b4j Wolverine Rmax4

2022
SERVICE MANUAL
Wolverine
RMAX4
YXF10WRAN
YXF10WRZN
YXF10WRLN
LIT-11616-35-22 B4J-F8197-11
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.
Please refer to “BASIC INFORMATION” (separate volume, Y0B-28197-10*) for basic instructions that
must be observed during servicing. Repair and maintenance work attempted by anyone without this
knowledge is likely to render the vehicle 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 their 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
• * If the contents of the manual are revised, the last digit of the manual number will be increased by
one.
• This Service Manual contains information regarding periodic maintenance to the emission control sys-
tem. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EBS30001
IMPORTANT MANUAL INFORMATION

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

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

NOTICE age to the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.
EBS20002
YXF10WRAN/YXF10WRZN/YXF10WRLN
SERVICE MANUAL
©2022 by Yamaha Motor Corporation, U.S.A.
First edition, June 2021
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-11616-35-22
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.
5
2
6
7
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 Molybdenum disulfide oil

M
Filling fluid Brake fluid

BF
Lubricant B Wheel bearing grease
Special tool LS Lithium-soap-based grease
Tightening torque M Molybdenum disulfide grease

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

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

E
Gear oil
G
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
APPENDIX 10
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER ..................................................... 1-1
MODEL LABEL.......................................................................................... 1-1
FEATURES...................................................................................................... 1-2
1
INSTRUMENT FUNCTIONS ..................................................................... 1-2
SPECIAL TOOLS ............................................................................................ 1-6

IDENTIFICATION
EBS20009
IDENTIFICATION
EBS30003
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the frame.
1
EBS30004
MODEL LABEL
The model label “1” is affixed to the frame under
the driver seat. This information will be needed
to order spare parts.
1-1
FEATURES
EBS20010
Odometer and tripmeters
FEATURES
EBS30008
INSTRUMENT FUNCTIONS
Multi-function meter unit 1
1
2 6
3 2 3
4 1. Odometer/Tripmeter A/Tripmeter B/Service
5 7 tripmeter/Fault code display
2. “SELECT” button
3. “RESET” button
8 9 10
The odometer shows the total distance traveled
1. D-mode indicator by the vehicle.
2. Speedometer The tripmeters show the distance traveled since
3. Speed management icon “ ” they were last reset. The tripmeters can be used
4. Odometer/Tripmeter A/Tripmeter B/Service to record the distance traveled on a single trip, or
tripmeter/Fault code display to estimate the distance that can be traveled
5. Clock/Hour meter/Voltage display/Coolant with a full tank of gas, etc. The service tripmeter
temperature display
shows the distance traveled since it was reset at
6. Fuel gauge
the last maintenance.
7. Suspension mode indicator (YXF10WRLN)
Push the “SELECT” button to switch between
8. “MODE” button
the odometer “ODO”, the tripmeters “TRIP A”
and “TRIP B”, and the service tripmeter “ ” in
the following order:
The multi-function meter unit is equipped with
the following: ODO → TRIP A → TRIP B → → ODO
• speedometer
• odometer To reset a tripmeter, set the display to the trip-
• tripmeters meter you want to reset, then push the “RESET”
• clock button until it is reset.
• hour meter TIP
• voltage display • The odometer will lock at 199999.
• coolant temperature display • The tripmeters will reset and continue counting
• speed management icon after 9999.9 is reached.
• fuel gauge
• D-mode indicator
• suspension mode indicator (YXF10WRLN)
• brightness control mode
• fault code display
Speedometer
The speedometer shows the vehicle’s traveling
speed. The speedometer can be set to “MPH” or
“km/h”. This also changes the odometer and trip-
meter units between miles and kilometers. To
change the display between “MPH” and “km/h”,
turn the key to “ ” (off), then while holding the
“SELECT” button pushed, turn the key to “ ”
(on).
1-2
FEATURES
Clock, hour meter, voltage display and cool- This display shows the battery voltage. If the bat-
ant temperature display tery voltage is less than 10 volts, “Lo” is dis-
played, and if the voltage is above 18 volts, “Hi”
is displayed.
ECB02020
NOTICE
If the voltage display indicates “LO” or “HI”,
1 there may be trouble with the battery
charging circuit or the battery may be faulty.
If this occurs, check or repair the vehicle.
2 3 4
Coolant temperature display
1. Clock/Hour meter/Voltage display/Coolant
temperature display
2. “MODE” button
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. The coolant temperature display 1
shows the temperature of the coolant.
Push the “MODE” button to switch between the 1. Coolant temperature display
clock “CLOCK”, the hour meter “HOUR”, the
When the coolant is in normal operating tem-
voltage display “VOLT”, and the coolant tem-
perature range, the temperature is displayed.
perature display “ ” in the following order:
When the coolant temperature is low, “Lo” will be
displayed. When the coolant temperature rises,
CLOCK → HOUR → VOLT → → CLOCK
the coolant temperature display will begin to
flash. If the coolant temperature continues to
To set the clock
rise, the message “Hi” will flash.
1. Set the display to the clock.
TIP
2. Push both the “SELECT” button and “RE-
SET” button until the hour digits start flashing. • The coolant temperature display can be set to
3. Use the “RESET” button to set the hours. “°C” or “°F”. To switch the temperature units,
4. Push the “SELECT” button, and the minute turn the key to “ ” (off), then while holding the
digits will start flashing. “RESET” button pushed, turn the key to “ ”
5. Use the “RESET” button to set the minutes. (on).
6. Push the “SELECT” button, and then release • The radiator fan turns on and off automatically
it to start the clock. according to the coolant temperature.
Voltage display Speed management icon
1
1
1. Voltage display 1. Speed management icon “ ”
1-3
FEATURES
This indicator comes on when the speed limiter • On vehicles not equipped with D-mode, the D-
is turned on. mode indicator will read “T” only.
(YXF10WRAN)
Fuel gauge
Suspension mode indicator (YXF10WRLN)
1
1. Fuel gauge
The fuel gauge indicates the amount of fuel in 1. Suspension mode indicator
the fuel tank. The display segments of the fuel
The suspension mode indicator shows which
gauge disappear from “F” (full) towards “E”
mode is currently selected: “F” (FIRM), “M” (ME-
(empty) as the fuel level decreases. When the
DIUM) or “C” (COMFORT).
last segment starts flashing, approximately 9.5 L
(2.51 US gal, 2.09 Imp.gal) of fuel remains. Re- Brightness control mode
fuel as soon as possible.
TIP 1
If the electrical circuit for the fuel gauge is not
working correctly, all display segments will flash
repeatedly. Refer to “SIGNALING SYSTEM” on
page 9-19 and “CHECKING THE FUEL ME-
TER/FUEL LEVEL WARNING LIGHT” on page
9-133.
D-mode indicator
1. Brightness level display
This mode allows you to adjust the brightness of
1
the multi-function meter unit when the vehicle is
stopped.
To adjust the brightness

1. Push the “SELECT” button until the bright-
ness level is displayed.
2. Use the “RESET” button to set the brightness
level.
1. D-mode indicator 3. Push the “SELECT” button to confirm the se-
The D-mode indicator shows which mode is cur- lected brightness level and exit the bright-
rently selected: “S” (SPORT), “T” (TRAIL) or “C” ness control mode.
(CRAWL).
TIP
• When the Speed Management System switch
is set to the “ ” (on) position, the D-mode
function is deactivated and the D-mode indica-
tor disappears.
1-4
FEATURES
Fault code display
1
1. Fault code display
This model is equipped with a self-diagnostic de-
vice for various electrical circuits.
If a problem is detected in any of those circuits,
the warning light will come on or flash, and the
display will indicate a fault code.
If the display indicates a fault code, note the
code number, and then check the fuel injection
system, EPS system or electronically adjustable
suspension system (YXF10WRLN). Refer to
“FUEL INJECTION SYSTEM” on page 9-41,
“EPS (ELECTRIC POWER STEERING) SYS-
TEM” on page 9-81 or “ELECTRONICALLY AD-
JUSTABLE SUSPENSION SYSTEM
(YXF10WRLN)” on page 9-103.
ECB02030
NOTICE
If the display indicates a fault code, the vehi-
cle should be checked as soon as possible
in order to avoid engine damage.
1-5
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
Thickness gauge 3-5
90890-03268
Feeler gauge set
YU-26900-9
Valve lapper (ø14) 90890-04101

3-5
90890-04101
Valve lapper (ø14)
YM-A8998
YM-A8998
Vacuum gauge 3-8

90890-03094
Vacuummate
YU-44456
YU-44456
Yamaha diagnostic tool USB (US) 3-8, 3-9, 9-44,

90890-03269 9-83, 9-106
Yamaha diagnostic tool (A/I) 3-8, 3-9, 9-44,

90890-03264 9-83, 9-106
1-6
SPECIAL TOOLS
Reference
pages
Oil filter wrench 3-18
90890-01426
Oil filter wrench
YU-38411
Ring nut wrench (R60) 3-33

R60
90890-01584
Ring nut wrench (R60)
YM-01584
Ring nut wrench (R60 1/2square wrench) 3-33

90890-01585 R60
Ring nut wrench (R60 1/2square wrench)
YM-01585
Ball joint installer 4-96, 4-101

90890-01586
YM-01586
Steering Knuckle ball joint tool 4-96

90890-01905 57.5
Steering Knuckle ball joint tool 110
110 45
YM-01905
Compression gauge 90890-03081 5-5

90890-03081
Engine compression tester
YU-33223
YU-33223
Rotor holding tool 5-26, 5-30, 5-30

90890-01235
Universal magneto and rotor holder
YU-01235
Valve spring compressor 5-29

90890-01253
Valve spring compressor
YM-01253
1-7
SPECIAL TOOLS
Reference
pages
Yamaha bond No. 1215 5-32, 5-49, 5-87,
90890-85505 5-110
Three bond No. 1215®
Valve spring compressor 5-39, 5-43

90890-04200
YM-04019
Valve spring compressor attachment (ø26) 5-39, 5-43

90890-01243
Valve spring compressor attachment (ø26)
YM-01253-1
Valve guide remover & installer set (ø5.5) 5-40

90890-04016
Valve guide remover (5.5 mm)
YM-01122
Rotor holding tool 5-47, 5-47, 5-48,

90890-04166 5-49
Rotor holding tool
YM-04166
Flywheel puller 5-47

90890-01362
Heavy duty puller
YU-33270-B
Flywheel puller attachment 5-47

90890-04089
Crankshaft protector
YM-33282
1-8
SPECIAL TOOLS
Reference
pages
Digital circuit tester (CD732) 5-53, 9-126,
90890-03243 9-127, 9-129,
Model 88 Multimeter with tachometer 9-129, 9-130,
YU-A1927 9-131, 9-131,
9-132, 9-132,
9-133, 9-134,
9-135, 9-136,
9-136, 9-136,
9-137, 9-137,
9-138, 9-139
Sheave holder 5-70, 5-76, 5-81,
90890-01903 5-83
Primary clutch holder
YS-01880-A
Secondary sheave holding tool (58–62mm) 5-70, 5-70, 5-75,

90890-04201 62
5-76
Secondary sheave holding tool (58–62mm)
YM-04201 58
Extension handle 5-70, 5-70, 5-75,

90890-04187 5-76
Extension handle
YM-04187
Middle drive shaft nut wrench (55 mm) 5-70, 5-75,

90890-04054 5-122, 5-123
Offset wrench 55 mm
YM-04054
YM-04054
Sheave fixed block ø52–58–62mm 5-70, 5-74

52
90890-04202
Sheave fixed block ø52–58–62mm
58
YM-04202
62
1-9
SPECIAL TOOLS
Reference
pages
Sheave spring compressor 5-70, 5-74
90890-04134
Sheave spring compressor
YM-04134
Collar installing tool (ø40) 5-73

90890-04190
Collar installing tool (ø40)
YM-04190
ø40
Oil seal guide (ø48) 5-74

90890-04189
Oil seal guide (ø48)
YM-04189
ø48
Piston pin puller set 5-92

90890-01304
Piston pin puller
YU-01304
YU-01304
Piston ring compressor 5-97

90890-05158
Piston ring compressor
YM-08037
1-10
SPECIAL TOOLS
Reference
pages
Engine adjuster 5-106, 5-106,
90890-01516 5-107
Engine mount spacer wrench
YS-01516
ø18.5
Universal joint holder 5-122, 5-123,

90890-04160 30 24
8-13, 8-15
Universal joint holder 25
YM-04062 30 20
24
25
20
Gear lash measurement tool 5-124

90890-01467
Gear lash measurement tool
YM-01467
Radiator cap tester 6-10

90890-01325
Mityvac cooling system tester kit
YU-24460-A
YU-24460-A
Radiator cap tester adapter 6-10

90890-01352
Pressure tester adapter
YU-33984
YU-33984
Mechanical seal installer (ø33) 6-18

90890-04132
Water pump seal installer (ø33)
YM-33221-A
Middle driven shaft bearing driver 6-18

90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058
1-11
SPECIAL TOOLS
Reference
pages
Vacuum/pressure pump gauge set 7-8, 9-132
90890-06756
Mityvac brake bleeding tool
YS-42423
Pressure gauge 7-10, 7-16

90890-03153
Pressure gauge
YU-03153
Fuel pressure adapter 7-10

90890-03186
Fuel pressure adapter
YM-03186
Fuel injector pressure adapter 7-16

90890-03210
Fuel injector pressure adapter
YU-03210
Boots band installation tool screw type 8-12, 8-12

90890-01554
Boots band installation tool screw type
YM-01554
Ring gear fix bolt (M14) 8-17, 8-37

90890-01524
Ring gear fix bolt (M14)
YM-01524
M14×P1.5
Coupling gear holding tool (ø46) 8-31, 8-32

90890-04191
Coupling gear holding tool (ø46)
YM-04191
Final gear backlash band 8-37

90890-01511
Middle drive gear lash tool
YM-01230
Ignition checker 9-130

90890-06754
Oppama pet–4000 spark checker
YM-34487
1-12
SPECIAL TOOLS
Reference
pages
Test harness– lean angle sensor (3P) 9-131
90890-03213
Test harness– lean angle sensor (3P)
YU-03213
1-13
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................ 2-2
CHASSIS SPECIFICATIONS .......................................................................... 2-7
ELECTRICAL SPECIFICATIONS ................................................................. 2-10

2
TIGHTENING TORQUES ..............................................................................2-12
ENGINE TIGHTENING TORQUES .........................................................2-12
CHASSIS TIGHTENING TORQUES .......................................................2-13
CABLE ROUTING .........................................................................................2-15

GENERAL SPECIFICATIONS
EBS20014
GENERAL SPECIFICATIONS
Model
Model B4J9 (YXF10WRAN)
B4J8 (YXF10WRZN)
B4JB (YXF10WRLN)
Dimensions
Overall length 3255 mm (128.1 in)
Overall width 1677 mm (66.0 in)
Overall height 2110 mm (83.1 in)
Wheelbase 2290 mm (90.2 in)
Ground clearance 340 mm (13.4 in)
Minimum turning radius 6.0 m (19.69 ft)
Maximum water depth 41 cm (16 in)
Weight
Curb weight 917.0 kg (2022 lb) (YXF10WRAN)
930.0 kg (2050 lb) (YXF10WRZN)
934.0 kg (2059 lb) (YXF10WRLN)
Maximum load 510.0 kg (1124 lb)
Loading
Trailer hitch pulling load limit 8888 N (907 kgf, 2000 lbf)
Trailer hitch vertical load limit 620 N (63 kgf, 141 lbf)
2-1
ENGINE SPECIFICATIONS
EBS20015
Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train DOHC
Cylinder arrangement Inline
Number of cylinders 2-cylinder
Displacement 999 cm³
Bore × stroke 93.0 × 73.5 mm (3.66 × 2.89 in)
Compression ratio 11.2 : 1
Compression pressure 530–683 kPa/340 r/min (5.3–6.8 kgf/cm²/340 r/
min, 75.5–97.2 psi/340 r/min)
Lubrication system Dry sump
Starting system Electric starter
Fuel
Recommended fuel Premium unleaded gasoline (Gasohol [E10]
acceptable)
Fuel tank capacity 35 L (9.2 US gal, 7.7 Imp.gal)
Fuel reserve amount 9.5 L (2.51 US gal, 2.09 Imp.gal)
Engine oil
Recommended brand YAMALUBE
SAE viscosity grades 0W-30, 10W-30, 10W-40
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Quantity
Oil change 3.90 L (4.12 US qt, 3.43 Imp.qt)
With oil filter removal 4.15 L (4.39 US qt, 3.65 Imp.qt)
Quantity (disassembled) 5.50 L (5.81 US qt, 4.84 Imp.qt)
Transmission oil
Type SAE 80W-90 API GL-5 Hypoid gear oil
Differential gear oil

Final gear oil

Oil filter
Oil filter type Cartridge
2-2
Oil pump
Oil pressure 395.0 kPa/8500 r/min (3.95 kgf/cm²/8500 r/min,
57.3 psi/8500 r/min)
Cooling system
Coolant quantity
Radiator (including all routes) 4.35 L (4.60 US qt, 3.83 Imp.qt)
Coolant reservoir (up to the maximum level
mark) 0.45 L (0.48 US qt, 0.40 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) 7.0 mm (0.28 in)
Water pump
Impeller shaft tilt limit 0.15 mm (0.006 in)
Spark plug (s)

Manufacturer/model NGK/LMAR8GI-8
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 24.500–24.521 mm (0.9646–0.9654 in)
Camshaft journal diameter 24.459–24.472 mm (0.9630–0.9635 in)
Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in)
Camshaft lobe dimensions
Lobe height (Intake) limit 38.850 mm (1.5295 in)
Lobe height (Exhaust) limit 38.350 mm (1.5098 in)
Camshaft runout limit 0.030 mm (0.0012 in)
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.11–0.20 mm (0.0043–0.0079 in)
Exhaust 0.24–0.30 mm (0.0094–0.0118 in)
Valve dimensions
Valve seat contact width (intake) 1.10–1.30 mm (0.0433–0.0512 in)
Valve seat contact width (intake) limit 1.8 mm (0.07 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 5.445 mm (0.2144 in)
Valve stem diameter (exhaust) limit 5.430 mm (0.2138 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
Free length (intake) 37.78 mm (1.49 in)
Free length limit (intake) 35.89 mm (1.41 in)
Free length (exhaust) 36.49 mm (1.44 in)
Free length limit (exhaust) 34.66 mm (1.36 in)
Cylinder
Bore 93.000–93.010 mm (3.6614–3.6618 in)
Wear limit 93.060 mm (3.6638 in)
Piston
Piston-to-cylinder clearance 0.020–0.045 mm (0.0008–0.0018 in)
Diameter 92.965–92.980 mm (3.6600–3.6606 in)
Measuring point (from piston skirt bottom) 8.0 mm (0.31 in)
Piston pin bore inside diameter limit 22.045 mm (0.8679 in)
Piston pin outside diameter limit 21.971 mm (0.8650 in)
Piston ring
Top ring
End gap (installed) 0.19–0.29 mm (0.007–0.011 in)
End gap (installed) limit 0.54 mm (0.0213 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Ring side clearance limit 0.115 mm (0.0045 in)
2nd ring
End gap (installed) 0.44–0.54 mm (0.02–0.02 in)
End gap (installed) limit 0.89 mm (0.0350 in)
Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in)
Ring side clearance limit 0.115 mm (0.0045 in)
Connecting rod
Oil clearance 0.034–0.058 mm (0.0013–0.0023 in)
Bearing color code
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Crankshaft
Runout limit 0.030 mm (0.0012 in)
Journal oil clearance 0.021–0.045 mm (0.0008–0.0018 in)
Bearing color code
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Code 5 Yellow
Balancer
Balancer shaft journal to balancer shaft bearing
clearance 0.017–0.041 mm (0.0007–0.0016 in)
Bearing color code
Code 1 Blue
2-4
Code 2 Black
Code 3 Brown
Code 4 Green
Code 5 Yellow
Clutch
Clutch type Wet, centrifugal, shoe
Clutch shoe thickness 2.5 mm (0.10 in)
Clutch shoe thickness limit 1.5 mm (0.06 in)
Clutch housing inside diameter 150.0 mm (5.91 in)
Clutch housing inside diameter limit 150.5 mm (5.93 in)
Compression spring free length limit 110.7 mm (4.36 in)
Clutch-in revolution 2080–2480 r/min
Clutch-stall revolution 3820–4320 r/min
V-belt
V-belt width limit 36.5 mm (1.44 in)
Drivetrain
Primary reduction ratio 1.000
Transmission type CVT automatic with reverse
Drive axle runout limit 0.06 mm (0.0024 in)
Weight outside diameter 35.0 mm (1.38 in)
Weight outside diameter limit 34.5 mm (1.36 in)
Gear ratio
Low range 2.524 (53/21)
High range 1.533 (46/30)
Reverse gear 2.333 (39/27 × 42/26)
Transmission ratio 2.789–0.676 : 1
Secondary reduction ratio 10.335 (69/36 × 25/17 × 33/9)
Final drive Shaft
Shaft drive
Middle gear backlash 0.10–0.30 mm (0.004–0.012 in)
Final gear backlash 0.05–0.30 mm (0.002–0.012 in)
Differential gear backlash 0.10–0.20 mm (0.004–0.008 in)
Air filter
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
ID mark B4J1
Fuel injector
Fuel line pressure 300.0–390.0 kPa (3.00–3.90 kgf/cm², 43.5–56.6
psi)
Resistance 12.0 Ω
2-5
Idling condition
Engine idling speed 1250–1350 r/min
CO% 2.5–3.5 %
Difference in vacuum pressure between the
cylinders 0 kPa–1.3 kPa (0 mmHg–10 mmHg, 0 inHg–0.4
inHg)
Coolant temperature 75–85 °C (167–185 °F)
Engine oil temperature 55–65 °C (131–149 °F)
Accelerator pedal free play 10.0–15.0 mm (0.39–0.59 in)
Air induction system

Solenoid resistance 18–22 Ω
2-6
CHASSIS SPECIFICATIONS
EBS20016
Chassis
Caster angle 5.05 °
Camber angle -0.8 °
Kingpin angle 11.4 °
Kingpin offset 16.2 mm (0.64 in)
Trail 29.0 mm (1.14 in)
Toe-in (with tires touching the ground) 10.0 to 20.0 mm (0.39 to 0.79 in)
Front track 1579.0 mm (62.17 in)
Rear track 1607.0 mm (63.27 in)
Front wheel
Rim size 14x6.5AT
Wheel material Aluminum
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)
Rear wheel
Rim size 14x8.0AT
Wheel material Aluminum
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)
Front tire
Size 29x9.00R14 NHS
Manufacturer/model GBC/DIRT COMMANDER (YXF10WRAN)
MAXXIS/ML19A/CARNAGE (YXF10WRZN,
YXF10WRLN)
Rear tire
Size 29x11.00R14 NHS
Manufacturer/model GBC/DIRT COMMANDER (YXF10WRAN)
MAXXIS/ML19A/CARNAGE (YXF10WRZN,
YXF10WRLN)
Tire air pressure (measured on cold tires)

Vehicle load 0.0–200.0 kg (0–441 lb)
Recommended
Front 110.0 kPa (1.100 kgf/cm², 16.0 psi)
Rear 110.0 kPa (1.100 kgf/cm², 16.0 psi)
Minimum
Vehicle load 200.0–510.0 kg (441–1124 lb)
Recommended
Minimum
2-7
Front brake
Type Hydraulic disc brake
Brake disc thickness 5.5 mm (0.22 in)
Brake disc thickness limit 5.0 mm (0.20 in)
Brake disc runout 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, 32.03 mm (1.26 in, 1.26 in)
Rear brake
Type Hydraulic disc brake
Brake disc thickness 5.5 mm (0.22 in)
Caliper cylinder inside diameter 27.00 mm, 27.00 mm (1.06 in, 1.06 in)
Brake fluid
Specified brake fluid DOT 4
Parking brake
Type Mechanical disc brake
Lever free play 3 clicks
Front suspension
Type Double wishbone
Spring Coil spring
Shock absorber Gas-hydraulic damper
Wheel travel 361 mm (14.3 in)
Spring preload
Adjusting system Mechanical adjustable type
Unit for adjustment mm
Adjustment value (Soft) 519.3 mm (20.44 in)
Adjustment value (STD) 509.3 mm (20.05 in)
Adjustment value (Hard) 499.3 mm (19.66 in)
Compression damping
Adjusting system Electronically adjustable type (YXF10WRLN)
Mechanical adjustable type (YXF10WRAN,
YXF10WRZN)
Unit for adjustment Click (YXF10WRAN, YXF10WRZN)
Adjustment start position Maximum (Hard) (YXF10WRAN, YXF10WRZN)
Minimum (Soft) 1 (YXF10WRAN, YXF10WRZN)
Standard 2 (YXF10WRAN, YXF10WRZN)
Maximum (Hard) 3 (YXF10WRAN, YXF10WRZN)
Rear suspension
Type Double wishbone
Spring Coil spring
Shock absorber Gas-hydraulic damper
2-8
Wheel travel 337 mm (13.3 in)

Spring preload
Adjusting system Mechanical adjustable type
Adjusting system mm
Adjustment value (Soft) 475.2 mm (18.71 in)
Adjustment value (STD) 460.2 mm (18.12 in)
Adjustment value (Hard) 445.2 mm (17.53 in)
Rebound damping
Adjusting system Mechanical adjustable type (YXF10WRAN,
YXF10WRZN)
Compression damping
Adjusting system Electronically adjustable type (YXF10WRLN)
Mechanical adjustable type (YXF10WRAN,
YXF10WRZN)
Unit for adjustment Click (YXF10WRAN, YXF10WRZN)
Adjustment start position Maximum (Hard) (YXF10WRAN, YXF10WRZN)
Minimum (Soft) 1 (YXF10WRAN, YXF10WRZN)
Standard 2 (YXF10WRAN, YXF10WRZN)
Maximum (Hard) 3 (YXF10WRAN, YXF10WRZN)
2-9
ELECTRICAL SPECIFICATIONS
EBS20017
Electrical system
System voltage 12 V
Engine control unit

Model F8T86971
Ignition system
Ignition system TCI
Ignition timing (B.T.D.C.) 5.0 °/1300 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, 47.6 A at 5000 r/min
Standard output 14.0 V, 666 W at 5000 r/min
Stator coil resistance 0.14–0.22 Ω
Rectifier/regulator
Regulated voltage (DC) 14.3–14.7 V
Battery
Model U1-H11L
Voltage, capacity 12 V, 28.0 Ah
Lights
Headlight LED
Tail/brake light LED
Interior light LED (YXF10WRZN, YXF10WRLN)
Auxiliary light LED
Meter lighting LED
Neutral indicator light LED
High beam indicator light LED
Reverse indicator light LED
Coolant temperature warning light LED
Parking brake indicator light LED
Engine trouble warning light LED
High-range indicator light LED
Low-range indicator light LED
Differential gear lock indicator light LED
EPS warning light LED
Suspension system warning light LED (YXF10WRLN)
Battery voltage warning light LED
Helmet reminder light LED
Seat belt reminder light LED
Starter motor
Brush overall length limit 6.50 mm (0.26 in)
2-10
Brush spring force 6.02–6.51 N (614–664 gf, 21.69–23.45 oz)

Mica undercut (depth) 0.70 mm (0.03 in)
Fuel sender unit

Sender unit resistance (full) 19.0–21.0 Ω
Sender unit resistance (empty) 138.5–141.5 Ω
Auxiliary DC output
Front auxiliary DC jack capacity 10.0 A (120 W)
Rear auxiliary DC jack capacity 10.0 A (120 W) (YXF10WRZN, YXF10WRLN)
Fuel injection sensor

