10 2 55 Nm (5.5 m·kgf, 40 ft·lbf)
Steering wheel position adjusting
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
dumper nut
Reverse gear lock cable locknut M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Reverse gear lock lever bracket bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Reverse gear lock lever bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
EPS unit cover bolt M6 3 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
EPS unit support bolt M8 4 16 Nm (1.6 m·kgf, 12 ft·lbf)
EPS unit bolt M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
Pedal assembly bolt M8 4 16 Nm (1.6 m·kgf, 12 ft·lbf)
Brake pedal pivot nut M10 1 40 Nm (4.0 m·kgf, 29 ft·lbf)
Brake pedal rod locknut M8 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
Brake master cylinder bolt M8 2 20 Nm (2.0 m·kgf, 14 ft·lbf)
Brake master cylinder reservoir hose
M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
joint clamp bolt
Brake master cylinder reservoir bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Brake master cylinder reservoir cap — 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Brake master secondary piston stop
M6 1 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
bolt
Front brake hose joint bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Front brake hose holder bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear brake pipe joint bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear brake hose joint bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear brake hose holder bolt M6 6 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front brake hose union bolt M10 2 27 Nm (2.7 m·kgf, 20 ft·lbf)
Rear brake hose union bolt M10 2 27 Nm (2.7 m·kgf, 20 ft·lbf)
Brake caliper bleed screw M8 4 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Front brake caliper bolt M10 4 48 Nm (4.8 m·kgf, 35 ft·lbf)
Rear brake caliper bolt M10 4 48 Nm (4.8 m·kgf, 35 ft·lbf)
Front brake caliper guide pin bolt M8 2 22 Nm (2.2 m·kgf, 16 ft·lbf)
2-23
TIGHTENING TORQUES
Thread
size
Rear brake caliper guide pin bolt M8 2 22 Nm (2.2 m·kgf, 16 ft·lbf)
Front brake caliper retaining pin bolt M8 2 22 Nm (2.2 m·kgf, 16 ft·lbf)
Rear brake caliper retaining pin bolt M8 2 22 Nm (2.2 m·kgf, 16 ft·lbf)
Brake pipe flare nut M10 6 19 Nm (1.9 m·kgf, 14 ft·lbf)
Brake disc bolt M8 16 43 Nm (4.3 m·kgf, 31 ft·lbf) LT
Front brake disc guard bolt M6 6 12 Nm (1.2 m·kgf, 8.7 ft·lbf)

Rear brake disc guard bolt M6 6 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Rear brake disc cleaning plate bolt M6 4 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Parking brake lever bolt M6 2 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Parking brake switch screw M4 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Parking brake cable adjusting lock-
M8 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
nut (parking brake lever side)
Parking brake cable adjusting lock-
M8 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
nut (parking brake caliper side)
Parking brake caliper bolt M10 2 40 Nm (4.0 m·kgf, 29 ft·lbf)
Parking brake cable holder bolt M6 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Parking brake caliper guide pin M8 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
Parking brake caliper retaining pin
M8 1 22 Nm (2.2 m·kgf, 16 ft·lbf) LT
nut
Parking brake pad bolt M10 2 17 Nm (1.7 m·kgf, 12 ft·lbf)
Parking brake caliper arm nut M8 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
Parking brake caliper arm shaft re-
M22 1 22 Nm (2.2 m·kgf, 16 ft·lbf)
tainer
Parking brake disc nut M6 6 17 Nm (1.7 m·kgf, 12 ft·lbf)
Clutch pedal rod locknut M8 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
Clutch master cylinder bolt M8 2 16 Nm (1.6 m·kgf, 12 ft·lbf)
Clutch master cylinder hose joint
M4 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
screw
Clutch master cylinder reservoir bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Clutch master cylinder reservoir cap — 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Clutch hose union bolt M10 2 27 Nm (2.7 m·kgf, 20 ft·lbf)
Front drive shaft yoke nut (differen-
M14 1 62 Nm (6.2 m·kgf, 45 ft·lbf)
tial assembly side)
Differential assembly bolt (M10 × 25) M10 1 90 Nm (9.0 m·kgf, 65 ft·lbf)
Differential assembly bolt (M10 × 40) M10 2 60 Nm (6.0 m·kgf, 43 ft·lbf)
Differential assembly nut M12 1 105 Nm (10.5 m·kgf, 76 ft·lbf)
Differential gear oil filler bolt M14 1 23 Nm (2.3 m·kgf, 17 ft·lbf)
Differential gear oil drain bolt M10 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Differential motor bolt M6 3 11 Nm (1.1 m·kgf, 8.0 ft·lbf)
Differential case bolt (M8 × 50) M8 2 24 Nm (2.4 m·kgf, 17 ft·lbf)
Differential case bolt (M8 × 40) M8 3 24 Nm (2.4 m·kgf, 17 ft·lbf)
Differential case ring gear bolt M8 14 34 Nm (3.4 m·kgf, 25 ft·lbf) LT
Final drive assembly bolt M10 2 55 Nm (5.5 m·kgf, 40 ft·lbf)
2-24
TIGHTENING TORQUES
Thread
size
Final drive assembly nut (lower side) M12 1 105 Nm (10.5 m·kgf, 76 ft·lbf)
Final drive assembly nut (upper side) M12 2 105 Nm (10.5 m·kgf, 76 ft·lbf)
Final gear oil filler bolt M10 1 23 Nm (2.3 m·kgf, 17 ft·lbf)
Final gear oil drain bolt M10 1 23 Nm (2.3 m·kgf, 17 ft·lbf)
Left-hand
threads
Final drive pinion gear bearing re- Three
M65 1 170 Nm (17 m·kgf, 123 ft·lbf)
tainer Bond
No.1305N
®
Three
Bond
Final drive case cover bolt M10 8 52 Nm (5.2 m·kgf, 38 ft·lbf)
No.1324N
®
Final drive pinion gear bearing hous-
M8 4 27 Nm (2.7 m·kgf, 20 ft·lbf)
ing bolt
Three
Bond
Ring gear stopper nut M8 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
No.1324N
®
Rear drive shaft coupling gear nut Stake.
M14 1 290 Nm (29 m·kgf, 210 ft·lbf)
(final drive assembly side) LT
Engine ground lead bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)

Transmission ground lead bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Main switch nut — 1 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Meter assembly screw M5 3 1.6 Nm (0.16 m·kgf, 1.2 ft·lbf)
Meter assembly bracket bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Starter relay lead bolt M6 2 3.6 Nm (0.36 m·kgf, 2.6 ft·lbf)
Lean angle sensor bolt M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Battery holding bracket bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Positive battery lead nut M8 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Negative battery lead nut M8 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Starter motor cover bolt M5 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Starter motor terminal nut M6 1 11 Nm (1.1 m·kgf, 8.0 ft·lbf)
Starter motor lead nut M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
EPS (electric power stearing) control
M6 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
unit bolt
Rectifier/regulator bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Parking brake buzzer bolt M5 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Tail/brake light screw M5 2 2.8 Nm (0.28 m·kgf, 2.0 ft·lbf)
Tail/brake light cover bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
TIP
Enclosure bolt and nut
Tighten the enclosure bolts and nuts to specification in the proper tightening sequence.
2-25
TIGHTENING TORQUES
Enclosure tightening sequence:
7 2
4
1
3 6
TIP
Fuel pump nut
Tighten the fuel pump nuts to 7 Nm (0.7 m·kgf, 5.1 ft·lbf) in the proper tightening sequence.
Fuel pump tightening sequence:

4
6
2
FWD
1
5
3
TIP
Cargo bed bolt
Tighten the cargo bed bolts to 12 Nm (1.2 m·kgf, 8.7 ft·lbf) in the proper tightening sequence.
Cargo bed tightening sequence:
FWD
1 3 9
2
1 6
5 4
8 7
TIP
Bead lock bolt
1. Tighten the bead lock bolts to 5 Nm (0.5 m·kgf, 3.6 ft·lbf) in the proper tightening sequence as shown.
2. Tighten the bead lock bolts to 12 Nm (1.2 m·kgf, 8.7 ft·lbf) in the proper tightening sequence as
shown.
3. Inflate the tire to the specified tire pressure. (Refer to “CHECKING THE TIRES” on page 3-33.)
4. Starting with the bead lock bolt indicated by “1” in the illustration, tighten the bead lock bolts to 17
Nm (1.7 m·kgf, 12 ft·lbf) in a clockwise tightening sequence.
5. Inflate the tire to 250 kPa (2.5 kgf/cm², 36 psi) and check that the tire does not become dislodged
from the rim.
6. Adjust the tire pressure. (Refer to “CHECKING THE TIRES” on page 3-33.)
2-26
TIGHTENING TORQUES
Bead lock tightening sequence:
9 1 15
14 4
6 12
11 7
3 2
8 10
13 5
TIP
Steering assembly bolt
Tighten the steering assembly bolts to 48 Nm (4.8 m·kgf, 35 ft·lbf) in the proper tightening sequence.
Steering assembly tightening sequence:

2 3
4 1
2-27
LUBRICATION AND SEALING POINTS
EBS20019

EBS30021
ENGINE
Lubrication point Lubricant/Sealant
Oil seal lips LS
O-rings LS
Bearings E
Valve lifter outer surfaces E
Camshaft lobes and journals M
Valve stems and stem ends (intake and exhaust) M
Crankshaft big ends E
Piston surfaces E
Piston pins E
Connecting rod bolts M
Crankshaft journals E
AC magneto rotor bolts E
Engine oil pump rotors (inner and outer) and engine oil pump housing LS
Oil nozzle O-rings LS or E
Blind plug LS
Engine mounting collar outer surfaces E
Starter idle gear inner surfaces E
Starter clutch gear inner surfaces E
Starter clutch E
Torque damper cam inner surfaces and contact surfaces M
Primary drive gear inner surface and outer surface (torque damper cam contact
M
surfaces)
Clutch housing inner surfaces and ends E
Long clutch push rod outer surfaces and ends LS
Short clutch push rod outer surfaces and ends LS
Ball LS
Conical spring washer E
Clutch boss nut E
Inner surfaces of transmission gears, and ends, and transmission collar M
Outer surfaces of transmission gears (shift fork contact surfaces) M
Torque damper cam inner surfaces and contact surfaces M
Middle driven gear inner surface and outer surface (torque damper cam contact
M
surfaces)
Transmission oil pump rotors (inner and outer) and transmission oil pump housing E
Shift drum moving surfaces and shift drum grooves E
Long shift fork guide bar and short shift fork guide bar E
Shift shaft moving surfaces E
2-28
Lubrication point Lubricant/Sealant

Reverse idle gear shaft moving surfaces E
Shift fork pawl M
Three Bond
Cylinder head cover and cylinder head mating surface
No.1541C®
Yamaha bond No.1215
Crankcase mating surface (Three Bond
No.1215®)
Yamaha bond No.1215
Stator coil assembly lead grommet (Three Bond
No.1215®)
Yamaha bond No.1215
Transmission case mating surface (Three Bond
No.1215®)
2-29
LUBRICATION SYSTEM CHART AND DIAGRAMS
EBS20020

EBS30022
ENGINE OIL LUBRICATION CHART
16 15 14 11 10
13 12 9 8 4 5
1
2 3
1. Oil pan
2. Oil strainer 1 (engine)
4. Scavenging pump 1 (engine)
6. Oil cooler
7. Engine oil tank
8. Oil feed pump (engine)
9. Relief valve
10. Oil filter cartridge
11. Crankshaft
12. Oil nozzle
13. AC magneto
14. Timing chain tensioner
15. Exhaust camshaft
16. Intake camshaft
2-30
EBS30699
TRANSMISSION OIL LUBRICATION CHART
3 4 5 6 7
1
2
1. Transmission case
2. Oil strainer (transmission)
3. Oil pump (transmission)
4. Primary driven shaft
5. Main axle
6. Transmission shower
7. Drive axle
2-31
2-32
EBS30023
LUBRICATION DIAGRAMS
1
2
4
8 10
5 9
9
7
10
14
11 2
12 12
11
20
FWD
1
13
14
14
4
19 18 17 16 15 6
2-33
1. Oil pump drive sprocket

2. Crankcase (upper)
3. Crankcase (lower)
4. Oil pump driven sprocket
5. Oil pump assembly
6. Oil pan
8. Timing chain tensioner
9. Oil tank outlet pipe 3
10. AC magneto cover
11. Oil tank inlet pipe 1
12. Oil cooler
13. Crankshaft
14. Main gallery bolt
19. Oil feed pump (engine)
20. Oil nozzle
2-34
1 2 1 2
4 3
2-35
1. Oil pump assembly

2. Oil pan
5. Oil cooler
6. Crankcase (upper)
7. Crankcase (lower)
2-36
1 2
1 2
2
4
5
2-37
1. Exhaust camshaft
2. Intake camshaft
3. Cylinder head
4. Camshaft cap
5. Engine oil check bolt
2-38
11 10
2-39
1. Oil tank inlet hose 1

4. Dipstick (engine oil tank)
5. Engine oil tank
6. Engine oil drain bolt (oil tank)
8. Oil tank outlet hose 1
2-40
12
3
11
10
3
9
8
7
6 5 4
2-41
1. Engine oil tank

2-42
1 2
1 2
1
1 1
1
1 2
1
5
8
7
6
12
10
1 11
2-43
1. Transmission oil gallery bolt

2. Transmission case (front)
3. Transmission oil filler cap
4. Main axle
5. Reverse idle gear shaft
6. Drive axle
7. Transmission oil check bolt
8. Oil pump drive gear (transmission)
9. Primary driven shaft
10. Oil pump (transmission)
11. Oil strainer (transmission)
12. Oil pump driven gear (transmission)
2-44
COOLING SYSTEM DIAGRAMS
EBS20021
1 2 3
6 5
4
6
2
4
1
5 3
2-45
1. Radiator
2. Radiator inlet hose
3. Radiator outlet pipe
4. Radiator inlet pipe
5. Radiator outlet hose
6. Radiator cap
2-46
3 4 5
1 2
6
11 10 9 8
1 2 9
11 10
2-47

2. Thermostat outlet hose
3. Thermostat
4. Thermostat inlet hose
5. Water jacket joint
6. Water jacket joint air bleed bolt
7. Oil cooler outlet hose
8. Water pump air bleed hose
9. Water pump outlet hose
10. Water pump inlet hose
2-48
1 2 3 4 5
FWD
7 6
2
3
2-49

6. Thermostat
8. Water pump
2-50
CABLE ROUTING
EBS20022
CABLE ROUTING
Frame front (left view)
E
G
7 3
2
6 A B 1
C
6 D
1
I 6
6 8
1
I H
2-51
CABLE ROUTING
1. Clutch hose
2. Reverse gear lock cable
3. EPS motor lead
4. Wire harness
5. Coolant reservoir breather hose
6. Throttle cable
7. Meter assembly lead
8. Rear brake pipe 1
A. Fasten the coolant reservoir breather hose to the
frame with the plastic clip.
B. Fasten the clutch hose with the holder.
C. Fasten the wire harness at the white mark on the
harness with the plastic band.
D. Fasten the throttle cable at the white mark on the
throttle cable with the plastic band.
E. 20–40°
F. Route the throttle cable through the hole in the left
side of the air scoop (right).
G. Fasten the meter assembly lead to the meter
assembly lead bracket with the plastic band.
Make sure that there is no slack in the meter
assembly lead.
H. Fasten the throttle cable and clutch hose with the
plastic band.
I. Fasten the throttle cable and clutch hose to the
frame with the plastic band.
2-52
CABLE ROUTING
Frame rear (left view)
3 10 H I
G
9
3 4
1 A 2
8 7 F E D 6 5 C B
J 11 J
12
K
3
3
Q
8
4
6 4
D
L 8 3 6
P
13
O
M
N 14
2-53
CABLE ROUTING
1. On-Command four-wheel-drive switch lead

2. Light switch lead
3. Wire harness
4. Throttle cable
5. Oil pressure switch lead
6. Engine ground lead
8. Starter motor lead
9. Fuel rail
10. Tail/brake light lead
11. Joint coupler
12. Air induction system solenoid lead
13. Seat belt switch lead
14. Rear stabilizer
A. Fasten the wire harness at the white mark on the
B. Make sure that there is no slack in the starter
motor lead.
C. Install the engine ground lead at the angle shown
in the illustration.
D. Fasten the wire harness, engine ground lead, and
throttle cable with the plastic band.
E. Fasten the wire harness to the water pump inlet
hose protector with the plastic band before the seat
belt switch lead branches off from the harness.
Point the end of the plastic band outward.
F. Fasten the wire harness and throttle cable to the
water pump inlet hose protector with the plastic
band. Point the end of the plastic band outward.
G. Fasten the wire harness at the white mark on the
harness to the fuel rail with the plastic band.
H. Route the tail/brake light lead through the hole of
the tail/brake light cover.
I. Route the tail/brake light lead through the guide.
J. Fasten the wire harness to the frame with the
plastic band.
K. Fasten the air induction system solenoid lead with
the holder.
L. Fasten the wire harness, engine ground lead,
starter motor lead, and throttle cable with the
plastic band.
M. Fasten the seat belt switch lead with the holder.
N. Fasten the oil pressure switch lead and engine
ground lead with the plastic band.
O. Fasten the wire harness and engine ground lead
with the plastic band.
P. Fasten the starter motor lead with the plastic band.
Point the end of the plastic band upward.
Q. Make sure that there is no slack in the wire
harness, leads, and cable in the area shown in the
illustration.
R. Fasten the wire harness with the plastic band.
2-54
CABLE ROUTING
Frame front (right view)
K 22 L 23
20 I 21 J
G 3
19 1
H
3
14 15
19
15
N
5
6 7 F 24 F M
A B
A 8
1 2 3 4
C
10
11
12
18 17 16 F 15 14 E D 13
14
25
F
3
26 19
1
O
F
27 15
F F F
2-55
CABLE ROUTING
1. Wire harness L. Fasten the inner headlight lead (right) and outer
2. Neutral switch lead headlight lead (right) with the holder.
3. Transmission case breather hose 1 M. Fasten the inner headlight lead (right) and outer
4. Indicator light assembly lead headlight lead (right) with the plastic band.
5. Main switch lead N. Fasten the inner headlight lead (left) and outer
headlight lead (left) with the plastic band.
6. Parking brake buzzer lead
O. Fasten the wire harness, reverse gear lock cable,
transmission case breather hose 2, and
8. AC magneto lead transmission case breather hose 1 with the plastic
9. Frame ground lead clip. Position the plastic clip to the front of the sub-
10. Rectifier/regulator lead frame.
11. Front brake hose
12. Differential case breather hose
13. Differential motor lead
14. Fuel tank breather hose (fuel tank to fuel tank
breather hose joint)
15. Transmission case breather hose 2
16. Gear position sensor lead
17. Fuel pump lead
18. Fuel hose
20. Outer headlight lead (left)
21. Inner headlight lead (left)
22. Inner headlight lead (right)
23. Outer headlight lead (right)
24. Front brake pipe
25. Sub-frame
A. Fasten the wire harness and differential case
breather hose with the plastic clip. Be sure to
position the holder above the plastic band.
B. Fasten the wire harness to the frame with the
plastic band. Be sure to position the plastic band
above the bracket.
C. Fasten the wire harness to the frame with the
near the center of the frame tube.
D. Fasten the wire harness at the white mark on the
E. Fasten the wire harness and differential case
position the plastic clip to the rear of the plastic
band indicated in instruction “D”.
F. Fasten the wire harness with the holder.
G. Fasten the reverse gear lock cable, transmission
case breather hose 2, transmission case breather
hose 1, and fuel tank breather hose (fuel tank to
fuel tank breather hose joint) with the holder.
H. Fasten the wire harness, reverse gear lock cable,
transmission case breather hose 2, and
transmission case breather hose 1 with the plastic
clip. Position the plastic clip to the rear of the split
in the wire harness.
I. Fasten the inner headlight lead (left) and outer
headlight lead (left) with the holder.
J. Make sure that there is no slack in the inner
headlight lead (left) and outer headlight lead (left).
K. Make sure that there is no slack in the inner
headlight lead (right) and outer headlight lead
(right).
2-56
CABLE ROUTING
Frame rear (right view)
5 7
8 9 10
3
4
11
A 1 B C B A D E 2 3 F
K
6
J 5 I 4 H
5 4 6 5 4 5
6
12 6
2 L
N M
4
2-57
CABLE ROUTING

2. Wire harness
3. Fuel hose
4. Parking brake cable
5. Final drive case breather hose
6. Stator coil assembly
7. Rear panel (right)
8. Battery
9. Electrical components tray
10. Center console side panel (right)
11. Sub-frame
12. Coolant temperature sensor lead
A. Fasten the tail/brake light lead with the holder.
B. Fasten the tail/brake light lead to the frame with the
plastic band. Be sure to fasten the plastic band
around the protective sleeve of the lead, not the
lead itself.
C. Position the tail/brake light coupler at the location
D. Fasten the tail/brake light lead to the frame with the
plastic band.
E. Fasten the tail/brake light lead to the frame with the
under the bracket.
F. Fasten the wire harness and parking brake cable
to the frame with the plastic band.
G. To the fuel tank
H. Fasten the parking brake cable and final drive case
position the holder to the front of the plastic band
indicated in instruction “M”.
I. Fasten the parking brake cable and final drive case
breather hose with the plastic clip.
J. Fasten the final drive case breather hose with the
holder.
K. Fasten the parking brake cable and final drive case
position the holder to the rear of the plastic band
indicated in instruction “N”.
L. Fasten the wire harness, stator coil assembly lead,
parking brake cable, and final drive case breather
hose with the holder.
M. Fasten the stator coil assembly lead, parking brake
cable, and coolant temperature sensor lead to the
engine bracket with the plastic band.
N. Fasten the stator coil assembly lead and parking
brake cable to the engine bracket with the plastic
band.
2-58
CABLE ROUTING
Electrical components tray front (top view)
15
1
E
16
4 5 A 6 B 7
2 3
14 13 D 12 D 11 D 10 C 9 C 8
2-59
CABLE ROUTING
1. Wire harness
2. Indicator light assembly
3. Differential motor relay 1
5. ECU (Engine Control Unit)
6. ECU band
8. Headlight relay (low beam)
9. Headlight relay (high beam)
10. Radiator fan motor relay
11. Fuel injection system relay
12. Load control relay
13. Light switch
14. On-Command four-wheel-drive switch
15. Center console
16. Sponge
A. Hook the band onto the electrical components tray.
B. Route the wire harness through the slot in the side
of the electrical components tray.
C. Route the wire harness to the rear of the ECU
(Engine Control Unit), and install the relays in the
locations shown in the illustration.
D. Install the relays in the locations shown in the
illustration.
E. Align the sponge with the tape mark on the wire
harness. Fit the sponge and wire harness into the
slot in the electrical components tray, making sure
that the sponge contacts the bottom of the tray.
2-60
CABLE ROUTING
Electrical components tray rear (top view)
D 2
E
2
11
12
10 A 2 B
3
4
1
5
6
7
10
9
8
C
2-61
CABLE ROUTING
1. Battery
2. Wire harness
3. Main fuse
4. EPS fuse
5. Fuse box
6. Fuel injection system fuse
7. Starter relay
8. Starter motor lead
9. Negative battery lead
11. Lean angle sensor
12. Lean angle sensor lead
A. Route the wire harness through the slot in the
electrical components tray.
B. After connecting the couplers, place the couplers
in the space between the battery and the electrical
components tray.
C. Route the wire harness, starter motor lead, and
negative battery lead through the slot in the
electrical components tray.
D. Fasten the wire harness with the plastic band.
E. Make sure that there is no slack in the wire
harness in the area shown in the illustration.
2-62
CABLE ROUTING
Frame front (top view)
10 24
25 2
3
N
O
22 23 3 24 23
A B C 4 5 6 7 8 D
E
1 2 3 2
9
10
23
1 24 F
22 11
S C
M
10
11 8
21
10 3 R G
20
12
L 19 K J 18 17 16 15 14 I 13 H
10 24 6 7
2-63
CABLE ROUTING
1. EPS motor lead Q. Fasten the wire harness, reverse gear lock cable,
2. EPS control unit lead transmission case breather hose 1, and
3. EPS torque sensor lead transmission case breather hose 2 with the holder.
4. Coolant reservoir breather hose R. Fasten the wire harness and EPS torque sensor
lead with the plastic band.
5. Radiator fan motor breather hose
S. Fasten the reverse gear lock cable and EPS motor
lead with the plastic band.
8. Differential case breather hose
9. Radiator fan motor lead
10. Wire harness
11. Auxiliary DC jack lead
12. Clutch hose
13. Indicator light assembly lead
14. Gear position sensor lead
16. Light switch lead
17. On-Command four-wheel-drive switch lead
18. Speed sensor lead
19. Throttle cable
20. Parking brake buzzer lead
22. Brake light switch lead
23. Clutch switch lead
25. Clutch fluid reservoir hose
A. Make sure that the coolant reservoir breather hose
is not pinched between the hood and the front
fender.
B. Route the coolant reservoir breather hose through
the hole in the front fender.
C. Fasten the wire harness to the frame with the
plastic band.
D. Fasten the wire harness and reverse gear lock
cable with the plastic band. Align the plastic band
with the white mark on the wire harness.
E. Fasten the wire harness and auxiliary DC jack lead
F. Fasten the wire harness and differential case
breather hose with the plastic clip.
G. Fasten the throttle cable and clutch hose with the
plastic band.
H. Fasten the parking brake switch lead with the
holder.
I. Fasten the wire harness with the holder.
J. Fasten the speed sensor lead with the holder.
K. Fasten the throttle cable with the holder.
L. Fasten the clutch hose with the holder.
M. Fasten the wire harness and EPS torque sensor
lead to the frame with the plastic band.
N. Fasten the wire harness, reverse gear lock cable,
EPS torque sensor lead, brake light switch lead,
and clutch switch lead with the plastic band. Align
the plastic band with the white mark on the wire
harness.
O. Fasten the reverse gear lock cable, EPS control
unit lead, EPS torque sensor lead, clutch fluid
reservoir hose, and clutch switch lead with the
plastic clip.
P. Fasten the wire harness, differential case breather
hose, and auxiliary DC jack lead with the holder.
2-64
CABLE ROUTING
Frame rear (top view)
21 H
22
19
3 1
2
G
3 A
I
19 20
21
B
F
19
3 26 23
18
3
17 G
19 25 24
4
E
16 5
6
15
14
13
C
12
7
11
8
10
D
2-65
CABLE ROUTING
1. Fuel pump lead

2. Fuel hose
3. Wire harness
4. Intake air temperature sensor lead
5. Fuel injector #1 lead
7. TPS (throttle position sensor) lead
10. Ignition coil #3 lead
11. ISC (idle speed control) unit lead
12. Intake air pressure sensor #1 lead
14. Intake air pressure sensor #2 lead
16. Air induction system solenoid lead
18. Seat belt switch lead
20. Throttle cable
21. Sub-frame
23. Connector cover
24. AC magneto lead coupler 1
25. Crankshaft position sensor coupler
26. AC magneto lead coupler 2
A. Fasten the fuel pump lead and fuel hose with the
holder.
B. Fasten the wire harness and parking brake cable
C. Fasten the stator coil assembly lead with the
holder.
D. Position the tail/brake light coupler at the location
E. Fasten the wire harness with the plastic band.
F. Fasten the throttle cable with the holder.
G. To the electrical components tray
H. Make sure that the parking brake cable and wire
harness do not contact the electrical components
tray.
I. Fasten the wire harness and parking brake cable
with the plastic band.
2-66
CABLE ROUTING
Fuel tank (top view)
A B FWD
2
3
1
C
E D
2-67
CABLE ROUTING
1. Fuel hose
3. Fuel tank breather hose (fuel tank breather hose
joint to atmosphere)
A. Secure the holder by inserting the projection on
the holder into the hole in the sub-frame. Fasten
the grommet on the fuel hose with the holder.
B. Secure the holder by inserting the projection on
the holder into the hole in the flywheel housing.
Fasten the grommet on the fuel hose with the
holder.
C. Fasten the fuel tank breather hose (fuel tank
breather hose joint to atmosphere) with the holder.
D. Route the fuel tank breather hose (fuel tank to fuel
tank breather hose joint) through the guide.
E. 0–3.0 mm (0–0.12 in)
F. Fasten the fuel hose with the portion of the holder
that has the larger diameter and fasten the ISC
(Idle Speed Control) unit inlet hose with the portion
of the holder that has the smaller diameter.
2-68
CABLE ROUTING
Fuel tank (right view)
1 5
2
3 4 A
6
5
D C B
2-69
CABLE ROUTING
1. Fuel hose
2. Throttle bodies
4. Fuel tank breather hose joint
5. Fuel tank breather hose (fuel tank breather hose
joint to atmosphere)
6. Frame
A. 0–3.0 mm (0–0.12 in)
B. Fasten the fuel tank breather hose (fuel tank
breather hose joint to atmosphere) with the holder.
C. White paint mark
D. Insert the end of the fuel tank breather hose (fuel
tank breather hose joint to atmosphere) into the
hole in the frame. Insert the hose until the white
paint mark on the hose reaches the hole in the
frame.
2-70
CABLE ROUTING
Engine oil tank (rear view)
2
E
A
1
8
B
11 D 10 C
2-71
CABLE ROUTING

5. Engine oil tank
A. Fit oil tank inlet pipe 2 into oil tank inlet hose 2,
making sure that the raised portion of the pipe
contacts the hose.
B. Fit oil tank outlet pipe 2 into oil tank outlet hose 1,
contacts the hose.
C. Fit oil tank outlet pipe 2 into oil tank outlet hose 2,
contacts the hose.
D. Fit oil tank outlet hose 2 onto oil tank outlet pipe 3,
making sure that the end of the hose is aligned
with the center of the black paint mark on the pipe.
E. Fasten each grommet on the oil tank inlet pipe 2
and oil tank outlet pipe 2 with the oil pipe guides.
F. 2.0–3.0 mm (0.08–0.12 in)
2-72
CABLE ROUTING
Engine oil tank (right view)
12
11
10
3
6 5 4
2-73
CABLE ROUTING
1. Engine oil tank

A. Fit oil tank inlet hose 1 onto oil tank inlet pipe 1,
making sure that the end of the hose is aligned
with the center of the black paint mark on the pipe.
B. Fit oil tank inlet pipe 2 into oil tank inlet hose 1,
contacts the hose.
2-74
CABLE ROUTING
Oil separator (front and left view)
1 2 3
A
2
G 3
H
H
I
1 5
J
I 4
1 2
6 5 4
1 C
L
G
H
3
F
6
7
E 4
D
2-75
CABLE ROUTING
1. Oil tank breather hose

2. Air filter case breather hose
3. Oil separator
4. Cylinder head breather hose (hose joint to cylinder
head cover)
5. Hose joint
6. Cylinder head breather hose (oil separator to hose
joint)
7. ISC (Idle Speed Control) unit inlet hose
A. Point the ends of the hose clamp to the left.
B. 12.0–16.0 mm (0.47–0.63 in)
C. 2.0–4.0 mm (0.08–0.16 in)
D. Install the cylinder head breather hose with its
white paint mark facing upward.
E. Route the cylinder head breather hose (hose joint
to cylinder head cover) under the ignition coil
leads.
F. 45°
G. 1.0–6.0 mm (0.04–0.24 in)
H. 0–1.0 mm (0–0.04 in)
I. 2.0–7.0 mm (0.08–0.28 in)
J. Align the paint mark on the oil tank breather hose
with the parting line on the oil separator.
K. Align the paint mark on the cylinder head breather
hose (oil separator to hose joint) with the parting
line on the oil separator.
L. Align the paint mark on the air filter case breather
hose with the parting line on the oil separator.
2-76
CABLE ROUTING
Air cut-off valve (left view)
A
E
3
A
B
7
A
4
C C
6
5
2-77
CABLE ROUTING
1. Air cut-off valve

2. Air filter case
3. Air induction system hose (air filter case to air cut-
off valve)
4. Air induction system hose (air cut-off valve to reed
valve cover) (cylinders #2 and #3)
5. Reed valve cover (cylinders #2 and #3)
6. Reed valve cover (cylinder #1)
7. Air induction system hose (air cut-off valve to reed
valve cover) (cylinder #1)
A. Point the ends of the hose clamp downward.
B. Face the white paint mark on the air induction
system hose (air cut-off valve to reed valve cover)
(cylinders #2 and #3) upward.
C. Point the ends of the hose clamp to the left.
D. Face the white paint mark on the air induction
system hose (air cut-off valve to reed valve cover)
(cylinder #1) upward.
E. Point the ends of the hose clamp upward.
F. Face the white paint mark on the air induction
system hose (air filter case to air cut-off valve)
upward.
2-78
CABLE ROUTING
Cooling system front (top and left view)
1 A 2 3
6 5
6 B
2 C
4
1
D
E
F 5 F 3
2-79
CABLE ROUTING
1. Radiator
2. Radiator inlet hose
5. Radiator outlet hose
6. Radiator cap
A. Point the ends of the hose clamp upward.
B. Align the edge of the hose clamp with the white
paint mark on the radiator inlet hose.
C. Point the ends of the hose clamp to the right. Align
the edge of the hose clamp with the white paint
mark on the radiator inlet hose.
D. 3.0–5.0 mm (0.12–0.20 in)
E. 0–1.0 mm (0–0.04 in)
F. Point the ends of the hose clamp to the right.
2-80
CABLE ROUTING
Cooling system rear (top and left view)
C
B
D
3 4 5
1 2
6
11 10 9 8
E
G
F
B 1 2 9
C
A 11 10
2-81
CABLE ROUTING

2. Thermostat outlet hose
3. Thermostat
10. Water pump inlet hose
A. Install the radiator inlet pipe and radiator outlet
pipe so that the holders are positioned between the
punch marks on the pipes and the marks are
visible after the bolts are tightened. Make sure that
the punch marks are facing to the left.
B. 3.0–5.0 mm (0.12–0.20 in)
C. 0–1.0 mm (0–0.04 in)
D. Align the edge of the hose clamp with the white
paint mark on the thermostat outlet hose.
E. Point the ends of the hose clamp downward.
F. Fasten the water pump inlet hose and water pump
breather hose with the plastic band. Point the end
of the plastic band forward.
G. Align the edge of the hose clamp with the white
paint mark on the water pump inlet hose. Point the
ends of the hose clamp forward.
2-82
CABLE ROUTING
Water pump and thermostat (right view)
1 2 3 A 4 5
E
F
G
B
C
FWD
D 7 6
2
3
2-83
CABLE ROUTING

6. Thermostat
8. Water pump
A. Align the arrow mark on the thermostat housing
with the paint mark on the water jacket joint.
B. From water pump
C. To radiator
D. Face the paint mark on the water pump outlet hose
outward.
E. Make sure not to install the hose clamp on the
raised portion of the hose fitting.
F. 3.0 mm (0.12 in) or more
G. 0–1.0 mm (0–0.04 in)
H. Face the paint mark on the water pump outlet hose
forward.
I. Make sure that the end of the hose clamp contacts
the water pump.
J. 1.0–2.0 mm (0.04–0.08 in)
2-84
CABLE ROUTING
Front brake caliper (top and left view)

1 A 2 B 3
D 1
C 3
2-85
CABLE ROUTING
1. Front brake hose

2. Front brake pipe
A. Face the paint mark upward.
B. Fasten rear brake pipe 1 with the holder.
C. Route the front brake hose under the front upper
arm.
D. Fasten the front brake hose with the holder.
E. Fasten the front brake pipe with the holder.
2-86
CABLE ROUTING
Brake pipe (top and left view)
FWD
1 2 A A A
FWD
1 2
2-87
CABLE ROUTING

A. Fasten rear brake pipe 2 with the holder.
2-88
CABLE ROUTING
Rear brake caliper (top and left view)
E
1 A B
2
D
2
2-89
CABLE ROUTING

2. Rear brake hose
A. Fasten rear brake pipe 2 with the holder.
B. Face the paint mark upward.
C. Install the hose holder so that the portion of the
holder securing the hose is positioned to the rear
of the mounting bolt.
D. Install the hose holder so that the portion of the
holder securing the hose is positioned lower than
the mounting bolt.
E. Fasten the rear brake hose with the holder.
2-90
CABLE ROUTING
Brake master cylinder (left view)
A 1
3
4
5
2-91
CABLE ROUTING
1. Clutch master cylinder reservoir hose

2. Brake master cylinder reservoir hose
3. Clutch switch lead
4. Brake light switch lead
5. Clutch master cylinder
6. Clutch hose
7. Brake master cylinder
A. Install the clutch master cylinder reservoir hose
with its white paint mark facing outward.
2-92
CABLE ROUTING
Parking brake (left view)
A
1
1
1
B
C
2-93
CABLE ROUTING

A. Fit the parking brake cable into the holder on the
parking brake caliper.
B. Fit the parking brake cable into the slot in the
parking brake caliper.
C. Fit the parking brake cable into the slot in the
parking brake lever.
2-94
CABLE ROUTING
2-95
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 .......................3-2
CHECKING THE FUEL LINE .................................................................... 3-4
ADJUSTING THE VALVE CLEARANCE .................................................. 3-4
CHECKING THE SPARK PLUGS ............................................................. 3-7
CHECKING THE BREATHER HOSE........................................................3-8
CHECKING THE EXHAUST SYSTEM......................................................3-8
CLEANING THE SPARK ARRESTER ......................................................3-9
SYNCHRONIZING THE THROTTLE BODIES.......................................... 3-9
CHECKING THE AIR INDUCTION SYSTEM..........................................3-11
CHECKING THE COOLING SYSTEM ....................................................3-11
CHECKING THE COOLANT LEVEL.......................................................3-12
3
CHANGING THE COOLANT................................................................... 3-12
CLEANING THE PRIMARY AIR FILTER ELEMENT ..............................3-14
REPLACING THE SECONDARY AIR FILTER ELEMENT .....................3-16
CHECKING THE ENGINE OIL LEVEL....................................................3-17
CHANGING THE ENGINE OIL ...............................................................3-18
MEASURING THE ENGINE OIL PRESSURE ........................................ 3-19
CHECKING THE TRANSMISSION OIL LEVEL ...................................... 3-20
CHANGING THE TRANSMISSION OIL.................................................. 3-20
MEASURING THE TRANSMISSION OIL PRESSURE........................... 3-21
CHECKING THE FINAL GEAR OIL LEVEL ............................................3-22
CHANGING THE FINAL GEAR OIL........................................................ 3-22
CHECKING THE DIFFERENTIAL GEAR OIL LEVEL............................. 3-22
CHANGING THE DIFFERENTIAL GEAR OIL ........................................ 3-23
CHECKING THE CLUTCH FLUID LEVEL .............................................. 3-23
BLEEDING THE HYDRAULIC CLUTCH SYSTEM .................................3-24
ADJUSTING THE CLUTCH PEDAL........................................................ 3-25
CHECKING THE CLUTCH HOSES ........................................................ 3-26
CHECKING THE FRONT BRAKE PADS ................................................ 3-26
CHECKING THE REAR BRAKE PADS .................................................. 3-26
CHECKING THE BRAKE FLUID LEVEL................................................. 3-27
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-27
CHECKING THE BRAKE HOSES AND BRAKE PIPES ......................... 3-28
ADJUSTING THE BRAKE PEDAL .......................................................... 3-29
LUBRICATING THE CLUTCH PEDAL, BRAKE PEDAL AND
ACCELERATOR PEDAL ........................................................................3-30
ADJUSTING THE PARKING BRAKE......................................................3-30
CHECKING THE PARKING BRAKE PADS ............................................3-31
ADJUSTING THE ACCELERATOR PEDAL FREE PLAY ......................3-31
ADJUSTING THE REVERSE GEAR LOCK LEVER FREE PLAY ..........3-32
CHECKING THE WHEELS ..................................................................... 3-33
CHECKING THE TIRES..........................................................................3-33
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES ............. 3-34
ADJUSTING THE FRONT SHOCK ABSORBER ASSEMBLIES ............3-35
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................ 3-37
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY.................. 3-37
CHECKING THE STEERING SYSTEM .................................................. 3-39
ADJUSTING THE TOE-IN....................................................................... 3-40
CHECKING THE STABILIZER BUSHING .............................................. 3-41
LUBRICATING THE UPPER AND LOWER ARM PIVOTS.....................3-41
LUBRICATING THE REAR KNUCKLE PIVOTS ..................................... 3-41
LUBRICATING THE DRIVE SHAFT UNIVERSAL JOINTS ....................3-41
CHECKING THE ENGINE MOUNT ........................................................ 3-42
CHECKING THE CONSTANT VELOCITY SHAFT ASSEMBLY
DUST BOOTS ........................................................................................ 3-42
CHECKING THE FASTENER .................................................................3-42
PERIODIC MAINTENANCE
EBS20023
EBS30024
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EBS30025
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

• For vehicles not equipped with an odometer or hour meter, follow the month maintenance intervals.
• For vehicles equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance
intervals. However, keep in mind that if the vehicle isn’t used for a long period of time, the month main-
tenance intervals should be followed.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
INITIAL EVERY
month 1 3 6 6 12
NO. ITEM ROUTINE Whichever
comes first km (mi) 320 1300 2500 2500 5000
(200) (800) (1600) (1600) (3200)
hours 20 80 160 160 320
• Check fuel hose for cracks or damage.

1 * Fuel line √ √ √
• Replace if necessary.
• Check valve clearance.
2 * Valves • Adjust if necessary. √ √ √ √
• Check condition.
3 * Spark plugs • Adjust gap and clean. √ √ √ √ √
• Replace if necessary.
• Check breather hose for cracks or damage.
4 * Breather system • Replace if necessary. √ √ √
5 * Fuel injection • Adjust synchronization. √ √ √ √ √

• Check for leakage.
• Check for looseness and tighten all screw clamps
6 * Exhaust system √ √ √
and joints if necessary.
• Replace gasket(s) if necessary.
• Check the air cut-off valve, reed valve, and hose for
7 * Air induction system damage. √ √ √
• Check condition and clean or replace if necessary.
8 Spark arrester • Clean. √ √ √
3-1
EBS30026
GENERAL MAINTENANCE AND LUBRICATION CHART

INITIAL EVERY
month 1 3 6 6 12
comes first km (mi) 320 1300 2500 2500 5000
(200) (800) (1600) (1600) (3200)
hours 20 80 160 160 320
• Check coolant leakage.

√ √ √ √ √
1 * Cooling system • Repair if necessary.
• Replace coolant. Every 2 years
Primary air filter • Clean. Every 300–600 km (200–400 mi)
(foam) • Replace if necessary. (more often in wet or dusty conditions)
2
Secondary air filter Every 2000–5000 km (1200–3000 mi)
* (paper) • Replace. (more often in wet or dusty conditions)
3 Engine oil • Replace (warm engine before draining). √ √ √ √
Engine oil filter car-
4 tridge • Replace. √ √ √
5 Transmission oil • Check oil level and for leakage. √ √ √ √

• Change.
Final gear oil/Differ- • Check oil level/oil leakage.
6 √ √
ential gear oil • Replace.
• Check operation and for fluid leakage.
7 * Clutch • Correct if necessary. √ √ √ √ √
• Check operation, brake pad wear, and for fluid leak-

8 * Brake system age. √ √ √ √ √
• Correct if necessary, replace pads if worn to the limit.
• Check operation and free play/brake pad wear.
9 * Parking brake • Correct if necessary. Replace pads if worn to the lim- √ √ √ √ √
it.
• Change the brake fluid.
10 * Brake fluid and inter- • Replace internal components of master cylinder and Every 2 years
nals
calipers.
11 * Brake hoses • Replace. Every 4 years
12 * Accelerator pedal • Check operation and free play. √ √ √ √ √
13 * Reverse lock release • Check operation and adjust or replace if necessary. √ √ √

cable
• Check balance, runout, and for damage.
• Balance wheel if necessary. √ √ √ √
• Replace wheel if damaged or if runout is over speci-
14 * Wheels fied limits.
• Check and tighten the bead lock (for equipped mod- Every 500 km (300 mi)
els).
• Check bearing assemblies for looseness/damage.
15 * Wheel bearings √ √ √ √
• Replace if damaged.
Front and rear sus- • Check operation and for leakage.
16 * pension • Correct if necessary. √ √
• Check operation and for looseness. Replace if dam-

17 * Steering system aged. √ √ √ √ √
• Check toe-in. Adjust if necessary.
18 * Stabilizer bushes • Check for cracks or other damage, and replace if nec- √ √ √
essary.
Upper and lower arm
19 * • Lubricate with lithium-soap-based grease. √ √ √
pivots
Rear upper and low-
20 * er knuckle pivots • Lubricate with lithium-soap-based grease. √ √ √
21 * Drive shaft universal • Lubricate with lithium-soap-based grease. √ √ √

joint
• Check for cracks or damage.
22 * Engine mount √ √ √
• Check bolt tightness.
Front and rear axle • Check for cracks or other damage, and replace if nec-
23 * boots essary. √ √
3-2
INITIAL EVERY
month 1 3 6 6 12
comes first km (mi) 320 1300 2500 2500 5000
(200) (800) (1600) (1600) (3200)
hours 20 80 160 160 320
• Check all chassis fittings and fasteners.

24 * Fittings and fasteners • Correct if necessary. √ √ √ √ √
TIP
• Inspect and service the vehicle more frequently if you drive aggressively or in severe conditions such
as rain, mud, sand or unusually dusty areas.
• Service the clutch system in similar fashion and at similar intervals to the brake system.
• The service items contained herein should not be considered exhaustive, therefore:
• replace any damaged or visibly worn part immediately.
3-3
EBS30027
2. Remove:
CHECKING THE FUEL LINE
• Crankshaft end accessing screw “1”
1. Remove:
• Timing mark accessing screw “2”
• Center console side panel (right)
Refer to “GENERAL CHASSIS (4)” on page
4-7.
• Under-seat upper panel (left)
4-12.
2. Check:
• Fuel hose “1” 2
Cracks/damage → Replace.
Loose connection → Connect properly. 1
3. Measure:
• Valve clearance
1 Out of specification → Adjust.
Valve clearance (cold)

Intake
0.15–0.22 mm (0.0059–0.0087 in)
Exhaust
0.21–0.27 mm (0.0083–0.0106 in)
3. Install: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
• Under-seat upper panel (left)
b. When piston #3 is at TDC on the compres-
sion stroke, align the TDC mark “a” on the AC
4-12.
magneto rotor with the AC magneto cover
mark “b”.
4-7.
b
EBS30028
ADJUSTING THE VALVE CLEARANCE

The following procedure applies to all of the a
valves.
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 TIP
(TDC) on the compression stroke. When the piston is at TDC on the compression
1. Remove: stroke, the camshaft lobes “a” are positioned as
• Ignition coils shown in the illustration. If the camshaft lobes
• Spark plugs are not positioned as shown in the illustration,
• Cylinder head cover turn the crankshaft an additional 360° clockwise
Refer to “CAMSHAFTS” on page 5-10. to position the piston at TDC on the compression
ECB03070 stroke.
NOTICE
Before removing the spark plugs, blow away
any dirt accumulated in the spark plug wells
with compressed air to prevent it from falling
into the cylinders.
3-4
B
a
3 D
C 1 D
2 D
c. Measure the valve clearance with a thickness B. degrees that the crankshaft is turned
gauge “1”. clockwise.
C. Cylinder
Thickness gauge D. Combustion cycle
90890-03180
Feeler gauge set Cylinder #1 240°
YU-26900-9 Cylinder #2 480°
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Remove:
1 • Camshafts
Refer to “CAMSHAFTS” on page 5-10.
5. Adjust:
• Valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve lifter “1” and the valve pad
“2” with a valve lapper “3”.
TIP Valve lapper

90890-04101
• If the valve clearance is incorrect, record the
Valve lapping tool
measured reading. YM-A8998
• Measure the valve clearance in the following
sequence. TIP
• Cover the timing chain opening with a rag to
Valve clearance measuring sequence prevent the valve pad from falling into the
Cylinder #3 → #1 → #2 crankcase.
• Make a note of the position of each valve lifter
“1” and valve pad “2” so that they can be in-
A stalled in the correct place.
A. Front
d. To measure the valve clearances of the other
cylinders, starting with cylinder #3 at TDC,
turn the crankshaft clockwise as specified in
the following table.
3-5
Number “a” Thickness

138 1.375 mm (0.05413 in)
140 1.400 mm (0.05512 in)
142 1.425 mm (0.05610 in)
145 1.450 mm (0.05709 in)
148 1.475 mm (0.05807 in)
150 1.500 mm (0.05906 in)
2 1
152 1.525 mm (0.06004 in)
b. Calculate the difference between the speci- 155 1.550 mm (0.06102 in)
fied valve clearance and the measured valve 156 1.562 mm (0.06150 in)
clearance.
158 1.575 mm (0.06201 in)
Example:
Specified valve clearance = 0.15–0.25 mm 159 1.587 mm (0.06248 in)
(0.0059–0.0098 in) 160 1.600 mm (0.06299 in)
Measured valve clearance = 0.32 mm 161 1.612 mm (0.06346 in)
(0.0126 in)
162 1.625 mm (0.06398 in)
0.32 mm (0.0126 in)–0.25 mm (0.0098 in) =
0.07 mm (0.0028 in) 164 1.637 mm (0.06445 in)
c. Check the thickness of the current valve pad, 165 1.650 mm (0.06496 in)
and then calculate the sum of the values ob- 166 1.662 mm (0.06543 in)
tained to determine the required valve pad 168 1.675 mm (0.06594 in)
thickness and the valve pad number.
169 1.687 mm (0.06642 in)
TIP
170 1.700 mm (0.06693 in)
• The number “a” marked on the valve pad indi-
cate the valve pad thickness. 171 1.712 mm (0.06740 in)
• Refer to the following table for the available 172 1.725 mm (0.06791 in)
valve pads. 174 1.737 mm (0.06839 in)
• If there are no available valve pads with the
175 1.750 mm (0.06890 in)
same thickness as the calculated valve pad
thickness, select the next thickest valve pad. 176 1.762 mm (0.06937 in)
178 1.775 mm (0.06988 in)
179 1.787 mm (0.07035 in)
180 1.800 mm (0.07087 in)
a
181 1.812 mm (0.07134 in)
158 182 1.825 mm (0.07185 in)
184 1.837 mm (0.07232 in)
185 1.850 mm (0.07283 in)
186 1.862 mm (0.07331 in)
188 1.875 mm (0.07382 in)
Number “a” Thickness 189 1.887 mm (0.07429 in)
120 1.200 mm (0.04724 in) 190 1.900 mm (0.07480 in)
122 1.225 mm (0.04823 in) 191 1.912 mm (0.07528 in)
125 1.250 mm (0.04921 in) 192 1.925 mm (0.07579 in)
128 1.275 mm (0.05020 in) 194 1.937 mm (0.07626 in)
130 1.300 mm (0.05118 in) 195 1.950 mm (0.07677 in)
132 1.325 mm (0.05217 in) 196 1.962 mm (0.07724 in)
135 1.350 mm (0.05315 in) 198 1.975 mm (0.07776 in)
3-6
Number “a” Thickness

199 1.987 mm (0.07823 in) 2
1
200 2.000 mm (0.07874 in)
201 2.012 mm (0.07921 in)
202 2.025 mm (0.07972 in)
204 2.037 mm (0.08020 in)
205 2.050 mm (0.08071 in)
206 2.062 mm (0.08118 in)
208 2.075 mm (0.08169 in) e. Install the exhaust and intake camshafts, tim-
ing chain and camshaft cap.
209 2.087 mm (0.08217 in)
210 2.100 mm (0.08268 in) Camshaft cap bolt
211 2.112 mm (0.08315 in) 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
212 2.125 mm (0.08366 in)
TIP
214 2.137 mm (0.08413 in) • Refer to “CAMSHAFTS” on page 5-10.
215 2.150 mm (0.08465 in) • Lubricate the camshaft lobes and camshaft
216 2.162 mm (0.08512 in) journals with molybdenum disulfide oil.
218 2.175 mm (0.08563 in) • First, install the intake camshaft.
• Align the camshafts marks with the camshaft
219 2.187 mm (0.08610 in)
cap marks.
220 2.200 mm (0.08661 in) • Turn the crankshaft clockwise several full turns
222 2.225 mm (0.08760 in) to seat the parts.
225 2.250 mm (0.08858 in) f. Measure the valve clearance again.
228 2.275 mm (0.08957 in) g. If the valve clearance is still out of specifica-
230 2.300 mm (0.09055 in) tion, repeat all of the valve clearance adjust-
ment steps until the specified clearance is
232 2.325 mm (0.09154 in)
obtained.
235 2.350 mm (0.09252 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
238 2.375 mm (0.09350 in) 6. Install:
240 2.400 mm (0.09449 in) • Cylinder head cover
Example:
• Spark plugs
1.575 mm (0.06201 in) + 0.07 mm (0.0028 in)
• Ignition coils
= 1.645 mm (0.06476 in)
The valve pad number is 165. EBS30029
d. Install a new valve pad “1” and the valve lifter CHECKING THE SPARK PLUGS
“2”. The following procedure applies to all of the
TIP spark plugs.
1. Remove:
• Lubricate the valve pad with molybdenum di-
• Ignition coils
sulfide oil.
• Spark plugs
• Lubricate the valve lifter (Top side) with molyb-
denum disulfide oil. ECB03070
• Lubricate the valve lifter (Outer side) with en- NOTICE

gine oil. Before removing the spark plugs, blow away
• Install the valve lifter and the valve pad in the any dirt accumulated in the spark plug wells
correct place. with compressed air to prevent it from falling
• The valve lifter must turn smoothly when rotat- into the cylinders.
ed by hand.
3-7
2. Check: • Throttle body breather hose “2”

• Spark plug type • Air filter case breather hose “3”
Incorrect → Change. • Oil tank breather hose “4”
Manufacturer/model Loose connection → Connect properly.
NGK/CR9EB ECB03080
NOTICE
3. Check: Make sure the cylinder head breather hoses
• Electrodes “1” are routed correctly.
Damage/wear → Replace the spark plug.
• Insulator “2”
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan. 1
4. Clean:
• Spark plug
(with a spark plug cleaner or wire brush)
5. Measure: 2
• Spark plug gap “a”
(with a wire thickness gauge)
Out of specification → Regap.
Spark plug gap 4

0.7–0.8 mm (0.028–0.031 in)
3
3. Install:
• Cargo bed compartment panel
4-10.
6. Install:
• Spark plugs EBS30031
• Ignition coils CHECKING THE EXHAUST SYSTEM

1. Check:
Spark plug • Exhaust pipe “1”
13 Nm (1.3 m·kgf, 9.4 ft·lbf) • Muffler “2”
T.
R.
Ignition coil bolt • Muffler bracket “3”

8 Nm (0.8 m·kgf, 5.8 ft·lbf) • Exhaust pipe joint clamp “4”
• Gaskets “5”
TIP Exhaust gas leaks → Replace.
Before installing the spark plug, clean the spark 2. Check:
plug and gasket surface. • Tightening torque
EBS30030 Exhaust pipe nut

CHECKING THE BREATHER HOSE 20 Nm (2.0 m·kgf, 14 ft·lbf)
T.
R.
1. Remove: Muffler bracket bolt

• Cargo bed compartment panel 55 Nm (5.5 m·kgf, 40 ft·lbf)
Refer to “GENERAL CHASSIS (5)” on page Muffler bolt
4-10. 90 Nm (9.0 m·kgf, 65 ft·lbf)
Exhaust pipe joint clamp bolt
2. Check:
20 Nm (2.0 m·kgf, 14 ft·lbf)
• Cylinder head breather hoses “1”
3-8
f. Replace the sponge damper “6” that is affixed

5 5 to the tailpipe cover with a new one.
4 2
1
3
6 New
EBS30032
CLEANING THE SPARK ARRESTER

1. Clean: g. Install the gasket, tailpipe, and align the bolt
• Spark arrester holes.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ h. Insert the bolts and tighten it.
EWB03080
WARNING
Tailpipe bolt
• Select a well-ventilated area free of com- 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
bustible materials.
• Always let the exhaust system cool before i. Install the tailpipe cover and align the bolt
performing this operation. holes.
• Do not start the engine when removing the j. Insert the bolts and tighten it.
tailpipe from the muffler.
Tailpipe cover bolt
a. Remove the bolts “1”. 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
T.
R.
b. Remove the tailpipe cover “2”.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1 EBS30617
SYNCHRONIZING THE THROTTLE BODIES

TIP
Before synchronizing the throttle bodies, check
2 the following items:
1 • Valve clearance
• Spark plugs
• Air filter elements
• Throttle body joints
c. Remove the bolts “3”.
• Fuel hose
d. Remove the tailpipe “4” by pulling it out of the
• Exhaust system
muffler and the gasket “5”.
• Breather hoses
4
5
Checking the throttle body synchronization
1. Remove:
• Air filter case
Refer to “AIR FILTER CASE AND OIL SEP-
ARATOR” on page 7-6.
3 2. Remove:
• Caps “1”
• Intake air pressure sensor #2 hose “2”
e. Tap the tailpipe lightly with a soft-face ham-
mer 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 muffler.
3-9
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 a. Start the engine, warm it up for several min-
utes, and then let it run at the specified en-
gine idling speed.
2 Engine idling speed
1400–1500 r/min
b. Using the throttle bodies that has the bypass

air screw “1” with a white paint mark as the
standard, adjust the other throttle bodies by
3. Install: turning its bypass air screw in or out.
• Vacuum gauge “1”
TIP
Vacuum gauge • After each step, rev the engine two or three
90890-03094 times, each time for less than a second, and
Vacuummate check the synchronization again.
YU-44456 • If a bypass air screw was removed, turn the
screw in fully and be sure to synchronize the
1 throttle bodies.
• If the throttle body synchronization can not be
adjusted using the bypass air screw, clean or
replace the throttle bodies.
• The difference in vacuum pressure between
the throttle bodies should not exceed 1.33 kPa
(10 mmHg).
1
4. Install:
• Air filter case
5. Check:
• Throttle body synchronization
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Start the engine, warm it up for several min-
utes, and then let it run at the specified en- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
gine idling speed. 2. Stop the engine and remove the measuring
equipment.
Engine idling speed 3. Install:
1400–1500 r/min
• Intake air pressure sensor #2 hose
b. Check the vacuum pressure. • Caps
4. Install:
Difference in vacuum pressure • Air filter case
between the cylinders Refer to “AIR FILTER CASE AND OIL SEP-
1.3 kPa (10 mmHg, 0.4 inHg) ARATOR” on page 7-6.
5. Adjust:
If out of specification → Adjust the throttle • Accelerator pedal free play
body synchronization. Refer to “ADJUSTING THE ACCELERATOR
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ PEDAL FREE PLAY” on page 3-31.
Adjusting the throttle body synchronization Accelerator pedal free play
1. Adjust: 10.0–25.0 mm (0.39–0.98 in)
• Throttle body synchronization
3-10
EBS30033
CHECKING THE AIR INDUCTION SYSTEM

Refer to “CHECKING THE AIR INDUCTION 1 2
SYSTEM” on page 7-20.
3
EBS30034
CHECKING THE COOLING SYSTEM

1. Remove:
• Floor board (left)
4-12.
• Front fender 9
8
4-21.
• Electrical components tray 4
4-26.
• Throttle bodies 6
Refer to “THROTTLE BODIES” on page 5
7-11.
• Flywheel housing 7
• Sub-frame
Refer to “TRANSMISSION (1)” on page 5-87.
2. Check: 14 13
• Radiator “1”
• Coolant reservoir hose “2”
10
• Coolant reservoir “3”
• Radiator inlet hose “4” 12 11
• Radiator outlet hose “5”
• Radiator inlet pipe “6”
• Radiator outlet pipe “7”
• Thermostat outlet hose “8”
• Water pump inlet hose “9”
• Thermostat cover “10”
• Thermostat “11” 16
• Thermostat housing “12” 15
• Thermostat inlet hose “13”
• Water jacket joint “14”
• Oil cooler “15”
• Oil cooler outlet hose “16”
• Water pump outlet hose “17”
• Water pump air bleed hose “18”
• Water pump assembly “19”
Coolant leakage → Replace any damaged
hose and pipe. 18 17
Refer to “RADIATOR” on page 6-3, “THER-
MOSTAT” on page 6-6, “OIL COOLER” on
page 6-1, and “WATER PUMP” on page 6-9. 19
3. Install:
• Sub-frame
3-11
• Flywheel housing 4. If the coolant is at or below the minimum level

Refer to “TRANSMISSION (1)” on page 5-87. mark, remove the reservoir cap “1”, add cool-
• Throttle bodies ant or distilled water to the maximum level
Refer to “THROTTLE BODIES” on page mark “a”, install the reservoir cap.
7-11.
• Electrical components tray Coolant reservoir (up to the maxi-
Refer to “GENERAL CHASSIS (12)” on page mum level mark)
4-26. 0.31 L (0.33 US qt, 0.28 Imp.qt)
• Front fender
4-21. 1
4-12.
a
EBS30035
CHECKING THE COOLANT LEVEL

1. Place the vehicle on a level surface.
TIP
The coolant level must be checked on a cold en- 5. Install:
gine since the level varies with engine tempera- • Hood
ture. Refer to “GENERAL CHASSIS (4)” on page
4-7.
2. Remove:
• Hood EBS30036
Refer to “GENERAL CHASSIS (4)” on page CHANGING THE COOLANT

4-7. 1. Remove:
3. Check: • Hood
• Coolant level Refer to “GENERAL CHASSIS (4)” on page
The coolant level should be between the 4-7.
maximum level mark “a” and minimum level 2. Remove:
mark “b”. • Coolant reservoir cap “1”
Below the minimum level mark → Add the 3. Disconnect:
recommended coolant to the proper level. • Coolant reservoir hose “2”
ECB01300
NOTICE 1
• Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.
• Use only distilled water. However, if dis- 2
tilled water is not available, soft water may
be used.
4. Drain:
• Coolant
(from the coolant reservoir)
5. Connect:
• Coolant reservoir hose
6. Remove:
a • Radiator cap “1”
3-12
EWB02770
10.Fill:
WARNING • Cooling system
A hot radiator is under pressure. Therefore, (with the specified amount of the recom-
do not remove the radiator cap when the en- mended coolant)
gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in- Recommended antifreeze
jury. When the engine has cooled, open the High-quality ethylene glycol an-
radiator cap as follows: tifreeze containing corrosion in-
Place a thick rag or a towel over the radiator hibitors for aluminum engines
cap and slowly turn the radiator cap counter- Mixing ratio
1:1 (antifreeze:water)
clockwise toward the detent to allow any re-
Radiator (including all routes)
sidual pressure to escape. When the hissing 3.75 L (3.96 US qt, 3.30 Imp.qt)
sound has stopped, press down on the radi- Coolant reservoir (up to the maxi-
ator cap and turn it counterclockwise to re- mum level mark)
move. 0.31 L (0.33 US qt, 0.28 Imp.qt)
Handling notes for coolant

Coolant is potentially harmful and should be
handled with special care.
EWB02780
WARNING
• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
1 tor.
• If coolant splashes on your clothes, quickly
wash it away with water and then with soap
7. Remove:
and water.
• Coolant drain bolt “1”
• If coolant is swallowed, induce vomiting
(along with the copper washer)
and get immediate medical attention.
TIP ECB01310
Place a container under the engine, and then re- NOTICE

move the coolant drain bolt. • 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
be used.
• If coolant comes into contact with painted
1 surfaces, immediately wash them with wa-
ter.
8. Drain: • Do not mix different types of antifreeze.
• Coolant 11.Install:
(from the engine and radiator) • Radiator cap
9. Install: 12.Fill:
• Coolant drain bolt • Coolant reservoir
(along with the copper washer New ) (with the recommended coolant to the maxi-
mum level mark “a”)
Coolant drain bolt (radiator outlet 13.Install:
pipe)
• Coolant reservoir cap “1”
T.
R.
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
3-13
EBS30623
CLEANING THE PRIMARY AIR FILTER

1 ELEMENT
1. Check:
• Check hose “1”
TIP
a There is an air filter check hose at the bottom of
the air filter case. If dust and/or water collects in
this hose, clean the air filter element, filter frame,
and air filter case.
14.Bleed:
• Cooling system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the water jacket joint air bleed bolt
“1”, without removing it, to allow all of the air
to escape from the air bleed bolt hole. 1
2. Remove:
4-10.
3. Remove:
• Primary air filter cover “1”
b. When coolant begins to flow out of the bolt
hole, tighten the water jacket joint air bleed TIP
bolt to specification. Remove the primary air filter cover by turning the
primary air filter cover lock “2” counterclockwise.
Water jacket joint air bleed bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
15.Start the engine, warm it up for ten minutes, 1
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
2
coolant level has dropped after the engine
has cooled, add sufficient coolant until it
reaches the top of the radiator, and then in- 4. Remove:
stall the radiator cap. • Primary air filter element assembly “1”
18.Check:
• Coolant level
Refer to “CHECKING THE COOLANT LEV-
EL” on page 3-12. 1
19.Start the engine, and then check for coolant
leakage.
20.Install:
• Hood
4-7.
3-14
5. Disassemble:
• Primary air filter element “1”
• Primary air filter element frame “2”
ECB01800
NOTICE
The engine should never be run without the
air filter; excessive piston and/or cylinder
wear may result.
1 2 c. Properly dispose of the used solvent.

d. Carefully wash the air filter element in soap
water.
6. Check:
• Primary air filter element
• Primary air filter element frame
Damage → Replace.
7. Clean:
• Primary air filter element e. Thoroughly rinse the air filter element with
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ water, and then let it dry.
ECB01290
a. Carefully wash the air filter element in sol-
NOTICE
vent.
EWB02760 Do not twist the air filter element when
WARNING squeezing it.
Never use low flash point solvents, such as f. Pour the recommended oil into a storage bag
gasoline, to clean the air filter element. Such large enough for the air filter element.
solvents may cause a fire or an explosion.
Air filter oil grade
Foam air-filter oil
g. Place the air filter element into the storage

bag and repeatedly squeeze the element un-
til the air filter element is saturated with oil.
TIP
The air filter element should be wet but not drip-
ping.
b. After cleaning, squeeze the air filter element

to remove the excess solvent.
ECB01290
NOTICE
Do not twist the air filter element when
squeezing it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-15
8. Assemble:
• Primary air filter element frame
9. Install:
• Primary air filter element assembly
10.Install:
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the primary air filter cover and lock it
into place by turning the primary air filter cov-
er lock clockwise. 2. Remove:
• Cargo bed
1 Refer to “GENERAL CHASSIS (5)” on page
4-10.
3. Remove:
• Air filter case
• Secondary air filter cover “1”
TIP
1
Make sure that the match mark “a” on the cover
lock is aligned with the match mark “b” on the pri-
mary air filter cover.
4. Remove:
• Secondary air filter element “1”
a b 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
11.Install:
4-10.
EBS30624
5. Check:
REPLACING THE SECONDARY AIR FILTER • Secondary air filter element
ELEMENT Damage → Replace.
1. Check: TIP
• Check hose “1” • Replace the secondary air filter element every
TIP 2000 – 5000 km (1200 – 3000 mi) of operation.
There is an air filter check hose at the bottom of • The air filter needs more frequent service if you
the air filter case. If dust and/or water collects in are riding in unusually wet or dusty areas.
this hose, clean the air filter check hose and re- 6. Install:
place the air filter element. • Secondary air filter element
• Secondary air filter cover
3-16
Secondary air filter cover screw