Crankshaft position sensor resistance 446–545 Ω
Intake air temperature sensor resistance 5400–6600 Ω at 0 °C (5400–6600 Ω at 32 °F)
Intake air temperature sensor resistance 290–390 Ω at 80 °C (290–390 Ω at 176 °F)
Coolant temperature sensor resistance 2513–2777 Ω at 20 °C (2513–2777 Ω at 68 °F)
Coolant temperature sensor resistance 210–221 Ω at 100 °C (210–221 Ω at 212 °F)
Lean angle sensor output voltage

Operating angle 65 °
Output voltage up to operating angle 3.6–4.5 V
Output voltage over operating angle 0.7–1.4 V
Fuses
Main fuse 50.0 A
Headlight fuse 7.5 A
Signaling system fuse 7.5 A
Ignition fuse 15.0 A
Radiator fan motor fuse 30.0 A
Auxiliary DC jack fuse 10.0 A
ETV fuse 10.0 A
Accessory fuse 20.0 A
Fuel injection system fuse 10.0 A
Backup fuse 7.5 A
Four-wheel-drive motor fuse 7.5 A
EPS fuse 40.0 A
SCU fuse 15.0 A (YXF10WRLN)
2-11
TIGHTENING TORQUES
EBS20018
TIGHTENING TORQUES
EBS30019
ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Spark plug M14 2 13 N·m (1.3 kgf·m, 9.6 lb·ft)
Cylinder head cover bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Cylinder head cover bolt (for oil pres-
M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
sure check)
Thermostat cover air bleed bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Oil filter cartridge M20 1 17 N·m (1.7 kgf·m, 13 lb·ft)
Oil filter cartridge union bolt M20 1 80 N·m (8.0 kgf·m, 59 lb·ft) E
Engine oil drain bolt (crankcase) M10 2 20 N·m (2.0 kgf·m, 15 lb·ft)
Oil cooler drain bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
AC magneto cover bolt M6 9 10 N·m (1.0 kgf·m, 7.4 lb·ft)
AC magneto rotor bolt M12 1 130 N·m (13 kgf·m, 96 lb·ft) E
Water pump housing and AC mag-

M6 5 10 N·m (1.0 kgf·m, 7.4 lb·ft)
neto cover bolt
Transmission oil drain bolt M12 1 20 N·m (2.0 kgf·m, 15 lb·ft)
Dipstick guide bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Primary sheave assembly nut M22 1 305 N·m (30.5 kgf·m, 225 lb·ft)
Secondary sheave assembly nut M22 1 245 N·m (24.5 kgf·m, 181 lb·ft)
Coolant drain bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Differential gear oil filler bolt M14 1 23 N·m (2.3 kgf·m, 17 lb·ft)
Differential gear oil drain bolt M12 1 20 N·m (2.0 kgf·m, 15 lb·ft)
Final gear oil filler bolt M14 1 23 N·m (2.3 kgf·m, 17 lb·ft)
Final gear oil drain bolt M12 1 20 N·m (2.0 kgf·m, 15 lb·ft)
2-12
TIGHTENING TORQUES
EBS30020
CHASSIS TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Engine oil drain bolt (oil tank) M6 1 9 N·m (0.9 kgf·m, 6.6 lb·ft)
Battery holding bracket bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Battery lead nut M8 2 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Front shock absorber assembly nut M10 4 70 N·m (7.0 kgf·m, 52 lb·ft)
Rear shock absorber assembly nut M12 4 90 N·m (9.0 kgf·m, 66 lb·ft)
Steering knuckle nut (upper side) M12 2 See TIP.
Steering knuckle nut (lower side) M12 2 See TIP.
Seat belt bolt (upper) (M11) M11 4 59 N·m (5.9 kgf·m, 44 lb·ft)
Front seat belt buckle bolt M12 2 59 N·m (5.9 kgf·m, 44 lb·ft)
Rear seat belt bolt (lower) M12 2 52 N·m (5.2 kgf·m, 38 lb·ft)
Front seat belt bolt (lower) M12 2 59 N·m (5.9 kgf·m, 44 lb·ft)
Rear seat belt buckle bolt M12 2 52 N·m (5.2 kgf·m, 38 lb·ft)
Seat belt retractor bolt M12 4 59 N·m (5.9 kgf·m, 44 lb·ft)
Seat belt adjuster bolt M6 4 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Front wheel nut M12 8 95 N·m (9.5 kgf·m, 70 lb·ft)
Rear wheel nut M12 8 95 N·m (9.5 kgf·m, 70 lb·ft)
Front brake caliper bolt M10 4 50 N·m (5.0 kgf·m, 37 lb·ft)
Front brake caliper retaining pin bolt M8 2 22 N·m (2.2 kgf·m, 16 lb·ft) LT
Front brake caliper guide pin bolt M8 2 22 N·m (2.2 kgf·m, 16 lb·ft)
Rear brake caliper bolt M10 4 50 N·m (5.0 kgf·m, 37 lb·ft)
Rear brake caliper retaining pin bolt M8 2 22 N·m (2.2 kgf·m, 16 lb·ft) LT
Rear brake caliper guide pin bolt M8 2 22 N·m (2.2 kgf·m, 16 lb·ft)
Throttle cable adjusting locknut M6 1 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
Parking brake cable adjusting lock-
M8 1 17 N·m (1.7 kgf·m, 13 lb·ft)
nut
Parking brake caliper bolt M10 2 40 N·m (4.0 kgf·m, 30 lb·ft)
Parking brake caliper guide pin bolt M8 1 17 N·m (1.7 kgf·m, 13 lb·ft)
Parking brake caliper retaining pin
M8 1 22 N·m (2.2 kgf·m, 16 lb·ft)
nut
TIP
Steering knuckle nut
1. Tighten the steering knuckle nut (upper side and lower side) to 120 N·m (12 kgf·m, 89 lb·ft).
2. Loosen and retighten the steering knuckle nut (upper side and lower side) to 75 N·m (7.5 kgf·m, 55
lb·ft). After loosening a steering knuckle nut, do not remove the ball joint.
2-13
TIGHTENING TORQUES
2-14
CABLE ROUTING
EBS20022
CABLE ROUTING
Frame front (left view)
1 A 2 3 4 B 5
17 10
16
11
12
13
15 14 C
4 11
12
13
2-15
CABLE ROUTING
1. Winch contactor (YXF10WRZN/YXF10WRLN)

2. Fuse box
3. Coolant reservoir hose
4. Radiator fan motor breather hose
5. Speed management system switch
6. GPS monitor (YXF10WRZN/YXF10WRLN)
7. Meter assembly
8. Winch switch (YXF10WRZN/YXF10WRLN)
9. Interior light (center) (YXF10WRZN/YXF10WRLN)
10. USB jack (YXF10WRZN/YXF10WRLN)
11. Wire harness
12. Throttle cable
13. Frame
14. Differential motor lead
15. Differential assembly breather hose
16. Winch power lead 3 (blue) (YXF10WRZN/
YXF10WRLN)
17. Winch power lead 4 (yellow) (YXF10WRZN/
YXF10WRLN)
A. Fasten the coolant reservoir hose and radiator fan
motor breather hose with the holder.
B. Fasten the coolant reservoir hose with the holder.
C. Fasten the wire harness with the plastic band.
D. Fasten the radiator fan motor breather hose with
the holder.
2-16
CABLE ROUTING
Frame front (left view) (YXF10WRLN)
B 2 4 3 2 A
C 5 6 7
13 2 B
14
10
12
8
A 2 10
11
12
C C
2-17
CABLE ROUTING
1. Sub-wire harness (front speaker)

2. Sub-wire harness (SCU)
3. AUX input socket lead
4. Audio control panel lead
5. Suspension mode switch
6. Audio control panel
7. AUX input socket
8. Front speaker (right)
9. Front speaker (left)
10. Wire harness
11. Sub-wire harness (rear speaker)
12. Frame
13. Negative battery lead 1
14. Engine ground lead
A. To rear shock absorber stepping motor (left)
B. To rear shock absorber stepping motor (right)
C. Fasten the leads and wire harness with the plastic
locking tie.
2-18
CABLE ROUTING
Rear speaker (YXF10WRZN)

2 3
A
7
2
1
3
7 7
3
1 1
1 7
1
7
4
1
5
1
7
5
7 1
1 6
2-19
CABLE ROUTING

2. Rear speaker lead (left)
3. Rear speaker (left)
4. Wire harness
5. Rear speaker lead (right)
6. Rear speaker lead (right)
7. Frame
A. Forward
2-20
CABLE ROUTING
Frame center (left view)
9 10
B
10 C
11
3 4 5
1 2
8 7
2-21
CABLE ROUTING
1. Buzzer lead
2. Parking brake switch lead
3. TPS/Coolant temperature sensor lead
4. Rear auxiliary DC jack lead (YXF10WRZN/
YXF10WRLN)
5. Air induction system solenoid lead
6. TPS (throttle position sensor) lead
7. Seat belt switch lead
8. Wire harness
9. Transmission case breather hose
10. Parking brake cable
11. Thermostat outlet hose
A. Fasten the wire harness with the plastic band.
B. Fasten the transmission case breather hose with
the holders on the air intake accumulator case.
C. Fasten the thermostat outlet hose with the holder,
and then fasten the TPS/coolant temperature
sensor lead and parking brake cable.
2-22
CABLE ROUTING
Frame rear (left view)
F
E
1 6 G
5
1 C D 2 D 3
2-23
CABLE ROUTING
1. O2 sensor lead
2. Wire harness
3. Tail/brake light lead (left)
4. O2 sensor
5. Final drive assembly breather hose
6. Sub-wire harness (SCU) (YXF10WRLN)
A. Fasten the wire harness at the white tape with the
plastic band. Face the end of the plastic band
forward.
B. Fasten the wire harness with the plastic band.
Face the end of the plastic band forward.
C. Fasten the O2 sensor lead with the plastic band.
D. Route the wire harness to the outside of the frame.
Fasten the wire harness with the plastic band.
Face the end of the plastic band upward.
E. Fasten the final drive assembly breather hose with
the holder.
F. For YXF10WRLN
G. Fasten the O2 sensor lead and sub-wire harness
(SCU) (YXF10WRLN)
2-24
CABLE ROUTING
Frame front (right view)
E 8
17
6
7
10 8
16
1 2 3 4 5
15
14
13
12
6
11
20
D B 10 C B 9 8
19
18 17
2-25
CABLE ROUTING
1. Frame ground lead

2. Rectifier/regulator lead 2 (gray)
3. Rectifier/regulator lead 1 (black)
4. Fuse box
YXF10WRLN)
YXF10WRLN)
9. Radiator fan motor lead
10. Differential motor lead
11. Interior light (right) (YXF10WRZN/YXF10WRLN)
12. USB jack (YXF10WRZN/YXF10WRLN)
15. Meter assembly
16. GPS monitor (YXF10WRZN/YXF10WRLN)
17. Frame
18. Starter motor lead
19. Wire harness
20. Negative battery lead
A. Fasten the winch power lead 3 (blue) and winch
power lead 4 (yellow) with the plastic band.
(YXF10WRZN/YXF10WRLN)
B. Fasten the differential assembly breather hose with
the holder.
C. Fasten the radiator fan motor lead with the plastic
band.
D. Fasten the negative battery lead, starter motor
lead, and wire harness with the plastic band.
E. Fasten the radiator outlet hose with the plastic
band. Route the differential assembly breather
hose over the plastic band.
2-26
CABLE ROUTING
Frame center (right view)

6
9 10
8 5
A 5 4
2-27
CABLE ROUTING
1. Intake air temperature sensor lead

3. Canister breather hose (3-way joint to frame)
4. Gear position switch lead
5. Wire harness
6. Fuel injector #1 lead
7. Fuel injector #2 lead
8. Intake air pressure sensor lead
B. Fasten the wire harness to the fuel rail with the
plastic band. Make sure that the end of the plastic
band upward and it does not contact the hoses.
C. Fasten the negative battery lead, starter motor
lead and wire harness with the plastic band.
2-28
CABLE ROUTING
Frame rear (right view)
1 2 A
4
E
F
6
5 4
2-29
CABLE ROUTING
1. Tail/brake light lead (right)

2. Rear light coupler (optional)
3. Wire harness
5. Frame
A. Route the wire harness to the outside of the frame.
Fasten the wire harness with the plastic band.
Face the end of the plastic band upward.
B. Fasten the wire harness with the plastic band.
C. Fasten the wire harness at the white tape with the
plastic band. Face the end of the plastic band
inward.
D. For YXF10WRLN
E. Fasten the sub-wire harness (SCU)
F. Fasten the sub-wire harness (SCU). Face the end
of the plastic band forward.
G. Fasten the sub-wire harness (SCU) and wire
harness at the white tape on the wire harness with
the plastic band. Face the end of the plastic band
inward.
2-30
CABLE ROUTING
Frame front (top view 1/2)

5 6 7 8
3 4
9
1 2
10
11
12
23
24
22
21
13 A
21 14
15
16
20 19 18 17
25 26 27 B C 24 D 28 29 30 E
31
32
33
42 41 G 40 39 38 37 36 35 34
2-31
CABLE ROUTING
1. Auxiliary light (left) G. Fasten the EPS motor lead and EPS torque sensor
2. Auxiliary light lead (left) lead at the tape on each lead with the plastic band.
3. Headlight lead (left)
4. Headlight assembly (left)
5. EPS control unit
6. Headlight assembly (right)
7. Headlight lead (right)
8. Auxiliary light lead (right)
10. Fuse box 1
11. Fuse box 2
12. Auxiliary light (right)
13. Positive battery lead (red)
14. Sub-wire harness (GPS) (YXF10WRZN/
YXF10WRLN)
15. USB converter lead (YXF10WRZN/YXF10WRLN)
16. USB converter (YXF10WRZN/YXF10WRLN)
17. Accelerator position sensor
18. Front auxiliary DC jack
19. Wire harness
21. Coolant reservoir hose
22. EPS control unit coupler
23. Joint coupler
24. Radiator fan motor breather hose
25. On-Command four-wheel-drive switch lead
26. Light switch lead
27. Brake light switch lead
29. Speed management system switch coupler
30. D-mode switch lead (YXF10WRZN/YXF10WRLN)
31. Optional battery connector
32. GPS monitor adapter lead (YXF10WRZN/
YXF10WRLN)
33. GPS monitor adapter coupler (YXF10WRZN/
YXF10WRLN)
34. D-mode switch (YXF10WRZN/YXF10WRLN)
35. D-mode switch coupler (YXF10WRZN/
YXF10WRLN)
36. Main switch
37. Main switch lead
38. EPS motor lead
39. Meter assembly lead
40. EPS torque sensor lead
41. Light switch
42. On-Command four-wheel-drive switch
A. Fasten the radiator fan motor breather hose and
coolant reservoir hose with the holder.
B. Fasten the brake light switch lead, light switch lead
and On-Command four-wheel-drive switch lead
with the plastic band.
D. Fasten the radiator fan motor breather hose with
the holder on the front cover.
E. Fasten the radiator fan motor breather hose with
the holder.
F. Fasten the main switch lead and meter assembly
lead at the tape on each lead with the plastic band.
2-32
CABLE ROUTING
Frame front (top view 2/2)
9
11
10 J 12
I
11
D
5 F
3 B 4 C E
1 2 A
G
H
8
7 6
13 13 11
11
L
K 15 14
A G
2-33
CABLE ROUTING

2. Light switch
3. Main switch
4. USB jack lead (YXF10WRZN/YXF10WRLN)
5. Accelerator position sensor
6. Interior light (right) (YXF10WRZN/YXF10WRLN)
7. Interior light (left) (YXF10WRZN/YXF10WRLN)
9. Accelerator position sensor lead
10. Throttle cable
11. Frame
13. Wire harness
B. Route the coolant reservoir breather hose through
the down tube.
C. Fasten the differential assembly breather hose with
the holder.
D. Fasten the differential assembly breather hose and
transmission case breather hose to the front cover.
E. Fasten the transmission case breather hose and
canister breather hose (3-way joint to frame) with
the holder.
F. Fasten the wire harness, USB jack lead
(YXF10WRZN/YXF10WRLN), and winch switch
lead (YXF10WRZN/YXF10WRLN) at the white
tape on each lead with the plastic band.
G. Fasten the wire harness, negative battery lead,
and starter motor lead with the plastic band.
H. Fasten the wire harness at the white tape with the
plastic band.
I. Fasten the accelerator position sensor lead and
throttle cable with the plastic band.
J. Route the canister breather hose (3-way joint to
frame) through the hole in the frame.
K. Pass the plastic band through the hole in the
frame, and then fasten the wire harness, starter
motor lead, and negative battery lead with the
plastic band.
L. Pass the plastic band through the hole in the
frame, and then fasten the wire harness with the
plastic band.
2-34
CABLE ROUTING
Frame center (top view)

10 11 12
13
15
16
2 4
17
2
14
H
15 15
19 K
18
J 14
16 16
16 4 4 2
14
I
14 4
14 4 1 A 2 3 B
16
15
20
G F E 9 8 D 7 C 6
2-35
CABLE ROUTING
1. Buzzer lead
2. AC magneto lead
3. AC magneto lead coupler
5. Oil pressure switch lead
6. Ignition coil lead #2
7. Purge cut valve solenoid lead
8. Ignition coil lead #1
9. Coolant temperature sensor lead
10. Reverse switch lead
11. Gear position switch lead
12. Speed sensor lead
13. Fuel pump lead
15. Frame
16. Wire harness
17. Water pump inlet hose
18. Fuel hose
19. Canister purge hose (3-way joint to canister)
20. Rear auxiliary DC jack (YXF10WRZN/
YXF10WRLN)
A. Fasten the wire harness, negative battery lead,
and starter motor lead with the plastic band. Align
the white tape on the wire harness with the plastic
band.
B. AC magneto leads may be routed in any order.
C. Purge cut valve solenoid leads may be routed in
any order.
D. Identified by the white tape on the ignition coil lead
#1.
E. Install the larger diameter side of the holder on the
thermostat outlet hose, and then install the smaller
diameter side of the holder on the TPS/Coolant
temperature sensor lead.
F. Fasten the wire harness with the plastic band.
G. Fasten the wire harness with the holder.
H. Fasten the water pump inlet hose, wire harness,
negative battery lead, AC magneto lead, and
starter motor lead with the plastic band.
I. Fasten the negative battery lead, starter motor
lead, and wire harness with the plastic band, and
then install the fuel hose and canister purge hose
(3-way joint to canister).
J. Fasten the wire harness, negative battery lead,
and starter motor lead with the plastic band.
K. Fasten the wire harness, negative battery lead,
starter motor lead, and AC magneto lead with the
plastic band.
2-36
CABLE ROUTING
Frame center (top view) (YXF10WRLN)
2
3 D E
3 C
4
3 1
A 5 3 F
A 6
6
3 F 7
1
B A
2-37
CABLE ROUTING
1. Wire harness
7. Engine ground lead
A. Fasten the leads and wire harness with the plastic
locking tie.
B. Route the sub-wire harness (rear speaker) to the
outside of the holder.
C. To suspension mode switch
D. Fasten the sub-wire harness (rear speaker) and
sub-wire harness (SCU) at the white mark with the
plastic locking tie.
E. To rear shock absorber stepping motor (left)
F. To rear shock absorber stepping motor (right)
2-38
CABLE ROUTING
Frame rear (top view)
1 A B 2 A 3 A 1
A A
6 5
2 3
D
A
2-39
CABLE ROUTING
1. Wire harness
2. O2 sensor lead
4. Rear light coupler (optional)
5. Tail/brake light lead (right)
6. Tail/brake light lead (left)
B. Fasten the tail/brake light lead (left) and O2 sensor
lead with the plastic band.
D. Fasten the final drive assembly breather hose with
the holder.
E. Fasten the wire harness with the plastic band.
Face the end of the plastic band inward.
2-40
CABLE ROUTING
Frame rear (top view) (YXF10WRLN)
1 1
2
1 2 1
2-41
CABLE ROUTING

2. O2 sensor lead
A. Blue tape
2-42
CABLE ROUTING
Electrical components tray (top view)

33 35 H 37
35 I
4
4
H 36 35
3 4
H
34 35
F 4
15 35
A
G 37
32 33
1
36
E 33 4 15 5 6
1
4
2 3
31
30
29
28
7
27
8
26
25
24
23
22 9
21
20
D 10
33
20 19
C 18 17 15 14 13 12 11
35
16 B 9
19
1 15
P 2 10
2 38 J
1
C 19 20
M
20 19 33 L
O
4
17 9 10
33 P 37
K
N 36 35
18 H
35
2-43
CABLE ROUTING
1. Winch power lead 1 (red) (YXF10WRZN/ H. Fasten the wire harness with the plastic band.
YXF10WRLN) I. Fasten the EPS torque sensor lead and EPS motor
2. Winch power lead 2 (black) (YXF10WRZN/ lead with the plastic band. Fasten the each leads at
YXF10WRLN) the positioning tape with the plastic band.
3. Negative battery lead J. Fasten the auxiliary light lead (left) and headlight
4. Wire harness lead (left) at the white tape on each lead with the
5. ECU lead 1 plastic band.
6. ECU lead 2 K. Fasten the EPS torque sensor lead, EPS motor
lead, auxiliary light lead (left), and headlight lead
7. EPS motor coupler (2pin)
(left) with the plastic band.
8. EPS torque sensor coupler (4pin)
L. Fasten the winch power lead 1 (red)
9. Auxiliary light lead (left) (YXF10WRZN/YXF10WRLN), winch power lead 2
10. Headlight lead (left) (black) (YXF10WRZN/YXF10WRLN), headlight
11. Lean angle sensor coupler lead (right), auxiliary light lead (right), sub-wire
12. EPS control unit coupler harness (winch) (YXF10WRZN/YXF10WRLN),
and EPS control unit lead with the plastic band.
13. EPS control unit
M. Blue
14. Sub-wire harness coupler (winch) (2pin)
(YXF10WRZN/YXF10WRLN) N. Yellow
15. Sub-wire harness (winch) (YXF10WRZN/ O. Red
YXF10WRLN) P. Fasten the auxiliary light lead (right) and headlight
16. Terminal cover lead (right) at the white tape on each lead with the
plastic band.
YXF10WRLN)
YXF10WRLN)
19. Headlight lead (right)
20. Auxiliary light lead (right)
22. Fuse box 1
23. Fuse box 2
24. Diode (winch) (YXF10WRZN/YXF10WRLN)
25. Load control relay
26. Accessory relay
27. Starter relay lead
28. Radiator fan motor relay
29. Main relay
30. EPS fuse
31. Main fuse
32. Positive battery lead
33. Electrical components tray (right)
35. Electrical components tray (left)
36. EPS torque sensor lead
37. EPS motor lead
38. EPS control unit lead
A. Fasten the EPS torque sensor lead and EPS motor
lead with the plastic band.
B. Install the coupler cover completely till contact with
the winch power leads. (YXF10WRZN/
YXF10WRLN)
C. Black
D. Green
E. Fasten the positive battery lead with the plastic
band.
F. Fasten the wire harness, negative battery lead,
starter motor lead, and sub-wire harness (winch)
(YXF10WRZN/YXF10WRLN) with the plastic
band.
G. Fasten the wire harness and sub-wire harness
(winch) (YXF10WRZN/YXF10WRLN) with the
plastic band.
2-44
CABLE ROUTING
Electrical components tray (top view) (YXF10WRZN/YXF10WRLN)
4 17 D 5 6
9 5
8 9
18 7
1 4 6 13 14
10
19 11 2 E
3 9
12
1 A 2
C
15
16
19 21
22 20
9 3
3 23
9 7
2-45
CABLE ROUTING

2. Antenna lead
3. Sub-wire harness (SCU) (YXF10WRLN)
4. Sub-wire harness (front speaker)
5. Suspension mode switch lead
6. Sub-wire harness (audio pilot unit power supply)
7. EPS control unit lead
8. Winch switch lead
9. Wire harness
11. USB jack lead
12. Auxiliary DC jack lead
13. AUX input socket lead
14. Audio control panel lead
15. Audio pilot unit
16. SCU (Suspension Control Unit) (YXF10WRLN)
17. Antenna
19. Sub-wire harness (winch)
20. Winch power lead 1 (red)
21. Winch power lead 2 (black)
22. Winch power lead 3 (blue)
23. Winch power lead 4 (yellow)
A. Connect the sub-wire harness coupler (rear
speaker) with the sub-wire harness coupler (front
speaker).
B. Connect the sub-wire harness coupler (front
speaker), sub-wire harness coupler (rear speaker),
antenna connector, sub-wire harness coupler
(audio pilot unit power supply), AUX input socket
coupler, and audio control panel connector with the
audio pilot unit couplers.
C. Connect the sub-wire harness coupler (SCU)
(YXF10WRLN) with the wire harness coupler.
D. Route the antenna as shown in the illustration.
E. Route the antenna lead uppermost.
2-46
CABLE ROUTING
Electrical components tray (front view)

ECB03980
NOTICE
• This model is equipped with connectors for genuine accessories.
• If genuine accessories are not installed, do not remove the protective caps.
• Do not exceed the accessory coupler maximum current draw specified below.
Maximum current draw (single

accessory coupler)
7.0 A
Maximum current draw (total of
all accessory couplers)
20.0 A (YXF10WRAN)
16.5 A (YXF10WRZN/
YXF10WRLN)
3 5 4 2
6
1. Accessory coupler
2. Rear light switch coupler
3. Sub-wire harness coupler (winch)
4. Winch switch coupler (YXF10WRZN/
YXF10WRLN)
5. GPS coupler (YXF10WRZN/YXF10WRLN)
6. Sub-wire harness coupler (GPS)
2-47
CABLE ROUTING
2-48
CABLE ROUTING
Fuel tank (top view)
1 A 2 3 4
B
C
B
B D
B
1
B
6
2-49
CABLE ROUTING
1. Fuel hose
2. Fuel tank breather hose (fuel tank to rollover valve)
5. Fuel tank pressure control valve
6. Rollover valve
A. Fasten the canister purge hose (3-way joint to
canister) with the holder.
B. 0–3 mm (0–0.12 in)
C. Forward
D. Route the fuel tank breather hose (fuel tank to
rollover valve) through the guides (three locations)
on the front floor board (right).
E. 0–1.5mm (0–0.06 in)
F. Fasten the fuel hose with the holder.
2-50
CABLE ROUTING
Canister (side view)
3
2
8 F
C 4
10
2
1
5 4
G
11
D C
3 6
4 C
4 E C
C
6 7 9
12
J 14
H
I 13
A B
11
K
12
2-51
CABLE ROUTING
1. Purge cut valve solenoid

2. Canister purge hose (3-way joint to purge cut valve
solenoid)
3. Wire harness
5. Air intake accumulator case
6. Fuel hose
7. Oil tank outlet pipe 2
11. Canister
12. Canister breather hose (canister to 3-way joint)
13. Canister breather hose (3-way joint to one-way
valve)
14. One-way valve
A. Route the canister breather hose (3-way joint to
frame) to the inside of the frame bracket.
B. Insert the end of the canister breather hose (3-way
joint to frame) into the hole in the frame. Insert the
hose until the white paint mark on the hose
reaches the hole in the frame.
C. 0–3 mm (0–0.12 in)
D. Fasten the canister purge hose (3-way joint to
canister) and wire harness with the holder.
E. Fasten the oil tank outlet pipe 2 with the plastic
band, and then install the fuel hose and canister
purge hose (3-way joint to canister).
F. Fasten the canister breather hose (3-way joint to
frame) and transmission case breather hose with
the holder.
G. Fasten the canister breather hose (3-way joint to
frame) and transmission case breather hose with
the holder.
H. Fasten the canister breather hose (3-way joint to
one-way valve) at the white paint mark with the
holder.
I. Fasten the canister breather hose (3-way joint to
one-way valve) with the holder.
J. Install the one-way valve as shown in the
illustration.
K. Install the canister breather hose (canister to 3-
way joint) to the canister so that it is aligned with
the end of the indentation in the canister as shown
in the illustration.
2-52
CABLE ROUTING
Front brake caliper (left view)
1 2
3
3
A
2-53
CABLE ROUTING
1. Rear brake pipe

2. Front brake pipe
3. Front brake hose
A. When installing the brake hose onto the front brake
caliper, fit the projection on the brake hose into the
hole in the brake caliper.
2-54
CABLE ROUTING
Rear brake caliper (left view)
3 4
A 2 A
2
A
A 2 3
B
2 2
2-55
CABLE ROUTING
1. Rear brake pipe

2. Rear brake hose
3. Rear brake hose protector
4. Frame
A. Fasten the rear brake hose with the holder.
B. Face the paint mark forward.
C. When installing the rear brake hose onto the rear
brake caliper, make sure that the projection on the
brake hose contacts the rib on the brake caliper.
2-56
CABLE ROUTING
Front brake caliper (top view)
A 1 B C
1 2
D C
2-57
CABLE ROUTING
1. Front brake pipe

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

2. Rear brake hose
3. Frame
A. Fasten the rear brake pipe with the holder.
B. Fasten the rear brake hose with the holder.
C. Fasten the grommet on the rear brake hose with
the holder.
2-60
CABLE ROUTING
Cooling system front (left view)

A
B
1
2
3
A 4 5
B D
6
4
6
E 7
F 8
2-61
CABLE ROUTING
1. Radiator outlet hose

2. Frame
3. Radiator inlet hose
4. Radiator inlet pipe
5. Oil outlet pipe/hose 2
6. Oil inlet pipe/hose 2
7. Oil cooler outlet hose
8. Oil cooler inlet hose
A. 3–5 mm (0.12–0.20 in)
B. 0–1 mm (0–0.04 in)
C. Face the white paint mark on the radiator inlet
hose to the left.
D. Pass the oil inlet pipe/hose 2 and oil outlet pipe/
hose 2 through the guide.
E. Fasten the oil cooler outlet hose with the plastic
band. Position the end of the plastic band outward.
F. Fasten the oil cooler inlet hose with the plastic
band. Position the end of the plastic band outward.
2-62
CABLE ROUTING
Cooling system front (top view)
2 C A
A 1 B
7 A 6 5
4 3 D A
3 F 8
2-63
CABLE ROUTING

2. Radiator outlet pipe
4. Frame
A. Point the ends of the hose clamp upward.
B. Fasten the radiator outlet hose with the plastic
band. Be sure to install the plastic band around the
hose protector of the radiator outlet hose, not the
hose itself.
C. Fasten the radiator outlet pipe with the holder.
Make sure that the marks on the pipe are
positioned on both sides of the holder as shown in
the illustration.
D. Fasten the radiator inlet pipe with the holder. Make
sure that the marks on the pipe are positioned on
both sides of the holder as shown in the illustration.
E. Face the white paint mark on the radiator outlet
hose to the right.
F. Align the edge of the hose clamp with the center of
the white paint mark on the thermostat outlet hose.
2-64
CABLE ROUTING
Cooling system (rear view)

D
E F
G
1 A 2 3
10
C 8 9 10 B 7 6
E
D
H
10
2-65
CABLE ROUTING

3. Water pump outlet hose
5. Oil tank inlet hose
A. Fasten the water pump inlet hose with the plastic
band.
B. Secure each plastic band by inserting the
projection on the band into the hole in the drive belt
case, and then fasten the thermostat outlet hose
with the band.
C. Secure the plastic band by inserting the projection
on the band into the hole in the engine mounting
bracket, and then fasten the thermostat outlet hose
with the band.
D. 3–5 mm (0.12–0.20 in)
E. 0–1 mm (0–0.04 in)
F. Align the edge of the hose clamp with the center of
the white paint mark on the thermostat outlet hose.
G. 45°
H. Point the ends of the hose clamp upward.
2-66
CABLE ROUTING
Cooling system (engine)
A 3
C
2-67
CABLE ROUTING

2. Water pump housing cover
3. Water jacket joint
A. 3 mm (0.12 in) or more
B. Install the water pump outlet hose onto the hose
fitting of the water pump housing cover until the
end of the hose contacts the projection on the hose
fitting. Align the paint mark on the hose with the
projection on the hose fitting. The screwhead of the
screw clamp may be facing in any direction.
C. Install the water pump outlet hose onto the hose
fitting of the water jacket joint until the end of the
hose contacts the projection on the hose fitting.
Align the white paint mark on the hose with the
projection on the hose fitting.
D. Position the clamp screw within the range shown in
the illustration.
2-68
CABLE ROUTING
Purge control system
A
2 B
C 3 B
1 2
2-69
CABLE ROUTING
1. Purge cut valve solenoid

2. Canister purge hose 1 (purge cut valve to throttle
body)
3. Canister purge hose 2 (purge cut valve to throttle
body)
4. Cylinder head breather hose
A. Forward
B. Install the canister purge hoses completely onto
the purge cut valve solenoids.
C. Make sure that the paint marks are facing in the
direction shown in the illustration.
2-70
CABLE ROUTING
Engine oil tank
E
C
F
8 9
6 G
10 1 H
6 7 D 1
A
7
6
2
4 A 3 B
2-71
CABLE ROUTING
1. Engine oil tank breather hose

2. Engine oil tank
4. Oil tank outlet hose 1
8. Air intake accumulator case
9. Crankcase
10. V-belt cooling exhaust duct
A. The ends of the hose clamp may be pointing in any
direction.
B. Install oil tank outlet pipe 1 to the engine oil tank so
that it is pointing in the direction shown in the
illustration.
C. Align the edge of the hose clamp with the center of
the blue paint mark on the engine oil tank breather
hose. Face the blue paint mark on the engine oil
tank breather hose upward.
D. Align the edge of the hose clamp with the center of
the white paint mark on the engine oil tank
breather hose.
E. Align the projection on the air intake accumulator
case with the white paint mark on the engine oil
tank breather hose.
F. Position the ends of the hose clamp is 10 mm
(0.39 in) or more from the V-belt cooling exhaust
duct.
G. Fasten the oil tank inlet hose with the holder by
inserting the projection on the holder into the hole
in the stay of the oil tank outlet pipe 2.
H. Make sure that the engine oil tank breather hose
are routed to the hook-shaped part of the V-belt
cooling exhaust duct.
2-72
CABLE ROUTING
2-73
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 .................................... 3-1
CHECKING THE FUEL LINE .................................................................... 3-4
ADJUSTING THE VALVE CLEARANCE .................................................. 3-4
CHECKING THE SPARK PLUGS ............................................................. 3-7
CHECKING THE BREATHER HOSE........................................................ 3-7
SYNCHRONIZING THE THROTTLE BODIES.......................................... 3-8
CHECKING THE EXHAUST SYSTEM...................................................... 3-9
CHECKING THE CANISTER ..................................................................3-10
CLEANING THE SPARK ARRESTER ....................................................3-11
CHECKING THE AIR INDUCTION SYSTEM..........................................3-12
CHECKING THE COOLING SYSTEM ....................................................3-12
3
CHECKING THE COOLANT LEVEL .......................................................3-13
CHANGING THE COOLANT...................................................................3-13
CLEANING THE AIR FILTER ELEMENT................................................3-15
CHECKING THE ENGINE OIL LEVEL....................................................3-17
CHANGING THE ENGINE OIL ...............................................................3-18
CHECKING THE ENGINE OIL PRESSURE ........................................... 3-19
CHECKING THE TRANSMISSION OIL LEVEL ......................................3-20
CHANGING THE TRANSMISSION OIL ..................................................3-21
CHECKING THE FINAL GEAR OIL LEVEL ............................................3-21
CHANGING THE FINAL GEAR OIL ........................................................ 3-22
CHECKING THE DIFFERENTIAL GEAR OIL LEVEL.............................3-22
CHANGING THE DIFFERENTIAL GEAR OIL ........................................3-23
CHECKING THE FRONT BRAKE PADS ................................................3-23
CHECKING THE REAR BRAKE PADS ..................................................3-23
CHECKING THE PARKING BRAKE .......................................................3-24
CHECKING THE BRAKE FLUID LEVEL.................................................3-24
BLEEDING THE HYDRAULIC BRAKE SYSTEM ...................................3-25
CHECKING THE BRAKE HOSES AND BRAKE PIPES .........................3-26
ADJUSTING THE BRAKE PEDAL ..........................................................3-27
ADJUSTING THE ACCELERATOR PEDAL FREE PLAY ......................3-27
CHECKING THE V-BELT ........................................................................3-28
REPLACING THE V-BELT ......................................................................3-29
LUBRICATING THE PRIMARY SHEAVE SPACER ...............................3-30
CHECKING THE WHEELS .....................................................................3-30
CHECKING THE TIRES .......................................................................... 3-31
CHECKING THE SHOCK ABSORBER ASSEMBLIES ...........................3-32
ADJUSTING THE SHOCK ABSORBER ASSEMBLIES .........................3-32
CHECKING THE STEERING SYSTEM ..................................................3-34
ADJUSTING THE TOE-IN .......................................................................3-35
CHECKING THE STABILIZER BUSHING ..............................................3-36
LUBRICATING THE REAR KNUCKLE PIVOTS .....................................3-36
CHECKING THE ENGINE MOUNT ........................................................ 3-36
CHECKING THE CONSTANT VELOCITY SHAFT ASSEMBLY DUST
BOOTS ...................................................................................................3-36
CHECKING THE FASTENER ................................................................. 3-36
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

Even if the vehicle isn’t driven for the stated mileage or engine hours, the month maintenance intervals
should still 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) 240 1300 2500 2500 5000
(150) (800) (1600) (1600) (3200)
hours 15 80 160 160 320
1 * Fuel line • Check fuel hose for cracks or damage. √ √ √

• Replace if necessary.
2 * Valves • Check valve clearance and adjust if necessary. Every 5000 km (3200 mi).
• 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.
Evaporative emis- • Check control system for damage.
7 * sion control system • Replace if necessary. √ √ √
• Check the air cut-off valve, reed valve, and hose for
8 * Air induction system damage. √ √ √
• Check condition and clean or replace if necessary.
9 Spark arrester • Clean. √ √ √
EBS30835
GENERAL MAINTENANCE AND LUBRICATION

Even if the vehicle isn’t driven for the stated mileage or engine hours, the month maintenance intervals
should still 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
comes first km (mi) 240 1300 2500 2500 5000
(150) (800) (1600) (1600) (3200)
hours 15 80 160 160 320
• Check coolant leakage.

√ √ √ √ √
1 * Cooling system • Repair if necessary.
• Change coolant. Every 2 years
3-1
INITIAL EVERY
month 1 3 6 6 12
comes first km (mi) 240 1300 2500 2500 5000
(150) (800) (1600) (1600) (3200)
hours 15 80 160 160 320
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 (1200–3200 mi)
• Replace.
(paper) (more often in wet or dusty conditions)
3 Engine oil • Change (warm engine before draining). √ √ √ √
Engine oil filter car-
4 • Replace. √ √ √
tridge
• Check oil level and for leakage. √ √ √ √ √
5 Transmission oil
• Change. √ √ √
• Check oil level. √ √ √ √ √
6 Final gear oil
• Change. √ √
• Check oil level. √ √ √ √ √
7 Differential gear oil
• Change. √ √
• Check operation/brake pad wear/fluid leakage.
8 * Front brake • Correct if necessary. Replace pads if worn to the lim- √ √ √ √ √
it.
• Check operation/brake pad wear/fluid leakage.
9 * Rear brake • Correct if necessary. Replace pads if worn to the lim- √ √ √ √ √
it.
• Check operation and free play/brake pad wear.
10 * Parking brake • Correct if necessary. Replace pads if worn to the lim- √ √ √ √ √
it.
11 * Brake fluid • Change. Every 2 years
12 * Accelerator pedal • Check operation and free play. √ √ √ √ √
13 * V-belt • Check operation. √ √ √ √

• Check for wear, cracks, or damage.
• Clean and lubricate with polyurea grease.
Primary sheave spac-
14 * er • Check for wear, cracks, or damage and replace if √ √ √
necessary.
• Check balance, runout and for damage.
15 * Wheels • Replace if necessary. √ √ √ √
16 * Wheel bearings • Check bearing assemblies for looseness/damage. √ √ √ √

• Replace if damaged.
17 * Front and rear sus- • Check operation and for oil leakage. √ √
pension • Correct if necessary.
• Check operation and for looseness. Replace if dam-
18 * Steering system aged. √ √ √ √ √
• Check toe-in. Adjust if necessary.
• Check for cracks or other damage, and replace if nec-
19 * Stabilizer bushes essary. √ √ √
20 * Rear knuckle upper • Lubricate with lithium-soap-based grease. √ √ √

and lower pivots
• Check for cracks or damage.
21 * Engine mounts √ √ √
• Check bolt tightness.
Front and rear axle • Check for cracks or other damage, and replace if nec-
22 * √ √
boots essary.
• Check all chassis fittings and fasteners.
23 * Fittings and fasteners • Correct if necessary. √ √ √ √ √
3-2
TIP
• Some maintenance items need more frequent service if you drive in unusually wet, dusty, sandy or
muddy areas, or at full throttle.
• Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the calipers, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
• Transmission service
• Have the V-belt inspected regularly.
• Replace when worn or sooner if damaged.
3-3
EBS30027
• When the valve clearance is to be measured or
CHECKING THE FUEL LINE
adjusted, the piston must be at top dead center
1. Remove:
(TDC) on the compression stroke.
• Rear door latch striker (right)
Refer to “GENERAL CHASSIS (1)” on page 1. Remove:
4-1. • Ignition coil
• Driver seat frame • Spark plug
• Front passenger seat frame • Cylinder head cover
Refer to “GENERAL CHASSIS (2)” on page Refer to “CAMSHAFTS” on page 5-23.
ECB03070
4-7.
NOTICE
• Center cover
Refer to “GENERAL CHASSIS (5)” on page Before removing the spark plugs, blow away
4-16. any dirt accumulated in the spark plug wells
• Rear floor board (right) with compressed air to prevent it from falling
Refer to “GENERAL CHASSIS (7)” on page into the cylinders.
4-25. 2. Remove:
2. Check: • Crankshaft end accessing screw
• Fuel hose “1” • Timing mark accessing screw
Cracks/damage → Replace. Refer to “CAMSHAFTS” on page 5-23.
Loose connection → Connect properly. 3. Measure:
• Valve clearance
Out of specification → Adjust.
Valve clearance (cold)

Intake
1 0.11–0.20 mm (0.0043–0.0079 in)
Exhaust
0.24–0.30 mm (0.0094–0.0118 in)
a. Turn the crankshaft counterclockwise.

b. When piston #1 is at TDC on the compres-
3. Install:
sion stroke, align the TDC mark “a” (“H”
• Rear floor board (right)
side) on the AC magneto rotor with the slot
Refer to “GENERAL CHASSIS (7)” on page
“b” in the AC magneto cover.
4-25.
• Center cover b a
4-16.
• Front passenger seat frame
• Driver seat frame
4-7.
4-1.
TIP
EBS30028
When the piston is at TDC on the compression
ADJUSTING THE VALVE CLEARANCE
stroke, the camshaft lobes “a” are positioned as
The following procedure applies to all of the
shown in the illustration. If the camshaft lobes
valves.
are not positioned as shown in the illustration,
TIP turn the crankshaft an additional 360° counter-
• Valve clearance adjustment should be made clockwise to position the piston at TDC on the
on a cold engine, at room temperature. compression stroke.
3-4
4. Remove:
a • Camshaft
Refer to “CAMSHAFTS” on page 5-23.
5. Adjust:
• Valve clearance
a. Remove the valve lifter and the valve pad
with a valve lapper.
Valve lapper (ø14)

90890-04101
c. Measure the valve clearance with a thick- Valve lapper (ø14)
YM-A8998
ness gauge.
Thickness gauge TIP

90890-03268 • Cover the timing chain opening with a rag to
Feeler gauge set prevent the valve pad from falling into the
YU-26900-9 crankcase.
• Make a note of the position of each valve lifter
TIP and valve pad so that they can be installed in
• If the valve clearance is incorrect, record the the correct place.
measured reading.
b. Calculate the difference between the
• Measure the valve clearance in the following
specified valve clearance and the mea-
sequence.
sured valve clearance.
Example:
Valve clearance measuring sequence Specified valve clearance = 0.11–0.20
Cylinder #1 → #2 mm (0.0043–0.0079 in)
Measured valve clearance = 0.32 mm
(0.0126 in)
#2 #1
0.32 mm (0.0126 in)–0.16 mm (0.0063 in)
= 0.16 mm (0.0063 in)
c. Check the thickness of the current valve
pad, and then calculate the sum of the val-
ues obtained to determine the required
valve pad thickness and the valve pad
number.
A TIP
• The number “a” marked on the valve pad indi-
A. Front
cate the valve pad thickness.
• Refer to the following table for the available
valve pads.
• If there are no available valve pads with the
same thickness as the calculated valve pad
thickness, select the next thickest valve pad.
B. Degrees that the crankshaft is turned

counterclockwise.
C. Cylinder
D. Combustion cycle
3-5
Number “a” Thickness

195 1.950 mm (0.07677 in)
a
196 1.962 mm (0.07724 in)
198 1.975 mm (0.07776 in)
199 1.987 mm (0.07823 in)
200 2.000 mm (0.07874 in)
201 2.012 mm (0.07921 in)
G101581
202 2.025 mm (0.07972 in)
Number “a” Thickness 204 2.037 mm (0.08020 in)
150 1.500 mm (0.05906 in) 205 2.050 mm (0.08071 in)
152 1.525 mm (0.06004 in) 206 2.062 mm (0.08118 in)
155 1.550 mm (0.06102 in) 208 2.075 mm (0.08169 in)
156 1.562 mm (0.06150 in) 209 2.087 mm (0.08217 in)
158 1.575 mm (0.06201 in) 210 2.100 mm (0.08268 in)
159 1.587 mm (0.06248 in) 211 2.112 mm (0.08315 in)
160 1.600 mm (0.06299 in) 212 2.125 mm (0.08366 in)
161 1.612 mm (0.06346 in) 214 2.137 mm (0.08413 in)
162 1.625 mm (0.06398 in) 215 2.150 mm (0.08465 in)
164 1.637 mm (0.06445 in) 216 2.162 mm (0.08512 in)
165 1.650 mm (0.06496 in) 218 2.175 mm (0.08563 in)
166 1.662 mm (0.06543 in) 219 2.187 mm (0.08610 in)
168 1.675 mm (0.06594 in) 220 2.200 mm (0.08661 in)
169 1.687 mm (0.06642 in) 222 2.225 mm (0.08760 in)
170 1.700 mm (0.06693 in) 225 2.250 mm (0.08858 in)
171 1.712 mm (0.06740 in) 228 2.275 mm (0.08957 in)
172 1.725 mm (0.06791 in) 230 2.300 mm (0.09055 in)
174 1.737 mm (0.06839 in) 232 2.325 mm (0.09154 in)
175 1.750 mm (0.06890 in) 235 2.350 mm (0.09252 in)
176 1.762 mm (0.06937 in) 238 2.375 mm (0.09350 in)
178 1.775 mm (0.06988 in) 240 2.400 mm (0.09449 in)
179 1.787 mm (0.07035 in) Example:
180 1.800 mm (0.07087 in) 1.575 mm (0.06201 in) + 0.160 mm
181 1.812 mm (0.07134 in) (0.00630 in) = 1.735 mm (0.06831 in)
The valve pad number is 174.
182 1.825 mm (0.07185 in)
d. Install a new valve pad “1” and the valve
184 1.837 mm (0.07232 in) lifter “2”.
185 1.850 mm (0.07283 in) TIP
186 1.862 mm (0.07331 in) • Lubricate the valve pad with molybdenum di-
188 1.875 mm (0.07382 in) sulfide oil.
189 1.887 mm (0.07429 in)
• Lubricate the valve lifter (top) with molybde-
num disulfide oil.
190 1.900 mm (0.07480 in) • Lubricate the valve lifter (side) with engine oil.
191 1.912 mm (0.07528 in) • Install the valve lifter and the valve pad in the
192 1.925 mm (0.07579 in) correct place.
194 1.937 mm (0.07626 in)
3-6
• The valve lifter must turn smoothly when rotat- Normal color is medium-to-light tan.
ed by hand. 4. Clean:
• Spark plug
e. Install the exhaust and intake camshafts,
(with a spark plug cleaner or wire brush)
timing chain and camshaft cap.
5. Measure:
Camshaft cap bolt • Spark plug gap “a”
10 N·m (1.0 kgf·m, 7.4 lb·ft) (with a wire thickness gauge)
T.
Out of specification → Regap.

R.
TIP
Spark plug gap
• Refer to “CAMSHAFTS” on page 5-23. 0.7–0.8 mm (0.028–0.031 in)
• Lubricate the camshaft lobes and camshaft
journals with molybdenum disulfide oil.
• Turn the crankshaft counterclockwise several
full turns to seat the parts.
f. Measure the valve clearance again.
g. If the valve clearance is still out of specifi-
cation, repeat all of the valve clearance
adjustment steps until the specified clear-
ance is obtained.
6. Install: G101421
• Timing mark accessing screw
• Crankshaft end accessing screw 6. Install:
• Cylinder head cover • Spark plug
• Spark plug • Ignition coil
• Ignition coil
Spark plug
Refer to “CAMSHAFTS” on page 5-23. 13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
EBS30029
CHECKING THE SPARK PLUGS TIP

The following procedure applies to all of the Before installing the spark plug, clean the spark
spark plugs. plug and gasket surface.
1. Remove:
• Ignition coil EBS30030
• Spark plug CHECKING THE BREATHER HOSE

Refer to “CAMSHAFTS” on page 5-23. 1. Remove:
ECB03070
NOTICE
Before removing the spark plugs, blow away Refer to “GENERAL CHASSIS (2)” on page
any dirt accumulated in the spark plug wells 4-7.
with compressed air to prevent it from falling • Center cover
into the cylinders. Refer to “GENERAL CHASSIS (5)” on page
2. Check: 4-16.
• Spark plug type 2. Check:
Incorrect → Change. • Engine oil tank breather hose “1”
• Cylinder head breather hose “2”
Manufacturer/model Cracks/damage → Replace.
NGK/LMAR8GI-8 Loose connection → Connect properly.
ECB01680
3. Check: NOTICE
• Electrodes “1” Make sure the cylinder head breather hose is
Damage/wear → Replace the spark plug. routed correctly.
• Insulator “2”
Abnormal color → Replace the spark plug.
3-7
• Intake air pressure sensor hose

Refer to “THROTTLE BODIES” on page
7-11.
3. Install:
1 • Vacuum gauge “1”
• Vacuum gauge hose #1 “2”
• Vacuum gauge hose #2 “3”
Vacuum gauge
90890-03094
Vacuummate
YU-44456
2 3
1 2
3. Install:
• Center cover
4. Check:
• Throttle body synchronization
4-16.
a. Start the engine, warm it up for several
minutes, and then let it run at the specified
engine idling speed.
4-7. Engine idling speed
EBS30617
1250–1350 r/min
SYNCHRONIZING THE THROTTLE BODIES
TIP Yamaha diagnostic tool USB (US)
Before synchronizing the throttle bodies, check 90890-03269
the following items: Yamaha diagnostic tool (A/I)
• Valve clearance 90890-03264
• Spark plugs
• Primary air filter element TIP
• Secondary air filter element Use the “Monitoring” function of the Yamaha di-
• Throttle body joints agnostic tool to check the engine idling speed.
• Fuel hose For information about using the Yamaha diag-
• Exhaust system nostic tool, refer to the operation manual that is
• Breather hoses included with the tool.
• Canister purge hoses
b. Check the vacuum pressure.
Checking the throttle body synchronization Difference in vacuum pressure

1. Remove: between the cylinders
• Rear cover 0 kPa–1.3 kPa (0 mmHg–10
Refer to “GENERAL CHASSIS (5)” on page mmHg, 0 inHg–0.4 inHg)
4-16.
If out of specification → Adjust the throttle
2. Remove:
body synchronization.
• Cap
3-8
Adjusting the throttle body synchronization • Cap

1. Adjust: Refer to “THROTTLE BODIES” on page
• Throttle body synchronization 7-11.
a. Start the engine, warm it up for several 4. Install:
minutes, and then let it run at the specified • Rear cover
engine idling speed. Refer to “GENERAL CHASSIS (5)” on page
4-16.
Engine idling speed 5. Adjust:
1250–1350 r/min • Accelerator pedal free play
Refer to “ADJUSTING THE ACCELERATOR
Yamaha diagnostic tool USB (US) PEDAL FREE PLAY” on page 3-27.
90890-03269
Yamaha diagnostic tool (A/I) Accelerator pedal free play
90890-03264 10.0–15.0 mm (0.39–0.59 in)
EBS30031
TIP CHECKING THE EXHAUST SYSTEM
Use the “Monitoring” function of the Yamaha di- 1. Remove:
agnostic tool to check the engine idling speed. • Rear door latch striker (left and right)
For information about using the Yamaha diag- Refer to “GENERAL CHASSIS (1)” on page
nostic tool, refer to the operation manual that is 4-1.
included with the tool. • Driver seat frame
b. Using the throttle body that has the bypass • Passenger seat frame
air screws “1” with the white paint mark as Refer to “GENERAL CHASSIS (2)” on page
the standard, adjust the other throttle body 4-7.
by turning its bypass air screw in or out. • Rear passenger seat belt (left and right)
• Rear passenger seat belt buckle (left and
TIP
right)
• After each step, rev the engine two or three Refer to “GENERAL CHASSIS (3)” on page
times, each time for less than a second, and 4-12.
check the synchronization again. • Center cover
• If a bypass air screw was removed, turn the Refer to “GENERAL CHASSIS (5)” on page
screw in fully and be sure to synchronize the 4-16.
throttle bodies. • Rear floor board (left and right)
• If the throttle body synchronization can not be Refer to “GENERAL CHASSIS (7)” on page
adjusted using the bypass air screw, clean or 4-25.
replace the throttle bodies. • Rear fender (left and right)
• The difference in vacuum pressure between • Cargo bed
the throttle bodies should not exceed 1.3 kPa Refer to “GENERAL CHASSIS (15)” on page
(10 mmHg, 0.4 inHg). 4-47.
• Cargo bed heat protector plate
1 Refer to “ENGINE REMOVAL (1)” on page
5-7.
2. Check:
• Exhaust pipe 1 “1”
• Exhaust pipe 2 “2”
• Muffler “3”
• Spring “4”
Cracks/damage → Replace.
• Gasket “5”
2. Stop the engine and remove the measuring Exhaust gas leaks → Replace.
equipment. 3. Check:
3. Install: Tightening torque
• Intake air pressure sensor hose • Exhaust pipe bolt “6”
3-9
• Exhaust pipe nut “7” • Rear door latch striker (left and right)
• Muffler bolt “8” Refer to “GENERAL CHASSIS (1)” on page
4-1.
Exhaust pipe bolt
26 N·m (2.6 kgf·m, 19 lb·ft) EBS30830
T.
CHECKING THE CANISTER