T.
R.
1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
ECA14401
NOTICE
Never operate the engine without the air filter
element installed. Unfiltered air will cause
rapid wear of engine parts and may damage b
the engine. Operating the engine without the a
air filter element will also affect carburetor
synchronization, leading to poor engine per- Recommended brand
formance and possible overheating. YAMALUBE
7. Install: Type
• Air filter case SAE 5W-30, 10W-30, 10W-40,
Refer to “AIR FILTER CASE AND OIL SEP- 15W-40, 20W-40 or 20W-50
Recommended engine oil grade
API service SG type or higher,
• Cargo bed JASO standard MA
4-10.
0 10 30 50 70 90 110 130 ˚F
EBS30038
CHECKING THE ENGINE OIL LEVEL SAE 5W-30
1. Place the vehicle on a level surface. SAE 10W-30
2. Remove: SAE 10W-40
• Cargo bed compartment panel SAE 15W-40

Refer to “GENERAL CHASSIS (5)” on page SAE 20W-40
4-10. SAE 20W-50
3. Start the engine and warm it up until the en-
gine oil has reached a normal temperature of –20 –10 0 10 20 30 40 50 ˚C
ECB01810
60 °C (140 °F), then let the engine idle for a
NOTICE
minimum of ten seconds before turning the
engine off. Do not allow foreign materials to enter the
TIP crankcase.
To achieve the proper engine oil temperature for 5. Start the engine, warm it up for several min-
an accurate oil level reading, the engine must utes, and then turn it off.
have first completely cooled down, and then be 6. Check the engine oil level again.
ECB01830
warmed up again for several minutes to normal
NOTICE
operating temperature.
Be sure the engine oil is at the correct level,
4. Check: otherwise engine damage may result.
• Engine oil level
The engine oil level should be between the TIP
minimum level mark “a” and maximum level Before checking the engine oil level, wait a few
mark “b”. minutes until the oil has settled.
Below the minimum level mark → Add the
7. Install:
recommended engine oil to the proper level.
TIP Refer to “GENERAL CHASSIS (5)” on page
• Before checking the engine oil level, wait a few 4-10.
minutes until the oil has settled.
• Do not screw the dipstick in when inspecting
the oil level.
3-17
EBS30039
CHANGING THE ENGINE OIL TIP

1. Start the engine, warm it up for several min- A “ ” mark “a” is stamped on the crankcase
utes, and then turn it off. near the engine oil drain bolt for easy identifica-
2. Remove: tion.
• Skid plate (center)
4-1. a
• Oil tank cover
4-10.
3. Place a container under the engine oil drain
bolts. 1
4. Remove:
• Dipstick (engine oil tank) “1” 8. Drain:
• Engine oil
(completely from the oil tank and crankcase)
9. If the oil filter cartridge is also to be replaced,
perform the following procedure.
1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the oil filter cartridge “1” with the oil
filter wrench “2”.
Oil filter wrench

90890-01426
5. Remove: Oil filter wrench
YU-38411
• Cylinder head cap “1”
2
1
6. Remove: b. Lubricate the O-ring “3” of a new oil filter car-

• Engine oil drain bolt (oil tank) “1” tridge with a thin coat of engine oil.
(along with the gasket) ECB01280
NOTICE
Make sure the O-ring “3” is positioned cor-
rectly in the groove of the oil filter cartridge.
7. Remove:
• Engine oil drain bolt (crankcase) “1”
(along with the gasket)
3-18
TIP
3 Pour the engine oil in two stages. First, pour in
2.00 L (2.11 US qt, 1.76 Imp.qt) of oil, then start
the engine and rev it 3 to 5 times. Stop the en-
gine, and then pour in the remainder of the spec-
ified amount.
ECB03090
NOTICE
When starting the engine, make sure the dip-
c. Tighten the new oil filter cartridge to specifi- stick is securely fitted into the oil tank.
cation with an oil filter wrench. 14.Fill: (when engine is disassembled)
• Crankcase and oil tank
Oil filter cartridge (with the specified amount of the recom-
17 Nm (1.7 m·kgf, 12 ft·lbf) mended engine oil)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Engine oil quantity

10.Check: Quantity (disassembled)
• Engine oil drain bolt gaskets 3.40 L (3.59 US qt, 2.99 Imp.qt)
Damage → Replace. Without oil filter cartridge re-
11.Install: placement
• Engine oil drain bolt (oil tank) 2.50 L (2.64 US qt, 2.20 Imp.qt)
(along with the gasket) With oil filter cartridge replace-
ment
Engine oil drain bolt (oil tank) 2.70 L (2.85 US qt, 2.38 Imp.qt)
16 Nm (1.6 m·kgf, 12 ft·lbf)
T.
15.Install:
R.
12.Check: • Dipstick
• Engine oil drain bolt (crankcase) 16.Start the engine, warm it up for several min-
(along with the gasket) utes, and then turn it off.
17.Check:
Engine oil drain bolt (crankcase) • Engine
10 Nm (1.0 m·kgf, 7.2 ft·lbf) (for engine oil leaks)
T.
R.
18.Check:
13.Fill: • Engine oil level
• Oil tank Refer to “CHECKING THE ENGINE OIL
(with the specified amount of the recom- LEVEL” on page 3-17.
mended engine oil) 19.Install:
• Oil tank cover
Engine oil quantity
Quantity (disassembled)
3.40 L (3.59 US qt, 2.99 Imp.qt) Refer to “GENERAL CHASSIS (5)” on page
Without oil filter cartridge re- 4-10.
placement • Skid plate (center)
2.50 L (2.64 US qt, 2.20 Imp.qt) Refer to “GENERAL CHASSIS (1)” on page
With oil filter cartridge replace- 4-1.
ment
EBS30458
2.70 L (2.85 US qt, 2.38 Imp.qt) MEASURING THE ENGINE OIL PRESSURE
1. Check:
• Engine oil pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slightly loosen the oil check bolt “1”.
3-19
b
a
b. Start the engine and keep it idling until engine
oil starts to seep from the oil check bolt. If no Recommended transmission oil
engine oil comes out after one minute, turn grade
the engine off so that it will not seize. YAMALUBE
Type
c. Check the engine oil passages, the oil filter
SAE 5W-30, 10W-30, 10W-40,
cartridge and the oil pump assembly for dam- 15W-40, 20W-40 or 20W-50
age or leakage.
Refer to “OIL PAN AND OIL PUMP” on page ECB03310
5-38. NOTICE
d. Start the engine after solving the problem(s) • Transmission oil also lubricates the clutch
and check the engine oil pressure again. and the wrong oil types or additives could
e. Tighten the oil check bolt to specification. cause clutch slippage. Therefore, do not
add any chemical additives or use engine
Oil check bolt (M8) oils with a grade of “CD” or higher and do
20 Nm (2.0 m·kgf, 14 ft·lbf) not use oils labeled “ENERGY CONSERV-
T.
R.
ING II”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Take care not to allow foreign material to
EBS30557
enter the transmission case.
CHECKING THE TRANSMISSION OIL LEVEL
1. Place the vehicle on a level surface. 5. Install:
2. Remove: • Transmission oil filler cap
• Center console side panel (right) 6. Install:
Refer to “GENERAL CHASSIS (4)” on page • Center console side panel (right)
4-7. Refer to “GENERAL CHASSIS (4)” on page
3. Remove: 4-7.
• Transmission oil filler cap “1” EBS30618
4. Check: CHANGING THE TRANSMISSION OIL
• Transmission oil level 1. Place the vehicle on a level surface.
The transmission oil level should be between 2. Place a container under the transmission
the minimum level mark “a” and maximum case.
level mark “b”. Below the minimum level mark 3. Remove:
→ Add the recommended engine oil to the • Center console side panel (right)
proper level. Refer to “GENERAL CHASSIS (4)” on page
TIP 4-7.
Do not screw the transmission oil filler cap in 4. Remove:
when inspecting the oil level. • Transmission oil filler cap “1”
• Transmission oil drain bolt “2”
Completely drain the transmission case of its
oil.
3-20
8. Install:
• Transmission oil filler cap
9. Install:
1 4-7.
EBS30620
MEASURING THE TRANSMISSION OIL

PRESSURE
1. Remove:
• Center console side cover (left)
4-7.
2. Check:
• Transmission oil pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slightly loosen the transmission oil check bolt
“1”.
2
5. Install:
• Transmission oil drain bolt
Transmission oil drain bolt 1

20 Nm (2.0 m·kgf, 14 ft·lbf)
T.
R.
6. Fill:
• Transmission case b. Start the engine and keep it idling until engine
(with the specified amount of the recom- oil starts to seep from the transmission oil
mended transmission oil) check bolt. If no engine oil comes out after
one minute, turn the engine off so that it will
Type
SAE 5W-30, 10W-30, 10W-40, not seize.
15W-40, 20W-40 or 20W-50 c. Check the transmission oil passages, the
Quantity transmission oil pump assembly for damage
1.50 L (1.59 US qt, 1.32 Imp.qt) or leakage.
Refer to “TRANSMISSION (3)” on page 5-99.
ECB03310
d. Start the engine after solving the problem(s)
NOTICE and check the engine oil pressure again.
• Transmission oil also lubricates the clutch e. Tighten the transmission oil check bolt to
and the wrong oil types or additives could specification.
cause clutch slippage. Therefore, do not
add any chemical additives or use engine Transmission oil check bolt (M6 ×
oils with a grade of “CD” or higher and do 10)
T.
R.
not use oils labeled “ENERGY CONSERV- 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
ING II”.
• Take care not to allow foreign material to ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
enter the transmission case. 3. Install:
• Center console side cover (left)
7. Check:
• Oil level
4-7.
Refer to “CHECKING THE TRANSMISSION
OIL LEVEL” on page 3-20.
3-21
EBS30040
CHECKING THE FINAL GEAR OIL LEVEL

1. Place the vehicle on a level surface. 1
2. Remove:
• Final gear oil filler bolt “1”
3. Check:
• Final gear oil level
The final gear oil level should be up to the
brim “2” of the hole. 2
Below the brim → Add the recommended fi-
4. Install:
nal gear oil to the proper level.
• Final gear oil drain bolt
Type (along with the gasket New )
SAE 80 API GL-4 Hypoid gear
oil Final gear oil drain bolt
23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
ECB01690
NOTICE 5. Fill:
Take care not to allow foreign material to en- • Final drive case
ter the final drive case. (with the specified amount of the recom-
mended final gear oil)
1 Type
oil
2 Quantity (disassembled)
0.52 L (0.55 US qt, 0.46 Imp.qt)
Quantity
0.47 L (0.50 US qt, 0.41 Imp.qt)
ECB01690
NOTICE
4. Install:
Take care not to allow foreign material to en-
• Final gear oil filler bolt
ter the final drive case.
(along with the gasket New )
6. Check:
Final gear oil filler bolt • Oil level
23 Nm (2.3 m·kgf, 17 ft·lbf) Refer to “CHECKING THE FINAL GEAR OIL
T.
R.
LEVEL” on page 3-22.

EBS30041 7. Install:
CHANGING THE FINAL GEAR OIL • Final gear oil filler bolt
2. Place a container under the final drive case.
3. Remove: Final gear oil filler bolt
• Final gear oil filler bolt “1” 23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.

• Final gear oil drain bolt “2” EBS30042
(along with the gasket) CHECKING THE DIFFERENTIAL GEAR OIL

Completely drain the final drive case of its oil. LEVEL
2. Remove:
• Differential gear oil filler bolt “1”
3-22
3. Check:
• Differential gear oil level
The differential gear oil level should be up to
the brim “2” of the hole.
Below the brim → Add the recommended dif-
ferential gear oil to the proper level.
Type
oil
2
ECB01600
4. Install:
NOTICE
• Differential gear oil drain bolt
Take care not to allow foreign material to en-
ter the differential case.
Differential gear oil drain bolt
1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
5. Fill:
• Differential case
2 (with the specified amount of the recom-
mended differential gear oil)
Type
oil
4. Install: Quantity (disassembled)
• Differential gear oil filler bolt 0.20 L (0.21 US qt, 0.18 Imp.qt)
(along with the gasket New ) Quantity
0.18 L (0.19 US qt, 0.16 Imp.qt)
Differential gear oil filler bolt
ECB01600
23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
NOTICE
R.
EBS30043 Take care not to allow foreign material to en-

CHANGING THE DIFFERENTIAL GEAR OIL ter the differential case.
6. Check:
2. Place a container under the differential case.
• Oil level
3. Remove:
Refer to “CHECKING THE DIFFERENTIAL
• Differential gear oil filler bolt “1”
GEAR OIL LEVEL” on page 3-22.
7. Install:
• Differential gear oil drain bolt “2”
• Differential gear oil filler bolt
Completely drain the differential case of its (along with the gasket New )
oil.
Differential gear oil filler bolt
23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
EBS30613
CHECKING THE CLUTCH FLUID LEVEL

TIP
When checking the clutch fluid level, make sure
that the top of the clutch master cylinder reser-
1 voir is horizontal.
3-23
2. Remove: EBS30614
BLEEDING THE HYDRAULIC CLUTCH

• Hood
SYSTEM
Refer to “GENERAL CHASSIS (4)” on page EWB04030
4-7. WARNING
3. Check: Bleed the hydraulic clutch system whenever:
• Clutch fluid level • the system was disassembled,
Below the minimum level mark “a” → Add the • a clutch hose was loosened or removed,
specified clutch fluid to the proper level. • the clutch fluid level is very low,
Specified brake and clutch fluid • clutch operation is faulty.
DOT 4 TIP
• Be careful not to spill any clutch fluid or allow
the clutch master cylinder reservoir to over-
flow.
• When bleeding the hydraulic clutch system,
make sure there is always enough clutch fluid
before applying the clutch. Ignoring this pre-
caution could allow air to enter the hydraulic
clutch system, considerably lengthening the
a
bleeding procedure.
• If bleeding is difficult, it may be necessary to let
EWB04020 the clutch fluid settle for a few hours. Repeat
WARNING the bleeding procedure when the tiny bubbles
• Use only the designated clutch fluid. Other in the hose have disappeared.
clutch fluids may cause the rubber seals to 1. Remove:
deteriorate, causing leakage and poor • Hood
clutch performance. • Center console side panel (right)
• Refill with the same type of clutch fluid that Refer to “GENERAL CHASSIS (4)” on page
is already in the system. Mixing clutch flu- 4-7.
ids may result in a harmful chemical reac- 2. Bleed:
tion, leading to poor clutch performance. • Hydraulic clutch system
• When refilling, be careful that water does ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
not enter the clutch fluid reservoir. Water a. Add the specified clutch fluid to the proper
will significantly lower the boiling point of level.
the clutch fluid and could cause vapor lock. b. Install the clutch master cylinder reservoir di-
ECB03110 aphragm.
NOTICE c. Connect a clear plastic hose “1” tightly to the
Clutch fluid may damage painted surfaces or bleed screw “2”.
plastic parts. Therefore, always clean up any
spilt clutch fluid immediately.
TIP
In order to ensure a correct reading of the clutch
fluid level, make sure the top of the reservoir is
horizontal.
1
4. Install: 2
• Hood
d. Place the other end of the hose into a con-
4-7.
tainer.
e. Slowly apply the clutch several times.
f. Fully depress the clutch pedal and hold it in
position.
3-24
g. Loosen the bleed screw. 3. Adjust:

TIP • Clutch pedal free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Loosen the bleed screw will release the pres-
a. Check that the gap “a” between the clutch
sure and cause the clutch pedal to fully extend.
pedal and the stopper on the pedal assembly
h. Tighten the bleed screw and then release the bracket is 0 mm (0 in).
clutch pedal.
i. Repeat steps (e) to (h) until all of the air bub-
bles have disappeared from the clutch fluid in
the plastic hose.
j. Tighten the bleed screw to specification.
a
Clutch release cylinder bleed
screw
T.
R.
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
k. Fill the clutch master cylinder reservoir to the

b. Loosen the locknut “1”.
proper level with the specified clutch fluid.
c. Turn the clutch pedal rod “2” in direction “b” or
Refer to “CHECKING THE CLUTCH FLUID
“c” until the correct free play is obtained.
EWB04040
WARNING Direction “b”

Clutch pedal free play is increased.
After bleeding the hydraulic clutch system, Direction “c”
check the clutch operation. Clutch pedal free play is decreased.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Hood
Refer to “GENERAL CHASSIS (4)” on page 2
4-7. c
b
EBS30615
ADJUSTING THE CLUTCH PEDAL 1

1. Remove:
• Pedal assembly cover
Refer to “GENERAL CHASSIS (1)” on page d. Tighten the locknut to specification.
4-1.
2. Check: Clutch pedal rod locknut
• Clutch pedal free play “a” 17 Nm (1.7 m·kgf, 12 ft·lbf)
T.
R.
Out of specification → Adjust.

e. Check again that the gap between the clutch
Clutch pedal free play pedal and the stopper on the pedal assembly
0.0 mm (0.00 in) bracket is 0 mm (0 in). If the gap is out of
specification, repeat the procedure from step
(b).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
a Refer to “GENERAL CHASSIS (1)” on page
4-1.
3-25
EBS30616
2. Operate the brake.
CHECKING THE CLUTCH HOSES
3. Check:
1. Remove:
• Front brake pad wear limit “a”
• Mudguard (left)
Out of specification → Replace the brake
pads and brake pad spring as a set.
4-1.
Refer to “FRONT AND REAR BRAKES” on
• Hood
page 4-35.
4-7. Brake pad lining thickness limit
• Floor board (left) 1.0 mm (0.04 in)
4-12.
2. Check: a
• Clutch hose “1” a
• Clutch master cylinder reservoir hose “2”
Cracks/damage/wear → Replace.
4. Install:
• Front wheels
Refer to “FRONT AND REAR WHEELS” on
page 4-29.
1
EBS30050
3. Apply the clutch several times. CHECKING THE REAR BRAKE PADS
4. Check: The following procedure applies to all of the rear
• Clutch hose brake pads.
• Clutch master cylinder reservoir hose 1. Remove:
Clutch fluid leakage → Replace the damaged • Rear wheels
hose. Refer to “FRONT AND REAR WHEELS” on
Refer to “CLUTCH” on page 5-46. page 4-29.
5. Install: 2. Operate the brake.
• Floor board (left) 3. Check:
Refer to “GENERAL CHASSIS (6)” on page • Rear brake pad wear limit “a”
4-12. Out of specification → Replace the brake
• Hood pads and brake pad spring as a set.
Refer to “GENERAL CHASSIS (4)” on page Refer to “FRONT AND REAR BRAKES” on
4-7. page 4-35.
• Mudguard (left)
Refer to “GENERAL CHASSIS (1)” on page Brake pad lining thickness limit
4-1. 1.0 mm (0.04 in)
EBS30044
CHECKING THE FRONT BRAKE PADS a

The following procedure applies to all of the front a
brake pads.
1. Remove:
• Front wheels
page 4-29.
3-26
4. Install:
• Rear wheels
page 4-29.
EBS30045
CHECKING THE BRAKE FLUID LEVEL

TIP
a
When checking the brake fluid level, make sure
that the top of the brake master cylinder reser-
voir is horizontal. 4. Install:
• Hood
2. Remove: Refer to “GENERAL CHASSIS (4)” on page
• Hood 4-7.
4-7. EBS30046
3. Check: BLEEDING THE HYDRAULIC BRAKE

• Brake fluid level SYSTEM
EWB02800
Below the minimum level mark “a” → Add the WARNING
specified brake fluid to the proper level.
Bleed the hydraulic brake system whenever:
Specified brake and clutch fluid • the system is disassembled.
DOT 4 • a brake hose is loosened, disconnected or
replaced.
EWB02880
• the brake fluid level is very low.
WARNING • brake operation is faulty.
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to TIP
deteriorate, causing leakage and poor • Be careful not to spill any brake fluid or allow
brake performance. the brake master cylinder reservoir to overflow.
• Refill with the same type of brake fluid that • When bleeding the hydraulic brake system,
is already in the system. Mixing brake fluids make sure there is always enough brake fluid
may result in a harmful chemical reaction, before applying the brake. Ignoring this pre-
leading to poor brake performance. caution could allow air to enter the hydraulic
• When refilling, be careful that water does brake system, considerably lengthening the
not enter the brake master cylinder reser- bleeding procedure.
voir. Water will significantly lower the boil- • If bleeding is difficult, it may be necessary to let
ing point of the brake fluid and could cause the brake fluid settle for a few hours. Repeat
vapor lock. the bleeding procedure when the tiny bubbles
ECB01320
in the hose have disappeared.
NOTICE 1. Remove:
Brake fluid may damage painted surfaces • Hood
and plastic parts. Therefore, always clean up Refer to “GENERAL CHASSIS (4)” on page
any spilt brake fluid immediately. 4-7.
• Rear wheels
TIP
In order to ensure a correct reading of the brake page 4-29.
fluid level, make sure the top of the brake master 2. Bleed:
cylinder reservoir is horizontal. • Hydraulic brake system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the brake master cylinder reservoir to the
proper level with the specified brake fluid.
b. Install the diaphragm (brake master cylinder
reservoir).
3-27
c. Connect a clear plastic hose “1” tightly to the 3. Install:

bleed screw “2”. • Rear wheels
A Refer to “FRONT AND REAR WHEELS” on
page 4-29.
• Hood
2 Refer to “GENERAL CHASSIS (4)” on page
4-7.
EBS30047
CHECKING THE BRAKE HOSES AND

1 BRAKE PIPES
1. Remove:
B Refer to “GENERAL CHASSIS (6)” on page
4-12.
• Front fender
2 4-21.
2. Check:
• Front brake hoses “1”
1 3. Check:
• Front brake pipe “2”
A. Front brake Cracks/damage → Replace.
B. Rear brake 4. Check:
• Rear brake pipe “3”
d. Place the other end of the hose into a con-
tainer.
5. Check:
e. Slowly apply the brake several times.
• Rear brake hoses “4”
f. Fully depress the brake pedal and hold it in
position.
g. Loosen the bleed screw.
TIP
Loosening the bleed screw will release the pres-
sure and cause the brake pedal to fully extend.
h. Tighten the bleed screw, and then release
the brake pedal.
i. Repeat steps (e) to (h) until all of the air bub-
bles have disappeared from the brake fluid in 1 1
the plastic hose.
j. Tighten the bleed screw to specification.
2
Brake caliper bleed screw
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
T.
R.
k. Fill the brake master cylinder reservoir to the

proper level with the specified brake fluid.
Refer to “CHECKING THE BRAKE FLUID
EWB02810 1
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-28
6. Check:
3 • Brake hose holders
Loose → Tighten the holder bolts.
Damage → Replace.
7. Apply the brake several times.
8. Check:
• Brake hoses
• Brake pipe
Brake fluid leakage → Replace any damaged
2
hose and pipe.
page 4-35.
9. Install:
• Front fender
4-21.
4-12.
EBS30048
ADJUSTING THE BRAKE PEDAL

1. Remove:
4-1.
2. Check:
3 • Brake pedal free play “a”
TIP
Make sure that the brake pedal “1” contacts the
stopper on the pedal assembly bracket “2”.
3 4
Brake pedal free play
0 mm (0 in)
2
4
a
1
4 4
3. Adjust:
• Brake pedal free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1”.
b. Turn the brake pedal rod “2” in direction “a” or
“b” until the correct free play is obtained.
3-29
EBS30478
Direction “a” ADJUSTING THE PARKING BRAKE

Brake pedal free play is increased. 1. Place the vehicle on a level surface.
Direction “b” 2. Check:
Brake pedal free play is decreased. • Parking brake lever free play “a”
The maximum free play is equal to one click
of the parking brake lever.
1 2 Incorrect → Adjust.
a
a
c. Tighten the locknut to specification.
Brake pedal rod locknut 3. Remove:

17 Nm (1.7 m·kgf, 12 ft·lbf) • Center console side panel (right)
T.
R.
EWB03090
WARNING 4-7.
4. Adjust:
After this adjustment is performed, lift the
• Parking brake lever free play
front and rear wheels off the ground by plac-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
ing a block under the frame, and spin the a. Release the parking brake lever.
front and rear wheels to ensure there is no b. Slide back the rubber cover “1”.
brake drag. If any brake drag is noticed per- c. Loosen the locknut “2”.
form the above steps again. d. Turn the adjusting nut “3” in direction “a” or “b”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ until the correct free play is obtained.
4. Install:
Direction “a”
• Pedal assembly cover Parking brake cable free play is in-
Refer to “GENERAL CHASSIS (1)” on page creased.
4-1. Direction “b”
EBS30622
Parking brake cable free play is de-
LUBRICATING THE CLUTCH PEDAL, creased.
BRAKE PEDAL AND ACCELERATOR
PEDAL
Lubricate the pivoting point and metal-to-metal
moving parts of the pedal.
Recommended lubricant 2 3
1
Lithium-soap-based grease
a
e. Tighten the locknut to specification.
Parking brake cable adjusting

locknut (parking brake lever side)
T.
R.
16 Nm (1.6 m·kgf, 12 ft·lbf)
3-30
f. Slide the rubber cover to its original position. b. Slide back the rubber cover “2”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ c. Finger tighten the locknut “3” and adjusting
5. Install: nut “4” in direction “a” until they stop.
• Center console side panel (right) 1
4-7.
EBS30051 a
CHECKING THE PARKING BRAKE PADS 3
1. Operate the parking brake. 4
2. Check: 2
• Parking brake pads
Wear indicator groove “a” has almost disap-
peared → Replace the brake pads and brake
d. Slide back the rubber cover “5”.
pad spring as a set.
e. Loosen the locknut “6”.
Refer to “PARKING BRAKE” on page 4-48.
f. Turn the adjusting nut “7” in direction “b” or “c”
a until the specified accelerator pedal free play
is obtained.
Direction “b”
Accelerator pedal free play is in-
creased.
Direction “c”
Accelerator pedal free play is de-
creased.
EBS30054
ADJUSTING THE ACCELERATOR PEDAL 6

FREE PLAY c
1. Check: d
7
• Accelerator pedal free play “a” b
5
Accelerator pedal free play
10.0–25.0 mm (0.39–0.98 in)
TIP
If length “d” is 16.0 mm (0.63 in) or more, loosen
locknut “3” and turn the adjusting nut “4” in direc-
tion “e” or “f” until the specified accelerator pedal
free play is obtained.
a Direction “e”
Accelerator pedal free play is in-
creased.
2. Remove: Direction “f”
• Electrical components tray Accelerator pedal free play is de-
Refer to “GENERAL CHASSIS (12)” on page creased.
4-26.
3. Adjust:
• Accelerator pedal free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the throttle cable housing cover “1”.
3-31
Reverse gear lock lever free play

3 1.0–3.0 mm (0.04–0.12 in)
e
4 f
g. Tighten the locknuts to specification. a
Throttle cable locknut (throttle

bodies)
T.
R.
1.0 Nm (0.10 m·kgf, 0.72 ft·lbf)

Throttle cable locknut (throttle 2. Remove:
cable) • EPS unit cover
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) Refer to “GENERAL CHASSIS (11)” on page
4-23.
h. Slide the rubber covers to their original posi- 3. Adjust
tions. • Reverse gear lock lever free play
i. Check the throttle valve pulley stopper gap. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
TIP a. Loosen the locknut “1”.
When the accelerator pedal is fully depressed b. Turn the adjusting nut “2” in direction “a” or “b”
(throttle valve fully open), the gap “g” between until the correct free play is obtained.
the throttle valve pulley “8” and the pulley stop-
per “9” should be 0 mm (0 in). Direction “a”
Reverse gear lock lever free play is in-
creased.
8
Direction “b”
Reverse gear lock lever free play is de-
creased.
9 1
g 2
a
j. Install a new gasket and the throttle cable
housing cover.
Throttle cable housing cover bolt b

2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
T.
R.
c. Tighten the locknut to specification.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install: Reverse gear lock cable locknut
• Electrical components tray 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-26.
4. Remove:
EBS30621
• EPS unit cover
ADJUSTING THE REVERSE GEAR LOCK
LEVER FREE PLAY
4-23.
1. Check:
• Reverse gear lock lever free play “a”
3-32
EBS30057 EWB02960
CHECKING THE WHEELS WARNING

The following procedure applies to all of the This model is equipped with low-pressure
wheels. tires. It is important that they be inflated cor-
1. Check: rectly and maintained at the proper pres-
• Bead lock “1” sures.
• Wheel “2”
Damage/bends → Replace.
EWB03010 Tire characteristics
EWB02970
WARNING
WARNING
• Never attempt even small repairs to the
wheel. Tire characteristics influence the handling of
• Ride conservatively after installing a tire to vehicles. The tires listed below have been
allow it to seat itself properly on the rim. approved by Yamaha Motor Co., Ltd. for this
model. If other tire combinations are used,
they can adversely affect your vehicle’s han-
1 2
dling characteristics and are therefore not
recommended.
Front tire
Type
Tubeless
Size
27 × 9.00R-14NHS
Manufacturer/model
2. Measure: MAXXIS/MU09
• Radial wheel runout Rear tire
• Lateral wheel runout Type
Refer to “CHECKING THE WHEELS” on Tubeless
page 4-31. Size
27 × 11.00R-14NHS
3. Check:
Manufacturer/model
• Wheel bearings MAXXIS/MU10
Refer to “CHECKING THE STEERING
KNUCKLES AND FRONT WHEEL BEAR-
INGS” on page 4-66 and “CHECKING THE Tire pressure
EWB02980
REAR KNUCKLES AND REAR WHEEL WARNING
BEARINGS” on page 4-75.
4. Check: • Tire pressure below the minimum specifi-
• Tightening torque cation could cause the tire to dislodge from
Refer to “INSTALLING THE BEAD LOCKS” the rim under severe riding conditions.
on page 4-33. • Use no more than the following pressures
when seating the tire beads.
Bead lock bolt (final tightening Front
torque) 250 kPa (2.5 kgf/cm²) (36 psi)
T.
R.
17 Nm (0.17 m·kgf, 12 ft·lbf) Rear

250 kPa (2.5 kgf/cm²) (36 psi)
EBS30058 Higher pressures and fast inflation may
CHECKING THE TIRES cause a tire to burst. Inflate the tires very
The following procedure applies to all of the slowly and carefully.
tires.
3-33
• In order to insure an accurate reading, make

Tire air pressure (measured on sure that the gauge is clean before use.
cold tires)
Recommended
Vehicle load
0 – 195 kg (0 – 430 lb)
Front
114.0 kPa (1.140 kgf/cm², 16.5
psi)
Rear
128.0 kPa (1.280 kgf/cm², 18.5
psi) 1
Minimum
Vehicle load
0 – 195 kg (0 – 430 lb) 2. Check:
Front • Tire surfaces
110.0 kPa (1.100 kgf/cm², 16.0 Wear/damage → Replace.
psi)
Rear Wear limit (front)
124.0 kPa (1.240 kgf/cm², 18.0 3.0 mm (0.12 in)
psi) Wear limit (rear)
3.0 mm (0.12 in)
Maximum loading limit EWB03100
EWB02990
WARNING
WARNING
It is dangerous to ride with a worn-out tire.
Be extra careful of the vehicle balance and When the tire tread reaches the wear limit, re-
stability when towing a trailer. place the tire immediately.
Maximum loading limit

326.0 kg (719 lb)
(Total weight of operator, pas-
senger, cargo, and
accessories)
Rear carrier load limit
136.0 kg (300 lb)
Storage compartment load limit
4.5 kg (10 lb)
1. Measure: a. Wear limit

• Tire pressure
Out of specification → Adjust. EBS30059
EWB03000 CHECKING THE FRONT SHOCK ABSORBER

WARNING ASSEMBLIES
Uneven or improper tire pressure may ad- The following procedure applies to both of the
versely affect the handling of this vehicle front shock absorber assemblies.
and may cause loss of control. 1. Place the vehicle on a level place.
• Maintain proper tire pressures. 2. Check:
• Set tire pressures when the tires are cold. • Front shock absorber assembly
• Tire pressures must be equal in both front Refer to “CHECKING THE FRONT SHOCK
tires and equal in both rear tires. ABSORBER ASSEMBLIES” on page 4-71.
3. Check:
TIP • Operation
• The tire pressure gauge “1” is included as stan- Pump the front shock absorber assembly up
dard equipment. and down several times.
3-34
Unsmooth operation → Replace front shock TIP

absorber assembly. • Be sure to remove all dirt and mud from around
Refer to “FRONT ARMS AND FRONT the locknut and adjusting ring before adjust-
SHOCK ABSORBER ASSEMBLIES” on ment.
page 4-69. • The length of the spring (installed) changes 1.8
EBS30430 mm (0.07 in) per turn of the adjusting ring.
ADJUSTING THE FRONT SHOCK
ABSORBER ASSEMBLIES
The following procedure applies to both of the
front shock absorber assemblies.
EWB03600
b
WARNING 1
Always adjust the spring preload, rebound a
damping force and compression damping
force of both front shock absorbers to the 2
same setting. Uneven adjustment can result
in poor handling and loss of stability.
1. Adjust:
• Spring preload
Ring nut wrench 1

90890-01584
YM-01584
c
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Elevate the front wheels by placing a suitable
stand under the frame.
b. Loosen the locknut “1”. c. Spring preload adjusting positions
c. Turn the adjusting ring “2” in direction “a” or
“b”. d. Tighten the locknut “1” with a ring nut wrench
“3”.
Direction “a”
Spring preload is increased (suspen- Ring nut wrench 2
sion is harder). 90890-01585
Direction “b” YM-01585
Spring preload is decreased (suspen-
sion is softer).
Locknut
41 Nm (4.1 m·kgf, 30 ft·lbf)
T.
R.

Minimum TIP
428.2 mm (16.86 in) • Set the torque wrench at a right angle to the
Standard ring nut wrench.
415.5 mm (16.36 in) • Always tighten the locknut against the adjust-
Maximum ing ring, then torque it to specification.
402.8 mm (15.86 in)
ECB02470
NOTICE
Never attempt to turn the adjusting ring be-
yond the maximum or minimum setting.
3-35
3. Adjust:
• Compression damping force (fast compres-
sion damping)
3 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting bolt “1” in direction “a” or
“b”.
1 Direction “a”
Compression damping force is in-
creased (suspension is harder).
Direction “b”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping force is de-
2. Adjust: creased (suspension is softer).
• Rebound damping force
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw “1” in direction “a” or Compression damping setting (for
“b”. fast compression damping)
Minimum
Direction “a” 4 turn(s) out from the fully
Rebound damping force is increased turned in position
(suspension is harder). Standard
Direction “b” 2 turn(s) out from the fully
Rebound damping force is decreased turned in position
(suspension is softer). Maximum
Adjusting bolt fully turned in
ECB02480
Rebound damping adjusting posi-
tions NOTICE
Minimum Do not force the adjuster past the minimum
26 click(s) out from the fully or maximum extent of adjustment. The ad-
turned in position juster may be damaged.
Standard
12 click(s) out from the fully
turned in position
Maximum
1 click out from the fully turned a
in position
b
ECB02480
NOTICE
1
Do not force the adjuster past the minimum
or maximum extent of adjustment. The ad-
juster may be damaged. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Adjust:
• Compression damping force (slow compres-
a sion damping)
1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw “1” in direction “a” or
“b”.
b
Direction “a”
Direction “b”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Compression damping force is de-
creased (suspension is softer).
3-36
EWB03610
Compression damping setting (for WARNING

slow compression damping) Always adjust the spring preload, rebound
Minimum damping force and compression damping
4 turn(s) out from the fully force of both rear shock absorbers to the
turned in position same setting. Uneven adjustment can result
Standard
in poor handling and loss of stability.
1 1/2 turn(s) out from the fully
turned in position 1. Adjust:
Maximum • Spring preload
Adjusting screw fully turned in
Ring nut wrench 1
ECB02480
90890-01584
NOTICE YM-01584
or maximum extent of adjustment. The ad- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
juster may be damaged. a. Elevate the rear wheels by placing a suitable
stand under the frame.
b. Loosen the locknut “1”.
c. Turn the adjusting ring “2” in direction “a” or
“b”.
a
Direction “a”
b Spring preload is increased (suspen-
sion is harder).
1 Direction “b”
Spring preload is decreased (suspen-
sion is softer).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30060
CHECKING THE REAR SHOCK ABSORBER Minimum
ASSEMBLIES 496.8 mm (19.56 in)
The following procedure applies to both of the Standard
rear shock absorber assemblies. 484.1 mm (19.06 in)
1. Place the vehicle on a level place. Maximum
2. Check: 471.4 mm (18.56 in)
• Rear shock absorber assembly
ECB02470
Refer to “CHECKING THE REAR SHOCK
NOTICE
ABSORBER ASSEMBLIES” on page 4-78.
3. Check: Never attempt to turn the adjusting ring be-
• Operation yond the maximum or minimum setting.
Pump the rear shock absorber assembly up TIP
and down several times.
• Be sure to remove all dirt and mud from around
Unsmooth operation → Replace rear shock
the locknut and adjusting ring before adjust-
absorber assembly.
ment.
Refer to “REAR STABILIZER, REAR ARMS,
• The length of the spring (installed) changes 1.8
AND REAR SHOCK ABSORBER ASSEM-
mm (0.07 in) per turn of the adjusting ring.
BLIES” on page 4-76.
EBS30431
ADJUSTING THE REAR SHOCK ABSORBER

ASSEMBLY
rear shock absorber assemblies.
3-37
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 a. Turn the adjusting screw “1” in direction “a” or
“b”.
2
b Direction “a”
Rebound damping force is increased
a (suspension is harder).
Direction “b”
Rebound damping force is decreased
(suspension is softer).
Rebound damping adjusting posi-

tions
Minimum
26 click(s) out from the fully
turned in position
Standard
c 8 click(s) out from the fully
turned in position
Maximum
1 click out from the fully turned
c. Spring preload adjusting positions in position
d. Tighten the locknut “1” with a ring nut wrench ECB02480
“3”. NOTICE
Ring nut wrench 2 or maximum extent of adjustment. The ad-
90890-01585
juster may be damaged.
YM-01585
Locknut
41 Nm (4.1 m·kgf, 30 ft·lbf)
T.
R.
TIP b
a
• Set the torque wrench at a right angle to the
ring nut wrench.
• Always tighten the locknut against the adjust-
ing ring, then torque it to specification. 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
• Compression damping force (fast compres-
3 sion damping)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting bolt “1” in direction “a” or
“b”.
1
Direction “a”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Direction “b”
2. Adjust: Compression damping force is de-
• Rebound damping force creased (suspension is softer).
3-38
ECB02480
Compression damping setting (for NOTICE

fast compression damping) Do not force the adjuster past the minimum
Minimum or maximum extent of adjustment. The ad-
4 turn(s) out from the fully juster may be damaged.
turned in position
Standard
1 1/2 turn(s) out from the fully
turned in position
Maximum
Adjusting bolt fully turned in
ECB02480
NOTICE b a
1
or maximum extent of adjustment. The ad-
juster may be damaged.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30061
CHECKING THE STEERING SYSTEM

2. Check:
• EPS unit
• Steering wheel nut
b a Move the steering wheel up and down, and
1 back and forth.
Excessive play → Check that the steering
column bolts, EPS unit bolts, or steering
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ wheel nut are tightened to specification.
4. Adjust: Refer to “STEERING SYSTEM” on page
• Compression damping force (slow compres- 4-58.
sion damping)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw “1” in direction “a” or
“b”.
Direction “a”
Direction “b”
Compression damping force is de-
creased (suspension is softer).
3. Check:
• Tie-rod ends
Compression damping setting (for Free play → Replace the tie-rod end.
slow compression damping) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Minimum a. Turn the steering wheel left until it stops.
4 turn(s) out from the fully b. Move the steering wheel slightly to the right
turned in position and left.
Standard c. Check for play in the tie-rod ends.
1 1/2 turn(s) out from the fully d. Turn the steering wheel right until it stops.
turned in position e. Move the steering wheel slightly to the left
Maximum and right.
Adjusting screw fully turned in f. Check for play in the tie-rod ends.
3-39
Toe-in = “B” – “A”
g. If the toe-in is incorrect, adjust it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Raise the front end of the vehicle so that
there is no weight on the front wheels.
5. Check:
• Ball joints and wheel bearings
Move the wheels laterally back and forth.
Excessive free play → Replace the front
arms (upper and lower) and/or wheel bear-
ings.
C. Forward
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
• Toe-in
EWB03110
EBS30062
WARNING
ADJUSTING THE TOE-IN
1. Place the vehicle on a level surface. • Be sure that both tie-rods are turned the
2. Measure: same amount. If not, the vehicle will drift
• Toe-in right or left even though the steering wheel
Out of specification → Adjust. is straight. This may lead to mishandling
and an accident.
Toe-in (with tires touching the • After setting the toe-in to specification, run
ground) the vehicle slowly for some distance with
-5.0–5.0 mm (-0.20–0.20 in) both hands lightly holding the steering
wheel and check that the steering wheel re-
TIP sponds correctly. If not, turn either the right
Before measuring the toe-in, make sure that the or left tie-rod within the toe-in specification.
tire pressure is correct. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Mark both tie-rods ends.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Mark both front tire tread centers. This reference point will be needed during
b. Face the steering wheel straight ahead. adjustment.
c. Measure the width “A” between the marks. b. Loosen the tie-rod end locknuts “1” of both
d. Rotate the front tires 180° until the marks are tie-rods.
exactly opposite one another. c. The same number of turns should be given to
e. Measure the width “B” between the marks. both the right and left tie-rods “2” until the
f. Calculate the toe-in using the formula given specified toe-in is obtained. This is to keep
below. the length of the tie-rods the same.
3-40
• Rear upper arm pivots
Recommended lubricant
1 2 2 1
d. Tighten the tie-rod end locknuts to specifica-

tion.
Tie-rod end locknut

50 Nm (5.0 m·kgf, 36 ft·lbf)
T.
R.
EBS30065
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ LUBRICATING THE REAR KNUCKLE

4. Check: PIVOTS
• Steering wheel 1. Lubricate:
• Rear knuckle pivots
TIP
After adjusting the toe-in, the steering wheel Recommended lubricant
should be centered. Lithium-soap-based grease
Refer to “INSTALLING THE STEERING
WHEEL” on page 4-25.
EBS30064
CHECKING THE STABILIZER BUSHING

1. Check:
• Stabilizer bushings
Damage/wear → Replace.
Refer to “STEERING KNUCKLES AND
FRONT STABILIZER” on page 4-64 and
“REAR STABILIZER, REAR ARMS, AND
REAR SHOCK ABSORBER ASSEMBLIES” EBS30066
on page 4-76. LUBRICATING THE DRIVE SHAFT

EBS30619
UNIVERSAL JOINTS
LUBRICATING THE UPPER AND LOWER 1. Remove:
ARM PIVOTS • Skid plate (center)
1. Lubricate: Refer to “GENERAL CHASSIS (1)” on page
• Front upper and lower arm pivots 4-1.
2. Lubricate:
Recommended lubricant • Front drive shaft universal joint
3-41
1 1
1 1
EBS30067 A. Front
CHECKING THE ENGINE MOUNT B. Rear
1. Check:
• Engine bracket EBS30069
CHECKING THE FASTENER

1. Check:
• Engine mounting bolts
• Fasteners
• Engine mounting nuts
Damage/pitting → Replace.
• Engine bracket bolts
Loosen → Tighten.
4-1, “GENERAL CHASSIS (2)” on page 4-2,
Refer to “ENGINE REMOVAL (3)” on page
“GENERAL CHASSIS (4)” on page 4-7,
5-6.
“GENERAL CHASSIS (5)” on page 4-10,
EBS30068 “GENERAL CHASSIS (6)” on page 4-12,
CHECKING THE CONSTANT VELOCITY “GENERAL CHASSIS (10)” on page 4-21,
SHAFT ASSEMBLY DUST BOOTS “GENERAL CHASSIS (11)” on page 4-23
1. Check: and “GENERAL CHASSIS (12)” on page
• Dust boots “1” 4-26.
Damage → Replace.
Refer to “FRONT CONSTANT VELOCITY
SHAFT ASSEMBLIES, DIFFERENTIAL AS-
SEMBLY AND FRONT DRIVE SHAFT” on
page 8-4 and “REAR CONSTANT VELOCI-
TY SHAFT ASSEMBLIES, FINAL DRIVE
ASSEMBLY AND REAR DRIVE SHAFT” on
page 8-19.
3-42
3-43
CHASSIS
GENERAL CHASSIS (1) ................................................................................. 4-1
GENERAL CHASSIS (2) ................................................................................. 4-2

REMOVING THE SIDE FENDERS ........................................................... 4-3
INSTALLING THE SIDE FENDERS.......................................................... 4-3
INSTALLING THE DOORS ....................................................................... 4-3
GENERAL CHASSIS (3) ................................................................................. 4-5

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

REMOVING THE HOOD ...........................................................................4-8
REMOVING THE BATTERY COVER .......................................................4-8
INSTALLING THE BATTERY COVER ......................................................4-8
INSTALLING THE HOOD..........................................................................4-8 4
GENERAL CHASSIS (5) ............................................................................... 4-10
REMOVING THE CARGO BED COMPARTMENT PANEL ....................4-11
INSTALLING THE CARGO BED............................................................. 4-11
INSTALLING THE CARGO BED COMPARTMENT PANEL................... 4-11
GENERAL CHASSIS (6) ............................................................................... 4-12
GENERAL CHASSIS (7) ............................................................................... 4-14

INSTALLING THE SEAT BELTS............................................................. 4-15
GENERAL CHASSIS (8) ............................................................................... 4-16

INSTALLING THE SUN TOP .................................................................. 4-17
GENERAL CHASSIS (9) ............................................................................... 4-18

REMOVING THE ENCLOSURE ............................................................. 4-19
INSTALLING THE ENCLOSURE ............................................................ 4-19
GENERAL CHASSIS (10) ............................................................................. 4-21
GENERAL CHASSIS (11) ............................................................................. 4-23

REMOVING THE STEERING WHEEL....................................................4-25
INSTALLING THE STEERING WHEEL .................................................. 4-25
GENERAL CHASSIS (12) ............................................................................. 4-26
FRONT AND REAR WHEELS ...................................................................... 4-29

REMOVING THE WHEELS..................................................................... 4-31
REMOVING THE WHEEL HUBS ............................................................ 4-31
REMOVING THE BEAD LOCKS............................................................. 4-31
CHECKING THE WHEELS ..................................................................... 4-31
CHECKING THE WHEEL HUBS............................................................. 4-32
INSTALLING THE BRAKE DISCS .......................................................... 4-32
INSTALLING THE WHEEL HUBS........................................................... 4-32
INSTALLING THE BEAD LOCKS ........................................................... 4-33
INSTALLING THE WHEELS ................................................................... 4-34
FRONT AND REAR BRAKES....................................................................... 4-35

INTRODUCTION .....................................................................................4-42
CHECKING THE BRAKE DISCS ............................................................ 4-42
REPLACING THE BRAKE PADS............................................................ 4-43
DISASSEMBLING THE BRAKE CALIPERS ...........................................4-44
CHECKING THE BRAKE CALIPERS .....................................................4-44
ASSEMBLING THE BRAKE CALIPERS ................................................. 4-44
INSTALLING THE BRAKE CALIPERS ...................................................4-45
CHECKING THE BRAKE MASTER CYLINDER ..................................... 4-46
CHECKING THE BRAKE PIPES............................................................. 4-46
INSTALLING THE BRAKE MASTER CYLINDER ................................... 4-46
PARKING BRAKE......................................................................................... 4-48

REMOVING THE PARKING BRAKE CALIPER ...................................... 4-53
CHECKING THE PARKING BRAKE CALIPER....................................... 4-53
CHECKING THE PARKING BRAKE DISC ............................................. 4-53
REPLACING THE PARKING BRAKE PADS ..........................................4-53
INSTALLING THE PARKING BRAKE LEVER ........................................ 4-54
PEDAL ASSEMBLY ......................................................................................4-55

INSTALLING THE PEDAL ASSEMBLY .................................................. 4-57
STEERING SYSTEM .....................................................................................4-58

REMOVING THE TIE-ROD ..................................................................... 4-61
CHECKING THE STEERING JOINT.......................................................4-61
CHECKING THE TIE-ROD ENDS........................................................... 4-61
INSTALLING THE STEERING SYSTEM ................................................ 4-61
LUBRICATING THE STEERING SHAFT ................................................ 4-63
STEERING KNUCKLES AND FRONT STABILIZER ................................... 4-64

REMOVING THE STEERING KNUCKLES ............................................. 4-66
CHECKING THE STEERING KNUCKLES AND
FRONT WHEEL BEARINGS .................................................................. 4-66
CHECKING THE STEERING KNUCKLE BALL JOINTS ........................ 4-66
CHECKING THE FRONT STABILIZER .................................................. 4-67
INSTALLING THE FRONT STABILIZER ................................................ 4-67
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES ............. 4-69
CHECKING THE FRONT ARMS............................................................. 4-71
HANDLING THE FRONT SHOCK ABSORBER ASSEMBLIES.............. 4-71
DISPOSING OF A FRONT SHOCK ABSORBER ASSEMBLY............... 4-71
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES ............. 4-71
CHECKING THE FRONT ARM BALL JOINTS ....................................... 4-72
INSTALLING THE FRONT ARMS AND FRONT SHOCK
ABSORBER ASSEMBLIES .................................................................... 4-72
REAR KNUCKLES ........................................................................................ 4-74

CHECKING THE REAR KNUCKLES AND REAR WHEEL
BEARINGS ............................................................................................. 4-75
REAR STABILIZER, REAR ARMS, AND REAR SHOCK ABSORBER

ASSEMBLIES...............................................................................................4-76
CHECKING THE REAR ARMS ...............................................................4-78
HANDLING THE REAR SHOCK ABSORBER ASSEMBLIES ................ 4-78
DISPOSING OF A REAR SHOCK ABSORBER ASSEMBLY ................. 4-78
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................ 4-78
CHECKING THE REAR LOWER ARM BALL JOINTS............................ 4-79
INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER
ASSEMBLIES ......................................................................................... 4-79
CHECKING THE REAR STABILIZER.....................................................4-80
INSTALLING THE REAR STABILIZER...................................................4-80
GENERAL CHASSIS (1)
EBS20024
GENERAL CHASSIS (1)

Removing the skid plates
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 7
T.R
.
(4) 4
5
(4)
(9)
8
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
(5)
3
6
(3)
(4) 2 (3)
1 (5) (6)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

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

1 Mudguard (left) 1
2 Pedal assembly cover 1
3 Skid plate (left) 1
4 Skid plate (right) 1
5 Mudguard (right) 1
6 Skid plate (front) 1
7 Skid plate (rear) 1
8 Skid plate (center) 1
4-1
GENERAL CHASSIS (2)
EBS20087
GENERAL CHASSIS (2)

Removing the doors, side panels, and rear fenders
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 9 Nm (0.9 m•kgf, 6.5 ft•Ibf)
T.R
T.R
.
.
11 Nm (1.1 m•kgf, 8.0 ft•Ibf)
T.R
.
3
2 8
23 Nm (2.3 m•kgf, 17 ft•Ibf)
T.R
.
(4)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
5
6 9 Nm (0.9 m•kgf, 6.5 ft•Ibf)
T.R
.
7 1
4
7
11
17 Nm (1.7 m•kgf, 12 ft•Ibf)

T.R
.
10
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

The following procedure applies to both of
the doors.
1 Side fender 1
2 Rear fender 1
3 Rear fender bracket 1
4 Door panel 1
5 Door 1
6 Door handle latch 1
7 Door hinge 2
8 Rubber damper 1
9 Door latch striker 1
10 Fuel tank cap 1 Right side only.
11 Side panel 1
4-2
GENERAL CHASSIS (2)
EBS30625
REMOVING THE SIDE FENDERS

The following procedure applies to both of the a
side fenders.
1. Remove: b
• Side fender “1”
b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30419
INSTALLING THE DOORS

1 The following procedure applies to both of the
doors.
1. Install:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bolts and quick fastener. • Door latch striker “1”
b. Lift the side fender and remove it. • Rubber damper
Door latch striker bolt

23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
TIP R.
Install the bolts so that the centers of the door

latch striker bolt holes are aligned with the cen-
ters of the installation holes in the frame.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
EBS30626
INSTALLING THE SIDE FENDERS

side fenders.
1. Install:
• Side fender “1”
Side fender bolt 2. Install:

7 Nm (0.7 m·kgf, 5.1 ft·lbf) • Door hinge assemblies
T.
R.
Door hinge bolt

9 Nm (0.9 m·kgf, 6.5 ft·lbf)
T.
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the door hinge collar “1” into the top of
the door hinge.
b. Install the door hinge spring “2” onto the door
hinge collar “1”.
1 c. Install the door hinge collar “3” into the bottom
of the door hinge.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the projections “a” on the side fender into
the holes “b” in the front fender.
4-3
GENERAL CHASSIS (2)
d. Install the door hinge assembly “4” to the ve-

hicle.
TIP
Fit the end “a” of the door hinge spring into the
hole “b” in the frame.
b 4
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Door
Door hinge plate bolt

17 Nm (1.7 m·kgf, 12 ft·lbf)
T.
R.
Door handle latch bolt

9 Nm (0.9 m·kgf, 6.5 ft·lbf)
TIP
Adjust the position of the door handle latch so
that it fully engages the door latch striker on the
frame when the door is closed.
4-4
GENERAL CHASSIS (3)
EBS20088
GENERAL CHASSIS (3)

Removing the seats
5
(3)
3
6 Nm (0.6 m•kgf, 4.3 ft•Ibf)
T.R
.
(3)
New
5
2 (3)
(4)
(3)
(4)
New
32 Nm (3.2 m•kgf, 23 ft•Ibf)
T.R
.

1 Seat cushion 2
2 Driver seat frame 1
3 Passenger seat frame 1
4 Seat back 2
5 Shoulder bolster 2
4-5
GENERAL CHASSIS (3)
EBS30340 EBS30073
REMOVING THE SEATS ADJUSTING THE DRIVER SEAT POSITION

The following procedure applies to both of the The driver seat position can be adjusted to suit
seats. the driver’s preference.
1. Remove: 1. Adjust:
• Seat cushion “1” • Driver seat position
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Lift the front of the seat cushion. a. Pull the driver seat adjusting lever “1” upward
b. Pull the cushion off. and move the seat “2” to the desired position.
TIP
1 Make sure that the seat is locked in place.
1 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30342
INSTALLING THE SEATS

The following procedure applies to both of the ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
seats.
1. Install:
• Seat cushion “1”
EWB03120
WARNING
A loose seat could cause the operator to lose
control, or cause the operator or passengers
to fall.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Insert the projections “a” on the rear of the
seat cushion under the seat frame.
b. Insert the projection “b” on the front of the
cushion into the grommet while pushing the
cushion downward.
TIP
Make sure the seats are properly secured before
riding.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-6
GENERAL CHASSIS (4)
EBS20089
GENERAL CHASSIS (4)

Removing the hood and battery cover
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.
6 3
2
5
4
1
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.

Driver seat frame/Passenger seat frame 4-5.
1 Hood 1
2 Battery cover 1
3 Air intake duct cover 1
4 Center console cover 1
5 Center console side panel (left) 1
6 Center console side panel (right) 1
4-7
GENERAL CHASSIS (4)
EBS30627
REMOVING THE HOOD

1. Remove: a
• Hood “1”
c
1
d
b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30450
INSTALLING THE BATTERY COVER

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1. Install:
a. Remove the bolts. • Battery cover “1”
b. Slide the hood rearward and lift it up to un-
hook its projections “a” from the holes “b” in
the front fender.
a
1
b a
a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b a. Fit the projection “a” on the battery cover into
b
the hole “b” in the center console cover.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Fit the projections “c” on the battery cover into
EBS30449
the grommets “d”.
REMOVING THE BATTERY COVER
1. Remove: c
• Battery cover “1”
b
d
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30628
INSTALLING THE HOOD

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Lift the rear of the battery cover to remove the 1. Install:
projections “a” on the cover from the grom- • Hood “1”
mets “b”.
b. Slide the battery cover rearward to unhook its
projection “c” from the hole “d” in the center
console cover.
4-8
GENERAL CHASSIS (4)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the projections “a” on the hood into the
holes “b” in the front fender.
b a
a
b b
b. Install the bolts.
Hood bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-9
GENERAL CHASSIS (5)
EBS20090
GENERAL CHASSIS (5)

Removing the cargo bed
(5)
1
3 7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
2
12 Nm (1.2 m•kgf, 8.7 ft•Ibf)

T.R
.
(6)
(9)
11 Nm (1.1 m•kgf, 8.0 ft•Ibf) 4

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

T.R
.
2.8 Nm (0.28 m•kgf, 2.0 ft•Ibf)

6
T.R
.
7
8

Rear fenders 4-2.
Seat frames 4-5.
Battery cover 4-7.
Side frames 4-18.
1 Storage compartment cover 1
2 Cargo bed compartment panel 1
3 Oil tank cover 1
4 Cargo bed 1
5 Heat protector 1
6 Tail/brake light coupler 1 Disconnect.
7 Tail/brake light cover 1
8 Tail/brake light 1
4-10
GENERAL CHASSIS (5)
EBS30629
REMOVING THE CARGO BED 1

COMPARTMENT PANEL
1. Remove:
• Cargo bed compartment panel “1”
TIP
Remove the quick fastener screws “2”, and then
pull the panel off as shown.
1 2
2 2
EBS30420
INSTALLING THE CARGO BED

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

12 Nm (1.2 m·kgf, 8.7 ft·lbf)
T.
R.
TIP
Tighten the cargo bed bolts in the proper tighten-
ing sequence as shown.
FWD
1 3 9
2
1 6
5 4
8 7
EBS30630
INSTALLING THE CARGO BED

COMPARTMENT PANEL
1. Install:
• Cargo bed compartment panel “1”
TIP
Place the panel in the original position, and then
install the quick fastener screws.
4-11
GENERAL CHASSIS (6)
EBS20091
GENERAL CHASSIS (6)

Removing the floor boards and driver seat position adjuster assembly
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
4
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
(7)
59 Nm (5.9 m•kgf, 43 ft•Ibf)
T.R
.
2
3
21 Nm (2.1 m•kgf, 15 ft•Ibf)
T.R
.
59 Nm (5.9 m•kgf, 43 ft•Ibf)
T.R
(4)
.
6 (4)
1
(4)
(5)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 32 Nm (3.2 m•kgf, 23 ft•Ibf)

T.R
T.R
.

Skid plate (left)/Skid plate (right) 4-1.
Side panels 4-2.
Center console side panels 4-7.
Cargo bed 4-10.
1 Driver seat belt bolt 1
2 Passenger seat belt bolt 1
3 Under-seat upper panel (left) 1
4 Under-seat panel (right) 1
5 Seat belt switch coupler 1 Disconnect.
6 Driver seat buckle bolt 1
4-12
GENERAL CHASSIS (6)
Removing the floor boards and driver seat position adjuster assembly
10
11
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
13
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 9
T.R
.
(7) 14
59 Nm (5.9 m•kgf, 43 ft•Ibf)
T.R
.
21 Nm (2.1 m•kgf, 15 ft•Ibf)
T.R
.
59 Nm (5.9 m•kgf, 43 ft•Ibf)
T.R
(4)
.
7 (4)
(4)
(5)
12 8

T.R
T.R
.

7 Driver seat position adjuster assembly 1
8 Under-seat lower panel (left) 1
9 Rear panel (left) 1
10 Final drive case breather hose 1 Disconnect.
11 Rear panel (right) 1
12 Floor board (right) 1
Fuel tank breather hose (fuel tank to fuel tank
13 1 Disconnect.
14 Floor board (left) 1
4-13
GENERAL CHASSIS (7)
EBS20092
GENERAL CHASSIS (7)

Removing the seat belts
59 Nm (5.9 m•kgf, 43 ft•Ibf)
T.R
.
59 Nm (5.9 m•kgf, 43 ft•Ibf)
T.R
.
2
59 Nm (5.9 m•kgf, 43 ft•Ibf)
T.R
.
5
59 Nm (5.9 m•kgf, 43 ft•Ibf)

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

T.R
T.R
.
.

Side panels 4-2.
Cargo bed 4-10.
Rear panels 4-12.
1 Driver seat belt 1
2 Passenger seat belt 1
4 Driver seat belt buckle 1
5 Passenger seat belt buckle 1
4-14
GENERAL CHASSIS (7)
EBS30343
INSTALLING THE SEAT BELTS

1. Install:
• Seat belt buckles
• Seat belts
Seat belt buckle bolt

59 Nm (5.9 m·kgf, 43 ft·lbf)
T.
Seat belt bolt (M12 × 20)

R.
59 Nm (5.9 m·kgf, 43 ft·lbf)

Seat belt bolt (M12 × 18)
59 Nm (5.9 m·kgf, 43 ft·lbf)
Seat belt guide bolt
59 Nm (5.9 m·kgf, 43 ft·lbf)
TIP
Fit the projection “a” on each seat belt “1” into
the slits “b” in the frame.
b
a
4-15
GENERAL CHASSIS (8)
EBS20102
GENERAL CHASSIS (8)

Removing the sun top
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
2
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)
T.R
.
3 (5)
(5)
1
(10)
3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)

T.R
.

1 Sun top holder 5
2 Sun top 1
3 Damper 5
4-16
GENERAL CHASSIS (8)
EBS30596
INSTALLING THE SUN TOP

1. Install:
• Dampers
• Sun top “1”
• Sun top holders “2”
2. Tighten:
• Sun top bracket screws “3”
Sun top bracket screw

3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
T.
R.
3. Tighten:
• Sun top rear side bolts “4”
Sun top rear side bolt

7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.
4. Tighten:
• Sun top holder screws “5”
Sun top holder screw

3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
T.
R.
4
1
3
(5)
(5)
2 (10)
5
4-17
GENERAL CHASSIS (9)
EBS20103
GENERAL CHASSIS (9)

Removing the enclosure
T.R
.
T.R
.
70 Nm (7.0 m•kgf, 51 ft•Ibf)
T.R
.
1
59 Nm (5.9 m•kgf, 43 ft•Ibf)

5
T.R
.
2
4
70 Nm (7.0 m•kgf, 51 ft•Ibf) 6

T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf)

1
T.R
.
70 Nm (7.0 m•kgf, 51 ft•Ibf)
T.R
.
T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf)
70 Nm (7.0 m•kgf, 51 ft•Ibf)

T.R
.

Sun top 4-16.
1 Seat belt bolt 2
2 Sun top bracket 1
3 Top frame 1
4 Rear frame 1
5 Side frame (right) 1
6 Side frame (left) 1
4-18
GENERAL CHASSIS (9)
EBS30702
REMOVING THE ENCLOSURE

TIP
To make removal of the enclosure easier, place
a suitable jack at the location shown in the illus-
tration and raise the vehicle to support the vehi-
cle weight without lifting the wheels off the
ground.
1. Install:
• Side frame (left) “1”
• Side frame (right) “2”
• Rear frame “3”
• Top frame “4”
• Sun top bracket “5”
TIP
Do not fully tighten the bolts and nuts.
EBS30344
INSTALLING THE ENCLOSURE 5 4

2
TIP
3
To make installation of the enclosure easier,
place a suitable jack at the location shown in the
illustration and raise the vehicle to support the
vehicle weight without lifting the wheels off the
ground. 1
2. Tighten:
• Rear frame bolts
• Top frame bolts (rear)
• Top frame bolts (front)
• Side frame nuts (rear)
• Side frame nuts (front)
• Side frame nuts (center)
• Sun top bracket bolts
TIP
Tighten the bolts and nuts in the proper tighten-
ing sequence as shown ( 1, 2, and so on).
4-19
GENERAL CHASSIS (9)
Rear frame bolt (left)

T.
R.
70 Nm (7.0 m·kgf, 51 ft·lbf)
Rear frame bolt (right)
70 Nm (7.0 m·kgf, 51 ft·lbf)
Top frame bolt
70 Nm (7.0 m·kgf, 51 ft·lbf)
Side frame nut (rear left)
70 Nm (7.0 m·kgf, 51 ft·lbf)
Side frame nut (rear right)
70 Nm (7.0 m·kgf, 51 ft·lbf)
Side frame nut (front left)
70 Nm (7.0 m·kgf, 51 ft·lbf)
Side frame nut (front right)
70 Nm (7.0 m·kgf, 51 ft·lbf)
Side frame nut (center left)
48 Nm (4.8 m·kgf, 35 ft·lbf)
Side frame nut (center right)
48 Nm (4.8 m·kgf, 35 ft·lbf)
Sun top bracket bolt
70 Nm (7.0 m·kgf, 51 ft·lbf)
7 2
4
1
3 6
4-20
GENERAL CHASSIS (10)
EBS20104

Remove the front fender
2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf) 7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
5
T.R
T.R
.
.
6
4 (6)
1
2
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf) 3
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
16 Nm (1.6 m•kgf, 12 ft•Ibf)

T.R
.
(4)
(4)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf)

T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Side fenders 4-2.
Hood 4-7.
Side frames 4-18.
Refer to “GENERAL CHASSIS (12)” on
Center console page 4-26.
1 Coolant reservoir breather hose 1 Disconnect.
2 Differential case breather hose 1 Disconnect.
3 Transmission case breather hose 2 Disconnect.
4 Radiator fan motor breather hose 1 Disconnect.
5 EPS (electric power steering) control unit 1
6 Front fender 1
4-21
Remove the front fender

T.R
T.R
.
.
(6)
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
16 Nm (1.6 m•kgf, 12 ft•Ibf)

T.R
.
8
8
(4)
10 9
(4)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf)

T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

7 Upper cover 1
8 Headlight coupler 4 Disconnect.
9 Front grill 1
10 Front guard 1
4-22
EBS20123

Removing the steering assembly
4
1.6 Nm (0.16 m•kgf, 1.2 ft•Ibf)
T.R
.
6 3
1.3 Nm (0.13 m•kgf, 0.94 ft•Ibf)

9
T.R
.
7 2
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

1
T.R
.
8
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf) 35 Nm (3.5 m•kgf, 25 ft•Ibf)
T.R
.
T.R
.

1 Steering wheel cover 1
2 Steering wheel 1
3 Meter assembly cover 1
4 Meter assembly coupler 1 Disconnect.
5 Meter assembly 1
6 Main switch coupler 1 Disconnect.
7 Main switch 1
8 EPS unit cover 1
9 Meter assembly bracket 1
4-23
Removing the Instrument panel assembly

3 3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)
T.R
.
2
4
1
(8)
(4) 7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Center console side panels 4-7.
Front fender page 4-21.
EPS unit/Steering wheel position adjusting Refer to “STEERING SYSTEM” on page
damper upper bolts 4-58.
1 Passenger handhold 1
2 Auxiliary DC jack coupler 1 Disconnect.
3 Instrument panel 1
4 Auxiliary DC jack 1
4-24
EBS30345
REMOVING THE STEERING WHEEL

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

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

35 Nm (3.5 m·kgf, 25 ft·lbf)
T.
R.
TIP
Install the steering wheel onto the steering col-
umn so that it is centered as shown in the illus-
tration.
4-25
EBS20124

Removing the Instrument panel assembly
1
6
2
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

T.R
.
10
8
4
5

Center console cover/Center console side pan- Refer to “GENERAL CHASSIS (4)” on page
els 4-7.
1 Shift knob 1
2 Indicator light assembly 1
3 Indicator light assembly coupler 1 Disconnect.
4 On-Command four-wheel-drive switch coupler 1 Disconnect.
5 Light switch coupler 1 Disconnect.
6 Parking brake lever rubber cover 1
7 On-Command four-wheel-drive switch 1
8 Light switch 1
9 Center console 1
10 Shift lever base cover 1
4-26
Removing the electrical components tray
1 8 7
10
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 9
2
T.R
.
6
5
4 3.6 Nm (0.36 m•kgf, 2.6 ft•Ibf)
T.R
3
.
3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf)
T.R
.
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
T.R
.
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.

Rear panels 4-12.
Air filter case assembly
1 Battery holding bracket 1
2 Negative battery lead 1 Disconnect.
3 Positive battery lead 1 Disconnect.
4 Battery 1
5 Lean angle sensor 1
6 Starter relay 1
7 Fuse box 1
8 Auxiliary DC jack fuse 1
9 Main fuse 1
10 EPS fuse 1
4-27
Removing the electrical components tray
22
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 22

T.R
.
3.6 Nm (0.36 m•kgf, 2.6 ft•Ibf)
T.R
.
3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf)
T.R
.
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
T.R
.
17
14 13
18 15 23
19 16
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
11
T.R
.
12
20
21

11 ECU band 1
12 ECU (Engine Control Unit) 1
13 Differential motor relay 2 1
14 Differential motor relay 1 1
15 Headlight relay (high beam) 1
16 Headlight relay (low beam) 1
17 Radiator fan motor relay 1
18 Fuel injection system relay 1
19 Load control relay 1
20 Oil pressure switch coupler 1 Disconnect.
22 Negative battery lead coupler 2 Disconnect.
23 Electrical components tray 1
4-28
FRONT AND REAR WHEELS
EBS20025

Removing the wheels and brake discs
43 Nm (4.3 m•kgf, 31 ft•Ibf)
T.R
.
LT
6
5
New 3
2
4
370 Nm (37 m•kgf, 268 ft•lbf)

T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf)

T.R
.
75 Nm (7.5 m•kgf, 54 ft•Ibf)

T.R
WD
.

The following procedure applies to all of the
wheels.
1 Wheel 1
2 Wheel cap 1
3 Wheel axle nut 1
TIP
4 Brake caliper 1 Do not apply the brake pedal when the
brake caliper is off of the brake disc as the
brake pads will be forced shut.
5 Wheel hub 1
6 Brake disc 1
4-29
Removing the bead lock
1st 5 Nm (0.5 m•kgf, 3.6 ft•Ibf)

2nd 12 Nm (1.2 m•kgf, 8.7 ft•Ibf)
T.R
.
3nd 17 Nm (1.7 m•kgf, 12 ft•Ibf)
(15)

bead locks.
1 Bead lock 1
4-30
EBS30083
REMOVING THE WHEELS TIP

1. Place the vehicle on a level surface. Before removing the bead lock, deflate the tire.
2. Elevate: 1. Remove:
• Wheels • Bead lock “1”
TIP TIP
Place the vehicle on a suitable stand so that the Working in a crisscross pattern, loosen each bolt
wheels are elevated. 1/4 of a turn. Remove them after all of them are
loosened.
EBS30084
REMOVING THE WHEEL HUBS

wheel hubs.
1. Straighten the wheel axle nut rib “a”.
1
EBS30085
CHECKING THE WHEELS

wheels.
2. Remove: 1. Check:
• Wheel axle nut • Tire
3. Remove: Refer to “CHECKING THE TIRES” on page
• Brake caliper 3-33.
TIP • Wheel
Refer to “CHECKING THE WHEELS” on
Do not apply the brake pedal when removing the
page 3-33.
brake caliper.
• Bead lock
4. Remove: Cracks/damage → Replace.
• Wheel hub “1” EWB03020
WARNING
TIP
Use a general puller “2” to separate the wheel After replacing the tire, ride conservatively to
hub and constant velocity shaft. allow the tire to be properly seated in the rim.
Failure to do so may cause an accident re-
1 sulting in vehicle damage and possible inju-
ry.
2
EBS30632
REMOVING THE BEAD LOCKS

bead locks. 2. Measure:
• Radial wheel runout “1”
4-31
• Lateral wheel runout “2”

Over the specified limit → Replace the wheel
or check the wheel bearing play.
Refer to “CHECKING THE STEERING 1
KNUCKLES AND FRONT WHEEL BEAR-
INGS” on page 4-66 and “CHECKING THE
2
REAR KNUCKLES AND REAR WHEEL
BEARINGS” on page 4-75.
Front wheel
Radial wheel runout limit EBS30087
2.0 mm (0.08 in) INSTALLING THE BRAKE DISCS
Lateral wheel runout limit The following procedure applies to all of the
2.0 mm (0.08 in)
brake discs.
Rear wheel
Radial wheel runout limit 1. Install:
2.0 mm (0.08 in) • Brake disc
Lateral wheel runout limit
2.0 mm (0.08 in) Brake disc bolt
43 Nm (4.3 m·kgf, 31 ft·lbf)
T.
R.
LOCTITE®
TIP
Install the brake disc so that the recessed por-
tion of the bolt hole faces away from the hub.
EBS30088
INSTALLING THE WHEEL HUBS

wheel hubs.
1. Install:
• Wheel hub “1”
EBS30086
TIP
CHECKING THE WHEEL HUBS
The following procedure applies to all of the Tap lightly on the wheel hub with a soft-face
wheel hubs. hammer until five threads on the end of the con-
1. Check: stant velocity shaft will be exposed when the
• Wheel hub “1” washer is installed.
• Splines (wheel hub) “2”
Wear/damage → Replace the wheel hub.
4-32
1
1
2. Install: 2. Install:
• Wheel axle nut New • Bead lock “1”
TIP
Front wheel axle nut Align the slot “a” in the bead lock with the air
370 Nm (37 m·kgf, 268 ft·lbf) valve stem “2”.
T.
R.
Rear wheel axle nut

370 Nm (37 m·kgf, 268 ft·lbf)
Bead lock bolt (final tightening
TIP torque)
T.
R.
17 Nm (1.7 m·kgf, 12 ft·lbf)
• 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.
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Tighten the bead lock bolts to 5 Nm (0.5 m·k-
3. Check: gf, 3.6 ft·lbf) in the proper tightening se-
• Brake disc quence as shown.
Refer to “CHECKING THE BRAKE DISCS” b. Tighten the bead lock bolts to 12 Nm (1.2
on page 4-42. m·kgf, 8.7 ft·lbf) in the proper tightening se-
quence as shown.
EBS30633
INSTALLING THE BEAD LOCKS 9 1 15

The following procedure applies to all of the 14 4
bead locks.
1. Lubricate: 6 12
• Tire 11 7
(with the recommended lubricant)
3 2
Recommended lubricant 8 10
Silicone grease 13 5
TIP
c. Inflate the tire to the specified tire pressure.
Lubricate the bead “1” of the tire with silicone
grease.
4-33
Front 1
114.0 kPa (1.140 kgf/cm², 16.5
psi)
Rear
128.0 kPa (1.280 kgf/cm², 18.5
psi)
d. Starting with the bead lock bolt indicated by

“1” in the illustration, tighten the bead lock
bolts to 17 Nm (1.7 m·kgf, 12 ft·lbf) in a clock-
wise tightening sequence.
e. Inflate the tire to 250 kPa (2.5 kgf/cm², 36 psi)
and check that the tire does not become dis-
lodged from the rim.
EWB02980
WARNING
• Tire pressure below the minimum specifi-
cation could cause the tire to dislodge from
the rim under severe riding conditions.
• Use no more than the following pressures
when seating the tire beads.
Front
250 kPa (2.5 kgf/cm²) (36 psi)
Rear
250 kPa (2.5 kgf/cm²) (36 psi)
Higher pressures and fast inflation may
cause a tire to burst. Inflate the tires very
slowly and carefully.
f. Clean the surface of the tire to remove ex-
cess grease.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
• Tire pressure
Refer to “Tire pressure” on page 3-33.
EBS30089
INSTALLING THE WHEELS

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

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

75 Nm (7.5 m·kgf, 54 ft·lbf)
EWB03130
WARNING
Tapered wheel nuts are used for both the
front and rear wheels. Install each nut with
its tapered side towards the wheel.
4-34
FRONT AND REAR BRAKES
EBS20026

Removing the front brake pads
5 Nm (0.5 m•kgf, 3.6 ft•Ibf) S

T.R
.
3
1
22 Nm (2.2 m•kgf, 16 ft•Ibf)

T.R
.
D
FW

the front brake calipers.
Front wheel page 4-29.
1 Front brake caliper retaining pin bolt 1
2 Brake pad 2
3 Brake pad spring 2
4-35
Removing the rear brake pads
FW
D
5 Nm (0.5 m•kgf, 3.6 ft•Ibf)
T.R
.
2
22 Nm (2.2 m•kgf, 16 ft•Ibf)

T.R
.

the rear brake calipers.
Rear wheel page 4-29.
1 Rear brake caliper guide pin bolt 1
2 Rear brake caliper retaining pin bolt 1
3 Brake pad 2
4-36
Removing the front brake calipers
48 Nm (4.8 m•kgf, 35 ft•Ibf)

T.R
.
4
27 Nm (2.7 m•kgf, 20 ft•Ibf)
T.R
.
1
2 New 5
D
FW

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-27.
1 Brake hose union bolt 1
2 Copper washer 2
3 Brake hose 1 Disconnect.
4 Brake caliper bolt 2
5 Brake caliper 1
4-37
Removing the rear brake calipers
FW
D
48 Nm (4.8 m•kgf, 35 ft•Ibf)
T.R
.
4
3
1
27 Nm (2.7 m•kgf, 20 ft•Ibf)

2 New
T.R
.
5

Rear wheel page 4-29.
Drain.
1 Brake hose union bolt 1
2 Copper washer 2
3 Brake hose 1 Disconnect.
4 Brake caliper bolt 2
5 Brake caliper 1
4-38
Disassembling the front brake calipers

5 Nm (0.5 m•kgf, 3.6 ft•Ibf)
T.R
3
.
22 Nm (2.2 m•kgf, 16 ft•Ibf)

T.R
.
S
11 6
BF S
9 5
2
10
7 8
22 Nm (2.2 m•kgf, 16 ft•Ibf)

T.R
4
.
S
S BF

1 Front brake caliper guide pin bolt 1
2 Front brake caliper retaining pin bolt 1
3 Brake pad 2
5 Brake caliper bracket 1
6 Brake caliper guide pin 1
7 Brake caliper retaining pin 1
8 Brake caliper piston 2
9 Brake caliper piston dust seal 2
10 Brake caliper piston seal 2
11 Bleed screw 1
4-39
Disassembling the rear brake calipers

3 5 Nm (0.5 m•kgf, 3.6 ft•Ibf)
T.R
.
22 Nm (2.2 m•kgf, 16 ft•Ibf)
T.R
.
1
11
S
6
S BF
9 2
10
8 7 BF
22 Nm (2.2 m•kgf, 16 ft•Ibf)
T.R
.
S
4
S

1 Rear brake caliper retaining pin bolt 1
2 Rear brake caliper guide pin bolt 1
3 Brake pad 2
6 Brake caliper retaining pin 1
7 Brake caliper guide pin 1
9 Brake caliper piston dust seal 2
11 Bleed screw 1
4-40
Removing the brake master cylinder

1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
T.R
.
D
FW
1
19 Nm (1.9 m•kgf, 14 ft•Ibf)

T.R
.
S
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
8
4
6
7
9
5
T.R
T.R
.
.

Instrument panel page 4-23.
Drain.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm hold-
2 1
er
3 Brake master cylinder reservoir diaphragm 1
4 Brake master cylinder reservoir 1
5 Brake master cylinder reservoir hose 1
6 Rear brake pipe 1 1 Disconnect.
7 Front brake pipe 1 Disconnect.
8 Rubber boot 1
9 Brake master cylinder 1
4-41
EBS30090
b. Measure the deflection 3.0 mm (0.12 in) be-
INTRODUCTION
EWB02930
low the edge of the brake disc.
WARNING
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
• Never disassemble brake components un-
less absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Never use solvents on internal brake com- 4. Measure:

ponents. • Brake disc thickness “a”
• Use only clean or new brake fluid for clean- Measure the brake disc thickness at a few dif-
ing brake components. ferent locations.
• Brake fluid may damage painted surfaces Out of specification → Replace.
and plastic parts. Therefore, always clean
Front brake
up any spilt brake fluid immediately.
Brake disc thickness limit
• Avoid brake fluid coming into contact with 5.0 mm (0.20 in)
the eyes as it can cause serious injury. Rear brake
FIRST AID FOR BRAKE FLUID ENTERING Brake disc thickness limit
THE EYES: 5.0 mm (0.20 in)
• Flush with water for 15 minutes and get im-
mediate medical attention.
a
EBS30091
CHECKING THE BRAKE DISCS

brake discs.
1. Remove:
• Wheels
page 4-29.
2. Check: 5. Adjust:
• Brake disc • Brake disc deflection
Damage/galling → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3. Measure: a. Remove the brake disc.
• Brake disc deflection b. Rotate the brake disc by one bolt hole.
Out of specification → Correct the brake disc c. Install the brake disc.
deflection or replace the brake disc.
Brake disc bolt
Front brake 43 Nm (4.3 m·kgf, 31 ft·lbf)
T.
R.
Brake disc deflection limit LOCTITE®

0.10 mm (0.0039 in)
Rear brake TIP
Brake disc deflection limit Install the brake disc so that the recessed por-
0.10 mm (0.0039 in)
tion of the bolt hole faces away from the hub.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the dial gauge at a right angle against
the brake disc surface.
4-42
• Brake pads
TIP
Always install new brake pads and brake pad
springs as a set.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose “1” tightly to the
bleed screw “2”. Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with your
d. Measure the brake disc deflection.
finger.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within 1 2
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• Wheels
page 4-29.
EBS30092 c. Tighten the bleed screw.
REPLACING THE BRAKE PADS
The following procedure applies to all of the Brake caliper bleed screw
brake calipers. 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
T.
R.
TIP
d. Install the brake pad springs and brake pads.
When replacing the brake pads, it is not neces- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
sary to disconnect the brake hose or disassem-
3. Install:
ble the brake caliper.
• Brake caliper
1. Measure:
• Brake pad wear limit “a” Front brake caliper retaining pin
Out of specification → Replace the brake bolt
T.
R.
pads as a set. 22 Nm (2.2 m·kgf, 16 ft·lbf)

Rear brake caliper retaining pin
Front brake bolt
Brake pad lining thickness limit 22 Nm (2.2 m·kgf, 16 ft·lbf)
1.0 mm (0.04 in) Rear brake caliper guide pin bolt
Rear brake 22 Nm (2.2 m·kgf, 16 ft·lbf)
Brake pad lining thickness limit Front brake caliper bolt
1.0 mm (0.04 in) 48 Nm (4.8 m·kgf, 35 ft·lbf)
Rear brake caliper bolt
48 Nm (4.8 m·kgf, 35 ft·lbf)
4. Check:
• Brake fluid level
a specified brake fluid to the proper level.
5. Check:
• Brake pedal operation
Soft or spongy feeling → Bleed the brake sys-
2. Install:
tem.
• Brake pad springs
4-43
Refer to “BLEEDING THE HYDRAULIC Recommended brake component replacement

BRAKE SYSTEM” on page 3-27. schedule
EBS30093 Brake pads If necessary
DISASSEMBLING THE BRAKE CALIPERS
Piston seals, piston
The following procedure applies to all of the Every two years
dust seals
brake calipers.
Brake hoses Every four years
TIP
Every two years and
Before disassembling the brake caliper, drain Brake fluid whenever the brake is
the brake fluid from the entire brake system. disassembled
1. Remove: 1. Check:
• Brake caliper pistons “1” • Brake caliper pistons “1”
• Brake caliper piston dust seals “2” Rust/scratches/wear → Replace the brake
• Brake caliper piston seals “3” caliper pistons.
• Brake caliper cylinders “2”
Scratches/wear → Replace the brake caliper.
3 • Brake caliper body “3”
Cracks/damage → Replace the brake cali-
2
per.
• Brake fluid delivery passages
3 (brake caliper body)
2 Obstruction → Blow out with compressed air.
EWB03140
1
WARNING
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Whenever a brake caliper is disassembled,
a. Blow compressed air into the brake hose joint
replace the brake caliper piston dust seals
opening “a” to force out the pistons from the
and brake caliper piston seals.
brake caliper.
EWB02890
WARNING
• Cover the brake caliper piston with a rag. 2
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- 3
ton.
1 2
EBS30095
ASSEMBLING THE BRAKE CALIPERS

brake calipers.
EWB03150
WARNING
a • Before installation, all internal brake com-
ponents should be cleaned and lubricated
b. Remove the brake caliper piston dust seals with clean or new brake fluid.
and piston seals. • Never use solvents on internal brake com-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ponents as they will cause the brake caliper
EBS30094 piston dust seals and brake caliper piston
CHECKING THE BRAKE CALIPERS seals to swell and distort.
brake calipers.
4-44
• Whenever a brake caliper is disassembled,

B 2
replace the brake caliper piston dust seals
and brake caliper piston seals.
1
Specified brake and clutch fluid
DOT 4
a
EBS30096
INSTALLING THE BRAKE CALIPERS

The following procedure applies to all of the 3
brake calipers.
1. Install: C
• Front brake caliper guide pin bolt
2
(to the front brake caliper)
• Brake caliper “1”
(temporarily)
• Copper washers New
• Brake hose “2”
• Brake hose union bolt “3” 3
1
a
Front brake caliper guide pin bolt
22 Nm (2.2 m·kgf, 16 ft·lbf)
T.
D 2
R.
Front brake hose union bolt 1

27 Nm (2.7 m·kgf, 20 ft·lbf)
Rear brake hose union bolt
27 Nm (2.7 m·kgf, 20 ft·lbf) a
EWB02870
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation. 3
ECB03160
NOTICE A. Front brake (left)

B. Front brake (right)
When installing the brake hose onto the C. Rear brake (left)
brake caliper, fit the projection “a” on the D. Rear brake (right)
brake hose into the hole in the brake caliper.
2. Remove:
A 2 • Brake caliper
3. Install:
• Brake pad springs
• Brake pads
a • Brake caliper
Refer to “REPLACING THE BRAKE PADS”
1 on page 4-43.
4-45
7. Check:
Front brake caliper retaining pin • Brake pedal operation
T.
R.
bolt Soft or spongy feeling → Bleed the brake sys-
22 Nm (2.2 m·kgf, 16 ft·lbf) tem.
Rear brake caliper retaining pin
Refer to “BLEEDING THE HYDRAULIC
bolt
22 Nm (2.2 m·kgf, 16 ft·lbf) BRAKE SYSTEM” on page 3-27.
Rear brake caliper guide pin bolt EBS30097
22 Nm (2.2 m·kgf, 16 ft·lbf) CHECKING THE BRAKE MASTER
Front brake caliper bolt CYLINDER
48 Nm (4.8 m·kgf, 35 ft·lbf) 1. Check:
Rear brake caliper bolt • Brake master cylinder
48 Nm (4.8 m·kgf, 35 ft·lbf) Damage/scratches/wear → Replace.
• Brake fluid delivery passages
4. 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)
Specified brake and clutch fluid Cracks/damage → Replace the brake master
DOT 4 cylinder.
• Brake master cylinder reservoir diaphragm
EWB02880
• Brake master cylinder reservoir diaphragm
WARNING holder
• Use only the designated brake fluid. Other Cracks/damage → Replace.
brake fluids may cause the rubber seals to • Brake master cylinder reservoir hose
deteriorate, causing leakage and poor Cracks/damage/wear → Replace.
brake performance. 3. Check:
• Refill with the same type of brake fluid that • Brake pipes
is already in the system. Mixing brake fluids Cracks/damage → Replace.
may result in a harmful chemical reaction,
EBS30098
leading to poor brake performance.
CHECKING THE BRAKE PIPES
• When refilling, be careful that water does
not enter the brake master cylinder reser-
brake pipes.
voir. Water will significantly lower the boil-
1. Check:
ing point of the brake fluid and could cause
• Brake pipe end (flare nut)
vapor lock.
Damage → Replace the brake master cylin-
ECB01320
der, brake pipes, and related parts as a set.
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
5. Bleed:
• Brake system
6. Check:
Below the minimum level mark → Add the EBS30099
specified brake fluid to the proper level. INSTALLING THE BRAKE MASTER
Refer to “CHECKING THE BRAKE FLUID CYLINDER
LEVEL” on page 3-27. 1. Install:
• Brake master cylinder
• Brake pipes
4-46

Brake master cylinder bolt LEVEL” on page 3-27.
T.
R.
20 Nm (2.0 m·kgf, 14 ft·lbf) 6. Check:
Brake pipe flare nut • Brake pedal operation
19 Nm (1.9 m·kgf, 14 ft·lbf)
Soft or spongy feeling → Bleed the brake sys-
EWB03160 tem.
WARNING Refer to “BLEEDING THE HYDRAULIC
Proper brake pipe routing is essential to in- BRAKE SYSTEM” on page 3-27.
sure safe vehicle operation.
2. Install:
• Brake master cylinder reservoir hose
EWB04050
WARNING
Proper brake master cylinder reservoir hose
routing is essential to insure safe vehicle op-
eration.
3. Fill:
brake fluid)

DOT 4
EWB02880
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
ECB01320
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
4. Bleed:
• Brake system
5. Check:
specified brake fluid to the proper level.
4-47
PARKING BRAKE
EBS20027
PARKING BRAKE
Removing the parking brake pads
D
FW
7
5
3
5
2
8
9
2 17 Nm (1.7 m•kgf, 12 ft•Ibf) 4 1
T.R
.

T.R
.
T.R
.

Skid plate (rear) 4-1.
1 Parking brake cable 1 Disconnect.
2 Parking brake caliper bolt 2
3 Parking brake caliper 1
4 Spring 1
5 Parking brake pad bolt 2
6 Parking brake pad 2
8 Parking brake caliper arm nut 1
9 Parking brake caliper arm 1
4-48
PARKING BRAKE
Removing the parking brake caliper
D
FW
2
1
40 Nm (4.0 m•kgf, 29 ft•Ibf)

T.R
.

Skid plate (rear) 4-1.
2 Parking brake caliper bolt 2
3 Parking brake caliper 1
4-49
PARKING BRAKE
Disassembling the parking brake caliper
17 Nm (1.7 m•kgf, 12 ft•Ibf)

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

T.R
.
22 Nm (2.2 m•kgf, 16 ft•Ibf)

T.R
.

1 Spring 1
2 Parking brake pad bolt 2
3 Parking brake pad 2
5 Parking brake caliper arm nut 1
6 Parking brake caliper arm 1
8 Push rod 1
9 Parking brake caliper arm shaft 1 Left-hand threads
10 Parking brake caliper arm shaft retainer 1
12 Parking brake caliper guide pin 1
13 Parking brake caliper retaining pin 1
14 Parking brake cable holder 1
4-50
PARKING BRAKE
Removing the parking brake lever
1 D
FW
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

T.R
.
3
13 Nm (1.3 m•kgf, 9.4 ft•Ibf)
T.R
.
16 Nm (1.6 m•kgf, 12 ft•Ibf)
T.R
.

1 Parking brake switch coupler 1 Disconnect.
2 Parking brake switch 1
4 Parking brake lever 1
4-51
PARKING BRAKE
Removing the parking brake disc
17 Nm (1.7 m•kgf, 12 ft•Ibf)
T.R
.
(6)
(6)
D
FW

Refer to “REAR CONSTANT VELOCITY
SHAFT ASSEMBLIES, FINAL DRIVE AS-
Final drive assembly SEMBLY AND REAR DRIVE SHAFT” on
page 8-19.
1 Parking brake disc 1
4-52
PARKING BRAKE
EBS30100
REMOVING THE PARKING BRAKE CALIPER

1. Move the parking brake lever to the released
position, and then loosen the parking brake
cable adjuster so that the parking brake cable a
is slack.
EBS30101
CHECKING THE PARKING BRAKE CALIPER

1. Check:
• Brake caliper piston
Scratches/rust/wear → Replace. 2. Install:
• Brake caliper body • Brake pad spring
Cracks/damage → Replace the parking • Parking brake pads
brake caliper. • Parking brake pad bolts
EBS30102
CHECKING THE PARKING BRAKE DISC Parking brake pad bolt

17 Nm (1.7 m·kgf, 12 ft·lbf)
T.
1. Check:
R.
• Brake disc
TIP
Galling/damage → Replace.
2. Measure: Always install new brake pads and brake pad
• Brake disc deflection spring as a set.
• Brake disc thickness “a” 3. Adjust:
Out of specification → Replace. • Brake pad clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Brake disc deflection limit a. Fully turn in the parking brake caliper arm
0.10 mm (0.0039 in) shaft “1”.
Brake disc thickness limit
3.0 mm (0.12 in)
TIP 1
Measure the deflection 3.0 mm (0.12 in) below
the edge of the brake disc.
TIP
The parking brake arm shaft has left hand
threads. To turn in the shaft, turn it counterclock-
wise.
b. Install the parking brake caliper arm “2” onto
the parking brake caliper arm shaft, and then
EBS30103
REPLACING THE PARKING BRAKE PADS rotate the arm until it contacts the stopper “a”.
1. Measure: 2
• Brake pad wear limit “a”
Out of specification → Replace the brake a
pads and brake pad spring as a set.
Parking brake
Brake pad lining thickness limit
1.0 mm (0.04 in)
4-53
PARKING BRAKE
c. Install the parking brake caliper arm nut “3”,

and then temporarily tighten it.
b
a
3
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
d. Insert a suitable tool “4” with a thickness of • Parking brake lever free play
4.7 mm (0.19 in) between the brake pads “5”, Refer to “ADJUSTING THE PARKING
and then finger tighten the push rod “6”. BRAKE” on page 3-30.
5
4
5
e. Tighten the parking brake caliper arm nut.
Parking brake caliper arm nut

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

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30105
INSTALLING THE PARKING BRAKE LEVER

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

13 Nm (1.3 m·kgf, 9.4 ft·lbf)
T.
R.
2. Install:
• Parking brake switch “1”
Parking brake switch screw

1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
T.
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Release the parking brake lever.
b. Align the projection “a” on the parking brake
switch with the hole “b” in the parking brake
lever.
4-54
PEDAL ASSEMBLY
EBS20028
PEDAL ASSEMBLY
Removing the pedal assembly
FW 16 Nm (1.6 m•kgf, 12 ft•Ibf)

T.R
16 Nm (1.6 m•kgf, 12 ft•Ibf)
.
D
T.R
.
1 2
2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)
T.R
.
5
6
4

Clutch master cylinder Refer to “CLUTCH” on page 5-46.
Brake master cylinder
page 4-35.
1 Clutch switch coupler 1 Disconnect.
2 Brake light switch coupler 1 Disconnect.
3 Clutch switch 1
4 Brake light switch 1
5 Throttle cable 1 Disconnect.
6 Pedal assembly 1
7 Pedal assembly rubber cover 1
4-55
PEDAL ASSEMBLY
Disassembling the pedal assembly

4 3
13 1
2 New
3
LS
LS
12
12 40 Nm (4.0 m•kgf, 29 ft•Ibf)
T.R
.
8
10
New 11 LS
5
9
7 S
LS
New
17 Nm (1.7 m•kgf, 12 ft•Ibf)
T.R
.
13 6

1 Spring 1
2 Circlip 1
3 Washer 2
4 Accelerator pedal 1
5 Spring 1
6 Brake pedal 1
7 Collar 1
8 Pin 1
9 Brake pedal rod 1
10 Spring 1
11 Circlip 1
12 Washer 2
13 Pedal assembly bracket 1
4-56
PEDAL ASSEMBLY
EBS30106
INSTALLING THE PEDAL ASSEMBLY

1. Install:
• Throttle cable
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the nut “1” until it stops, and then install 2
the throttle cable to the plate.
b. Tighten the locknut “2” to specification. a
1
Throttle cable locknut (accelera-
tor pedal) b
T.
R.
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• Accelerator pedal free play
Refer to “ADJUSTING THE ACCELERATOR
PEDAL FREE PLAY” on page 3-31.
3. Adjust:
• Brake pedal free play
Refer to “ADJUSTING THE BRAKE PEDAL”
on page 3-29.
4. Adjust:
• Brake light operation timing
TIP
Adjustment is correct when the brake light
comes on by depressing the brake pedal less
than 5.0–10.0 mm (0.20–0.39 in).
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the main body “1” of the brake light
switch so that it does not rotate and turn the
adjusting nut “2” in direction “a” or “b” until the
brake light comes on at the proper time.
Direction “a”
Brake light comes on sooner.
Direction “b”
Brake light comes on later.
4-57
STEERING SYSTEM
EBS20029
STEERING SYSTEM
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
40 Nm (4.0 m•kgf, 29 ft•Ibf) 2
T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf)

T.R
.
3 1
(4)
21 Nm (2.1 m•kgf, 15 ft•Ibf)
T.R
.
33 Nm (3.3 m•kgf, 24 ft•Ibf)
T.R
.
LS
New 6 5
LS
New
(4) 4 7
8
* New
LS
55 Nm (5.5 m•kgf, 40 ft•Ibf) 6 33 Nm (3.3 m•kgf, 24 ft•Ibf)

T.R
T.R
.
.
50 Nm (5.0 m•kgf, 36 ft•Ibf) *
T.R
.
40 Nm (4.0 m•kgf, 29 ft•Ibf)

New
T.R
.
New
50 Nm (5.0 m•kgf, 36 ft•Ibf)
T.R
.
* Apply MOLYKOTE® EM-30L GREASE

Front fender/Upper cover page 4-21.
EPS unit cover/Meter assembly bracket page 4-23.
Front wheels page 4-29.
1 Reverse gear lock cable 1 Disconnect.
2 Reverse gear lock lever 1
3 Reverse gear lock lever bracket 1
4 EPS motor coupler 1 Disconnect.
5 EPS torque sensor coupler 1 Disconnect.
6 Steering joint bolt 2
7 EPS unit 1
8 Steering joint 1
4-58
STEERING SYSTEM
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
40 Nm (4.0 m•kgf, 29 ft•Ibf)
T.R
.
48 Nm (4.8 m•kgf, 35 ft•Ibf)

T.R
.
(4)
21 Nm (2.1 m•kgf, 15 ft•Ibf)
T.R
.
33 Nm (3.3 m•kgf, 24 ft•Ibf)
T.R
.
LS
New 14 LS
New
9
(4)
14
10 11 12
13
* New
LS

T.R
T.R
.
.
13
50 Nm (5.0 m•kgf, 36 ft•Ibf) *
T.R
.
40 Nm (4.0 m•kgf, 29 ft•Ibf)

New 12
T.R
.
New
50 Nm (5.0 m•kgf, 36 ft•Ibf)
T.R
11
.
10
* Apply MOLYKOTE® EM-30L GREASE

9 Steering assembly 1
10 Tie-rod end 2
11 Tie-rod end locknut 2
12 Dust boot 2
TIP
13 Tie-rod 2 Replace the tie-rod and lock washer as a
set.
TIP
14 Lock washer 2 Replace the tie-rod and lock washer as a
set.
4-59
STEERING SYSTEM
Removing the EPS unit bracket

LS
2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf) 6
T.R
.
LS
55 Nm (5.5 m•kgf, 40 ft•Ibf)

T.R
.
LS
5
4 1
LS
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

Instrument panel page 4-23.
TIP
Steering wheel position adjusting damper upper The steering wheel position adjusting damp-
1 1
bolt er upper bolt must be removed before re-
moving the instrument panel assembly.
Steering wheel position adjusting damper lower

2 1
bolt
3 Steering wheel position adjusting damper 1
4 EPS unit bracket 1
5 Rubber cover 1
6 Parking brake buzzer 1
4-60
STEERING SYSTEM
EBS30488
REMOVING THE TIE-ROD

1. Straighten the staked points “a” (4 locations)
of the lock washer “1”.
1
a
a
2. Check:
• Tie-rod end
Bends/damage → Replace.
Rubber boot damage → Replace the tie-rod
2. Loosen:
end.
• Tie-rod “1”
EBS30109
INSTALLING THE STEERING SYSTEM

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

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

tie-rod ends.
1. Check:
• Tie-rod end free play and movement 1
Rough movement → Replace the tie-rod end.
4-61
STEERING SYSTEM
3. Stake the lock washer “1” at the indentations TIP

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

21 Nm (2.1 m·kgf, 15 ft·lbf)
T.
R.
Steering joint bolt
33 Nm (3.3 m·kgf, 24 ft·lbf)
1 New TIP
• Align the alignment mark “a” on the steering
b assembly shaft and the slit “b” in the steering
joint with the alignment mark “c” on the steering
b. Crimp the portion “c” of the boot band with the assembly housing.
boots band installation tool “2”. • Fit the steering joint onto the EPS unit shaft so
that the bolt hole “d” in the joint is aligned with
Boots band installation tool the area “e” on the shaft that does not have
90890-01526 splines.
YM-01526 c
a
b 1
2
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• Steering assembly “1” 1
d
Steering assembly bolt
48 Nm (4.8 m·kgf, 35 ft·lbf) e
T.
R.
4-62
STEERING SYSTEM
7. Adjust:
• Toe-in
Refer to “ADJUSTING THE TOE-IN” on page
3-40.
• Reverse gear lock lever free play
Refer to “ADJUSTING THE REVERSE
GEAR LOCK LEVER FREE PLAY” on page
3-32.
EBS30426
LUBRICATING THE STEERING SHAFT

Lubricate the pivoting point and metal-to-metal
moving parts of the shaft.
4-63
STEERING KNUCKLES AND FRONT STABILIZER
EBS20138

Removing the steering knuckles and front stabilizer
60 Nm (6.0 m•kgf, 43 ft•Ibf)
T.R
.
60 Nm (6.0 m•kgf, 43 ft•Ibf)
T.R
.
LS 12 Nm (1.2 m•kgf, 8.7 ft•Ibf)
T.R
.
30 Nm (3.0 m•kgf, 22 ft•Ibf)
T.R
.
70 Nm (7.0 m•kgf, 51 ft•Ibf)
T.R
1
.
LS New
6
2
3 LS
2
4
3 New
New
7 New
New
60 Nm (6.0 m•kgf, 43 ft•Ibf)
T.R
.
LS
1 New 5
New
60 Nm (6.0 m•kgf, 43 ft•Ibf)
D
T.R
.
FW New
70 Nm (7.0 m•kgf, 51 ft•Ibf)
T.R
.

the steering knuckles.
Front wheel hub page 4-29.
Disconnect.
Tie-rod end Refer to “STEERING SYSTEM” on page
4-58.
1 Stabilizer joint 2
2 Stabilizer holder 2
3 Bushing 2
4 Front stabilizer 1
5 Brake disc guard 1
6 Steering knuckle 1
7 Circlip 1
4-64
Removing the steering knuckles and front stabilizer

60 Nm (6.0 m•kgf, 43 ft•Ibf)
T.R
.
60 Nm (6.0 m•kgf, 43 ft•Ibf)
T.R
.
LS 12 Nm (1.2 m•kgf, 8.7 ft•Ibf)
T.R
.
30 Nm (3.0 m•kgf, 22 ft•Ibf)
T.R
.
70 Nm (7.0 m•kgf, 51 ft•Ibf)
T.R
.
LS New
LS
10 New
11
9 New
New
10 New
60 Nm (6.0 m•kgf, 43 ft•Ibf)
T.R
.
LS 8 New
9 New
60 Nm (6.0 m•kgf, 43 ft•Ibf)
D
T.R
New
.
FW
70 Nm (7.0 m•kgf, 51 ft•Ibf)
T.R
.

8 Ball joint 1
9 Oil seal 2
10 Bearing 2
11 Spacer 1
4-65
EBS30110
e. Apply lithium-soap-based grease to the spac-
REMOVING THE STEERING KNUCKLES
er, new bearings and oil seals.
f. Install the spacer to the steering knuckle.
steering knuckles.
g. Install the new bearings.
1. Remove:
• Steering knuckle “1” TIP
TIP
Install the wheel side bearing first.
ECB01620
Use a general puller to separate the ball joints
NOTICE
“2” from the steering knuckle “1” or the front low-
er arm “3”. Do not strike the inner race or balls of the
bearing. Contact should be made only with
the outer race.
h. Install the new oil seals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30112
CHECKING THE STEERING KNUCKLE BALL

JOINTS
steering knuckle ball joints.
1. Check:
EBS30111
• Ball joint (steering knuckle)
CHECKING THE STEERING KNUCKLES Damage/pitting → Replace the ball joint.
AND FRONT WHEEL BEARINGS Rubber boot damage → Replace the ball
The following procedure applies to both of the joint.
steering knuckles and front wheel bearings. Rough movement → Replace the ball joint.
1. Check:
• Steering knuckle
2. Check:
• Front wheel bearings “1”
Rough movement/excessive free play → Re-
place.
• Oil seals “2”
Damage → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the surface of the steering knuckle. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b. Remove the oil seals. a. Clean the surface of the steering knuckle.
c. Drive out the bearings. b. Remove the circlip “1”.
EWB03030
WARNING
Eye protection is recommended when using
striking tools.
d. Remove the spacer “3”.
1
2 2
1
c. Remove the ball joint “2”.

TIP
Use a suitable socket “3” to separate the ball
3 joint “2” from the steering knuckle “4”.
4-66
8 10
7
4
9
3 6
12
2 8 11
d. Measure the ball joint bore inside diameter
“a”. 6 7 9 8 10 5 11
Out of specification → Replace the steering 12
knuckle.
Ball joint bore inside diameter

41.90–41.95 mm (1.650–1.652 in)
8 4
f. Hold the base plate “12” in place while turning
in the long bolt “6” to install the new ball joint
“5” into the steering knuckle “4”.
g. Remove the special tools.
h. Install a new circlip.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a
EBS30636
e. Attach the special tools and a new ball joint CHECKING THE FRONT STABILIZER
“5” to the steering knuckle “4”. 1. Check:
TIP
• Front stabilizer
Bends/cracks/damage → Replace.
• Always use a new ball joint.
• Do not tap or damage the top of the ball joint or EBS30637
rubber boot. INSTALLING THE FRONT STABILIZER

1. Install:
• Front stabilizer “1”
Ball joint installer
90890-01586 • Bushings “2”
YM-01586 • Stabilizer holders “3”
Front stabilizer holder bolt

No. Tool name Tool No. 30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.
6 Long bolt
7 Body TIP
8 Guide bolt Install the bushing with its slit “a” facing down-
ward.
9 Installer washer
90890-01586
Ball joint installer at- YM-01586
10
tachment 47.5 mm
Ball joint installer at-
11
tachment 42.5 mm
12 Base plate
4-67
2 3
1
4-68
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES
EBS20031

Removing the front arms and front shock absorber assemblies
65 Nm (6.5 m•kgf, 47 ft•Ibf)
T.R
.
D 3
FW 3
90 Nm (9.0 m•kgf, 65 ft•Ibf)
T.R
.
90 Nm (9.0 m•kgf, 65 ft•Ibf)
T.R
.
6 6
4
6
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
LS
New 5
2
LS LS
New LS
LS
New 3
LS New
New
LS
LS 2 65 Nm (6.5 m•kgf, 47 ft•Ibf)

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

T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 1

T.R
.

the front upper arms, front lower arms, and
front shock absorber assemblies.
Stabilizer joint/Steering knuckle FRONT STABILIZER” on page 4-64.
1 Front constant velocity shaft dust boot guard 1
2 Front brake hose holder 2
3 Nut/Bolt (front shock absorber assembly) 2/2
4 Front shock absorber assembly cover 1
5 Front shock absorber assembly 1
6 Nut/Bolt (front upper arm) 2/2
4-69
Removing the front arms and front shock absorber assemblies

65 Nm (6.5 m•kgf, 47 ft•Ibf)
T.R
.
D
FW
90 Nm (9.0 m•kgf, 65 ft•Ibf)
T.R
.
90 Nm (9.0 m•kgf, 65 ft•Ibf)
T.R
.
11
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
LS
11 10 New 9 8
11 8
LS LS
10
10 8
8 9 13 15 7
New LS
LS 13 15 14 16
New 13
LS New
14 15
13 New 17
LS
LS 12
65 Nm (6.5 m•kgf, 47 ft•Ibf)
T.R
.

T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

7 Front upper arm 1
8 Dust cover 4
9 Spacer 2
10 Bushing 4
11 Nut/Bolt (front lower arm) 2/2
12 Front lower arm 1
13 Dust cover 4
14 Spacer 2
15 Bushing 4
16 Circlip 1
17 Ball joint 1
4-70
EBS30113
damage or personal injury that may result
CHECKING THE FRONT ARMS
from improper handling of the front shock
absorber and gas cylinder.
front upper arms and front lower arms.
• Do not tamper or attempt to open the front
1. Check:
shock absorber or gas cylinder.
• Front arm free play
• Do not subject the front shock absorber or
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the front arm side play “A” by moving gas cylinder to an open flame or any other
it from side to side. source of high heat. High heat can cause an
If side play is noticeable, check the bushings. explosion due to excessive gas pressure.
• Do not deform or damage the front shock
absorber or gas cylinder in any way. If the
front shock absorber, gas cylinder or both
are damaged, damping performance will
suffer.
A
EBS30115
DISPOSING OF A FRONT SHOCK

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

3. Check: ASSEMBLIES
• Bushings The following procedure applies to both of the
Wear/damage → Replace. front shock absorber assemblies.
EBS30114 1. Check:
HANDLING THE FRONT SHOCK ABSORBER • Front shock absorber assembly
ASSEMBLIES Gas leaks → Replace the front shock absorb-
EWB03170
er assembly.
WARNING
• Front shock absorber rod
Shock absorbers and gas cylinders contain Bends/damage → Replace the front shock
highly compressed nitrogen gas. Before absorber assembly.
handling the front shock absorber or gas cyl- • Spring
inder, read and make sure you understand Move the spring up and down.
the following information. The manufacturer Fatigue → Replace the front shock absorber
cannot be held responsible for property assembly.
4-71
EBS30117
• Do not tap or damage the top of the ball joint or
CHECKING THE FRONT ARM BALL JOINTS
rubber boot.
front arm ball joints.
1. Check: Ball joint installer
• Ball joint (front upper arm) 90890-01586
YM-01586
Damage/pitting → Replace the ball joint.
Rubber boot damage → Replace the ball
No. Tool name Tool No.
joint.
Rough movement → Replace the ball joint. 6 Long bolt
7 Body
8 Guide bolt
9 Installer washer
90890-01586
Ball joint installer at- YM-01586
10
tachment 47.5 mm
Ball joint installer at-
11
tachment 42.5 mm
12 Base plate
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the surface of the front upper arm. 8 10
b. Remove the circlip “1”. 7
9
6
1 12
8 11
c. Remove the ball joint “2”. 7

8
TIP
9
10
joint “2” from the front upper arm “4”.
4
8 5
12 11
3
e. Hold the base plate “12” in place while turning
in the long bolt “6” to install the new ball joint
4 “5” into the front upper arm “4”.
f. Remove the special tools.
g. Install a new circlip.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2
EBS30118
INSTALLING THE FRONT ARMS AND

d. Attach the special tools and a new ball joint FRONT SHOCK ABSORBER ASSEMBLIES
“5” to the front upper arm “4”. The following procedure applies to both of the
TIP front upper arms, front lower arms, and front
• Always use a new ball joint. shock absorber assemblies.
1. Install:
• Front upper arm
4-72
• Front lower arm

7,8
• Front shock absorber assembly
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the front upper arm “1” and front lower
arm “2”.
6
TIP
• Be sure to position the front upper and lower
arm bolts “3” and “4” so that the bolt heads face 7,8
away from the arms.
• Temporarily tighten the front upper and lower 1
arm nuts “5”.
b. Install the front shock absorber assembly “6”, 9
bolts “7”, and nuts “8”.
Front shock absorber assembly

nut
T.
R.
65 Nm (6.5 m·kgf, 47 ft·lbf) 3,4,5

2
TIP
• Install the front shock absorber assembly so
that the gas cylinder is facing outward.
• Be sure to position the front shock absorber ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
bolts “7” so that the bolt heads face forward.

c. Install the steering knuckle “9”.
FRONT STABILIZER” on page 4-64.
Steering knuckle nut (upper side)

70 Nm (7.0 m·kgf, 51 ft·lbf)
T.
R.
Steering knuckle nut (lower side)

70 Nm (7.0 m·kgf, 51 ft·lbf)
d. Tighten the front upper and lower arm bolts

“3” to specification.
Front upper arm bolt

90 Nm (9.0 m·kgf, 65 ft·lbf)
T.
R.
Front lower arm bolt

90 Nm (9.0 m·kgf, 65 ft·lbf)
4-73
REAR KNUCKLES
EBS20127
REAR KNUCKLES
Removing the rear knuckles
FW
D
New 7 3
New 8 3
5
LS
LS
3
12 Nm (1.2 m•kgf, 8.7 ft•Ibf) 7 New 7 New
6
T.R
.
12 Nm (1.2 m•kgf, 8.7 ft•Ibf) 5

T.R
.
5 LS
LS LS
1
9 4
7 New
10 New 6
11 New 5
2 8 New LS
LS
85 Nm (8.5 m•kgf, 61 ft•Ibf)
T.R
.

the rear knuckles.
Rear wheel hub page 4-29.
1 Rear brake disc cleaning plate 1
2 Brake disc guard 1
3 Nut/Bolt (rear knuckle) 2/2
4 Rear knuckle 1
5 Dust cover 4
6 Spacer 2
7 Bushing 4
8 Oil seal 2
9 Spacer 1
10 Circlip 1
11 Bearing 1
4-74
REAR KNUCKLES
EBS30119
CHECKING THE REAR KNUCKLES AND

REAR WHEEL BEARINGS
rear knuckles and rear wheel bearings.
1. Check:
• Rear knuckle
2. Check:
• Rear wheel bearing “1”
Rough movement/excessive free play → Re-
place.
• Spacer “3”
Damage → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the surface of the rear knuckle.
b. Remove the oil seals.
c. Remove the spacer and circlip “4”.
d. Drive out the bearing.
EWB03030
WARNING
Eye protection is recommended when using
striking tools.
4 1
3
2 2
e. Apply lithium-soap-based grease to the new

bearing and oil seals.
f. Install the new bearing.
ECB01620
NOTICE
Do not strike the inner race or balls of the
bearing. Contact should be made only with
the outer race.
g. Install the new circlip “4” and spacer.
h. Install the new oil seals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-75
REAR STABILIZER, REAR ARMS, AND REAR SHOCK ABSORB-
ER ASSEMBLIES
EBS20139
REAR STABILIZER, REAR ARMS, AND REAR SHOCK ABSORBER

ASSEMBLIES
Removing the rear stabilizer, rear arms, and rear shock absorber assemblies
120 Nm (12 m•kgf, 87 ft•lbf)
T.R
.
FW 100 Nm (10 m•kgf, 72 ft•lbf)
90 Nm (9.0 m•kgf, 65 ft•Ibf)
D
T.R
.
T.R
.
120 Nm (12 m•kgf, 87 ft•lbf)
65 Nm (6.5 m•kgf, 47 ft•Ibf)
T.R
.
T.R
.
82 Nm (8.2 m•kgf, 59 ft•Ibf)
T.R
.
6
2 4 1
3 6
2
3
LS
100 Nm (10 m•kgf, 72 ft•lbf) 5
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

New
T.R
.
1
5
LS 5
7
LS
New
New New
LS LS
6
100 Nm (10 m•kgf, 72 ft•lbf)
T.R
.
New New
82 Nm (8.2 m•kgf, 59 ft•Ibf)
T.R
.

the rear upper arms, rear lower arms, and
rear shock absorber assemblies.
Skid plate (center) 4-1.
Nuts/Bolts (rear knuckle) Refer to “REAR KNUCKLES” on page 4-74.
1 Stabilizer joint 2
2 Stabilizer holder 2
3 Bushing 2
4 Rear stabilizer 1
5 Rear brake hose holder 3
6 Nut/Bolt (rear shock absorber) 2/2
7 Rear shock absorber assembly 1
4-76
ER ASSEMBLIES
Removing the rear stabilizer, rear arms, and rear shock absorber assemblies
120 Nm (12 m•kgf, 87 ft•lbf)
T.R
.
FW 100 Nm (10 m•kgf, 72 ft•lbf)
90 Nm (9.0 m•kgf, 65 ft•Ibf)
D
T.R
.
T.R
.
120 Nm (12 m•kgf, 87 ft•lbf)
65 Nm (6.5 m•kgf, 47 ft•Ibf)
T.R
.
T.R
.
82 Nm (8.2 m•kgf, 59 ft•Ibf)
T.R
.
13
8
13
LS
100 Nm (10 m•kgf, 72 ft•lbf)
T.R
.
12 New 8
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 10 9
T.R
.
13 13
12
11
LS 10
16
15
15
LS
New
17 New New
LS 18
LS
100 Nm (10 m•kgf, 72 ft•lbf)

T.R
.
14 19 New New
82 Nm (8.2 m•kgf, 59 ft•Ibf)
T.R
.
8 Nut/Bolt (rear upper arm–frame) 1/1

9 Rear upper arm 1
10 Dust cover 2
11 Spacer 1
12 Bushing 2
13 Nut/Bolt (rear lower arm–frame) 2/2
14 Rear lower arm 1
15 Collar 2
16 Dust boot 1
17 Ball joint 1
18 Dust boot 1
19 Ball joint 1
4-77
ER ASSEMBLIES
EBS30122
property damage or personal injury that may
CHECKING THE REAR ARMS
result from improper handling of the rear
shock absorber and gas cylinder.
rear upper arms and rear lower arms.
• Do not tamper or attempt to open the rear
1. Check:
shock absorber or gas cylinder.
• Rear arm free play
• Do not subject the rear shock absorber or
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the rear arm side play “A” by moving it gas cylinder to an open flame or any other
from side to side. source of high heat. High heat can cause an
If side play is noticeable, check the bushings. explosion due to excessive gas pressure.
• Do not deform or damage the rear shock
absorber or gas cylinder in any way. If the
rear shock absorber, gas cylinder or both
are damaged, damping performance will
A suffer.
EBS30124
DISPOSING OF A REAR SHOCK ABSORBER

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

3. Check: ASSEMBLIES
• Bushings The following procedure applies to both of the
Wear/damage → Replace. rear shock absorber assemblies.
EBS30123 1. Check:
HANDLING THE REAR SHOCK ABSORBER • Rear shock absorber assembly
ASSEMBLIES Gas leaks → Replace the rear shock absorb-
EWB03190
er assembly.
WARNING
• Rear shock absorber rod
This rear shock absorber and gas cylinder Bends/damage → Replace the rear shock
contain highly compressed nitrogen gas. Be- absorber assembly.
fore handling the rear shock absorber or gas • Spring
cylinder, read and make sure you under- Move the spring up and down.
stand the following information. The manu- Fatigue → Replace the rear shock absorber
facturer cannot be held responsible for assembly.
4-78
ER ASSEMBLIES
EBS30635
f. Install new circlips “5” into the groove of the
CHECKING THE REAR LOWER ARM BALL
rear lower arm.
JOINTS
The following procedure applies to both of the 5 New
rear lower arm ball joints.
1. Check:
• Dust boots 5 New
Damage → Replace the dust boots.
• Ball joints (rear lower arm)
Damage/pitting → Replace the ball joint.
Rough movement → Replace the ball joint.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30126
INSTALLING THE REAR ARMS AND REAR

SHOCK ABSORBER ASSEMBLIES
rear upper arms, rear lower arms, and rear
shock absorber assemblies.
1. Install:
• Rear upper arm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the surface of the rear lower arm. • Rear lower arm
b. Remove the dust boots. • Rear shock absorber assembly
c. Remove the circlips “1”. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the rear upper arm “1” and rear lower
1 arm “2”.
TIP
• Be sure to position the rear lower arm bolt “3”
1 so that the bolt head face outward.
• Be sure to position the rear upper arm bolt “4”
and rear lower arm bolt “5” so that the bolt
heads face rearward.
• Temporarily tighten the rear upper and lower
arm nuts “6”.
d. Remove the ball joints “2”. b. Install the rear shock absorber assembly “7”,
TIP bolts “8”, and nuts “9”.
joints “2” from the rear lower arm “4”. Rear shock absorber assembly
bolt
T.
R.
82 Nm (8.2 m·kgf, 59 ft·lbf)

3
TIP
4
• Install the rear shock absorber assembly so
2
3 that the gas cylinder is facing forward.
• Be sure to position the rear shock absorber
4 bolts “8” so that the bolt heads face rearward.
2 c. Install the rear knuckle bolts “10”, and nuts
“11”.
e. Press the new ball joints into their respective Refer to “REAR KNUCKLES” on page 4-74.
locations in the rear lower arm using a suit-
Rear knuckle bolt
able socket.
85 Nm (8.5 m·kgf, 61 ft·lbf)
T.
R.
4-79
ER ASSEMBLIES
d. Tighten the rear upper arm bolt “4” to specifi-
cation. 3 a
2
Rear upper arm bolt
90 Nm (9.0 m·kgf, 65 ft·lbf) 1
T.
R.
e. Tighten the rear lower arm bolts “3” and “5” to

specification.
Rear lower arm bolt

120 Nm (12 m·kgf, 87 ft·lbf)
T.
R.
9
8
7
6
4
11
6 1
10
5
3,6 2 8
11 9 10
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30638
CHECKING THE REAR STABILIZER

1. Check:
• Rear stabilizer
Bends/cracks/damage → Replace.
EBS30639
INSTALLING THE REAR STABILIZER

1. Install:
• Rear stabilizer “1”
• Bushings “2”
• Stabilizer holders “3”
Rear stabilizer holder bolt

65 Nm (6.5 m·kgf, 47 ft·lbf)
T.
R.
TIP
Install the bushing with its slit “a” facing rear-
ward.
4-80
ER ASSEMBLIES
4-81
ENGINE
ENGINE INSPECTION .................................................................................... 5-1

MEASURING THE COMPRESSION PRESSURE....................................5-1
ENGINE REMOVAL (1) ................................................................................... 5-2

INSTALLING THE EXHAUST PIPE AND MUFFLER................................5-3
ENGINE REMOVAL (2) ................................................................................... 5-4

CHECKING THE OIL TANK OUTLET PIPE 1 (OIL STRAINER) ..............5-5
ENGINE REMOVAL (3) ................................................................................... 5-6

INSTALLING THE ENGINE....................................................................... 5-9
CAMSHAFTS.................................................................................................5-10
REMOVING THE CAMSHAFTS..............................................................5-12
CHECKING THE CAMSHAFTS ..............................................................5-13
CHECKING THE CAMSHAFT SPROCKETS .........................................5-14
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-14
INSTALLING THE CAMSHAFTS ............................................................ 5-15
CYLINDER HEAD.......................................................................................... 5-19

REMOVING THE CYLINDER HEAD.......................................................5-20
CHECKING THE CYLINDER HEAD .......................................................5-20
5
INSTALLING THE CYLINDER HEAD .....................................................5-20
VALVES AND VALVE SPRINGS.................................................................. 5-22

REMOVING THE VALVES...................................................................... 5-23
CHECKING THE VALVES AND VALVE GUIDES ..................................5-23
CHECKING THE VALVE SEATS ............................................................ 5-25
CHECKING THE VALVE SPRINGS........................................................ 5-26
CHECKING THE VALVE LIFTERS ......................................................... 5-27
INSTALLING THE VALVES .................................................................... 5-27
AC MAGNETO AND STARTER CLUTCH ....................................................5-29

REMOVING THE AC MAGNETO ROTOR.............................................. 5-31
REMOVING THE STARTER CLUTCH ...................................................5-31
CHECKING THE STARTER CLUTCH ....................................................5-31
INSTALLING THE STARTER CLUTCH .................................................. 5-32
INSTALLING THE AC MAGNETO ROTOR ............................................5-32
ELECTRIC STARTER ...................................................................................5-34

CHECKING THE STARTER MOTOR .....................................................5-36
ASSEMBLING THE STARTER MOTOR................................................. 5-36
OIL PAN AND OIL PUMP ............................................................................. 5-38
REMOVING THE OIL PAN AND OIL PUMP DRIVEN SPROCKET ....... 5-41
CHECKING THE OIL PUMP DRIVEN SPROCKET................................5-41
CHECKING THE OIL PUMP (CRANKCASE) .........................................5-41
CHECKING THE OIL STRAINER ........................................................... 5-41
CHECKING THE RELIEF VALVE ........................................................... 5-42
CHECKING THE CHECK BALL ..............................................................5-42
ASSEMBLING THE OIL PUMP (CRANKCASE) ..................................... 5-42
INSTALLING THE OIL PUMP .................................................................5-42
SHIFT LEVER................................................................................................5-44
INSTALLING THE SHIFT ARM ...............................................................5-45
ADJUSTING THE SHIFT LEVER ROD...................................................5-45
INSTALLING THE REVERSE GEAR LOCK ARM ..................................5-45
CLUTCH ........................................................................................................5-46
REMOVING THE CLUTCH ..................................................................... 5-54
CHECKING THE FRICTION PLATES.....................................................5-55
CHECKING THE CLUTCH PLATES .......................................................5-55
CHECKING THE CLUTCH SPRING PLATE...........................................5-55
CHECKING THE CLUTCH HOUSINGS.................................................. 5-56
CHECKING THE CLUTCH BOSS........................................................... 5-56
CHECKING THE PRESSURE PLATE ....................................................5-56
CHECKING THE CLUTCH PUSH RODS ............................................... 5-56
CHECKING THE PRIMARY DRIVEN GEAR ..........................................5-56
INSTALLING THE CLUTCH.................................................................... 5-57
DISASSEMBLING THE CLUTCH MASTER CYLINDER ........................ 5-58
CHECKING THE CLUTCH MASTER CYLINDER................................... 5-59
ASSEMBLING THE CLUTCH MASTER CYLINDER ..............................5-59
INSTALLING THE CLUTCH MASTER CYLINDER.................................5-59
REMOVING THE CLUTCH RELEASE CYLINDER ................................5-60
CHECKING THE CLUTCH RELEASE CYLINDER .................................5-60
ASSEMBLING THE CLUTCH RELEASE CYLINDER............................. 5-60
INSTALLING THE CLUTCH RELEASE CYLINDER ...............................5-61
SHIFT SHAFT................................................................................................5-63
CHECKING THE SHIFT SHAFT ............................................................. 5-64
CHECKING THE STOPPER LEVER ......................................................5-64
INSTALLING THE SHIFT SHAFT ........................................................... 5-64
CRANKCASE ................................................................................................5-65
DISASSEMBLING THE UNIVERSAL JOINT (ENGINE SIDE)................ 5-68
REMOVING THE PRIMARY DRIVE SHAFT ASSEMBLY ......................5-68
SEPARATING THE CRANKCASE.......................................................... 5-68
CHECKING THE TIMING CHAIN, OIL PUMP DRIVE CHAIN,
AND TIMING CHAIN GUIDES ...............................................................5-69
CHECKING THE CRANKCASE ..............................................................5-69
ASSEMBLING THE CRANKCASE.......................................................... 5-69
INSTALLING THE PRIMARY DRIVE SHAFT ASSEMBLY.....................5-71
CONNECTING RODS AND PISTONS .......................................................... 5-72
REMOVING THE CONNECTING RODS AND PISTONS.......................5-73
CHECKING THE CYLINDER AND PISTON ...........................................5-73
CHECKING THE PISTON RINGS........................................................... 5-74
CHECKING THE PISTON PIN ................................................................5-75
CHECKING THE CONNECTING RODS................................................. 5-75
INSTALLING THE CONNECTING RODS AND PISTONS .....................5-77
CRANKSHAFT AND BALANCER SHAFT ...................................................5-80

REMOVING THE CRANKSHAFT AND BALANCER SHAFT.................. 5-82
CHECKING THE CRANKSHAFT ............................................................ 5-82
CHECKING THE BALANCER SHAFT ....................................................5-84
INSTALLING THE BALANCER SHAFT .................................................. 5-84
INSTALLING THE CRANKSHAFT .......................................................... 5-85
TRANSMISSION (1) ......................................................................................5-87

INSTALLING THE TRANSMISSION CASE ............................................5-90
TRANSMISSION (2) ......................................................................................5-91

DISASSEMBLING THE UNIVERSAL JOINT
(PRIMARY DRIVEN GEAR SIDE).......................................................... 5-94
REMOVING THE PRIMARY DRIVEN SHAFT YOKE ............................. 5-94
REMOVING THE REAR DRIVE SHAFT COUPLING GEAR
(MIDDLE DRIVEN GEAR SIDE) ............................................................ 5-94
SEPARATING THE TRANSMISSION CASE ..........................................5-94
CHECKING THE TRANSMISSION OIL STRAINER ...............................5-95
CHECKING THE BEARINGS.................................................................. 5-95
CHECKING THE TRANSMISSION CASE .............................................. 5-95
ASSEMBLING THE TRANSMISSION CASE..........................................5-95
INSTALLING THE GEAR POSITION SENSOR...................................... 5-96
INSTALLING THE REAR DRIVE SHAFT COUPLING GEAR
(MIDDLE DRIVEN GEAR SIDE) ............................................................ 5-97
INSTALLING THE PRIMARY DRIVEN SHAFT YOKE............................ 5-97
ASSEMBLING THE UNIVERSAL JOINT
(PRIMARY DRIVEN GEAR SIDE).......................................................... 5-98
TRANSMISSION (3) ......................................................................................5-99

DISASSEMBLING THE PRIMARY DRIVEN SHAFT ............................5-102
CHECKING THE OIL PUMP (TRANSMISSION CASE)........................5-102
CHECKING THE PRIMARY DRIVEN SHAFT ASSEMBLY ..................5-102
ASSEMBLING THE OIL PUMP (TRANSMISSION CASE) ...................5-102
ASSEMBLING THE PRIMARY DRIVEN SHAFT ASSEMBLY..............5-103
TRANSMISSION (4) ....................................................................................5-104

CHECKING THE SHIFT FORKS...........................................................5-108
CHECKING THE SHIFT DRUM ............................................................5-108
CHECKING THE TRANSMISSION .......................................................5-108
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ............................5-109
INSTALLING THE SHIFT FORKS AND SHIFT DRUM.........................5-110
MIDDLE GEAR ............................................................................................5-111
(MIDDLE DRIVEN GEAR SIDE) ..........................................................5-115
REMOVING THE FRONT DRIVE SHAFT YOKE
DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY...........5-115
CHECKING THE TORQUE LIMITER....................................................5-115
ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY.................5-115
ASSEMBLING THE TORQUE LIMITER HOUSING..............................5-116
INSTALLING THE FRONT DRIVE SHAFT YOKE
ENGINE INSPECTION
EBS20105
ENGINE INSPECTION Standard compression pressure

(at sea level)
EBS30135
1500–1800 kPa (15.0–18.0
MEASURING THE COMPRESSION kgf/cm², 213.3–256.0 psi)
PRESSURE
The following procedure applies to all of the cyl- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
inders. a. With the throttle wide open, crank the engine
TIP by turning the main switch to “ ” (start) until
Insufficient compression pressure will result in a the reading on the compression gauge stabi-
loss of performance. lizes.
EWB04090
1. Measure: WARNING
• Valve clearance To prevent sparking, ground all spark plug
Out of specification → Adjust. leads before cranking the engine.
Refer to “ADJUSTING THE VALVE CLEAR-
b. If the compression pressure is above the
ANCE” on page 3-4.
maximum specification, check the cylinder
2. Start the engine, warm it up for several min-
head, valve surfaces and piston crown for
utes, and then turn it off.
carbon deposits.
3. Disconnect:
Carbon deposits → Eliminate.
• Ignition coil couplers
c. If the compression pressure is below the min-
4. Remove:
imum specification, pour a teaspoonful of en-
• Ignition coils
gine oil into the spark plug bore and measure
• Spark plugs
ECB03280
again.
NOTICE Refer to the following table.
Before removing the spark plugs, blow away Compression pressure (with oil applied into the
any dirt accumulated in the spark plug wells cylinder)
with compressed air to prevent it from falling Reading Diagnosis
into the cylinders. Piston ring(s) wear or
Higher than without oil
damage → Repair.
5. Install:
• Extension “1” Piston, valves, cylinder
head gasket, or piston
• Compression gauge “2” Same as without oil
ring(s) possibly defec-
tive → Repair.
Extension
90890-04136 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Compression gauge
90890-03081 7. Install:
Engine compression tester • Spark plugs
YU-33223 • Ignition coils
Spark plug
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
T.
21
R.
2
TIP
Before installing the spark plugs, clean the spark
plugs and gasket surfaces.
8. Connect:
• Ignition coil couplers
6. Measure:
• Compression pressure
Out of specification → Refer to steps (b) and
(c).
5-1
ENGINE REMOVAL (1)
EBS20034
ENGINE REMOVAL (1)

Removing the muffler and exhaust pipe
FW 90 Nm (9.0 m•kgf, 65 ft•Ibf)
T.R
.
D
New 2 20 Nm (2.0 m•kgf, 14 ft•Ibf)
T.R
.
90 Nm (9.0 m•kgf, 65 ft•Ibf)
T.R
.
LS
2 New
(6) 5
LS
4 New
3
55 Nm (5.5 m•kgf, 40 ft•Ibf)
6
T.R
.

T.R
.
T.R
.

1 Exhaust pipe 1
2 Gasket 3
3 Exhaust pipe joint clamp 1
4 Gasket 1
5 Muffler 1
6 Muffler bracket 1
5-2
ENGINE REMOVAL (1)
EBS30127
INSTALLING THE EXHAUST PIPE AND TIP

MUFFLER • Fit the projection “a” on the exhaust pipe joint
1. Install: clamp into the slit “b” in the muffler.
• Muffler bracket “1” • Temporarily tighten the exhaust pipe nuts and
• Muffler exhaust joint clamp bolt.
TIP
• Fit the projections “a” on the muffler bracket Installed depth of exhaust pipe
into the holes “b” in the frame. “c”
1.0–3.0 mm (0.04–0.12 in)
• Temporarily tighten the muffler bracket bolts
and muffler bolts.
1 1
b
c
a
a 3
a
b
4. Tighten:
2. Install: • Exhaust pipe nuts “1”
• Muffler bracket bolts “2”
• Gasket “1” New
• Muffler bolts “3”
(to muffler)
ECB01640 • Exhaust pipe joint clamp bolt “4”
NOTICE
Exhaust pipe nut
Be careful not to damage the muffler contact 20 Nm (2.0 m·kgf, 14 ft·lbf)
T.
surface of the gasket.