R.
Exhaust pipe nut

20 N·m (2.0 kgf·m, 15 lb·ft) 1. Remove:
Muffler bolt • Front over fender (right)
23 N·m (2.3 kgf·m, 17 lb·ft) • Front door (right)
6 4-1.
4 7 • Front passenger seat frame
5 Refer to “GENERAL CHASSIS (2)” on page
1 4-7.
• Center cover
4 4-16.
• Dashboard (right)
4-17.
• Front floor board (right)
5 4-25.
8 2. Check:
• Canister purge hose (throttle body to purge
cut valve solenoid) “1”
3 • Canister purge hose (purge cut valve sole-
noid to 3-way joint) “2”
4. Install: • Canister purge hose (3-way joint to canister)
• Cargo bed heat protector plate “3”
Refer to “ENGINE REMOVAL (1)” on page • Canister “4”
5-7. • Fuel tank breather hose (fuel tank to rollover
• Cargo bed valve) “5”
• Rear fender (left and right) • Fuel tank breather hose (rollover valve to 3-
Refer to “GENERAL CHASSIS (15)” on page way joint) “6”
4-47. • Fuel tank breather hose (3-way joint to fuel
• Rear floor board (left and right) tank pressure control valve) “7”
Refer to “GENERAL CHASSIS (7)” on page • Fuel tank breather hose (3-way joint to canis-
4-25. ter) “8”
• Center cover • Canister breather hose (canister to 3-way
Refer to “GENERAL CHASSIS (5)” on page joint) “9”
4-16. • Canister breather hose (3-way joint to one
• Rear passenger seat belt buckle (left and way valve) “10”
right) • Canister breather hose (3-way joint to frame)
• Rear passenger seat belt (left and right) “11”
Refer to “GENERAL CHASSIS (3)” on page Cracks/damage → Replace.
4-12.
• Passenger seat frame
4-7.
3-10
• Front door (right)

• Front over fender (right)
2
4-1.
EBS30032
CLEANING THE SPARK ARRESTER

1. Clean:
1 • Spark arrester
EWB03080
WARNING
• Select a well-ventilated area free of com-
5 6 7 3 8 11 bustible materials.
• Always let the exhaust system cool before
performing this operation.
• Do not start the engine when removing the
tailpipe from the muffler.
a. Remove the bolts “1”.
b. Remove the tailpipe “2” by pulling it out of
the muffler and gasket “3”.
1 1
10 9 4
3. Check: 3
• Purge cut valve solenoid 2
Use the diagnostic code numbers “46” and
“94”.
Refer to “DIAGNOSTIC CODE: ACTUATOR
OPERATION TABLE” on page 10-4.
4. Install:
Refer to “GENERAL CHASSIS (7)” on page c. Tap the tailpipe lightly with a soft-face
4-25. hammer or suitable tool, then use a wire
• Dashboard (right) brush to remove any carbon deposits from
Refer to “GENERAL CHASSIS (6)” on page the spark arrester portion of the tailpipe
4-17. and the inner contact surfaces of the muf-
• Center cover fler.
Refer to “GENERAL CHASSIS (5)” on page d. Install a new gasket, and then insert the
4-16. tailpipe “2” into the muffler and align the
• Driver seat frame bolt holes.
• Front passenger seat frame TIP
Refer to “GENERAL CHASSIS (2)” on page Make sure that the tailpipe is positioned at a 48°
4-7. angle as shown.
3-11
• Water pump outlet hose “12”

• Water pump housing cover “13”
1
• Water pump inlet hose “14”
Coolant leakage → Replace any damaged
hose and pipe
Refer to “RADIATOR” on page 6-7, “THER-
MOSTAT” on page 6-12, and “WATER
PUMP” on page 6-14.
48°
e. Install the bolts and tighten them. 5 10
6
Spark arrester bolt 4
10 N·m (1.0 kgf·m, 7.4 lb·ft) 2
T.
R.
7
EBS30033
3
CHECKING THE AIR INDUCTION SYSTEM
Refer to “CHECKING THE AIR INDUCTION
SYSTEM” on page 7-21. 1 9 8
EBS30034
CHECKING THE COOLING SYSTEM

1. Remove:
11
• Front over fender (left and right)
• Front door (left and right) 14
• Rear door latch striker (left and right)
12
4-1.
• Driver seat frame 13
3. Install:
4-7.
• Center cover
4-16.
4-25.
• Dashboard (left and right)
• Dashboard (left and right)
4-17.
4-17.
• Center cover
4-16.
4-25.
2. Check:
• Radiator “1”
• Coolant reservoir “2”
4-7.
• Coolant reservoir hose “3”
• Rear door latch striker (left and right)
• Coolant reservoir breather hose “4”
• Front door (left and right)
• Radiator outlet hose “5”
• Radiator outlet pipe “6”
• Thermostat outlet hose “7”
4-1.
• Radiator inlet pipe “8”
• Radiator inlet hose “9”
• Thermostat cover “10”
• Water jacket joint “11”
3-12
EBS30035 EBS30036
CHECKING THE COOLANT LEVEL CHANGING THE COOLANT

1. Place the vehicle on a level surface. 1. Remove:
TIP • Hood
The coolant level must be checked on a cold en- Refer to “GENERAL CHASSIS (4)” on page
gine since the level varies with engine tempera- 4-15.
ture. • Rear cover
2. Check: 4-16.
• Coolant level 2. Remove:
The coolant level should be between the min- • Coolant reservoir cap “1”
imum level mark “a” and maximum level mark 3. Disconnect:
“b”. • Coolant reservoir hose “2”
Below the minimum level mark → Add the
recommended coolant to the proper level.
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-
tilled water is not available, soft water may
be used.
b
a
4. Drain:
• Coolant
3. If the coolant is at or below the minimum level (from the coolant reservoir)
mark, remove the reservoir cap, add coolant 5. Connect:
or distilled water to the maximum level mark • Coolant reservoir hose
“a”, install the reservoir cap. 6. Remove:
• Radiator cap access cover
Coolant reservoir (up to the maxi- Refer to “GENERAL CHASSIS (14)” on page
mum level mark)
4-42.
0.45 L (0.48 US qt, 0.40 Imp.qt)
• Radiator cap “1”
EWB02770
WARNING
A hot radiator is under pressure. Therefore,
a do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in-
jury. When the engine has cooled, open the
radiator cap as follows:
3-13
Place a thick rag or a towel over the radiator

cap and slowly turn the radiator cap counter- Recommended antifreeze
clockwise toward the detent to allow any re- High-quality ethylene glycol an-
sidual pressure to escape. When the hissing tifreeze containing corrosion in-
hibitors for aluminum engines
sound has stopped, press down on the radi-
Mixing ratio
ator cap and turn it counterclockwise to re- 1:1 (antifreeze:water)
move. Radiator (including all routes)
4.35 L (4.60 US qt, 3.83 Imp.qt)
Coolant reservoir (up to the maxi-
mum level mark)
1 0.45 L (0.48 US qt, 0.40 Imp.qt)
Handling notes for coolant

Coolant is potentially harmful and should be
handled with special care.
EWB02780
WARNING
• If coolant splashes in your eyes, thorough-
7. Remove: ly wash them with water and consult a doc-
• Coolant drain bolt “1” tor.
(along with the copper washer) • If coolant splashes on your clothes, quickly
TIP wash it away with water and then with soap
Place a container under the drain bolt, and then and water.
remove the coolant drain bolt. • If coolant is swallowed, induce vomiting
and get immediate medical attention.
ECB01310
NOTICE
• Adding water instead of coolant dilutes the
antifreeze concentration of the coolant. If
water is used instead of coolant; check,
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However, if dis-
1 tilled water is not available, soft water may
8. Drain: be used.
• Coolant • If coolant comes into contact with painted
(from the engine and radiator) surfaces, immediately wash them with wa-
9. Install: ter.
• Coolant drain bolt • Do not mix different types of antifreeze.
(along with the copper washer New ) 11.Install:
• Radiator cap
Coolant drain bolt 12.Fill:
10 N·m (1.0 kgf·m, 7.4 lb·ft) • Coolant reservoir
T.
R.
(with the recommended coolant to the maxi-

10.Fill:
mum level mark “a”)
• Cooling system
13.Install:
(with the specified amount of the recom-
• Coolant reservoir cap
mended coolant)
3-14
• Rear cover
4-16.
a • Hood
4-15.
EBS30037
CLEANING THE AIR FILTER ELEMENT

1. Check:
• Check hoses “1”
14.Bleed:
TIP
• Cooling system
a. Loosen the thermostat cover air bleed bolt There are check hoses “1” at the bottom of the
“1”, without removing it, to allow all of the air filter case and on the air intake duct. If dust
air to escape from the air bleed bolt hole. and/or water collects in these hoses, clean the
air filter element, filter frame, and air filter case.
A
1
b. When coolant begins to flow out of the bolt 1

hole, tighten the thermostat cover air
bleed bolt to specification. B
Thermostat cover air bleed bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
15.Start the engine, warm it up for ten minutes

so that the radiator fan runs, and then rev the
engine five times.
16.Pour the recommended coolant into the radi- 1
ator until it is full.
17.Stop the engine and allow it to cool. If the A. Air filter check hose
coolant level has dropped after the engine B. Air intake duct check hose
has cooled, add sufficient coolant until it
2. Remove:
reaches the top of the radiator, and then in-
• Hood
stall the radiator cap.
18.Check:
4-15.
• Coolant level
3. Remove:
Refer to “CHECKING THE COOLANT LEV-
• Air filter case cover
EL” on page 3-13.
4. Remove:
19.Start the engine, and then check for coolant
• Primary air filter
leakage.
20.Install:
4-38.
• Radiator cap access cover
5. Disassemble:
• Air filter element lock plate “1”
4-42.
• Foam air filter element “2”
• Air filter element frame “3”
3-15
ECB01800
NOTICE
The engine should never be run without the
air filter; excessive piston and/or cylinder
wear may result.
2
G101423
1 c. Properly dispose of the used solvent.

d. Carefully wash the air filter element in
soap water.
6. Check:
• Foam air filter element
• Air filter element frame
• Air filter element lock plate
Damage → Replace.
TIP
• Replace the foam air filter element every 300– G101422
600 km (200–400 mi) of operation. e. Thoroughly rinse the air filter element with
• The air filter needs more frequent service if you water, and then let it dry.
are riding in unusually wet or dusty areas. ECB01290
NOTICE
7. Clean:
• Foam air filter element Do not twist the air filter element when
a. Carefully wash the air filter element in sol- squeezing it.
vent. f. Pour the recommended oil into a storage
EWB02760
bag large enough for the air filter element.
WARNING
Never use low flash point solvents, such as Air filter oil grade
gasoline, to clean the air filter element. Such Foam air-filter oil
solvents may cause a fire or an explosion.
g. Place the air filter element into the storage
bag and repeatedly squeeze the element
until the air filter element is saturated with
oil.
TIP
The air filter element should be wet but not drip-
ping.
G101422
b. After cleaning, squeeze the air filter ele-

ment to remove the excess solvent.
ECB01290
NOTICE
Do not twist the air filter element when
squeezing it.
G101425
3-16
8. Remove: 3. Start the engine and warm it up until the en-

• Secondary air filter element “1” gine oil has reached a normal temperature of
60 °C (140 °F), then let the engine idle for a
minimum of ten seconds before turning the
1 engine off.
TIP
To achieve the proper engine oil temperature for
an accurate oil level reading, the engine must
have first completely cooled down, and then be
warmed up again for several minutes to normal
operating temperature.
9. Check: 4. Check:
• Secondary air filter element • Engine oil level
TIP The engine oil level should be between the tip
of the dipstick “a” and maximum level mark
• Replace the secondary air filter element every
“b”.
2000–5000 km (1200–3200 mi) of operation.
Below the tip of the dipstick → Add the rec-
• The air filter needs more frequent service if you
ommended engine oil to the proper level.
are riding in unusually wet or dusty areas.
TIP
10.Install: • Before checking the engine oil level, wait a few
• Secondary air filter element minutes until the oil has settled.
• Do not screw the dipstick in when inspecting
Secondary air filter element
screw the oil level.
T.
R.
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
11.Assemble:
• Air filter element frame
• Foam air filter element
• Air filter element lock plate
12.Install:
• Primary air filter
13.Install: b
• Air filter case cover a
14.Install:
• Hood Recommended brand
Refer to “GENERAL CHASSIS (4)” on page YAMALUBE
4-15. SAE viscosity grades
0W-30, 10W-30, 10W-40
EBS30038
Recommended engine oil grade
CHECKING THE ENGINE OIL LEVEL API service SG type or higher,
1. Place the vehicle on a level surface. JASO standard MA
2. Remove:
• Rear cover 0 10 30 50 70 90 110 130 °F
4-16.
SAE 0W-30
SAE 10W-30
SAE 10W-40
–20 –10 0 10 20 30 40 50 °C
3-17
ECB03850
NOTICE
• Do not use oils with a diesel specification
of “CD” or oils of a higher quality than
specified. In addition, do not use oils la-
beled “ENERGY CONSERVING II” or high- 2
er.
• Take care not to allow foreign material en-
ters the oil tank. 1
5. Start the engine, warm it up for several min-
utes, and then turn it off. 6. Remove:
6. Check the engine oil level again. • Engine oil drain bolt (crankcase) “1”
ECB01830 (along with the gaskets “2”)
NOTICE
Be sure the engine oil is at the correct level,
otherwise engine damage may result.
TIP
Before checking the engine oil level, wait a few
minutes until the oil has settled. 2
7. Install:
• Rear cover 1
4-16. 7. Remove:
• Oil cooler drain bolt “1”
EBS30039 (along with the gaskets “2”)
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several min-
utes, and then turn it off.
2. Remove:
• Rear cover
4-16.
2
3. Place a container under the engine oil drain
bolts.
4. Remove: 1
• Dipstick “1” 8. Drain:
• Engine oil filler cap “2” • Engine oil
(completely from the oil tank, crankcase, and
oil cooler)
9. Remove:
• Rear mudguard (right)
4-25.
10.If the oil filter cartridge is also to be replaced,
perform the following procedure.
1 a. Remove the oil filter cartridge with the oil
filter wrench.
5. Remove:
• Engine oil drain bolt (oil tank) “1” Oil filter wrench
(along with the gasket “2”) 90890-01426
Oil filter wrench
YU-38411
3-18
b. Lubricate the O-ring of a new oil filter car-

tridge with a thin coat of engine oil. Oil tank
ECB03820 Quantity
NOTICE Oil change
Make sure the O-ring is positioned correctly 2.05 L (2.17 US qt, 1.80 Imp. qt)
With oil filter removal
in the groove of the oil filter cartridge.
2.05 L (2.17 US qt, 1.80 Imp. qt)
c. Tighten the new oil filter cartridge to spec- Reference data
ification with an oil filter wrench. Quantity (total *1)
Oil change
Oil filter cartridge 2.40 L (2.54 US qt, 2.11 Imp. qt)
17 N·m (1.7 kgf·m, 13 lb·ft) With oil filter removal
T.
R.
2.65 L (2.80 US qt, 2.33 Imp. qt)

11.Install:
• Engine oil drain bolt (oil tank) *1: 2.05 L + engine oil replenishment
(along with the gasket New ) amount after warming up
15.Install:
Engine oil drain bolt (oil tank) • Engine oil filler cap
9 N·m (0.9 kgf·m, 6.6 lb·ft) • Dipstick
T.
R.
16.Start the engine and warm it up to 60 °C (140

12.Install: °F), and then stop the engine, wait 10 min-
• Engine oil drain bolt (crankcase) utes.
ECB03090
(along with the gaskets New )
NOTICE
Engine oil drain bolt (crankcase) When starting the engine, make sure the dip-
20 N·m (2.0 kgf·m, 15 lb·ft) stick is securely fitted into the oil tank.
T.
R.
13.Install: 17.Remove the dipstick, and then add the rec-

• Oil cooler drain bolt ommended engine oil to raise it to the maxi-
mum level mark on the dipstick.
(along with the gaskets New )
18.Install:
Oil cooler drain bolt • Dipstick
10 N·m (1.0 kgf·m, 7.4 lb·ft) 19.Start the engine, warm it up for several min-
T.
R.
utes, and then turn it off.

14.Fill: 20.Check:
Crankcase and oil tank • Engine
a. Add the crankcase with the specified (for engine oil leaks)
amount of the recommended engine oil. 21.Check:
• Engine oil level
Crankcase Refer to “CHECKING THE ENGINE OIL
Quantity LEVEL” on page 3-17.
Oil change 22.Install:
1.50 L (1.59 US qt, 1.32 Imp.qt)
• Rear cover
With oil filter removal
1.50 L (1.59 US qt, 1.32 Imp.qt)
4-16.
b. Add the oil tank with the specified amount EBS30954
of the recommended engine oil. CHECKING THE ENGINE OIL PRESSURE

1. Check:
• Engine oil pressure
a. Slightly loosen the cylinder head cover
bolt “1”.
3-19
5. Check:
1 • Transmission oil level
The transmission oil level should be between
the minimum level mark “a” and maximum
level mark “b”. Below the minimum level mark
→ Add the recommended transmission oil to
the proper level.
b. Start the engine and keep it idling until en- 1

gine oil starts to seep from the cylinder
head cover bolt. If no engine oil comes out
after one minute, turn the engine off so
that it will not seize. b
c. Check the engine oil passages, the oil fil- a
ter cartridge and the oil pump assembly for
damage or leakage.
Refer to “OIL PAN AND OIL PUMP” on Recommended brand
page 5-55. YAMALUBE
d. Start the engine after solving the prob- Type
SAE 80W-90 API GL-5 Hypoid
lem(s) and check the engine oil pressure
gear oil
again.
e. Tighten the cylinder head cover bolt to ECB02810
specification. NOTICE
Take care not to allow foreign material to en-
Cylinder head cover bolt (for oil ter the transmission case.
pressure check)
T.
R.
10 N·m (1.0 kgf·m, 7.4 lb·ft) 6. Install:

• Transmission oil dipstick
EBS30557
TIP
CHECKING THE TRANSMISSION OIL LEVEL
1. Place the vehicle on a level surface. Install the dipstick completely into the dipstick
2. Remove: guide with the arrow mark “a” pointing outward.
• Front passenger seat cushion
4-7.
3. Pull the tab to lift up the passenger seat belt
buckle rubber cover “1”.
a
1
7. Install:
4-7.
4. Remove:
• Transmission oil dipstick “1”
3-20
EBS30618
CHANGING THE TRANSMISSION OIL Recommended brand

1. Place the vehicle on a level surface. YAMALUBE
2. Place a container under the transmission Type
case. SAE 80W-90 API GL-5 Hypoid
3. Remove: gear oil
• Front passenger seat cushion Quantity (disassembled)
Refer to “GENERAL CHASSIS (2)” on page 1.40 L (1.48 US qt, 1.23 Imp.qt)
4-7. Oil change
4. Remove: 1.40 L (1.48 US qt, 1.23 Imp.qt)
• Transmission oil dipstick “1” ECB02810
• Transmission oil drain bolt “2” NOTICE

(along with the gasket “3”) Take care not to allow foreign material to en-
Completely drain the transmission case of its ter the transmission case.
oil.
7. Check:
• Oil level
Refer to “CHECKING THE TRANSMISSION
1
OIL LEVEL” on page 3-20.
8. Install:
• Transmission oil dipstick
Refer to “CHECKING THE TRANSMISSION
OIL LEVEL” on page 3-20.
9. Install:
4-7.
EBS30040
CHECKING THE FINAL GEAR OIL LEVEL

1. Place the vehicle on a level surface.
2. Remove:
3
• Final gear oil filler bolt “1”
(along with the gasket)
2 3. Check:
• Final gear oil level
5. Install: The final gear oil level should be up to the
• Transmission oil drain bolt brim “2” of the hole.
(along with the gasket New ) Below the brim → Add the recommended fi-
nal gear oil to the proper level.
Transmission oil drain bolt
20 N·m (2.0 kgf·m, 15 lb·ft) Recommended brand
T.
YAMALUBE
R.
6. Fill: Type
• Transmission case SAE 80W-90 API GL-5 Hypoid
gear oil
mended transmission oil) ECB01690
NOTICE
Take care not to allow foreign material to en-
ter the final drive case.
3-21
1 Recommended brand
YAMALUBE
Type
gear oil
2
Quantity (disassembled)
0.45 L (0.48 US qt, 0.40 Imp.qt)
Oil change
0.40 L (0.42 US qt, 0.35 Imp.qt)
4. Install: ECB01690
• Final gear oil filler bolt NOTICE
(along with the gasket New ) Take care not to allow foreign material to en-
ter the final drive case.
Final gear oil filler bolt 6. Check:
23 N·m (2.3 kgf·m, 17 lb·ft) • Oil level
T.
R.
Refer to “CHECKING THE FINAL GEAR OIL

EBS30041
CHANGING THE FINAL GEAR OIL LEVEL” on page 3-21.

1. Place the vehicle on a level surface. EBS30042
2. Place a container under the final drive case. CHECKING THE DIFFERENTIAL GEAR OIL
3. Remove: LEVEL
• Final gear oil drain bolt “1” 1. Place the vehicle on a level surface.
(along with the gasket “2”) 2. Remove:
Completely drain the final drive case of its oil. • Differential gear oil filler bolt “1”
(along with the gasket)
2 1 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.
Recommended brand
YAMALUBE
4. Install: Type
• Final gear oil drain bolt
gear oil
(along with the gasket New )
ECB01600
Final gear oil drain bolt NOTICE

20 N·m (2.0 kgf·m, 15 lb·ft) Take care not to allow foreign material to en-
T.
R.
ter the differential case.

5. Fill:
• Final drive case
1
mended final gear oil)
3-22
4. Install: 6. Check:
• Differential gear oil filler bolt • Oil level
(along with the gasket New ) Refer to “CHECKING THE DIFFERENTIAL
GEAR OIL LEVEL” on page 3-22.
Differential gear oil filler bolt
EBS30044
23 N·m (2.3 kgf·m, 17 lb·ft) CHECKING THE FRONT BRAKE PADS
T.
R.
The following procedure applies to all of the front

EBS30043
CHANGING THE DIFFERENTIAL GEAR OIL brake pads.

1. Place the vehicle on a level surface. 1. Remove:
2. Place a container under the differential case. • Front wheel
3. Remove: Refer to “FRONT AND REAR WHEELS” on
• Differential gear oil drain bolt “1” page 4-54.
(along with the gasket “2”) 2. Operate the brake.
Completely drain the differential case of its 3. Check:
oil. • Front brake pad wear limit “a”
Out of specification → Replace the brake
pads and brake pad spring as a set.
Refer to “FRONT AND REAR BRAKES” on
page 4-59.
Brake pad lining thickness limit

2 1.0 mm (0.04 in)
1 a
a
4. Install:
• Differential gear oil drain bolt
(along with the gasket New )
Differential gear oil drain bolt

20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
5. Fill:
4. Install:
• Differential case
• Front wheel
Refer to “FRONT AND REAR WHEELS” on
mended differential gear oil)
page 4-54.
Recommended brand EBS30050
YAMALUBE CHECKING THE REAR BRAKE PADS
Type The following procedure applies to all of the rear
SAE 80W-90 API GL-5 Hypoid brake pads.
gear oil 1. Remove:
Quantity (disassembled) • Rear wheel
0.35 L (0.37 US qt, 0.31 Imp.qt)
Oil change
0.31 L (0.33 US qt, 0.27 Imp.qt) page 4-54.
2. Operate the brake.
ECB01600 3. Check:
NOTICE • Rear brake pad wear limit “a”
Take care not to allow foreign material to en- Out of specification → Replace the brake
ter the differential case. pads and brake pad spring as a set.
page 4-59.
3-23
Refer to “PARKING BRAKE” on page

Brake pad lining thickness limit 4-71.
1.0 mm (0.04 in) b. Remove the parking brake pads, and then
measure the parking brake pad lining
a thickness.
a Brake pad lining thickness limit
1.0 mm (0.04 in)
4. Install:
• Rear wheel
Refer to “FRONT AND REAR WHEELS” on a
page 4-54.
EBS30975
CHECKING THE PARKING BRAKE 5. Install:

1. Place the vehicle on a level surface. • Parking brake caliper
2. Block the all wheels. Refer to “PARKING BRAKE” on page 4-71.
3. Check: 6. Adjust:
• Parking brake lever free play “a” • Parking brake lever free play
The maximum free play is equal to 3 clicks of Refer to “ADJUSTING THE PARKING
the parking brake lever. BRAKE LEVER FREE PLAY” on page 4-78.
Incorrect → Check the parking brake pads. 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.
2. Check:
• Brake fluid level
4. Check: specified brake fluid to the proper level.
• Parking brake pad lining thickness “a”
Specified brake fluid
Within specification → Adjust the parking
DOT 4
brake pad clearance.
Refer to “ADJUSTING THE PARKING EWB02880
BRAKE PAD CLEARANCE” on page 4-77. WARNING

Out of specification → Replace the brake • Use only the designated brake fluid. Other
pads and brake pad spring as a set. brake fluids may cause the rubber seals to
TIP deteriorate, causing leakage and poor
After replacing the parking brake pads, adjust brake performance.
the parking brake pad clearance. • Refill with the same type of brake fluid that
Refer to “ADJUSTING THE PARKING BRAKE is already in the system. Mixing brake fluids
PAD CLEARANCE” on page 4-77. may result in a harmful chemical reaction,
leading to poor brake performance.
a. Remove the parking brake caliper.
3-24
• When refilling, be careful that water does c. Connect a clear plastic hose “1” tightly to
not enter the brake master cylinder reser- the bleed screw “2”.
voir. Water will significantly lower the boil-
A
ing point of the brake fluid and could cause 2
vapor lock. 1
ECB01320
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
TIP
In order to ensure a correct reading of the brake
fluid level, make sure the top of the brake master B
2
cylinder reservoir is horizontal.
EBS30046
1
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
EWB02800
WARNING
Bleed the hydraulic brake system whenever:
• the system is disassembled.
• a brake hose is loosened, disconnected or A. Front brake
replaced. B. Rear brake
• the brake fluid level is very low. d. Place the other end of the hose into a con-
• brake operation is faulty. tainer.
TIP e. Slowly apply the brake several times.
f. Fully depress the brake pedal and hold it
• Be careful not to spill any brake fluid or allow
in position.
the brake master cylinder reservoir to overflow.
g. Loosen the bleed screw.
• When bleeding the hydraulic brake system,
make sure there is always enough brake fluid TIP
before applying the brake. Ignoring this pre- Loosening the bleed screw will release the pres-
caution could allow air to enter the hydraulic sure and cause the brake pedal to fully extend.
brake system, considerably lengthening the h. Tighten the bleed screw, and then release
bleeding procedure. the brake pedal.
• If bleeding is difficult, it may be necessary to let i. Repeat steps (e) to (h) until all of the air
the brake fluid settle for a few hours. Repeat bubbles have disappeared from the brake
the bleeding procedure when the tiny bubbles fluid in the plastic hose.
in the hose have disappeared. j. Tighten the bleed screw to specification.
1. Remove:
Brake caliper bleed screw
• Front wheel
5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
• Rear wheel
R.
Refer to “FRONT AND REAR WHEELS” on k. Fill the brake master cylinder reservoir to
page 4-54. the proper level with the specified brake
2. Bleed: fluid.
• Hydraulic brake system Refer to “CHECKING THE BRAKE FLUID
a. Fill the brake master cylinder reservoir to LEVEL” on page 3-24.
the proper level with the specified brake EWB02810
fluid. WARNING
b. Install the diaphragm (brake master cylin- After bleeding the hydraulic brake system,
der reservoir). check the brake operation.
3-25
3. Install:
• Rear wheel
• Front wheel
page 4-54.
EBS30047
3
CHECKING THE BRAKE HOSES AND
BRAKE PIPES
2
1. Remove:
• Brake master cylinder cover
• Front over fender (left)
• Front door (left)
• Rear door latch striker (left)
4-1.
• Seat rails 3
4-7.
• Center cover
4-16.
• Dashboard (left) 4
4-17.
• Rear floor board (left)
• Front floor board (left)
4-25.
2. Check:
• Front brake hoses “1” 6. Check:
Cracks/damage/wear → Replace. • Brake hose holder
3. Check: Loose → Tighten the holder bolts.
• Front brake pipe “2” Damage → Replace.
Cracks/damage → Replace. 7. Apply the brake several times.
4. Check: 8. Check:
• Rear brake pipe “3” • Brake hose
Cracks/damage → Replace. • Brake pipe
5. Check: Brake fluid leakage → Replace any damaged
• Rear brake hoses “4” hose and pipe.
Cracks/damage/wear → Replace. Refer to “FRONT AND REAR BRAKES” on
page 4-59.
9. Install:
• Front floor board (left)
4-25.
• Dashboard (left)
1 4-17.
3-26
• Center cover
Refer to “GENERAL CHASSIS (5)” on page a
4-16.
• Seat rails
• Front passenger seat frame 2
4-7.
• Front door (left) 3 1
• Front over fender (left)
• Brake master cylinder cover EWB03090
Refer to “GENERAL CHASSIS (1)” on page WARNING