R.
Muffler bracket bolt

TIP 55 Nm (5.5 m·kgf, 40 ft·lbf)
Muffler bolt
Install the gasket with the chamfer “a”, located 90 Nm (9.0 m·kgf, 65 ft·lbf)
on an inner rim of the gasket, and the chamfer Exhaust pipe joint clamp bolt
“b”, located on an outer rim of the gasket, as 20 Nm (2.0 m·kgf, 14 ft·lbf)
shown.
3
Installed depth “c” 1
2.5–3.5 mm (0.10–0.14 in) 4
(6)
1 New b
c 2
3
a
3. Install:
• Exhaust joint clamp “1”
(to muffler “2”)
• Exhaust pipe “3”
5-3
ENGINE REMOVAL (2)
EBS20093
ENGINE REMOVAL (2)

Removing the engine oil tank
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
14
New
LS
11 8
New 13
10 9
2
New
3
4
New
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
12
LS

T.R
.
7 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
6 16 Nm (1.6 m•kgf, 12 ft•Ibf)

10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 5
T.R
.
T.R
.

Cargo bed compartment panel/Oil tank cover 4-10.
1 Oil tank breather hose 1 Disconnect.
2 Oil pipe guide 2 1
3 Oil pipe guide 1 1
4 Oil tank outlet hose 1 1
5 Oil tank outlet pipe 2 1
6 Oil tank outlet hose 2 1
8 Oil tank inlet hose 2 1
9 Oil tank inlet pipe 2 1
10 Oil tank inlet hose 1 1
11 Oil tank inlet pipe 1 1
13 Engine oil tank 1
14 Dipstick (engine oil tank) 1
5-4
ENGINE REMOVAL (2)
EBS30647
CHECKING THE OIL TANK OUTLET PIPE 1

(OIL STRAINER)
1. Check:
• Oil strainer “a”
Damage → Replace the oil tank outlet pipe 1
“1”.
Contaminants → Clean with solvent.
5-5
ENGINE REMOVAL (3)
EBS20120
ENGINE REMOVAL (3)

Disconnecting the cable, hoses, couplers, and leads
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-12.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-18.
Exhaust pipe/Muffler 5-2.
Oil tank 5-4.
Refer to “TRANSMISSION (1)” on page
Flywheel housing 5-87.
Oil cooler Refer to “OIL COOLER” on page 6-1.
Water jacket joint Refer to “THERMOSTAT” on page 6-6.
5-6
ENGINE REMOVAL (3)
Disconnecting the cable, hoses, couplers, and leads

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

T.R
.

Oil separator ARATOR” on page 7-6.
Refer to “THROTTLE BODIES” on page
Throttle bodies 7-11.
Refer to “AIR INDUCTION SYSTEM” on
Air cut-off valve page 7-17.
1 Starter motor lead 1 Disconnect.
2 Oil level switch coupler 1 Disconnect.
3 Engine ground lead 1 Disconnect.
4 Water pump inlet hose 1 Disconnect.
5 Ignition coil coupler 3 Disconnect.
6 Crankshaft position sensor coupler 1 Disconnect.
7 AC magneto lead coupler 2 Disconnect.
5-7
ENGINE REMOVAL (3)
Removing the engine
D
FW
60 Nm (6.0 m•kgf, 43 ft•Ibf) 6
T.R
25 Nm (2.5 m•kgf, 18 ft•Ibf)

.
T.R
.
5
5
5
5
4
3
3
55 Nm (5.5 m•kgf, 40 ft•Ibf)
T.R
.
25 Nm (2.5 m•kgf, 18 ft•Ibf)

T.R
.

1 Engine mounting bolt (rear upper) 2
2 Engine mounting bolt (rear lower) 2
3 Engine bracket bolt 2
4 Engine bracket 1
5 Engine mounting nut/bolt (front) 2/2
TIP
6 Engine 1 Remove the engine from the right side of the
vehicle.
5-8
ENGINE REMOVAL (3)
EBS30351
INSTALLING THE ENGINE

1. Install:
• Engine “1”
• Engine mounting nuts/bolts (front) “2”
• Engine bracket “3”
• Engine bracket bolts “4”
• Engine mounting bolts (rear lower) “5”
• Engine mounting bolts (rear upper) “6”
ECB01630
NOTICE
Make sure that the engine does not strike the
brake pipe when installing it.
TIP
Do not fully tighten the bolts and nuts.
2. Tighten:
• Engine bracket bolts “4”
• Engine mounting bolts (rear lower) “5”
• Engine mounting bolts (rear upper) “6”
• Engine mounting nuts “2”
Engine bracket bolt

55 Nm (5.5 m·kgf, 40 ft·lbf)
T.
R.
Engine mounting bolt (rear lower)

25 Nm (2.5 m·kgf, 18 ft·lbf)
Engine mounting bolt (rear up-
per)
25 Nm (2.5 m·kgf, 18 ft·lbf)
Engine mounting nut
60 Nm (6.0 m·kgf, 43 ft·lbf)
2 2
1
2
5
3
5-9
CAMSHAFTS
EBS20106
CAMSHAFTS
Removing the cylinder head cover
FW 8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
T.R
.
D
3
4 13 Nm (1.3 m•kgf, 9.4 ft•Ibf)
T.R
4 3
.
4
New
LS 2
1
5
12 Nm (1.2 m•kgf, 8.7 ft•Ibf)
T.R
.
New 6

Refer to “AIR INDUCTION SYSTEM” on
Reed valve assemblies page 7-17.
Cylinder head breather hose (hose joint to cylin-
1 1 Disconnect.
der head cover)
2 Ignition coil coupler 3 Disconnect.
3 Ignition coil 3
4 Spark plug 3
5 Cylinder head cover 1
6 Cylinder head cover gasket 1
7 Timing chain guide (upper side) 1
5-10
CAMSHAFTS
Removing the camshafts
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)

FW
T.R
.
D
LS
E
(4)
(4) 6 7
(8)
M
5
E
1
E
9 New
8 11
2
New 4
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 3

T.R
.
M 10 LS
24 Nm (2.4 m•kgf, 17 ft•Ibf)

T.R
.
12 Nm (1.2 m•kgf, 8.7 ft•Ibf) 1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

T.R
T.R
.

1 Crankshaft end accessing screw 1
2 Timing mark accessing screw 1
3 Timing chain tensioner 1
4 Timing chain tensioner gasket 1
5 Exhaust camshaft cap 1
6 Intake camshaft cap 1
7 Camshaft cap 1
8 Exhaust camshaft 1
9 Intake camshaft 1
10 Exhaust camshaft sprocket 1
11 Intake camshaft sprocket 1
5-11
CAMSHAFTS
EBS30432
REMOVING THE CAMSHAFTS EX IN

1. Remove:
• Crankshaft end accessing screw “1”
• Timing mark accessing screw “2”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2 3. Remove:
• Timing chain tensioner
1
• Timing chain tensioner gasket
2. Align: 4. Remove:
• “I” mark “a” on the AC magneto rotor • Exhaust camshaft cap “1”
(with the stationary pointer “b” on the AC • Intake camshaft cap “2”
magneto cover) • Camshaft cap “3”
ECB03120
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
NOTICE
a. Turn the crankshaft clockwise.
To prevent damage to the cylinder head,
camshafts or camshaft caps, loosen the
camshaft cap bolts in stages and in a criss-
cross pattern, working from the outside in.
3
b. When piston #3 is at TDC on the exhaust
stroke, align the “I” mark “a” on the AC mag-
neto rotor with the stationary pointer “b” on 1
the AC magneto cover.
5. Remove:
b • Exhaust camshaft “1”
• Intake camshaft “2”
TIP
a To prevent the timing chain from coming off the
crankshaft sprocket, fasten it with a wire “3”.
TIP
TDC on the exhaust stroke can be found when
the camshaft lobes for cylinder #3 are turned
away from each other.
5-12
CAMSHAFTS
2 3
6. Remove:
• Camshaft sprockets “1”
TIP
Use the rotor holding tool “2” and loosen the
camshaft sprocket bolts.
Rotor holding tool

90890-01235
Universal magneto and rotor
holder
YU-01235 3. Measure:
• Camshaft runout
Out of specification → Replace.
2 Camshaft runout limit

1 0.030 mm (0.0012 in)
EBS30433
CHECKING THE CAMSHAFTS

1. Check:
• Camshaft lobes
Blue discoloration/pitting/scratches → Re- 4. Measure:
place the camshaft. • Camshaft-journal-to-camshaft-cap clearance
2. Measure: limit
• Camshaft lobe dimensions “a” and “b” Out of specification → Measure the camshaft
Out of specification → Replace the camshaft. journal diameter.
Camshaft lobe dimensions Camshaft-journal-to-camshaft-
Lobe height (Intake) limit cap clearance limit
32.750 mm (1.2894 in) 1.200 mm (0.0472 in)
Base circle diameter (Intake) limit
24.850 mm (0.9783 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Lobe height (Exhaust) limit a. Install the camshafts into the cylinder head
33.250 mm (1.3091 in) (without the camshaft caps).
Base circle diameter (Exhaust) b. Position a strip of Plastigauge® “1” onto the
limit
camshaft journal as shown.
24.850 mm (0.9783 in)
5-13
CAMSHAFTS
1
c. Install the camshaft caps. EBS30434
TIP CHECKING THE CAMSHAFT SPROCKETS

• Tighten the camshaft cap bolts in stages and in 1. Check:
a crisscross pattern, working from the inner • Camshaft sprocket
caps out. More than 1/4 tooth wear “a” → Replace the
• Do not turn the camshaft when measuring the camshaft sprockets and timing chain as a set.
camshaft journal-to-camshaft cap clearance
limit with the Plastigauge®.
Camshaft cap bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
d. Remove the camshaft caps, and then mea-

sure the width of the Plastigauge® “2”.
a. 1/4 tooth
b. Correct
1. Timing chain
2. Camshaft sprocket
EBS30435
CHECKING THE TIMING CHAIN TENSIONER

1. Check:
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Cracks/damage → Replace.
5. Measure: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Squeeze the timing chain tensioner clip “1”
• Camshaft journal diameter “a”
while pushing the timing chain tensioner rod
Out of specification → Replace the camshaft.
“2” into the timing chain tensioner housing
Within specification → Replace the cylinder
“3”.
head and camshaft caps as a set.
Camshaft journal diameter

22.800–23.000 mm (0.8976– 2
0.9055 in) 1
5-14
CAMSHAFTS
b. Keep pressing the timing chain tensioner rod,

timing chain tensioner mount clip “4” into b
groove “5”, and lock the timing chain tension-
er rod.
a
a b
4
5 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
• Intake camshaft sprocket “1”
• Exhaust camshaft sprocket “2”
c. Push the timing chain tensioner rod in direc-
tion “a”. Camshaft sprocket bolt
d. Make sure that the timing chain tensioner rod 24 Nm (2.4 m·kgf, 17 ft·lbf)
T.
R.
can smoothly move out from the timing chain
tensioner housing in direction “b”. If not TIP
smooth, replace the timing chain tensioner • Make sure that the holes “a” in the cylinder #3
assembly. camshaft lobe and marks “b” in the camshaft
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ sprockets are in the position shown in the illus-
EBS30436 tration.
INSTALLING THE CAMSHAFTS • Tighten the camshaft sprocket bolt with the ro-
1. Align: tor holding tool “3”.
• “I” mark “a” on the AC magneto rotor • Tighten the camshaft sprocket bolt “4” that is
(with the stationary pointer “b” on the AC installed in the 7.3 mm (0.29 in) diameter bolt
magneto cover) hole, and then tighten the camshaft sprocket
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ bolt “5” that is installed in the 7.5 mm (0.30 in)
a. Turn the crankshaft clockwise. diameter bolt hole.
Rotor holding tool

90890-01235
holder
YU-01235
2 EX a a IN 1
b
4 b
b. When piston #3 is at TDC on the exhaust b 4
stroke, align the “I” mark “a” on the AC mag-
neto rotor with the stationary pointer “b” on
the AC magneto cover.
c 5 c
c. Cylinder #3 camshaft lobes
5-15
CAMSHAFTS
TIP
• Make sure each camshaft cap is installed in its
3 original place. Refer to the identification marks
as follows:
“I”: Intake side camshaft cap mark
“E”: Exhaust side camshaft cap mark
• Make sure the arrow mark “a” on each cam-
shaft points toward the rear side of the engine.
I a
3. Install:
• Timing chain
I
(onto the camshaft sprockets)
• Intake camshaft “1”
• Exhaust camshaft “2”
TIP
E
• Make sure the holes “a” on each camshaft fac-
es up. E a
• When installing the timing chain, start with the 5. Tighten:
intake camshaft and be sure to keep the timing • Camshaft cap bolts
chain as tight as possible on the intake side.
• Make sure the marks “b” on the timing chain Camshaft cap bolt
sprockets are parallel with the edge of the cyl- 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
inder head.
TIP
1 a Tighten the camshaft cap bolts in stages and in
a crisscross pattern, working from the inner caps
out.
ECB03140
NOTICE
• Lubricate the camshaft cap bolts with the
2 engine oil.
• The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
EX IN camshaft caps, and camshafts will result.
• Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
6. Check:
• Camshaft holes “a”
Make sure the holes “a” on the camshaft is
b b b aligned with the camshaft cap alignment
c c
mark “b”.
c. Cylinder #3 camshaft lobes
4. Install:
• Camshaft cap
• Intake camshaft cap
• Exhaust camshaft cap
5-16
CAMSHAFTS
TIP
b
• Be sure to install the timing chain tensioner
a
gasket so that its section with the “L” mark “a”
is protruding from the lower left side of the tim-
ing chain tensioner.
• The arrow mark “b” on the timing chain ten-
sioner should face up.
b
a
b
7. Install:
• Timing chain tensioner gasket New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Squeeze the timing chain tensioner clip “1” 6
while pushing the timing chain tensioner rod a 7
“2” into the timing chain tensioner housing
“3”.
d. Push the timing chain guide “8” as shown in
the illustration to release the timing chain ten-
sioner rod.
2 1
8
b. Keep pressing the timing chain tensioner rod,
timing chain tensioner mount clip “4” into
groove “5”, and lock the timing chain tension-
er rod. e. Check that the timing chain is taut. If the
chain is slack, reinstall the timing chain ten-
sioner.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 8. Turn:
• Crankshaft
(several turns clockwise)
5 9. Check:
• “I” mark “a”
Make sure the “I” mark “a” on the AC magne-
to rotor is aligned with the stationary pointer
c. Install the timing chain tensioner gasket “6” “b” in the AC magneto cover.
and timing chain tensioner “7” in the cylinder • Camshaft holes “c”
block. Make sure the holes “c” in the cylinder #3
camshaft lobe are aligned with the camshaft
Timing chain tensioner bolt cap alignment mark “d”.
12 Nm (1.2 m·kgf, 8.7 ft·lbf) Out of alignment → Adjust.
T.
R.
Refer to the installation steps above.

• Timing chain guide
Make sure that the timing chain guide and
timing chain are positioned correctly.
5-17
CAMSHAFTS
b
1
d
c
a
d
c
10.Measure:
• Valve clearance
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-4.
11.Install:
• Cylinder head cover gasket New
• Cylinder head cover
Cylinder head cover bolt

12 Nm (1.2 m·kgf, 8.7 ft·lbf)
T.
R.
TIP
• Apply Yamaha bond No. 1215 “1” onto the
mating surfaces of the cylinder head cover
gasket.
• After installing the cylinder head gasket to the
cylinder head cover, cut off the “a” section.
• Tighten the cylinder head cover bolts stages
and in a crisscross pattern.
Yamaha bond No. 1215

90890-85505
5-18
CYLINDER HEAD
EBS20035
CYLINDER HEAD
Removing the cylinder head
3 New
FW
D
1st 25 Nm (2.5 m•kgf, 18 ft•lbf) 4
2nd 25 Nm (2.5 m•kgf, 18 ft•lbf)
T.R
.
3rd Specified angle 175–185˚
(8) New
2 20 Nm (2.0 m•kgf, 14 ft•Ibf)

T.R
.
1
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
12 Nm (1.2 m•kgf, 8.7 ft•Ibf)

T.R
.

Drain.
page 3-12.
Drain.
page 3-18.
Cylinder head cover/Intake camshaft/Exhaust Refer to “CAMSHAFTS” on page 5-10.
camshaft
Thermostat housing/Water jacket joint Refer to “THERMOSTAT” on page 6-6.
Throttle bodies
7-11.
1 Timing chain bolt 1
2 Cylinder head 1
3 Cylinder head gasket 1
4 Dowel pin 2
5-19
CYLINDER HEAD
EBS30438
REMOVING THE CYLINDER HEAD Warpage limit

1. Remove: 0.10 mm (0.0039 in)
• Cylinder head bolt (M6) (×2)
• Cylinder head bolt (M10) (×8)
• Cylinder head
TIP
• Loosen the bolts in the proper sequence as
shown.
• Loosen each bolt 1/2 of a turn at a time. After
all of the bolts are fully loosened, remove them.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge “1” and a thickness
gauge “2” across the cylinder head.
×2 ×8
1
2
5 9 7 3
1
2
b. Measure the warpage.
4 8 10 6 c. If the limit is exceeded, resurface the cylinder
head as follows.
d. Place a 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder head
using a figure-eight sanding pattern.
EBS30439 TIP
CHECKING THE CYLINDER HEAD
To ensure an even surface, rotate the cylinder
1. Eliminate:
head several times.
• Combustion chamber carbon deposits
(with a rounded scraper) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ECB01851
EBS30440
NOTICE INSTALLING THE CYLINDER HEAD
Do not use a sharp instrument; otherwise, 1. Install:
the following may be damaged or scratched: • Cylinder head
• Spark plug bore threads • Cylinder head bolt (M10) (×8)
• Valve seats • Cylinder head bolt (M6) (×2)
2. Check: TIP
• Cylinder head • Pass the timing chain through the timing chain
Damage/scratches → Replace. cavity.
• Cylinder head water jacket • Lubricate the cylinder head bolt (M10) threads
Mineral deposits/rust → Eliminate. and washer with engine oil.
3. Measure:
2. Tighten:
• Cylinder head warpage
• Cylinder head bolts (M10) “1”–“8”
Out of specification → Resurface the cylinder
• Cylinder head bolts (M6) “9”, “10”
head.
5-20
CYLINDER HEAD
Cylinder head bolt (M10)

T.
R.
1st: 25 Nm (2.5 m·kgf, 18 ft·lbf)
*2nd: 25 Nm (2.5 m·kgf, 18 ft·lbf)
3rd: Specified angle 175–185°
Cylinder head bolt (M6)
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
* Following the tightening order, loosen the

bolt one by one and then retighten it to the
specific torque.
TIP
Tighten the cylinder head bolts “1”–“8” in the
proper tightening sequence as shown.
×2 ×8
6 2 4 8
10
7 3 1 5
5-21
VALVES AND VALVE SPRINGS
EBS20037

Removing the valves and valve springs
M
1
2 M
3
4
5 New
M 9
10 M
1 2 3 4 New
6 9 10 11 New
E New
M
11
M
M
7

Cylinder head Refer to “CYLINDER HEAD” on page 5-19.
1 Valve lifter 12
2 Valve pad 12
3 Valve cotter 24
4 Valve spring retainer 12
5 Intake valve spring 6
6 Exhaust valve spring 6
7 Intake valve 6
8 Exhaust valve 6
9 Valve stem seal 12
10 Valve spring seat 12
11 Valve guide 12
5-22
EBS30141
REMOVING THE VALVES TIP

The following procedure applies to all of the Remove the valve cotters by compressing the
valves and related components. valve spring with the valve spring compressor
TIP
“1” and the valve spring compressor attachment
“2”.
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal. Valve spring compressor
90890-04019
1. Remove: Valve spring compressor
• Valve lifter “1” YM-04019
• Valve pad “2” Valve spring compressor attach-
TIP ment
90890-04114
Make a note of the position of each valve lifter Valve spring compressor adapt-
and valve pad so that they can be reinstalled in er 19.5 mm
their original place. YM-04114
2 1
2. Check:
• Valve sealing 4. Remove:
Leakage at the valve seat → Check the valve • Valve spring retainer “1”
face, valve seat, and valve seat width. • Valve spring “2”
Refer to “CHECKING THE VALVE SEATS” • Valve “3”
on page 5-25. • Valve stem seal “4”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Valve spring seat “5”
a. Pour a clean solvent “a” into the intake and TIP
exhaust ports. Identify the position of each part very carefully so
b. Check that the valves properly seal. that it can be reinstalled in its original place.
TIP
There should be no leakage at the valve seat “1”. 1
2
3
EBS30142
CHECKING THE VALVES AND VALVE

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
GUIDES
3. Remove:
valves and valve guides.
• Valve cotters
5-23
1. Measure:
• Valve-stem-to-valve-guide clearance
Out of specification → Replace the valve
guide.
• Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” -
Valve stem diameter “b”
Valve-stem-to-valve-guide clear-
ance (intake) limit
0.080 mm (0.0032 in) b. Install the new valve guide with the valve
Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remover
ance (exhaust) limit “1”.
0.100 mm (0.0039 in)
Valve guide position
14.8–15.2 mm (0.583–0.598 in)
a. Valve guide position

c. After installing the valve guide, bore the valve
guide with the valve guide reamer “3” to ob-
tain the proper valve-stem-to-valve-guide
clearance.
3
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.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide with the valve guide TIP
remover “1”. After replacing the valve guide, reface the valve
seat.
5-24
2. Check:
Valve guide remover (ø4.5) • Valve seat
90890-04116 Pitting/wear → Replace the cylinder head.
Valve guide remover (4.5 mm) 3. Measure:
YM-04116
• Valve seat width “a”
Valve guide installer (ø4.5)
90890-04117 Out of specification → Replace the cylinder
Valve guide installer (4.5 mm) head.
YM-04117
Valve guide reamer (ø4.5) Valve seat contact width (intake)
90890-04118 limit
Valve guide reamer (4.5 mm) 1.6 mm (0.06 in)
YM-04118 Valve seat contact width (ex-
haust) limit
1.6 mm (0.06 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
4. Check:
• Valve face
Pitting/wear → Grind the valve face.
• Valve stem end
Mushroom shape or diameter larger than the
body of the valve stem → Replace the valve.
5. Measure:
• Valve stem runout ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Out of specification → Replace the valve. a. Apply blue layout fluid “b” onto the valve face.
TIP
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always re-
place the valve stem seal.
Valve stem runout

0.010 mm (0.0004 in)
b. Install the valve into the cylinder head.

c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width.
TIP
Where the valve seat and valve face contacted
one another, the blueing will have been re-
moved.
EBS30143
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE VALVE SEATS
The following procedure applies to all of the 4. Lap:
valves and valve seats. • Valve face
1. Eliminate: • Valve seat
• Carbon deposits
(from the valve face and valve seat)
5-25
TIP
After replacing the cylinder head or replacing the
valve and valve guide, the valve seat and valve
face should be lapped.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound “a” to the
valve face.
ECB01360
NOTICE
Do not let the lapping compound enter the
h. Install the valve into the cylinder head.
gap between the valve stem and the valve
i. Press the valve through the valve guide and
guide.
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width “c” again. If the
valve seat width is out of specification, reface
and lap the valve seat.
b. Apply engine oil onto the valve stem.

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

1.8 mm (0.07 in)
Spring tilt (exhaust)
1.8 mm (0.07 in)
e. Apply a fine lapping compound to the valve

face and repeat the above steps.
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.
5-26
EBS30441
• Install the valve springs with the larger pitch “a”
CHECKING THE VALVE LIFTERS
facing up.
valve lifters.
1. Check: 5
• Valve lifter
Damage/scratches → Replace the valve lift- 4 3
ers and cylinder head.
EBS30145
2 New
INSTALLING THE VALVES
The following procedure applies to all of the 1
valves and related components.
1. Deburr:
• Valve stem end
(with an oil stone)
b. Smaller pitch
4. Install:
2. Lubricate:
• Valve cotters
• Valve stem “1”
• Valve stem seal “2” TIP
(with the recommended lubricant) Install the valve cotters by compressing the
valve spring with the valve spring compressor
Recommended lubricant “1” and the valve spring compressor attachment
Molybdenum disulfide oil “2”.
2 Valve spring compressor

90890-04019
Valve spring compressor
YM-04019
Valve spring compressor attach-
1 ment
90890-04114
M Valve spring compressor adapt-
er 19.5 mm
YM-04114
3. Install:
• Valve spring seat “1”
(into the cylinder head)
• Valve stem seal “2” New
• Valve “3”
• Valve spring “4”
• Valve spring retainer “5”
TIP
• Make sure each valve is installed in its original
place.
5-27
5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
ECB01370
NOTICE
Hitting the valve tip with excessive force
could damage the valve.
6. Lubricate:
• Valve pad
Molybdenum disulfide oil
• Valve lifter
Engine oil
7. Install:
• Valve pad
• Valve lifter
TIP
• The valve lifter must move smoothly when ro-
tated with a finger.
• Each valve lifter and valve pad must be rein-
stalled in their original position.
5-28
AC MAGNETO AND STARTER CLUTCH
EBS20039

Removing the AC magneto and starter clutch
16 Nm (1.6 m•kgf, 12 ft•Ibf)

T.R
.
FW
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) D
T.R
.
(6)
LT
LT
2
LT
E
8
9
E
1 7
(8)
(3)
LT
130 Nm (13 m•kgf, 94 ft•lbf)
T.R
.
6 3
LT 12 Nm (1.2 m•kgf, 8.7 ft•Ibf)
T.R
4
.
New
7
LS
5
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
6 Nm (0.6 m•kgf, 4.3 ft•Ibf) New LT LT

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

Oil tank outlet pipe 3 5-4.
1 AC magneto lead coupler 2 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
3 Stator coil assembly lead holder 2 1
5 AC magneto cover 1
6 AC magneto cover gasket 1
7 Dowel pin 2
9 Crankshaft position sensor 1
5-29
Removing the AC magneto and starter clutch
16 Nm (1.6 m•kgf, 12 ft•Ibf)
T.R
.
FW
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) D
(6)
17 16 LT
LT
14 12
LT
10 E
13
E
15
(8)
(3) 11
LT
130 Nm (13 m•kgf, 94 ft•lbf)
T.R
.
LT 12 Nm (1.2 m•kgf, 8.7 ft•Ibf)
T.R
.
New
LS
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
6 Nm (0.6 m•kgf, 4.3 ft•Ibf) New LT LT

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

10 Stator coil 1
11 AC magneto rotor 1
12 Woodruff key 1
13 Starter clutch gear 1
14 Washer 1
15 Starter clutch 1
16 Starter idle gear shaft 1
17 Starter idle gear 1
5-30
EBS30151
• Make sure the flywheel puller is centered over
REMOVING THE AC MAGNETO ROTOR
the AC magneto rotor.
1. Remove:
• AC magneto cover
Flywheel puller
TIP
90890-01362
Loosen each bolt 1/4 of a turn at a time, in stag- Heavy duty puller
es and in a crisscross pattern. After all of the YU-33270-B
bolts are fully loosened, remove them.
2
1
EBS30152
2. Remove:
REMOVING THE STARTER CLUTCH
• AC magneto rotor bolt “1”
1. Remove:
• Washer
• Starter clutch bolts “1”
TIP
TIP
Hold the AC magneto rotor “2” with the rotor
Hold the AC magneto rotor “2” with the rotor
holding tool “3” while loosening the AC magneto
holding tool “3” while removing the starter clutch
rotor bolt.
bolts.
Rotor holding tool

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

2. Check:
To protect the end of the crankshaft, place an
• Starter idle gear
appropriate sized socket between the fly-
• Starter clutch gear
wheel puller set center bolt and the crank-
Burrs/chips/roughness/wear → Replace the
shaft.
defective part(s).
TIP
• Use the flywheel puller “2”.
5-31
3. Check:
• Starter clutch gear contact surfaces 1 a
Damage/pitting/wear → Replace the defec-
tive part(s).
4. Check: 2
• Starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch and stater clutch gear
“1” onto the AC magneto rotor “2”, and hold
the AC magneto rotor.
b. When turning the starter clutch gear counter-
clockwise “A”, the starter clutch and the start-
er clutch gear should engage; otherwise, the 3
starter clutch is faulty and must be replaced. 2
c. When turning the starter clutch gear clock-
wise “B”, it should turn freely; otherwise, the
starter clutch is faulty and must be replaced.
1
B
EBS30156
INSTALLING THE AC MAGNETO ROTOR

1. Install:
• Woodruff key
• AC magneto rotor
A • Washer
2 • AC magneto rotor bolt
TIP
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30155
• Clean the tapered portion of the crankshaft and
INSTALLING THE STARTER CLUTCH the AC magneto rotor hub.
1. Install: • When installing the AC magneto rotor, make
• Starter clutch “1” sure the woodruff key is properly seated in the
keyway of the crankshaft.
Starter clutch bolt • Lubricate the threads of the AC magneto rotor
16 Nm (1.6 m·kgf, 12 ft·lbf) bolt and washer with engine oil.
T.
R.
LOCTITE®
2. Tighten:
TIP • AC magneto rotor bolt “1”
• Install the starter clutch so that the side of the AC magneto rotor bolt
starter clutch roller assembly with the arrow 130 Nm (13 m·kgf, 94 ft·lbf)
T.
R.
mark “a” is toward the AC magneto rotor “2”.

• While holding the AC magneto rotor “2” with TIP
the rotor holding tool “3”, tighten the starter Hold the AC magneto rotor “2” with the rotor
clutch bolts. holding tool “3” while tightening the AC magneto
rotor bolt.
Rotor holding tool
90890-04166 Rotor holding tool
YM-04166 90890-04166
YM-04166
5-32
3 4
3
1
2
1
2
2 2
3. Apply:
• Sealant
(onto the stator coil assembly lead grommet)

90890-85505
4. Install:
• AC magneto cover
• Stator coil assembly lead holder 3
• Stator coil assembly lead holder 2
AC magneto cover bolt “1”

12 Nm (1.2 m·kgf, 8.7 ft·lbf)
T.
R.
LOCTITE®
AC magneto cover bolt “2”
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Stator coil assembly lead holder
3 bolt “3”
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
LOCTITE®
Stator coil assembly lead holder
2 bolt “4”
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
TIP
Tighten the AC magneto cover bolts in stages
and in a crisscross pattern.
5-33
ELECTRIC STARTER
EBS20040
ELECTRIC STARTER
Removing the starter motor
FW
D
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
27 Nm (2.7 m•kgf, 20 ft•Ibf)

T.R
.

1 Starter motor lead 1 Disconnect.
2 Starter motor 1
5-34
ELECTRIC STARTER
Disassembling the starter motor

8
7
11 Nm (1.1 m•kgf, 8.0 ft•Ibf)
T.R
.
New
3
6
5 New
New
5 New
New 1 New
5 Nm (0.5 m•kgf, 3.6 ft•Ibf) LS

T.R
.

1 O-ring 1
2 Starter motor front cover 1
3 Starter motor yoke 1
4 Armature assembly 1
5 Gasket 2
6 Brush holder set 1
7 Starter motor rear cover 1
8 Lead guide 1
5-35
ELECTRIC STARTER
EBS30157
CHECKING THE STARTER MOTOR

1. Check: M
• Commutator
Dirt → Clean with 600 grit sandpaper.
2
2. Measure:
• Mica undercut “a” 1
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) 1. Armature coil resistance

0.70 mm (0.03 in) 2. Insulation resistance
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP
4. Measure:
The mica of the commutator must be undercut to
• Brush length “a”
ensure proper operation of the commutator.
Out of specification → Replace the brush
holder set.
a
Brush overall length limit
6.50 mm (0.26 in)
a
a
3. Measure:
• Armature assembly resistances (commutator a
and insulation)
Out of specification → Replace the starter
motor.
5. Check:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the armature assembly resistances • Gear teeth
with the digital circuit tester. Damage/wear → Replace the starter motor.
6. Check:
Digital circuit tester • Bearing
90890-03174 • Oil seal
Model 88 Multimeter with ta- Damage/wear → Replace the starter motor
chometer front cover.
YU-A1927
EBS30158
ASSEMBLING THE STARTER MOTOR

Armature coil resistance 1. Install:
0.005–0.015 Ω • Lead guide “1”
Insulation resistance TIP
Above 1 MΩ at 20 °C (68 °F)
Make sure that the slot “a” in the lead guide is
b. If any resistance is out of specification, re- facing in the direction shown in the illustration.
place the starter motor.
5-36
ELECTRIC STARTER
a
1
2. Install:
• Starter motor yoke “1”
• Starter motor rear cover “2”
TIP
Align the projection “a” on the starter motor rear
cover with the slot “b” in the starter motor yoke.
2 1
a b
3. Install:
• Starter motor yoke “1”
• Starter motor front cover “2”
TIP
Align the match mark “a” on the starter motor
yoke with the match mark “b” on the starter mo-
tor front cover.
a b
1 2
5-37
OIL PAN AND OIL PUMP
EBS20132

Removing the oil pan and oil pump
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 12 Nm (1.2 m•kgf, 8.7 ft•Ibf) 15 Nm (1.5 m•kgf, 11 ft•Ibf)
T.R
T.R
T.R
.
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
(5)
T.R
.
8
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
7
(15) New
New
9
9
New
13 Nm (1.3 m•kgf, 9.4 ft•Ibf)
4
T.R
.
1 LS
LT
2
3
6
80 Nm (8.0 m•kgf, 58 ft•Ibf)
T.R
.
New 5 17 Nm (1.7 m•kgf, 12 ft•Ibf)

T.R
.

Engine 5-6.
1 Oil pressure switch 1
2 Oil filter cartridge 1
3 Oil filter cartridge union bolt 1
4 Oil pan 1
5 Oil pan gasket 1
6 Dowel pin 2
7 Oil pump driven sprocket 1
8 Oil pump assembly 1
9 Dowel pin 2
5-38
Disassembling the oil pump assembly

1.3 Nm (0.13 m•kgf, 0.94 ft•Ibf)
T.R
.
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
2
.
15
14
12
10 E
9
New
11
(4) E
8
13 1
2
New 4
New
10 (5)
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

T.R
.
E 6
4 3
5 T.R
.
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

7
E
6
5

1 Oil pan divider 1
2 Oil strainer 2
3 Oil pump housing cover 1 1
4 Pin 2
5 Oil pump inner rotor 2 2
6 Oil pump outer rotor 2 2
7 Spacer 1
8 Pin 2
9 Oil pump housing cover 2 1
10 Pin 2
11 Washer 1
12 Oil pump shaft 1
13 Pin 1
14 Oil pump inner rotor 1 1
15 Oil pump outer rotor 1 1
5-39
Disassembling the oil pump assembly

1.3 Nm (0.13 m•kgf, 0.94 ft•Ibf)
T.R
.
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.
E
21
22
23
16
E
24
New
(4) E
20
19
16 18
New New 17
(5)
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

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

16 Oil seal 2
17 Check ball seat 1
18 Check ball 1
19 Spring 1
20 Spacer 1
21 Relief valve cover 1
22 Spring 1
23 Relief valve 1
24 Oil pump housing 1
5-40
EBS30652 EBS30189
REMOVING THE OIL PAN AND OIL PUMP CHECKING THE OIL PUMP (CRANKCASE)
DRIVEN SPROCKET 1. Check:
1. Remove: • Oil pump
• Oil pan “1” Cracks/damage/wear → Replace the oil
TIP pump assembly.
Loosen each bolt 1/4 of a turn at a time, in stag- 2. Measure:
es and in a crisscross pattern. After all of the • Inner-rotor-to-outer-rotor-tip clearance “a”
bolts are fully loosened, remove them. • Outer-rotor-to-oil-pump-housing clearance
“b”
1 Inner-rotor-to-outer-rotor-tip
clearance
0.09–0.15 mm (0.0035–0.0059 in)
Limit
0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing
clearance
0.03–0.08 mm (0.0012–0.0032 in)
Limit
0.15 mm (0.0059 in)
2. Remove:
• Oil pump driven sprocket “1”
b
TIP
• While holding the oil pump driven sprocket with 1
the rotor holding tool “2”, loosen the oil pump
driven sprocket bolt.
• To prevent the oil pump chain falling into the
crankcase, fasten it with a wire. 2
a
Rotor holding tool 3
90890-01235
Universal magneto and rotor 1. Inner rotor
holder 2. Outer rotor
YU-01235 3. Oil pump housing
3. Check:
• Oil pump operation
Rough movement → Replace the oil pump
assembly.
EBS30653
CHECKING THE OIL PUMP DRIVEN

SPROCKET
1. Check:
• Oil pump driven sprocket EBS30190
Cracks/wear/damage → Replace. CHECKING THE OIL STRAINER

1. Check:
• Oil strainer
Damage → Replace the oil pump.
5-41
Contaminants → Clean with solvent. • Oil pump inner rotor “3”

• Oil pump shaft “4”
EBS30184
CHECKING THE RELIEF VALVE • Pin “5”

1. Check: TIP
• Relief valve body “1” When installing the inner rotor, align the pin in
• Relief valve “2” the oil pump shaft with the groove “a” on the in-
• Spring “3” ner rotor.
Damage/wear → Replace the defective
part(s). 1
3
2
3
2
1 a
4 5
3. Check:
EBS30654
CHECKING THE CHECK BALL Refer to “CHECKING THE OIL PUMP

1. Check: (CRANKCASE)” on page 5-41.
• Check ball seat “1” EBS30655
• Check ball “2” INSTALLING THE OIL PUMP

• Spring “3” 1. Install:
• Spacer “4” • Oil pump driven sprocket “1”
Damage/wear → Replace the defective part(-
s). Oil pump driven sprocket bolt
15 Nm (1.5 m·kgf, 11 ft·lbf)
T.
R.
TIP
• Install the oil pump driven sprocket with the
stamped mark “4XV” facing towards the oil
4 pump assembly.
3
2 • While holding the oil pump driven sprocket with
1 the rotor holding tool “2”, tighten the oil pump
driven sprocket bolt.
EBS30192 Rotor holding tool

ASSEMBLING THE OIL PUMP 90890-01235
(CRANKCASE) Universal magneto and rotor
1. Lubricate: holder
• Inner rotor YU-01235
• Outer rotor
• Oil pump shaft
Engine oil
2. Install: 2
• Oil pump housing “1”
• Oil pump outer rotor “2” 1
5-42
2. Install:
• Dowel pins
• Oil pan gasket New
• Oil pan
• Gasket New
• Oil pan bolts
Oil pan bolt (M6 × 25)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
Oil pan bolt (M6 × 35)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Engine oil drain bolt (crankcase)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
TIP
Tighten the oil pan bolts in stages and in a criss-
cross pattern.
M6 × 35 mm bolts: “1 ”
Engine oil drain bolt (crankcase): “2”
M6 × 25 mm bolts: “3”
3 2 3
3
1
3 3
5-43
SHIFT LEVER
EBS20042
SHIFT LEVER
Removing the shift lever rod and shift lever
LS
27 Nm (2.7 m•kgf, 20 ft•Ibf)
T.R
.
2
15 Nm (1.5 m•kgf, 11 ft•Ibf)
T.R
.
24 Nm (2.4 m•kgf, 17 ft•Ibf)
T.R
.
LT
LT
1
5 LT
LT
4
LS
6
FW 7
D
3
T.R
T.R
.

Passenger seat frame 4-5.
Center console/Shift lever base cover page 4-26.
1 Shift lever rod 1
2 Shift lever 1
3 Shift arm 1
4 Reverse gear lock cable 1 Disconnect.
5 Reverse gear lock cable bracket 1
6 Reverse gear lock arm 1
7 Reverse gear lock arm spring 1
5-44
SHIFT LEVER
EBS30657
INSTALLING THE SHIFT ARM

1. Install:
• Shift arm “1”
3
Shift arm bolt
15 Nm (1.5 m·kgf, 11 ft·lbf)
T.
R.
TIP
Align the punch mark “a” on the shift arm with the
paint mark “b” on the shift shaft.
d. Adjust the length of the shift lever rod so that
there is 1–3 mm (0.04–0.12 in) of clearance
1 “b” between the shift lever “4” and the frame
“5”.
b a 4
EBS30697
ADJUSTING THE SHIFT LEVER ROD b 5

1. Adjust:
• Shift lever rod e. Tighten the locknuts.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the both locknuts “1”. Shift lever rod locknut
15 Nm (1.5 m·kgf, 11 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30658
INSTALLING THE REVERSE GEAR LOCK

1 ARM
1. Install:
• Reverse gear lock arm spring “1”
• Reverse gear lock arm “2”
TIP
TIP Install the reverse gear lock arm spring and re-
The shift lever rod locknut (shift arm side) has verse gear lock arm as shown in the illustration.
left-hand threads.
b. Move the shift arm “2” to the shift-up position
“a” and hold it in that position.
1 2
c. Turn the front drive shaft “3” until it stops.
5-45
CLUTCH
EBS20044
CLUTCH
Removing the clutch cover
FW
D
3 New
2
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
(9)
2
New
New
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.

Electrical components tray page 4-26.
1 Clutch cover 1
2 Dowel pin 2
3 Clutch cover gasket 1
5-46
CLUTCH
Removing the clutch
FW
D
E
E 10 New
9
E
LS
New
7 E
E
New 6 13
8 12
5 E 11
LS
E
4
3 (6)
105 Nm (10.5 m•kgf, 76 ft•lbf)
T.R
.
2 1 8 Nm (0.8 m•kgf, 5.8 ft•Ibf)

T.R
.

Clutch release cylinder Refer to “CLUTCH” on page 5-46.
1 Clutch spring plate retainer 1
2 Clutch spring plate 1
3 Clutch spring plate seat 1
4 Pressure plate 1
5 Bearing 1
6 Short clutch push rod 1
7 Ball 1
8 Long push rod 1
9 Friction plate 1 8 Inside diameter: 124 mm (4.88 in)
10 Clutch plate 7
11 Clutch boss nut 1
12 Conical spring washer 1
13 Plain washer 1
5-47
CLUTCH
Removing the clutch
FW
D
E
25 21
20 19 24
E 23
22
18
17
16
E 15
14 New
E
LS
New
E
E
New
E
LS
E
(6)
105 Nm (10.5 m•kgf, 76 ft•lbf)
T.R
.
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)

T.R
.

14 Wire circlip 1
15 Clutch plate 3
16 Friction plate 2 3 Inside diameter: 135 mm (5.31 in)
17 Clutch damper spring 3
18 Clutch damper spring seat 3
19 Clutch boss 1
20 Thrust washer 1
21 Clutch housing 1
22 Bearing 1
23 Spacer 1
24 Spacer 1
25 Thrust plate 1
5-48
CLUTCH
Removing the clutch master cylinder
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

T.R
.
5 27 Nm (2.7 m•kgf, 20 ft•Ibf)
T.R
.
16 Nm (1.6 m•kgf, 12 ft•Ibf)
T.R
.
6
New
LS
New
7

Pedal assembly cover 4-1.
Hood 4-7.
Drain.
Clutch fluid Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” on page 3-24.
1 Clutch master cylinder reservoir cap 1
Clutch master cylinder reservoir diaphragm
2 1
holder
3 Clutch master cylinder reservoir diaphragm 1
4 Clutch master cylinder reservoir 1
5 Clutch master cylinder reservoir hose 1
6 Pin 1
7 Clutch hose union bolt 1
5-49
CLUTCH
Removing the clutch master cylinder
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

T.R
.
27 Nm (2.7 m•kgf, 20 ft•Ibf)
T.R
.
16 Nm (1.6 m•kgf, 12 ft•Ibf)
T.R
.
10
8 New
LS
New
9

8 Copper washer 2
9 Clutch hose 1
10 Clutch master cylinder 1
5-50
CLUTCH
Disassembling the clutch master cylinder
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
T.R
.
4
New
BF
3
S
2 New
17 Nm (1.7 m•kgf, 12 ft•Ibf)

T.R
.

1 Clutch master cylinder joint 1
2 Clutch master cylinder kit 1
3 Clutch master cylinder body 1
4 Clutch master cylinder hose joint 1
5-51
CLUTCH
Removing the clutch release cylinder
LS
FW
D
6 New
New 7 5
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
LT
LT
LT
LT
5 3
4
LT
New 2
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 1
T.R
.
27 Nm (2.7 m•kgf, 20 ft•Ibf)

T.R
.

Shift lever rod Refer to “SHIFT LEVER” on page 5-44.
1 Clutch hose union bolt 1
2 Copper washer 2
3 Clutch hose 1
4 Clutch release cylinder 1
5 Dowel pin 2
6 Clutch release cylinder gasket 1
7 Oil seal 1
5-52
CLUTCH
Disassembling the clutch release cylinder
5 Nm (0.5 m•kgf, 3.6 ft•Ibf)
T.R
.
1
2
3 New
BF

1 Bleed screw 1
2 Clutch release cylinder piston 1
3 Clutch release cylinder kit 1
4 Clutch release cylinder body 1
5-53
CLUTCH
EBS30177
REMOVING THE CLUTCH

1. Remove:
• Clutch cover “1”
• Clutch cover gasket
TIP
1
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.
5. Straighten the clutch boss nut rib “a”.
1 a
2. Remove:
• Clutch spring plate retainer “1”
• Clutch spring plate “2” 6. Loosen:
• Clutch spring plate seat • Clutch boss nut “1”
• Pressure plate TIP
• Bearing While holding the clutch boss “2” with the univer-
• Short clutch push rod sal clutch holder “3”, loosen the clutch boss nut.
• Ball
TIP Universal clutch holder
Loosen the clutch spring plate retainer bolts in 90890-04086
stages and in a crisscross pattern. Universal clutch holder
YM-91042
2
1
1
2
3. Remove:
• Friction plates 1 7. Remove:
• Clutch plates • Clutch boss nut “1”
4. Remove: • Conical spring washer “2”
• Long clutch push rod “1” • Plain washer “3”
TIP • Wire circlip “4”
Push the long clutch push rod into the clutch re- • Clutch plates “5”
lease cylinder side of the transmission case, and • Friction plates 2 “6”
remove it from the clutch side of the transmis- • Clutch damper springs “7”
sion case. • Clutch damper spring seats “8”
• Clutch boss “9”
5-54
CLUTCH
TIP
It is not necessary to remove the wire circlip,
clutch plates, friction plates 2, clutch damper
springs, and clutch damper spring seats unless
there is serious clutch chattering.
EBS30598
CHECKING THE CLUTCH PLATES

8 clutch plates.
7
6 1. Check:
5
8 • Clutch plate
7
6 Damage → Replace the clutch plates as a
5
8 set.
7 2. Measure:
6
5 • Clutch plate wargape
4
(with a surface plate and thickness gauge “1”)
Out of specification → Replace the clutch
plates as a set.
Thickness gauge
3 90890-03180
2
1 Feeler gauge set
EBS30597
YU-26900-9
CHECKING THE FRICTION PLATES
The following procedure applies to all of the fric-
Clutch plate thickness
tion plates. 1.90–2.10 mm (0.07–0.08 in)
1. Check: Warpage limit
• Friction plate 0.20 mm (0.0079 in)
Damage/wear → Replace the friction plates
as a set.
2. Measure:
• Friction plate thickness
Out of specification → Replace the friction
plates as a set.
TIP
Measure the friction plate at four places.
Friction plate thickness 1

2.92–3.08 mm (0.11–0.12 in)
Wear limit EBS30599
2.80 mm (0.1102 in) CHECKING THE CLUTCH SPRING PLATE

Friction plate thickness 2 1. Check:
2.92–3.08 mm (0.11–0.12 in) • Clutch spring plate retainer
Wear limit Damage → Replace.
2.8 mm (0.11 in) 2. Check:
• Clutch spring plate seat
Damage → Replace.
5-55
CLUTCH
3. Measure:
• Clutch spring free height
Out of specification → Replace the clutch
spring plate.
Clutch spring height

6.50 mm (0.26 in)
Minimum height
6.1 mm (0.24 in)
EBS30602
CHECKING THE PRESSURE PLATE

1. Check:
• Pressure plate
• Bearing
EBS30603
CHECKING THE CLUTCH PUSH RODS

EBS30600
1. Check:
CHECKING THE CLUTCH HOUSINGS • Short clutch push rod
1. Check: • Long clutch push rod
• Clutch housing dogs • Ball
Damage/pitting/wear → Deburr the clutch Cracks/damage/wear → Replace the defec-
housing dogs or replace the clutch housing. tive part(s).
TIP 2. Measure:
Pitting on the clutch housing dogs will cause er- • Long clutch push rod bending limit
ratic clutch operation. (with a centering device and dial gauge “1”)
Push rod bending limit

0.3 mm (0.01 in)
EBS30601
CHECKING THE CLUTCH BOSS

1. Check:
• Clutch boss splines
Damage/pitting/wear → Replace the clutch EBS30604
boss. CHECKING THE PRIMARY DRIVEN GEAR

1. Check:
TIP
• Primary driven gear “1”
Pitting on the clutch boss splines will cause er- Damage/wear → Replace the primary drive
ratic clutch operation. and primary driven gears as a set.
Excessive noise during operation → Replace
the clutch housing and crankshaft as a set.
5-56
CLUTCH
1
1
2
3
4
5
2
EBS30181 3
INSTALLING THE CLUTCH 4
5
1. Install: 2
3
• Thrust plate “1” 4
5
• Spacer 6
• Spacer
• Bearing
• Clutch housing
TIP
Install the thrust plate “1” with the paint mark “a” New
facing out.
4. Install:
• Thrust washer
• Clutch boss “1”
a • Plain washer
1 • Conical spring washer “2”
• Clutch boss nut “3” New
Clutch boss nut

105 Nm (10.5 m·kgf, 76 ft·lbf)
T.
R.
TIP
2. Lubricate: • Lubricate the plane washer, conical spring
• Friction plates 2 washer and clutch boss nut threads with en-
(with the recommended lubricant) gine oil.
• Install the conical spring washer “2” with the
Engine oil “OUT” mark “a” facing out.
• While holding the clutch boss with the univer-
3. Install: sal clutch holder “4”, tighten the clutch boss
• Clutch boss “1” nut.
• Clutch damper spring seats “2” • Stake the clutch boss nut “3” at cutouts “b” in
• Clutch damper springs “3” the main axle.
• Friction plates 2 “4”
• Clutch plates “5” Universal clutch holder
• Wire circlip “6” New 90890-04086
Universal clutch holder
TIP YM-91042
• Install the clutch damper springs “3” with the
“OUT SIDE” mark facing out.
• Install clutch plates “5” with its rounded side
facing outward.
• If the wire circlip “6” has been removed, care-
fully install a new one.
5-57
CLUTCH
4
3 New
2
b
1
a 2
5. Lubricate: • Gasket New
• Friction plates 1 • Clutch cover
• Clutch plates • Dowel pins “1”
• Copper washers “2” New
Clutch cover bolt
Engine oil
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
6. Install:
TIP
• Friction plates 1
• Clutch plates Tighten the clutch cover bolts in stages, using a
TIP
crisscross pattern.
• First, install a friction plate 1 and then alternate
between a clutch plate and a friction plate 1. 1
• Align a projection on each friction plate 1 “1”
with the “” mark “a” on the clutch housing and
align a projection on the last friction plate 1 “2”
with the “” mark “b” on the housing.
1
a
b 1 New 2
EBS30605
2 DISASSEMBLING THE CLUTCH MASTER
CYLINDER
ECB03250
NOTICE
• Clutch components rarely require disas-
sembly.
7. Install: • Therefore, always follow these preventive
• Pressure plate measures:
• Clutch spring plate seat • Never disassemble clutch components un-
• Clutch spring plate “1” less absolutely necessary.
• Clutch spring plate retainer “2” • If any connection on the hydraulic clutch
system is disconnected, the entire clutch
Clutch spring plate retainer bolt
system must be disassembled, drained,
8 Nm (0.8 m·kgf, 5.8 ft·lbf)
T.
cleaned, properly filled, and bled after reas-

R.
sembly.
TIP
• Never use solvents on internal clutch com-
Tighten the clutch spring plate retainer bolts in ponents.
stages and in a crisscross pattern. • Use only clean or new clutch fluid for clean-
ing clutch components.
5-58
CLUTCH
• Clutch fluid may damage painted surfaces 3. Check:

and plastic parts. Therefore, always clean • Clutch master cylinder reservoir
up any spilt fluid immediately. Cracks/damage → Replace.
• Avoid clutch fluid coming into contact with 4. Check:
the eyes as it can cause serious injury. • Clutch master cylinder reservoir diaphragm
• First aid for clutch fluid entering the eyes: • Clutch master cylinder reservoir diaphragm
• Flush with water for 15 minutes and get im- holder
mediate medical attention. Cracks/damage → Replace.
5. Check:
TIP
• Clutch hose
Before disassembling the clutch master cylinder, • Clutch master cylinder reservoir hose
drain the clutch fluid from the entire clutch sys- Cracks/damage/wear → Replace.
tem.
EBS30607
1. Remove: ASSEMBLING THE CLUTCH MASTER
• Clutch hose union bolt “1” CYLINDER
• Clutch hose gaskets “2” EWB04080
• Clutch hose “3” WARNING

TIP • Before installation, all internal clutch com-
To collect any remaining clutch fluid, place a ponents must be cleaned and lubricated
container under the master cylinder and the end with clean or new clutch fluid.
of the clutch hose. • Never use solvents on internal clutch com-
ponents as they will cause the piston seals
to swell and distort.
1
• Whenever a clutch master cylinder is disas-
3 sembled, replace the piston seals.

DOT 4
EBS30608
2 INSTALLING THE CLUTCH MASTER
CYLINDER
EBS30606 1. Install:
CHECKING THE CLUTCH MASTER • Clutch master cylinder
CYLINDER
Clutch master cylinder bolt
Recommended clutch component replace-
16 Nm (1.6 m·kgf, 12 ft·lbf)
T.
ment schedule
R.
Piston seals Every two years 2. Install:

Clutch hose Every four years • Clutch hose gaskets “1” New
Every two years and • Clutch hose “2”
Clutch fluid whenever the clutch is • Clutch hose union bolt “3”
disassembled
Clutch hose union bolt
1. Check: 27 Nm (2.7 m·kgf, 20 ft·lbf)
T.
R.
• Clutch master cylinder body

Cracks/damage → Replace the clutch mas- EWB02870
ter cylinder. WARNING

• Clutch fluid delivery passage Proper brake hose routing is essential to in-
(clutch master cylinder body) sure safe vehicle operation.
2. Check:
• Clutch master cylinder kit
Rust/scratches/wear → Replace.
5-59
CLUTCH
ECB03260
NOTICE LEVEL” on page 3-23.
When installing the clutch hose onto the
EBS30609
clutch master cylinder, make sure the clutch
REMOVING THE CLUTCH RELEASE
pipe “a” touches the projection “b” as
CYLINDER
shown.
1. Remove:
• Clutch hose union bolt “1”
3 • Clutch hose gaskets “2”
a
2 • Clutch hose “3”
TIP
b Put the end of the clutch hose into a container
and pump out the clutch fluid carefully.
1 New
3. Fill:
• Clutch master cylinder reservoir 2 3
brake and clutch fluid)

DOT 4 1
EBS30610
EWB04020
CHECKING THE CLUTCH RELEASE
WARNING
CYLINDER
• Use only the designated clutch fluid. Other
clutch fluids may cause the rubber seals to Recommended clutch component replace-
ment schedule
deteriorate, causing leakage and poor
clutch performance. Piston seals Every two years
• Refill with the same type of clutch fluid that Clutch hose Every four years
is already in the system. Mixing clutch flu- Every two years and
ids may result in a harmful chemical reac- Clutch fluid whenever the clutch is
tion, leading to poor clutch performance. disassembled
not enter the clutch fluid reservoir. Water 1. Check:
will significantly lower the boiling point of • Clutch release cylinder body
the clutch fluid and could cause vapor lock. Cracks/damage → Replace the clutch re-
ECB03110
lease cylinder.
NOTICE • Clutch release cylinder piston
Rust/scratches/wear → Replace the clutch
Clutch fluid may damage painted surfaces or
release cylinder and clutch release cylinder
plastic parts. Therefore, always clean up any
piston as a set.
spilt clutch fluid immediately.
2. Check:
4. Bleed: • Clutch release cylinder
• Clutch system
EBS30611
Refer to “BLEEDING THE HYDRAULIC ASSEMBLING THE CLUTCH RELEASE
CLUTCH SYSTEM” on page 3-24. CYLINDER
5. Check: EWB04100
• Clutch fluid level WARNING

Below the minimum level mark → Add the • Before installation, all internal clutch com-
specified brake and clutch fluid to the proper ponents must be cleaned and lubricated
level. with clean or new clutch fluid.
5-60
CLUTCH
• Never use solvents on internal clutch com- ECB03270
ponents as they will cause the piston seal NOTICE

to swell and distort. When installing the clutch hose onto the
• Whenever a clutch release cylinder is dis- clutch release cylinder, make sure the pipe
assembled, replace the piston seal. “a” touches the projection “b” on the clutch
release cylinder body.
DOT 4
EBS30612
INSTALLING THE CLUTCH RELEASE 1 New

2
CYLINDER
3
1. Install: a
• Oil seal “1” New
(to the transmission case “2”)
b
Install depth “a”
0–0.5 mm (0–0.02 in) 4. Fill:
• Clutch master cylinder reservoir
brake and clutch fluid)

DOT 4
New 1
EWB04020
WARNING
• Use only the designated clutch fluid. Other
2 clutch fluids may cause the rubber seals to
a deteriorate, causing leakage and poor
2. Install: clutch performance.
• Clutch release cylinder gasket New • Refill with the same type of clutch fluid that
• Dowel pins is already in the system. Mixing clutch flu-
• Clutch release cylinder ids may result in a harmful chemical reac-
tion, leading to poor clutch performance.
Clutch release cylinder bolt • When refilling, be careful that water does
10 Nm (1.0 m·kgf, 7.2 ft·lbf) not enter the clutch fluid reservoir. Water
T.
R.
LOCTITE® will significantly lower the boiling point of

the clutch fluid and could cause vapor lock.
3. Install: ECB03110
• Clutch hose gaskets “1” New NOTICE

• Clutch hose “2” Clutch fluid may damage painted surfaces or
• Clutch hose union bolt “3” plastic parts. Therefore, always clean up any
Clutch hose union bolt spilt clutch fluid immediately.
27 Nm (2.7 m·kgf, 20 ft·lbf) 5. Bleed:
T.
R.
• Clutch system
EWB02870
WARNING
CLUTCH SYSTEM” on page 3-24.
Proper brake hose routing is essential to in- 6. Check:
sure safe vehicle operation. • Clutch fluid level
specified brake and clutch fluid to the proper
level.
5-61
CLUTCH

5-62
SHIFT SHAFT
EBS20137
SHIFT SHAFT
Removing the shift shaft and stopper lever
New
LS 11 2 1
8
LT
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
9
10 New
FW 4
D LT 5
6 E
7
22 Nm (2.2 m•kgf, 16 ft•Ibf) 3

T.R
.