4-1. After this adjustment is performed, lift the
front and rear wheels off the ground by plac-
EBS30048
ing a block under the frame, and spin the
ADJUSTING THE BRAKE PEDAL
front and rear wheels to ensure there is no
1. Check:
brake drag. If any brake drag is noticed per-
• Brake pedal position
form the above steps again.
The brake pedal should contact the edge “a”
of the pedal assembly bracket. EBS30054
Brake pedal does not contact the pedal as- ADJUSTING THE ACCELERATOR PEDAL
sembly bracket → Adjust. FREE PLAY
1. Check:
a
• Accelerator pedal free play “a”
Accelerator pedal free play

10.0–15.0 mm (0.39–0.59 in)
2. Adjust:
• Brake pedal position
a. Remove the pin “1”, and then check that
the brake pedal contacts the edge “a” of
the pedal assembly bracket.
a
b. Loosen the locknut “2”, and then adjust the
length of the brake pedal rod “3” so that
the hole in the brake pedal rod bracket is 2. Remove:
aligned with the hole in the brake pedal. • Dashboard trim bolt
c. Install the pin, and then tighten the lock- • Hood
nut. • Electrical compartment inner cover
• Front cover
Brake pedal rod locknut Refer to “GENERAL CHASSIS (4)” on page
17 N·m (1.7 kgf·m, 13 lb·ft) 4-15.
T.
R.
3. Adjust:
d. Check that the brake pedal contacts the • Accelerator pedal free play
edge of the pedal assembly bracket. a. Remove the throttle cable housing cover
“1”.
3-27
TIP
When the accelerator pedal is fully depressed
(throttle valve fully open), the gap “b” between
the throttle valve pulley “7” and the pulley stop-
per “8” should be 1.0 mm (0.04 in) or less.
7
1
b. Slide back the rubber cover “2”. 8

c. Loosen the locknut “3”.
d. Turn the adjusting nut “4” until the speci-
fied accelerator pedal free play is ob-
tained. b
h. Install a new gasket and the throttle cable
housing cover.
Throttle cable housing cover

4
screw
T.
R.
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
2
3
4. Install:
• Front cover
• Electrical compartment inner cover
TIP • Hood
If length “a” is 0.5 mm (0.02 in) or more, loosen • Dashboard trim bolt
locknut “5” and turn the adjusting nut “6” until the Refer to “GENERAL CHASSIS (4)” on page
specified accelerator pedal free play is obtained. 4-15.
EBS30055
CHECKING THE V-BELT

5 1. Remove:
6 • Front over fender (left and right)
a
4-1.
• Seat rails
e. Tighten the locknuts to specification. Refer to “GENERAL CHASSIS (2)” on page
4-7.
Throttle cable locknut (accelera- • Front cover
tor position sensor unit side) Refer to “GENERAL CHASSIS (4)” on page
T.
R.
0.8 N·m (0.08 kgf·m, 0.59 lb·ft) 4-15.

Throttle cable adjusting locknut • Center cover
4.0 N·m (0.40 kgf·m, 3.0 lb·ft) Refer to “GENERAL CHASSIS (5)” on page
4-16.
f. Slide the rubber cover to its original posi-
• Dashboard (left, right, and center)
tion.
g. Check the throttle valve pulley stopper
4-17.
gap.
3-28
• Front floor board (left) • Dashboard (left, right, and center)

Refer to “GENERAL CHASSIS (7)” on page Refer to “GENERAL CHASSIS (6)” on page
4-25. 4-17.
• V-belt cooling intake duct • Center cover
• V-belt cooling exhaust duct Refer to “GENERAL CHASSIS (5)” on page
Refer to “GENERAL CHASSIS (16)” on page 4-16.
4-51. • Front cover
2. Remove: Refer to “GENERAL CHASSIS (4)” on page
• Drive belt cover 4-15.
Refer to “PRIMARY AND SECONDARY • Front passenger seat frame
SHEAVES” on page 5-66. • Seat rails
3. Check: Refer to “GENERAL CHASSIS (2)” on page
• V-belt “1” 4-7.
Cracks/damage/wear → Replace. • Rear door latch striker (left)
Grease/oil → Clean the primary and second- • Front door (left and right)
ary sheaves. • Front over fender (left and right)
Refer to “REPLACING THE V-BELT” on Refer to “GENERAL CHASSIS (1)” on page
page 3-29. 4-1.
4. Measure:
EBS30056
• V-belt width “a” REPLACING THE V-BELT
Out of specification → Replace. 1. Remove:
Refer to “REPLACING THE V-BELT” on • Front over fender (left and right)
page 3-29. • Front door (left and right)
V-belt width limit
36.5 mm (1.44 in) Refer to “GENERAL CHASSIS (1)” on page
4-1.
• Seat rails
2 1 • Front passenger seat frame
a
4-7.
• Front cover
3 4-15.
• Center cover
G101430 4-16.
2. Plastic board • Dashboard (left, right, and center)
3. Ruler Refer to “GENERAL CHASSIS (6)” on page
4-17.
5. Install: • Rear floor board (left)
• Drive belt cover • Front floor board (left)
Refer to “PRIMARY AND SECONDARY • Driver seat rail bracket
SHEAVES” on page 5-66. Refer to “GENERAL CHASSIS (7)” on page
6. Install: 4-25.
• V-belt cooling intake duct • V-belt cooling intake duct
• V-belt cooling exhaust duct • V-belt cooling exhaust duct
Refer to “GENERAL CHASSIS (16)” on page Refer to “GENERAL CHASSIS (16)” on page
4-51. 4-51.
• Front floor board (left) 2. Remove:
• Rear floor board (left) • Bearing housing
Refer to “GENERAL CHASSIS (7)” on page Refer to “PRIMARY AND SECONDARY
4-25. SHEAVES” on page 5-66.
3-29
3. Replace: 5. Install:
• V-belt • V-belt cooling intake duct
a. Install the bolts “1” (90101-06018) into the • V-belt cooling exhaust duct
secondary fixed sheave holes. Refer to “GENERAL CHASSIS (16)” on page
TIP 4-51.
Tightening the bolts “1” will push the secondary • Driver seat rail bracket
sliding sheave away, causing the gap between • Front floor board (left)
the secondary fixed and sliding sheaves to wid- • Rear floor board (left)
en. Refer to “GENERAL CHASSIS (7)” on page
4-25.
• Dashboard (left, right, and center)
4-17.
a • Center cover
4-16.
• Front cover
1 4-15.
a. 50 mm (1.97 in) or more • Seat rails
b. Remove the V-belt “2” from the primary Refer to “GENERAL CHASSIS (2)” on page
sheave and secondary sheave. 4-7.
4-1.
EBS30976
LUBRICATING THE PRIMARY SHEAVE

SPACER
1. Lubricate:
G101432
• Primary sheave spacer
c. Install a new V-belt.
Recommended lubricant
TIP
Yamalube polyurea grease or
Install the new V-belt so that its arrow faces the Yamaha grease F
direction shown in the illustration.
Refer to “PRIMARY AND SECONDARY
SHEAVES” on page 5-66.
EBS30057
CHECKING THE WHEELS

wheels.
1. Check:
• Wheel
Damage/bends → Replace.
G101433 EWB03010
WARNING
d. Remove the bolts.
4. Install: • Never attempt even small repairs to the
• Bearing housing wheel.
Refer to “PRIMARY AND SECONDARY • Ride conservatively after installing a tire to
SHEAVES” on page 5-66. allow it to seat itself properly on the rim.
3-30
2. Measure: Tire pressure

• Radial wheel runout EWB02980
• Lateral wheel runout WARNING

Refer to “CHECKING THE WHEELS” on • Tire pressure below the minimum specifi-
page 4-56. cation could cause the tire to dislodge from
3. Check: the rim under severe riding conditions.
• Wheel bearings • Use no more than the following pressures
Refer to “CHECKING THE STEERING when seating the tire beads.
KNUCKLES AND FRONT WHEEL BEAR- Front
INGS” on page 4-95 and “CHECKING THE 250 kPa (2.5 kgf/cm²) (36 psi)
REAR KNUCKLES AND REAR WHEEL Rear
BEARINGS” on page 4-104. 250 kPa (2.5 kgf/cm²) (36 psi)
Higher pressures and fast inflation may
EBS30058
cause a tire to burst. Inflate the tires very
CHECKING THE TIRES
slowly and carefully.
tires.
EWB02960 Tire air pressure (measured on
WARNING cold tires)
This model is equipped with low-pressure Vehicle load
tires. It is important that they be inflated cor- 0.0–200.0 kg (0–441 lb)
Recommended
rectly and maintained at the proper pres-
Front
sures. 110.0 kPa (1.100 kgf/cm², 16.0
psi)
Tire characteristics Rear
EWB02970 110.0 kPa (1.100 kgf/cm², 16.0
WARNING psi)
Tire characteristics influence the handling of Minimum
vehicles. The tires listed below have been Front
approved by Yamaha Motor Co., Ltd. for this 103.0 kPa (1.030 kgf/cm², 15.0
model. If other tire combinations are used, psi)
Rear
they can adversely affect your vehicle’s han-
103.0 kPa (1.030 kgf/cm², 15.0
dling characteristics and are therefore not psi)
recommended.
Maximum loading limit
Front tire EWB02990
Size WARNING
29x9.00R14 NHS
Manufacturer/model Be extra careful of the vehicle balance and
GBC/DIRT COMMANDER stability when towing a trailer.
(YXF10WRAN)
MAXXIS/ML19A/CARNAGE
(YXF10WRZN, YXF10WRLN)
Rear tire
Size
29x11.00R14 NHS
Manufacturer/model
GBC/DIRT COMMANDER
(YXF10WRAN)
MAXXIS/ML19A/CARNAGE
(YXF10WRZN, YXF10WRLN)
3-31
Vehicle load
200.0–510.0 kg (441–1124 lb)
Recommended
Front
117.0 kPa (1.170 kgf/cm², 17.0
psi)
Rear
200.0 kPa (2.000 kgf/cm², 29.0
psi)
G101429
Minimum
Front a. Wear limit
110.0 kPa (1.100 kgf/cm², 16.0
psi) EBS30977
Rear CHECKING THE SHOCK ABSORBER

193.0 kPa (1.930 kgf/cm², 28.0 ASSEMBLIES
psi) The following procedure applies to all of the
Trailer hitch pulling load limit shock absorber assemblies.
8888 N (907 kgf, 2000 lbf) 1. Place the vehicle on a level place.
Trailer hitch vertical load limit 2. Check:
620 N (63 kgf, 141 lbf) • Front shock absorber assembly
Refer to “CHECKING THE FRONT SHOCK
1. Measure: ABSORBER ASSEMBLIES” on page 4-100.
• Tire pressure • Rear shock absorber assembly
Out of specification → Adjust. Refer to “CHECKING THE REAR SHOCK
EWB03000
WARNING ABSORBER ASSEMBLIES” on page 4-107.

3. Check:
Uneven or improper tire pressure may ad-
• Operation
versely affect the handling of this vehicle
Pump the front and rear shock absorber as-
and may cause loss of control.
sembly up and down several times.
• Maintain proper tire pressures.
Unsmooth operation → Replace shock ab-
• Set tire pressures when the tires are cold.
sorber assembly.
• Tire pressures must be equal in both front
Refer to “FRONT ARMS AND FRONT
tires and equal in both rear tires.
SHOCK ABSORBER ASSEMBLIES” on
TIP page 4-98 or refer to “REAR STABILIZER,
• The tire pressure gauge is included as stan- REAR SHOCK ABSORBER ASSEMBLIES,
dard equipment. AND REAR ARMS” on page 4-105.
• In order to insure an accurate reading, make EBS30978
sure that the gauge is clean before use. ADJUSTING THE SHOCK ABSORBER
ASSEMBLIES
2. Check:
The following procedure applies to both of the
• Tire surfaces
front and rear shock absorber assemblies.
Wear/damage → Replace. EWB00401
WARNING
Wear limit (front)
3.0 mm (0.12 in) Always adjust the shock absorber assem-
Wear limit (rear) blies on the left and right side to the same
3.0 mm (0.12 in) setting. Uneven adjustment can cause poor
handling and loss of stability, which could
EWB03100
lead to an accident.
WARNING
1. Remove:
It is dangerous to ride with a worn-out tire.
• Front over fender
When the tire tread reaches the wear limit, re-
place the tire immediately.
4-1.
3-32
• Front guard TIP

Refer to “GENERAL CHASSIS (11)” on page • Be sure to remove all dirt and mud from around
4-33. the locknut and adjusting ring before adjust-
• Front fender ment.
• Front grill • The length of the spring (installed) changes 1.5
Refer to “GENERAL CHASSIS (12)” on page mm (0.06 in) per turn of the adjusting ring.
4-36.
2. Adjust: A
• Spring preload a
1
Ring nut wrench (R60)
b
90890-01584
Ring nut wrench (R60) c
YM-01584 2
a. Elevate the front or rear wheels by placing
a suitable stand under the frame.
b. Loosen the lock nut “1”.
c. Turn the adjusting ring “2” in direction “a” B
or “b”.
a
Direction “a” b
Spring preload is increased (suspen- 1 c
sion is harder).
Direction “b” 2
Spring preload is decreased (suspen-
sion is softer).
A. Front
Front spring preload setting:
Adjustment value (Soft) B. Rear
519.3 mm (20.44 in) c. Spring preload adjusting position
Adjustment value (STD) d. Tighten the locknut “1” with a ring nut
509.3 mm (20.05 in)
wrench “3”.
Adjustment value (Hard)
499.3 mm (19.66 in) Ring nut wrench (R60 1/2square
wrench)
90890-01585
Rear spring preload setting:
Ring nut wrench (R60 1/2square
Adjustment value (Soft)
wrench)
475.2 mm (18.71 in)
YM-01585
Adjustment value (STD)
460.2 mm (18.12 in)
Adjustment value (Hard) Locknut
445.2 mm (17.53 in) 41 N·m (4.1 kgf·m, 30 lb·ft)
T.
R.
ECB02470
NOTICE TIP
Never attempt to turn the adjusting ring be- • Set the torque wrench at a right angle to the
yond the maximum or minimum setting. ring nut wrench.
• Always tighten the locknut against the adjust-
ing ring, then torque it to specification.
3-33
2
3
3. Adjust:
• Compression damping force A. YXF10WRAN/YXF10WRZN
a. Turn the adjuster “1” in direction “a” or “b” B. YXF10WRLN
(YXF10WRAN/YXF10WRZN), or push 4. Install:
the suspension mode switch “2” • Front grill
(YXF10WRLN). • Front fender
Direction “a”
4-36.
Compression damping force is in-
creased (suspension is harder). • Front guard
Direction “b” Refer to “GENERAL CHASSIS (11)” on page
Compression damping force is de- 4-33.
creased (suspension is softer). • Front over fender
4-1.
Compression damping setting
EBS30061
Minimum (Soft)
CHECKING THE STEERING SYSTEM
1 (YXF10WRAN, YXF10WRZN)
Standard 1. Place the vehicle on a level surface.
2 (YXF10WRAN, YXF10WRZN) 2. Check:
Maximum (Hard) • EPS unit
3 (YXF10WRAN, YXF10WRZN) • Steering wheel nut
Move the steering wheel up and down, and
ECB02480
back and forth.
NOTICE Excessive play → Check that the steering
Do not force the adjuster past the minimum column bolts, EPS unit bolts, or steering
or maximum extent of adjustment. The ad- wheel nut are tightened to specification.
juster may be damaged. Refer to “STEERING SYSTEM” on page
4-83.
A
3. Check:
• Tie-rod ends “1”
b a Free play → Replace the tie-rod end.
a. Turn the steering wheel left until it stops.
b. Move the steering wheel slightly to the
2 right and left.
1 c. Check for play in the tie-rod ends.
1
d. Turn the steering wheel right until it stops.

e. Move the steering wheel slightly to the left
and right.
f. Check for play in the tie-rod ends.
3-34
1 1
G101435
4. Raise the front end of the vehicle so that C. Forward

there is no weight on the front wheels.
5. Check: 3. Adjust:
• Ball joints and wheel bearings • Toe-in
EWB03110
Move the wheels laterally back and forth. WARNING
Excessive free play → Replace the front
• Be sure that both tie-rods are turned the
arms (upper and lower) and/or wheel bear-
same amount. If not, the vehicle will drift
ings.
right or left even though the steering wheel
EBS30062 is straight. This may lead to mishandling
ADJUSTING THE TOE-IN and an accident.
1. Place the vehicle on a level surface. • After setting the toe-in to specification, run
2. Measure: the vehicle slowly for some distance with
• Toe-in both hands lightly holding the steering
Out of specification → Adjust. wheel and check that the steering wheel re-
sponds correctly. If not, turn either the right
Toe-in (with tires touching the
or left tie-rod within the toe-in specification.
ground)
10.0 to 20.0 mm (0.39 to 0.79 in) a. Mark both tie-rods ends.
This reference point will be needed during
TIP adjustment.
Before measuring the toe-in, make sure that the b. Loosen the tie-rod end locknuts “1” of both
tire pressure is correct. tie-rods.
c. The same number of turns should be giv-
a. Mark both front tire tread centers. en to both the right and left tie-rods “2” until
b. Face the steering wheel straight ahead. the specified toe-in is obtained. This is to
c. Measure the width “A” between the marks. keep the length of the tie-rods the same.
d. Rotate the front tires 180° until the marks
are exactly opposite one another.
e. Measure the width “B” between the marks.
f. Calculate the toe-in using the formula giv-
en below.
Toe-in = “B” – “A” 1 2

2 1
g. If the toe-in is incorrect, adjust it.
d. Tighten the tie-rod end locknuts to specifi-

cation.
Tie-rod end locknut

55 N·m (5.5 kgf·m, 41 lb·ft)
T.
R.
4. Check:
• Steering wheel
3-35
TIP Refer to “FRONT CONSTANT VELOCITY

After adjusting the toe-in, the steering wheel SHAFT ASSEMBLIES, DIFFERENTIAL AS-
should be centered. SEMBLY AND FRONT DRIVE SHAFT” on
page 8-4 and “REAR CONSTANT VELOCI-
Refer to “INSTALLING THE STEERING TY SHAFT ASSEMBLIES, FINAL DRIVE
WHEEL” on page 4-24. ASSEMBLY AND REAR DRIVE SHAFT” on
EBS30064
page 8-22.
CHECKING THE STABILIZER BUSHING A
1. Check:
• Stabilizer bushing
Damage/wear → Replace.
Refer to “STEERING KNUCKLES AND
FRONT STABILIZER” on page 4-93 and
“REAR STABILIZER, REAR SHOCK AB-
SORBER ASSEMBLIES, AND REAR
ARMS” on page 4-105.
1 1
EBS30065
LUBRICATING THE REAR KNUCKLE B

PIVOTS
rear knuckle pivots.
1. Lubricate:
• Rear knuckle pivot
Lithium-soap-based grease 1 1
A. Front
B. Rear
EBS30069
CHECKING THE FASTENER

1. Check:
• Fastener
Damage/pitting → Replace.
4-1, “GENERAL CHASSIS (2)” on page 4-7,
EBS30067
“GENERAL CHASSIS (3)” on page 4-12,
CHECKING THE ENGINE MOUNT “GENERAL CHASSIS (4)” on page 4-15,
1. Check: “GENERAL CHASSIS (5)” on page 4-16,
• Engine bracket “GENERAL CHASSIS (6)” on page 4-17,
Cracks/damage → Replace. “GENERAL CHASSIS (7)” on page 4-25,
• Engine mounting bolt “GENERAL CHASSIS (8)” on page 4-28,
• Engine bracket bolt “GENERAL CHASSIS (9)” on page 4-29,
Loosen → Tighten. “GENERAL CHASSIS (10)” on page 4-30,
Refer to “ENGINE REMOVAL (3)” on page “GENERAL CHASSIS (11)” on page 4-33,
5-16. “GENERAL CHASSIS (12)” on page 4-36,
EBS30068
CHECKING THE CONSTANT VELOCITY
SHAFT ASSEMBLY DUST BOOTS
and “GENERAL CHASSIS (16)” on page
1. Check:
4-51.
• Dust boot “1”
Damage → Replace.
3-36
3-37
CHASSIS
GENERAL CHASSIS (1) ................................................................................. 4-1

REMOVING THE DOORS (YXF10WRZN/YXF10WRLN) ......................... 4-5
DISASSEMBLING THE FRONT DOORS ................................................. 4-5
DISASSEMBLING THE REAR DOORS .................................................... 4-5
ASSEMBLING THE FRONT DOORS ....................................................... 4-5
ASSEMBLING THE REAR DOORS .......................................................... 4-6
INSTALLING THE DOORS ....................................................................... 4-6
GENERAL CHASSIS (2) ................................................................................. 4-7

REMOVING THE FRONT SEAT CUSHIONS .........................................4-10
INSTALLING THE FRONT SEAT CUSHIONS........................................4-10
ADJUSTING THE DRIVER SEAT POSITION .........................................4-10
MOVING A REAR PASSENGER SEAT FORWARD ..............................4-10
INSTALLING THE REAR SEAT BACK LATCH ......................................4-11
GENERAL CHASSIS (3) ...............................................................................4-12

INSTALLING THE SEAT BELTS.............................................................4-14
4
GENERAL CHASSIS (4) ...............................................................................4-15
GENERAL CHASSIS (5) ...............................................................................4-16
GENERAL CHASSIS (6) ...............................................................................4-17

REMOVING THE STEERING WHEEL....................................................4-23
REMOVING THE DASHBOARD .............................................................4-23
REMOVING THE STEERING COLUMN COVER ...................................4-23
INSTALLING THE PASSENGER HANDHOLD .......................................4-23
INSTALLING THE STEERING WHEEL ..................................................4-24
GENERAL CHASSIS (7) ...............................................................................4-25
GENERAL CHASSIS (8) ...............................................................................4-28
GENERAL CHASSIS (9) ...............................................................................4-29
GENERAL CHASSIS (10) .............................................................................4-30

INSTALLING THE ENCLOSURE ............................................................4-32
GENERAL CHASSIS (11) .............................................................................4-33

WINCH (YXF10WRZN/YXF10WRLN).....................................................4-35
INSTALLING THE HOOK (YXF10WRZN/YXF10WRLN) ........................4-35
INSTALLING THE WINCH (YXF10WRZN/YXF10WRLN) ......................4-35
GENERAL CHASSIS (12) .............................................................................4-36
GENERAL CHASSIS (13) .............................................................................4-38

INSTALLING THE AIR INTAKE ACCUMULATOR.................................. 4-41
GENERAL CHASSIS (14) .............................................................................4-42
GENERAL CHASSIS (15) .............................................................................4-47

DISASSEMBLING THE CARGO BED ....................................................4-50
ASSEMBLING THE CARGO BED ..........................................................4-50
GENERAL CHASSIS (16) .............................................................................4-51

INSTALLING THE V-BELT COOLING DUCTS .......................................4-53
FRONT AND REAR WHEELS ......................................................................4-54

REMOVING THE WHEELS.....................................................................4-56
REMOVING THE WHEEL HUBS ............................................................4-56
CHECKING THE WHEELS .....................................................................4-56
CHECKING THE WHEEL HUBS.............................................................4-57
INSTALLING THE BRAKE DISCS ..........................................................4-57
INSTALLING THE WHEEL HUBS...........................................................4-57
INSTALLING THE WHEELS ...................................................................4-57
FRONT AND REAR BRAKES.......................................................................4-59

INTRODUCTION ..................................................................................... 4-66
CHECKING THE BRAKE DISCS ............................................................4-66
REPLACING THE BRAKE PADS............................................................4-66
REMOVING THE REAR BRAKE CALIPERS ..........................................4-67
DISASSEMBLING THE BRAKE CALIPERS ........................................... 4-68
CHECKING THE BRAKE CALIPERS .....................................................4-68
ASSEMBLING THE BRAKE CALIPERS .................................................4-68
INSTALLING THE BRAKE CALIPERS ...................................................4-68
CHECKING THE BRAKE MASTER CYLINDER .....................................4-70
CHECKING THE BRAKE PIPES.............................................................4-70
INSTALLING THE BRAKE MASTER CYLINDER ...................................4-70
PARKING BRAKE.........................................................................................4-71
REMOVING THE PARKING BRAKE CALIPER ......................................4-77
CHECKING THE PARKING BRAKE CALIPER.......................................4-77
CHECKING THE PARKING BRAKE DISC ............................................. 4-77
ADJUSTING THE PARKING BRAKE PAD CLEARANCE ......................4-77
INSTALLING THE PARKING BRAKE LEVER ........................................4-78
ADJUSTING THE PARKING BRAKE LEVER FREE PLAY ....................4-78
PEDAL ASSEMBLY ......................................................................................4-79

INSTALLING THE PEDAL ASSEMBLY ..................................................4-82
LUBRICATING THE BRAKE PEDAL AND ACCELERATOR PEDAL .....4-82
STEERING SYSTEM ..................................................................................... 4-83
DISCONNECTING THE TIE-ROD ENDS ...............................................4-88
REMOVING THE STEERING JOINT ...................................................... 4-88
REMOVING THE TIE-ROD .....................................................................4-88
CHECKING THE STEERING JOINT.......................................................4-88
CHECKING THE TIE-ROD ENDS...........................................................4-88
CHECKING THE STEERING GEAR ASSEMBLY .................................. 4-88
REMOVING THE STEERING PINION ....................................................4-89
INSTALLING THE STEERING PINION...................................................4-89
INSTALLING THE TIE-RODS ................................................................. 4-90
INSTALLING THE STEERING ASSEMBLY............................................4-91
LUBRICATING THE STEERING SHAFT ................................................4-92
STEERING KNUCKLES AND FRONT STABILIZER ...................................4-93

REMOVING THE STEERING KNUCKLES ............................................. 4-95
CHECKING THE STEERING KNUCKLES AND FRONT WHEEL
BEARINGS .............................................................................................4-95
CHECKING THE STEERING KNUCKLE BALL JOINTS ........................4-95
CHECKING THE FRONT STABILIZER ..................................................4-96
INSTALLING THE STEERING KNUCKLES............................................4-96
INSTALLING THE FRONT STABILIZER ................................................4-97
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES .............4-98

CHECKING THE FRONT ARMS...........................................................4-100
HANDLING THE FRONT SHOCK ABSORBER ASSEMBLIES ............4-100
DISPOSING OF A FRONT SHOCK ABSORBER ASSEMBLY.............4-100
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES ...........4-100
CHECKING THE FRONT ARM BALL JOINTS .....................................4-101
INSTALLING THE FRONT ARMS AND FRONT SHOCK
ABSORBER ASSEMBLIES ..................................................................4-101
REAR KNUCKLES ......................................................................................4-103

CHECKING THE REAR KNUCKLES AND REAR WHEEL
BEARINGS ...........................................................................................4-104
REAR STABILIZER, REAR SHOCK ABSORBER ASSEMBLIES,

AND REAR ARMS......................................................................................4-105
CHECKING THE REAR ARMS .............................................................4-107
HANDLING THE REAR SHOCK ABSORBER ASSEMBLIES ..............4-107
DISPOSING OF A REAR SHOCK ABSORBER ASSEMBLY ...............4-107
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES ..............4-107
INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER
ASSEMBLIES .......................................................................................4-108
CHECKING THE REAR STABILIZER ...................................................4-108
INSTALLING THE REAR STABILIZER .................................................4-108
GENERAL CHASSIS (1)
EBS20024
GENERAL CHASSIS (1)

Removing the brake master cylinder cover and front over fenders
4 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
5
3
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
1
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

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

1 Brake master cylinder cover 1
2 Front over fender (left) 1
3 Front over fender inner panel (left) 1
4 Front over fender (right) 1
5 Front over fender inner panel (right) 1
4-1
GENERAL CHASSIS (1)
Removing the front doors

36 N•m (3.6 kgf•m, 27 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
2
16 N•m (1.6 kgf•m, 12 lb•ft)
T.R
.
New
4
(3)
7
10
5 6 9
(6)
3
1
(8)
(11)
36 N•m (3.6 kgf•m, 27 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft) 16 N•m (1.6 kgf•m, 12 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
T.R
T.R
.
.