Clutch assembly Refer to “CLUTCH” on page 5-46.
Shift arm Refer to “SHIFT LEVER” on page 5-44.
1 Circlip 1
2 Washer 1
3 Shift shaft 1
4 Washer 1
5 Circlip 1
6 Washer 1
7 Shift shaft spring 1
8 Stopper lever spring 1
9 Stopper lever 1
10 Shift shaft spring stopper 1
11 Oil seal 1
5-63
SHIFT SHAFT
EBS30683
CHECKING THE SHIFT SHAFT 5

1. Check: 2
• Shift shaft
Bends/damage/wear → Replace.
• Shift shaft spring
Damage/wear → Replace. 4
EBS30163
CHECKING THE STOPPER LEVER 3

1. Check: 1
• Stopper lever 3. Install:
Bends/damage → Replace. • Washer
Roller turns roughly → Replace the stopper
• Circlip “1” New
lever.
TIP
EBS30685
Be sure the circlip sharp-edged corner “a” is po-
INSTALLING THE SHIFT SHAFT
sitioned opposite side to the washer.
1. Install:
(to the transmission case “2”) 1 New
Installed depth “a”
1.0 - 1.5 mm (0.04 - 0.06 in) a
1 New 2
1 New
a
2. Install:
• Shift shaft spring stopper “1”
• Shift shaft assembly
• Stopper lever spring “2”
Shift shaft spring stopper

22 Nm (2.2 m·kgf, 16 ft·lbf)
T.
R.
LOCTITE®
TIP
• Hook the end of the shift shaft spring “3” onto
the shift shaft spring stopper “1”.
• Hook the ends of the stopper lever spring “2”
onto the stopper lever “4” and the transmission
case boss “5”.
• Mesh the stopper lever with the shift drum seg-
ment assembly.
5-64
CRANKCASE
EBS20045
CRANKCASE
Removing the primary drive shaft
New
3
2 37 Nm (3.7 m•kgf, 27 ft•Ibf)
T.R
.
LS
(6)
New
New 4
(6)
1
New
E
(4)
New
12 Nm (1.2 m•kgf, 8.7 ft•Ibf)
*
T.R
.
120 Nm (12 m•kgf, 87 ft•lbf)

T.R
.
LS
* ISO FLEX TOPAS NB52

Engine 5-6.
Cylinder head Refer to “CYLINDER HEAD” on page 5-19.
Refer to “AC MAGNETO AND STARTER
AC magneto rotor CLUTCH” on page 5-29.
Refer to “ELECTRIC STARTER” on page
Starter motor 5-34.
Refer to “OIL PAN AND OIL PUMP” on page
Oil pump assembly 5-38.
Water pump Refer to “WATER PUMP” on page 6-9.
1 Primary drive shaft yoke 1
2 Universal joint (engine side) 1
3 Universal joint yoke (engine side) 1
4 Flywheel 1
5-65
CRANKCASE
Removing the primary drive shaft

New
37 Nm (3.7 m•kgf, 27 ft•Ibf)
T.R
.
LS
(6)
New
5 New
(6)
New
10 8
E
11 (4)
7 New
9
12 Nm (1.2 m•kgf, 8.7 ft•Ibf)
*
T.R
.
6
120 Nm (12 m•kgf, 87 ft•lbf)
T.R
.
LS
* ISO FLEX TOPAS NB52

5 Primary drive shaft assembly 1
6 Circlip 1
7 Primary drive shaft bearing housing 1
8 Oil seal 1
9 Bearing 1
10 Collar 1
11 Primary drive shaft 1
5-66
CRANKCASE
Separating the crankcase
1st 15 Nm (1.5 m•kgf, 11 ft•lbf) 1st 15 Nm (1.5 m•kgf, 11 ft•lbf)

2nd 15 Nm (1.5 m•kgf, 11 ft•lbf) New 2nd 15 Nm (1.5 m•kgf, 11 ft•lbf)
T.R
T.R
.
.
3rd Specified angle 95–100˚ 3rd Specified angle 75–80˚
(4)
24 Nm (2.4 m•kgf, 17 ft•Ibf) 12 Nm (1.2 m•kgf, 8.7 ft•Ibf)
T.R
T.R
.
.
12 Nm (1.2 m•kgf, 8.7 ft•Ibf) (4)
T.R
(3)
.
* E
24 Nm (2.4 m•kgf, 17 ft•Ibf) (3) E E

T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
E 4
12 Nm (1.2 m•kgf, 8.7 ft•Ibf)

1
T.R
.
(5) (3)
6 2
E
7 LT
5
3
LT
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
* Apply Yamaha bond No. 1215 (90890-85505).
1 Oil pump drive chain guide 1

2 Timing chain guide (exhaust side) 1
3 Timing chain guide (intake side) 1
4 Oil pump drive chain 1
5 Timing chain 1
6 Crankcase (lower) 1
7 Dowel pin 1
5-67
CRANKCASE
EBS30648
DISASSEMBLING THE UNIVERSAL JOINT Rotor holding tool

(ENGINE SIDE) 90890-01235
1. Remove: Universal magneto and rotor
• Universal joint (engine side) holder
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ YU-01235
a. Remove the circlips “1”
b. Place the universal joint in a press.
c. With a suitable diameter pipe “2” beneath the
primary drive shaft yoke “3”, press the bear- 1
ing “4” into the pipe as shown.
TIP
It may be necessary to lightly tap the primary
drive shaft yoke with a punch.
2 3
EBS30182
1 SEPARATING THE CRANKCASE
3
1. Remove:
• Crankcase bolts
TIP
• Place the engine upside down.
2 • Loosen the bolts in decreasing numerical order
of the embossed numbers on the crankcase.
• Loosen each bolt 1/4 of a turn at a time. After
4
all of the bolts are fully loosened, remove them.
1
×4 ×4 ×3 ×1 ×5 ×3 ×3 ×1
d. Repeat the steps for the opposite bearing.
e. Remove the universal joint.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 23
EBS30649 24 22 20 19 21
REMOVING THE PRIMARY DRIVE SHAFT 11
ASSEMBLY 1 3 7
9 5
1. Remove:
• Flywheel “1”
• Primary drive shaft assembly 6 2 4 8
10
TIP 12
18 17
Use the rotor holding tool “2” and loosen the fly- 16 14 13 15
wheel bolts and primary drive shaft assembly
bolt “3”.
2. Remove:
• Crankcase (lower)
5-68
CRANKCASE
ECB03210
TIP
NOTICE
Do not allow any sealant to come into contact
Tap on one side of the crankcase with a soft-
with the oil gallery, or crankshaft journal bear-
face hammer. Tap only on reinforced por-
ings.
tions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully 1
and make sure that the crankcase halves
separate evenly.
EBS30650
CHECKING THE TIMING CHAIN, OIL PUMP

DRIVE CHAIN, AND TIMING CHAIN GUIDES
1. Check:
• Timing chain 1
• Oil pump drive chain
Damage/stiffness → Replace the chain and 3. Install:
camshaft sprocket as a set. • Dowel pin
4. Fit the crankcase (lower) onto the upper
crankcase. Tap lightly on the crankcase with
a soft-face hammer.
5. Install:
• Crankcase bolts
TIP
• Lubricate the bolts “1”–“8” thread, mating sur-
faces and washers with engine oil.
• Lubricate the bolts “9”–“15”, “19”–“24” thread,
mating surfaces with engine oil.
2. Check:
• Apply Yamaha bond No.1215 to the threads of
• Timing chain guide (exhaust side)
the bolts “16”–“18”.
• Timing chain guide (intake side)
• Finger tighten the bolts.
EBS30186
• M9 × 160 mm : “1”–“4” New
CHECKING THE CRANKCASE • M9 × 105 mm : “5”–“8” New
1. Thoroughly wash the crankcase halves in a • M8 × 70 mm : “9”, “10”, “12”
mild solvent. • M8 × 55 mm : “11”
2. Thoroughly clean all the gasket surfaces and • M6 × 80 mm : “15”, “19”, “20”
crankcase mating surfaces. • M6 × 80 mm (black) : “16”–“18”
3. Check: • M6 × 55 mm : “13”, “14”, “21”, “22”, “24”
• Crankcase • M6 × 52 mm : “23”
• Oil delivery passages
EBS30187
ASSEMBLING THE CRANKCASE

1. Thoroughly clean the crankcase mating sur-
faces.
2. Apply:
• Sealant “1”
(onto the crankcase mating surfaces)

90890-85505
5-69
CRANKCASE
×4 ×4 ×3 ×1 ×5 ×3 ×3 ×1 ×4 ×4
23
24 22 20 19 21
11
1 3 7 1 3 7
9 5 5
6 2 4 8 6 2 4 8
10
12
18 17
16 14 13 15
6. Tighten: 7. Tighten:
• Crankcase bolts “1”–“8” • Crankcase bolts “9”–“24”
Crankcase bolts “1”–“4” Crankcase bolts “9”–“12”

1st: 15 Nm (1.5 m·kgf, 11 ft·lbf) 24 Nm (2.4 m·kgf, 17 ft·lbf)
T.
T.
R.
R.
*2nd: 15 Nm (1.5 m·kgf, 11 ft·lbf) Crankcase bolts “13”–“24”

3rd: 95–100° 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Crankcase bolts “5”–“8”
1st: 15 Nm (1.5 m·kgf, 11 ft·lbf) TIP
*2nd: 15 Nm (1.5 m·kgf, 11 ft·lbf) Tighten the bolts in the tightening sequence cast
3rd: 75–80°
on the crankcase.
* Following the tightening order, loosen the
bolt one by one and then retighten it to the
specific torque.
EWB04060
WARNING
If the crankcase bolt is tightened more than
the specified angle, do not loosen the bolt
and then re-tighten it. Instead, replace the ×3 ×1 ×5 ×3 ×3 ×1
crankcase bolt with a new one and perform
the procedure again. 23
ECB03220
24 22 20 19 21
NOTICE
Do not use a torque wrench to tighten the 11
crankcase bolt to the specified angle. 9
TIP
Tighten the bolts in the tightening sequence cast 10
on the crankcase. 12
18 17
16 14 13 15
5-70
CRANKCASE
EBS30651
INSTALLING THE PRIMARY DRIVE SHAFT

ASSEMBLY 1
1. Install:
(into the bearing housing “2”)
• Bearing “3”
• Primary drive shaft “4”
• Circlip “5” New 3 2
5.0–5.5 mm (0.20–0.22 in)
TIP
Be sure the circlip sharp-edged corner “b” is po-
sitioned opposite side to the bearing.
a 1 New
4
2
3 5 New
b
2. Install:
• Primary drive shaft assembly
• Flywheel “1”
TIP
Tighten the primary drive shaft assembly bolt “2”
and flywheel bolts with the rotor holding tool “3”.
Rotor holding tool

90890-01235
holder
YU-01235
Primary drive shaft assembly bolt

120 Nm (12 m·kgf, 87 ft·lbf)
T.
R.
Flywheel bolt
37 Nm (3.7 m·kgf, 27 ft·lbf)
5-71
CONNECTING RODS AND PISTONS
EBS20133

Removing the connecting rods and pistons
1st 20 Nm (2.0 m•kgf, 14 ft•lbf)
New
T.R
2nd Specified angle 115–125˚
.
3 New New
4 1 M
2
M
5
E
3 New
E
10
E
8
E
7

Crankcase (lower) Refer to “CRANKCASE” on page 5-65.
1 Connecting rod cap 3
2 Big end lower bearing 3
3 Piston pin clip 6
4 Piston pin 3
5 Piston 3
6 Connecting rod 3
7 Big end upper bearing 3
8 Top ring 3
9 2nd ring 3
10 Oil ring 3
5-72
EBS30656
REMOVING THE CONNECTING RODS AND 4

PISTONS 3
The following procedure applies to all of the con-
necting rods and pistons.
1. Remove: 2
• Connecting rod cap “1”
• Connecting rod 1
• Big end bearings
TIP
Identify the position of each big end bearing so
that it can be reinstalled in its original place. 3 2
5
3. Remove:
• Top ring
2. Remove: • 2nd ring
• Piston pin clips “1” • Oil ring
• Piston pin “2” TIP
• Piston “3” When removing a piston ring, open the end gap
• Connecting rod “4” with your fingers and lift the other side of the ring
ECB01380
over the piston crown.
NOTICE
Do not use a hammer to drive the piston pin
out.
TIP
• For reference during installation, put identifica-
tion marks on the piston crown.
• Before removing the piston pin, deburr the pis-
ton pin clip groove and the piston pin bore ar-
ea. If both areas are debarred and the piston
pin is still difficult to remove, remove it with the
piston pin puller set “5”. EBS30147
CHECKING THE CYLINDER AND PISTON

Piston pin puller set 1. Check:
90890-01304 • Piston wall
Piston pin puller • Cylinder wall
YU-01304 Vertical scratches → Replace the cylinder,
and replace the piston and piston rings as a
set.
2. Measure:
• Piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the cylinder
bore gauge.
5-73
TIP
Measure cylinder bore “C” by taking side-to-side
a
and front-to-back measurements of the cylinder.
Bore
80.000–80.010 mm (3.1496– P
3.1500 in)
Wear limit
80.080 mm (3.1528 in)
Taper limit
0.050 mm (0.0020 in) a. 8.0 mm (0.31 in) from the bottom edge of the
Out of round limit piston
0.050 mm (0.0020 in)
h. If out of specification, replace the piston and
piston rings as a set.
“C” = maximum of D1, D2, D3, D4, D5, D6
i. Calculate the piston-to-cylinder clearance
Taper (front-to-back) = maximum difference be- with the following formula.
tween D1, D3, D5
Piston-to-cylinder clearance = Cylinder bore “C” –
Taper (side-to-side) = maximum difference be- Piston skirt diameter “P”
tween D2, D4, D6
Out of round (top) = difference between D1, D2
Piston-to-cylinder clearance
Out of round (middle) = difference between D3,
0.035–0.060 mm (0.0014–0.0024
D4
in)
Out of round (bottom) = difference between D5,
D6 j. If out of specification, replace the cylinder,
and replace the piston and piston rings as a
set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30148
CHECKING THE PISTON RINGS

1. Measure:
• Piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
TIP
f. If out of specification, replace the cylinder, Before measuring the piston ring side clearance,
and replace the piston and piston rings as a eliminate any carbon deposits from the piston
set. ring grooves and piston rings.
g. Measure piston skirt diameter “P” with the mi-
crometer. Piston ring
Top ring
Piston Ring side clearance limit
Diameter 0.12 mm (0.0047 in)
79.950–79.965 mm (3.1476– 2nd ring
3.1482 in) Ring side clearance limit
0.12 mm (0.0047 in)
5-74
1. Check:
• Piston pin
Blue discoloration/grooves → Replace the
piston pin, and then check the lubrication sys-
tem.
2. Measure:
• Piston pin outside diameter “a”
Out of specification → Replace the piston pin.
Piston pin outside diameter limit

2. Install: 18.971 mm (0.7469 in)
• Piston ring
(into the cylinder)
TIP
Use the piston crown to level the piston ring near
bottom of cylinder “a”, where cylinder wear is
lowest.
3. Measure:
• Piston pin bore diameter “b”
Out of specification → Replace the piston.
Piston pin bore inside diameter

b limit
19.045 mm (0.7498 in)
b. Upper of cylinder
3. Measure:
• Piston ring end gap
Out of specification → Replace the piston
ring.
TIP
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces- b
sive, replace all three piston rings.
Top ring EBS30666
End gap (installed) limit CHECKING THE CONNECTING RODS

0.50 mm (0.0197 in) 1. Measure:
2nd ring • Crankshaft-pin-to-big-end-bearing clearance
End gap (installed) limit Out of specification → Replace the big end
0.70 mm (0.0276 in) bearings.
•
EBS30149
Oil clearance (using plasti-
CHECKING THE PISTON PIN gauge®)
The following procedure applies to all of the pis- 0.032–0.050 mm (0.0013–0.0020
ton pins. in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
connecting rods.
5-75
ECB03230
• Make sure that the characters “d” on both the
NOTICE connecting rod and connecting rod cap are
Do not interchange the big end bearings and aligned.
connecting rods. To obtain the correct
crankshaft-pin-to-big-end-bearing clear-
ance and prevent engine damage, the big d
end bearings must be installed in their origi-
nal positions.
a. Clean the big end bearings, crankshaft pins,
and the inside of the connecting rods halves.
b. Install the big end upper bearing into the con- c
necting rod and the big end lower bearing into
the connecting rod cap.
TIP
Align the projections “a” on the big end bearings
with the notches “b” in the connecting rod and
connecting rod cap.
b a C
d
e. Tighten the connecting rod bolts.
Refer to “INSTALLING THE CONNECTING
RODS AND PISTONS” on page 5-77.
f. Remove the connecting rod and big end
c. Put a piece of Plastigauge® “1” on the crank- bearings.
shaft pin. g. Measure the compressed Plastigauge®
width on the crankshaft pin. If the crankshaft-
1 pin-to-big-end-bearing clearance is out of
specification, select replacement big end
bearings.
d. Assemble the connecting rod halves.

TIP
• Do not move the connecting rod or crankshaft
until the clearance measurement has been
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
completed.
2. Select:
• Apply molybdenum disulfide oil onto the bolts,
• Big end bearings (P1-P3)
threads, and bolt seats.
• Make sure that the “Y” mark “c” on the connect- TIP
ing rod faces towards the rear side (AC mag- • The numbers “A” stamped into the crankshaft
neto rotor side) of the crankshaft. web and the numbers “B” on the connecting
rods are used to determine the replacement
big end bearings sizes.
5-76
• “P1”–“P3” refer to the bearings shown in the TIP

crankshaft illustration. • Be sure to reinstall each big end bearing in its
For example, if the connecting rod “P1” and original place.
• Align the projections “a” on the big end bear-
the crankshaft web “P1” numbers are 6 and 4
ings with the notches “b” in the connecting rods
respectively, then the bearing size for “P1” is: and connecting rod caps.
“P1” (connecting rod) - “P1” (crankshaft) = 6 - 4 =
2 (black) b a
Bearing color code

1. Blue 2. Black 3. Brown 4.
Green 5. Yellow 6. Pink
P1 2. Install:
• Oil ring expander “1”
P2 P3 • Lower oil ring rail “2”
• Upper oil ring rail “3”
• 2nd ring “4”
• Top ring “5”
(into the piston)
A TIP
P1 Be sure to install the piston rings so that the
P2 4
33
44
manufacturer’s marks “a” face up.
P3 44
5
4
3
1
2
3. Install:
• Piston “1”
C (onto the respective connecting rod “2”)
• Piston pin “3”
• Piston pin clips “4” New
B TIP
EBS30673 • Apply engine oil onto the piston pin.
INSTALLING THE CONNECTING RODS AND • Make sure that the “Y” mark “a” on the connect-
PISTONS ing rod faces left when the punch mark “b” on
The following procedure applies to all of the con- the piston is pointing up as shown.
necting rods and pistons. • Install the piston pin clips, so that the clip ends
1. Install: are 3 mm (0.12 in) “c” or more from the cutout
• Big end bearings in the piston.
• Reinstall each piston into its original cylinder.
5-77
a b Recommended lubricant
Engine oil
1
7. Install:
2 3 • Piston assemblies “1”
New 4 (into the cylinder “2” and onto the crankshaft
pin)

90890-05158
YM-08037
c 1
4 New 2
4. Lubricate:
• Piston
• Piston rings
• Cylinder 8. Install:
(with the recommended lubricant) • Connecting rod caps
• Connecting rod bolts
Recommended lubricant TIP
Engine oil • Make sure the “Y” marks “a” on the connecting
rods face towards the rear side (AC magneto
5. Offset:
rotor side) of the crankshaft.
• Piston ring end gaps
• Make sure that the projection “b” on the con-
necting rod cap faces the same direction as the
90˚ “Y” mark “a” on the connecting rod.
b,e c • Apply Molybdenum disulfide oil to the bolt
threads and seats.
90˚ a
a,d
45˚
a. Top ring
b. 2nd ring
c. Upper oil ring rail
d. Oil ring expander b
e. Lower oil ring rail
A. Exhaust side 9. Tighten:
• Connecting rod bolts “1”
6. Lubricate:
• Crankshaft pins
• Connecting rod big end bearing inner surface
5-78
EWB04070
1 WARNING
If the connecting rod bolt is tightened more
than the specified angle, do not loosen the
bolt and then re-tighten it. Instead, replace
the connecting rod bolt with a new one and
perform the procedure again.
ECB03240
NOTICE
Do not use a torque wrench to tighten the
connecting rod bolt to the specified angle.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
TIP ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Tighten the connecting rod bolts using the fol-

lowing procedure.
a. Tighten the connecting rod bolts with a torque
wrench.
Connecting rod bolt (1st)

20 Nm (2.0 m·kgf, 14 ft·lbf)
T.
R.
b. Put a mark “1” on the corner of the connecting

rod bolt “2” and the connecting rod cap “3”.
c. Tighten the connecting rod bolts further to

reach the specified angle 115–125°.
Connecting rod bolt (final)

Specified angle 115–125°
T.
R.
115-125˚
5-79
CRANKSHAFT AND BALANCER SHAFT
EBS20136

Removing the crankshaft and balancer shaft
E
3
3
3
E
LS
4 2
New 4
4
35 Nm (3.5 m•kgf, 25 ft•Ibf) New 4
T.R
.
LS
E E
New
E
New 1
New
E
5
6
8
9
10 35 Nm (3.5 m•kgf, 25 ft•Ibf)
T.R
. E
7
6
5
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) LT New

T.R
.

Crankcase (lower) Refer to “CRANKCASE” on page 5-65.
Refer to “CONNECTING RODS AND PIS-
Connecting rods
TONS” on page 5-72.
1 Bearing 1
2 Crankshaft 1
3 Crankshaft journal lower bearing 4
4 Crankshaft journal upper bearing 4
5 Lock washer 2
6 Washer 2
7 Rear balancer weight 1
8 Front balancer weight 1
9 Water pump drive gear 1
10 Washer 1
5-80
Removing the crankshaft and balancer shaft
LS
New
20
35 Nm (3.5 m•kgf, 25 ft•Ibf) New
T.R
.
LS
E
20 20 E
New
E
New
New
E
15
18
19
12 35 Nm (3.5 m•kgf, 25 ft•Ibf)
T.R
.
13
14 E
17
11
16
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) LT New

T.R
.

11 Balancer shaft 1
12 Bearing 1
13 Bearing inner race 1
14 Washer 1
15 Balancer driven gear 1
16 Bearing retainer 1
17 Bearing 1
18 Circlip 1
19 Bearing outer race 1
20 Oil nozzle 3
5-81
EBS30674
REMOVING THE CRANKSHAFT AND

BALANCER SHAFT
1. Remove:
• Crankshaft
• Crankshaft journal bearings
TIP
Identify the position of each crankshaft journal
bearings so that it can be reinstalled in its origi-
nal place.
2. Straighten the lock washer tab.
3. Loosen: 2. Check:
• Balancer weight bolts “1” • Crankshaft journal surfaces
• Crankshaft pin surfaces
TIP
• Bearing surfaces
Place a piece of wood “a” between the balancer Scratches/wear → Replace the crankshaft.
weight “2” and crankcase. 3. Check:
• Balancer drive gear
• Balancer driven gear
a Damage/wear → Replace the crankshaft as-
sembly and balancer driven gear as a set.
Excessive noise during operation → Replace
1 the crankshaft assembly and balancer driven
gear as a set.
2 4. Measure:
• Crankshaft-journal-to-crankshaft-journal-
bearing clearance
Out of specification → Replace the crank-
shaft journal bearings.
Journal oil clearance (using plas-

tigauge®)
1 0.027–0.045 mm (0.0011–0.0018
2 in)
a ECA13920
NOTICE
EBS30676
Do not interchange the crankshaft journal
CHECKING THE CRANKSHAFT bearings. To obtain the correct crankshaft-
1. Measure: journal-to-crankshaft-journal-bearing clear-
• Crankshaft runout ance and prevent engine damage, the crank-
Out of specification → Replace the crankshaft journal bearings must be installed in
shaft. their original positions.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Runout limit a. Clean the crankshaft journal bearings, crank-
0.030 mm (0.0012 in) shaft journals, and bearing portions of the
crankcase.
b. Place the upper crankcase upside down on a
bench.
c. Install the crankshaft journal upper bearings
“1” and the crankshaft into the upper crank-
case.
5-82
TIP g. Remove the crankcase (lower) and the

Align the projections “a” on the crankshaft jour- crankshaft journal lower bearings.
nal upper bearings with the notches “b” in the up- h. Measure the compressed Plastigauge®
per crankcase. width “e” on each crankshaft journal.
If the crankshaft-journal-to-crankshaft-jour-
nal-bearing clearance is out of specification,
1 select replacement crankshaft journal bear-
a ings.
d. Put a piece of Plastigauge® “2” on each

crankshaft journal.
TIP
Do not put the Plastigauge® over the oil hole in ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
the crankshaft journal. 5. Select:
• Crankshaft journal bearings (J1 –J4)
TIP
2
• The numbers “A” stamped into the crankshaft
web and the numbers “B” stamped into the
crankcase (lower) are used to determine the
replacement crankshaft journal bearing sizes.
• “J1”–“J4” refer to the bearings shown in the
crankshaft and crankcase (lower) illustration.
• If “J1”–“J4” are the same, use the same size for
all of the bearings.
e. Install the crankshaft journal lower bearings
“3” into the crankcase (lower) and assemble For example, if the crankcase “J1” and crank-
the crankcase halves. shaft web “J1” numbers are 6 and 4 respec-
TIP tively, then the bearing size for “J1” is:
• Align the projections “c” of the crankshaft jour- “J1” (crankcase) - “J1” (crankshaft web) +2 = 6 - 4
nal lower bearings with the notches “d” in the + 2 = 4 (green)
crankcase (lower).
• Do not move the crankshaft until the clearance
measurement has been completed. Bearing color code
2. Black 3. Brown 4. Green 5.
Yellow 6. Pink 7. Red 8. White
3
d
J1 J2 J3 J4
f. Tighten the bolts to specification in the tight-

ening sequence cast on the crankcase.
Refer to “CRANKCASE” on page 5-65.
5-83
A
1
J1
4
J2 33
44
J3 44 a c
J4
b
2
2. Install:
• Water pump drive gear “1”
TIP
Align the punch mark “a” on the water pump
gear with the shorter spline “b” on the balancer
shaft end.
a
J4 J3 J2 J1 B
1
EBS30677
CHECKING THE BALANCER SHAFT

1. Measure: b
• Balancer shaft runout
Out of specification → Replace the balancer
shaft.
Balancer shaft runout limit 3. Install:

0.200 mm (0.0079 in) • Rear balancer weight “1”
• Front balancer weight “2”
• Washers
• Lock washers New
• Balancer weight bolts
TIP
Align the punch mark “a” on the balancer weight
with the shorter spline “b” on the balancer shaft
end.
EBS30678
INSTALLING THE BALANCER SHAFT

1. Install:
• Balancer driven gear “1”
• Balancer shaft “2”
TIP
• Face the punch mark “a” on the balancer driv-
en gear inward.
• Align the projection “b” on the balancer shaft
with the slot “c” in the balancer driven gear.
5-84
5. Bend the lock washer tab.
1 EBS30679
INSTALLING THE CRANKSHAFT

1. Install:
a • Crankshaft journal upper bearings
(into the upper crankcase)
b
• Crankshaft journal lower bearings
(into the lower crankcase)
• Crankshaft
TIP
• Align the projections “a” on the crankshaft jour-
a
nal bearings “1” with the notches “b” in the
2 crankcase.
• Be sure to install each crankshaft journal bear-
ings in its original place.
b
1
a
4. Tighten:
• Balancer weight bolts “1”
TIP
Place a wood “a” between the balancer weight
“2” and crankcase. b
Balancer weight bolt 2. Install:

35 Nm (3.5 m·kgf, 25 ft·lbf) • Crankshaft “1”
T.
R.
TIP
2 • Align the punch mark “a” of the balancer drive
gear “2” with the punch mark “b” of the balanc-
er driven gear “3”.
• Align the hole “c” in the bearing “4” with the pro-
1 jection “d” on the upper crankcase.
1
a
2
5-85
2 3
1
5-86
TRANSMISSION (1)
EBS20047
TRANSMISSION (1)
Disconnecting the lead, hoses, and couplers
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Floor boards 4-12.
Parking brake lever Refer to “PARKING BRAKE” on page 4-48.
Shift lever/Shift arm/Reverse gear lock arm Refer to “SHIFT LEVER” on page 5-44.
Clutch release cylinder Refer to “CLUTCH” on page 5-46.
Drain.
Transmission oil Refer to“CHANGING THE TRANSMISSION
OIL” on page 3-20.
Fuel tank breather hoses/Fuel hose/Fuel pump Refer to “FUEL TANK” on page 7-1.
coupler
5-87
TRANSMISSION (1)
Disconnecting the lead, hoses, and couplers
3 5
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Differential assembly/Front drive shaft SEMBLY AND FRONT DRIVE SHAFT” on
page 8-4.
Refer to “REAR CONSTANT VELOCITY
SHAFT ASSEMBLIES, FINAL DRIVE AS-
Final drive assembly/Rear drive shaft SEMBLY AND REAR DRIVE SHAFT” on
page 8-19.
1 Transmission case breather hose 1 1 Disconnect.
2 Transmission case breather hose 2 1 Disconnect.
3 Neutral switch coupler 1 Disconnect.
4 Gear position sensor coupler 1 Disconnect.
5 Speed sensor coupler 1 Disconnect.
6 Ground lead 1 Disconnect.
5-88
TRANSMISSION (1)
Removing the transmission case
32 Nm (3.2 m•kgf, 23 ft•Ibf) 4 32 Nm (3.2 m•kgf, 23 ft•Ibf)
T.R
.
T.R
.
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
T.R
.
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
60 Nm (6.0 m•kgf, 43 ft•Ibf)
T.R
.
LS
1
New
2
5 17 Nm (1.7 m•kgf, 12 ft•Ibf)
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

1 Drive shaft cover 1
2 Drive shaft universal joint cover 1
3 Flywheel housing 1
4 Sub-frame 1
5 Transmission case 1
5-89
TRANSMISSION (1)
EBS30659
INSTALLING THE TRANSMISSION CASE

1. Install:
• O-ring New
• Transmission case “1”
Transmission case nut

60 Nm (6.0 m·kgf, 43 ft·lbf)
T.
R.
TIP
Make sure that the universal joint yoke “a” on the
transmission case and the universal joint yoke
“b” on the engine are aligned as shown in the il-
lustration.
1
b
a
New
2. Install:
• Sub-frame
• Flywheel housing “1”
• Drive shaft universal joint cover “2”
• Drive shaft cover “3”
Sub-frame bolt (front)

17 Nm (1.7 m·kgf, 12 ft·lbf)
T.
R.
Sub-frame bolt (rear)

32 Nm (3.2 m·kgf, 23 ft·lbf)
Flywheel housing bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Drive shaft universal joint cover
bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Drive shaft cover bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
3
2
5-90
TRANSMISSION (2)
EBS20129
TRANSMISSION (2)
Separating the transmission case
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
(5) 190 Nm (19 m•kgf, 137 ft•lbf)
T.R
.
(16) 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
LS
17 Nm (1.7 m•kgf, 12 ft•Ibf)
T.R
.
New
5 1
New 2
6
LS
New
New
New
New
LS 3 New
LT
New
LT
20 Nm (2.0 m•kgf, 14 ft•Ibf) 4

T.R
.
New
LS
20 Nm (2.0 m•kgf, 14 ft•Ibf)

T.R
.
New 115 Nm (11.5 m•kgf, 83 ft•lbf)

T.R
.
LT
7
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) LT
LT
T.R
.
LS 4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

New
T.R
.

Clutch assembly Refer to “CLUTCH” on page 5-46.
Torque limiter Refer to “MIDDLE GEAR” on page 5-111.
Transmission case 5-87.
1 Universal joint yoke (Primary driven gear side) 1
2 Universal joint (Primary driven gear side) 1
3 Primary driven shaft yoke bolt 1
4 Primary driven shaft yoke 1
Rear drive shaft coupling gear nut (middle driv-
5 1
en gear side)
Rear drive shaft coupling gear (middle driven
6 1
gear side)
7 Gear position sensor 1
5-91
TRANSMISSION (2)
Separating the transmission case

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
(5) 190 Nm (19 m•kgf, 137 ft•lbf)
T.R
.
(16)
11
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
LS
17 Nm (1.7 m•kgf, 12 ft•Ibf)
T.R
.
New
12
New
LS
New 10
New
New
8
New
LS New
LT
New
LT
20 Nm (2.0 m•kgf, 14 ft•Ibf)

T.R
.
New
LS
20 Nm (2.0 m•kgf, 14 ft•Ibf)

T.R
.
New T.R 115 Nm (11.5 m•kgf, 83 ft•lbf)
.
LT
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 9 LT

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

New
T.R
.

8 Neutral switch 1
9 Speed sensor 1
10 Dipstick 1
11 Oil strainer 1
12 Transmission case (rear) 1
5-92
TRANSMISSION (2)
Removing the transmission case bearings
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
2 LT
LT
2
1
E
2
2 2
E 3
E 2
E

Primary driven shaft assembly/Transmission oil Refer to “TRANSMISSION (3)” on page
pump assembly 5-99.
Reverse idle gear shaft/Shift drum/Main axle as- Refer to “TRANSMISSION (4)” on page
sembly/Drive axle assembly 5-104.
Middle driven shaft assembly Refer to “MIDDLE GEAR” on page 5-111.
1 Main axle bearing retainer 1
2 Bearing 8
3 Washer 1
5-93
TRANSMISSION (2)
EBS30661
DISASSEMBLING THE UNIVERSAL JOINT Universal joint holder

(PRIMARY DRIVEN GEAR SIDE) 90890-04062
1. Remove: Universal joint holder
• Universal joint (primary driven gear side) YM-04062
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
universal joint yoke “3”, press the bearing “4”
into the pipe as shown.
TIP
It may be necessary to lightly tap the universal
joint yoke with a punch.
EBS30663
REMOVING THE REAR DRIVE SHAFT

COUPLING GEAR (MIDDLE DRIVEN GEAR
SIDE)
1. Remove:
• Rear drive shaft coupling gear nut (middle
driven gear side)
• Washer
• Rear drive shaft coupling gear (middle driven
gear side)
TIP
Use the coupling gear/middle shaft tool “1” to
hold the rear drive shaft coupling gear, then
loosen the rear drive shaft coupling gear nut.
Coupling gear/middle shaft tool

90890-01229
Gear holder
YM-01229
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30662
REMOVING THE PRIMARY DRIVEN SHAFT

YOKE
1. Remove:
1
• Primary driven shaft yoke bolt
• Washer
• Primary driven shaft yoke
TIP
Use the universal joint holder “1” to hold the pri- EBS30664
mary driven shaft yoke, then loosen the primary SEPARATING THE TRANSMISSION CASE
driven shaft yoke bolt. 1. Remove:
• Transmission case bolts
5-94
TRANSMISSION (2)
EBS30668
TIP ASSEMBLING THE TRANSMISSION CASE
Loosen each bolt 1/4 of a turn at a time, in stag- 1. Install:
es and in a crisscross pattern. After all of the • Washer
bolts are fully loosened, remove them. • Bearings
• Main axle bearing retainer
Main axle bearing retainer bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
LOCTITE®
TIP
Be sure to install the main axle bearing “1” and
drive axle bearing “2” so that the seals “3” are
facing outward.
EBS30665
CHECKING THE TRANSMISSION OIL 3

STRAINER
1. Check:
• Oil strainer
Damage → Replace the transmission oil
pump assembly.
Contaminants → Clean with solvent.
EBS30185
CHECKING THE BEARINGS

1. Check:
1
• Bearings
Clean and lubricate, then rotate the inner
race with a finger.
Roughness → Replace.
2
2. Thoroughly clean the transmission case mat-

ing surfaces.
3. Apply:
• Sealant “1”
EBS30667
(onto the transmission case mating surfaces)
CHECKING THE TRANSMISSION CASE
1. Thoroughly wash the transmission case
90890-85505
halves in a mild solvent. (Three bond No.1215®)
2. Thoroughly clean all the gasket surfaces and
transmission case mating surfaces. TIP
3. Check:
Do not allow any sealant to come into contact
• Transmission case
with the oil gallery.
• Oil delivery passages
5-95
TRANSMISSION (2)
1 2
×5 ×16
2
2
1
2
2 1
2
4. Fit the left transmission case (rear) onto the 7. Check:
transmission case (front). Tap lightly on the • Transmission operation
transmission case with a soft-face hammer. Rough operation → Repair.
ECB03290
NOTICE EBS30669
INSTALLING THE GEAR POSITION SENSOR

Before tightening the transmission case ECB03300
bolts, make sure the transmission gears NOTICE

shift correctly when the shift drum assembly To prevent damage to the gear position sen-
is turned by hand. sor, keep magnets (including any pickup tool
5. Install: with a magnet, magnetized screwdrivers,
• Transmission case bolts etc.) away from the gear position sensor.
6. Tighten: 1. Install:
• Transmission case bolts
• O-ring New
Transmission case bolt (M6 × 45) • Gear position sensor “1”
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
Gear position sensor bolt

R.
Transmission case bolt (M6 × 60)

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
T.
10 Nm (1.0 m·kgf, 7.2 ft·lbf)

R.
LOCTITE®
M6 × 60 “1”
M6 × 45 “2” TIP
TIP
• Lubricate the O-ring with lithium-soap-based
grease.
Tighten the bolts in stages, using a crisscross
• Fit the end “a” of the shift drum assembly into
pattern.
the opening “b” in the gear position sensor “1”.
5-96
TRANSMISSION (2)
1 Coupling gear/middle shaft tool

90890-01229
Gear holder
YM-01229
a b
a
EBS30670
INSTALLING THE REAR DRIVE SHAFT

COUPLING GEAR (MIDDLE DRIVEN GEAR
SIDE)
1. Install:
(to the rear transmission case “2”)

0.5–1.0 mm (0.02–0.04 in)
1 New
EBS30671
a INSTALLING THE PRIMARY DRIVEN SHAFT
2
YOKE
1. Install:
2. Install: (to the rear transmission case “2”)
• Rear drive shaft coupling gear (middle driven
gear side) Installed depth “a”
• Washer 1.5–2.0 mm (0.06–0.08 in)
• Rear drive shaft coupling gear nut (middle
driven gear side)
Rear drive shaft coupling gear 1 New

nut (middle driven gear side)
T.
a
R.
190 Nm (19 m·kgf, 137 ft·lbf)
TIP 2
• Apply LOCTITE® to the threads of the middle
driven shaft in the 2.0 mm (0.08 in) wide “a”
area shown in the illustration.
• Use the coupling gear/middle shaft tool “1” to 2. Install:
hold the rear drive shaft coupling gear, then • Primary driven shaft yoke
tighten the rear drive shaft coupling gear nut. • Washer
• Primary driven shaft yoke bolt “1”
Primary driven shaft yoke bolt

115 Nm (11.5 m·kgf, 83 ft·lbf)
T.
R.
LOCTITE®
5-97
TRANSMISSION (2)
TIP and forth on the bearings. If a needle is out of

• Apply LOCTITE to the primary driven shaft place, the yoke will not go all the way onto
yoke bolt in the 2.0 mm (0.08 in) wide “a” and the bearings.
10.0 mm (0.39 in) long “b” area shown in the il-
lustration.
• Use the universal joint holder “2” to hold the pri-
mary driven shaft yoke, then tighten the prima-
ry driven shaft yoke nut.
Universal joint holder

90890-04062
YM-04062
d. Press each bearing into the primary driven
shaft yoke using a suitable socket.
2 TIP
The bearing must be inserted far enough into the
universal joint yoke and primary driven shaft
yoke so that the circlip can be installed.
b
e. Install new circlips “2” into the groove of each
a 1
bearing.
EBS30672

(PRIMARY DRIVEN GEAR SIDE)
1. Install:
• Universal joint (primary driven gear side)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the universal joint into the primary driv-
en shaft yoke.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Apply lithium-soap-based grease to the bear-

ings.
c. Install the bearing “1” onto the primary driven
shaft yoke.
ECB01670
NOTICE
The needles can easily fall out of their races,
so check each bearing carefully. Slide the
universal joint driven yoke assembly back
5-98
TRANSMISSION (3)
EBS20130
TRANSMISSION (3)
Removing the primary driven shaft assembly and transmission oil pump assembly
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
T.R
.
2

Separate.
Transmission case Refer to “TRANSMISSION (2)” on page
5-91.
1 Primary driven shaft assembly 1
2 Transmission oil pump assembly 1
5-99
TRANSMISSION (3)
Disassembling the primary driven shaft
M 3
M
3

1 Spring retainer 2
2 Oil pump drive gear 1
3 Conical spring washer 6
4 Torque damper cam 1
5 Primary drive gear 1
6 Primary driven shaft 1
5-100
TRANSMISSION (3)
Disassembling the transmission oil pump
E
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
4 3
2
E

1 Oil pump housing 1
2 Oil pump outer rotor 1
3 Oil pump inner rotor 1
4 Pin 1
5 Oil pump housing cover 1
6 Oil pump driven gear 1
5-101
TRANSMISSION (3)
EBS30680
DISASSEMBLING THE PRIMARY DRIVEN b

SHAFT
1
1. Remove:
• Spring retainers “1”
TIP
While compressing the conical spring washers 2
with the damper spring compressor “2”, remove a
the spring retainers. 3
Damper spring compressor (120 1. Inner rotor

mm) 2. Outer rotor
90890-01588 3. Oil pump housing
YM-01588
3. Check:
Rough movement → Repeat step (1) and (2)
2 or replace the defective part(s).
EBS30681
CHECKING THE OIL PUMP (TRANSMISSION

CASE)
1. Check: EBS30682
• Oil pump driven gear CHECKING THE PRIMARY DRIVEN SHAFT

• Oil pump housing ASSEMBLY
• Oil pump housing cover 1. Check:
Cracks/damage/wear → Replace the defec- • Oil pump drive gear
tive part(s). Damage/wear → Replace.
2. Measure: 2. Check:
• Inner-rotor-to-outer-rotor-tip clearance “a” • Torque damper cam surface
• Outer-rotor-to-oil-pump-housing clearance Scratches/wear → Replace.
“b” 3. Check:
• Conical spring washers
Inner-rotor-to-outer-rotor-tip Checks/damage → Replace.
clearance
0.15 mm (0.0059 in) EBS30684
Limit ASSEMBLING THE OIL PUMP

0.23 mm (0.0091 in) (TRANSMISSION CASE)
Outer-rotor-to-oil-pump-housing 1. Lubricate:
clearance • Inner rotor
0.10–0.15 mm (0.0039–0.0059 in) • Outer rotor
Limit • Oil pump driven gear shaft
0.22 mm (0.0087 in) (with the recommended lubricant)
Engine oil
2. Install:
• Oil pump driven gear
5-102
TRANSMISSION (3)
• Oil pump housing cover “1” TIP

• Washer While compressing the conical spring washers
• Pin “2” with the damper spring compressor “2”, install
• Oil pump inner rotor “3” the spring retainers.
• Oil pump outer rotor
• Dowel pins
Damper spring compressor (120
• Oil pump housing
mm)
TIP 90890-01588
When installing the inner rotor, align the pin “2” YM-01588
in the oil pump driven gear shaft with the groove
“a” in the inner rotor “3”.
2
1
3
2
a
1
3. Check:
Refer to “CHECKING THE OIL PUMP
(TRANSMISSION CASE)” on page 5-102.
EBS30686
ASSEMBLING THE PRIMARY DRIVEN

SHAFT ASSEMBLY
1. Install:
• Conical spring washers “1”
TIP
Install the conical spring washers to the primary
driven shaft “2” so that they are facing in the di-
rections shown in the illustration.
1
1
1
2. Install:
• Oil pump drive gear
5-103
TRANSMISSION (4)
EBS20131
TRANSMISSION (4)
Removing the transmission, shift drum and shift forks
1 10 8
7 4
E
2 M M M
E
New 5
6 E
11 9
3 M
M
M
M 12
E
LS
New

Separate.
Transmission case Refer to “TRANSMISSION (2)” on page
5-91.
1 Reverse idle gear 1
2 Bearing 1
3 Reverse idle gear shaft 1
4 Long shift fork guide bar 1
5 Shift fork “LR” (rear) 1
6 Shift fork “LR” (front) 1
7 Short shift fork guide bar 1
8 Shift drum assembly 1
9 Shift fork “C” 1
10 Main axle assembly 1
11 Drive axle assembly 1
12 Reverse shift shaft 1
5-104
TRANSMISSION (4)
Disassembling the main axle assembly
1 2
3
4
5
6
7
8
10 9
11
12 M
13
14
M
M

1 Circlip 1
2 1st pinion gear 1
3 Toothed lock washer 1
4 Toothed washer retainer 1
5 5th pinion gear 1
6 Collar 1
7 Washer 1
8 Circlip 1
9 2nd pinion gear 1
10 Circlip 1
11 Washer 1
12 4th pinion gear 1
13 Collar 1
14 Main axle 1
5-105
TRANSMISSION (4)
Disassembling the drive axle assembly

1 2
3
4
5
6
7
8
9
M 10
11
M 12
13
M
M M
14
M

1 Circlip 1
2 Middle drive gear 1
3 Toothed lock washer 1
4 Toothed washer retainer 1
5 1st wheel gear 1
6 Collar 1
7 Washer 1
8 Circlip 1
9 5th wheel gear 1
10 Circlip 1
11 Washer 1
12 3rd wheel gear 1
13 Collar 1
14 Circlip 1
5-106
TRANSMISSION (4)
Disassembling the drive axle assembly
24 M
23 M
22
21
20 M
19
18 M
17
M
16
M M
15
M

15 Washer 1
16 Reverse wheel gear 1
17 Bearing 1
18 Washer 1
19 4th wheel gear 1
20 Circlip 1
21 Washer 1
22 2nd wheel gear 1
23 Collar 1
24 Drive axle 1
5-107
TRANSMISSION (4)
EBS30196 EBS30197
CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM

The following procedure applies to all of the shift 1. Check:
forks. • Shift drum grooves
1. Check: Damage/scratches/wear → Replace the shift
• Shift fork cam follower “1” drum.
• Shift fork pawl “2” • Shift drum segment “1”
Bends/damage/scoring/wear → Replace the Damage/wear → Replace the shift drum as-
shift fork. sembly.
• Shift drum bearing “2”
Damage/pitting → Replace the shift drum as-
sembly.
1
2
2
1
2. Check:
• Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends → Replace. EBS30198
EWB02750
CHECKING THE TRANSMISSION
WARNING 1. Measure:
Do not attempt to straighten a bent shift fork • Main axle runout
guide bar. (with a centering device and dial gauge“1”)
Out of specification → Replace the main axle.
Main axle runout limit

0.06 mm (0.0024 in)
3. Check:
• Shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift forks
and shift fork guide bar as a set.
2. Measure:
• Drive axle runout
(with a centering device and dial gauge “1”)
Out of specification → Replace the drive axle.
Drive axle runout limit

0.06 mm (0.0024 in)
5-108
TRANSMISSION (4)
b
1 New 1
a
3. Check: 2. Install:
• Transmission gears • Toothed lock washer retainer “1”
Blue discoloration/pitting/wear → Replace • Toothed lock washer “2”
the defective gear(s). TIP
• Transmission gear dogs • With the toothed lock washer retainer in the
Cracks/damage/rounded edges → Replace groove “a” in the axle, align the projection on
the defective gear(s). the retainer with an axle spline, and then install
the toothed lock washer.
• Be sure the toothed lock washer retainer
sharp-edged corner “b” is positioned opposite
side to the gear.
• Be sure to align the projection on the toothed
lock washer that is between the alignment
marks “c” with the alignment mark “d” on the re-
tainer.
A
4. Check: d
• Transmission gear engagement 2
(each pinion gear to its respective wheel
1
gear) c
Incorrect → Reassemble the transmission
axle assemblies.
5. Check: b a
• Transmission gear movement 2 1
Rough movement → Replace the defective
part(s). B
d
EBS30689
ASSEMBLING THE MAIN AXLE AND DRIVE 2

AXLE
1
1. Install: c
TIP b a
Install the circlip so that a spline “a” is in the cen-
ter of the gap between the circlip ends “b” as 2 1
shown. A. Main axle
B. Drive axle
5-109
TRANSMISSION (4)
EBS30202
INSTALLING THE SHIFT FORKS AND SHIFT TIP

DRUM • Engage the concave part “a” of the transmis-
1. Install: sion case and convex part “b” of the reverse
idle gear shaft.
• Be sure the circlip sharp-edged corner “c” is
(to the transmission case)
positioned opposite side to the washer.
• Reverse shift shaft “2”
• Washers
1
• Circlip “3” New b
Install depth “a”
0–0.5 mm (0–0.02 in)
TIP a
sitioned opposite side to the washer.
3 New 1 New
b
a
3
2 c
2 New
2. Install:
• Drive axle assembly 4. Check:
• Main axle assembly • Shift operation
• Shift fork “C” Rough operation → Repair.
• Shift drum assembly TIP
• Short shift fork guide bar • Oil each gear and bearing thoroughly.
• Shift fork “LR” (front) • Before assembling the transmission case,
• Shift fork “LR” (rear) make sure that the transmission is in neutral
• Long shift fork guide bar and that the gears turn freely.
TIP
The embossed marks on the shift forks should
face towards the rear side of the transmission
case and be in the following sequence: “LR”
(front), “C”, “LR” (rear). Be sure that the shift fork
cam follower is properly seated in the shift drum
groove.
3. Install:
• Reverse idle gear shaft “1”
• Washer “3”
• Bearing
• Reverse idle gear
• Washer
5-110
MIDDLE GEAR
EBS20048
MIDDLE GEAR
Removing the torque limiter assembly
190 Nm (19 m•kgf, 137 ft•lbf)
T.R
.
2
New
New
3
New
LT
(5)
1
New
LS
LT
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

Floor boards 4-12.
Shift arm Refer to “SHIFT LEVER” on page 5-44.
Differential assembly/Front drive shaft SEMBLY AND FRONT DRIVE SHAFT” on
page 8-4.
Drain.
Transmission oil Refer to “CHANGING THE TRANSMISSION
OIL” on page 3-20.
1 Torque limiter housing 1
2 Universal joint (middle driven gear side) 1
3 Universal joint yoke (middle driven gear side) 1
5-111
MIDDLE GEAR
Removing the torque limiter assembly

190 Nm (19 m•kgf, 137 ft•lbf)
T.R
.
4
New
5
New
New
LT
6
(5)
New
LS
LT
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

Front drive shaft yoke nut (middle driven gear
4 1
side)
5 Front drive shaft yoke (middle driven gear side) 1
6 Torque limiter assembly 1
5-112
MIDDLE GEAR
Removing the middle driven shaft assembly

Drive axle assembly 5-104.
1 Middle driven shaft assembly 1
5-113
MIDDLE GEAR
Disassembling the middle driven shaft assembly
1
2
3
4
M
5
M 6

1 Spring retainer 2
2 Washer 1
3 Middle driven gear 1
4 Torque damper cam 1
5 Spring 1
6 Spring seat 1
7 Middle driven shaft 1
5-114
MIDDLE GEAR
EBS30687

(MIDDLE DRIVEN GEAR SIDE) 1
1. Remove:
• Universal joint (middle driven gear side)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EBS30692
TIP
DISASSEMBLING THE MIDDLE DRIVEN
It may be necessary to lightly tap the universal SHAFT ASSEMBLY
joint yoke with a punch. 1. Remove:
• Washer
TIP
While compressing the spring with the damper
spring compressor “2”, remove the spring retain-
ers and washer.
Damper spring compressor (120

mm)
90890-01588
YM-01588
d. Repeat the steps for the opposite bearing. 1

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EBS30154
CHECKING THE TORQUE LIMITER

EBS30688
REMOVING THE FRONT DRIVE SHAFT 1. Check:

YOKE (MIDDLE DRIVEN GEAR SIDE) • Torque limiter
1. Remove: Damage/wear → Replace.
• Front drive shaft yoke (middle driven gear TIP
side) Do not disassemble the torque limiter.
TIP
EBS30694
Use the universal joint holder “1” to hold the front ASSEMBLING THE MIDDLE DRIVEN SHAFT
drive shaft yoke, then loosen the middle driven ASSEMBLY
shaft yoke nut. 1. Install:
• Washer
Universal joint holder • Spring retainers “1”
90890-04062
YM-04062
5-115
MIDDLE GEAR
TIP • Front drive shaft yoke (middle driven gear

While compressing the spring with the damper side) “1”
spring compressor “2”, install the washer and • Washer
spring retainers. • Front drive shaft yoke nut (middle driven gear
side)
Damper spring compressor (120 Front drive shaft yoke nut (mid-
mm) dle driven gear side)
T.
R.
90890-01588 190 Nm (19 m·kgf, 137 ft·lbf)
YM-01588
TIP
• Apply LOCTITE® to the threads of the torque
limiter assembly shaft in the 2.0 mm (0.08 in)
2 wide “a” area shown in the illustration.
• Use the universal joint holder “2” to hold the
front drive shaft yoke, then tighten the front
drive shaft yoke nut.

1 90890-04062
EBS30690
ASSEMBLING THE TORQUE LIMITER YM-04062
HOUSING
1. Install:
• Bearing
1
• Oil seal “2”
Installed depth of oil seal “a”

0.5–1.0 mm (0.020–0.039 in) a
TIP
2
2
a 3
1 New EBS30698

3. Torque limiter housing (MIDDLE DRIVEN GEAR SIDE)
1. Install:
EBS30691
INSTALLING THE FRONT DRIVE SHAFT • Universal joint (middle driven gear side)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
YOKE (MIDDLE DRIVEN GEAR SIDE)
a. Install the universal joint into the front drive
1. Install:
shaft yoke.
• Torque limiter assembly
(to the torque limiter housing)
5-116
MIDDLE GEAR

ings.
c. Install the bearing “1” onto the front drive
shaft yoke.
ECB01670
NOTICE
The needles can easily fall out of their races,
so check each bearing carefully. Slide the
universal joint driven yoke assembly back
and forth on the bearings. If a needle is out of
place, the yoke will not go all the way onto
the bearings.
d. Press each bearing into the front drive shaft

yoke using a suitable socket.
TIP
universal joint yoke and front drive shaft yoke so
that the circlip can be installed.
bearing.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-117
COOLING SYSTEM
OIL COOLER...................................................................................................6-1
CHECKING THE OIL COOLER ................................................................6-2
INSTALLING THE OIL COOLER .............................................................. 6-2
RADIATOR ...................................................................................................... 6-3

CHECKING THE RADIATOR.................................................................... 6-5
INSTALLING THE RADIATOR..................................................................6-5
THERMOSTAT ................................................................................................6-6
CHECKING THE THERMOSTAT.............................................................. 6-7
INSTALLING THE THERMOSTAT............................................................ 6-7
WATER PUMP.................................................................................................6-9
REMOVING THE WATER PUMP ........................................................... 6-11
DISASSEMBLING THE WATER PUMP.................................................. 6-11
CHECKING THE WATER PUMP ............................................................ 6-11
ASSEMBLING THE WATER PUMP........................................................ 6-11
INSTALLING THE WATER PUMP .......................................................... 6-13
6
OIL COOLER
EBS20050
OIL COOLER
Removing the oil cooler
D
FW
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
T.R
.
2
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
T.R
.
LT
1
New LT

Drain.
page 3-18.
Drain.
page 3-12.
1 Oil cooler outlet hose 1
2 Water pump outlet hose 1 Disconnect.
3 Oil cooler 1
6-1
OIL COOLER
EBS30211
CHECKING THE OIL COOLER

1. Check:
• Oil cooler
2. Check:
• Oil cooler outlet hose
EBS30212
INSTALLING THE OIL COOLER

1. Clean:
• Mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
2. Install:
• O-ring New
• Oil cooler
Oil cooler bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
LOCTITE®
TIP
Make sure the O-ring is positioned properly.
3. Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-12.
• Oil tank
mended engine oil)
Refer to “CHANGING THE ENGINE OIL” on
page 3-18.
4. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
5. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-5.
6-2
RADIATOR
EBS20051
RADIATOR
Removing the radiator
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 8 Nm (0.8 m•kgf, 5.8 ft•Ibf) 8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
T.R
T.R
.
.
T.R
.
9 Nm (0.9 m•kgf, 6.5 ft•Ibf) 4

T.R
.
1 (4) 2
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)

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

Floor board (left) 4-12.
Flywheel housing 5-87.
Drain.
page 3-12.
1 Radiator cap 1
2 Coolant reservoir hose 1
3 Coolant reservoir breather hose 1
4 Coolant reservoir cap 1
6-3
RADIATOR
Removing the radiator

12
T.R
T.R
.
.
T.R
.
T.R
. 9 Nm (0.9 m•kgf, 6.5 ft•Ibf) 16
(4)
15
17
8
9
13
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
T.R
.
14 6
10
11
New
7
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
T.R
T.R
.
T.R
.

5 Coolant reservoir 1
6 Radiator inlet hose 1
7 Radiator outlet hose 1
8 Thermostat outlet hose 1
9 Water pump inlet hose 1
10 Radiator inlet pipe 1
11 Radiator outlet pipe 1
12 Radiator fan motor coupler 1 Disconnect.
13 Air scoop (upper) 1
14 Air scoop (right) 1
15 Radiator 1
16 Radiator fan motor breather hose 1
17 Radiator fan 1
6-4
RADIATOR
EBS30213
CHECKING THE RADIATOR

1. Check:
• Radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the radia-
tor.
Damage → Repair or replace.
TIP
Straighten any flattened fins with a thin, flat-head
screwdriver. b. Apply the specified pressure for ten seconds
and make sure there is no drop in pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” on page 9-25.
EBS30214
INSTALLING THE RADIATOR

1. Install:
2. Check: • Radiator outlet pipe “1”
• Radiator hoses • Radiator inlet pipe “2”
• Radiator pipes TIP
• Thermostat outlet hose
Align the punch marks “a” on the radiator inlet
• Water pump inlet hose
pipe and outlet pipe with the hose clamp.
3. Measure:
• Radiator cap opening pressure a
radiator cap.
2
Radiator cap opening pressure a
107.9–137.3 kPa (1.1–1.4
kgf/cm², 15.6–19.9 psi)
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the radiator cap tester “1” and radiator
cap tester adapter “2” to the radiator cap “3”. 2. Fill:
• Cooling system
Radiator cap tester (with the specified amount of the recom-
90890-01325 mended coolant)
Mityvac cooling system tester kit Refer to “CHANGING THE COOLANT” on
YU-24460-A page 3-12.
Radiator cap tester adapter 3. Check:
90890-01352 • Cooling system
Pressure tester adapter
Leaks → Repair or replace any faulty part.
YU-33984
4. Measure:
radiator cap.
page 6-5.
6-5
THERMOSTAT
EBS20052
THERMOSTAT
Removing the thermostat
D
FW
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
T.R
.
3
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
T.R
.
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
8 LS
5
4 New
New 6
7
LS
New
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
10
.
New 23 Nm (2.3 m•kgf, 17 ft•Ibf)
T.R
.
9
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf) 2
T.R
.

Throttle bodies 7-11.
Drain.
page 3-12.
1 Coolant temperature sensor coupler 1 Disconnect.
2 Coolant temperature sensor 1
3 Thermostat outlet hose 1 Disconnect.
4 Thermostat housing 1
5 Thermostat cover 1
6 Thermostat 1
7 Thermostat inlet hose 1
8 Water pump air bleed hose 1 Disconnect.
9 Oil cooler outlet hose 1 Disconnect.
10 Water jacket joint 1
6-6
THERMOSTAT
EBS30215
• Thermostat housing
CHECKING THE THERMOSTAT
• Water jacket joint
1. Check:
• Thermostat inlet hose
• Thermostat
Does not open at 69–73 °C (156–163°F) →
Replace. EBS30216
INSTALLING THE THERMOSTAT

1. Install:
• Thermostat “1”
• O-ring New
• Thermostat cover
Thermostat cover bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
TIP
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Install the thermostat with its breather hole “a”
a. Suspend the thermostat “1” in a container “2” facing up.
filled with water.
b. Slowly heat the water “3”.
c. Place a thermometer “4” in the water.
d. While stirring the water, observe the thermo- a
stat and thermometer indicated temperature. 1
2. Install:
• Thermostat housing “1”
TIP
Align the “” mark “a” on the thermostat housing
with the paint mark “b” on the water jacket joint
“2”.
8 mm 2
(0.31 in) b
a
1
71±2˚C 85˚C
(159±3˚F) (185˚F)
A. Fully closed
B. Fully open
3. Install:
TIP
• Copper washer New
If the accuracy of the thermostat is in doubt, re- • Coolant temperature sensor
place it. A faulty thermostat could cause serious
overheating or overcooling.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Thermostat cover
6-7
THERMOSTAT
ECB01910
NOTICE
Use extreme care when handling the coolant
temperature sensor. Replace any part that
was dropped or subjected to a strong im-
pact.
Coolant temperature sensor

23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
4. Fill:
• Cooling system
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-12.
5. Check:
• Cooling system
Leak → Repair or replace any faulty part.
6. Measure:
radiator cap.
page 6-5.
6-8
WATER PUMP
EBS20053
WATER PUMP
Removing the water pump
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
T.R
.
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
T.R
.
2
3
LS
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
New
T.R
.
7
68
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
T.R
.
New
5
E New
(4)
1
(3)
12 Nm (1.2 m•kgf, 8.7 ft•Ibf)

T.R
.
4
12 Nm (1.2 m•kgf, 8.7 ft•Ibf)
T.R
.

Sub-frame 5-87.
Thermostat outlet hose Refer to “RADIATOR” on page 6-3.
1 Water pump inlet hose 1 Disconnect.
2 Water pump outlet hose 1
3 Water pump air bleed hose 1
4 Water pump breather hose 1
5 Water pump assembly 1
6 Circlip 1
7 Bearing 1
8 Blind plug 1
6-9
WATER PUMP
Disassembling the water pump

2 New
5 New
8 New
10
3 4 9 New
New
E 6
New
1
7
6 Nm (0.6 m•kgf, 4.3 ft•Ibf)

T.R
.

1 Water pump housing cover 1
2 Circlip 1
3 Water pump driven gear 1
4 Pin 2
5 Circlip 1
6 Impeller shaft 1
7 Mechanical seal 1
8 Bearing 1
9 Oil seal 1
10 Water pump housing 1
6-10
WATER PUMP
EBS30640
REMOVING THE WATER PUMP

1. Align:
• “I” mark “a” on the AC magneto rotor
(with the stationary pointer “b” on the AC
magneto cover)
TIP
• There are two “I” marks on the AC magneto ro-
tor. If the “I” mark (with the “H” mark) is shown,
turn the crankshaft 180° until the “I” mark (with-
out the “H” mark) is shown. 3. Remove:
• Turn the crankshaft clockwise. • Bearing “1”
TIP
b
Remove the bearing and oil seal from the out-
side of the water pump housing.
a
2. Remove:
• Water pump assembly
EBS30217
DISASSEMBLING THE WATER PUMP

1. Remove: EBS30218
• Mechanical seal (impeller side) “1” CHECKING THE WATER PUMP

(from the impeller, with a thin, flat-head 1. Check:
screwdriver) • Water pump housing cover
TIP • Water pump housing
Do not scratch the impeller shaft. • Impeller shaft
• Water pump outlet hose
• Water pump air bleed hose
2. Check:
• Bearings
Rough movement → Replace.
1 EBS30219
ASSEMBLING THE WATER PUMP

1. Install:
2. Remove: • Bearing “2”
• Mechanical seal (housing side) “1” (into the water pump housing)
TIP TIP
Remove the mechanical seal (housing side) • Before installing the oil seal, apply tap water or
from the inside of the water pump housing. coolant onto its outer surface.
• Install the oil seal with a socket that matches its
outside diameter.
6-11
WATER PUMP
TIP
-0.5–0.5 mm (-0.02–0.02 in) Before installing the mechanical seal (impeller
side), apply tap water or coolant onto its outer
surface.
New 1 a
1 New
2. Install:
• Mechanical seal (housing side) “1” New 4. Measure:
ECB03170
• Impeller shaft tilt
NOTICE Out of specification → Repeat steps (3) and
Never lubricate the mechanical seal (hous- (4).
ing side) surface with oil or grease. ECB03180
NOTICE
TIP
Make sure the mechanical seal (impeller
Use the special tools and a press to press the side) is flush with the impeller.
mechanical seal (housing side) straight in until it
touches the water pump housing. TIP
If the surface “a” of the mechanical seal (impeller
Mechanical seal installer side) that contacts the mechanical seal (housing
90890-01587 side) is dirty, clean it.
YM-01587
Middle driven shaft bearing driv- Impeller shaft tilt limit
er 0.15 mm (0.006 in)
90890-04058
Middle drive bearing installer 40
& 50 mm
YM-04058 1
1. Straightedge
2. Impeller
5. Install:
A. Push down • Impeller shaft “1”
2. Mechanical seal installer • Circlips New
3. Middle driven shaft bearing driver
TIP
3. Install: After installation, check that the impeller shaft ro-
• Mechanical seal (impeller side) “1” New tates smoothly.
6-12
WATER PUMP
Water pump housing bolt (M6 ×

40)
T.
R.
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Water pump housing bolt (M6 ×
25)
1 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
EBS30641
INSTALLING THE WATER PUMP

1. Align:
• “I” mark “a” on the AC magneto rotor
(with the stationary pointer “b” on the AC
magneto cover)
TIP
• There are two “I” marks on the AC magneto ro-
tor. If the “I” mark (with the “H” mark) is shown,
turn the crankshaft 180° until the “I” mark (with-
out the “H” mark) is shown.
• Turn the crankshaft clockwise.
2. Install:
• Bearing “1”
TIP
Be sure the circlip sharp-edged corner “a” is po-
1 a
New 2
3. Install:
• Water pump assembly
6-13
FUEL SYSTEM
FUEL TANK..................................................................................................... 7-1

REMOVING THE FUEL TANK ..................................................................7-2
REMOVING THE FUEL PUMP .................................................................7-2
CHECKING THE FUEL PUMP BODY.......................................................7-2
CHECKING THE FUEL TANK BREATHER HOSE JOINT .......................7-2
INSTALLING THE FUEL PUMP................................................................7-3
INSTALLING THE FUEL TANK.................................................................7-3
INSTALLING THE FUEL TANK BREATHER HOSE JOINT ..................... 7-4
CHECKING THE FUEL PRESSURE ........................................................7-4
AIR FILTER CASE AND OIL SEPARATOR ................................................... 7-6

REMOVING THE AIR FILTER CASE........................................................7-9
INSTALLING THE AIR FILTER CASE ......................................................7-9
INSTALLING THE OIL SEPARATOR .......................................................7-9
THROTTLE BODIES .....................................................................................7-11

REMOVING THE THROTTLE BODIES .................................................. 7-13
CHECKING THE FUEL INJECTORS......................................................7-13
CHECKING THE THROTTLE BODIES...................................................7-13
CHECKING THE THROTTLE BODY JOINTS ........................................ 7-13
INSTALLING THE THROTTLE BODIES................................................. 7-13
ADJUSTING THE THROTTLE POSITION SENSOR..............................7-14
AIR INDUCTION SYSTEM ............................................................................7-17

CHECKING THE AIR INDUCTION SYSTEM..........................................7-20
INSTALLING THE AIR INDUCTION SYSTEM........................................ 7-20
7
FUEL TANK
EBS20054
FUEL TANK
Removing the fuel tank
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
1
2
5
3 4
32 Nm (3.2 m•kgf, 23 ft•Ibf) (6) 1
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
10
6 7
New
7
9
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
9 FW
D

Floor board (right) 4-12.
1 Fuel tank breather hose 2
2 Fuel tank breather hose joint 1
3 Fuel pump coupler 1 Disconnect.
4 Fuel hose connector holder 1
5 Fuel hose 1
6 Fuel tank retainer 1
7 Damper 2
8 Fuel tank 1
9 Damper 3
10 Fuel pump 1
7-1
FUEL TANK
EBS30221
REMOVING THE FUEL TANK

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

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

EBS30225
1. Install:
INSTALLING THE FUEL PUMP
• Dampers “1”
1. Install:
TIP
• Fuel pump gasket “1” New
Fit the projections “a” on the dampers into the
TIP holes “b” in the frame.
• Always use a new fuel pump gasket.
• Install the fuel pump gasket with the lip side “a” 1
facing upward. a
New 1 a 1 1
b
2. Install:
• Dampers “1”
TIP
2. Install:
Fit the projection “a” on the dampers into the
• Fuel pump
hole “b” in the fuel tank retainer.
• Fuel pump bracket
Fuel pump nut 1

7 Nm (0.7 m·kgf, 5.1 ft·lbf) 1
T.
R.
a
b
TIP
• Do not damage the installation surfaces of the
fuel tank when installing the fuel pump.
• Install the fuel pump in the direction shown in
the illustration.
• Install the fuel pump bracket by aligning the
projections “a” on the fuel pump with the pro- 3. Install:
jection “b” on the fuel tank. • Fuel tank “1”
• Tighten the nuts to specification in the proper • Fuel tank bolts “2”
tightening sequence as shown. • Fuel tank retainer “3”
• Fuel tank retainer bolts “4”
TIP
Finger tighten the fuel tank bolts and fuel tank re-
tainer bolts.
7-3
FUEL TANK
4
3 4
1
2
4. Tighten: EBS30642
• Fuel tank bolts INSTALLING THE FUEL TANK BREATHER
• Fuel tank retainer bolts HOSE JOINT
1. Install:
Fuel tank bolt • Fuel tank breather hose joint “1”
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.
Fuel tank retainer bolt Fuel tank breather hose joint bolt
32 Nm (3.2 m·kgf, 23 ft·lbf) 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.
5. Install:
TIP
• Fuel hose
• Fuel hose connector holder “1” Install the fuel tank breather hose joint “1” so that
• Fuel pump coupler it contacts the frame.
ECB02010
NOTICE
1
When installing the fuel hose, make sure that
it is securely connected, and that the fuel
hose holder is in the correct position, other-
wise the fuel hose will not be properly in-
stalled.
TIP
• Install the fuel hose connector holder “1” se-
curely onto the fuel pump until a distinct “click”
EBS30227
is heard, and then make sure that it does not
CHECKING THE FUEL PRESSURE
come loose.
1. Check:
• To install the fuel hose onto the fuel rail, slide
• Fuel pressure
the fuel hose connector cover “2” on the end of ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
the hose in direction of the arrow shown. a. Disconnect the fuel hose “1” from the fuel rail.
Refer to “REMOVING THE THROTTLE
BODIES” on page 7-13.
b. Connect the pressure gauge “2” and adapter
“3” to the fuel rail and fuel hose.
Pressure gauge
90890-03153
Pressure gauge
YU-03153
90890-03176
YM-03176
7-4
FUEL TANK
2
c. Start the engine.
d. Measure the fuel pressure.
Out of specification → Replace the fuel
pump.
Fuel line pressure at idling

324–392 kPa (3.24–3.92 kgf/cm²,
46.1–55.7 psi)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-5
AIR FILTER CASE AND OIL SEPARATOR
EBS20128

Removing the air filter case
FW
T.R
T.R
.
.
D
9
New
7
10
(11)
New
New
1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf) 4
T.R
.
New
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
T.R
.
1 7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
9 Nm (0.9 m•kgf, 6.5 ft•Ibf)
T.R
.
2 3
5
3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf) 5 3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)
T.R
T.R
.

Cargo bed 4-10.
1 Intake air temperature sensor coupler 1 Disconnect.
2 ISC (Idle Speed Control) unit inlet hose 1 Disconnect.
Air induction system hose (air filter case to air
3 1 Disconnect.
cut-off valve)
4 Air filter case breather hose 1 Disconnect.
5 Air filter case joint clamp screw 3 Loosen.
6 Air filter case 1
7 Primary air filter cover 1
8 Primary air filter element 1
9 Primary air filter element frame 1
10 Primary air filter cover lock 1
7-6
Removing the air filter case

FW
T.R
T.R
.
.
D
New
11
New
(11)
12
New
1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)
T.R
.
New
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
T.R
.
13 7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
14 T.R
. 9 Nm (0.9 m•kgf, 6.5 ft•Ibf)
3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf) 3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)
T.R
T.R
.

11 Secondary air filter cover 1
12 Secondary air filter element 1
13 Intake air temperature sensor 1
14 Air filter case assembly bracket 1
7-7
Removing the oil separator
FW
D
5
23 Nm (2.3 m•kgf, 17 ft•Ibf)
T.R
.
6
2

Cylinder head breather hose (oil separator to
1 1
hose joint)
2 Hose joint 1
Cylinder head breather hose (hose joint to cylin-
3 1
der head cover)
4 Air filter case breather hose 1
5 Oil tank breather hose 1
6 Oil separator 1
7-8
EBS30696
REMOVING THE AIR FILTER CASE 1

1. Remove:
TIP
Remove the primary air filter cover by turning the
primary air filter cover lock “2” counterclockwise.
TIP
1 Make sure that the match mark “a” on the cover
lock is aligned with the match mark “b” on the pri-
mary air filter cover.
EBS30228
INSTALLING THE AIR FILTER CASE

1. Install:
• Primary air filter cover lock “1”
(to the primary air filter cover “2”)
a b
Primary air filter cover lock screw
1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP 4. Install:
Align the match mark “a” on the primary air filter • Air filter case joint clamps “1”
cover lock with the match mark “b” on the prima- (to the air filter case “2”)
ry air filter cover.
Air filter case joint clamp screw
3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
T.
R.
a TIP
Align the projection “a” on the air filter case joint
b with the slot “b” in the air filter case joint clamp.
1
a
2
a
a
2. Install:
• Primary air filter element frame b
b
3. Install:
2
• Primary air filter cover “1” b
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1
a. Install the primary air filter cover and lock it EBS30644
into place by turning the primary air filter cov- INSTALLING THE OIL SEPARATOR
er lock clockwise. 1. Install:
• Oil separator “1”
Oil separator bracket bolt

23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
7-9
TIP
Align the parting line “a” on the oil separator with
the paint mark “b” on the oil separator bracket
“2”.
a
b
1
2
7-10
THROTTLE BODIES
EBS20056
THROTTLE BODIES
Removing the throttle bodies
D
FW
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
T.R
.
1
2
5
5 10
3 5
4 6
New
7
LS
11
8
11
3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf) 9
T.R
.
11
9
9
3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)
T.R
.

Air filter case assembly ARATOR” on page 7-6.
1 Intake air pressure sensor #2 coupler 1 Disconnect.
2 Intake air pressure sensor #1 coupler 1 Disconnect.
3 ISC (Idle Speed Control) unit coupler 1 Disconnect.
4 Throttle position sensor coupler 1 Disconnect.
5 Fuel injector coupler 3 Disconnect.
6 Throttle cable housing cover 1
7 Throttle cable 1 Disconnect.
8 Fuel hose 1 Disconnect.
9 Throttle body joint clamp screw 6 Loosen.
10 Throttle bodies 1
11 Throttle body joint 3
7-11
THROTTLE BODIES
Disassembling the throttle bodies

3.5 Nm (0.35 m•kgf, 2.5 ft•Ibf)
D
T.R
.
FW
3.5 Nm (0.35 m•kgf, 2.5 ft•Ibf)
T.R
.
5
2
6 2
2
2
2 10
3 4
8
New
New 9
New New
7
1
3.5 Nm (0.35 m•kgf, 2.5 ft•Ibf)

T.R
.

1 ISC (Idle Speed Control) unit inlet hose 1
2 Negative pressure hose 5
3 Throttle body breather hose 1
4 ISC (Idle Speed Control) unit outlet hose 1
5 Intake air pressure sensor #2 1
6 Intake air pressure sensor #1 1
7 Throttle position sensor 1
8 Fuel rail 1
9 Fuel injector 3
10 Throttle bodies 1
7-12
THROTTLE BODIES
EBS30229 EBS30231
REMOVING THE THROTTLE BODIES CHECKING THE THROTTLE BODIES

1. Disconnect: 1. Check:
• Fuel hose • Throttle bodies
EWB03050
Cracks/damage → Replace the throttle bod-
WARNING ies.
Cover fuel hose connections with a cloth 2. Check:
when disconnecting them. Residual pres- • Fuel passages
sure in the fuel lines could cause fuel to Obstructions → Clean.
spurt out when removing the hose. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
ECB01700
a. Wash the throttle bodies in a petroleum-
NOTICE based solvent.
• Be sure to disconnect the fuel hose by Do not use any caustic carburetor cleaning
hand. Do not forcefully disconnect the solution.
hose with tools. b. Blow out all of the passages with compressed
• Although the fuel has been removed from air.
the fuel tank, be careful when removing the ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
fuel hose, since there may be fuel remain- EBS30232
ing in it. CHECKING THE THROTTLE BODY JOINTS

1. Check:
TIP • Throttle body joints
• To disconnect the fuel hose from the fuel rail, Cracks/damage → Replace.
slide the fuel hose connector cover “1” on the
EBS30233
end of the hose in direction of the arrow shown, INSTALLING THE THROTTLE BODIES
press the two buttons “2” on the sides of the 1. Install:
connector, and then disconnect the hose. • Throttle body joint clamps “1”
• Before disconnecting the hose, place a few
TIP
rags in the area under where it will be discon-
nected. Align the projection on the throttle body joint with
the gap in throttle body joint clamp.
EBS30427
CHECKING THE FUEL INJECTORS 2. Install:

1. Check: • Throttle body joints “1”
• Fuel injectors
Obstruction → Replace and check the fuel (cylinder head side)
T.
pump/fuel supply system.

R.
3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)

Deposit → Replace.
Damage → Replace. TIP
2. Check:
Align the projection “a” on the cylinder head with
• Fuel injector resistance
the slot “b” in the throttle body joint.
Refer to “CHECKING THE FUEL INJEC-
TORS” on page 9-108.
7-13
THROTTLE BODIES
1. Check:
• Throttle position sensor
1 Refer to “CHECKING THE THROTTLE PO-
SITION SENSOR” on page 9-106.
2. Adjust:
• Throttle position sensor angle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b a. Connect the test harness– TPS (3P) “1” to
the throttle position sensor and wire harness
a
as shown.
3. Install:
• Throttle bodies

(throttle body side) 1
T.
R.
3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
4. Connect:
• Fuel hose
ECB01920
NOTICE
b. Connect the digital circuit tester to the test
When installing the fuel hose, make sure that
harness– TPS (3P).
it is securely connected, and that the fuel
hose connector cover on the fuel hose is in Test harness– TPS (3P)
the correct position, otherwise the fuel hose 90890-03204
will not be properly installed. Test harness– TPS (3P)
YU-03204
TIP Digital circuit tester
• Connect the fuel hose securely onto the fuel 90890-03174
rail until a distinct “click” in heard. Model 88 Multimeter with ta-
• To connect the fuel hose onto the fuel rail, slide chometer
the fuel hose connector cover “1” on the end of YU-A1927
the hose in direction of the arrow shown.
• Positive tester probe
yellow (wire harness color)
• Negative tester probe
black/blue (wire harness color)
c. Turn the main switch to “ ” (on).

d. Measure the throttle position sensor voltage.
e. Adjust the throttle position sensor angle so
that the voltage is within the specified range.
1 Throttle position sensor output

voltage
EBS30234 0.63–0.73 V
ADJUSTING THE THROTTLE POSITION
SENSOR f. After adjusting the throttle position sensor an-
EWB03070
gle, tighten the throttle position sensor
WARNING
screws “2”.
• Handle the throttle position sensor with
special care. Throttle position sensor screw
• Never subject the throttle position sensor 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
T.
R.
to strong shocks. If the throttle position

sensor is dropped, replace it.
7-14
THROTTLE BODIES
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-15
THROTTLE BODIES
7-16
AIR INDUCTION SYSTEM
EBS20057
7
4
6
5
7-17
1. Air cut-off valve

2. Air filter case
3. Air induction system hose (air filter case to air
cut-off valve)
4. Air induction system hose (air cut-off valve to
reed valve cover) (cylinder #2 and #3)
5. Reed valve cover (cylinders #2 and #3)
6. Reed valve cover (cylinder #1)
7. Air induction system hose (air cut-off valve to
reed valve cover) (cylinder #1)
7-18
Removing the air cut-off valve and reed valves
FW
D
2 1
5
4
LT
6 3
7
8
LT
LT
LT
9
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
10
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 11

T.R
.

1 Air induction system solenoid coupler 1 Disconnect.
Air induction system hose (air cut-off valve to
2 1
reed valve cover) (cylinder #1)
Air induction system hose (air cut-off valve to
3 1
reed valve cover) (cylinder #2 and #3)
Air induction system hose (air filter case to air
4 1
cut-off valve)
5 Air cut-off valve 1
6 Reed valve cover (cylinder #1) 1
7 Reed valve assembly 1 1
8 Reed valve plate 1
9 Reed valve cover (cylinder #2 and #3) 1
10 Reed valve assembly 2 1
11 Reed valve plate 2
7-19
EBS30235
2. Check:
CHECKING THE AIR INDUCTION SYSTEM
• Reed valves
• Reed valve stoppers
Air injection
• Reed valve seats
The air induction system burns unburned ex-
Cracks/damage → Replace the reed valve
haust gases by injecting fresh air (secondary air)
assembly.
into the exhaust port, reducing the emission of
3. Check:
hydrocarbons. When there is negative pressure
• Air cut-off valve
at the exhaust port, the reed valve opens, allow-
ing secondary air to flow into the exhaust port.
4. Check:
The required temperature for burning the un-
• Air induction system solenoid
burned exhaust gases is approximately 600 to
Refer to “CHECKING THE AIR INDUCTION
700 °C (1112 to 1292 °F).
SYSTEM SOLENOID” on page 9-108.
Air cut-off valve EBS30236
The air cut-off valve is controlled by the signals INSTALLING THE AIR INDUCTION SYSTEM
from the ECU in accordance with the combus- 1. Install:
tion conditions. Ordinarily, the air cut-off valve • Reed valve plates “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 projection “a” on the cylinder head
ing driven. However, if the coolant temperature cover with the notch “b” in the reed valve plate
is below the specified value, the air cut-off valve “1”.
remains open and allows the air to flow into the • Align the projection “c” on the cylinder head
exhaust pipe until the temperature becomes cover with the hole “d” in the reed valve plate
higher than the specified value. “1”.
1 a
A A d
1
B B B B d
A. From the air filter case 2. Install:

B. To the reed valve • Reed valve assembly 1
• Reed valve assembly 2
1. Check:
TIP
• Hoses
Loose connections → Connect properly. • Install the reed valve assembly 1 so that the
Cracks/damage → Replace. open side turns to the exhaust side of the en-
gine.
7-20
• Install the reed valve assembly 2 so that the

open side turns to the intake side of the engine.
A. Reed valve assembly 1

B. Reed valve assembly 2
C. Exhaust side
3. Install:
• Reed valve covers
Reed valve cover bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
7-21
DRIVE TRAIN
TROUBLESHOOTING.....................................................................................8-1
CHECKING NOISES ................................................................................. 8-2
TROUBLESHOOTING CHART .................................................................8-3
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFERENTIAL

ASSEMBLY AND FRONT DRIVE SHAFT .....................................................8-4
(DIFFERENTIAL ASSEMBLY SIDE) ......................................................8-10
DISASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-10
CHECKING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-11
ASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-12
REMOVING THE FRONT DRIVE SHAFT YOKE
REMOVING THE DIFFERENTIAL GEAR ASSEMBLY........................... 8-14
CHECKING THE FRONT DRIVE SHAFT ............................................... 8-14
CHECKING THE DIFFERENTIAL ASSEMBLY ...................................... 8-14
CHECKING THE DIFFERENTIAL MOTOR OPERATION ......................8-14
ASSEMBLING THE DIFFERENTIAL ASSEMBLY ..................................8-15
MEASURING THE DIFFERENTIAL GEAR BACKLASH......................... 8-17
ADJUSTING THE DIFFERENTIAL GEAR BACKLASH .......................... 8-18
INSTALLING THE DIFFERENTIAL ASSEMBLY .................................... 8-18
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE

ASSEMBLY AND REAR DRIVE SHAFT .....................................................8-19
DISASSEMBLING THE REAR CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-25
CHECKING THE REAR CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-26
ASSEMBLING THE REAR CONSTANT VELOCITY SHAFT
ASSEMBLIES ......................................................................................... 8-26
DISASSEMBLING THE FINAL DRIVE ASSEMBLY ...............................8-28
CHECKING THE REAR DRIVE SHAFT.................................................. 8-29
CHECKING THE FINAL DRIVE ASSEMBLY..........................................8-29
8
ADJUSTING THE RING GEAR STOPPER............................................. 8-29
MEASURING THE FINAL GEAR BACKLASH ........................................ 8-30
ADJUSTING THE FINAL GEAR BACKLASH .........................................8-30
ASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY............. 8-31
TROUBLESHOOTING
EBS20058
TROUBLESHOOTING
The following conditions may indicate damaged shaft drive components:
Symptoms Possible Causes
1. A pronounced hesitation or “jerky” movement A. Bearing damage.
during acceleration, deceleration, or sustained B. Improper gear backlash.
speed. (This must not be confused with engine C. Gear tooth damage.
surging or transmission characteristics.) D. Broken drive shaft.
2. A “rolling rumble” noticeable at low speed; a high- E. Broken gear teeth.
pitched whine; a “clunk” from a shaft drive com- F. Seizure due to lack of lubrication.
ponent or area. G. Small foreign objects lodged between the moving
3. A locked-up condition of the shaft drive train parts.
mechanism, no power transmitted from the en-
gine to the front and/or rear wheels.
TIP
Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite subtle and
difficult to distinguish from normal vehicle operating noise. If there is reason to believe these compo-
nents are damaged, remove the components and check them.
8-1
TROUBLESHOOTING
EBS30237
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING NOISES a. Clean the entire vehicle thoroughly, then dry
1. Investigate any unusual noises. it.
b. Apply a leak detection compound or dry pow-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
der spray to the shaft drive.
The following “noises” may indicate a me-
c. Road test the vehicle for the distance neces-
chanical defect:
sary to locate the leak.
a. A “rolling rumble” noise during coasting, ac-
Leakage → Check the component housing,
celeration, or deceleration. The noise in-
gasket, and/or seal for damage.
creases with front and/or rear wheel speed,
Damage → Replace the component.
but it does not increase with higher engine or
transmission speeds. TIP
Diagnosis: Possible wheel bearing damage. • An apparent oil leak on a new or nearly new ve-
Refer to “TROUBLESHOOTING CHART” on hicle may be the result of a rust-preventative
page 8-3. coating or excessive seal lubrication.
b. A “whining” noise that varies with accelera- • Always clean the vehicle and recheck the sus-
tion and deceleration. pected location of an apparent leakage.
Diagnosis: Possible incorrect reassembly,
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
too little gear backlash.
Refer to “MEASURING THE DIFFERENTIAL
GEAR BACKLASH” on page 8-17 or “MEA-
SURING THE FINAL GEAR BACKLASH” on
page 8-30.
EWB02900
WARNING
Insufficient gear backlash is extremely de-
structive to the gear teeth. If a test ride, fol-
lowing reassembly, indicates these
symptoms, stop riding immediately to mini-
mize gear damage.
c. A slight “thunk” evident at low speed opera-
tion. This noise must be distinguished from
normal vehicle operation.
Diagnosis: Possible broken gear teeth.
EWB02910
WARNING
Stop riding immediately if broken gear teeth
are suspected. This condition could result in
the shaft drive assembly locking up, causing
a loss of control and possible injury to the
rider.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Drained oil
Drained oil shows large amounts of metal
particles → Check the bearing for seizure.
TIP
A small amount of metal particles in the oil is nor-
mal.
3. Check:
• Oil leakage
8-2
TROUBLESHOOTING
EBS30238
TROUBLESHOOTING CHART
When basic conditions (a) and (b) described in “CHECKING NOISES” exist, check the following points:
YES → Replace the wheel bearing(s). (Refer to
1. Elevate and spin both wheels. Feel “STEERING KNUCKLES AND FRONT
for wheel bearing(s) damage. STABILIZER” on page 4-64 and “REAR
KNUCKLES” on page 4-74.)
NO ↓
2. Check the wheel nuts and axle nuts NO → Torque to specification. (Refer to “FRONT
for tightness. AND REAR WHEELS” on page 4-29.
YES ↓
NO → Constant velocity shaft bearings and differ-
3. Check the front constant velocity
ential bearings are probably not damaged.
shaft assemblies. Feel for bearing
Repeat the test or remove the individual
damage.
components.
YES ↓
NO → Adjust per instructions. (Refer to “AD-
4. Check the parking brake adjust-
JUSTING THE PARKING BRAKE” on
ment.
page 3-30.)
YES ↓
NO → Constant velocity shaft bearings and final
5. Check the rear constant velocity
gear bearings are probably not damaged.
shaft assemblies. Feel for bearing
Repeat the test or remove the individual
damage.
components.
YES ↓
Remove the shaft drive components.
8-3
FRONT CONSTANT VELOCITY SHAFT ASSEMBLIES, DIFFEREN-
TIAL ASSEMBLY AND FRONT DRIVE 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
60 Nm (6.0 m•kgf, 43 ft•Ibf)
T.R
.
New
LS
LS
105 Nm (10.5 m•kgf, 76 ft•lbf) New New
T.R
.
2 New
New LS
1
New
LS

T.R
.

Skid plate (front)/Skid plate (center) 4-1.
Floor boards 4-12.
Steering knuckles FRONT STABILIZER” on page 4-64.
Drain.
Differential gear oil Refer to “CHANGING THE DIFFERENTIAL
GEAR OIL” on page 3-23.
1 Front constant velocity shaft assembly 2
2 Differential motor coupler 1 Disconnect.
3 Differential case breather hose 1 Disconnect.
8-4
Removing the front constant velocity shaft assemblies, differential assembly, and front drive shaft
60 Nm (6.0 m•kgf, 43 ft•Ibf)
T.R
.
New
8
LS 5
7 LS
105 Nm (10.5 m•kgf, 76 ft•lbf) New New
T.R
.
6 10
4
New
New LS
9
New
LS

T.R
.

4 Differential assembly 1
5 Front drive shaft 1
6 Spring 1
7 Dust seal (differential assembly side) 1
8 Dust seal (middle driven gear side) 1
9 Universal joint (differential assembly side) 1
10 Universal joint yoke (differential assembly side) 1
8-5
Disassembling the front constant velocity shaft assemblies
5 M
6 New
7 4 New
B 2 New
3
1 New
New 8
M
New 9
New A
A: Wheel side
B: Differential side

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

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

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

1 Differential motor 1
Front drive shaft yoke nut (differential assembly
2 1
side)
Front drive shaft yoke (differential assembly
3 1
side)
4 Bracket 1
5 Differential case cover 1
6 Differential gear assembly 1
Refer to “ADJUSTING THE DIFFEREN-
7 Differential gear assembly shim TIAL GEAR BACKLASH” on page 8-18.
8 Bearing 1
9 Bearing 1
10 Oil seal 1
8-8
Disassembling the differential assembly
11 Nm (1.1 m•kgf, 8.0 ft•Ibf)

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

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

(DIFFERENTIAL ASSEMBLY SIDE)
1. Remove: 1
• Universal joint (differential assembly side)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
TIP A. Wheel side
B. Differential side
It may be necessary to lightly tap the universal
joint yoke with a punch.
B
2. Remove:
• Clip “1”
• Double offset joint “2”
• Circlip “3”
• Ball bearing “4”
• Dust boot “5”
TIP
Before removing the clip, slide the dust boot
away from the double offset joint.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30240
DISASSEMBLING THE FRONT CONSTANT

VELOCITY SHAFT ASSEMBLIES
front constant velocity shaft assemblies.
1. Remove:
• Boot bands “1”
TIP
Remove each boot band using a chisel “2”.
8-10
B A
5
2
1
2
B
4 A. Wheel side
4. Remove:
3 • Dust boot
• Constant velocity joint
• Clip
TIP
Secure the constant velocity shaft in a vise, and
then remove the constant velocity joint using
B. Differential side hammers.
3. Remove: A
TIP
Use the boots band installation tool “2”.

90890-01526
YM-01526
A. Wheel side
A B EBS30241
CHECKING THE FRONT CONSTANT

1 VELOCITY SHAFT ASSEMBLIES
front constant velocity shaft assemblies.
1. Check:
• Double offset joint splines
• Constant velocity joint splines
• Constant velocity shaft splines
A. Wheel side Wear/damage → Replace.
B. Differential side 2. Check:
• Dust boots
ECB01590
NOTICE
Always use a new boot band.
3. Check:
• Balls and ball races
• Inner surface of double offset joint
Pitting/wear/damage → Replace.
8-11
EBS30242
ASSEMBLING THE FRONT CONSTANT
VELOCITY SHAFT ASSEMBLIES • Circlip “2” New
The following procedure applies to both of the • Double offset joint “3”
front constant velocity shaft assemblies. • Clip “4” New
1. Install: TIP
• Clip “1” New • Securely install the circlip into the groove in the
• Constant velocity joint “2” constant velocity shaft.
• Constant velocity shaft “3” • Securely install the clip into the groove in the
• Dust boot double offset joint.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a new clip. B
b. Install the constant velocity joint. 1
TIP
• Install the clip into the groove in the constant 2 New
velocity shaft as shown.
• Secure the constant velocity joint in a vise, and
then fit the constant velocity shaft into the con-
stant velocity joint using a soft-face hammer.
A B
New 1
3
3
4 New
A
3 B. Differential side
3. Apply:
• Molybdenum disulfide grease
(into the double offset joint, constant velocity
joint, and dust boots)
New 1
Molybdenum disulfide grease
2 50–70 g (1.8–2.5 oz) per dust
boot (wheel side)
A
45–65 g (1.6–2.3 oz) per dust
boot (differential side)
TIP
Molybdenum disulfide grease is included in the
repair kit.
4. Install:
• Boot bands “1” New
A. Wheel side
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
• Dust boot
8-12
A B B
1 New 2 New
4
2
A. Wheel side
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the boot bands “1”.

90890-01526
YM-01526
A
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Check:
3 • Thrust movement free play
1 Excessive play → Replace the constant ve-
locity shaft assembly.
A. Wheel side
b. Install the boot bands “2”.
TIP
• Insert the tips of the boots band installation tool
screw type “4” into the holes on the boot band,
and turn the handle to compress the boot
EBS30243
band. REMOVING THE FRONT DRIVE SHAFT
• Push down on the boots band installation tool YOKE (DIFFERENTIAL ASSEMBLY SIDE)
screw type lever so that the end of the boot 1. Remove:
band hooks onto the boot band tabs. • Front drive shaft yoke (differential assembly
side)
Boots band installation tool TIP
screw type
Use the universal joint holder “1” to hold the front
90890-01554
Boots band installation tool drive shaft yoke, then loosen the front drive shaft
screw type yoke nut.
YM-01554
90890-04062
YM-04062
8-13
• Differential case cover
TIP
When the differential case and/or the differential
case cover are replaced, be sure to adjust the
shim of the differential gear assembly.
2. Check:
1 • Gear teeth
Pitting/galling/wear → Replace.
EBS30244 TIP
REMOVING THE DIFFERENTIAL GEAR When the differential pinion gear and/or the dif-
ASSEMBLY ferential assembly are replaced, be sure to ad-
1. Remove: just the shim of the differential gear assembly.
• Differential gear assembly “1”
ECB01570 3. Check:
NOTICE • Bearings
The ring gear and differential gear are as- Damage → Replace.
sembled into a proper unit at the factory by EBS30247
means of specialized equipment. Do not at- CHECKING THE DIFFERENTIAL MOTOR
tempt to disassemble this unit. Disassembly OPERATION
will result in the malfunction of the unit. 1. Check:
• Differential motor operation
Does not operate → Replace.
ECB01930
1 NOTICE
Do not disassemble the differential motor or
remove the differential motor pinion gear.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect two C-size batteries to the differen-
tial motor terminals “1” (as shown in the illus-
trations).
ECB01940
EBS30245
NOTICE
CHECKING THE FRONT DRIVE SHAFT
1. Check: • Do not use a 12 V battery to operate the dif-
• Drive shaft splines ferential motor pinion gear.
Wear/damage → Replace. • Do not connect the batteries to the differen-
EWB03040 tial motor when it is installed in the differen-
WARNING tial case. The differential motor should be
Do not attempt to straighten a bent shaft; checked when it is removed from the differ-
this may dangerously weaken it. ential case.
2. Check:
• Support bearing
Damage → Replace.
3. Check:
• Support bearing housing
• Support bearing rubber
EBS30246
CHECKING THE DIFFERENTIAL ASSEMBLY

1. Check:
• Differential case
8-14
A
3V
3
1
a
2
2
B
3V 3. Differential case
4. Differential case cover
2. Measure:
• Gear backlash
Refer to “MEASURING THE DIFFERENTIAL
GEAR BACKLASH” on page 8-17.
2 3. Install:
1 • Differential motor
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
A. Check that the differential motor pinion gear a. Slide the shift fork sliding gear “1”, which is in-
“2” turns counterclockwise. stalled to the differential case cover, to the
B. Check that the differential motor pinion gear right front constant velocity shaft assembly
“2” turns clockwise.
side as shown in the illustration to put it into
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ the 2WD mode.
EBS30249
ASSEMBLING THE DIFFERENTIAL 1

ASSEMBLY
1. Install:

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

3 4
tial motor terminal “2” to operate the differen-
tial motor pinion gear “3”. Operate the
differential motor pinion gear until the mark
“a” on the differential motor pinion gear is
aligned with the mark “b” on the differential
motor case.
ECB01650
1 1 NOTICE
Do not use a 12 V battery to operate the dif-
ferential motor pinion gear.
8-15
a
2
3
3V
c. Insert 6 mm bolts “4” into the differential mo- 5. Install:
tor “5” and use them as a guide to set the mo- • Front drive shaft yoke (differential assembly
tor on the differential case cover “6” so that side)
the shift fork sliding gear “7” does not move. • Washer
ECB01950
• Front drive shaft yoke nut (differential assem-
NOTICE bly side)
If the position of the shift fork sliding gear is
moved, the position of the differential gear Front drive shaft yoke nut (differ-
assembly and the indicator light display may ential assembly side)
T.
R.
differ, and the 2WD or differential lock mode 62 Nm (6.2 m·kgf, 45 ft·lbf)
may not be activated.
TIP
4 5 Use the universal joint holder “1” to hold the front
4 4 drive shaft yoke, then tighten the front drive shaft
yoke nut.
7
6 90890-04062
YM-04062
d. Remove the 6 mm bolts, and then install the

motor with the differential motor bolts.
Differential motor bolt

11 Nm (1.1 m·kgf, 8.0 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Differential assembly operation 1
Unsmooth operation → Replace the differen-
EBS30250
tial assembly.
Insert the double offset joint into the differen-
(DIFFERENTIAL ASSEMBLY SIDE)
tial assembly, and turn the gears back and
1. Install:
forth.
• Universal joint (differential assembly side)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the universal joint into the front drive
shaft yoke.
8-16
EBS30251
MEASURING THE DIFFERENTIAL GEAR

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

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

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

yoke using a suitable socket.
TIP 2
universal joint yoke and front drive shaft yoke so
that the circlip can be installed.
a
bearing. a. Measuring point is 35.9 mm (1.49 in)
5. Measure:
• Gear backlash
Gently rotate the differential pinion gear from
engagement to engagement.
Differential gear backlash

0.05–0.25 mm (0.002–0.010 in)
TIP
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Measure the gear backlash at four positions. Ro-
tate the differential pinion gear 90° each time.
8-17
EBS30252
ADJUSTING THE DIFFERENTIAL GEAR

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

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

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30643
INSTALLING THE DIFFERENTIAL

ASSEMBLY
1. Install:
• Differential assembly “1”
TIP
Make sure that the universal joint yoke “a” on the
transmission case and the universal joint yoke
“b” on the differential assembly are aligned as
1
b a
8-18
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
105 Nm (10.5 m•kgf, 76 ft•lbf)

T.R
.
D 55 Nm (5.5 m•kgf, 40 ft•Ibf)

FW
T.R
.
105 Nm (10.5 m•kgf, 76 ft•lbf)
T.R
.
2 3
1
New New
New (6)
4 1
LS
(6)
LS
17 Nm (1.7 m•kgf, 12 ft•Ibf)

T.R
5
.
LS
LS

Skid plate (rear)/Skid plate (center) 4-1.
Rear knuckles Refer to “REAR KNUCKLES” on page 4-74.
Parking brake caliper Refer to “PARKING BRAKE” on page 4-48.
Drain.
Final gear oil Refer to “CHANGING THE DIFFERENTIAL
GEAR OIL” on page 3-23.
1 Rear constant velocity shaft assembly 2
3 Final drive assembly bracket 1
4 Final drive assembly 1
5 Rear drive shaft 1
8-19
Removing the rear constant velocity shaft assemblies, final drive assembly, and rear drive shaft
105 Nm (10.5 m•kgf, 76 ft•lbf)

T.R
.
D 55 Nm (5.5 m•kgf, 40 ft•Ibf)

FW
T.R
.
105 Nm (10.5 m•kgf, 76 ft•lbf)
T.R
.
New New
7
New (6)
LS
(6) 11
8 LS
10 9
17 Nm (1.7 m•kgf, 12 ft•Ibf)
6
T.R
.
LS
LS

6 Spring 1
7 Damper 1
8 Rear drive shaft coupling sleeve 1
9 Dust seal 1
10 Dust seal 1
11 Parking brake disc 1
8-20
Disassembling the rear constant velocity shaft assemblies
A
B
5 M
6 New
7 4 New
2 New
B 3
1 New
New 8
New 9
New A
A: Wheel side
B: Final drive side

the rear constant velocity shaft assemblies.
1 Boot band 1
2 Boot band 1
3 Dust boot 1
4 Clip 1
5 Double offset joint 1
6 Circlip 1
7 Ball bearing 1
8 Boot band 1
9 Boot band 1
8-21
Disassembling the rear constant velocity shaft assemblies
A
B
M
New
New
New
B
New
13
New
11
10
New
New 12 A
A: Wheel side
B: Final drive side

10 Dust boot 1
11 Constant velocity joint 1
12 Clip 1
13 Constant velocity shaft 1
8-22
Disassembling the final drive assembly
23 Nm (2.3 m•kgf, 17 ft•Ibf)
T.R
New
.
New
LS
New
New LS
LT 6
7
4 8
New
**
New
LS
10
3 11
New 9
LS 5
2
New 1
** New (8)
*
***
(4) 170 Nm (17 m•kgf, 123 ft•lbf)
T.R
.
LT
52 Nm (5.2 m•kgf, 38 ft•Ibf) LS
T.R
.
290 Nm (29 m•kgf, 210 ft•lbf)

***
T.R
.

T.R
T.R
.

** Apply Three Bond No.1305N®.
*** Apply Three Bond No.1324N®.

Rear drive shaft coupling gear nut (final drive
1 1
assembly side)
Rear drive shaft coupling gear (final drive as-
2 1
sembly side)
3 Final drive pinion gear bearing housing 1
4 Final drive pinion gear 1
5 Final drive pinion gear shim
6 Circlip 1
7 Washer 1
8 Collar 1
9 Oil seal 1
10 Final drive pinion gear bearing retainer 1 Left-hand threads
11 Bearing 1
8-23
Disassembling the final drive assembly
23 Nm (2.3 m•kgf, 17 ft•Ibf)
T.R
New
.
22
New 21
LS
New 17
19
15
18 New
16
LS
LT
20 New 14
12
**
New
LS
13
New
LS
New
** New (8)
*
***
(4) 170 Nm (17 m•kgf, 123 ft•lbf)
T.R
.
LT
52 Nm (5.2 m•kgf, 38 ft•Ibf) LS
T.R
.
290 Nm (29 m•kgf, 210 ft•lbf)

***
T.R
.

T.R
T.R
.

** Apply Three Bond No.1305N®.
*** Apply Three Bond No.1324N®.

12 Final drive case cover 1
13 Ring gear stopper 1
14 Oil seal 1
15 Final drive ring gear 1
Final drive ring gear shim (final drive case cover
16 side)
17 Final drive ring gear shim (final drive case side)
18 Bearing 1
19 Bearing 1
20 Bearing 1
21 Oil seal 1
22 Final drive case 1
8-24
EBS30253
DISASSEMBLING THE REAR CONSTANT B

VELOCITY SHAFT ASSEMBLIES 5
rear constant velocity shaft assemblies.
1. Remove:
• Boot bands “1” 2
TIP
1
Remove each boot band using a chisel “2”.
A B B
4
1
A. Wheel side B. Final drive side

B. Final drive side
3. Remove:
B
TIP
2
90890-01526
1 YM-01526
A B
B. Final drive side
1
2. Remove:
• Clip “1”
• Double offset joint “2”
• Circlip “3”
• Dust boot “5”
TIP
Before removing the clip, slide the dust boot A. Wheel side
away from the double offset joint. B. Final drive side
8-25
EBS30255
A ASSEMBLING THE REAR CONSTANT

2 rear constant velocity shaft assemblies.
1 1. Install:
• Clip “1” New
• Constant velocity joint “2”
• Constant velocity shaft “3”
• Dust boot
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
A. Wheel side a. Install a new clip.
4. Remove: b. Install the constant velocity joint.
• Dust boot TIP
• Constant velocity joint • Install the clip into the groove in the constant
• Clip velocity shaft as shown.
TIP • Secure the constant velocity joint in a vise, and
Secure the constant velocity shaft in a vise, and then fit the constant velocity shaft into the con-
then remove the constant velocity joint using stant velocity joint using a soft-face hammer.
hammers.
A
A New 1
A
3
A. Wheel side
EBS30254
CHECKING THE REAR CONSTANT

The following procedure applies to both of the New 1
rear constant velocity shaft assemblies.
1. Check: 2
• Double offset joint splines A
• Constant velocity joint splines
• Constant velocity shaft splines
Wear/damage → Replace.
2. Check:
• Dust boots
ECB01590
NOTICE
Always use a new boot band.
3. Check: A. Wheel side
• Balls and ball races
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Inner surface of double offset joint
2. Install:
Pitting/wear/damage → Replace.
• Dust boot
8-26
A B
• Double offset joint “3” 1 New 2 New
• Clip “4” New
TIP
• Securely install the circlip into the groove in the
constant velocity shaft.
• Securely install the clip into the groove in the
double offset joint.
A. Wheel side
B
1 B. Final drive side
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the boot bands “1”.
2 New

90890-01526
YM-01526
B
A
3
3 1
4 New
B. Final drive side

3. Apply: A. Wheel side
• Molybdenum disulfide grease b. Install the boot bands “2”.
(into the double offset joint, constant velocity TIP
joint, and dust boots)
Insert the tips of the boots band installation tool
Molybdenum disulfide grease screw type “4” into the holes on the boot band,
55–75 g (1.9–2.6 oz) per dust and turn the handle to compress the boot band.
boot (wheel side)
90–100 g (3.2–3.5 oz) per dust Boots band installation tool
boot (final drive side) screw type
90890-01554
TIP Boots band installation tool
Molybdenum disulfide grease is included in the screw type
repair kit. YM-01554
4. Install:
8-27
B Coupling gear holding tool (35)
90890-01571
YM-01571
4
2
B. Final drive side
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Check: 2
• Thrust movement free play 1
Excessive play → Replace the constant ve-
3. Remove:
locity shaft assembly.
• Final drive pinion gear “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside surface of the final drive
pinion gear.
b. Place the final drive gear in a hydraulic press.
ECB01580
NOTICE
• Never directly press the gear end with a hy-
draulic press, this will result in damage to
the gear thread.
• Install the suitable socket on the gear end
EBS30428 to protect the thread from damage.
DISASSEMBLING THE FINAL DRIVE
ASSEMBLY c. Press the gear end and remove the final drive
1. Straighten the rear drive shaft coupling gear pinion gear.
nut rib “a”
2
1
a
2. Suitable socket
2. Remove: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Rear drive shaft coupling gear nut (final drive
4. Remove:
assembly side)
• Final drive pinion gear bearing retainer
• Washer
• Bearing
• Rear drive shaft coupling gear (final drive as-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
sembly side) “1” a. Wrap the final drive pinion gear bearing hous-
TIP ing in a folded rag “1”, and then secure the fi-
• Secure the final drive assembly in a vise. nal drive pinion gear bearing housing edge in
• Use the coupling gear holding tool (35) “2” to a vise.
hold the rear drive shaft coupling gear. b. Attach the bearing retainer wrench “2”.
8-28
TIP
Bearing retainer wrench
90890-04128 When the final drive pinion gear and ring gear
Middle gear bearing retainer are replaced, be sure to adjust the shim of the fi-
YM-04128 nal drive pinion gear and/or ring gear.
ECB03190
3. Check:
NOTICE • Bearings
Damage → Replace.
The final drive pinion gear bearing retainer
has left-hand threads. To loosen the final EBS30259
drive pinion gear bearing retainer, turn it ADJUSTING THE RING GEAR STOPPER
clockwise. 1. Install:
• Ring gear stopper “1”
• Ring gear stopper nut “2”
2 TIP
1 • Apply Yamaha bond No.1215 to the ring gear
stopper threads.
• Apply Three Bond No.1324N® to the nut
threads.
2. Adjust:
• Ring gear stopper clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
c. Remove the final drive pinion gear bearing a. Finger tighten the ring gear stopper until it
retainer and bearing. contacts the ring gear “3”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30257
CHECKING THE REAR DRIVE SHAFT 3

1. Check:
• Drive shaft splines
• Coupling sleeve splines
Wear/damage → Replace. 1
EWB03040
WARNING
Do not attempt to straighten a bent shaft; 2
this may dangerously weaken it. b. Turn the ring gear stopper 120° counterclock-
wise.
EBS30258
CHECKING THE FINAL DRIVE ASSEMBLY

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

R.
Three Bond No.1324N®

pinion gear and ring gear as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-29
EBS30260
MEASURING THE FINAL GEAR BACKLASH Final gear backlash

1. Remove: 0.15–0.25 mm (0.006–0.010 in)
• Final gear oil filler bolt
• Gasket TIP
2. Install: • While pulling the final drive pinion gear outward
• Ring gear fix bolt (M10 × 1.5) “1” and gently turning the gear back and forth,
(into the filler bolt hole) measure the backlash.
• Measure the gear backlash at four positions.
Ring gear fix bolt (M10 x 1.5)
90890-01572 Rotate the final drive pinion gear 90° each
Ring gear fix bolt (M10 x 1.5) time.
YM-01572
EBS30261
ECB01250 ADJUSTING THE FINAL GEAR BACKLASH

NOTICE 1. Remove:
Finger tighten the bolt until it holds the ring • Final drive ring gear “1”
gear. Otherwise, the ring gear will be dam- • Bearings “2”
aged. • Final drive ring gear shim (final drive case
cover side) “3”
• Final drive ring gear shim (final drive case
side) “4”
1
2
3
4
2
1
3. Attach:
• Gear lash measurement tool “1”
• Dial gauge “2”
2. Adjust:
Gear lash measurement tool • Gear backlash
90890-01475 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Middle drive gear lash tool a. Select a suitable shim(s) using the following
YM-01475 chart.
Final gear backlash is in-
Thinner shim
creased.
2
Final gear backlash is de-
Thicker shim
creased.
b. If increased by more than 0.2 mm (0.008 in):

1 Reduce the final drive ring gear shim (final
drive case cover side) “3” thickness by 0.2
mm (0.008 in) for every 0.2 mm (0.008 in) that
the final drive ring gear shim (final drive case
a
side) “4” is increased.
c. If reduced by more than 0.2 mm (0.008 in):
a. Measuring point is 29.47 mm (1.16 in)
Increase the final drive ring gear shim (final
4. Measure: drive case cover side) “3” thickness by 0.2
• Gear backlash mm (0.008 in) for every 0.2 mm (0.008 in) that
Gently rotate the final drive pinion gear from the final drive ring gear shim (final drive case
engagement to engagement. side) “4” is decreased.
8-30
Final drive ring gear shims (final
drive case cover side) “3” 2
Thickness (mm) 1
0.2 0.3 0.4
TIP
Be sure to use one of each of the final drive ring
gear shim (final drive case cover side) “3” and fi-
nal drive ring gear shim (final drive case side) “4”
to obtain the shim thickness.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
Final drive ring gear shims (final • Collar “1”
drive case side) “4” (to the final drive pinion gear “2”)
Thickness (mm)
• Washer “3”
0.2 0.3
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ TIP
EBS30262 Be sure the circlip sharp-edged corner “a” is po-
ASSEMBLING THE FINAL DRIVE PINION sitioned opposite side to the washer.
GEAR ASSEMBLY
1. Install: 3
• Final drive pinion gear bearing retainer 2 4 New
TIP 1
a
Apply Three Bond No.1305N® to the threads of
the final drive pinion gear bearing retainer.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wrap the final drive pinion gear bearing hous-
ing in a folded rag “1”, and then secure the fi-
nal drive pinion gear bearing housing edge in
a vise. 3. Install:
b. Attach the bearing retainer wrench “2”. • Rear drive shaft coupling gear (final drive as-
sembly side) “1”
Bearing retainer wrench
90890-04128 Rear drive shaft coupling gear
Middle gear bearing retainer nut (final drive assembly side)
T.
R.
YM-04128 290 Nm (29 m·kgf, 210 ft·lbf)

LOCTITE®
c. Tighten the final drive pinion gear bearing re-
tainer. TIP
Final drive pinion gear bearing • Apply Three Bond No.1305N® to the splines of
retainer the final drive pinion gear.
T.
• Secure the rear differential assembly in a vise.

R.
170 Nm (17 m·kgf, 123 ft·lbf)

Three Bond No. 1305N® • Use the coupling gear holding tool (35) “2” to
hold the rear drive shaft coupling gear.
ECB03200
NOTICE
The final drive pinion gear bearing retainer 90890-01571
has left-hand threads. To tighten the final Coupling gear holding tool (35)
drive pinion gear bearing retainer, turn it YM-01571
counterclockwise.
8-31
2
1
TIP
After tightening the nut, stake the collar of the
nut into the notch of the shaft.
8-32
8-33
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 9-1

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

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

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

CIRCUIT DIAGRAM ................................................................................ 9-19
COOLING SYSTEM....................................................................................... 9-25

CIRCUIT DIAGRAM ................................................................................ 9-25
FUEL INJECTION SYSTEM..........................................................................9-29

CIRCUIT DIAGRAM ................................................................................ 9-29
ECU SELF-DIAGNOSTIC FUNCTION....................................................9-31
TROUBLESHOOTING METHOD............................................................ 9-32
YAMAHA DIAGNOSTIC TOOL ...............................................................9-33
TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM) ............9-35
FUEL PUMP SYSTEM...................................................................................9-67

CIRCUIT DIAGRAM ................................................................................ 9-67
2WD/4WD SELECTING SYSTEM.................................................................9-71

CIRCUIT DIAGRAM ................................................................................ 9-71
9
EPS (ELECTRIC POWER STEERING) SYSTEM.........................................9-75
CIRCUIT DIAGRAM ................................................................................ 9-75
EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION .....................9-77
EPS WARNING LIGHT DURING NORMAL OPERATION......................9-77
DIAGNOSTIC MODE .............................................................................. 9-78
SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)......................9-80
TROUBLESHOOTING DETAILS (EPS SYSTEM) ..................................9-81
ELECTRICAL COMPONENTS...................................................................... 9-85

CHECKING THE SWITCHES .................................................................9-91
ADJUSTING THE HEADLIGHT BEAMS................................................. 9-94
CHECKING THE FUSES ........................................................................9-94
CHECKING AND CHARGING THE BATTERY....................................... 9-95
CHECKING THE RELAYS ...................................................................... 9-97
CHECKING THE IGNITION COILS.......................................................9-100
CHECKING THE IGNITION SPARK GAP.............................................9-100
CHECKING THE CRANKSHAFT POSITION SENSOR........................9-101
CHECKING THE LEAN ANGLE SENSOR............................................9-101
CHECKING THE STARTER MOTOR OPERATION .............................9-102
CHECKING THE STATOR COIL ..........................................................9-102
CHECKING THE RECTIFIER/REGULATOR ........................................9-102
CHECKING THE OIL PRESSURE SWITCH.........................................9-103
CHECKING THE FUEL SENDER .........................................................9-103
CHECKING THE FUEL METER/FUEL LEVEL WARNING LIGHT .......9-104
CHECKING THE SPEED SENSOR ......................................................9-104
CHECKING THE PARKING BRAKE BUZZER......................................9-105
CHECKING THE RADIATOR FAN MOTOR .........................................9-105
CHECKING THE RADIATOR FAN MOTOR CIRCUIT BREAKER .......9-105
CHECKING THE COOLANT TEMPERATURE SENSOR.....................9-106
CHECKING THE THROTTLE POSITION SENSOR .............................9-106
CHECKING THE INTAKE AIR PRESSURE SENSORS .......................9-107
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ..................9-108
CHECKING THE FUEL INJECTORS....................................................9-108
CHECKING THE AIR INDUCTION SYSTEM SOLENOID ....................9-108
CHECKING THE DIFFERENTIAL MOTOR POSITION SWITCH .........9-109
CHECKING THE EPS MOTOR.............................................................9-109
CHECKING THE EPS TORQUE SENSOR...........................................9-110
EBS30264
EBS20074
B/W B/W
B/L Gy
Gy
A B
B/L B
W W W B R
B Y/R Gy L Br/W P G/Y G/R B/R Br/R R/G Br/L W/G P/L L/B B B
Gy B 1 (Gy) (B) B B
B/Lg B/L R/L W/B B/W R L/W O/W P/B Sb/W Y/B G/R O
P/B P
L/W W Y/G R/G Sb P/W B/W R/Y Y L/Y Y/R L/R O/G P Br Br/Y P/B
W W R Br/Y Br
31
Y P/B Y R O/L R/W Br B/G R/B G/B Gy/R (Gy) A C
W W (Gy)
2 W W
3 (B) (B)
R/W O
Gy Gy/R
W W W Br/R O/G
B
CIRCUIT DIAGRAM
P/B Br/R
38
(Gy) R/W
(Gy) R/L R/L R/B
R/W
R/L G/B
21 (Gy) O
W W W R/B R/B R/L
R/G R/G 24 (Gy) 41
(Gy) Br/R P/L P/L G/B G/B R/L
(Gy) Br/R
IGNITION SYSTEM
Br/R 19
Br/R Br/R W/G W/G L/B L/B R/L L
Br/R Br/R Br/L Br/L O Br/R
R/G 32 L R/G B/L
Br/R Br/R
Br/R Br/R R/L L/B 22 Br/W B/L
R Br/R B/L (L) (B)
Br/R R
W/G R/W R/G (Gy) 25
G/Y B/L Br/W B/L L
B (B) Br/L R/W P/L Br/W Y/G L Y/G B/L Br/R
39
R/B (B)
33
4 23 B/L
R R/B (B) (B)
B (Gy)
10 18 G/Y G/Y B/L
B R L Gy/R
R/B R/B Y/G
Br/R R R
Br/L B B/W R/G W L W B/L 41
R 34
B 20 L
Br/L BB/W 9 Y/R W B/L
R/B Br/B (L)
Br/R B B R R Br/B Br/B Y
R Br/B Br/R L/R Gy/R Br/R
Sb/W L
RR R/Y L/Y B/L Y L
Y
5 Y/B 35 (B)
R B/L
B/W G/R (B)
11 Y
14 L/W
Br/R Br/R Br L
B
8 L/W P/W 40
R/B Br/R O/L Y P 36 B/L P L
12 Sb B/L Br/R
R/L L/R 15 B/G
R/Y Br/B P (L)
6 O/G
R/L W/B L
B/W A B/W B O/L W/B
(off) B B/Y P/B P/B 41
Br/R L/R B/R 37 B/L P/B L
(on) Br/B Br/B P/W B/G B/Y Br/B B/R L/W B/L B/L
B B B B B
(start) R/Y L/W G/R
L/W G/R Sb (L)
B Y Br R L/Y B/L
(B) Y/B B O/G Br/R
B/Y O/W B B/L
Br/R L/W 7 16 B/L
Br/R R/B 17 Y/R B/W B B B B/L L
13 Br/R (B)
L/W Br/R B/Lg B/W 26 27 28 29 30 B/L L
2WD L/W G/R G/R L/W
Br/R B Y/B B/L L
(B) 4WD B/L L
B B
DIFF LOCK B/L L
(B) B B B B B B L/R B/L L
L/R B/L L
B/G P/W W/B B/R B O/L Br/B B/Y
B B B
B Y R B
(Gy) B Br B L/Y
(Gy)
9-1
B B/W
B B/W B B
Br/L
Br/R Y/R
73
Br Br Br/R Br/R R/W 51 B/Lg
Br
B/W 43
74 65 64 44 45 B R B R
Br/Y
Br/B B/Lg Y/R (Gy)
(off) B R 42
Br Y (Gy)
L W Y
75 R/W B/W
L H G R B W R B W Y
R/W W Y
Y G/R B L/W
76 Br/B L/W B/Lg
L L/Y L/W B/Lg
R R/B L/Y Br Br/R R/W B/Lg
Br/R B G/R R/W Y/R
L R/W Y/R
77 R/W Y/R
R/G (B) 52 53 R/W B
Br L G L/Y R/W B
Sb
B
Br/R 78 72 Br 54
R/G Br/L W W W/B G B G G R
67 G 66 B R
Y B W
79 L B 55 (Gy)
L/Y B (Gy) G R B W R B Y Y Y B/Lg B/Lg B/Lg Y/R Y/R Y/R B B B
G W/B W B
80 B Y B R/W R/W R/W R/W R/W R/W L/W L/W L/W W W W
G G 56 R G R B
W B (Gy)
R/G R/L Y/R B (B)
B
57 (Gy)
R/L R/B G W
Br/R Y/R G/R Sb
58 Br/R Br
71 LG 46 W/B
R/L O O/W
B
59 L/B L/B
Y G Y G Y G Y G L/B Br O
81 B L R/B B O/W Br/R L/B
Y 60 B G
G W G/R 47
Sb W
Br/Y 68 68 68 68 (Gy) (B) (B) (Gy) (B)
B 70 (B)
Y/R
Br
69 B/Lg
G B/W
R/W
L Br Y R/L G
Br/Y Br/Y
(B) G Y G Y G Y G Y
L
Y B B B B 63 62 48
82 L Y Y Br/Y 61
B (B) B B B B B Br/Y 49 50
Y G Y G Y G Y G B/W
L B B L B R/W Br/Y B/W Sb Sb/W
(B) B B B B B
(B) R/L B B/W G Y/R B/Lg G (B)
Y L
(B)
B B B Sb/W
(Dgy)
IGNITION SYSTEM
IGNITION SYSTEM
1. Crankshaft position sensor

5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
20.ECU (Engine Control Unit)
33.Lean angle sensor
38.Ignition coil #1
39.Ignition coil #2
40.Ignition coil #3
41.Spark plug
77.Ignition fuse
A. Wire harness
B. Negative battery sub-wire harness 1
C. Negative battery sub-wire harness 2
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. Battery cover
2. Meter assembly cover
3. AC magneto cover
1. Check the fuses. NG →

(Main and ignition)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 9-94.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 9-95.
OK ↓
3. Check the spark plugs. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plugs.
PLUGS” on page 3-7.
OK ↓
4. Check the ignition spark gap. OK →
Refer to “CHECKING THE IGNI- Ignition system is OK.
TION SPARK GAP” on page 9-100.
NG ↓
5. Check the ignition coils. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coils.
TION COILS” on page 9-100.
OK ↓
6. Check the crankshaft position sen- NG →
sor.
Replace the crankshaft position sen-
Refer to “CHECKING THE CRANK-
sor/stator assembly.
SHAFT POSITION SENSOR” on
page 9-101.
OK ↓
7. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 9-91.
OK ↓
8. Check the lean angle sensor. NG →
Refer to “CHECKING THE LEAN Replace the lean angle sensor.
ANGLE SENSOR” on page 9-101.
OK ↓
9-3
IGNITION SYSTEM
9. Check the entire ignition system NG →

wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 9-1.
OK ↓
Replace the ECU.
9-4
EBS30266
EBS20075
B/W B/W
B/L Gy
Gy
A B
B/L B
W W W B R
Gy B 1 (Gy) (B) B B
P/B P
W W R Br/Y Br
31
W W (Gy)
2 W W
3 (B) (B)
R/W O
Gy Gy/R
W W W Br/R O/G
B
CIRCUIT DIAGRAM
P/B Br/R
38
(Gy) R/W
(Gy) R/L R/L R/B
R/W
R/L G/B
21 (Gy) O
W W W R/B R/B R/L
R/G R/G 24 (Gy) 41
(Gy) Br/R
Br/R 19
R/G 32 L R/G B/L
Br/R Br/R
R Br/R B/L (L) (B)
Br/R R
W/G R/W R/G (Gy) 25
G/Y B/L Br/W B/L L
39
R/B (B)
33
4 23 B/L
R R/B (B) (B)
B (Gy)
10 18 G/Y G/Y B/L
B R L Gy/R
R/B R/B Y/G
Br/R R R
R 34
B 20 L
R/B Br/B (L)
Sb/W L
RR R/Y L/Y B/L Y L
Y
5 Y/B 35 (B)
R B/L
B/W G/R (B)
11 Y
14 L/W
Br/R Br/R Br L
B
8 L/W P/W 40
12 Sb B/L Br/R
R/L L/R 15 B/G
R/Y Br/B P (L)
6 O/G
R/L W/B L
B/W A B/W B O/L W/B
B B B B B G/R
ELECTRIC STARTING SYSTEM
(start) R/Y L/W

L/W G/R Sb (L)
B Y Br R L/Y B/L
(B) Y/B B O/G Br/R
B/Y O/W B B/L
Br/R L/W 7 16 B/L
13 Br/R (B)
L/W Br/R B/Lg B/W 26 27 28 29 30 B/L L
2WD L/W G/R G/R L/W
Br/R B Y/B B/L L
(B) 4WD B/L L
B B
DIFF LOCK B/L L
L/R B/L L
B B B
B Y R B
(Gy) B Br B L/Y
(Gy)
9-5
B B/W
B B/W B B
Br/L
Br/R Y/R
73
Br
B/W 43
74 65 64 44 45 B R B R
Br/Y
Br/B B/Lg Y/R (Gy)
(off) B R 42
Br Y (Gy)
L W Y
75 R/W B/W
L H G R B W R B W Y
R/W W Y
Y G/R B L/W
76 Br/B L/W B/Lg
L L/Y L/W B/Lg
Br/R B G/R R/W Y/R
L R/W Y/R
77 R/W Y/R
R/G (B) 52 53 R/W B
Br L G L/Y R/W B
Sb
B
Br/R 78 72 Br 54
67 G 66 B R
Y B W
79 L B 55 (Gy)
G W/B W B
G G 56 R G R B
W B (Gy)
R/G R/L Y/R B (B)
B
57 (Gy)
R/L R/B G W
Br/R Y/R G/R Sb
58 Br/R Br
71 LG 46 W/B
R/L O O/W
B
59 L/B L/B
Y 60 B G
G W G/R 47
Sb W
Br/Y 68 68 68 68 (Gy) (B) (B) (Gy) (B)
B 70 (B)
Y/R
Br
69 B/Lg
G B/W
R/W
L Br Y R/L G
Br/Y Br/Y
(B) G Y G Y G Y G Y
L
Y B B B B 63 62 48
82 L Y Y Br/Y 61
B (B) B B B B B Br/Y 49 50
Y G Y G Y G Y G B/W
(B) B B B B B
Y L
(B)
B B B Sb/W
(Dgy)

5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
12.Starter relay
13.Starter motor
26.Neutral switch
28.Clutch switch
42.Joint coupler
69.Brake light switch
75.Signaling system fuse
77.Ignition fuse
A. Wire harness
9-6
EBS30267
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the main switch is set to “ ” (start), the starter motor can only operate if at least one of the following
conditions is met:
• The transmission is in neutral (the neutral switch is closed) and brake pedal is pressed (the brake light
switch circuit is closed).
• The clutch pedal is pressed (the clutch switch circuit is closed).
12
11
1
5
3
6
4
9 10
1. Battery
2. Main fuse
3. Ignition fuse
4. Main switch
6. Signaling system fuse
7. Brake light switch
9. Neutral switch
10. Clutch switch
11. Starter relay
12. Starter motor
9-7
EBS30268
TROUBLESHOOTING
The starter motor fails to turn.
TIP
1. Battery cover
2. Center console side panel (right)

(Main, ignition, and signaling sys-
tem) Replace the fuse(s).
ES” on page 9-94.
OK ↓
page 9-95.
OK ↓
3. Check the starter motor operation. OK →
Starter motor is OK. Perform the electric
Refer to “CHECKING THE START-
starting system troubleshooting, starting
ER MOTOR OPERATION” on page
with step 5.
9-102.
NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-36.
OK ↓
5. Check the starter relay. NG →
Refer to “CHECKING THE RE- Replace the starter relay.
LAYS” on page 9-97.
OK ↓
6. Check the load control relay. NG →
Refer to “CHECKING THE RE- Replace the load control relay.
OK ↓
OK ↓
8. Check the brake light switch. NG →
Refer to “CHECKING THE Replace the brake light switch.
OK ↓
9-8
9. Check the neutral switch. NG →

Refer to “CHECKING THE Replace the neutral switch.
OK ↓
10.Check the clutch switch. NG →
Refer to “CHECKING THE Replace the clutch switch.
OK ↓
11.Check the entire starting system NG →
page 9-5.
OK ↓
Replace the ECU.
9-9
9-10
EBS30269
EBS20076
B/W B/W
B/L Gy
Gy
A B
B/L B
W W W B R
Gy B 1 (Gy) (B) B B
P/B P
W W R Br/Y Br
31
W W (Gy)
2 W W
3 (B) (B)
R/W O
Gy Gy/R
W W W Br/R O/G
B
CIRCUIT DIAGRAM
P/B Br/R
38
(Gy) R/W
(Gy) R/L R/L R/B
R/W
R/L G/B
21 (Gy) O
W W W R/B R/B R/L
R/G R/G 24 (Gy) 41
(Gy) Br/R
Br/R 19
R/G 32 L R/G B/L
Br/R Br/R
R Br/R B/L (L) (B)
Br/R R
CHARGING SYSTEM
W/G R/W R/G (Gy) 25

G/Y B/L Br/W B/L L
39
R/B (B)
33
4 23 B/L
R R/B (B) (B)
B (Gy)
10 18 G/Y G/Y B/L
B R L Gy/R
R/B R/B Y/G
Br/R R R
R 34
B 20 L
R/B Br/B (L)
Sb/W L
RR R/Y L/Y B/L Y L
Y
5 Y/B 35 (B)
R B/L
B/W G/R (B)
11 Y
14 L/W
Br/R Br/R Br L
B
8 L/W P/W 40
12 Sb B/L Br/R
R/L L/R 15 B/G
R/Y Br/B P (L)
6 O/G
R/L W/B L
B/W A B/W B O/L W/B
B B B B B
(start) R/Y L/W G/R
L/W G/R Sb (L)
B Y Br R L/Y B/L
(B) Y/B B O/G Br/R
B/Y O/W B B/L
Br/R L/W 7 16 B/L
13 Br/R (B)
L/W Br/R B/Lg B/W 26 27 28 29 30 B/L L
2WD L/W G/R G/R L/W
Br/R B Y/B B/L L
(B) 4WD B/L L
B B
DIFF LOCK B/L L
L/R B/L L
B B B
B Y R B
(Gy) B Br B L/Y
(Gy)
B B/W
B B/W B B
9-11
Br/L
Br/R Y/R
73
Br
B/W 43
74 65 64 44 45 B R B R
Br/Y
Br/B B/Lg Y/R (Gy)
(off) B R 42
Br Y (Gy)
L W Y
75 R/W B/W
L H G R B W R B W Y
R/W W Y
Y G/R B L/W
76 Br/B L/W B/Lg
L L/Y L/W B/Lg
Br/R B G/R R/W Y/R
L R/W Y/R
77 R/W Y/R
R/G (B) 52 53 R/W B
Br L G L/Y R/W B
Sb
B
Br/R 78 72 Br 54
67 G 66 B R
Y B W
79 L B 55 (Gy)
G W/B W B
G G 56 R G R B
W B (Gy)
R/G R/L Y/R B (B)
B
57 (Gy)
R/L R/B G W
Br/R Y/R G/R Sb
58 Br/R Br
71 LG 46 W/B
R/L O O/W
B
59 L/B L/B
Y 60 B G
G W G/R 47
Sb W
Br/Y 68 68 68 68 (Gy) (B) (B) (Gy) (B)
B 70 (B)
Y/R
Br
69 B/Lg
G B/W
R/W
L Br Y R/L G
Br/Y Br/Y
(B) G Y G Y G Y G Y
L
Y B B B B 63 62 48
82 L Y Y Br/Y 61
B (B) B B B B B Br/Y 49 50
Y G Y G Y G Y G B/W
(B) B B B B B
Y L
(B)
B B B Sb/W
(Dgy)
CHARGING SYSTEM
CHARGING SYSTEM
2. AC magneto
3. Rectifier/regulator
5. Frame ground
8. Battery
9. Main fuse
A. Wire harness
9-12
CHARGING SYSTEM
EBS30270
TROUBLESHOOTING
The battery is not being charged.
TIP
1. Battery cover
2. Upper cover
3. AC magneto cover
1. Check the fuse. NG →

(Main)
Replace the fuse.
ES” on page 9-94.
OK ↓
page 9-95.
OK ↓
3. Check the stator coil. NG →
Replace the crankshaft position sen-
Refer to “CHECKING THE STATOR
sor/stator assembly.
COIL” on page 9-102.
OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI-
Replace the rectifier/regulator.
FIER/REGULATOR” on page
9-102.
OK ↓
5. Check the entire charging system NG →
page 9-11.
OK ↓
The charging system circuit is OK.
9-13
CHARGING SYSTEM
9-14
EBS30271
EBS20077
B/W B/W
B/L Gy
Gy
A B
B/L B
W W W B R
Gy B 1 (Gy) (B) B B
P/B P
W W R Br/Y Br
31
W W (Gy)
2 W W
3 (B) (B)
R/W O
Gy Gy/R
W W W Br/R O/G
B
CIRCUIT DIAGRAM
P/B Br/R
38
(Gy) R/W
(Gy) R/L R/L R/B
R/W
R/L G/B
21 (Gy) O
W W W R/B R/B R/L
R/G R/G 24 (Gy) 41
(Gy) Br/R
Br/R 19
O Br/R
LIGHTING SYSTEM
Br/R Br/R Br/L Br/L L R/G B/L

Br/R Br/R R/G 32
R Br/R B/L (L) (B)
Br/R R
W/G R/W R/G (Gy) 25
G/Y B/L Br/W B/L L
39
R/B (B)
33
4 23 B/L
R R/B (B) (B)
B (Gy)
10 18 G/Y G/Y B/L
B R L Gy/R
R/B R/B Y/G
Br/R R R
R 34
B 20 L
R/B Br/B (L)
Sb/W L
RR R/Y L/Y B/L Y L
Y
5 Y/B 35 (B)
R B/L
B/W G/R (B)
11 Y
14 L/W
Br/R Br/R Br L
B
8 L/W P/W 40
12 Sb B/L Br/R
R/L L/R 15 B/G
R/Y Br/B P (L)
6 O/G
R/L W/B L
B/W A B/W B O/L W/B
B B B B B
(start) R/Y L/W G/R
L/W G/R Sb (L)
B Y Br R L/Y B/L
(B) Y/B B O/G Br/R
B/Y O/W B B/L
Br/R L/W 7 16 B/L
13 Br/R (B)
L/W Br/R B/Lg B/W 26 27 28 29 30 B/L L
2WD L/W G/R G/R L/W
Br/R B Y/B B/L L
(B) 4WD B/L L
B B
DIFF LOCK B/L L
L/R B/L L
B B B
B Y R B
(Gy) B Br B L/Y
(Gy)
B B/W
B B/W B B
9-15
Br/L
Br/R Y/R
73
Br
B/W 43
74 65 64 44 45 B R B R
Br/Y
Br/B B/Lg Y/R (Gy)
(off) B R 42
Br Y (Gy)
L W Y
75 R/W B/W
L H G R B W R B W Y
R/W W Y
Y G/R B L/W
76 Br/B L/W B/Lg
L L/Y L/W B/Lg
Br/R B G/R R/W Y/R
L R/W Y/R
77 R/W Y/R
R/G (B) 52 53 R/W B
Br L G L/Y R/W B
Sb
B
Br/R 78 72 Br 54
67 G 66 B R
Y B W
79 L B 55 (Gy)
G W/B W B
G G 56 R G R B
W B (Gy)
R/G R/L Y/R B (B)
B
57 (Gy)
R/L R/B G W
Br/R Y/R G/R Sb
58 Br/R Br
71 LG 46 W/B
R/L O O/W
B
59 L/B L/B
Y 60 B G
G W G/R 47
Sb W
Br/Y 68 68 68 68 (Gy) (B) (B) (Gy) (B)
B 70 (B)
Y/R
Br
69 B/Lg
G B/W
R/W
L Br Y R/L G
Br/Y Br/Y
(B) G Y G Y G Y G Y
L
Y B B B B 63 62 48
82 L Y Y Br/Y 61
B (B) B B B B B Br/Y 49 50
Y G Y G Y G Y G B/W
(B) B B B B B
Y L
(B)
B B B Sb/W
(Dgy)
LIGHTING SYSTEM
LIGHTING SYSTEM

5. Frame ground
6. Main switch
8. Battery
9. Main fuse
42.Joint coupler
65.Light switch
66.Headlight relay (high beam)
67.Headlight relay (low beam)
68.Headlight
70.Tail/brake light
74.Headlight fuse
77.Ignition fuse
A. Wire harness
9-16
LIGHTING SYSTEM
EBS30272
TROUBLESHOOTING
Any of the following fail to light: headlight or taillight.
TIP
1. Battery cover
2. Center console side panels

(Main, ignition, and headlight)
Replace the fuse(s).
ES” on page 9-94.
OK ↓
page 9-95.
OK ↓
OK ↓
4. Check the light switch. NG →
Refer to “CHECKING THE Replace the light switch.
OK ↓
5. Check the headlight relays (high NG →
beam and low beam). Replace the headlight relay (high beam) or
Refer to “CHECKING THE RE- headlight relay (low beam).
OK ↓
OK ↓
7. Check the entire lighting system NG →
page 9-15.
OK ↓
Replace the headlight or tail/brake
light assembly.
9-17
LIGHTING SYSTEM
9-18
EBS30273
EBS20078
B/W B/W
B/L Gy
Gy
A B
B/L B
W W W B R
Gy B 1 (Gy) (B) B B
P/B P
W W R Br/Y Br
31
W W (Gy)
2 W W
3 (B) (B)
R/W O
Gy Gy/R
W W W Br/R O/G
B
CIRCUIT DIAGRAM
P/B Br/R
38
(Gy) R/W
(Gy) R/L R/L R/B
R/W
R/L G/B
21 (Gy) O
W W W R/B R/B R/L
R/G R/G 24 (Gy) 41
(Gy) Br/R
Br/R 19
R/G 32 L R/G B/L
Br/R Br/R
R Br/R B/L (L) (B)
Br/R R
W/G R/W R/G (Gy)
SIGNALING SYSTEM
G/Y B/L
25 Br/W B/L L
39
B (B) Br/L R/W P/L Br/W Y/G L Y/G B/L
R/B 33 Br/R
4 23 (B) B/L
R R/B (B) (B)
B (Gy)
10 18 G/Y G/Y B/L
B R L Gy/R
R/B R/B Y/G
Br/R R R
R 34
B 20 L
R/B Br/B (L)
Sb/W L
RR R/Y L/Y B/L Y L
Y
5 Y/B 35 (B)
R B/L
B/W G/R (B)
11 Y
14 L/W
Br/R Br/R Br L
B
8 L/W P/W 40
12 Sb B/L Br/R
R/L L/R 15 B/G
R/Y Br/B P (L)
6 O/G
R/L W/B L
B/W A B/W B O/L W/B
B B B B B
(start) R/Y L/W G/R
L/W G/R Sb (L)
B Y Br R L/Y B/L
(B) Y/B B O/G Br/R
B/Y O/W B B/L
Br/R L/W 7 16 B/L
13 Br/R (B)
L/W Br/R B/Lg B/W 26 27 28 29 30 B/L L
2WD L/W G/R G/R L/W
Br/R B Y/B B/L L
(B) 4WD B/L L
B B
DIFF LOCK B/L L
L/R B/L L
B B B
B Y R B
(Gy) B Br B L/Y
(Gy)
B B/W
B B/W B B
9-19
Br/L
Br/R Y/R
73
Br
B/W 43
74 65 64 44 45 B R B R
Br/Y
Br/B B/Lg Y/R (Gy)
(off) B R 42
Br Y (Gy)
L W Y
75 R/W B/W
L H G R B W R B W Y
R/W W Y
Y G/R B L/W
76 Br/B L/W B/Lg
L L/Y L/W B/Lg
Br/R B G/R R/W Y/R
L R/W Y/R
77 R/W Y/R
R/G (B) 52 53 R/W B
Br L G L/Y R/W B
Sb
B
Br/R 78 72 Br 54
67 G 66 B R
Y B W
79 L B 55 (Gy)
G W/B W B
G G 56 R G R B
W B (Gy)
R/G R/L Y/R B (B)
B
57 (Gy)
R/L R/B G W
Br/R Y/R G/R Sb
58 Br/R Br
71 LG 46 W/B
R/L O O/W
B
59 L/B L/B
Y 60 B G
G W G/R 47
Sb W
Br/Y 68 68 68 68 (Gy) (B) (B) (Gy) (B)
B 70 (B)
Y/R
Br
69 B/Lg
G B/W
R/W
L Br Y R/L G
Br/Y Br/Y
(B) G Y G Y G Y G Y
L
Y B B B B 63 62 48
82 L Y Y Br/Y 61
B (B) B B B B B Br/Y 49 50
Y G Y G Y G Y G B/W
(B) B B B B B
Y L
(B)
B B B Sb/W
(Dgy)
SIGNALING SYSTEM
SIGNALING SYSTEM

5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
23.Coolant temperature sensor
26.Neutral switch
29.Seat belt switch
30.Parking brake switch
31.Parking brake buzzer
32.Gear position sensor
34.Speed sensor
42.Joint coupler
48.Indicator light assembly
49.Helmet indicator light
50.Seat belt indicator light
52.Meter assembly
56.Reverse indicator light
58.Coolant temperature warning light
59.Parking brake indicator light
60.Neutral indicator light
61.Multi-function meter
62.Fuel sender
69.Brake light switch
70.Tail/brake light
76.Backup fuse
77.Ignition fuse
A. Wire harness
9-20
SIGNALING SYSTEM
EBS30274
TROUBLESHOOTING
• Any of the following fail to light: warning light, brake light or an indicator light.
• The fuel meter fails to come on.
• The speedometer fails to operate.
• The parking brake buzzer fails to sound.
TIP
1. Battery cover
4. Under-seat upper panel (left)
5. Under-seat panel (right)

(Main, ignition, backup, and signal-
ing system) Replace the fuse(s).
ES” on page 9-94.
OK ↓
page 9-95.
OK ↓
OK ↓
OK ↓
5. Check the entire signaling system NG →
page 9-19.
OK ↓
Check the condition of each of the sig-
naling system circuits. Refer to
“Checking the signaling system”.
9-21
SIGNALING SYSTEM
Checking the signaling system

The tail/brake lights fail to come on.
1. Check the brake light switch. NG →
Refer to “CHECKING THE Replace the brake light switch.
OK ↓
page 9-19.
OK ↓
Replace the tail/brake light assembly.
The neutral indicator light fails to come on.