The following procedure applies to both of
the front doors.
1 Front speaker coupler 1 Disconnect.

YXF10WRZN/YXF10WRLN
2 Front door assembly 1
3 Front door panel (inner) 1
4 Cover 1 YXF10WRAN
5 Front speaker 1 YXF10WRZN/YXF10WRLN
6 Protector 1
7 Damper 1
8 Front door panel (outer) 1
9 Door handle link rod 1
10 Clip 1
4-2
GENERAL CHASSIS (1)
Removing the front doors

36 N•m (3.6 kgf•m, 27 lb•ft)
T.R
.
20 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
16 N•m (1.6 kgf•m, 12 lb•ft)
T.R
21
.
13 12 14 11 New 16
(3) 15
(6)
18
17 19
(8)
18
17
18 (11)
36 N•m (3.6 kgf•m, 27 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft) 16 N•m (1.6 kgf•m, 12 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
T.R
T.R
.
.

11 Circlip 1
12 Pin 1
13 Front door handle 1
14 Spring 1
15 Front door panel (rear) 1
16 Front door latch 1
17 Front door hinge 2
18 Bushing 4
19 Front door frame 1
20 Front door latch striker 1
21 Damper 1
4-3
GENERAL CHASSIS (1)
Removing the rear doors

9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
1
3 2
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
4
16 N•m (1.6 kgf•m, 12 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
10
9
11
15 8 New
(4)
(7)
14
13 12
7 6
14
5
36 N•m (3.6 kgf•m, 27 lb•ft) 14 (7)
T.R
.
13
14
16 N•m (1.6 kgf•m, 12 lb•ft)
T.R
.
36 N•m (3.6 kgf•m, 27 lb•ft)

T.R
.

the rear doors.
1 Rear door latch striker 1
2 Damper 1
3 Rear door assembly 1
4 Rear door panel (inner) 1
5 Rear door panel (outer) 1
6 Door handle link rod 1
7 Clip 2
8 Circlip 1
9 Pin 1
10 Rear door handle 1
11 Rear door handle link 1
12 Rear door latch 1
13 Rear door hinge 2
14 Bushing 4
15 Rear door frame 1
4-4
GENERAL CHASSIS (1)
EBS30996
REMOVING THE DOORS (YXF10WRZN/

YXF10WRLN)
doors.
1. Disconnect:
• Front speaker coupler “1”
TIP 3
Disconnect the front speaker coupler, and then 1
remove the plug portion “a” on the front speaker
lead. 2. Remove:
• Door handle link rod “1”
a. Turn the clip “2” in the direction shown in
the illustration and remove door handle
link rod from the door handle latch “3”.
1 a
1
2. Remove:
• Door assembly 2
3
EBS30962
DISASSEMBLING THE FRONT DOORS EBS30963

The following procedure applies to both of the DISASSEMBLING THE REAR DOORS
front doors. The following procedure applies to both of the
1. Remove: rear doors.
• Front door inner panel “1” 1. Remove:
a. Remove the bolts and quick fasteners. • Door handle link rod
b. Remove the portions “a” of the front door Refer to step 2 in “DISASSEMBLING THE
inner panel to the outside of front door out- FRONT DOORS” on page 4-5.
er panel “2”.
EBS30964
1 ASSEMBLING THE FRONT DOORS

front doors.
1. Install:
• Door handle link rod “1”
a. Install the link rod into the clip “2”.
2 a b. Turn the clip in the direction shown in the
a illustration to fasten the link rod.
c. With door latch lever “3” in its pulled state,

slide the front door inner panel in the direc-
tion of the arrow.
1
4-5
GENERAL CHASSIS (1)
2. Install:
• Front door inner panel “1” Front door latch striker bolt
a. Pull door latch lever “2” through hole “a” in 36 N·m (3.6 kgf·m, 27 lb·ft)
T.
R.
the front door inner panel, and slide the Rear door latch striker bolt
9 N·m (0.9 kgf·m, 6.6 lb·ft)
front door inner panel in the direction of
the arrow.
TIP
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.
2. Install:
• Front door assembly
• Rear door assembly
2 a
1 Front door assembly bolt
36 N·m (3.6 kgf·m, 27 lb·ft)
T.
R.
b. Put the portions “a” of the front door inner Rear door assembly bolt
panel inside front door outer panel “2”. 36 N·m (3.6 kgf·m, 27 lb·ft)
1 TIP
• Align pin “a” of the door latch striker with
groove “b” of the latch and tighten the door
bolts to the specified torque.
• Check that the door closes securely and that
the door latch is released smoothly from the
2 a door striker by pulling the door handle.
a
A B
c. Install the quick fasteners and bolts to a a
specified torque.
Front door inner panel bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
EBS30965
b
ASSEMBLING THE REAR DOORS b
rear doors. A. Front door
1. Install: B. Rear door
• Door handle link rod
Refer to step 1 in “ASSEMBLING THE
FRONT DOORS” on page 4-5.
EBS30966
INSTALLING THE DOORS

doors.
1. Install:
• Front door latch striker
• Rear door latch striker
4-6
GENERAL CHASSIS (2)
EBS20087
GENERAL CHASSIS (2)

Removing the front seats
(3) 7 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
LT
New (3)
38 N•m (3.8 kgf•m, 28 lb•ft)
T.R
.
4 20 N•m (2.0 kgf•m, 15 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
(4) LT (3)
(4)
(3)
3
2 New
1 6
38 N•m (3.8 kgf•m, 28 lb•ft)

T.R
.

1 Front seat cushion 2
2 Driver seat frame 1
3 Front passenger seat frame 1
4 Front seat back 2
5 Seat rail (left) 1
6 Seat rail (right) 1
7 Shoulder bolster 2
4-7
GENERAL CHASSIS (2)
Removing the rear seats

7 N•m (0.7 kgf•m, 5.2 lb•ft) (3) 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)
T.R
.
LT
LT
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
38 N•m (3.8 kgf•m, 28 lb•ft) (3)

T.R
.
7 6
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
1
4 6
2 2
(3) 4.0 N•m (0.40 kgf•m, 3.0 lb•ft) 38 N•m (3.8 kgf•m, 28 lb•ft)
T.R
.
T.R
.
53
LT 4
2
5
3 (3) 2
7 N•m (0.7 kgf•m, 5.2 lb•ft) LT

T.R
.

1 Rear seat cushion 2
2 Damper 4
3 Seat cushion hinge bracket 2
4 Seat cushion hinge 2
5 Damper 2
6 Rear passenger seat rail 2
7 Rear seat back 2
4-8
GENERAL CHASSIS (2)
Removing the rear seats

7 N•m (0.7 kgf•m, 5.2 lb•ft) (3) 16 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)
T.R
.
LT
14 16
8 12 LT
17 N•m (1.7 kgf•m, 13 lb•ft) 8
13
T.R
.
38 N•m (3.8 kgf•m, 28 lb•ft) 15 (3)

10
T.R
.
9 14
12
11
11 9 15 13
10 11
11
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
(3) 4.0 N•m (0.40 kgf•m, 3.0 lb•ft) 38 N•m (3.8 kgf•m, 28 lb•ft)
T.R
.
T.R
.
LT
(3)
7 N•m (0.7 kgf•m, 5.2 lb•ft) LT

T.R
.

8 Rear seat back frame 2
9 Seat back frame slider 4
10 Rear seat back latch holder 4
11 Damper 4
12 Rear seat back latch 2
13 Rear seat back latch cam (left) 2
14 Rear seat back latch cam (right) 2
15 Spring 2
16 Rear seat back latch cover 2
4-9
GENERAL CHASSIS (2)
EBS30857
a. Pull the driver seat adjusting lever “1” up-
REMOVING THE FRONT SEAT CUSHIONS
ward and move the seat “2” to the desired
position.
front seat cushions.
1. Remove: TIP
• Front seat cushion “1” Make sure that the seat is locked in place.
a. Lift the front of the seat cushion.
b. Pull the cushion off.
1 1 2
EBS30859
MOVING A REAR PASSENGER SEAT

EBS30858 FORWARD
INSTALLING THE FRONT SEAT CUSHIONS 1. Move:
The following procedure applies to both of the • Rear passenger seat
front seat cushions. a. Pull the rear of the seat cushion “1” to lift it
1. Install: up.
• Front seat cushion “1”
EWB03120
WARNING 1
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. b. While pulling the seat lock lever “2”, slide
TIP the seat “3” forward completely until it
Make sure the seats are properly secured before locks in place.
driving.
3
a
b
c. Remove the seat belt buckle storage com-

partment cover “4” and place the seat belt
EBS30073 buckles “5” in the compartment.
ADJUSTING THE DRIVER SEAT POSITION
The driver seat position can be adjusted to suit
the driver’s preference.
1. Adjust:
• Driver seat position
4-10
GENERAL CHASSIS (2)
d. Install the seat belt buckle storage com-

partment cover.
EBS30803
INSTALLING THE REAR SEAT BACK LATCH

rear seat back latches.
1. Install:
• Rear seat back latch “1”
TIP
Install the rear sheet back latch in the direction
shown in the illustration.
4-11
GENERAL CHASSIS (3)
EBS20088
GENERAL CHASSIS (3)

Removing the front seat belts
59 N•m (5.9 kgf•m, 44 lb•ft)
T.R
.
1
3
59 N•m (5.9 kgf•m, 44 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft) 59 N•m (5.9 kgf•m, 44 lb•ft)

T.R
.
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
59 N•m (5.9 kgf•m, 44 lb•ft)

T.R
.
59 N•m (5.9 kgf•m, 44 lb•ft)

T.R
.

1 Front center frame cover (left) 1
2 Front center frame cover (right) 1
3 Driver seat belt 1
4 Front passenger seat belt 1
4-12
GENERAL CHASSIS (3)
Removing the rear seat belts

T.R
T.R
.
.
59 N•m (5.9 kgf•m, 44 lb•ft)

T.R
. 3
59 N•m (5.9 kgf•m, 44 lb•ft)
T.R
.
2
5
59 N•m (5.9 kgf•m, 44 lb•ft)
T.R
.
1
52 N•m (5.2 kgf•m, 38 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
T.R
.
52 N•m (5.2 kgf•m, 38 lb•ft)

T.R
.

1 Rear passenger seat belt (left) 1
2 Rear passenger seat belt (right) 1
3 Seat belt buckle storage compartment cover 1
4 Rear passenger seat belt buckle (left) 1
5 Rear passenger seat belt buckle (right) 1
4-13
GENERAL CHASSIS (3)
EBS30343
INSTALLING THE SEAT BELTS

1. Install:
• Seat belt
Seat belt retractor bolt

59 N·m (5.9 kgf·m, 44 lb·ft)
T.
R.
Seat belt bolt (upper) (M11)

59 N·m (5.9 kgf·m, 44 lb·ft)
Front seat belt bolt (lower)
59 N·m (5.9 kgf·m, 44 lb·ft)
Rear seat belt bolt (lower)
52 N·m (5.2 kgf·m, 38 lb·ft)
Seat belt adjuster bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft)
TIP
Fit the projection “a” on each seat belt retractor
“1” into the holes “b” in the frame “2”.
a 1
2
b
2. Install:
• Front center frame cover “1”
a. Hook the projection “a” on the front center
cover into the portion “b” of the side frame
“2”.
2 b
a 1
b. Install the quick fasteners.
4-14
GENERAL CHASSIS (4)
EBS20089
GENERAL CHASSIS (4)

Removing the hood, electrical compartment inner cover, and front cover
6
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
8
1
2
(4)
3 7
5 1.3 N•m (0.13 kgf•m, 0.95 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

1 Dashboard trim bolt 1
2 Hood 1
3 Electrical compartment inner cover 1
4 Speed management system switch coupler 1 Disconnect.
5 Speed management system switch 1
6 Front cover 1
7 Front grill rear cover (left) 1
8 Front grill rear cover (right) 1
4-15
GENERAL CHASSIS (5)
EBS20090
GENERAL CHASSIS (5)

Removing the rear cover and center cover
5 1.3 N•m (0.13 kgf•m, 0.95 lb•ft)
T.R
.
(4) 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
2 4
6
1
3
(6)
(6)
9 8
10
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
Driver seat frame/Front passenger seat frame Refer to “GENERAL CHASSIS (2)” on page
4-7.
1 Rear cover 1
2 Dashboard trim 1
3 Suspension mode switch coupler 1 Disconnect.

YXF10WRLN
4 Suspension mode switch 1 YXF10WRLN
YXF10WRAN/YXF10WRZN: 6 pcs
5 Plug — YXF10WRLN: 5 pcs
6 Cover 1 YXF10WRAN
7 Center cover trim 1
8 Center cover 1
9 Parking brake lever rubber cover 1
10 Plug 4
4-16
GENERAL CHASSIS (6)
EBS20091
GENERAL CHASSIS (6)

Removing the steering wheel, meter assembly, and dashboard (left)
7 N•m (0.7 kgf•m, 5.2 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
T.R
.
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
1.6 N•m (0.16 kgf•m, 1.2 lb•ft)
T.R
.
FWD
50 N•m (5.0 kgf•m, 37 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
1.3 N•m (0.13 kgf•m, 0.95 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
Front over fenders/Front doors Refer to “GENERAL CHASSIS (1)” on page

4-1.
Driver seat frame/Passenger seat frame Refer to “GENERAL CHASSIS (2)” on page
4-7.
Front cover Refer to “GENERAL CHASSIS (4)” on page

4-15.
Center cover Refer to “GENERAL CHASSIS (5)” on page

4-16.
4-17
GENERAL CHASSIS (6)

T.R
T.R
.
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
1
3 4 5
8
1.6 N•m (0.16 kgf•m, 1.2 lb•ft) 10

T.R
.
9
FWD 7
6
50 N•m (5.0 kgf•m, 37 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
1.3 N•m (0.13 kgf•m, 0.95 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

1 Steering wheel cover 1
2 Steering wheel 1
3 Meter cover 1
4 Meter bracket 1
5 Meter assembly 1
Disconnect.
6 On-Command four-wheel-drive switch coupler — YXF10WRZN/YXF10WRLN: 2 pcs
YXF10WRAN: 1 pc
Disconnect.
7 Light switch coupler — YXF10WRZN/YXF10WRLN: 2 pcs
YXF10WRAN: 1 pc
8 D-mode switch coupler 2 Disconnect.

YXF10WRZN/YXF10WRLN
9 Interior light coupler (left) 1 Disconnect.

YXF10WRZN/YXF10WRLN
10 Dashboard (left) 1
4-18
GENERAL CHASSIS (6)

T.R
T.R
.
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
13
19
1.6 N•m (0.16 kgf•m, 1.2 lb•ft)
T.R
.
20 12
FWD 16 14
15 11
50 N•m (5.0 kgf•m, 37 lb•ft)
T.R
.
18
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
1.3 N•m (0.13 kgf•m, 0.95 lb•ft)
T.R
.
17
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

11 On-Command four-wheel-drive switch 1
12 Light switch 1
13 D-mode switch 1 YXF10WRZN/YXF10WRLN
14 Blind plug 1 YXF10WRAN
15 Interior light (left) 1 YXF10WRZN/YXF10WRLN
16 Plug 1 YXF10WRAN
17 Main switch coupler 1 Disconnect.
18 Steering wheel tilt lever 1
19 Steering column cover 1
20 Main switch 1
4-19
GENERAL CHASSIS (6)
Removing the passenger handhold and dashboard (right)

33 N•m (3.3 kgf•m, 24 lb•ft) 22 N•m (2.2 kgf•m, 16 lb•ft)
T.R
T.R
.
.
0.4 N•m (0.04 kgf•m, 0.30 lb•ft)
T.R
.
5
1 9
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
8
7 N•m (0.7 kgf•m, 5.2 lb•ft) 2

T.R
.
7 6
4
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

1 Passenger handhold grip 1
2 Interior light coupler (right) 1 Disconnect.

YXF10WRZN/YXF10WRLN
3 Auxiliary DC jack coupler 1 Disconnect.
4 Rubber cover 1
5 Dashboard (right) 1
6 Interior light (right) 1 YXF10WRZN/YXF10WRLN
7 Plug 1 YXF10WRAN
8 Auxiliary DC jack 1
9 Passenger handhold base 1
4-20
GENERAL CHASSIS (6)
Removing the dashboard (center)

0.4 N•m (0.04 kgf•m, 0.30 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
T.R
.
.
3
1
6
9 5
8
10
7 2 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
4
1.3 N•m (0.13 kgf•m, 0.95 lb•ft) T.R

.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
0.4 N•m (0.04 kgf•m, 0.30 lb•ft)

T.R
.
T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

1 GPS monitor 1 YXF10WRZN/YXF10WRLN
2 GPS monitor adapter coupler 1 Disconnect.

YXF10WRZN/YXF10WRLN
3 USB jack coupler 1 Disconnect.

YXF10WRZN/YXF10WRLN
4 Interior light coupler 1 Disconnect.

YXF10WRZN/YXF10WRLN
5 Winch switch coupler 1 Disconnect.

YXF10WRZN/YXF10WRLN
6 Audio control panel connector 1 Disconnect.

YXF10WRZN/YXF10WRLN
7 AUX input socket coupler 1 Disconnect.

YXF10WRZN/YXF10WRLN
8 Dashboard (center) 1
9 GPS monitor adapter 1 YXF10WRZN/YXF10WRLN
10 Plug 1 YXF10WRAN
4-21
GENERAL CHASSIS (6)
Removing the dashboard (center)

T.R
T.R
.
.
11
19 12
15
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
17
18
16
20 14
13
1.3 N•m (0.13 kgf•m, 0.95 lb•ft) T.R

.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
0.4 N•m (0.04 kgf•m, 0.30 lb•ft)

T.R
.
T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

11 USB jack 1 YXF10WRZN/YXF10WRLN
12 Plug 1 YXF10WRAN
13 Interior light (center) 1 YXF10WRZN/YXF10WRLN
14 Plug 1 YXF10WRAN
15 Winch switch 1 YXF10WRZN/YXF10WRLN
16 Plug 1 YXF10WRAN
17 Plug 2 YXF10WRAN/YXF10WRZN
18 USB converter 1 YXF10WRZN/YXF10WRLN
19 Audio control panel unit 1 YXF10WRZN/YXF10WRLN
20 AUX input socket 1 YXF10WRZN/YXF10WRLN
4-22
GENERAL CHASSIS (6)
EBS30808
REMOVING THE STEERING WHEEL

1. Turn the steering wheel so that it is straight
and the front wheels are pointing straight
3
ahead.
2. Remove: a
• Steering wheel cover “1” a a
2
TIP 1
While pushing the ends of the projections “a” to-
gether, remove the steering wheel cover from
the steering wheel. EBS30968
REMOVING THE STEERING COLUMN

COVER
1. Remove:
a
• Steering wheel tilt lever “1”
a. Pull the steering wheel tilt lever rearward
completely.
1 b. Quickly push the steering wheel tilt lever
forward and at the same time pull it out-
ward to remove the steering wheel tilt le-
ver.
3. Remove: 2. Remove the steering column cover “2”.
• Steering wheel “1”
TIP
Use a general puller “2” to separate the steering
wheel and steering column.
1 2
1
2 EBS30969
INSTALLING THE PASSENGER HANDHOLD

1. Install:
• Passenger handhold grip “1”
Passenger handhold grip bolt

EBS30967
33 N·m (3.3 kgf·m, 24 lb·ft)
T.
REMOVING THE DASHBOARD

R.
1. Remove:
TIP
• Light switch “1”
• On-Command four-wheel-drive switch “2” Tighten the passenger handhold bolts in the
proper tightening sequence as shown.
TIP
Push the portions “a” on the switch, and then re-
move the switch from the dashboard “3”. 1
3
4-23
GENERAL CHASSIS (6)
EBS30809
INSTALLING THE STEERING WHEEL

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

50 N·m (5.0 kgf·m, 37 lb·ft)
T.
R.
TIP
Install the steering wheel onto the steering col-
umn so that it is centered as shown in the illus-
tration.
2. Operate the vehicle at low speeds and make

sure that the steering wheel is straight when
the vehicle is advancing straight ahead.
4-24
GENERAL CHASSIS (7)
EBS20092
GENERAL CHASSIS (7)

Removing the rear floor boards
T.R
T.R
.
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
6
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
1.3 N•m (0.13 kgf•m, 0.95 lb•ft)
2
T.R
.
7 59 N•m (5.9 kgf•m, 44 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
8
4
3
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
17 N•m (1.7 kgf•m, 13 lb•ft)

1
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
Rear door strikers Refer to “GENERAL CHASSIS (1)” on page

4-1.
4-7.

4-16.
1 Floor board side cover 1
2 Fuel tank cover 1
3 Rear fender (lower left) 1
4 Rear mudguard (left) 1
5 Rear floor board (left) 1
6 Rear fender (lower right) 1
7 Rear mudguard (right) 1
8 Rear floor board (right) 1
4-25
GENERAL CHASSIS (7)
Removing the rear floor boards

T.R
T.R
.
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
12 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
1.3 N•m (0.13 kgf•m, 0.95 lb•ft)
T.R
.
59 N•m (5.9 kgf•m, 44 lb•ft)
T.R
.
16 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
13 10 17
15
14
9
11
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
14
17 N•m (1.7 kgf•m, 13 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

9 Seat belt switch coupler 1 Disconnect.
10 Driver seat belt buckle 1
11 Driver seat belt buckle rubber cover 1
12 Passenger seat belt buckle 1
13 Passenger seat belt buckle rubber cover 1
14 Rear floor board bracket 2
15 Auxiliary DC jack coupler 1 Disconnect.

YXF10WRZN/YXF10WRLN
16 Auxiliary DC jack cover 1 YXF10WRZN/YXF10WRLN
17 Auxiliary DC jack 1 YXF10WRZN/YXF10WRLN
4-26
GENERAL CHASSIS (7)
Removing the front floor boards
6 7 N•m (0.7 kgf•m, 5.2 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
T.R
.
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
7
5
1
(4)
4
8 3
6
2
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
T.R
.
T.R
.

Brake master cylinder cover/Front over fender Refer to “GENERAL CHASSIS (1)” on page
inner panels/Front doors 4-1.

4-15.
Dashboards (left, right, and center) Refer to “GENERAL CHASSIS (6)” on page
4-17.
1 Dust cover 1
2 Front mudguard (left) 1
3 Front floor board (left) 1
4 Front mudguard (right) 1
5 Front floor board (right) 1
6 Plug 4
7 Driver seat rail bracket 1
8 Floor board under bracket 1
4-27
GENERAL CHASSIS (8)
EBS20102
GENERAL CHASSIS (8)

Removing the sun top
4 4
4
4 4
3
4 3
3 2
2
3
3
2 2
3
2
1
2
1
T.R
.
T.R
.

1 Sun top holder 3
2 Sun top holder 6
3 Damper 6
4 Sun top bracket 6
5 Sun top 1
4-28
GENERAL CHASSIS (9)
EBS20103
GENERAL CHASSIS (9)

Removing the rear speaker
5 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
6 9
7 N•m (0.7 kgf•m, 5.2 lb•ft)
2
T.R
.
4
7
7 8
3 3
3 7
7 6
1
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft) 3

T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
11
10
Floor board side cover Refer to “GENERAL CHASSIS (7)” on page

4-25.
1 Rear speaker coupler (left) 1 Disconnect.
2 Rear speaker coupler (right) 1 Disconnect.
3 Speaker bracket 1 4
4 Rear speaker assembly (left) 1
5 Rear speaker assembly (right) 1
8 Rear speaker (left) 1
9 Rear speaker (right) 1
10 Sub-wire harness coupler (rear speaker) 2 Disconnect.
11 Sub-wire harness (rear speaker) 1 Disconnect.
4-29
GENERAL CHASSIS (10)
EBS20104

Removing the enclosure
120 N•m (12 kgf•m, 89 lb•ft) 6 1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
T.R
T.R
.
.
80 N•m (8.0 kgf•m, 59 lb•ft)
T.R
.
3
80 N•m (8.0 kgf•m, 59 lb•ft)
T.R
.
45 N•m (4.5 kgf•m, 33 lb•ft)

7 8 9
T.R
9 4
.
8
13 5
10
11
120 N•m (12 kgf•m, 89 lb•ft) 2

T.R
.
12
17 N•m (1.7 kgf•m, 13 lb•ft)

T.R
.
120 N•m (12 kgf•m, 89 lb•ft)

T.R
.
Floor board side cover Refer to “GENERAL CHASSIS (7)” on page

4-25.
Sun top Refer to “GENERAL CHASSIS (8)” on page

4-28.
Rear speaker (left and right) Refer to “GENERAL CHASSIS (9)” on page
4-29.
1 Rearview mirror 1 YXF10WRZN/YXF10WRLN
2 Rearview mirror bracket 1 YXF10WRZN/YXF10WRLN
3 Rear frame 1
4 Rear top frame 1
5 Rear side frame (left) 1
6 Rear side frame (right) 1
7 Front center frame 1
8 Rear passenger hand grip (lower) 2
9 Rear passenger hand grip (upper) 2
4-30
Removing the enclosure

120 N•m (12 kgf•m, 89 lb•ft) 6 1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
T.R
T.R
.
.
80 N•m (8.0 kgf•m, 59 lb•ft)
T.R
.
3
80 N•m (8.0 kgf•m, 59 lb•ft)
T.R
.
45 N•m (4.5 kgf•m, 33 lb•ft)

7 8 9
T.R
9 4
.
8
13 5
10
11
120 N•m (12 kgf•m, 89 lb•ft) 2

T.R
.
12
17 N•m (1.7 kgf•m, 13 lb•ft)

T.R
.
120 N•m (12 kgf•m, 89 lb•ft)

T.R
.

10 Center top frame 1
11 Front top frame 1
12 Front side frame (left) 1
13 Front side frame (right) 1
4-31
EBS30076
INSTALLING THE ENCLOSURE Front center frame upper bolt

1. Install: 80 N·m (8.0 kgf·m, 59 lb·ft)
T.
R.
• Front side frame (right) Front center frame lower bolt
• Front side frame (left) 80 N·m (8.0 kgf·m, 59 lb·ft)
• Front top frame “1” Center top frame bolt
• Center top frame 80 N·m (8.0 kgf·m, 59 lb·ft)
• Front center frame Front top frame bolt
• Rear side frame (right) 80 N·m (8.0 kgf·m, 59 lb·ft)
• Rear side frame (left) Rear frame bolt
80 N·m (8.0 kgf·m, 59 lb·ft)
• Rear top frame
Rear top frame bolt
• Rear frame 80 N·m (8.0 kgf·m, 59 lb·ft)
TIP Front side frame and rear side
• Install the front top frame so that the drain hole frame nut
“a” facing the left side of the vehicle. 120 N·m (12 kgf·m, 89 lb·ft)
• Do not fully tighten the bolts and nuts. Front side frame and frame nut
45 N·m (4.5 kgf·m, 33 lb·ft)
Front side frame and frame bolt
120 N·m (12 kgf·m, 89 lb·ft)
1 Rear side frame and frame nut
120 N·m (12 kgf·m, 89 lb·ft)
6
4 3 7
7 5
4 1
a
6
9 3
2
2. Tighten: 1
9 8 5
• Front center frame upper bolt (left and right) 2
• Front center frame lower bolt (left and right) 8 10
10
• Center top frame bolt (left and right)
• Front top frame bolt (left and right)
• Rear frame bolt (left and right)
• Rear top frame bolt (left and right)
• Front side frame and rear side frame nut (left
and right)
• Front side frame and frame nut (rear left and
right)
• Front side frame and frame bolt (front left and
right)
• Rear side frame and frame nut (left and right)
TIP
Tighten the bolts and nuts in the proper tighten-
ing sequence as shown (1, 2, and so on).
4-32
EBS20123

Removing the skid plate and front guard covers
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
4
2
3
7 N•m (0.7 kgf•m, 5.2 lb•ft)

(4)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft) (4)

T.R
.

1 Skid plate 1
2 Front guard cover (center) 1 YXF10WRZN/YXF10WRLN
3 Front guard cover (left) 1 YXF10WRZN/YXF10WRLN
4 Front guard cover (right) 1 YXF10WRZN/YXF10WRLN
4-33
Removing the front guard and winch

88 N•m (8.8 kgf•m, 65 lb•ft)
T.R
.
4.5 N•m (0.45 kgf•m, 3.3 lb•ft)
T.R
.
1
2
6
5
New
4
(4) 88 N•m (8.8 kgf•m, 65 lb•ft)

T.R
.
16 N•m (1.6 kgf•m, 12 lb•ft)

T.R
.
3
88 N•m (8.8 kgf•m, 65 lb•ft)
T.R
.
53 N•m (5.3 kgf•m, 39 lb•ft)

T.R
.

Disconnect.
Battery leads Refer to “GENERAL CHASSIS (14)” on
page 4-42.
1 Winch power lead 3 (blue)/4 (yellow) 1/1 Disconnect.

YXF10WRZN/YXF10WRLN
2 Front guard 1
3 Pin 1 YXF10WRZN/YXF10WRLN
4 Hook 1 YXF10WRZN/YXF10WRLN
5 Fairlead 1 YXF10WRZN/YXF10WRLN
6 Winch 1 YXF10WRZN/YXF10WRLN
4-34
EBS30953
• After connecting the winch power leads 3 and
WINCH (YXF10WRZN/YXF10WRLN)
4, cover the terminal with the terminal covers.
TIP
For information about checking the operation, Winch power lead nut
refer to the Winch Owner’s Manual. 4.5 N·m (0.45 kgf·m, 3.3 lb·ft)
T.
R.
EBS30937
INSTALLING THE HOOK (YXF10WRZN/

YXF10WRLN) 2
1
1. Install:
• Hook “1”
• Pin “2”
• Cotter pin “3” New
(to the winch rope “4”)
TIP a
• Bend the cotter pin as shown in the illustration.
• Make sure that the hook strap “5” is installed
correctly in the hook.
2
4
New
3 1
5
1
2
3
4
EBS30952
INSTALLING THE WINCH (YXF10WRZN/

YXF10WRLN)
1. Install:
• Winch power lead 3 (blue) “1”
• Winch power lead 4 (yellow) “2”
TIP
• Match the colors of the winch power leads to
the colors of the color washers “a”.
• When installing the winch power lead nut, hold
the lower nut and tighten the winch power lead
nut to specification.
4-35
EBS20124

Removing the front fenders and front grill
T.R
T.R
.
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
2.8 N•m (0.28 kgf•m, 2.1 lb•ft)
T.R
.
2.8 N•m (0.28 kgf•m, 2.1 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
Front over fenders Refer to “GENERAL CHASSIS (1)” on page

4-1.
Hood/Front cover/Front grill rear covers Refer to “GENERAL CHASSIS (4)” on page
4-15.
Front guard Refer to “GENERAL CHASSIS (11)” on

page 4-33.
4-36
Removing the front fenders and front grill

T.R
T.R
.
.
13 4
11
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
6
2
2.8 N•m (0.28 kgf•m, 2.1 lb•ft)

T.R
.
1
10 3
12
2.8 N•m (0.28 kgf•m, 2.1 lb•ft)
T.R
.
7
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

1 Front fender (left) 1
2 Front fender (right) 1
3 Headlight coupler (left) 1 Disconnect.
4 Headlight coupler (right) 1 Disconnect.
5 Auxiliary light coupler (left) 1 Disconnect.
6 Auxiliary light coupler (right) 1 Disconnect.
7 Front grill molding (left) 1
8 Front grill molding (right) 1
9 Front grill 1
10 Auxiliary light (left) 1
11 Auxiliary light (right) 1
12 Headlight (left) 1
13 Headlight (right) 1
4-37
EBS20161

Removing the air filter case and air intake accumulator
2.5 N•m (0.25 kgf•m, 1.8 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft) 3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
T.R
T.R
.
.
.
7 N•m (0.7 kgf•m, 5.2 lb•ft) 1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
T.R
.
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
New
.
New
(4) New
(10)
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.
4-7.
Hood Refer to “GENERAL CHASSIS (4)” on page

4-15.

4-16.
Air cut-off valve bracket 2 Refer to “AIR INDUCTION SYSTEM” on

page 7-18.
4-38

T.R
T.R
T.R
.
.
.
T.R
T.R
.
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
New
.
1 New
(4) New
3 6
4
(10)
7
5
8
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
9
2 10 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)
T.R
.

1 Air filter case cover 1
2 Primary air filter assembly 1
3 Air filter element lock plate 1
4 Foam air filter element 1
5 Air filter element frame 1
6 Secondary air filter element 1
7 Air filter case 1
8 Air filter case duct joint 1 1
10 Air filter case duct 1 1
4-39

T.R
T.R
T.R
.
.
.
T.R
T.R
21
.
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft) 22 18 12

T.R
New
.
20
New
(4) New 19
15
16 11
(10)
13
17
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
14
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.

11 Engine oil tank breather hose 1
12 Cylinder head breather hose 1
13 Air induction system hose (air intake accumula- 1

tor to air cut-off valve)
14 Intake air temperature sensor coupler 1 Disconnect.
15 Air intake accumulator assembly 1
17 Air filter case duct 2 1
18 Intake air temperature sensor 1
19 Air intake accumulator case (left) 1
20 Air intake accumulator case (right) 1
21 Plate 1
22 Damper 1
4-40
EBS30860
INSTALLING THE AIR INTAKE

ACCUMULATOR
1. Install:
• Air intake accumulator joint clamp “1”
Air intake accumulator joint

clamp screw
T.
R.
3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
TIP
Align the projection “a” on the air intake accumu-
lator joint with the slot “b” in the air intake accu-
mulator joint clamp.
1
b
a
a b
4-41
EBS20162

Removing the SCU and audio pilot unit (YXF10WRZN/YXF10WRLN)
T.R
T.R
.
.
1 8
2
7
6
5
4
Hood 1 Refer to “GENERAL CHASSIS (4)” on page

4-15.
1 SCU coupler 1 Disconnect.

YXF10WRLN
2 SCU (Suspension Control Unit) 1 YXF10WRLN
3 AUX input socket coupler 1 Disconnect.
4 Antenna connector 1 Disconnect.
5 Audio control panel connector 1 Disconnect.
6 Sub-wire harness coupler (speaker) 2 Disconnect.
7 Sub-wire harness coupler (audio pilot unit pow- 1 Disconnect.

er supply)
8 Audio pilot unit 1
4-42
Removing the battery, relays, fuses, ECU, EPS control unit, and winch contactor
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
4
5
3
3.6 N•m (0.36 kgf•m, 2.7 lb•ft) 2 6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
T.R
.
.
1 3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft) 6
13
T.R
.
12 9 8
7 N•m (0.7 kgf•m, 5.2 lb•ft) 7
10
T.R
.
11
4.5 N•m (0.45 kgf•m, 3.3 lb•ft)

T.R
.

4-15.
1 Winch power lead 2 (black) 1 YXF10WRZN/YXF10WRLN
2 Negative battery lead 1 Disconnect.
3 Positive battery lead 1 Disconnect.
4 Winch power lead 1 (red) 1 YXF10WRZN/YXF10WRLN
5 Battery holding bracket 1
6 Battery 1
7 Starter relay 1
8 Main fuse 1
9 EPS fuse 1
10 Load control relay 1
11 Accessory relay 1
12 Radiator fan motor relay 1
13 Main relay 1
4-43
Removing the battery, relays, fuses, ECU, EPS control unit, and winch contactor
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
T.R
T.R
.
.
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)
T.R
.
14 18
24
7 N•m (0.7 kgf•m, 5.2 lb•ft) 15
T.R
.
16
23 17
19
22
21
20
4.5 N•m (0.45 kgf•m, 3.3 lb•ft)

T.R
.

14 Reverse light relay 1
15 Differential motor relay 1 1
16 Differential motor relay 2 1
17 Band 1
18 ECU (Engine Control Unit) 1
19 EPS (electric power steering) control unit 1
20 Winch power lead 4 (yellow) 1 Disconnect.

YXF10WRZN/YXF10WRLN
21 Winch power lead 3 (blue) 1 Disconnect.

YXF10WRZN/YXF10WRLN
22 Winch contactor 1 YXF10WRZN/YXF10WRLN
23 Sub-wire harness (winch) 1 YXF10WRZN/YXF10WRLN
24 Lean angle sensor 1
4-44
Removing the electrical components tray
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
(7)
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
(7)

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-13.
Front over fenders/Front door (left) Refer to “GENERAL CHASSIS (1)” on page
4-1.
4-7.

4-15.

4-16.
Dashboard (left)/Steering column cover Refer to “GENERAL CHASSIS (6)” on page

4-17.
Front fenders Refer to “GENERAL CHASSIS (12)” on

page 4-36.
Air filter case Refer to “GENERAL CHASSIS (13)” on

page 4-38.
Coolant reservoir Refer to “RADIATOR” on page 6-7.
4-45
Removing the electrical components tray

4 2.5 N•m (0.25 kgf•m, 1.8 lb•ft)
T.R
.
1 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
3
6
2
(7)
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
5
(7)

1 Wire harness 1
2 Sub-wire harness (SCU) 1 YXF10WRLN
3 EPS motor lead 1
4 EPS torque sensor lead 1
5 Electrical components tray (left) 1
6 Radiator cap access cover 1
7 Electrical components tray (right) 1
4-46
EBS20163

Removing the rear fenders and tail/brake light assemblies
New
7 N•m (0.7 kgf•m, 5.2 lb•ft) 2

T.R
.
1
4
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
T.R
T.R
.

the rear fenders.
Rear door latch strikers Refer to “GENERAL CHASSIS (1)” on page

4-1.
4-7.

4-16.
Rear floor boards Refer to “GENERAL CHASSIS (7)” on page

4-25.
1 Rear fender 1
2 Tail/brake light assembly coupler 2 Disconnect.
3 Tail/brake light assembly bracket 1
4 Tail/brake light assembly 1
5 Shoulder bolster 1
4-47
Removing the cargo bed
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
(8) 1
(7) 10
(4)
(13) 4 6 7
9 N•m (0.9 kgf•m, 6.6 lb•ft)
5
T.R
.
6 8
9 5
7
11 2
3
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.
T.R
T.R
.
.

Rear passenger seat belts/Rear passenger seat Refer to “GENERAL CHASSIS (3)” on page
belt buckles 4-12.
1 Tailgate cable 2
2 Tailgate assembly 1
3 Tailgate shaft 1
4 Cargo bed release lever cover 1
5 Clip 2
6 Rod 2
7 Damper 2
8 Cargo bed release lever 1
9 Tailgate latch (left) 1
10 Tailgate latch (right) 1
11 Tailgate 1
4-48
Removing the cargo bed
15
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
(8)
14
(7) 13 (4)
9 N•m (0.9 kgf•m, 6.6 lb•ft) (13)
T.R
.
12
8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.R
.
12 9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.
T.R
T.R
.
.

12 Tailgate latch striker 2
13 Cap 7
14 Cargo bed 1
15 Seat belt buckle storage compartment cover 1
4-49
EBS30810
DISASSEMBLING THE CARGO BED

1. Remove:
• Tailgate “1” 1
TIP
Align the slot “a” in the left end of the tailgate
shaft with the flat portions of the projection “b” on
the frame, and then lift the left end of the tailgate.
b
c a
3. Install:
1 • Tailgate cable “1”
Tailgate cable bolt (frame side)

8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.
Tailgate cable bolt (tailgate side)
9 N·m (0.9 kgf·m, 6.6 lb·ft)
a
b
TIP
EBS30811
Connect the straight end “a” of each tailgate ca-
ASSEMBLING THE CARGO BED
ble to the tailgate, and the offset end “b” to the
1. Install:
cargo bed.
• Tailgate shaft “1”
Tailgate shaft screw

9 N·m (0.9 kgf·m, 6.6 lb·ft)
T.
R.
1
TIP
b
Install the tailgate shaft so that the end with the a
slot “a” is pointing to the left.
1
a
2. Install:
• Tailgate “1”
a. Fit the right end of the tailgate shaft onto
the projection “a” on the frame.
b. Align the slot “b” in the left end of the tail-
gate shaft with the flat portions of the pro-
jection “c” on the frame, and then fit the
tailgate shaft onto the projection.
TIP
When installing the tailgate, position the tailgate
at an angle as shown in the illustration.
4-50
EBS20164

Removing the V-belt cooling ducts
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft) 1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
T.R
.

Front over fenders/Front doors/Rear door latch Refer to “GENERAL CHASSIS (1)” on page
strikers 4-1.
Seat rails/Front passenger seat frame Refer to “GENERAL CHASSIS (2)” on page
4-7.

4-15.

4-16.
4-17.
Rear floor boards/Front floor boards Refer to “GENERAL CHASSIS (7)” on page
4-25.
Air intake accumulator assembly Refer to “GENERAL CHASSIS (13)” on

page 4-38.
4-51
Removing the V-belt cooling ducts
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.
6 3
5 4
7 9
10
8 2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft) 1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
T.R
.

1 V-belt cooling intake duct 1 1
2 V-belt cooling intake duct joint 1 1
9 V-belt cooling exhaust duct 1
10 V-belt cooling exhaust duct joint 1
4-52
EBS30348
INSTALLING THE V-BELT COOLING DUCTS

1. Install:
• V-belt cooling exhaust duct joint “1”
• V-belt cooling intake duct joint 2 “2”
TIP
• Fit the projection “a” on V-belt cooling exhaust
duct joint between the projections “b” on the
drive belt cover and V-belt cooling exhaust
duct.
• Fit the projection “c” on V-belt cooling intake
duct joint 2 between the projections “d” on the
crankcase “6”.
• Align the slit “e” in V-belt cooling intake duct
joint 4 with the projection “f” on the drive belt
cover.
• Position the screw clamp so that its screwhead
is facing in the direction shown in the illustra-
tion.
a b
b
a
c 6 f e
5
4 d
2
3
2
4-53
FRONT AND REAR WHEELS
EBS20025

Removing the front wheels and front brake discs
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
43 N•m (4.3 kgf•m, 32 lb•ft)
T.R
.
3 7
6 370 N•m (37 kgf•m, 273 lb•ft)
T.R
.
(4)
3 5 New
LT 2
4
50 N•m (5.0 kgf•m, 37 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
(4)
1
D
FW
95 N•m (9.5 kgf•m, 70 lb•ft)
T.R
.

the front wheels.
1 Wheel 1
2 Wheel cap 1
3 Brake hose holder 3
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 axle nut 1

6 Wheel hub 1
7 Brake disc 1
4-54
Removing the rear wheels and rear brake discs
FW
D
43 N•m (4.3 kgf•m, 32 lb•ft)
T.R
.
LT
(4)
6
5
3
4 New
370 N•m (37 kgf•m, 273 lb•ft)
2
T.R
.
50 N•m (5.0 kgf•m, 37 lb•ft)
T.R
.
(4)
95 N•m (9.5 kgf•m, 70 lb•ft)

T.R
.

the rear wheels.
Stabilizer joints/Rear shock absorber assem- Refer to “REAR STABILIZER, REAR

blies SHOCK ABSORBER ASSEMBLIES, AND
REAR ARMS” on page 4-105.
1 Wheel 1
2 Wheel cap 1
TIP
3 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.
4 Wheel axle nut 1

5 Wheel hub 1
6 Brake disc 1
4-55
EBS30083 EBS30085
REMOVING THE WHEELS CHECKING THE WHEELS

1. Place the vehicle on a level surface. The following procedure applies to all of the
2. Elevate: wheels.
• Wheel 1. Check:
TIP • Tire
Place the vehicle on a suitable stand so that the • Wheel
wheels are elevated. Refer to “CHECKING THE TIRES” on page
3-31 and “CHECKING THE WHEELS” on
EBS30084
page 3-30.
EWB03020
REMOVING THE WHEEL HUBS
WARNING
wheel hubs. After replacing the tire, ride conservatively to
1. Straighten the wheel axle nut rib “a”. allow the tire to be properly seated in the rim.
Failure to do so may cause an accident re-
sulting in vehicle damage and possible inju-
a ry.
G101441
2. Remove:
• Wheel axle nut
3. Remove: G101443
• Front brake caliper 2. Measure:

• Rear brake caliper • Radial wheel runout “1”
Refer to “REMOVING THE REAR BRAKE • Lateral wheel runout “2”
CALIPERS” on page 4-67. Over the specified limit → Replace the wheel
TIP or check the wheel bearing play.
Do not apply the brake pedal when removing the Refer to “CHECKING THE STEERING
brake caliper. KNUCKLES AND FRONT WHEEL BEAR-
INGS” on page 4-95 and “CHECKING THE
4. Remove: REAR KNUCKLES AND REAR WHEEL
• Wheel hub “1” BEARINGS” on page 4-104.
TIP
Use a general puller “2” to separate the wheel Front wheel
hub and constant velocity shaft. Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
1.0 mm (0.04 in)
Rear wheel
1 Radial wheel runout limit
2 1.0 mm (0.04 in)
Lateral wheel runout limit
1.0 mm (0.04 in)
4-56
TIP
Tap lightly on the wheel hub with a soft-face
2 hammer until five threads on the end of the con-
stant velocity shaft will be exposed when the
1 washer is installed.
G101442
EBS30086
CHECKING THE WHEEL HUBS 1

wheel hubs.
1. Check:
• Wheel hub
Cracks/damage → Replace. 2. Install:
• Splines (wheel hub) • Wheel axle nut New
Wear/damage → Replace the wheel hub.
Front wheel axle nut
EBS30087
370 N·m (37 kgf·m, 273 lb·ft)
T.
INSTALLING THE BRAKE DISCS
R.
Rear wheel axle nut
The following procedure applies to all of the 370 N·m (37 kgf·m, 273 lb·ft)
brake discs.
1. Install: TIP
• Brake disc
• Do not apply oil to the threads of the nut.
Brake disc bolt • After tightening the nut, stake the collar of the
43 N·m (4.3 kgf·m, 32 lb·ft) nut into the notch of the shaft.
T.
R.
LOCTITE®
TIP
Install the brake disc so that the recessed por-
tion of the bolt hole faces away from the hub.
G101604
3. Check:
• Brake disc
Refer to “CHECKING THE BRAKE DISCS”
on page 4-66.
G101444
EBS30089
EBS30088 INSTALLING THE WHEELS

INSTALLING THE WHEEL HUBS The following procedure applies to all of the
The following procedure applies to all of the wheels.
wheel hubs. 1. Tighten:
1. Install: • Wheel nut “1”
• Wheel hub “1”
Front wheel nut
95 N·m (9.5 kgf·m, 70 lb·ft)
T.
R.
Rear wheel nut

95 N·m (9.5 kgf·m, 70 lb·ft)
4-57
EWB03130
WARNING
Tapered wheel nuts are used for both the
front and rear wheels. Install each nut with
its tapered side towards the wheel.
G101445
4-58
FRONT AND REAR BRAKES
EBS20026

Removing the front brake pads
1
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
22 N•m (2.2 kgf•m, 16 lb•ft)

T.R
.
5 N•m (0.5 kgf•m, 3.7 lb•ft) 3

T.R
.
4
D
FW

the front brake calipers.
Front wheels Refer to “FRONT AND REAR WHEELS” on

page 4-54.
2 Front brake caliper retaining pin bolt 1
TIP
3 Brake pad 2 Replace the brake pads and brake pad
springs as a set.
4 Brake pad spring 2
4-59
Removing the rear brake pads
FW 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
D
.
5 N•m (0.5 kgf•m, 3.7 lb•ft)
1
T.R
.
22 N•m (2.2 kgf•m, 16 lb•ft)
T.R
.
2

the rear brake calipers.
Rear wheels Refer to “FRONT AND REAR WHEELS” on

page 4-54.
2 Rear brake caliper guide pin bolt 1
TIP
springs as a set.
4-60
Removing the front brake calipers
27 N•m (2.7 kgf•m, 20 lb•ft)

T.R
.
1
3
4
2 New
5
50 N•m (5.0 kgf•m, 37 lb•ft)

T.R
.
D
FW


page 4-54.
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-25.
1 Brake hose union bolt 1
2 Copper washer 2
3 Brake hose 1 Disconnect.
4 Brake caliper bolt 2
5 Brake caliper 1
4-61
Removing the rear brake calipers
FW
D
50 N•m (5.0 kgf•m, 37 lb•ft)
T.R
.
27 N•m (2.7 kgf•m, 20 lb•ft)
T.R
.
2 New
4
2 New
3 1
5 4
50 N•m (5.0 kgf•m, 37 lb•ft)

T.R
.


page 4-54.
Drain.
Rear stabilizer joints/Rear shock absorber as- Refer to “REAR STABILIZER, REAR
semblies SHOCK ABSORBER ASSEMBLIES, AND
1 Brake hose union bolt 1
2 Copper washer 2
3 Brake hose 1 Disconnect.
4 Brake caliper bolt 2
5 Brake caliper 1
4-62
Disassembling the front brake calipers

5 N•m (0.5 kgf•m, 3.7 lb•ft)
T.R
3
.
22 N•m (2.2 kgf•m, 16 lb•ft)

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

T.R
4
.
S
S BF
BF

1 Front brake caliper guide pin bolt 1
2 Front brake caliper retaining pin bolt 1
TIP
springs as a set.

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
4-63
Disassembling the rear brake calipers

5 N•m (0.5 kgf•m, 3.7 lb•ft)
T.R
.
3
22 N•m (2.2 kgf•m, 16 lb•ft)
T.R
.
1
11
S
6
S BF
BF
9 2
10
8 7 BF
22 N•m (2.2 kgf•m, 16 lb•ft)

4
T.R
.
S
S
BF

1 Rear brake caliper retaining pin bolt 1
2 Rear brake caliper guide pin bolt 1
TIP
springs as a set.

5 Brake caliper bracket 1
6 Brake caliper retaining pin 1
7 Brake caliper guide pin 1
9 Brake caliper piston dust seal 2
10 Brake caliper piston seal 2
11 Bleed screw 1
4-64
Removing the brake master cylinder
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)

T.R
.
1 19 N•m (1.9 kgf•m, 14 lb•ft)
T.R
.
3
5
4
D
FW
16 N•m (1.6 kgf•m, 12 lb•ft)
T.R
.
Brake master cylinder cover Refer to “GENERAL CHASSIS (1)” on page

4-1.
Dust cover Refer to “GENERAL CHASSIS (7)” on page

4-25.
Drain.
1 Brake master cylinder reservoir cap 1
2 Brake master cylinder reservoir diaphragm 1
3 Brake master cylinder reservoir diaphragm hold- 1

er
4 Front brake pipe 1 Disconnect.
5 Rear brake pipe 1 Disconnect.
6 Brake master cylinder 1
4-65
EBS30090
INTRODUCTION
EWB02930
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 G101446
system is disconnected, the entire brake
system must be disassembled, drained, 4. Measure:
cleaned, properly filled, and bled after reas- • Brake disc thickness
sembly. Measure the brake disc thickness at a few dif-
• Never use solvents on internal brake com- ferent locations.
ponents. Out of specification → Replace the brake
• Use only clean or new brake fluid for clean- disc.
ing brake components. Front brake
• Brake fluid may damage painted surfaces Brake disc thickness limit
and plastic parts. Therefore, always clean 5.0 mm (0.20 in)
up any spilt brake fluid immediately. Rear brake
• Avoid brake fluid coming into contact with Brake disc thickness limit
the eyes as it can cause serious injury. 5.0 mm (0.20 in)
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES: 5. Replace:
• Flush with water for 15 minutes and get im- • Brake disc
mediate medical attention. Refer to “INSTALLING THE BRAKE DISCS”
on page 4-57.
EBS30091 6. Install:
CHECKING THE BRAKE DISCS • Wheel
The following procedure applies to all of the Refer to “FRONT AND REAR WHEELS” on
brake discs. page 4-54.
1. Remove:
EBS30092
• Wheel REPLACING THE BRAKE PADS
Refer to “FRONT AND REAR WHEELS” on The following procedure applies to all of the
page 4-54. brake calipers.
2. Check:
TIP
• Brake disc
Damage/galling → Replace. When replacing the brake pads, it is not neces-
3. Measure: sary to disconnect the brake hose or disassem-
• Brake disc deflection ble the brake caliper.
Out of specification → Replace the brake 1. Measure:
disc. • Brake pad wear limit “a”
Out of specification → Replace the brake
Front brake
pads as a set.
Brake disc runout limit
0.10 mm (0.0039 in) Front brake
Rear brake Brake pad lining thickness limit
0.10 mm (0.0039 in) Rear brake
Brake pad lining thickness limit
a. Hold the dial gauge at a right angle against 1.0 mm (0.04 in)
the brake disc surface.
b. Measure the deflection 3.0 mm (0.12 in)
below the edge of the brake disc.
4-66
4. Check:
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
a LEVEL” on page 3-24.
5. Check:
• Brake pedal operation
Soft or spongy feeling → Bleed the brake sys-
tem.
2. Install: Refer to “BLEEDING THE HYDRAULIC
• Brake pad spring BRAKE SYSTEM” on page 3-25.
• Brake pad insulator
EBS30973
(rear brake only) REMOVING THE REAR BRAKE CALIPERS
• Brake pad shim The following procedure applies to both of the
(rear brake only) rear brake calipers.
• Brake pad 1. Remove:
TIP • Rear stabilizer joint
Always install new brake pads and brake pad • Rear shock absorber assembly
spring as a set. Refer to “REAR STABILIZER, REAR
SHOCK ABSORBER ASSEMBLIES, AND
a. Connect a clear plastic hose “1” tightly to
the bleed screw “2”. Put the other end of
2. Remove:
the hose into an open container.
• Rear brake caliper “1”
b. Loosen the bleed screw and push the
brake caliper pistons into the brake caliper TIP
with your finger. Raise rear arms “2” to a position parallel to the
ground as shown, and remove the rear brake
1 2 caliper lower bolt.
1 2
c. Tighten the bleed screw.
Brake caliper bleed screw