1. Check the neutral switch. NG →
Refer to “CHECKING THE Replace the neutral switch.
OK ↓
page 9-19.
OK ↓
Replace the meter assembly or ECU.
The reverse indicator light fails to come on.

1. Check the gear position sensor. NG → Replace the gear position sensor.
OK ↓
page 9-19.
OK ↓
The parking brake indicator light fails to come on.

1. Check the parking brake switch. NG →
Refer to “CHECKING THE Replace the parking brake switch.
OK ↓
9-22
SIGNALING SYSTEM

page 9-19.
OK ↓
The coolant temperature warning light fails to come on.

1. Check the coolant temperature sen- NG →
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 9-106.
OK ↓
page 9-19.
OK ↓
The fuel meter fails to come on.

1. Check the fuel sender. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump assembly.
SENDER” on page 9-103.
OK ↓
page 9-19.
OK ↓
Replace the meter assembly.
The speedometer fails to come on.

1. Check the speed sensor. NG →
Refer to “CHECKING THE SPEED Replace the speed sensor.
SENSOR” on page 9-104.
OK ↓
9-23
SIGNALING SYSTEM

page 9-19.
OK ↓
The helmet/seat belt indicator light fails to come on.

1. Check the seat belt switch. NG →
Refer to “CHECKING THE Replace the driver seat belt buckle.
OK ↓
page 9-19.
OK ↓
Replace the indicator light assembly or
ECU.
The parking brake buzzer fails to sound.

1. Check the parking brake buzzer. NG →
Refer to “CHECKING THE PARK-
Replace the parking brake buzzer.
ING BRAKE BUZZER” on page
9-105.
OK ↓
page 9-19.
OK ↓
Replace the ECU.
9-24
EBS30275
EBS20079
B/W B/W
B/L Gy
Gy
A B
B/L B
W W W B R
Gy B 1 (Gy) (B) B B
P/B P
W W R Br/Y Br
31
W W (Gy)
2 W W
3 (B) (B)
R/W O
Gy Gy/R
W W W Br/R O/G
B
CIRCUIT DIAGRAM
P/B Br/R
38
(Gy) R/W
(Gy) R/L R/L R/B
R/W
R/L G/B
21 (Gy) O
W W W R/B R/B R/L
R/G R/G 24 (Gy) 41
(Gy) Br/R
Br/R 19
COOLING SYSTEM

R/G 32 L R/G B/L
Br/R Br/R
R Br/R B/L (L) (B)
Br/R R
W/G R/W R/G (Gy) 25
G/Y B/L Br/W B/L L
39
R/B (B)
33
4 23 B/L
R R/B (B) (B)
B (Gy)
10 18 G/Y G/Y B/L
B R L Gy/R
R/B R/B Y/G
Br/R R R
R 34
B 20 L
R/B Br/B (L)
Sb/W L
RR R/Y L/Y B/L Y L
Y
5 Y/B 35 (B)
R B/L
B/W G/R (B)
11 Y
14 L/W
Br/R Br/R Br L
B
8 L/W P/W 40
12 Sb B/L Br/R
R/L L/R 15 B/G
R/Y Br/B P (L)
6 O/G
R/L W/B L
B/W A B/W B O/L W/B
B B B B B
(start) R/Y L/W G/R
L/W G/R Sb (L)
B Y Br R L/Y B/L
(B) Y/B B O/G Br/R
B/Y O/W B B/L
Br/R L/W 7 16 B/L
13 Br/R (B)
L/W Br/R B/Lg B/W 26 27 28 29 30 B/L L
2WD L/W G/R G/R L/W
Br/R B Y/B B/L L
(B) 4WD B/L L
B B
DIFF LOCK B/L L
L/R B/L L
B B B
B Y R B
(Gy) B Br B L/Y
(Gy)
B B/W
B B/W B B
9-25
Br/L
Br/R Y/R
73
Br
B/W 43
74 65 64 44 45 B R B R
Br/Y
Br/B B/Lg Y/R (Gy)
(off) B R 42
Br Y (Gy)
L W Y
75 R/W B/W
L H G R B W R B W Y
R/W W Y
Y G/R B L/W
76 Br/B L/W B/Lg
L L/Y L/W B/Lg
Br/R B G/R R/W Y/R
L R/W Y/R
77 R/W Y/R
R/G (B) 52 53 R/W B
Br L G L/Y R/W B
Sb
B
Br/R 78 72 Br 54
67 G 66 B R
Y B W
79 L B 55 (Gy)
G W/B W B
G G 56 R G R B
W B (Gy)
R/G R/L Y/R B (B)
B
57 (Gy)
R/L R/B G W
Br/R Y/R G/R Sb
58 Br/R Br
71 LG 46 W/B
R/L O O/W
B
59 L/B L/B
Y 60 B G
G W G/R 47
Sb W
Br/Y 68 68 68 68 (Gy) (B) (B) (Gy) (B)
B 70 (B)
Y/R
Br
69 B/Lg
G B/W
R/W
L Br Y R/L G
Br/Y Br/Y
(B) G Y G Y G Y G Y
L
Y B B B B 63 62 48
82 L Y Y Br/Y 61
B (B) B B B B B Br/Y 49 50
Y G Y G Y G Y G B/W
(B) B B B B B
Y L
(B)
B B B Sb/W
(Dgy)
COOLING SYSTEM
COOLING SYSTEM
5. Frame ground
6. Main switch
8. Battery
9. Main fuse
77.Ignition fuse
78.Radiator fan motor fuse
80.Radiator fan motor relay
81.Radiator fan motor circuit breaker
82.Radiator fan motor
A. Wire harness
9-26
COOLING SYSTEM
EBS30276
TROUBLESHOOTING
The radiator fan motor fails to turn.
TIP
1. Battery cover
3. Front fender

(Main, radiator fan motor, and igni-
tion) Replace the fuse(s).
ES” on page 9-94.
OK ↓
page 9-95.
OK ↓
OK ↓
4. Check the radiator fan motor. NG →
Refer to “CHECKING THE RADIA- Replace the radiator fan motor.
TOR FAN MOTOR” on page 9-105.
OK ↓
5. Check the radiator fan motor relay. NG →
Refer to “CHECKING THE RE- Replace the radiator fan motor relay.
OK ↓
6. Check the radiator fan motor circuit NG →
breaker.
Replace the radiator fan motor circuit
Refer to “CHECKING THE RADIA-
breaker.
TOR FAN MOTOR CIRCUIT
BREAKER” on page 9-105.
OK ↓
7. Check the coolant temperature sen- NG →
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 9-106.
OK ↓
9-27
COOLING SYSTEM
8. Check the entire cooling system NG →

page 9-25.
OK ↓
Replace the ECU.
9-28
EBS30277
EBS20080
B/W B/W
B/L Gy
Gy
A B
B/L B
W W W B R
Gy B 1 (Gy) (B) B B
P/B P
W W R Br/Y Br
31
W W (Gy)
2 W W
3 (B) (B)
R/W O
Gy Gy/R
W W W Br/R O/G
B
CIRCUIT DIAGRAM
P/B Br/R
38
(Gy) R/W
(Gy) R/L R/L R/B
R/W
R/L G/B
21 (Gy) O
W W W R/B R/B R/L
R/G R/G 24 (Gy) 41
(Gy) Br/R
Br/R 19
R/G 32 L R/G B/L
Br/R Br/R
R Br/R B/L (L) (B)
Br/R R
W/G R/W R/G (Gy) 25
G/Y B/L Br/W B/L L
39
R/B (B)
33
4 23 B/L
R R/B (B) (B)
B (Gy)
10 18 G/Y G/Y B/L
B R L Gy/R
R/B R/B Y/G
Br/R R R
R 34
B 20 L
R/B Br/B (L)
Sb/W L
RR R/Y L/Y B/L Y L
Y
Y/B 35 (B)
FUEL INJECTION SYSTEM
5 B/W G/R
R B/L
11 Y (B)
14 L/W
Br/R Br/R Br L
B
8 L/W P/W 40
12 Sb B/L Br/R
R/L L/R 15 B/G
R/Y Br/B P (L)
6 O/G
R/L W/B L
B/W A B/W B O/L W/B
B B B B B
(start) R/Y L/W G/R
L/W G/R Sb (L)
B Y Br R L/Y B/L
(B) Y/B B O/G Br/R
B/Y O/W B B/L
Br/R L/W 7 16 B/L
13 Br/R (B)
L/W Br/R B/Lg B/W 26 27 28 29 30 B/L L
2WD L/W G/R G/R L/W
Br/R B Y/B B/L L
(B) 4WD B/L L
B B
DIFF LOCK B/L L
L/R B/L L
B B B
B Y R B
(Gy) B Br B L/Y
(Gy)
B B/W
B B/W B B
9-29
Br/L
Br/R Y/R
73
Br
B/W 43
74 65 64 44 45 B R B R
Br/Y
Br/B B/Lg Y/R (Gy)
(off) B R 42
Br Y (Gy)
L W Y
75 R/W B/W
L H G R B W R B W Y
R/W W Y
Y G/R B L/W
76 Br/B L/W B/Lg
L L/Y L/W B/Lg
Br/R B G/R R/W Y/R
L R/W Y/R
77 R/W Y/R
R/G (B) 52 53 R/W B
Br L G L/Y R/W B
Sb
B
Br/R 78 72 Br 54
67 G 66 B R
Y B W
79 L B 55 (Gy)
G W/B W B
G G 56 R G R B
W B (Gy)
R/G R/L Y/R B (B)
B
57 (Gy)
R/L R/B G W
Br/R Y/R G/R Sb
58 Br/R Br
71 LG 46 W/B
R/L O O/W
B
59 L/B L/B
Y 60 B G
G W G/R 47
Sb W
Br/Y 68 68 68 68 (Gy) (B) (B) (Gy) (B)
B 70 (B)
Y/R
Br
69 B/Lg
G B/W
R/W
L Br Y R/L G
Br/Y Br/Y
(B) G Y G Y G Y G Y
L
Y B B B B 63 62 48
82 L Y Y Br/Y 61
B (B) B B B B B Br/Y 49 50
Y G Y G Y G Y G B/W
(B) B B B B B
Y L
(B)
B B B Sb/W
(Dgy)

5. Frame ground
6. Main switch
7. Engine ground
8. Battery
9. Main fuse
11.Fuel injection system fuse
14.Fuel injection system relay
18.Air induction system solenoid
19.ISC (Idle Speed Control) unit
21.Fuel injector #1
22.Fuel injector #3
24.Fuel injector #2
25.Intake air temperature sensor
26.Neutral switch
27.Oil pressure switch
28.Clutch switch
33.Lean angle sensor
34.Speed sensor
35.TPS (throttle position sensor)
36.Intake air pressure sensor #2
37.Intake air pressure sensor #1
38.Ignition coil #1
39.Ignition coil #2
40.Ignition coil #3
41.Spark plug
42.Joint coupler
51.Yamaha diagnostic tool coupler
52.Meter assembly
57.Engine trouble warning light
63.Fuel pump
76.Backup fuse
77.Ignition fuse
80.Radiator fan motor relay
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 when the main switch is being turned to start the engine.
• After the engine has been stopped, the lowest fault code number appears on the multi-function meter
display. Once a fault code has been displayed, it remains stored in the memory of the ECU until it is
deleted.
Engine trouble warning light indication and fuel injection system operation
Warning light indication ECU operation Fuel injection operation Vehicle operation
Warning provided when
Flashing* Operation stopped Cannot be operated
unable to start engine
Operated with substitute
Can or cannot be operat-
characteristics in accor-
Remains on Malfunction detected ed depending on the fault
dance with the descrip-
code
tion of the malfunction
* The warning light flashes when any one of the conditions listed below is present and the main switch
is turned to “ ” (start):
Lean angle sensor
12: Crankshaft position sensor 41:
(open or short-circuit)
Lean angle sensor ECU internal malfunction
30: 50:
(latch up detected) (faulty ECU memory)
Checking for a defective engine trouble warning light

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

If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-
nates the engine trouble warning light and provides the engine with alternate operating instructions that
are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue to operate or stop operating, depending on the conditions.
9-31
EBS30279
The engine operation is not normal, but the
TROUBLESHOOTING METHOD
engine trouble warning light does not come
on.
The engine operation is not normal and the
1. Check the operation of the following sensors
engine trouble warning light comes on.
and actuators in the diagnostic mode.
1. Check:
Refer to “TROUBLESHOOTING DETAILS
• Fault code number
(FUEL INJECTION SYSTEM)” on page 9-35
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the fault code number displayed on and “SELF-DIAGNOSTIC FUNCTION AND
the multi-function meter. DIAGNOSTIC CODE TABLE” on page 10-6.
b. Identify the faulty system with the fault code. 01: Throttle position sensor signal (throttle angle)
c. Identify the probable cause of the malfunc- 30: Ignition coil #1
tion. 31: Ignition coil #2
32: Ignition coil #3
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 36: Injector #1
2. Check and repair the probable cause of mal- 37: Injector #2
function. 38: Injector #3
48: Air induction system solenoid
Fault code No. No fault code No.
Check and repair. Refer Check and repair.
If a malfunction is detected in the sensors or
to “TROUBLESHOOT- actuators, repair or replace all faulty parts.
ING DETAILS (FUEL If no malfunction is detected in the sensors
INJECTION SYS- and actuators, check and repair inner parts of
TEM)” on page 9-35. the engine.
Monitor the operation of
the sensors and actua-
tors in the diagnostic
mode.
Refer to “TROUBLE-
SHOOTING DETAILS
(FUEL INJECTION
SYSTEM)” on page
9-35 and “SELF-DIAG-
NOSTIC FUNCTION
AND DIAGNOSTIC
CODE TABLE” on page
10-6.
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 9-35.
4. Turn the main switch to “ ” (off) and back to
“ ” (on), then check that no fault code num-
ber is displayed.
TIP
If another fault code are displayed, repeat steps
(1) to (4) until no fault code number is displayed.
5. Erase the malfunction history in the diagnos-
tic mode (code No. 62). Refer to “SELF-DI-
AGNOSTIC FUNCTION AND DIAGNOSTIC
CODE TABLE” on page 10-6.
TIP
Turning the main switch to “ ” (off) will not
erase the malfunction history.
9-32
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.
Yamaha diagnostic tool (US)

90890-03234
Features of the Yamaha diagnostic tool

You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional meth-
ods.
By connecting the adapter interface, which is connected to the USB port of a computer, to a vehicle’s
ECU using the communication cable, you can display information that is necessary for identifying mal-
functions and for maintenance to display on the computer. The displayed information includes the sen-
sor output data and information recorded in the ECU.
Functions of the Yamaha diagnostic tool
Fault diagnosis mode: Fault codes recorded on the ECU are read, and the contents are dis-
played.
Function diagnostic mode: Check the operation of the output value of each sensor and actuator.
Inspection mode: Determine whether each sensor or actuator is functioning properly.
Monitoring mode: Displays a graph of sensor output values for actual operating condi-
tions.
Logging mode: Records and saves the sensor output value in actual driving conditions.
View log: Displays the logging data.
ECU rewrite: If necessary, the ECU is rewritten using ECU rewrite data provided by
Yamaha.
Ignition timing adjustment, etc. cannot be changed from the vehicle’s
original state.
However, the diagnostic tool cannot be used to freely change the basic vehicle functions, such as ad-
justing the ignition timing.
Connecting the Yamaha diagnostic tool
Remove the protective cap, and then connect the Yamaha diagnostic tool to the coupler “1”.
TIP
When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter
and indicators will be different from the normal operation.
9-33
Operation of the Yamaha diagnostic tool (Malfunction mode)

Malfunction results are displayed in the top part of the window area.
3 4 5 6 7 8 9 10 11 12
1. Recovered
The item list of the malfunction detected in the past (already recovered) are displayed.
2. Detected
The item list of the malfunction currently occurred are displayed.
3. Code
The following icons and the fault code numbers for the detected malfunctions are displayed.
A B
A. Detected malfunction
B. Recovered malfunction
4. ECU
The types of the control units are displayed.
9-34
5. Item
The item names of the detected malfunction are displayed.
6. Condition
The current conditions are displayed. (Detected/Recovered)
7. Symptom
The symptoms of the detected malfunction are displayed.
8. Diagnosis code
The diagnosis codes related to the detected malfunction are displayed.
9. FFD (only for models that can display freeze frame data)
The mark “ ” is displayed when the freeze frame data is available.
10.ECU conduction time (hour: minute: second)
The total ECU conduction time (total hours the vehicle’s main switch was ON) when the malfunction
was detected is displayed.
11.Number of main switch operation after detection
The number of times the main switch was turned on between the malfunction detection and code
reading is displayed.
12.Number of occurrences
The number of malfunction occurrences between the malfunction detection and code reading is dis-
played.
EBS30281
TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM)

This section describes the measures per fault code number displayed on the multi-function meter dis-
play. Check and service the items or components that are the probable cause of the malfunction fol-
lowing the order given.
After the check and service of the malfunctioning part has been completed, reset the multi-function me-
ter display according to the “Confirmation of service completion”.
Fault code No.:
Fault code number displayed on the multi-function meter when the engine failed to work normally.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “SELF-DIAGNOS-
TIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 10-6.
Fault code No. 08

Fault code No. 08
Item Gear position sensor: open or short circuit detected.

Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. —
Indicated —
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of gear position Improperly connected → Con- Turn the main switch to “ ”
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.
Disconnect the coupler and Fault code number is displayed
check the pins (bent or broken → Go to item 2.
terminals and locking condition
of the pins).
9-35
Fault code No. 08
Item Gear position sensor: open or short circuit detected.

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 gear position sensor Fault code number is not dis-
coupler and ECU coupler. played → Service is finished.
red/green–red/green Fault code number is displayed
blue–blue → Go to item 4.
black/blue–black/blue
4 Installed condition of gear posi- Improperly installed sensor → Turn the main switch to “ ”
tion sensor. Reinstall or replace the sensor. (on).
Check for looseness or pinch- Refer to “INSTALLING THE Fault code number is not dis-
ing. GEAR POSITION SENSOR” on played → Service is finished.
page 5-96. Fault code number is displayed
→ Go to item 5.
5 Defective gear position sensor. Check that each gear is dis- Turn the main switch to “ ”
played correctly in the transmis- (on).
sion gear display of the multi- Fault code number is not dis-
function meter unit. played → Service is finished.
Selected gear is not displayed Fault code number is displayed
→ Replace the gear position → Go to item 6.
sensor.
6 Malfunction in ECU. Replace the ECU.
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
Indicated —
Procedure —
1 Connection of crankshaft posi- Improperly connected → Con- Crank the engine.
tion sensor coupler. nect the coupler securely or re- Fault code number is not flash-
Check the locking condition of place the wire harness. ing → Service is finished.
the coupler. Fault code number is flashing →
Disconnect the coupler and Go to item 2.
check the pins (bent or broken
of the pins).
9-36
Fault code No. 12
Crankshaft position sensor: no normal signals are received from the

Item
crankshaft position sensor.
2 Connection of ECU coupler. Improperly connected → Con- Crank the engine.
Check the locking condition of nect the coupler securely or re- Fault code number is not flash-
the coupler. place the wire harness. ing → Service is finished.
Disconnect the coupler and Fault code number is flashing →
check the pins (bent or broken Go to item 3.
of the pins).
3 Wire harness continuity. Open or short circuit → Replace Crank the engine.
the wire harness. Fault code number is not flash-
Between crankshaft position ing → Service is finished.
sensor coupler and ECU cou- Fault code number is flashing →
pler. Go to item 4.
gray–gray
4 Installed condition of crank- Improperly installed sensor → Crank the engine.
shaft position sensor. Reinstall or replace the sensor. Fault code number is not flash-
Check for looseness or pinch- ing → Service is finished.
ing. Fault code number is flashing →
Go to item 5.
5 Defective crankshaft position Check the crankshaft position Crank the engine.
sensor. sensor. Fault code number is not flash-
Refer to “CHECKING THE ing → Service is finished.
CRANKSHAFT POSITION Fault code number is flashing →
SENSOR” on page 9-101. Go to item 6.
Replace if defective.
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 #1: open or short circuit detected.
Fail-safe system
Diagnostic code No. 03
Indicated Displays the intake air pressure.
Turn and hold the main switch in the “ ” (start) position, then press the
Procedure
accelerator pedal. (If the display value changes, the performance is OK.)
1 Connection of intake air pres- Improperly connected → Con- Turn the main switch to “ ”
sure sensor #1 coupler. nect the coupler securely or re- (on).
of the pins).
9-37
Fault code No. 13
of the pins).
Between intake air pressure Fault code number is not dis-
sensor #1 coupler and ECU played → Service is finished.
coupler. Fault code number is displayed
pink/black–pink/black → Go to item 4.
blue–blue
4 Installed condition of intake air Improperly installed sensor → Turn the main switch to “ ”
pressure sensor #1. 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.
5 Defective intake air pressure Execute the diagnostic mode. Turn the main switch to “ ”
sensor #1. (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 #1.
Refer to “CHECKING THE IN-
TAKE AIR PRESSURE SEN-
SORS” on page 9-107.
Fault code No. 14

TIP
“13” first.
9-38
Fault code No. 14
Intake air pressure sensor #1: hose system malfunction (clogged or

Item
detached hose).
Fail-safe system
Procedure
1 Condition of intake air pressure Clogged or detached hose → Start the engine and let it idle
sensor #1 hose. Repair or replace the sensor for approximately 5 seconds.
Check the intake air pressure hose. Fault code number is not dis-
sensor #1 hose condition. played → Service is finished.
→ Go to item 2.
2 Defective intake air pressure Execute the diagnostic mode.
sensor #1. (Code No. 03)
When engine is stopped:
Atmospheric pressure at the
current altitude and weather
conditions is indicated.
(757.6 mmHg, 29.8 inHg)
mmHg, 26.6 inHg)
mmHg, 23.6 inHg)
mmHg, 20.7 inHg)
changes.
sensor #1.
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.
“15” first.
9-39
Fault code No. 15
Item Throttle position sensor: open or short circuit detected.

Fail-safe system
Throttle position sensor signal
Indicated
• 12–22 (fully closed position)
Procedure Check with throttle valve fully closed.
1 Connection of throttle position Improperly connected → Con- Turn the main switch to “ ”
sensor coupler. nect the coupler securely or re- (on).
of the pins).
of the pins).
Between throttle position sensor Fault code number is not dis-
yellow–yellow Fault code number is displayed
blue–blue → Go to item 4.
4 Installed condition of throttle po- Improperly installed sensor → Turn the main switch to “ ”
sition sensor. Reinstall or adjust the sensor. (on).
Check for looseness or pinch- Refer to “ADJUSTING THE Fault code number is not dis-
ing. THROTTLE POSITION SEN- played → Service is finished.
SOR” on page 7-14. Fault code number is displayed
→ Go to item 5.
5 Defective throttle position sen- Check throttle position sensor Turn the main switch to “ ”
sor. signal. (on).
Execute the diagnostic mode. Fault code number is not dis-
(Code No. 01) played → Service is finished.
When the throttle valve is fully Fault code number is displayed
closed: → Go to item 6.
A value of 12–22 is indicated.
An indicated value is out of the
specified range → Replace the
throttle position sensor.
Fault code No. 16

TIP
“15” first.
9-40
Fault code No. 16
Item Throttle position sensor: stuck throttle position sensor is detected.

Fail-safe system
Throttle position sensor signal
Indicated
• 12–22 (fully closed position)
Procedure Check with throttle valve fully closed.
1 Installed condition of throttle po- Improperly installed sensor → Turn the main switch to “ ”
sition sensor. Reinstall or adjust the sensor. (on), then operate the accelera-
Check for looseness or pinch- Refer to “ADJUSTING THE tor pedal.
ing. THROTTLE POSITION SEN- Fault code number is not dis-
SOR” on page 7-14. played → Service is finished.
→ Go to item 2.
2 Defective throttle position sen- Check throttle position sensor Turn the main switch to “ ”
sor. signal. (on), then operate the accelera-
Execute the diagnostic mode. tor pedal.
(Code No. 01) Fault code number is not dis-
When the throttle valve is fully played → Service is finished.
closed: Fault code number is displayed
A value of 12–22 is indicated. → Go to item 3.
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).
9-41
Fault code No. 21
Item Coolant temperature sensor: open or short circuit detected.

of the pins).
Between coolant temperature Fault code number is not dis-
sensor coupler and ECU cou- played → Service is finished.
pler. Fault code number is displayed
green/yellow–green/yellow → Go to item 4.
4 Installed condition of coolant Improperly installed sensor → Turn the main switch to “ ”
temperature sensor. Reinstall or replace the sensor. (on).
→ Go to item 5.
5 Defective coolant temperature Execute the diagnostic mode. Turn the main switch to “ ”
sensor. (Code No. 06) (on).
When engine is cold: Fault code number is not dis-
Displayed temperature is close played → Service is finished.
to the ambient temperature. Fault code number is displayed
The displayed temperature is → Go to item 6.
not close to the ambient tem-
perature → Check the coolant
temperature sensor.
Refer to “CHECKING THE
COOLANT TEMPERATURE
Fault code No. 22

TIP
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.
9-42
Fault code No. 22
Item Intake air temperature sensor: open or short circuit detected.

1 Connection of intake air tem- Improperly connected → Con- Turn the main switch to “ ”
perature sensor coupler. nect the coupler securely or re- (on).
of the pins).
of the pins).
Between intake air temperature Fault code number is not dis-
sensor coupler and ECU cou- played → Service is finished.
pler. Fault code number is displayed
brown/white–brown/white → Go to item 4.
4 Installed condition of intake air Improperly installed sensor → Turn the main switch to “ ”
temperature sensor. Reinstall or replace the sensor. (on).
→ Go to item 5.
5 Defective intake air temperature Execute the diagnostic mode. Turn the main switch to “ ”
sensor. (Code No. 05) (on).
When engine is cold: Fault code number is not dis-
Displayed temperature is close played → Service is finished.
to the ambient temperature. Fault code number is displayed
The displayed temperature is → Go to item 6.
not close to the ambient tem-
perature. → Check the intake
air temperature sensor.
TAKE AIR TEMPERATURE
Fault code No. 25

TIP
“25” first.
Fault code No. 25
Fail-safe system
9-43
Fault code No. 25
Procedure
1 Connection of intake air pres- Improperly connected → Con- Turn the main switch to “ ”
sure sensor #2 coupler. nect the coupler securely or re- (on).
of the pins).
of the pins).
Between intake air pressure Fault code number is not dis-
sensor #2 coupler and ECU played → Service is finished.
coupler. Fault code number is displayed
pink–pink → Go to item 4.
blue–blue
9-44
Fault code No. 25
4 Defective intake air pressure Execute the diagnostic mode. Turn the main switch to “ ”
sensor #2. (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 5.
(757.6 mmHg, 29.8 inHg)
mmHg, 26.6 inHg)
mmHg, 23.6 inHg)
mmHg, 20.7 inHg)
changes.
sensor #2.
Fault code No. 26

TIP
“25” first.
“26” first.
Fault code No. 26

Item
detached hose).
Fail-safe system
Procedure
9-45
Fault code No. 26

Item
detached hose).
1 Condition of intake air pressure Clogged or detached hose → Start the engine and let it idle
sensor #2 hose. Repair or replace the sensor for approximately 5 seconds.
Check the intake air pressure hose. Fault code number is not dis-
sensor #2 hose condition. played → Service is finished.
→ Go to item 2.
2 Defective intake air pressure Execute the diagnostic mode.
sensor #2. (Code No. 03)
When engine is stopped:
Atmospheric pressure at the
current altitude and weather
conditions is indicated.
(757.6 mmHg, 29.8 inHg)
mmHg, 26.6 inHg)
mmHg, 23.6 inHg)
mmHg, 20.7 inHg)
changes.
sensor #2.
Fault code No. 30

Fault code No. 30
Item Latch up detected.

Fail-safe system
Lean angle sensor output voltage
Indicated • 3.55–4.45 (upright)
• 0.65–1.35 (overturned)
Procedure Remove the lean angle sensor and incline it more than 65 degrees.
9-46
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 “ ” (off), and then
back to “ ” (on).
Fault code number is not dis-
played → Service is finished.
→ Go to item 2.
2 Installed condition of lean an- Check the installed direction Turn the main switch to “ ”
gle sensor. and condition of the sensor. (on), then to “ ” (off), and then
back to “ ” (on).
→ Go to item 3.
3 Defective lean angle sensor. Execute the diagnostic mode. Turn the main switch to “ ”
(Code No. 08) (on), then to “ ” (off), and then
An indicated value is out of the back to “ ” (on).
specified range → Check the Fault code number is not dis-
lean angle sensor. played → Service is finished.
Replace if defective. Fault code number is displayed
Refer to “CHECKING THE → Go to item 4.
LEAN ANGLE SENSOR” on
page 9-101.
4 Oil pressure dropped. Place the vehicle on a level sur- Turn the main switch to “ ”
face. (on), then to “ ” (off), and then
Check the engine oil level. back to “ ” (on).
Add the recommended engine Fault code number is not dis-
oil to the proper level if neces- played → Service is finished.
sary. Fault code number is displayed
Refer to “CHECKING THE EN- → Go to item 5.
GINE OIL LEVEL” on page
3-17.
5 Installed condition of oil pres- Improperly installed switch→ Turn the main switch to “ ”
sure switch. Reinstall or replace the switch. (on), then to “ ” (off), and then
Check for looseness or pinch- back to “ ” (on).
ing. Fault code number is not dis-
→ Go to item 6.
6 Defective oil pressure switch. Check the oil pressure switch. Turn the main switch to “ ”
Refer to “CHECKING THE OIL (on), then to “ ” (off), and then
PRESSURE SWITCH” on page back to “ ” (on).
9-103. Fault code number is not dis-
Replace if defective. played → Service is finished.
→ Go to item 7.
9-47
Fault code No. 33

Fault code No. 33
Ignition coil #1: open or short circuit detected in the primary lead of
Item
the ignition coil #1.
Able to start engine (depending on the number of faulty cylinders)
Fail-safe system
Able to drive vehicle (depending on the number of faulty cylinders)
Actuates the ignition coil #1 five times at one-second intervals.
Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen
come on each time the ignition coil #1 is actuated.
Check that a spark is generated five times.
Procedure
• Connect an ignition checker.
1 Connection of ignition coil #1 Improperly connected → Con- Start the engine and let it idle
connector. nect the connector securely or for approximately 5 seconds.
Check the locking condition of replace the wire harness. Fault code number is not dis-
the connector. played → Service is finished.
Disconnect the connector and Fault code number is displayed
of the pins).
2 Connection of ECU coupler. Improperly connected → Con- Start the engine and let it idle
Check the locking condition of nect the coupler securely or re- for approximately 5 seconds.
of the pins).
3 Wire harness continuity. Open or short circuit → Replace Start the engine and let it idle
the wire harness. for approximately 5 seconds.
Between ignition coil #1 con- Fault code number is not dis-
nector and ECU coupler. played → Service is finished.
orange–orange Fault code number is displayed
→ Go to item 4.
4 Installed condition of ignition Improperly installed ignition coil Start the engine and let it idle
coil #1. #1 → Reinstall or replace the ig- for approximately 5 seconds.
Check for looseness or pinch- nition coil #1. Fault code number is not dis-
→ Go to item 5.
5 Defective ignition coil #1. Measure the primary coil resis- Start the engine and let it idle
tance of the ignition coil #1. for approximately 5 seconds.
Replace if out of specification. Fault code number is not dis-
Refer to “CHECKING THE IG- played → Service is finished.
NITION COILS” on page 9-100. Fault code number is displayed
→ Go to item 6.
6 Malfunction in ECU. Execute the diagnostic mode.
(Code No. 30)
No spark → Replace the ECU.
9-48
Fault code No. 34

Fault code No. 34
Item
Fail-safe system
Procedure
of the pins).
of the pins).
gray/red–gray/red Fault code number is displayed
→ Go to item 4.
→ Go to item 5.
→ Go to item 6.
(Code No. 31)
9-49
Fault code No. 35

Fault code No. 35
Item
Fail-safe system
Procedure
of the pins).
of the pins).
orange/green–orange/green Fault code number is displayed
→ Go to item 4.
→ Go to item 5.
→ Go to item 6.
(Code No. 32)
9-50
Fault code No. 37

TIP
• Do not remove the ISC (Idle Speed Control) valve.
“15” first.
“26” first.
“46” first.
“42” first.
Fault code No. 37
Component other than ISC (Idle Speed Control) unit is defective

A
(ISC operating sound is heard).
Item
Defective ISC (Idle Speed Control) unit (ISC operating sound is
B
not heard).
Fail-safe system
Fully closes the ISC valve, and then opens the valve.
This operation takes approximately 3 seconds.
Actuation
The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen
come on during the operation.
Procedure The operating sound can be heard when ISC valve operates.
A-1 Locate the malfunction. Execute the diagnostic mode. ISC operating sound is heard →
(Code No. 54) Go to item A-2.
Fully closes the ISC (Idle Speed ISC operating sound is not
Control) valve, and then fully heard → Go to item B-2 for the
opens the valve. defective ISC (Idle Speed Con-
trol) unit.
A-2 Incorrect speed sensor signal. Check the speed sensor. Start the engine and let it idle
Execute the diagnostic mode. for approximately 10 seconds.
(Code No. 07) Fault code number is not dis-
While the rear wheels are played → Service is finished.
stopped, check that the indicat- Fault code number is displayed
ed value does not change. → Go to item A-3.
Rotate a rear wheel by hand
and check that the indicated
value increases.
Malfunction → Go to fault code
No. 42.
A-3 Throttle valve does not fully Check the throttle bodies. Start the engine and let it idle
close. Refer to “THROTTLE BODIES” for approximately 10 seconds.
on page 7-11. Fault code number is not dis-
Check the throttle cable. played → Service is finished.
Refer to “ADJUSTING THE AC- Fault code number is displayed
CELERATOR PEDAL FREE → Go to item A-4.
PLAY” on page 3-31.
9-51
Fault code No. 37

A
Item
B
not heard).
A-4 ISC (Idle Speed Control) valve Replace the throttle bodies. Start the engine and let it idle
is not moving correctly. for approximately 10 seconds.
→ Go to item A-5.
A-5 Malfunction in ECU. Replace the ECU.
Fault code No. 37

A
Item
B
not heard).
Fail-safe system
Fully closes the ISC valve, and then opens the valve.
This operation takes approximately 3 seconds.
Actuation
come on during the operation.
Procedure The operating sound can be heard when ISC valve operates.
B-1 Locate the malfunction. Execute the diagnostic mode. ISC operating sound is heard →
(Code No. 54) Go to item A-2 for the compo-
Fully closes the ISC (Idle Speed nent other than ISC (Idle Speed
Control) valve, and then fully Control) unit is defective.
opens the valve. ISC operating sound is not
heard → Go to item B-2.
B-2 Connection of ISC (Idle Speed Improperly connected → Con- Execute the diagnostic mode.
Control) unit coupler. nect the coupler securely or re- (Code No. 54)
Check the locking condition of place the wire harness. ISC operating sound is heard →
the coupler. Go to item B-8.
Disconnect the coupler and ISC operating sound is not
check the pins (bent or broken heard → Go to item B-3.
of the pins).
B-3 Connection of ECU coupler. Improperly connected → Con- Execute the diagnostic mode.
Check the locking condition of nect the coupler securely or re- (Code No. 54)
the coupler. place the wire harness. ISC operating sound is heard →
Disconnect the coupler and Go to item B-8.
check the pins (bent or broken ISC operating sound is not
terminals and locking condition heard → Go to item B-4.
of the pins).
9-52
Fault code No. 37

A
Item
B
not heard).
B-4 Wire harness continuity. Open or short circuit → Replace Execute the diagnostic mode.
the wire harness. (Code No. 54)
Between ISC (Idle Speed Con- ISC operating sound is heard →
trol) unit coupler and ECU cou- Go to item B-8.
pler. ISC operating sound is not
red/green–red/green heard → Go to item B-5.
pink/blue–pink/blue
white/green–white/green
brown/blue–brown/blue
Between ISC (Idle Speed Con-
trol) unit coupler and joint cou-
pler.
red/white–red/white
B-5 Installed condition of ISC (Idle Improperly installed ISC (Idle Execute the diagnostic mode.
Speed Control) unit. Speed Control) unit → Reinstall (Code No. 54)
Check for looseness or pinch- the ISC (Idle Speed Control) ISC operating sound is heard →
ing. unit. Go to item B-8.
ISC operating sound is not
B-6 ISC (Idle Speed Control) valve Replace the throttle bodies. Execute the diagnostic mode.
is not moving correctly. (Code No. 54)
ISC operating sound is heard →
Go to item B-8.
ISC operating sound is not
B-7 Malfunction in ECU. Replace the ECU.
B-8 Delete the fault code. Start the engine and let it idle
for approximately 10 seconds.
Check that the fault code num-
ber is not displayed.
Fault code No. 39

Fault code No. 39
Item Fuel injector: open or short circuit detected.

Fail-safe system
Diagnostic code No. 36, 37, 38
Actuates fuel injector #1 five times at one-second intervals.
36 come on each time the fuel injector #1 is actuated.
Disconnect the fuel pump coupler, and then check that fuel injector #1 is
Procedure
actuated five times by listening for the operating sound.
Procedure
9-53
Fault code No. 39

Procedure
1 Identify the malfunctioning in- Execute the diagnostic mode. —
jector. (Code Nos. 36, 37, 38)
Identify the injector that does
not produce an operating
sound.
Perform the following proce-
dures for the defective injector.
Refer to “CHECKING THE
FUEL INJECTORS” on page
9-108.
2 Connection of fuel injector #1, Improperly connected → Con- Execute the diagnostic mode.
#2 and/or injector #3 coupler. nect the coupler securely or re- (Code Nos. 36, 37, 38)
Check the locking condition of place the wire harness. Operating sound → Go to item
the coupler. 7.
Disconnect the coupler and No operating sound → Go to
check the pins (bent or broken item 3.
of the pins).
3 Defective fuel injector #1, #2 Measure the fuel injector resis- Execute the diagnostic mode.
and/or injector #3. tance. (Code Nos. 36, 37, 38)
Replace if out of specification. Operating sound → Go to item
Refer to “CHECKING THE 7.
FUEL INJECTORS” on page No operating sound → Go to
9-108. item 4.
4 Connection of ECU coupler. Improperly connected → Con- Execute the diagnostic mode.
Check the locking condition of nect the coupler securely or re- (Code Nos. 36, 37, 38)
the coupler. place the wire harness. Operating sound → Go to item
Disconnect the coupler and 7.
check the pins (bent or broken No operating sound → Go to
terminals and locking condition item 5.
of the pins).
5 Wire harness continuity. Open or short circuit → Replace Execute the diagnostic mode.
the wire harness. (Code Nos. 36, 37, 38)
Between fuel injector coupler Operating sound → Go to item
and ECU coupler. 7.
Injector #1 No operating sound → Go to
red/black–red/black item 6.
Injector #2
green/black–green/black
Injector #3
blue/black–blue/black
Between fuel injector coupler
and fuel injection system relay.
red/blue–red/blue
9-54
Fault code No. 39

7 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 • 3.55–4.45 (upright)
• 0.65–1.35 (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 “ ” (off), and then
Check the locking condition of place the wire harness. back to “ ” (on).
the coupler. Fault code number is not dis-
of the pins).
Check the locking condition of nect the coupler securely or re- (on), then to “ ” (off), and then
the coupler. place the wire harness. back to “ ” (on).
Disconnect the coupler and Fault code number is not dis-
check the pins (bent or broken played → Service is finished.
terminals and locking condition Fault code number is displayed
of the pins). → Go to item 3.
the wire harness. (on), then to “ ” (off), and then
Between lean angle sensor back to “ ” (on).
coupler and ECU coupler. Fault code number is not dis-
yellow/green–yellow/green played → Service is finished.
blue–blue Fault code number is displayed
black/blue–black/blue → Go to item 4.
4 Defective lean angle sensor. Check the lean angle sensor. Turn the main switch to “ ”
Replace if defective. (on), then to “ ” (off), and then
Refer to “CHECKING THE back to “ ” (on).
LEAN ANGLE SENSOR” on Fault code number is not dis-
page 9-101. played → Service is finished.
→ Go to item 5.
9-55
Fault code No. 42

TIP
“42” first.
Fault code No. 42
Speed sensor: no normal signals are received from the speed

A
sensor.
Item
B Neutral switch: open or short circuit is detected.
C Clutch switch: open or short circuit is detected.

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.
A-1 Locate the malfunction. Execute the diagnostic mode. Value does not increase → Go
(Code No. 07) to item A-2.
value increases.
Execute the diagnostic mode. Incorrect indication → Go to
(Code No. 21) item B-2 for the neutral switch.
When the transmission is in
neutral: “ON”
gear with the clutch pedal re-
leased: “OFF”
Start the engine, and then de- Engine stalls → Go to item C-2
press the clutch pedal and shift for the clutch switch.
the transmission into gear.
A-2 Connection of speed sensor Improperly connected → Con- Execute the diagnostic mode.
coupler. nect the coupler securely or re- (Code No. 07)
Check the locking condition of place the wire harness. Rotate a rear wheel by hand
the coupler. and check that the indicated
Disconnect the coupler and value increases.
check the pins (bent or broken Value increases → Go to item
terminals and locking condition A-7 and delete the fault code.
of the pins). Value does not increase → Go
to item A-3.
A-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. 07)
the coupler. place the wire harness. Rotate a rear wheel by hand
Disconnect the coupler and and check that the indicated
check the pins (bent or broken value increases.
terminals and locking condition Value increases → Go to item
of the pins). A-7 and delete the fault code.
Value does not increase → Go
to item A-4.
9-56
Fault code No. 42

A
sensor.
Item

A-4 Wire harness continuity. Open or short circuit → Replace Execute the diagnostic mode.
Between speed sensor coupler Rotate a rear wheel by hand
and ECU coupler. and check that the indicated
blue–blue value increases.
black/blue–black/blue Value increases → Go to item
Between speed sensor coupler A-7 and delete the fault code.
and joint coupler. Value does not increase → Go
white–white to item A-5.
Between joint coupler and ECU
coupler.
white–white
A-5 Defective speed sensor. Execute the diagnostic mode. Turn the main switch to “ ”
(Code No. 07) (on), and then rotate a rear
While the rear wheels are wheel by hand.
stopped, check that the indicat- Fault code number is not dis-
ed value does not change. played → Service is finished.
Rotate a rear wheel by hand Fault code number is displayed
and check that the indicated → Go to item A-6.
value increases.
Malfunction → Replace the
speed sensor.
A-6 Malfunction in ECU. Replace the ECU.
A-7 Delete the fault code. Start the engine, and input the
vehicle speed signals by operat-
ing the vehicle at 20 to 30 km/h
(12 to 19 mph).
Fault code No. 42

A
sensor.
Item

Fail-safe system
Neutral
Indicated • “ON” (when the transmission is in neutral)
• “OFF” (when the transmission is in gear or the clutch lever released)
Procedure Shift the transmission.
9-57
Fault code No. 42

A
sensor.
Item

B-1 Locate the malfunction. Execute the diagnostic mode. Value does not increase → Go
(Code No. 07) to item A-2 for the speed sen-
Rotate a rear wheel by hand sor.
value increases.
(Code No. 21) item B-2.
neutral: “ON”
leased: “OFF”
Start the engine, and then de- Engine stalls→ Go to item C-2
press the clutch pedal and shift for the clutch switch.
B-2 Connection of speed sensor Improperly connected → Con- Execute the diagnostic mode.
coupler. nect the coupler securely or re- (Code No. 21)
Check the locking condition of place the wire harness. When the transmission is in
the coupler. neutral: “ON”
Disconnect the coupler and When the transmission is in
check the pins (bent or broken gear with the clutch lever re-
terminals and locking condition leased: “OFF”
of the pins). Correct indication → Go to item
B-8 and delete the fault code
Incorrect indication → Go to
item B-3.
B-3 Connection of wire harness Improperly connected → Con- Execute the diagnostic mode.
ECU coupler. nect the coupler securely or re- (Code No. 21)
Check the locking condition of place the wire harness. When the transmission is in
the coupler. neutral: “ON”
Disconnect the coupler and When the transmission is in
check the pins (bent or broken gear with the clutch lever re-
terminals and locking condition leased: “OFF”
of the pins). Correct indication → Go to item
B-8 and delete the fault code.
item B-4.
B-4 Wire harness continuity. Open or short circuit → Replace Execute the diagnostic mode.
Between neutral switch lead When the transmission is in
and ECU coupler. neutral: “ON”
sky blue–sky blue When the transmission is in
gear with the clutch lever re-
leased: “OFF”
Correct indication → Go to item
item B-5.
9-58
Fault code No. 42

A
sensor.
Item

B-5 Defective neutral switch. Check the neutral switch. Execute the diagnostic mode.
Replace if defective. (Code No. 21)
Refer to “CHECKING THE When the transmission is in
SWITCHES” on page 9-91. neutral: “ON”
leased: “OFF”
item B-6.
B-6 Faulty shift drum (neutral detec- Malfunction → Replace the shift Execute the diagnostic mode.
tion area). drum. (Code No. 21)
Refer to “TRANSMISSION (4)” When the transmission is in
on page 5-104. neutral: “ON”
leased: “OFF”
item B-7.
B-7 Malfunction in ECU. Replace the ECU.
B-8 Delete the fault code. Start the engine, and input the
(12 to 19 mi/h).
Fault code No. 42

A
sensor.
Item

Fail-safe system
Indicated —
Procedure —
9-59
Fault code No. 42

A
sensor.
Item

C-1 Locate the malfunction. Execute the diagnostic mode. Value does not increase → Go
(Code No. 07) to item A-2 the speed sensor.
value increases.
(Code No. 21) item B-2 for the neutral switch.
neutral: “ON”
leased: “OFF”
Start the engine, and then de- Engine stalls → Go to item C-2.
press the clutch pedal and shift
C-2 Clutch pedal adjustment. Refer to “ADJUSTING THE Start the engine, and then de-
CLUTCH PEDAL” on page 3-25. press the clutch pedal and shift
Engine does not stall → Go to
item C-8 and delete the fault
code.
Engine stalls → Go to item C-3.
C-3 Connection of clutch switch Improperly connected → Con- Start the engine, and then de-
coupler. nect the coupler securely or re- press the clutch pedal and shift
Check the locking condition of place the wire harness. the transmission into gear.
the coupler. Engine does not stall → Go to
Disconnect the coupler and item C-8 and delete the fault
check the pins (bent or broken code.
terminals and locking condition Engine stalls → Go to item C-4.
of the pins).
C-4 Connection of wire harness Improperly connected → Con- Start the engine, and then de-
ECU coupler. nect the coupler securely or re- press the clutch pedal and shift
Check the locking condition of place the wire harness. the transmission into gear.
the coupler. Engine does not stall → Go to
Disconnect the coupler and item C-8 and delete the fault
check the pins (bent or broken code.
terminals and locking condition Engine stalls → Go to item C-5.
of the pins).
C-5 Wire harness continuity. Open or short circuit → Replace Start the engine, and then de-
the wire harness. press the clutch pedal and shift
Between clutch switch coupler the transmission into gear.
and ECU coupler. Engine does not stall → Go to
brown–brown item C-8 and delete the fault
Between clutch switch coupler code.
and frame ground. Engine stalls → Go to item C-6.
black–black
9-60
Fault code No. 42

A
sensor.
Item

C-6 Defective clutch switch. Check the clutch switch. Start the engine, and then de-
Replace if defective. press the clutch pedal and shift
Refer to “CHECKING THE the transmission into gear.
SWITCHES” on page 9-91. Engine does not stall → Go to
item C-8 and delete the fault
code.
Engine stalls → Go to item C-7.
C-7 Malfunction in ECU. Replace the ECU.
C-8 Delete the fault code. Start the engine, and input the
(12 to 19 mi/h).
Fault code No. 43

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

Item
and fuel pump.
Fail-safe system
Diagnostic code No. 09, 50
Fuel system voltage (battery voltage)
Indicated
Approximately 12.0
09 Turn the main switch to “ ” (on), and then compare the actually mea-
Procedure sured battery voltage with the display value. (If the actually measured
battery voltage is low, recharge the battery.)
Actuates the fuel injection system relay five times at one-second inter-
vals.
Actuation
50 come on each time the relay is actuated.
Check that the fuel injection system relay is actuated five times by listen-
Procedure
ing for the operating sound.
1 Connection of fuel injection sys- Improperly connected → Con- Start the engine and let it idle
tem relay coupler. nect the coupler securely or re- for approximately 5 seconds.
of the pins).
9-61
Fault code No. 43
Fuel system voltage: incorrect voltage supplied to the fuel injector

Item
and fuel pump.
of the pins).
Between fuel injection system Fault code number is not dis-
relay coupler and ECU coupler. played → Service is finished.
blue/red–blue/red Fault code number is displayed
red/blue–red/blue → Go to item 4.
Between ECU coupler and joint
coupler.
Between joint coupler and back-
up fuse.
Between main switch coupler
and ECU coupler.
brown/red–brown/red
4 Defective fuel injection system Execute the diagnostic mode. Start the engine and let it idle
relay. (Code No. 50) for approximately 5 seconds.
No operating sound → Replace Fault code number is not dis-
the fuel injection system relay. played → Service is finished.
→ Go to item 5.
5 Defective fuel injection system Execute the diagnostic mode. Start the engine and let it idle
relay. (Code No. 09) for approximately 5 seconds.
Fuel system voltage is below Fault code number is not dis-
3 V → Replace the fuel injection played → Service is finished.
system relay. Fault code number is displayed
→ Go to item 6.
Fault code No. 44

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

Item
writing on EEPROM.
Fail-safe system
The fault code No. 44 detected EEPROM errors are indicated.
• 00 indication: Normal status (no history)
• 01–03: Cylinder fault code number (history exists)
Indicated
If more than one cylinder is defective, the display switches every two
seconds to show the cylinder fault code numbers of all defective cylin-
ders in a repeating cycle.
Procedure —
9-62
Fault code No. 44
EEPROM fault code number: an error is detected while reading or

Item
writing on EEPROM.
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 9-11. Fault code number is not dis-
Defective rectifier/regulator or played → Service is finished.
AC magneto → Replace. Fault code number is displayed
Defective connection in the → Repeat the maintenance job.
charging system circuit → Prop-
erly connect or replace the wire
harness.
Fault code No. 50

Fault code No. 50
Faulty ECU (Engine Control Unit) memory. (When this malfunction is

Item
detected in the ECU, the fault code number might not appear.)
Fail-safe system
Indicated —
Procedure —
1 Malfunction in ECU. Replace the ECU. Turn the main switch to “ ”
(on).
9-63
Fault code No. 85

Fault code No. 85
Item Oil pressure switch: open or short circuit detected.

Fail-safe system
Indicated —
Procedure —
1 Connection of oil pressure Improperly connected → Con- Turn the main switch to “ ”
switch coupler. nect the coupler securely or re- (on).
of the pins).
of the pins).
Between oil pressure switch Fault code number is not dis-
yellow–yellow Fault code number is displayed
→ Go to item 4.
4 Installed condition of oil pres- Improperly installed switch → Turn the main switch to “ ”
sure switch. Reinstall or replace the switch. (on).
→ Go to item 5.
5 Defective oil pressure switch. Check the oil pressure switch. Crank the engine.
Refer to “CHECKING THE OIL Fault code number is not dis-
PRESSURE SWITCH” on page played → Service is finished.
9-103. Fault code number is displayed
Replace if defective. → Go to item 6.
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)
9-64
Fault code No. Err
Multi-function meter: signals cannot be transmitted between the

Item
ECU and the multi-function meter.
Indicated —
Procedure —
1 Connection of meter assembly Improperly connected → Con- Turn the main switch to “ ”
coupler. nect the coupler securely or re- (on).
of the pins).
of the pins).
Between meter assembly cou- Fault code number is not dis-
pler and joint coupler. played → Service is finished.
yellow/red–yellow/red Fault code number is displayed
black/light green–black/light → Go to item 4.
green
Between joint coupler and ECU
coupler.
yellow/red–yellow/red
black/light green–black/light
green
4 Defective meter assembly. Replace the meter assembly. Turn the main switch to “ ”
(on).
→ Go to item 5.
9-65
9-66
EBS30282
EBS20081
B/W B/W
B/L Gy
Gy
A B
B/L B
W W W B R
Gy B 1 (Gy) (B) B B
P/B P
W W R Br/Y Br
31
W W (Gy)
2 W W
3 (B) (B)
R/W O
Gy Gy/R
W W W Br/R O/G
B
CIRCUIT DIAGRAM
P/B Br/R
38
(Gy) R/W
(Gy) R/L R/L R/B
R/W
R/L G/B
21 (Gy) O
W W W R/B R/B R/L
R/G R/G 24 (Gy) 41
(Gy) Br/R
Br/R 19
R/G 32 L R/G B/L
Br/R Br/R
R Br/R B/L (L) (B)
Br/R R
W/G R/W R/G (Gy) 25
G/Y B/L Br/W B/L L
FUEL PUMP SYSTEM

39
R/B (B)
33
4 23 B/L
R R/B (B) (B)
B (Gy)
10 18 G/Y G/Y B/L
B R L Gy/R
R/B R/B Y/G
Br/R R R
R 34
B 20 L
R/B Br/B (L)
Sb/W L
RR R/Y L/Y B/L Y L
Y
5 Y/B 35 (B)
R B/L
B/W G/R (B)
11 Y
14 L/W
Br/R Br/R Br L
B
8 L/W P/W 40
12 Sb B/L Br/R
R/L L/R 15 B/G
R/Y Br/B P (L)
6 O/G
R/L W/B L
B/W A B/W B O/L W/B
B B B B B
(start) R/Y L/W G/R
L/W G/R Sb (L)
B Y Br R L/Y B/L
(B) Y/B B O/G Br/R
B/Y O/W B B/L
Br/R L/W 7 16 B/L
13 Br/R (B)
L/W Br/R B/Lg B/W 26 27 28 29 30 B/L L
2WD L/W G/R G/R L/W
Br/R B Y/B B/L L
(B) 4WD B/L L
B B
DIFF LOCK B/L L
L/R B/L L
B B B
B Y R B
(Gy) B Br B L/Y
(Gy)
B B/W
B B/W B B
9-67
Br/L
Br/R Y/R
73
Br
B/W 43
74 65 64 44 45 B R B R
Br/Y
Br/B B/Lg Y/R (Gy)
(off) B R 42
Br Y (Gy)
L W Y
75 R/W B/W
L H G R B W R B W Y
R/W W Y
Y G/R B L/W
76 Br/B L/W B/Lg
L L/Y L/W B/Lg
Br/R B G/R R/W Y/R
L R/W Y/R
77 R/W Y/R
R/G (B) 52 53 R/W B
Br L G L/Y R/W B
Sb
B
Br/R 78 72 Br 54
67 G 66 B R
Y B W
79 L B 55 (Gy)
G W/B W B
G G 56 R G R B
W B (Gy)
R/G R/L Y/R B (B)
B
57 (Gy)
R/L R/B G W
Br/R Y/R G/R Sb
58 Br/R Br
71 LG 46 W/B
R/L O O/W
B
59 L/B L/B
Y 60 B G
G W G/R 47
Sb W
Br/Y 68 68 68 68 (Gy) (B) (B) (Gy) (B)
B 70 (B)
Y/R
Br
69 B/Lg
G B/W
R/W
L Br Y R/L G
Br/Y Br/Y
(B) G Y G Y G Y G Y
L
Y B B B B 63 62 48
82 L Y Y Br/Y 61
B (B) B B B B B Br/Y 49 50
Y G Y G Y G Y G B/W
(B) B B B B B
Y L
(B)
B B B Sb/W
(Dgy)
FUEL PUMP SYSTEM
FUEL PUMP SYSTEM
5. Frame ground
6. Main switch
8. Battery
9. Main fuse
11.Fuel injection system fuse
14.Fuel injection system relay
63.Fuel pump
77.Ignition fuse
A. Wire harness
9-68
FUEL PUMP SYSTEM
EBS30283
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
1. Battery cover
3. Under-seat panel (right)

(Main, fuel injection system, and ig-
nition) Replace the fuse(s).
ES” on page 9-94.
OK ↓
page 9-95.
OK ↓
OK ↓
4. Check the fuel injection system re- NG →
lay.
Replace the fuel injection system relay.
Refer to “CHECKING THE RE-
OK ↓
5. Check the fuel pump. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump assembly.
PUMP BODY” on page 7-2.
OK ↓
6. Check the entire fuel pump system NG →
page 9-67.
OK ↓
Replace the ECU.
9-69
FUEL PUMP SYSTEM
9-70
EBS30284
EBS20082
B/W B/W
B/L Gy
Gy
A B
B/L B
W W W B R
Gy B 1 (Gy) (B) B B
P/B P
W W R Br/Y Br
31
W W (Gy)
2 W W
3 (B) (B)
R/W O
Gy Gy/R
W W W Br/R O/G
B
CIRCUIT DIAGRAM
P/B Br/R
38
(Gy) R/W
(Gy) R/L R/L R/B
R/W
R/L G/B
21 (Gy) O
W W W R/B R/B R/L
R/G R/G 24 (Gy) 41
(Gy) Br/R
Br/R 19
R/G 32 L R/G B/L
Br/R Br/R
R Br/R B/L (L) (B)
Br/R R
W/G R/W R/G (Gy) 25
G/Y B/L Br/W B/L L
39
R/B (B)
33
4 23 B/L
R R/B (B) (B)
B (Gy)
10 18 G/Y G/Y B/L
B R L Gy/R
R/B R/B Y/G
Br/R R R
R 34
B 20 L
R/B Br/B (L)
Sb/W L
RR R/Y L/Y B/L Y L
Y
5 Y/B 35 (B)
R B/L
B/W G/R (B)
11 Y
14 L/W
Br/R Br/R Br L
B
8 L/W P/W 40
12 Sb B/L Br/R
R/L L/R 15 B/G
R/Y Br/B P (L)
6 O/G
R/L W/B L
B/W A B/W B O/L W/B
B B B B B
(start) R/Y L/W G/R
L/W G/R Sb (L)
B Y Br B/L
2WD/4WD SELECTING SYSTEM
(B) Y/B B R L/Y O/G Br/R

B/Y O/W B B/L
Br/R L/W 7 16 B/L
13 Br/R (B)
L/W Br/R B/Lg B/W 26 27 28 29 30 B/L L
2WD L/W G/R G/R L/W
Br/R B Y/B B/L L
(B) 4WD B/L L
B B
DIFF LOCK B/L L
L/R B/L L
B B B
B Y R B
(Gy) B Br B L/Y
(Gy)
B B/W
B B/W B B
9-71
Br/L
Br/R Y/R
73
Br
B/W 43
74 65 64 44 45 B R B R
Br/Y
Br/B B/Lg Y/R (Gy)
(off) B R 42
Br Y (Gy)
L W Y
75 R/W B/W
L H G R B W R B W Y
R/W W Y
Y G/R B L/W
76 Br/B L/W B/Lg
L L/Y L/W B/Lg
Br/R B G/R R/W Y/R
L R/W Y/R
77 R/W Y/R
R/G (B) 52 53 R/W B
Br L G L/Y R/W B
Sb
B
Br/R 78 72 Br 54
67 G 66 B R
Y B W
79 L B 55 (Gy)
G W/B W B
G G 56 R G R B
W B (Gy)
R/G R/L Y/R B (B)
B
57 (Gy)
R/L R/B G W
Br/R Y/R G/R Sb
58 Br/R Br
71 LG 46 W/B
R/L O O/W
B
59 L/B L/B
Y 60 B G
G W G/R 47
Sb W
Br/Y 68 68 68 68 (Gy) (B) (B) (Gy) (B)
B 70 (B)
Y/R
Br
69 B/Lg
G B/W
R/W
L Br Y R/L G
Br/Y Br/Y
(B) G Y G Y G Y G Y
L
Y B B B B 63 62 48
82 L Y Y Br/Y 61
B (B) B B B B B Br/Y 49 50
Y G Y G Y G Y G B/W
(B) B B B B B
Y L
(B)
B B B Sb/W
(Dgy)

5. Frame ground
6. Main switch
8. Battery
9. Main fuse
15.Differential motor relay 1
16.Differential motor
17.On-Command four-wheel-drive switch
42.Joint coupler
52.Meter assembly
55.On-Command differential gear lock indicator
light
64.Differential motor relay 2
73.Differential motor fuse
77.Ignition fuse
A. Wire harness
9-72
EBS30285
TROUBLESHOOTING
• The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential
gear lock indicator fails to come on.
• The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential
gear lock indicator flashes.
TIP
1. Battery cover
The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential gear

lock indicator fails to come on.
(Main, differential motor, ignition,
and signaling system) Replace the fuse(s).
ES” on page 9-94.
OK ↓
page 9-95.
OK ↓
OK ↓
4. Check the On-Command four- NG →
wheel-drive switch. Replace the On-Command four-wheel-
Refer to“CHECKING THE drive switch.
OK ↓
5. Check the differential motor relay 1. NG →
Refer to “CHECKING THE RE- Replace the differential motor relay 1.
OK ↓
6. Check the differential motor relay 2. NG →
Refer to “CHECKING THE RE- Replace the differential motor relay 2.
OK ↓
OK ↓
9-73
8. Check the differential motor opera- NG →

tion.
Refer to “CHECKING THE DIF- Replace the differential motor.
FERENTIAL MOTOR OPERATION”
on page 8-14.
OK ↓
9. Check the entire 2WD/4WD select- NG →
ing system wiring. Properly connect or replace the 2WD/4WD
Refer to “CIRCUIT DIAGRAM” on selecting system wiring.
page 9-71.
OK ↓
The On-Command differential gear lock indicator light/On-Command four-wheel-drive/differential gear

lock indicator flashes.
1. Check the differential motor posi- NG →
tion switch.
Refer to “CHECKING THE DIF- Replace the differential motor.
FERENTIAL MOTOR POSITION
SWITCH” on page 9-109.
OK ↓
2. Check the entire 2WD/4WD select- NG →
ing system wiring. Properly connect or replace the 2WD/4WD
Refer to “CIRCUIT DIAGRAM” on selecting system wiring.
page 9-71.
OK ↓
Replace the ECU.
9-74
EBS30286
EBS20083
B/W B/W
B/L Gy
Gy
A B
B/L B
W W W B R
Gy B 1 (Gy) (B) B B
P/B P
W W R Br/Y Br
31
W W (Gy)
2 W W
3 (B) (B)
R/W O
Gy Gy/R
W W W Br/R O/G
B
CIRCUIT DIAGRAM
P/B Br/R
38
(Gy) R/W
(Gy) R/L R/L R/B
R/W
R/L G/B
21 (Gy) O
W W W R/B R/B R/L
R/G R/G 24 (Gy) 41
(Gy) Br/R
Br/R 19
R/G 32 L R/G B/L
Br/R Br/R
R Br/R B/L (L) (B)
Br/R R
W/G R/W R/G (Gy) 25
G/Y B/L Br/W B/L L
39
R/B (B)
33
4 23 B/L
R R/B (B) (B)
B (Gy)
10 18 G/Y G/Y B/L
B R L Gy/R
R/B R/B Y/G
Br/R R R
R 34
B 20 L
R/B Br/B (L)
Sb/W L
RR R/Y L/Y B/L Y L
Y
5 Y/B 35 (B)
R B/L
B/W G/R (B)
11 Y
14 L/W
Br/R Br/R Br L
B
8 L/W P/W 40
12 Sb B/L Br/R
R/L L/R 15 B/G
R/Y Br/B P (L)
6 O/G
R/L W/B L
B/W A B/W B O/L W/B
B B B B B
(start) R/Y L/W G/R
L/W G/R Sb (L)
B Y Br R L/Y B/L
(B) Y/B B O/G Br/R
B/Y O/W B B/L
Br/R L/W 7 16 B/L
13 Br/R (B)
L/W Br/R B/Lg B/W 26 27 28 29 30 B/L L
2WD L/W G/R G/R L/W
Br/R B Y/B B/L L
(B) 4WD B/L L
B B
DIFF LOCK B/L L
L/R B/L L
B B B
B Y R B
(Gy) B Br B L/Y
(Gy)
B B/W
B B/W B B
9-75
Br/L
Br/R Y/R
73
Br
B/W 43
74 65 64 44 45 B R B R
Br/Y
Br/B B/Lg Y/R (Gy)
(off) B R 42
Br Y (Gy)
L W Y
75 R/W B/W
L H G R B W R B W Y
R/W W Y
Y G/R B L/W
76 Br/B L/W B/Lg
L L/Y L/W B/Lg
EPS (ELECTRIC POWER STEERING) SYSTEM
Br/R B G/R R/W Y/R

L R/W Y/R
77 R/W Y/R
R/G (B) 52 53 R/W B
Br L G L/Y R/W B
Sb
B
Br/R 78 72 Br 54
67 G 66 B R
Y B W
79 L B 55 (Gy)
G W/B W B
G G 56 R G R B
W B (Gy)
R/G R/L Y/R B (B)
B
57 (Gy)
R/L R/B G W
Br/R Y/R G/R Sb
58 Br/R Br
71 LG 46 W/B
R/L O O/W
B
59 L/B L/B
Y 60 B G
G W G/R 47
Sb W
Br/Y 68 68 68 68 (Gy) (B) (B) (Gy) (B)
B 70 (B)
Y/R
Br
69 B/Lg
G B/W
R/W
L Br Y R/L G
Br/Y Br/Y
(B) G Y G Y G Y G Y
L
Y B B B B 63 62 48
82 L Y Y Br/Y 61
B (B) B B B B B Br/Y 49 50
Y G Y G Y G Y G B/W
(B) B B B B B
Y L
(B)
B B B Sb/W
(Dgy)

5. Frame ground
6. Main switch
8. Battery
9. Main fuse
10.EPS fuse
34.Speed sensor
42.Joint coupler
43.EPS unit
44.EPS torque sensor
45.EPS motor
46.EPS control unit
47.EPS self-diagnosis signal connector
52.Meter assembly
53.EPS warning light
77.Ignition fuse
A. Wire harness
9-76
EBS30287
EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION

The EPS control unit is equipped with a self-diagnostic function. If this function detects a malfunction in
the EPS system, it lights the EPS warning light to alert the rider that a malfunction has occurred in the
system. Once a malfunction has been detected, it becomes stored in the EPS control unit memory in
the form of a fault code.
• The EPS warning light comes on when the main switch is turned to “ ” (on), and then goes off once
the engine is started. If the warning light remains on or comes on after the engine is started, the EPS
system may be defective.
• The electrical circuit of the warning light can be checked by turning the main switch to “ ” (on). If the
warning light does not come on, the electrical circuit may be defective.
1
1. EPS warning light

TIP
If the steering usage is too heavy (i.e., excessive steering use when the vehicle is traveling at a slow
speed), the power assist is reduced to protect the EPS motor from overheating.
EBS30288
EPS WARNING LIGHT DURING NORMAL OPERATION

The EPS warning light comes on initially for 2 seconds after the main switch is turned to “ ” (on). How-
ever, the warning light remains on until the engine is started.
In addition, if a malfunction is detected while the warning light comes on initially, the warning light re-
mains on.
Furthermore, the warning light comes on whenever a malfunction has occurred.
TIP
The EPS system does not operate while the EPS warning light is on.
e
a d
g
f i
b
g
f
c
h
a. Main switch f. Off
b. EPS warning light (no malfunction detected) g. Comes on.
c. EPS warning light (malfunction detected) h. Initial lighting: 2 seconds
d. “ ” (off) i. Goes off.
e. “ ” (on)
9-77
EBS30289
DIAGNOSTIC MODE
Setting the diagnostic mode (present and past malfunctions)

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

Ground the connector “1” quickly* to the battery negative terminal “2” over 2 times.
* Quickly = from 20 to 76 ms interval
TIP
To set the diagnostic mode, this step should be started within 5 seconds and completed within 10 sec-
onds after the main switch is turned to “ON”.
The EPS warning light starts to show present fault codes.
• Past malfunction signaling mode
While the present malfunction mode is activated, briefly disconnect the connector “1”, ground it
again, and leave it grounded. The signaling mode is activated after 5 seconds.
The EPS warning light starts to show past fault codes.
4. Turn the main switch to “ ” (off) to cancel the diagnostic mode.
TIP
• The diagnostic mode can also be canceled by riding the vehicle at speeds above 2 km/h (1.2 mi/h).
• When the diagnostic mode is selected and during the initial lighting of the EPS warning light, the EPS
control unit does not receive input from the EPS self-diagnosis signal connector.
5. Connect the EPS self-diagnosis signal connector.
Identifying fault codes

When the diagnostic mode is activated, the fault codes determined by the fail-safe specifications are
signaled by the EPS warning light as follows.
• Present malfunction signaling mode: Currently detected fault codes are signaled.
• Past malfunction signaling mode: Previously detected fault codes are signaled.
9-78
Signaling method
Example 1: Fault code No. 23
5
d d
a g i g
j k
b h
B
e A
c f
5 2 1 3 2
i
0.5 × 3 0.5 × 5
a. EPS self-diagnosis signal connector B. Display of the present malfunctions stops

b. Diagnostic mode when the past malfunction display mode is
c. EPS warning light selected.
d. Disconnected
e. On
f. Off
g. Grounded
h. Normal mode (diagnostic mode not activated)
i. Mode selection judgment
j. Present malfunction signaling mode
k. Past malfunction signaling mode
A. The EPS warning light comes on for 5
seconds during the diagnostic mode selection
judgment.
After the mode selection judgment is completed (present or past malfunction mode), the current fault
code signaling stops immediately, and then the first code of the mode is signaled 2 seconds later.
When a fault code is signaled, the EPS warning light goes off for 1 second between the units of 10 and
the units of 1 for the code. After a fault code is signaled, the warning light goes off for 3 seconds, and
then the next code is signaled.
Example 2: No malfunctions are detected
a c
f
d A
b e
5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5

g
a. EPS self-diagnosis signal connector f. Grounded

b. EPS warning light g. Mode selection judgment
c. Disconnected
A. The EPS warning light comes on for 5
d. Comes on seconds during the diagnostic mode selection
e. Goes off judgment.
9-79
After the mode selection judgment is completed (present display or past malfunction mode), the current
fault code signaling stops immediately, and then the EPS warning light starts flashing at 1.5-second in-
tervals.
Deleting fault codes

To delete fault codes, ground the EPS self-diagnosis signal connector 3 or more times within 5 seconds
while the present or past malfunction mode is activated. The currently selected mode remains active
after the fault codes of that mode are deleted.
b
a c
T1 T1 T1 T1 T1 T2
a. EPS self-diagnosis signal connector c. Grounded

b. Disconnected
T1: Connector grounded - - - - 0.1 T1 1.6 seconds

T2: Fault codes deleted - - - - - Maximum 1.5 seconds required
EBS30290
SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)

Fault code Probable cause of mal-
Item Symptom
No. function
• Open or short circuit in
11 wire harness.
13 No normal signals are received from • Malfunction in torque sen-
EPS torque sensor
15 the EPS torque sensor. sor.
16 • Malfunction in EPS control
unit.
wire harness.
No normal signals are received from • Malfunction in speed sen-
21 Speed sensor
the speed sensor. sor.
• Malfunction in EPS control
unit.
wire harness.
No normal signals are received from
22 Engine speed signal • Malfunction in ECU.
the ECU.
unit.
41
wire harness.
42 No normal signals are received from
EPS motor • Malfunction in EPS motor.
43 the EPS motor.
45
unit.
Relay contacts in the EPS control unit Malfunction in EPS control
52 EPS control unit
are welded together. unit.
9-80
Fault code Probable cause of mal-

Item Symptom
No. function
• Faulty battery.
• Malfunction in the
charging system.
53 EPS control unit Battery voltage has dropped. Refer to “CHARGING
SYSTEM” on page 9-11.
unit.
Relay contacts in the EPS control unit Malfunction in EPS control
54 EPS control unit
are defective. unit.
• Malfunction in the
Battery voltage has increased. charging system.
Abnormality exists between the EPS Refer to “CHARGING
55 EPS control unit
and the ECU. SYSTEM” on page 9-11.
EPS control unit internal malfunction. • Malfunction in EPS control
unit.
EBS30291
TROUBLESHOOTING DETAILS (EPS SYSTEM)

TIP
The malfunction history is stored even if the main switch is turned to “ ” (off), therefore, be sure to
erase the history (present and past malfunction signaling modes) after repairing the cause of the EPS
system malfunction. The malfunction history must be erased in the diagnostic mode. Refer to “DIAG-
NOSTIC MODE” on page 9-78.
Fault code No. 11, 13, 15, 16

Fault code No. 11, 13, Symptom EPS torque sensor: no normal signals are received from the
15, 16 EPS torque sensor.
Order Item/components and probable cause Check or maintenance job Reinstatement

method
1 Connections • Check the locking condition of the Turning the main
• EPS torque sensor coupler coupler. switch to “ ”
• Disconnect the coupler and check (off) and then to
the pins (bent or broken terminals “ ” (on).
and locking condition of the pins).
• If there is a malfunction, connect
the coupler securely or replace the
wire harness.
2 Open or short circuit in EPS torque sen- • Replace if there is an open or short
sor lead. circuit.
• Between EPS torque sensor cou-
pler and EPS control unit coupler.
white–white
red–red
green–green
black–black
3 Defective EPS torque sensor. • Replace if defective.
Refer to “CHECKING THE EPS
TORQUE SENSOR” on page
9-110.
4 Malfunction in EPS control unit. Replace the EPS control unit.
9-81
Fault code No. 21

Fault code No. 21 Symptom Speed sensor: no normal signals are received from the speed
sensor.

method
1 Connections • Check the locking condition of the Starting the en-
• Speed sensor coupler coupler. gine and activat-
• EPS control unit coupler at the wire • Disconnect the coupler and check ing the vehicle
harness the pins (bent or broken terminals speed sensor by
and locking condition of the pins). operating the ve-
• If there is a malfunction, connect hicle above 5
the coupler securely or replace the km/h (3 mi/h), or
wire harness. turning the main
2 Open or short circuit in wire harness. • Replace if there is an open or short switch to “ ”
circuit. (off), then to “ ”
• Between speed sensor coupler (on), and then
and joint coupler. deleting the fault
white–white codes. Refer to
• Between joint coupler and EPS “DIAGNOSTIC
control unit coupler. MODE” on page
white–white 9-78.
3 Defective speed sensor. • Replace if defective.

Refer to “CHECKING THE SPEED
Fault code No. 22

Fault code No. 22 Symptom No normal signals are received from the ECU.

method
• EPS control unit coupler at the wire coupler. switch to “ ”
harness • Disconnect the coupler and check (off) and then to
• ECU coupler at the wire harness the pins (bent or broken terminals “ ” (on).
wire harness.
2 Open or short circuit in wire harness. • Replace if there is an open or short
circuit.
• Between ECU coupler and EPS
control unit coupler.
orange/white–orange/white
9-82
Fault code No. 41, 42, 43, 45

Fault code No. 41, 42, Symptom EPS motor: no normal signals are received from the EPS motor.
43, 45

method
• EPS motor coupler coupler. switch to “ ”
• Disconnect the coupler and check (off) and then to
the pins (bent or broken terminals “ ” (on).
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 9-109.
Fault code No. 52

Fault code No. 52 Symptom Relay contacts in the EPS control unit are welded together.

method
1 Malfunction in EPS control unit. Replace the EPS control unit. Turning the main
switch to “ ”
(off) and then to
“ ” (on).
Fault code No. 53

Fault code No. 53 Symptom Battery voltage has dropped.

method
1 Faulty battery. Replace or charge the battery. Turning the main
Refer to “CHECKING AND switch to “ ”
CHARGING THE BATTERY” on (off) and then to
page 9-95. “ ” (on).
2 Malfunction in rectifier/regulator or Replace if defective.
charging system. Refer to “CHECKING THE RECTIFI-
ER/REGULATOR” on page 9-102.
9-83
Fault code No. 54

Fault code No. 54 Symptom Relay contacts in the EPS control unit are defective.

method
1 Malfunction in EPS control unit. Replace the EPS control unit. Turning the main
switch to “ ”
(off) and then to
“ ” (on).
Fault code No. 55

Fault code No. 55 Symptom Battery voltage has increased.
Abnormality exists between the EPS and the ECU.
EPS control unit internal malfunction.

method
1 Faulty battery. Replace the battery. Turning the main
Refer to “CHECKING AND switch to “ ”
CHARGING THE BATTERY” on (off) and then to
page 9-95. “ ” (on).
2 Malfunction in rectifier/regulator. Replace if defective.
Refer to “CHECKING THE RECTIFI-
ER/REGULATOR” on page 9-102.
9-84
ELECTRICAL COMPONENTS
EBS20084
10
9
11
7
6
5
8
12
4
15
14
13
16 17 18
1
19
20
28
21
27
22
26
23
25
24
9-85
1. Radiator fan motor

3. Clutch switch
4. Parking brake buzzer
5. Parking brake switch
6. Seat belt switch
7. Intake air temperature sensor
8. Air induction system solenoid
9. Intake air pressure sensor #1
10. Intake air pressure sensor #2
11. ISC (Idle Speed Control) unit
12. TPS (throttle position sensor)
13. Fuel injector #1
16. Ignition coil #1
20. Stator coil
21. Coolant temperature sensor
22. Oil pressure switch
23. Fuel sender
24. Fuel pump
25. Speed sensor
26. Neutral switch
27. Gear position sensor
28. Differential motor
9-86
2 3
11
10
9
7
8
9-87
1. Meter assembly
2. EPS control unit
3. Rectifier/regulator
4. Radiator fan motor circuit breaker
5. Auxiliary DC jack
7. Light switch
9. Main switch
10. EPS motor
11. EPS torque sensor
9-88
3 12 67
8
9
2 4 10
11
5
5 13
1
12
14
15
16
17
23 22
20
18
21
19
9-89
1. Lean angle sensor

2. Main fuse
3. EPS fuse
4. Auxiliary DC jack fuse
5. Fuse box
6. Headlight fuse
7. Signaling system fuse
8. Differential motor fuse
9. Backup fuse
10. Ignition fuse
11. Radiator fan motor fuse
12. Spare fuse
13. Fuel injection system fuse
14. Starter relay
15. Headlight relay (low beam)
16. Headlight relay (high beam)
17. Radiator fan motor relay
18. Fuel injection system relay
23. Battery
9-90
EBS30292
CHECKING THE SWITCHES
1 2
L/W B G/R Br L Y
2WD (off) 3 4
4WD
DIFF LOCK Br/R R/B L/W Br/R
(off) B L/R
L/W G/R
B
Br Y (on)
L (start)
B B
9 8 7 6
Sb
Br Y
(B)
B B
9-91

2. Light switch
3. Main switch
4. Parking brake switch
5. Seat belt switch
7. Clutch switch
9. Neutral switch
9-92
Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the
wiring connections and if necessary, replace the switch.
ECB01430
NOTICE
Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from
the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester
90890-03112
YU-03112-C
TIP
• Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back and forth between the switch positions a few times.
The switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated by
“ ”. There is continuity between the brown/red and red/black leads when the switch is set to
“ ” (on).
b
Br/R R/B L/W Br/R
(off)
a (on)
(start)
Br/R R/B
L/W Br/R
9-93
EBS30295
ADJUSTING THE HEADLIGHT BEAMS Amperage

No. Fuses Q’ty
The following procedure applies to all of the rating
headlights. 9 Backup 10.0 A 1
1. Adjust: 10 Auxiliary DC jack 10.0 A 1
• Headlight beam (vertically)
11 Spare 30.0 A 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw “1” in direction “a” or 12
Spare 15.0 A 2
“b”. 13
14 Spare 10.0 A 1
Direction “a”
Headlight beam is raised.
Direction “b” 2
Headlight beam is lowered.
1
12
b
a 1
5
7
8
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9
6
EBS30296 13 3
CHECKING THE FUSES
The following procedure applies to all of the fus-
es. 10
ECB01980 14 11
NOTICE
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
To avoid a short circuit, always set the main a. Connect the pocket tester to the fuse and
switch to “OFF” when checking or replacing check the continuity.
a fuse.
TIP
1. Remove: Set the pocket tester selector to “Ω × 1”.
• Battery cover
Pocket tester
4-7.
90890-03112
2. Check: Analog pocket tester
• Fuse YU-03112-C
Amperage
No. Fuses Q’ty
rating b. If the pocket tester indicates “∞”, replace the
1 Main 40.0 A 1
fuse.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2 EPS 40.0 A 1
3. Replace:
3 Radiator fan motor 30.0 A 1 • Blown fuse
4 Fuel injection system 15.0 A 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
5 Headlight 15.0 A 1 a. Turn the main switch to “ ” (off).
b. Install a new fuse of the correct amperage
6 Ignition 15.0 A 1
rating.
7 Signaling system 10.0 A 1 c. Set on the switches to verify if the electrical
8 Differential motor 10.0 A 1 circuit is operational.
9-94
d. If the fuse immediately blows again, check ECB01990
the electrical circuit. NOTICE

EWB02850 • This is a VRLA (Valve Regulated Lead Acid)
WARNING battery. Never remove the sealing caps be-
Never use a fuse with an amperage rating cause the balance between cells will not be
other than that specified. Improvising or us- maintained and battery performance will
ing a fuse with the wrong amperage rating deteriorate.
may cause extensive damage to the electri- • Charging time, charging amperage and
cal system, cause the lighting and ignition charging voltage for a VRLA (Valve Regu-
systems to malfunction and could possibly lated Lead Acid) battery are different from
cause a fire. those of conventional batteries. The VRLA
(Valve Regulated Lead Acid) battery should
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
be charged according to the appropriate
4. Install: charging method. If the battery is over-
• Battery cover charged, the electrolyte level will drop con-
Refer to “GENERAL CHASSIS (4)” on page siderably. Therefore, take special care
4-7. when charging the battery.
EBS30297
CHECKING AND CHARGING THE BATTERY TIP

EWB02830 Since VRLA batteries are sealed, it is not possi-
WARNING ble to check the charge state of the battery by
Batteries generate explosive hydrogen gas measuring the specific gravity of the electrolyte.
and contain electrolyte which is made of poi- Therefore, the charge of the battery has to be
sonous and highly caustic sulfuric acid. checked by measuring the voltage at the battery
Therefore, always follow these preventive terminals.
measures: 1. Remove:
• Wear protective eye gear when handling or • Battery cover
working near batteries. Refer to “GENERAL CHASSIS (4)” on page
• Charge batteries in a well-ventilated area. 4-7.
• Keep batteries away from fire, sparks or 2. Disconnect:
open flames (e.g., welding equipment, • Battery leads
lighted cigarettes). (from the battery terminals)
• DO NOT SMOKE when charging or han- ECB01340
dling batteries. NOTICE

• KEEP BATTERIES AND ELECTROLYTE First, disconnect the negative battery lead
OUT OF REACH OF CHILDREN. “1”, and then positive battery lead “2”.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury. 1
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water. 2
• Eyes — Flush with water for 15 minutes and
get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical atten- 3. Remove:
tion. • Battery
4-26.
4. Check:
• Battery charge
9-95
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a pocket tester to the battery termi-
nals.
• Positive tester probe →
positive battery terminal
• Negative tester probe →
negative battery terminal
TIP
• The charge state of a VRLA (Valve Regulated
Lead Acid) battery can be checked by measur-
ing its open-circuit voltage (i.e., the voltage
when the positive battery terminal is discon- A. Open-circuit voltage (V)
nected). B. Charging condition of the battery (%)
• No charging is necessary when the open-cir- C. Ambient temperature 20 °C (68 °F)
cuit voltage equals or exceeds 12.8 V.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Check the charge of the battery, as shown in 5. Charge:
the charts and the following example. • Battery
Example (refer to the appropriate charging method)
EWB02840
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours WARNING
Charge of the battery = 20–30% Do not quick charge a battery.
ECB02000
NOTICE
• Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause bat-
tery overheating and battery plate damage.
• If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
• When charging a battery, be sure to remove
it from the vehicle. (If charging has to be
A. Open-circuit voltage (V) done with the battery mounted on the vehi-
B. Charging time (hours) cle, disconnect the negative battery lead
C. Relationship between the open-circuit voltage from the battery terminal.)
and the charging time at 20 °C (68 °F) • To reduce the chance of sparks, do not
D. These values vary with the temperature, the plug in the battery charger until the battery
condition of the battery plates, and the charger leads are connected to the battery.
electrolyte level. • Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
• Make sure the battery charger lead clips are
in full contact with the battery terminal and
that they are not shorted. A corroded bat-
tery charger lead clip may generate heat in
the contact area and a weak clip spring may
cause sparks.
• If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot
batteries can explode!
9-96
• As shown in the following illustration, the 12.8 V or more --- Charging is complete.
open-circuit voltage of a VRLA (Valve Reg- 12.7 V or less --- Recharging is required.
ulated Lead Acid) battery stabilizes about Under 12.0 V --- Replace the battery.
30 minutes after charging has been com-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
pleted. Therefore, wait 30 minutes after
charging is completed before measuring 6. Install:
the open-circuit voltage. • Battery
4-26.
7. Connect:
• Battery leads
(to the battery terminals)
ECB01330
NOTICE
First, connect the positive battery lead “1”,
and then the negative battery lead “2”.
2
A. Open-circuit voltage (V)
B. Time (minutes)
C. Charging 1
D. Ambient temperature 20 °C (68 °F)
E. Check the open-circuit voltage.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Charging method using a constant volt-
age charger 8. Check:
a. Measure the open-circuit voltage prior to • Battery terminals
charging. Dirt → Clean with a wire brush.
TIP Loose connection → Connect properly.
9. Install:
Voltage should be measured 30 minutes after
• Battery cover
the engine is stopped.
b. Connect a charger and ammeter to the bat- 4-7.
tery and start charging.
EBS30298
c. Make sure that the current is higher than the CHECKING THE RELAYS
standard charging current written on the bat- Check each switch for continuity with the pocket
tery. tester. If the continuity reading is incorrect, re-
TIP place the relay.
If the current is lower than the standard charging
current written on the battery, this type of battery Pocket tester
charger cannot charge the VRLA (Valve Regu- 90890-03112
lated Lead Acid) battery. A variable voltage Analog pocket tester
charger is recommended. YU-03112-C
d. Charge the battery until the battery’s 1. Disconnect the relay from the wire harness.
charging voltage is 15 V. 2. Connect the pocket tester (Ω × 1) and battery
TIP (12 V) to the relay terminal as shown.
Set the charging time at 20 hours (maximum). Check the relay operation.
e. Measure the battery open-circuit voltage after
leaving the battery unused for more than 30
minutes.
9-97
Starter relay 2. Negative battery terminal

3 3. Positive tester probe
4. Negative tester probe
R
Result
Br/BBr/B Continuity
R/Y L/W (between “3” and “4”)
B
2 1 Headlight relay (low beam)
4 3
1. Positive battery terminal 4 +
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe 2 1
B L
Result G
Continuity Br
(between “3” and “4”)
1. Positive battery terminal
Load control relay 2. Negative battery terminal
3 4. Negative tester probe
4 +
Result
2 Continuity
1 (between “3” and “4”)
B Br/R
Br/L
Radiator fan motor relay
R

Br/R
Result R/L
Continuity R/G
Headlight relay (high beam) 2. Negative battery terminal
3 4. Negative tester probe
4 +
Result
2 Continuity
1 (between “3” and “4”)
B L/Y
Y
G
9-98
Fuel injection system relay Second step:

3 3
5 +
4
4
2 2
1 1
Y/B B Br/R
Br/R
Br/R
B/Y

Result
Continuity Result
(between “3” and “4”) No continuity
Continuity
Differential motor relay 1 (between “3” and “5”)
First step:
Differential motor relay 2
1
First step:
3
1
2 3
Y/B B Br/R
Br/R
B/Y 2
G/R B Br/R
Br/R
1. Positive tester probe Br/B
Result 3. Negative tester probe
Continuity
No continuity Result
(between “1” and “3”) Continuity
No continuity
9-99
Second step:
1
3
5 +
4
2
2
1
G/R B Br/R
Br/R
Br/B
c. Measure the primary coil resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Secondary coil resistance
Secondary coil resistance
Result 8.50–11.50 kΩ
No continuity
(between “3” and “4”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Continuity a. Connect the pocket tester (Ω × 1k) to the ig-
(between “3” and “5”) nition coil as shown.
EBS30300
Pocket tester
CHECKING THE IGNITION COILS 90890-03112
The following procedure applies to all of the igni- Analog pocket tester
tion coils. YU-03112-C
1. Check:
• Primary coil resistance • Negative tester probe →
brown/red “1”
Out of specification → Replace. • Negative tester probe →
spark plug terminal “2”
Primary coil resistance
1.19–1.61 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the ignition coil from the spark plug.
b. Connect the pocket tester (Ω × 1) to the igni-
1
tion coil as shown.
Pocket tester
90890-03112
Analog pocket tester 2
YU-03112-C
b. Measure the secondary coil resistance.
• Positive tester probe → ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
brown/red “1”
EBS30301
CHECKING THE IGNITION SPARK GAP

Cylinder-#1 ignition coil
orange “2” The following procedure applies to all of the igni-
Cylinder-#2 ignition coil tion coils.
gray/red “2” 1. Check:
Cylinder-#3 ignition coil • Ignition spark gap
orange/green “2” Out of specification → Perform the ignition
system troubleshooting, starting with step 5.
Refer to “TROUBLESHOOTING” on page
9-3.
9-100
Minimum ignition spark gap Pocket tester

6.0 mm (0.24 in) 90890-03112
TIP YU-03112-C
If the ignition spark gap is within specification,
the ignition system circuit is operating normally. • Positive tester probe →
gray “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Negative tester probe →
a. Remove the ignition coil from the spark plug. black “2”
b. Connect the ignition checker “1” as shown.
Ignition checker
90890-06754
Oppama pet–4000 spark checker
YM-34487
Gy B
1 2
b. Measure the crankshaft position sensor re-

sistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30303
CHECKING THE LEAN ANGLE SENSOR

1. Remove:
2. Ignition coil • Battery cover
c. Measure the ignition spark gap “a”. Refer to “GENERAL CHASSIS (4)” on page
d. Crank the engine by turning the main switch 4-7.
to “ ” (start) and gradually increase the • Lean angle sensor
spark gap until a misfire occurs. 2. Check:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Lean angle sensor output voltage
EBS30302
CHECKING THE CRANKSHAFT POSITION

SENSOR Less than 65°: 3.55–4.45 V
1. Disconnect: More than 65°: 0.65–1.35 V
• Crankshaft position sensor coupler
(from the wire harness) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2. Check: a. Connect the test harness– lean angle sensor
• Crankshaft position sensor resistance (3P) “1” between the lean angle sensor and
Out of specification → Replace the crank- wire harness as shown.
shaft position sensor/stator assembly. b. Connect the pocket tester (DC 20 V) to the
test harness– lean angle sensor (3P).
Crankshaft position sensor resis-
tance Test harness– lean angle sensor
445–544 Ω (3P)
90890-03213
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Test harness– lean angle sensor
a. Connect the pocket tester (Ω × 100) to the (3P)
crankshaft position sensor coupler as shown. YU-03213
Pocket tester
90890-03112
YU-03112-C
9-101
EBS30305
• Positive tester probe → CHECKING THE STATOR COIL
yellow/green (wire harness color)
• Negative tester probe → 1. Disconnect:
black/blue (wire harness color) • Stator coil couplers
(from the wire harness)
1 2. Check:
• Stator coil resistance
Out of specification → Replace the crank-
65˚ 65˚ shaft position sensor/stator assembly.
Stator coil resistance

0.15–0.23 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the digital circuit tester to the stator
coil coupler as shown.
d. Turn the lean angle sensor to 65°. Digital circuit tester
e. Measure the lean angle sensor output volt- 90890-03174
age. Model 88 Multimeter with ta-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ chometer
EBS30304
YU-A1927
CHECKING THE STARTER MOTOR
OPERATION • Positive tester probe →
1. Check: white “1”
• Starter motor operation white “2”
Does not operate → Perform the electric
starting system troubleshooting, starting with • Positive tester probe →
step 4. white “1”
Refer to “TROUBLESHOOTING” on page • Negative tester probe →
9-8. white “3”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive battery terminal “1” and • Positive tester probe →
starter motor lead “2” with a jumper lead “3”. white “2”
EWB02920 • Negative tester probe →
WARNING white “3”
• A wire that is used as a jumper lead must
have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may
burn.
• This check is likely to produce sparks,
therefore, make sure no flammable gas or
fluid is in the vicinity. W W W
3 2 1
b. Measure the stator coil resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30306
Br/B Br/B CHECKING THE RECTIFIER/REGULATOR

R/Y L/W 1. Check:
• Charging voltage
Out of specification → Replace the rectifi-
b. Check the starter motor operation. er/regulator.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9-102
Charging voltage Pocket tester

above 14 V at 5000 r/min 90890-03112
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ YU-03112-C
a. Connect the engine tachometer to the spark Vacuum/pressure pump gauge
plug lead. set
b. Connect the pocket tester (DC 20 V) to the 90890-06756
battery as shown. Mityvac brake bleeding tool
YS-42423
Pocket tester
90890-03112
YU-03112-C 2 1
• Positive tester probe →

positive battery terminal “1”
negative battery terminal “2”
2
b. Check the oil pressure switch for continuity.
Result
1 Continuity
c. Apply positive pressure to the oil pressure

switch slowly, and then check that continuity
is lost in the range of the working pressure.
c. Start the engine and let it run at approximate- Working pressure
ly 5000 r/min. 14–24 kPa (0.15–0.25 kgf/cm², 2–
d. Measure the charging voltage. 4 psi)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30701 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE OIL PRESSURE SWITCH 3. Install:
1. Remove: • Oil pressure switch
• Oil pressure switch Refer to “OIL PAN AND OIL PUMP” on page
Refer to “OIL PAN AND OIL PUMP” on page 5-38.
5-38.
EBS30307
2. Check: CHECKING THE FUEL SENDER
• Oil pressure switch continuity 1. Disconnect:
Out of specification → Replace the oil pres- • Fuel pump coupler
sure switch. (from the wire harness)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1) and the 2. Remove:
vacuum/pressure pump gauge set “1” to the • Fuel pump assembly
oil pressure switch “2” as shown. (from the fuel tank)
3. Check:
• Fuel sender resistance
Out of specification → Replace the fuel pump
assembly.
9-103
EBS30308
Sender unit resistance (full) CHECKING THE FUEL METER/FUEL LEVEL

19.00–21.00 Ω WARNING LIGHT
Sender unit resistance (empty) This model is equipped with a self-diagnosis de-
138.50–141.50 Ω vice for the fuel level detection circuit.
1. Check:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Fuel meter/fuel level warning light “1”
a. Connect the pocket tester (Ω × 10 or Ω × 100) (Turn the main switch to “ ” [on].)
to the fuel sender terminals as shown. Warning light comes on for a few seconds,
Pocket tester then goes off → Warning light is OK.
90890-03112 Warning light does not come on → Replace
Analog pocket tester the meter assembly.
YU-03112-C Warning light flashes eight times, then goes
off for 3 seconds in a repeated cycle (mal-
• Positive tester probe → function detected in fuel sender) → Replace
orange/black “1” the fuel pump assembly.
black/white “2”
R/L B B/W G 1
EBS30309
1 2 CHECKING THE SPEED SENSOR
1. Remove:
b. Move the fuel sender float to minimum “3”
• Skid plate (center)
and maximum “4” level positions.
4-1.
2. Check:
• Speed sensor output voltage
4
Output voltage reading cycle
0.6 V–4.8 V–0.6 V–4.8 V–0.6 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the test harness– speed sensor (3P)
“1” between the speed sensor coupler and
wire harness as shown.
b. Connect the pocket tester (DC 20 V) to the
test harness– speed sensor (3P).
c. Measure the fuel sender resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9-104
Test harness S– pressure sensor

(3P)
90890-03207
Test harness S– pressure sensor 1
P Br
(3P)
YU-03207 2
Pocket tester
90890-03112
YU-03112-C
c. Check the parking brake buzzer sound.
• Positive tester probe → ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
white (wire harness color) EBS30310
• Negative tester probe → CHECKING THE RADIATOR FAN MOTOR
1. Check:
• Radiator fan motor
Faulty/rough movement → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the radiator fan motor coupler
1 from the wire harness.
b. Connect the battery to the radiator fan motor
coupler as shown.
• Positive battery terminal →
blue “1”
• Negative battery terminal →
black “2”
d. Elevate the rear wheels and slowly rotate
them.
e. Measure the voltage (DC 20 V) of white and
black/blue. With each full rotation of the rear
wheels, the voltage reading should cycle
from 0.6 V to 4.8 V to 0.6 V to 4.8 V.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30354
CHECKING THE PARKING BRAKE BUZZER

1. Check:
• Parking brake buzzer c. Check the radiator fan motor movement.
Does not sound → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EBS30311
a. Disconnect the parking brake buzzer coupler CHECKING THE RADIATOR FAN MOTOR
from the wire harness. CIRCUIT BREAKER
b. Connect the battery to the parking brake 1. Remove:
buzzer coupler as shown. • Radiator fan motor circuit breaker
• Positive battery terminal → (from the wire harness)
brown “1”
• Negative battery terminal →
pink “2”
9-105
2. Check:
• Coolant temperature sensor resistance
Coolant temperature sensor re-

sistance
2.32–2.59 kΩ at 20 °C (68 °F)
310–326 Ω at 80 °C (176 °F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1k or Ω × 100)
2. Check: to the coolant temperature sensor terminals
• Radiator fan motor circuit breaker resistance as shown.
Out of specification → Replace the radiator
fan motor circuit breaker. Pocket tester
90890-03112
Fan motor circuit breaker resis- Analog pocket tester
tance YU-03112-C
0–0.05 Ω at 25 °C (77 °F)
b. Immerse the coolant temperature sensor “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ in a container filled with coolant “2”.
a. Connect the digital circuit tester to the radia-
TIP
tor fan motor circuit breaker as shown.
Make sure the coolant temperature sensor ter-
Digital circuit tester minals do not get wet.
90890-03174 c. Place a thermometer “3” in the coolant.
Model 88 Multimeter with ta-
chometer
YU-A1927
3
1
d. Heat the coolant or let it cool down to the

specified temperatures.
e. Measure the coolant temperature sensor re-
b. Measure the radiator fan motor circuit break- sistance.
er resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install:
EBS30312
• Coolant temperature sensor
CHECKING THE COOLANT TEMPERATURE
SENSOR Coolant temperature sensor
1. Remove: 23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
• Coolant temperature sensor

EBS30313
EWB02950
WARNING CHECKING THE THROTTLE POSITION

SENSOR
• Handle the coolant temperature sensor
1. Remove:
with special care.
• Throttle position sensor
• Never subject the coolant temperature sen-
(from the throttle bodies)
sor to strong shocks. If the coolant tem-
perature sensor is dropped, replace it.
9-106
EWB03070 EBS30314
WARNING CHECKING THE INTAKE AIR PRESSURE

• Handle the throttle position sensor with SENSORS
special care. The following procedure applies to both of the in-
• Never subject the throttle position sensor take air pressure sensors.
EWB03210
to strong shocks. If the throttle position WARNING
sensor is dropped, replace it.
• Handle the intake air pressure sensor with
2. Check: special care.
• Throttle position sensor maximum resistance • Never subject the intake air pressure sen-
Out of specification → Replace the throttle sor to strong shocks. If the intake air pres-
position sensor. sure sensor is dropped, replace it.
Resistance 1. Check:
2.64–6.16 kΩ • Intake air pressure sensor output voltage
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1k) to the Intake air pressure sensor output
throttle position sensor terminals as shown. voltage
3.51–3.77 V
Pocket tester
90890-03112 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Analog pocket tester a. Connect the test harness S– pressure sensor
YU-03112-C 5S7 (3P) “1” between the intake air pressure
sensor and wire harness as shown.
• Positive tester probe → b. Connect the digital circuit tester to the test
blue “1” harness S– pressure sensor 5S7 (3P).
black/blue “2” Test harness S– pressure sensor
(3P)
90890-03207
Test harness S– pressure sensor
(3P)
YU-03207
Digital circuit tester
90890-03174
Model 88 Multimeter with ta-
chometer
YU-A1927
b. Measure the throttle position sensor maxi- • Positive tester probe →

pink (wire harness color) (intake air pressure
mum resistance. sensor #1)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ pink/black (wire harness color) (intake air pres-
3. Install: sure sensor #2)
• Throttle position sensor • Negative tester probe →
TIP
When installing the throttle position sensor, ad-
just its angle properly. Refer to “ADJUSTING
THE THROTTLE POSITION SENSOR” on page
7-14.
9-107
c. Turn the main switch to “ ” (on). d. Heat the water or let it cool down to the spec-
d. Measure the intake air pressure sensor out- ified temperatures.
put voltage. e. Measure the intake air temperature sensor
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ resistance.
EBS30315 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE INTAKE AIR EBS30316
TEMPERATURE SENSOR CHECKING THE FUEL INJECTORS

1. Remove: The following procedure applies to all of the fuel
• Intake air temperature sensor injectors.
(from the air filter case.) 1. Check:
EWB02940
• Fuel injector resistance
WARNING Out of specification → Replace the fuel injec-
• Handle the intake air temperature sensor tor.
with special care.
• Never subject the intake air temperature Resistance
sensor to strong shocks. If the intake air 11.5–12.5 Ω
temperature sensor is dropped, replace it.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2. Check: a. Disconnect the fuel injector coupler from wire
• Intake air temperature sensor resistance harness.
Out of specification → Replace. b. Connect the pocket tester (Ω × 1) to the fuel
injector terminals as shown.
Intake air temperature sensor re-
sistance Pocket tester
5.40–6.60 kΩ at 0 °C (32 °F) 90890-03112
290–390 Ω at 80 °C (176 °F) Analog pocket tester
YU-03112-C
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1k or Ω × 100)
• Positive tester probe
to the intake air temperature sensor terminals Fuel injector terminal “1”
as shown. • Negative tester probe
Fuel injector terminal “2”
Pocket tester
90890-03112
YU-03112-C 1 2
b. Immerse the intake air temperature sensor R/L R/B

“1” in a container filled with water “2”.
TIP
Make sure that the intake air temperature sensor
terminals do not get wet.
c. Place a thermometer “3” in the water.
c. Measure the fuel injector resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 EBS30317
1 CHECKING THE AIR INDUCTION SYSTEM

SOLENOID
1. Check:
• Air induction system solenoid resistance
2
Solenoid resistance
20–24 Ω
9-108
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the air induction system solenoid 2WD position
coupler from the wire harness. No continuity
b. Connect the pocket tester (Ω × 1) to the air in- (between “1” and “3”)
duction system solenoid terminals as shown. (between “2” and “3”)
4WD position
Pocket tester Continuity
90890-03112 (between “2” and “3”)
Analog pocket tester No continuity
YU-03112-C (between “1” and “3”)
DIFF LOCK position
• Positive tester probe → Continuity
Air induction system solenoid terminal “1” (between “1” and “3”)
• Negative tester probe → No continuity
Air induction system solenoid terminal “2” (between “2” and “3”)
2 1
Br/R R
1 2 3
c. Measure the air induction system solenoid re- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
sistance. a. Turn the main switch to “ ” (on).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Set the On-Command four-wheel-drive
EBS30318
switch to “2WD”, “4WD”, or “DIFF LOCK” po-
CHECKING THE DIFFERENTIAL MOTOR sition.
POSITION SWITCH c. Turn the main switch to “ ” (off).
1. Check: d. Disconnect the differential motor coupler.
• Differential motor position switch e. Connect the pocket tester (Ω × 1) to the differ-
Out of specification → Replace. ential motor terminals.
f. Check the differential motor position switch
Pocket tester continuity.
90890-03112 g. Check the differential motor position switch
Analog pocket tester no continuity.
YU-03112-C ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30319
TIP CHECKING THE EPS MOTOR
Check the differential motor position switch for 1. Remove:
continuity between the terminals “1” and “3” and • EPS unit
between the terminals “2” and “3” when the On- 2. Check:
Command four-wheel-drive switch is set to the • EPS motor
“2WD”, “4WD”, and “DIFF LOCK” positions. Out of specification → Replace the EPS unit.
TIP
The pocket tester and the analog pocket tester
readings are shown in the following table.
9-109
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Continuity a. Connect the pocket tester (Ω × 1k) to the EPS
Positive tester probe → red “1” torque sensor coupler terminals as shown.
Negative tester probe → black
“2” Pocket tester
No continuity 90890-03112
Positive tester probe → red “1” Analog pocket tester
Negative tester probe → EPS YU-03112-C
motor body “3”
No continuity • Positive tester probe →
Positive tester probe → black red “1”
“2” • Negative tester probe →
Negative tester probe → EPS black “2”
motor body “3”
3 1
2
G R
B W
B R
2 1
b. Measure the EPS torque sensor resistance.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. Connect the pocket tester (Ω × 1) to the EPS
motor coupler terminal and EPS motor body.
Pocket tester
90890-03112
YU-03112-C
b. Check the EPS motor for continuity.

c. Check the EPS motor for no continuity.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30320
CHECKING THE EPS TORQUE SENSOR

1. Remove:
• EPS unit
ECB01660
NOTICE
Make sure do not remove the torque sensor
and its protector from the EPS unit.
2. Check:
• EPS torque sensor resistance
Out of specification → Replace the steering
column.
EPS torque sensor

Coil resistance
1.00–1.50 kΩ
9-110
9-111
TROUBLESHOOTING
TROUBLESHOOTING...................................................................................10-1
GENERAL INFORMATION ..................................................................... 10-1
STARTING FAILURES............................................................................10-1
INCORRECT ENGINE IDLING SPEED .................................................. 10-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......................... 10-2
FAULTY DRIVE TRAIN ...........................................................................10-3
FAULTY GEAR SHIFTING...................................................................... 10-4
SHIFT LEVER DOES NOT MOVE .......................................................... 10-4
JUMPS OUT OF GEAR...........................................................................10-4
FAULTY CLUTCH ...................................................................................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..........10-6

SELF-DIAGNOSTIC FUNCTION TABLE ................................................ 10-6
COMMUNICATION ERROR WITH THE METER ................................... 10-7
DIAGNOSTIC CODE: SENSOR OPERATION TABLE ........................... 10-7
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ......................10-9
10
TROUBLESHOOTING
EBS20085
Electrical system
TROUBLESHOOTING 1. Battery
EBS30321
• Discharged battery
GENERAL INFORMATION • Faulty battery
TIP 2. Fuse(s)
• Blown, damaged or incorrect fuse
The following guide for troubleshooting does not
• Improperly installed fuse
cover all the possible causes of trouble. It should
3. Spark plug(s)
be helpful, however, as a guide to basic trouble-
• Incorrect spark plug gap
shooting. Refer to the relative procedure in this
• Incorrect spark plug heat range
manual for checks, adjustments, and replace-
• Fouled spark plug
ment of parts.
• Worn or damaged electrode
EBS30322
• Worn or damaged insulator
STARTING FAILURES 4. Ignition coil(s)
• Cracked or broken ignition coil body
Engine • Broken or shorted primary or secondary coils
1. Cylinder(s) and cylinder head(s) 5. Ignition system
• Loose spark plug • Faulty ECU
• Loose cylinder head or cylinder • Faulty crankshaft position sensor
• Damaged cylinder head gasket • Broken AC magneto rotor woodruff key
• Worn or damaged cylinder 6. Switches and wiring
• Incorrect valve clearance • Faulty main switch
• Improperly sealed valve • Broken or shorted wiring
• Incorrect valve-to-valve-seat contact • Faulty gear position sensor
• Incorrect valve timing • Faulty neutral switch
• Faulty valve spring • Faulty clutch switch
• Seized valve • Improperly grounded circuit
2. Piston(s) and piston ring(s) • Loose connections
• Improperly installed piston ring • Faulty brake light switch
• Damaged, worn or fatigued piston ring 7. Starting system
• Seized piston ring • Faulty starter motor
• Seized or damaged piston • Faulty starter relay
3. Air filter • Faulty starter clutch
• Improperly installed air filter EBS30323
• Clogged air filter element INCORRECT ENGINE IDLING SPEED
4. Crankcase and crankshaft
• Improperly assembled crankcase Engine
• Seized crankshaft 1. Cylinder(s) and cylinder head(s)
• Incorrect valve clearance
Fuel system • Damaged valve train components
1. Fuel tank 2. Air filter
• Empty fuel tank • Clogged air filter element
• Clogged fuel tank breather hose joint
• Clogged fuel tank breather hose joint hose Fuel system
• Deteriorated or contaminated fuel 1. Throttle body(-ies)
2. Fuel pump • Damaged or loose throttle body joint
• Faulty fuel pump • Improperly synchronized throttle bodies
• Faulty fuel injection system relay • Faulty ISC (Idle Speed Control) unit
• Clogged or damaged fuel hose • Improper throttle cable free play
3. Throttle body(-ies) • Flooded throttle body
• Deteriorated or contaminated fuel • Faulty air induction system
• Sucked-in air
10-1
TROUBLESHOOTING
Electrical system
1. Battery
• Discharged battery
• Faulty battery
2. Spark plug(s)
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
3. Ignition coil(s)
• Broken or shorted primary or secondary coils
• Cracked or broken ignition coil
4. Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
• Broken AC magneto rotor woodruff key
EBS30324
POOR MEDIUM-AND-HIGH-SPEED
PERFORMANCE
Refer to “STARTING FAILURES” on page 10-1.
Engine
1. Air filter
• Clogged air filter element
Fuel system
1. Throttle body(-ies)
• Faulty throttle body
2. 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
2. Transmission oil
FAULTY GEAR SHIFTING
• Incorrect oil level
• Incorrect oil viscosity (low)
Shifting is difficult
• Deteriorated oil
Refer to “FAULTY CLUTCH” on page 10-4.
EBS30327 Clutch drags
SHIFT LEVER DOES NOT MOVE 1. Clutch
• Air in hydraulic clutch system
Shift shaft • Warped pressure plate
• Improperly adjusted shift lever rod • Bent clutch plate
• Bent shift shaft • Swollen friction plate
• Bent clutch push rod(s)
Shift drum and shift forks • Damaged clutch boss
• Foreign object in a shift drum groove • Burnt primary driven gear bushing
• Seized shift fork • Damaged clutch release cylinder
• Bent shift fork guide bar • Match marks not aligned
2. Transmission oil
Transmission • Incorrect oil level
• Seized transmission gear • Incorrect oil viscosity (high)
• Foreign object between transmission gears • Deteriorated oil
• Improperly assembled transmission
EBS30330
EBS30328
OVERHEATING
JUMPS OUT OF GEAR
Engine
Shift shaft 1. Clogged coolant passages
• Incorrect shift lever position 2. Cylinder head(s) and piston(s)
• Improperly returned stopper lever • Heavy carbon buildup
3. Engine oil
Shift forks
• Incorrect oil level
• Worn shift fork
• Incorrect oil viscosity
• Inferior oil quality
Shift drum
• Incorrect axial play
Cooling system
• Worn shift drum groove
1. Coolant
• Low coolant level
Transmission
2. Radiator
• Worn gear dog
• Damaged or leaking radiator
EBS30329 • Faulty radiator cap
FAULTY CLUTCH • Bent or damaged radiator fin
3. Water pump
Clutch slips • Damaged or faulty water pump
1. Clutch 4. Thermostat
• Improperly assembled clutch • Thermostat stays closed
• Improperly assembled clutch master cylinder 5. Oil cooler
• Improperly assembled clutch release cylinder • Clogged or damaged oil cooler
• Incorrect clutch fluid level 6. Hose(s) and pipe(s)
• Damaged clutch hose • Damaged hose
• Loose or fatigued clutch spring • Improperly connected hose
• Loose union bolt • Damaged pipe
• Worn friction plate • Improperly connected pipe
• Worn clutch plate
• Damaged clutch release cylinder
10-4
TROUBLESHOOTING
Fuel system EBS30334
UNSTABLE HANDLING
1. Throttle body(-ies)
1. Steering wheel
• Faulty throttle body
• Bent or improperly installed steering wheel
• Damaged or loose throttle body joint
2. Steering components
2. Air filter
• Incorrect toe-in
• Clogged air filter element
• Bent steering shaft
Chassis • Improperly installed steering shaft
1. Brake(s) • Damaged bearing or bearing race
• Dragging brake • Bent tie-rods
• Deformed steering knuckles
Electrical system 3. Shock absorber assembly(-ies)
1. Spark plug(s) • Faulty shock absorber spring
• Incorrect spark plug gap • Leaking gas
• Incorrect spark plug heat range 4. Tire(s)
2. Ignition system • Uneven tire pressures (left and right)
• Faulty ECU • Incorrect tire pressure
3. Radiator fan • Uneven tire wear
• Faulty fan motor 5. Wheel(s)
• Disconnected circuit breaker terminal • Damaged wheel bearing
• Faulty coolant temperature sensor • Bent or loose wheel axle
• Excessive wheel runout
EBS30331
6. Frame
OVERCOOLING • Bent frame
• Damaged frame
Cooling system
1. Thermostat EBS30335
• Thermostat stays open FAULTY LIGHTING OR SIGNALING SYSTEM
EBS30332
Headlight does not come on
POOR BRAKING PERFORMANCE • Faulty light switch
• Worn brake pad • Too many electrical accessories
• Worn brake disc • Hard charging
• Air in hydraulic brake system • Incorrect connection
• Leaking brake fluid • Improperly grounded circuit
• Faulty brake caliper kit • Poor contacts (light switch)
• Faulty brake caliper seal • Faulty headlight relay
• Loose union bolt • Faulty headlight assembly
• Damaged brake hose
• Oil or grease on the brake disc Tail/brake light does not come on
• Oil or grease on the brake pad • Faulty brake light switch
• Incorrect brake fluid level • Too many electrical accessories
EBS30333 • Incorrect connection
FAULTY SHOCK ABSORBER ASSEMBLY • Faulty tail/brake light assembly
Leaking gas
• Bent or damaged damper rod
• Cracked or damaged shock absorber
• Damaged oil seal lip
Malfunction
• Fatigued or damaged shock absorber spring
• Bent or damaged damper rod
10-5
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EBS20086

EBS30336
SELF-DIAGNOSTIC FUNCTION TABLE

TIP
For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 9-32.
Fault code
Item
No.
08 Gear position sensor: open or short circuit detected.
Crankshaft position sensor: no normal signals are received from the crankshaft position sen-
12
sor.
13 Intake air pressure sensor #1: open or short circuit detected.
14 Intake air pressure sensor #1: 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.
25 Intake air pressure sensor #2: open or short circuit detected.
26 Intake air pressure sensor #2: hose system malfunction (clogged or detached hose).
30 Latch up detected.
33 Ignition coil #1: open or short circuit detected in the primary lead of the ignition coil #1.
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.
Speed sensor: no normal signals are received from the speed sensor.
42 Neutral switch: open or short circuit is detected.
Clutch switch: open or short circuit is detected.
43 Fuel system voltage: incorrect voltage supplied to the fuel injector and fuel pump.
44 EEPROM fault code number: an error is detected while reading or writing on EEPROM.
46 Charging voltage is abnormal.
Faulty ECU (Engine Control Unit) memory. (When this malfunction is detected in the ECU, the
50
fault code number might not appear.)
85 Oil pressure switch: open or short circuit detected.
10-6
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
Item Display Procedure
code No.
01 Throttle position sensor sig- Check with throttle valve fully
nal closed.
• Fully closed position 12–22
03 Intake air pressure #1 Displays the intake air pres- Turn and hold the main
sure. switch in the “ ” (start) posi-
tion, then press the accelera-
tor pedal. (If the display value
changes, the performance is
OK.)
04 Intake air pressure #2 Displays the intake air pres- Turn and hold the main
sure. switch in the “ ” (start) posi-
tion, then press the accelera-
tor pedal. (If the display value
changes, the performance is
OK.)
05 Intake air temperature When engine is cold: Dis- Compare the actually mea-
plays temperature closer to sured intake air temperature
ambient temperature. with the indicated value.
When engine is hot: Displays
temperature approximately
20 °C (68 °F) higher than
ambient temperature.
06 Coolant temperature When engine is cold: Dis- Compare the actually mea-
plays temperature closer to sured coolant temperature
ambient temperature. with the indicated value.
When engine is hot: Displays
current coolant temperature.
07 Vehicle speed pulse 0–999 Check that the number in-
creases when the rear
wheels are rotated. The
number is cumulative and
does not reset each time the
wheel is stopped.
08 Lean angle sensor Lean angle sensor output Remove the lean angle sen-
voltage sor and incline it more than
65 degrees.
• Upright 3.55–4.45
• Overturned 0.65–1.35
10-7
Diagnostic
Item Display Procedure
code No.
09 Fuel system voltage (battery Approximately 12.0 Turn the main switch to “ ”
voltage) (on), and then compare the
actually measured battery
voltage with the display val-
ue. (If the actually measured
battery voltage is low, re-
charge the battery.)
21 Neutral switch Shift the transmission.
• Transmission is in neutral ON
• Transmission is in gear OFF
60 EEPROM fault code display
• No history 00 —
• No malfunctions detected
(If the fault code 44 is indi-
cated, the ECU is defec-
tive.)
• History exists 01–03 (Cylinder fault code)
• (If more than one cylinder is
defective, the display alter-
nates every two seconds to
show all the detected cylin-
der numbers.
When all cylinder numbers
are shown, the display re-
peats the same process.)
61 Malfunction history code dis-
play
• History exists Fault codes 08–85 —
• (If more than one code
number is detected, the
display alternates every
two seconds to show all the
detected code numbers.
When all code numbers are
shown, the display repeats
the same process.)
62 Malfunction history code era-
sure
• History exists • Displays the total number Save the malfunction history
of malfunctions, including to the computer, and then
the current malfunction, delete the fault codes.
that have occurred since
the history was last erased.
(For example, if there have
been three malfunctions,
“03” is displayed.)
70 Control number 0–254 [-] —
10-8
EBS30339
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diagnostic
Item Actuation Procedure
code No.
30 Ignition coil #1 Actuates the ignition coil five Check that a spark is gener-
times at one-second inter- ated five times.
vals. • Connect an ignition check-
The “CHECK” indicator and er.
“ ” on the Yamaha diag-
nostic tool screen come on
each time the ignition coil is
actuated.
actuated.
actuated.
36 Fuel injector #1 Actuates the fuel injector five Disconnect the fuel pump
times at one-second inter- coupler. Check that the fuel
vals. injector is actuated five times
The “CHECK” indicator and by listening for the operating
“ ” on the Yamaha diag- sound.
each time the fuel injector is
actuated.
actuated.
actuated.
10-9
Diagnostic
Item Actuation Procedure
code No.
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.
50 Fuel injection system relay Actuates the fuel injection Check that the fuel injection
system relay five times at system relay unit is actuated
one-second intervals. five times by listening for the
The “CHECK” indicator and operating sound.
each time the relay is actuat-
ed.
(When the relay is on, the
“CHECK” indicator and “ ”
on the Yamaha diagnostic
tool screen go off. When the
relay is off, the “CHECK” in-
dicator and “ ” on the
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 “ ”
on the Yamaha diagnostic
tool screen go off. When the
relay is off, the “CHECK” in-
dicator and “ ” on the
Yamaha diagnostic tool
screen come on.)
54 ISC valve Fully closes the ISC valve, The operating sound can be
and then opens the valve. heard when ISC valve oper-
This operation takes approxi- ates.
mately 3 seconds.
The “CHECK” indicator and
during the operation.
10-10
EBS20008
55. On-Command differential gear EBS30002
WIRING DIAGRAM lock indicator light COLOR CODE

YXZ10YPSG 2016 56. Reverse indicator light B Black
1. Crankshaft position sensor 57. Engine trouble warning light Br Brown
2. AC magneto 58. Coolant temperature warning Dgy Dark gray
3. Rectifier/regulator light G Green
4. Load control relay 59. Parking brake indicator light Gy Gray
5. Frame ground 60. Neutral indicator light L Blue
61. Multi-function meter O Orange
6. Main switch
62. Fuel sender P Pink
7. Engine ground
R Red
8. Battery 63. Fuel pump
Sb Sky blue
9. Main fuse 64. Differential motor relay 2
W White
10. EPS fuse 65. Light switch
Y Yellow
11. Fuel injection system fuse 66. Headlight relay (high beam) B/G Black/Green
12. Starter relay 67. Headlight relay (low beam) B/L Black/Blue
13. Starter motor 68. Headlight B/Lg Black/Light green
14. Fuel injection system relay 69. Brake light switch B/R Black/Red
15. Differential motor relay 1 70. Tail/brake light B/W Black/White
16. Differential motor 71. Transmission ground B/Y Black/Yellow
17. On-Command four-wheel-drive 72. Auxiliary DC jack Br/B Brown/Black
switch 73. Differential motor fuse Br/L Brown/Blue
18. Air induction system solenoid 74. Headlight fuse Br/R Brown/Red
19. ISC (Idle Speed Control) unit 75. Signaling system fuse Br/W Brown/White
20. ECU (Engine Control Unit) 76. Backup fuse Br/Y Brown/Yellow
21. Fuel injector #1 77. Ignition fuse G/B Green/Black
22. Fuel injector #3 78. Radiator fan motor fuse G/R Green/Red
23. Coolant temperature sensor 79. Auxiliary DC jack fuse G/Y Green/Yellow
24. Fuel injector #2 80. Radiator fan motor relay Gy/R Gray/Red
25. Intake air temperature sensor 81. Radiator fan motor circuit L/B Blue/Black
26. Neutral switch breaker L/R Blue/Red
82. Radiator fan motor L/W Blue/White
A. Wire harness L/Y Blue/Yellow
28. Clutch switch
O/G Orange/Green
29. Seat belt switch B. Negative battery sub-wire har-
O/L Orange/Blue
30. Parking brake switch ness 1
O/W Orange/White
31. Parking brake buzzer C. Negative battery sub-wire har-
P/B Pink/Black
32. Gear position sensor ness 2 P/L Pink/Blue
33. Lean angle sensor P/W Pink/White
34. Speed sensor R/B Red/Black
35. TPS (throttle position sensor) R/G Red/Green
36. Intake air pressure sensor #2 R/L Red/Blue
37. Intake air pressure sensor #1 R/W Red/White
38. Ignition coil #1 R/Y Red/Yellow
39. Ignition coil #2 Sb/W Sky blue/White
40. Ignition coil #3 W/B White/Black
41. Spark plug W/G White/Green
42. Joint coupler Y/B Yellow/Black
43. EPS unit Y/G Yellow/Green
44. EPS torque sensor Y/R Yellow/Red
45. EPS motor
46. EPS control unit
47. EPS self-diagnosis signal con-
nector
49. Helmet indicator light
50. Seat belt indicator light
51. Yamaha diagnostic tool cou-
pler
52. Meter assembly
53. EPS warning light
54. Shift timing indicator light
YXZ10YPSG 2016 WIRING DIAGRAM
A
B/W B/W
B/L Gy
Gy
A B
B/L B
W W W B R
Gy B 1 (Gy) (B) B/Lg B/L R/L W/B B/W R L/W O/W P/B Sb/W Y/B G/R O B B
P/B P
L/W W Y/G R/G Sb P/W B/W R/Y Y L/Y Y/R L/R O/G
W W R Y P/B Y R O/L R/W Br B/G R/B G/B Gy/R Br/Y Br
31 P Br Br/Y P/B
(Gy) A C
2 W
W
W
W
3 (B) (B)
(Gy)
R/W O
Gy Gy/R
W W W
B
Br/R O/G
P/B Br/R
38
(Gy) R/W
(Gy) R/L R/L R/B
R/W
21 (Gy)
R/L G/B
O
W W W R/G R/G R/B R/B R/L 24 (Gy) 41
(Gy)
Br/R
Br/R
Br/R
Br/R
19 W/G W/G L/B L/B R/L L
O Br/R
Br/R
Br/R
Br/R
Br/R
Br/L Br/L
22 Br/W B/L
R/G 32 L R/G B/L
Br/R Br/R R/L L/B B/L (B)
R Br/R Br/R R (L)
W/G R/W R/G (Gy)
G/Y B/L
25 Br/W B/L L
39
4
B
R/B
(B) Br/L R/W P/L Br/W
23 (B)
Y/G
B/L
33 L Y/G B/L Br/R
(B)
B R
R
10 R/B
18
(B)
G/Y G/Y B/L (Gy)
Gy/R
B R/B R/B Y/G L
Br/L B B/W
Br/R R R
R/G W 34 L W B/L 41
R
Br/L BB/W
B 9 Y/R
20 L
B/L
R/B Br/B W (L)
Sb/W L
R/Y
5 RR
Y/B
L/Y
R
Y
B/L
35 B/L Y L
(B)
B/W
11 14
G/R
L/W
Y (B)
8 Br/R Br/R P/W
Br L 40
R/B Br/R
B
12
L/W
O/L Y P 36 B/L P L
Br/R
R/Y R/L L/R 15 B/G
Sb
P
B/L
(L)
6 Br/B
R/L W/B L
O/G
(off)
B/W A B/W B B Br/R L/R B/Y
O/L W/B
B/R
P/B P/B
37 B/L P/B L
41
B B B B B R/Y L/W G/R
(start) Sb (L)
L/W G/R
B Y Br R L/Y B/L
(B) Y/B B O/G Br/R
B B/L
Br/R R/B
Br/R L/W 7 13
B/Y
16 17 O/W
B/W
B/L
L/W Br/R
Br/R
2WD G/R L/W
Y/R
B/Lg B/W 26 27 B
28 B
29 B
30 B/L
B/L
L
L
(B)
Br/R B Y/B L/W G/R B/L L
(B) 4WD B/L L
B B
DIFF LOCK B/L L
L/R B/L L
B B B
B Y R B
(Gy) B Br B L/Y
(Gy)
B B/W
B B/W B B
Br/L
73 Br/R Y/R
Br
Br
Br Br/R Br/R R/W 51 B/Lg
74 65
B/W 43 44 45
Br/Y
64 B R B R
(off)
Br/B B/Lg Y/R B R (Gy)
(Gy) 42
75 Br
L
Y L
H
R/W B/W W
W
Y
Y
R/W G R B W R B
W Y
Y G/R B L/W
76 L L/Y
Br/B L/W
L/W
B/Lg
B/Lg
Br/R B G/R R/W Y/R
77 L R/W Y/R
R/G Br L G L/Y
(B) 52 53 R/W
R/W
Y/R
B
Sb R/W B
Br/R 78 72 Br 54
B
Br/L W W W/B G R
R/G G B
67 G 66 G
B R
79 L B
L/Y
Y
B
55 B
(Gy)
W
G R B W R B (Gy)
Y Y Y B/Lg B/Lg B/Lg Y/R Y/R Y/R B B B
80 G W/B W B
B Y B
G G 56 R G R B
R/W R/W R/W R/W R/W R/W L/W L/W L/W W W W
W B (Gy)
R/G R/L Y/R
B
B
57 (Gy)
(B)
R/L R/B G W
Br/R Y/R 58 Br/R Br
46 G/R Sb
R/L 71 LG
B
O O/W W/B
59 L/B L/B
81 B L
Y
Y G Y G Y G Y G
60 R/B B B G
L/B Br O
O/W Br/R L/B
47
G W G/R
Sb W
B 70 Br/Y 68 68 68 68 (Gy) (B) (B) (Gy) (B)

(B)
Y/R
Br
69 G
B/Lg
B/W
R/W
L Br Y R/L G
Br/Y Br/Y
(B) G Y G Y G Y G Y
L
Y B B B B 63 62 48
82 L Y Y Br/Y 61
B (B) B B B B B Br/Y 49 50
Y G Y G Y G Y G B/W
(B) B B B B B
Y L
(B)
B B B Sb/W
(Dgy)
YXZ10YPSG 2016 WIRING DIAGRAM
A
A B
B
1 (Gy) (B)
31 (Gy) A C
2 3 (B) (B)
(Gy)
38
(Gy)
(Gy)
21 (Gy)
24 (Gy) 41
(Gy) (Gy)
19
22 32
(L) (B)
(Gy) 25 39
4
(B)
23 (B)
33
(B)
10 18
(B)
(Gy)
34 41
9 20
(L)
5 35 (B)
11 14
(B)
8 40
12 36
15 (L)
6
(off)
A
37 41
(on) B
(start) (L)
(B)
7 13 16 17
2WD
26 27 28 29 30 (B)
(B) 4WD
DIFF LOCK
(B)
(Gy)
(Gy)
73
51
74 65 43 44 45
64
(off) (Gy)
(Gy) 42
75 L
H
76
77
(B) 52 53
78 72 54
67 66
79 55 (Gy)
(Gy)
80
56
(Gy)
57 (Gy)
(B)
58 46
71
59
81 60 47
70 68 68 68 68 (Gy) (B) (B) (Gy) (B)
(B)
69
(B)
63 62 48
82 61
(B) 49 50
(B) (B)
(B)
(B)
(Dgy)

Manual de Servicio YXZ1000R 2HC-F8197-10 PDF

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Manual de Servicio YXZ1000R 2HC-F8197-10 PDF

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2016

IMPORTANT MANUAL INFORMATION

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

A NOTICE indicates special precautions that must be taken to avoid damage to

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

HOW TO USE THIS MANUAL

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

Filling fluid Molybdenum disulfide oil

Lubricant Brake fluid

Special tool B Wheel bearing grease

Tightening torque LS Lithium-soap-based grease

Wear limit, clearance M Molybdenum disulfide grease

Engine speed S Silicone grease

Electrical data Apply locking agent (LOCTITE®).

Engine oil New Replace the part with a new one.

IDENTIFICATION ............................................................................................ 1-1

IMPORTANT INFORMATION ......................................................................... 1-9

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

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

VEHICLE IDENTIFICATION NUMBER

OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM

1. Speed information from speed sensor

• self-diagnosis device NOTICE

CLOCK → HOUR → VOLTAGE → CLOCK

ODO → TRIP A → TRIP B → ODO

To reset a tripmeter, select it by pushing the “SE-

Fuel meter Self-diagnosis device

1. Transmission gear display

[To set the shift activation point]

PREPARATION FOR REMOVAL AND

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS RUBBER PARTS

BASIC SERVICE INFORMATION

TIP Turn the main switch to “OFF” before dis-

NOTICE Checking the electrical system

Intake air temperature sensor re-

Valve lapper 90890-04101

Vacuum gauge 3-10

Ring nut wrench 1 3-35, 3-37

Ring nut wrench 2 3-35, 3-38

Boots band installation tool 4-62, 8-11, 8-13,

Ball joint installer 4-67, 4-72

Compression gauge 90890-03081 5-1

Rotor holding tool 5-13, 5-15, 5-41,

Valve spring compressor 5-23, 5-27

Valve spring compressor attachment 5-23, 5-27

Valve guide remover (ø4.5) 5-25

Valve guide installer (ø4.5) 5-25

Valve guide reamer (ø4.5) 5-25

Rotor holding tool 5-31, 5-31, 5-32,

Flywheel puller 5-31

Universal clutch holder 5-54, 5-57

Piston pin puller set 5-73

Piston ring compressor 5-78

Coupling gear/middle shaft tool 5-94, 5-97

Damper spring compressor (120 mm) 5-102, 5-103,

Radiator cap tester 6-5

Radiator cap tester adapter 6-5

Middle driven shaft bearing driver 6-12

Pressure gauge 7-4

Fuel pressure adapter 7-4