5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
2
R.
3. Install:
• Brake caliper
Front brake caliper retaining pin

bolt
T.
R.
22 N·m (2.2 kgf·m, 16 lb·ft)

Rear brake caliper guide pin bolt
22 N·m (2.2 kgf·m, 16 lb·ft)
4-67
EBS30093
• Brake caliper cylinder
DISASSEMBLING THE BRAKE CALIPERS
Scratches/wear → Replace the brake caliper.
• Brake caliper body
brake calipers.
Cracks/damage → Replace the brake cali-
TIP per.
Before disassembling the brake caliper, drain • Brake fluid delivery passages
the brake fluid from the entire brake system. (brake caliper body)
1. Remove: Obstruction → Blow out with compressed air.
EWB03140
• Brake caliper piston WARNING
• Brake caliper piston dust seal
Whenever a brake caliper is disassembled,
• Brake caliper piston seal
replace the brake caliper piston dust seals
a. Blow compressed air into the brake hose
and brake caliper piston seals.
joint opening “a” to force out the pistons
from the brake caliper. EBS30095
EWB02890
WARNING
ASSEMBLING THE BRAKE CALIPERS
• Cover the brake caliper piston with a rag. brake calipers.
Be careful not to get injured when the pis- EWB03150
ton is expelled from the brake caliper. WARNING

• Never try to pry out the brake caliper pis- • Before installation, all internal brake com-
ton. ponents should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake com-
ponents as they will cause the brake caliper
piston dust seals and brake caliper piston
seals to swell and distort.
• Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seals
and brake caliper piston seals.
a
b. Remove the brake caliper piston dust DOT 4
seals and piston seals.
EBS30096
EBS30094 INSTALLING THE BRAKE CALIPERS
CHECKING THE BRAKE CALIPERS The following procedure applies to all of the
The following procedure applies to all of the brake calipers.
brake calipers. 1. Install:
Recommended brake component replacement • Brake caliper “1”
schedule (temporarily)
Brake pads If necessary • Copper washer New
Piston seals, piston • Brake hose “2”
Every two years • Brake hose union bolt “3”
dust seals
Brake hoses Every four years
Front brake hose union bolt
Every two years and 27 N·m (2.7 kgf·m, 20 lb·ft)
T.
R.
Brake fluid whenever the brake is Rear brake hose union bolt
disassembled 27 N·m (2.7 kgf·m, 20 lb·ft)
1. Check: EWB02870
• Brake caliper piston WARNING

Rust/scratches/wear → Replace the brake Proper brake hose routing is essential to in-
caliper pistons. sure safe vehicle operation.
4-68
ECB03910
NOTICE Front brake caliper retaining pin

• When installing the front brake hose onto bolt
T.
R.
the front brake caliper, fit the projection “a” 22 N·m (2.2 kgf·m, 16 lb·ft)
on the brake hose into the hole in the brake Rear brake caliper guide pin bolt
22 N·m (2.2 kgf·m, 16 lb·ft)
caliper.
Front brake caliper bolt
• When installing the rear brake hose onto
50 N·m (5.0 kgf·m, 37 lb·ft)
the rear brake caliper, make sure that the Rear brake caliper bolt
projection “b” on the brake hose contacts 50 N·m (5.0 kgf·m, 37 lb·ft)
the rib on the brake caliper.
4. Fill:
A B • Brake master cylinder reservoir
2 2 (with the specified amount of the specified
brake fluid)

DOT 4
EWB02880
1 1 WARNING
3 a a 3 • Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
C D
2 2 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.
1 1 • When refilling, be careful that water does
not enter the brake master cylinder reser-
3 b b 3 voir. Water will significantly lower the boil-
A. Front brake (left) ing point of the brake fluid and could cause
B. Front brake (right) vapor lock.
C. Rear brake (left) ECB01320
D. Rear brake (right) NOTICE

Brake fluid may damage painted surfaces
2. Remove:
and plastic parts. Therefore, always clean up
• Brake caliper
3. Install:
• Brake pad spring 5. Bleed:
• Brake pad insulator • Brake system
(rear brake only) Refer to “BLEEDING THE HYDRAULIC
• Brake pad shim BRAKE SYSTEM” on page 3-25.
(rear brake only) 6. Check:
• Brake pad • Brake fluid level
• Brake caliper Below the minimum level mark → Add the
Refer to “REPLACING THE BRAKE PADS” specified brake fluid to the proper level.
on page 4-66. Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-24.
7. Check:
• Brake pedal operation
Soft or spongy feeling → Bleed the brake sys-
tem.
4-69
Refer to “BLEEDING THE HYDRAULIC EWB03160
BRAKE SYSTEM” on page 3-25. WARNING

Proper brake pipe routing is essential to in-
EBS30097
sure safe vehicle operation.
CHECKING THE BRAKE MASTER
CYLINDER 2. Fill:
1. Check: • Brake master cylinder reservoir
• Brake master cylinder (with the specified amount of the specified
Damage/scratches/wear → Replace. brake fluid)
• Brake fluid delivery passages
(brake master cylinder body) Specified brake fluid
Obstruction → Blow out with compressed air. DOT 4
2. Check: EWB02880
• Brake master cylinder reservoir WARNING

Cracks/damage → Replace the brake master • Use only the designated brake fluid. Other
cylinder. brake fluids may cause the rubber seals to
• Brake master cylinder reservoir diaphragm deteriorate, causing leakage and poor
• Brake master cylinder reservoir diaphragm brake performance.
holder • Refill with the same type of brake fluid that
Cracks/damage → Replace. is already in the system. Mixing brake fluids
3. Check: may result in a harmful chemical reaction,
• Brake pipe leading to poor brake performance.
Cracks/damage → Replace. • When refilling, be careful that water does
EBS30098 not enter the brake master cylinder reser-
CHECKING THE BRAKE PIPES voir. Water will significantly lower the boil-
The following procedure applies to both of the ing point of the brake fluid and could cause
brake pipes. vapor lock.
1. Check: ECB01320
• Brake pipe end (flare nut) NOTICE

Damage → Replace the brake master cylin- Brake fluid may damage painted surfaces
der, brake pipes, and related parts as a set. and plastic parts. Therefore, always clean up
3. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
4. Check:
specified brake fluid to the proper level.
EBS30099
Refer to “CHECKING THE BRAKE FLUID
INSTALLING THE BRAKE MASTER LEVEL” on page 3-24.
CYLINDER 5. Check:
1. Install: • Brake pedal operation
• Brake master cylinder Soft or spongy feeling → Bleed the brake sys-
• Brake pipe tem.
Refer to “BLEEDING THE HYDRAULIC
Brake master cylinder bolt BRAKE SYSTEM” on page 3-25.
16 N·m (1.6 kgf·m, 12 lb·ft)
T.
R.
Brake pipe flare nut

19 N·m (1.9 kgf·m, 14 lb·ft)
4-70
PARKING BRAKE
EBS20027
PARKING BRAKE
Removing the parking brake caliper and parking brake pads
40 N•m (4.0 kgf•m, 30 lb•ft)
T.R
.
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
LT
17 N•m (1.7 kgf•m, 13 lb•ft)

T.R
.
D
FW

Front over fender (right)/Front door (right)/Rear Refer to “GENERAL CHASSIS (1)” on page
door striker (right) 4-1.
Seat rails/Passenger seat frames Refer to “GENERAL CHASSIS (2)” on page

4-7.
Hood/Front cover Refer to “GENERAL CHASSIS (4)” on page

4-15.

4-16.
Dashboard (right) Refer to “GENERAL CHASSIS (6)” on page

4-17.
Rear floor board (right)/Front floor board (right) Refer to “GENERAL CHASSIS (7)” on page
4-25.
Air intake accumulator assembly/Air filter case Refer to “GENERAL CHASSIS (13)” on
duct 2 page 4-38.
4-71
PARKING BRAKE
Removing the parking brake caliper and parking brake pads

40 N•m (4.0 kgf•m, 30 lb•ft)
T.R
.
1
1 17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
5
LT
9
3 2
8
17 N•m (1.7 kgf•m, 13 lb•ft)
4
T.R
.
D
FW

1 Parking brake caliper bracket 1 bolt 2
2 Parking brake caliper 1
3 Parking brake cable 1 Disconnect.
4 Spring 1
5 Parking brake pad bolt 2
6 Parking brake pad 2
8 Parking brake caliper arm nut 1
9 Parking brake caliper arm 1
4-72
PARKING BRAKE
Disassembling the parking brake caliper

T.R
T.R
.
.
2
S
LT
2
S
New 7
8
10
LT New
12
S
4
22 N•m (2.2 kgf•m, 16 lb•ft)
T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
3 11
S
9 6
40 N•m (4.0 kgf•m, 30 lb•ft) New
T.R
.
S
New 1
22 N•m (2.2 kgf•m, 16 lb•ft)
T.R
.
17 N•m (1.7 kgf•m, 13 lb•ft) 5

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
10 Brake caliper body 1
11 Parking brake caliper arm shaft retainer 1 Left-hand threads
12 Parking brake cable holder 1
4-73
PARKING BRAKE
Disassembling the parking brake caliper

T.R
T.R
.
.
S 15
LT
S
16
New
17 14
LT New
S
22 N•m (2.2 kgf•m, 16 lb•ft)

T.R
.
13
13 12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
S
40 N•m (4.0 kgf•m, 30 lb•ft) New

T.R
.
S
New
22 N•m (2.2 kgf•m, 16 lb•ft)
T.R
.
17 N•m (1.7 kgf•m, 13 lb•ft)

T.R
.

13 Brake caliper bracket 2 bolt 2
14 Brake caliper bracket 1 1
15 Brake caliper bracket 2 1
16 Parking brake caliper guide pin 1
17 Parking brake caliper retaining pin 1
4-74
PARKING BRAKE
Removing the parking brake lever
2 5
17 N•m (1.7 kgf•m, 13 lb•ft) 3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
T.R
.
17 N•m (1.7 kgf•m, 13 lb•ft)

T.R
.
Driver seat frame/Passenger seat frame Refer to “GENERAL CHASSIS (2)” on page
4-7.

4-16.
1 Parking brake switch coupler 1 Disconnect.
2 Parking brake cable 1 Disconnect.
3 Parking brake lever assembly 1
4 Buzzer coupler 1 Disconnect.
5 Buzzer 1
4-75
PARKING BRAKE
Removing the parking brake disc
(6)
17 N•m (1.7 kgf•m, 13 lb•ft)

T.R
.
(6)
D
FW

Drain.
Differential gear oil Refer to “CHANGING THE DIFFERENTIAL
GEAR OIL” on page 3-23.
Refer to “FRONT CONSTANT VELOCITY
Differential assembly/Front drive shaft SHAFT ASSEMBLIES, DIFFERENTIAL AS-
SEMBLY AND FRONT DRIVE SHAFT” on
page 8-4.
1 Parking brake disc 1
4-76
PARKING BRAKE
EBS30100
REMOVING THE PARKING BRAKE CALIPER

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

1. Check: b. Install the parking brake caliper arm “2”
• Brake caliper piston onto the parking brake caliper arm shaft,
Scratches/rust/wear → Replace. and then rotate the arm until it contacts the
• Brake caliper body stopper “a”.
Cracks/damage → Replace the parking
brake caliper. 2
EBS30102
a
CHECKING THE PARKING BRAKE DISC
1. Check:
• Brake disc
Galling/damage → Replace.
2. Measure:
• Brake disc deflection
• Brake disc thickness “a”
Out of specification → Replace the parking c. Install the parking brake caliper arm nut
brake disc. “3”, and then temporarily tighten it.
Brake disc runout limit

0.10 mm (0.0039 in) 3
Brake disc thickness limit
3.0 mm (0.12 in)
TIP
Measure the deflection 3.0 mm (0.12 in) below
the edge of the brake disc.
a d. Insert a suitable tool “4” with a thickness of

4.2 mm (0.17 in) between the brake pads
“5”, and then finger tighten the push rod
“6”.
5
6
G101584
EBS30970
ADJUSTING THE PARKING BRAKE PAD 5

CLEARANCE
1. Adjust:
4
• Brake pad clearance
a. Fully turn in the parking brake caliper arm e. Tighten the parking brake caliper arm nut.
shaft “1”.
4-77
PARKING BRAKE
Parking brake caliper arm nut Parking brake cable adjusting

T. 17 N·m (1.7 kgf·m, 13 lb·ft) locknut
T.
R.
R.
17 N·m (1.7 kgf·m, 13 lb·ft)
f. Install the spring.
f. Slide the rubber cover to its original posi-
EBS30105
INSTALLING THE PARKING BRAKE LEVER tion.

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

17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.
2. Adjust:
• Parking brake lever free play
Refer to “ADJUSTING THE PARKING
BRAKE LEVER FREE PLAY” on page 4-78.
EBS30971
ADJUSTING THE PARKING BRAKE LEVER

FREE PLAY
2. Block the all wheels.
3. Adjust:
• Parking brake lever free play “a”
Lever free play

3 clicks
a. Release the parking brake lever.

b. Slide back the rubber cover “1”.
c. Loosen the locknut “2”.
d. Turn the adjusting nut “3” until the correct
adjustment is obtained.
2
3
e. Tighten the locknut to specification.
4-78
PEDAL ASSEMBLY
EBS20028
PEDAL ASSEMBLY
Removing the pedal assembly and accelerator position sensor unit
0.8 N•m (0.08 kgf•m, 0.59 lb•ft)
FW T.R
.
D
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
.
New
LS
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.
33 N•m (3.3 kgf•m, 24 lb•ft)

T.R
.

Drain.
Brake master cylinder cover/Front doors/Rear Refer to “GENERAL CHASSIS (1)” on page
door latch strikers 4-1.
4-7.

4-15.

4-16.
4-17.
Rear floor board (left)/Front floor board (left) Refer to “GENERAL CHASSIS (7)” on page
4-25.
Brake master cylinder Refer to “FRONT AND REAR BRAKES” on

page 4-59.
4-79
PEDAL ASSEMBLY
Removing the pedal assembly and accelerator position sensor unit

0.8 N•m (0.08 kgf•m, 0.59 lb•ft)
FW
T.R
.
D
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
.
6
4 New
8
2
5 LS
1 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.
33 N•m (3.3 kgf•m, 24 lb•ft)

T.R
.

1 Brake light switch 1
2 Throttle cable (pedal side) 1 Disconnect.
3 Pedal assembly 1
4 Throttle cable housing cover 1
5 Throttle cable 1
6 Accelerator position sensor coupler 1 Disconnect.
7 Accelerator position sensor unit 1
8 Accelerator position sensor unit bracket 1
4-80
PEDAL ASSEMBLY
Disassembling the pedal assembly
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
2 LS LS 8 New
11 9
1
9
New
10
3 7
LS
5 6
New 4

1 Pin 1
2 Brake pedal rod 1
3 Spring 1
4 Circlip 1
5 Washer 2
6 Brake pedal 1
7 Spring 1
8 Circlip 1
9 Washer 2
10 Accelerator pedal 1
11 Pedal assembly bracket 1
4-81
PEDAL ASSEMBLY
EBS30106 EBS30868
INSTALLING THE PEDAL ASSEMBLY LUBRICATING THE BRAKE PEDAL AND

1. Install: ACCELERATOR PEDAL
• Throttle cable Lubricate the pivoting point and metal-to-metal
a. Turn the nut “1” until it stops, and then in- moving parts of the pedal.
stall the throttle cable to the plate.
b. Tighten the locknut “2” to specification. Recommended lubricant
Lithium-soap-based grease
Throttle cable locknut (accelera-
tor pedal side)
T.
R.
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
1 2
2. Adjust:
• Accelerator pedal free play
Refer to “ADJUSTING THE ACCELERATOR
PEDAL FREE PLAY” on page 3-27.
3. Adjust:
• Brake pedal free play
Refer to “ADJUSTING THE BRAKE PEDAL”
on page 3-27.
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” until the brake light
comes on at the proper time.
1 2
4-82
STEERING SYSTEM
EBS20029
STEERING SYSTEM
Removing the steering column assembly
16 N•m (1.6 kgf•m, 12 lb•ft)
T.R
.
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
(4)
(4) LS
LT LT
26 N•m (2.6 kgf•m, 19 lb•ft)

T.R
.
26 N•m (2.6 kgf•m, 19 lb•ft)

T.R
.
D
FW

Brake master cylinder cover/Front over fender Refer to “GENERAL CHASSIS (1)” on page
(left)/Front door (left) 4-1.
4-7.

4-15.

4-16.
Dashboard (left)/Steering column cover Refer to “GENERAL CHASSIS (6)” on page

4-17.
4-83
STEERING SYSTEM
Removing the steering column assembly

16 N•m (1.6 kgf•m, 12 lb•ft)
T.R
.
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
(4)
6
(4) LS
2 7
4
1
3
LT LT
1
26 N•m (2.6 kgf•m, 19 lb•ft)
T.R
.
8
26 N•m (2.6 kgf•m, 19 lb•ft)
T.R
.
D
FW

1 Steering joint bolt 2
2 EPS motor coupler 1 Disconnect.
3 EPS torque sensor coupler 1 Disconnect.
4 Steering column assembly 1
5 Steering column 1
6 Dust cover 1
7 EPS unit 1
8 Steering joint 1
4-84
STEERING SYSTEM
Removing the steering assembly

1st 3.9 N•m (0.39 kgf•m, 2.9 lb•ft)
T.R
2nd 4
*
.
*2
*1
LS
LS
25 N•m (2.5 kgf•m, 18 lb•ft)
T.R
New
.
40 N•m (4.0 kgf•m, 30 lb•ft)
T.R
7 New LS
.
55 N•m (5.5 kgf•m, 41 lb•ft)
New
T.R
.
1 6
New
7 New
LS
70 N•m (7.0 kgf•m, 52 lb•ft) *3 New

T.R
.
55 N•m (5.5 kgf•m, 41 lb•ft)

T.R
.
4
LS 7
New
7 *3 5
2 1 2
5 4 6 3
New 40 N•m (4.0 kgf•m, 30 lb•ft) 55 N•m (5.5 kgf•m, 41 lb•ft)
T.R
T.R
.
.
*1 Apply Three bond No.1102®

*2 Apply ULET AA-2
*3 Apply MOLYKOTE® EM-30L GREASE
*4 Loosen (less than 15 degree)

page 4-54.
1 Tie-rod end nut 2
2 Tie-rod end 2 Disconnect.
3 Steering assembly 1
4 Tie-rod end locknut 2
5 Tie-rod end 2
6 Dust boot 2
7 Tie-rod set 2
4-85
STEERING SYSTEM
Removing the steering assembly

1st 3.9 N•m (0.39 kgf•m, 2.9 lb•ft)
T.R
2nd 4
*
.
*2 11 10 8
9
*1
12
LS
LS
25 N•m (2.5 kgf•m, 18 lb•ft)
T.R
New
.
40 N•m (4.0 kgf•m, 30 lb•ft)
T.R
New LS 13
.
55 N•m (5.5 kgf•m, 41 lb•ft)
New
T.R
.
14
15
New
New
LS
70 N•m (7.0 kgf•m, 52 lb•ft) *3 New

T.R
.
55 N•m (5.5 kgf•m, 41 lb•ft)

T.R
.
LS
New
*3
New 40 N•m (4.0 kgf•m, 30 lb•ft) 55 N•m (5.5 kgf•m, 41 lb•ft)

T.R
T.R
.
.
*1 Apply Three bond No.1102®

*2 Apply ULET AA-2
*3 Apply MOLYKOTE® EM-30L GREASE
*4 Loosen (less than 15 degree)

8 Locknut 1
9 Adjusting screw 1
10 Spring 1
11 Washer 1
12 Pressure pad 1
13 Oil seal 1
14 Circlip 1
15 Steering pinion assembly 1
4-86
STEERING SYSTEM
Removing the EPS unit bracket
LS
LS
5
LS
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
1
1
2
3
2 55 N•m (5.5 kgf•m, 41 lb•ft)

T.R
.
1 Steering wheel position adjusting damper upper 1/1

nut/bolt
2 Steering wheel position adjusting damper lower 1/1

nut/bolt
3 Steering wheel position adjusting damper 1
4 EPS unit bracket nut/bolt 2/2
5 EPS unit bracket 1
4-87
STEERING SYSTEM
EBS30972 EBS30488
DISCONNECTING THE TIE-ROD ENDS REMOVING THE TIE-ROD

The following procedure applies to both of the 1. Straighten the staked points “a” (4 locations)
tie-rod ends. of the lock washer “1”.
1. Disconnect:
• Tie-rod end “1” 1
TIP a
• Install the locknut to the tie-rod end with the
locknut upside down so that it is flush with the
end of the bolt as shown in the illustration. a
• Use a general puller “2” to separate the tie-rod
end from the steering knuckle “3”.
2. Loosen:
• Tie-rod “1”
1
2
EBS30983
1
REMOVING THE STEERING JOINT
1. Remove:
• Steering joint EBS30107
a. Turn the steering wheel “1” to the straight- CHECKING THE STEERING JOINT
ahead position. 1. Check:
• Steering joint
Rough movement → Replace.
1 EBS30108
CHECKING THE TIE-ROD ENDS

tie-rod ends.
1. Check:
• Tie-rod end free play and movement
Rough movement → Replace the tie-rod end.
2. Check:
b. Make alignment mark “a” so it matches slit
• Tie-rod end
“b” of the steering joint.
Bends/damage → Replace.
Rubber boot damage → Replace the tie-rod
b end.
EBS30984
CHECKING THE STEERING GEAR

ASSEMBLY
1. Check:
• Steering gear
a
Excessive play/rough movement → Replace
the steering pinion set or steering assembly.
2. Check:
• Dust boot
Damage → Replace.
4-88
STEERING SYSTEM
3. Check:
1 1
• Tie-rod LS
EBS30985
REMOVING THE STEERING PINION

1. Remove: 2
• Locknut
• Adjusting screw
• Spring 2
• Washer
• Pressure pad 3. Install:
2. Remove: • Steering pinion “1” New
• Circlip • Circlip New
• Oil seal • Oil seal New
• Circlip
• Steering pinion assembly “1” • Circlip New
a. Remove the oil seal. (into the steering gear case “2”)
b. Secure the portion shaft “a” in the steering TIP
pinion in a vise. • Assemble the steering pinion and steering rack
c. Tap the portion “b” in the steering assem- “3” with their gears engaged together.
bly using a soft-face hammer. • Use a suitable socket “4” that matches the di-
ameter of the bearing outer race.
b • After assembly, make sure that the steering
1
pinion and steering rack move smoothly.
1 New
EBS30986
INSTALLING THE STEERING PINION 3

1. Lubricate:
• Steering rack “1”
lithium-soap-based grease 4 2
5.0 g (0.18 oz)
2. Install:
• Steering rack
(into the steering gear case “2”)
TIP 3
1
Install the steering rack in the direction shown in
the illustration. 4. Lubricate:
• Pressure pad “1”
ULET AA-2
1.0 g (0.04 oz)
5. Install:
• Pressure pad
4-89
STEERING SYSTEM
• Washer “2”
• Spring “3”
• Adjusting screw “4”
• Locknut “5”
TIP
• Apply ULET AA-2 grease to the sliding surface
of the pad. 1
• Apply Three Bond No.1102® to the threads of
adjusting screw.
3. Stake the lock washer “1” at the indentations
Adjusting screw
“a” (4 locations) in the tie-rod.
1st: 3.9 N·m (0.39 kgf·m, 2.9
T.
R.
lb·ft) a
2nd: Loosen (less than 15 de-
gree)
Locknut
25 N·m (2.5 kgf·m, 18 lb·ft) a
4. Align: (When the steering pinion was re-

placed)
• Steering rack length “a”
1
2
3 Steering rack length (steering
4
5 center position)
EBS30987
42.7 mm (1.68 in)
INSTALLING THE TIE-RODS
1. Install: TIP
• Lock washer “1” New After adjusting the steering rack length, make
alignment mark “b” at the position shown in the
TIP
illustration.
Align the tabs “a” on the lock washer with the
grooves “b” in the steering assembly.
a b
a a
New 1
2. Tighten:
• Tie-rod “1”
Tie-rod
55 N·m (5.5 kgf·m, 41 lb·ft)
T.
R.
4-90
STEERING SYSTEM
b 3 1 1
b
2 4
5. Install: 2. Install:
• Dust boot • Tie-rod end
(to the steering knuckle)
• Boot band New
a. Fit the tabs “a” into the holes “b” in the boot Tie-rod end nut
band “1”. 55 N·m (5.5 kgf·m, 41 lb·ft)
T.
R.
a TIP
If the slots in the tie-rod end nuts are not aligned
with the cotter pin hole, tighten the tie-rod end
nut until they are aligned.
1 New 3. Install:
• Steering joint “1”
b • Steering column assembly “2”
b. Crimp the portion “c” of the boot band with Steering column assembly
23 N·m (2.3 kgf·m, 17 lb·ft)
a general hand pincer “2”.
T.
R.
Steering joint bolt

26 N·m (2.6 kgf·m, 19 lb·ft)
LOCTITE®
2
TIP
c • Make sure that steering pinion shaft “2” is
aligned with alignment mark “a” on steering as-
sembly housing “3”.
• Align the slit “b” in the steering joint with the
d alignment mark “a”, and then install the steer-
ing joint.
d. 4.25–4.50 mm (0.167–0.177 in)
• Fit the steering joint onto the EPS unit shaft so
EBS30988 that the bolt hole “c” in the joint is aligned with
INSTALLING THE STEERING ASSEMBLY the area “d” on the shaft that does not have
1. Install: splines.
• Steering assembly “1” • Tighten the steering joint bolt (steering assem-
bly side), and then tighten the steering joint bolt
Steering assembly bolt (steering column assembly side).
70 N·m (7.0 kgf·m, 52 lb·ft) • Make sure that the distance “e” is the specified
T.
R.
distance.
TIP
Tighten the steering assembly bolts in the prop-
er tightening sequence as shown.
4-91
STEERING SYSTEM
b
2
a
e. 5.3–8.3 mm (0.21–0.33 in)

4. Adjust:
• Toe-in
Refer to “ADJUSTING THE TOE-IN” on page
3-35.
EBS30426
LUBRICATING THE STEERING SHAFT

Lubricate the pivoting point and metal-to-metal
moving parts of the shaft.
Lithium-soap-based grease
4-92
STEERING KNUCKLES AND FRONT STABILIZER
EBS20138

Removing the steering knuckles and front stabilizer
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
1st 120 N•m (12 kgf•m, 89 lb•ft)
T.
2nd 75 N•m (7.5 kgf•m, 55 lb•ft)
R.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.
R.
34 N•m (3.4 kgf•m, 25 lb•ft)

T.
R.
New
New
New
New
60 N•m (6.0 kgf•m, 44 lb•ft)

New
New
T.
R.
D
FW 1st 120 N•m (12 kgf•m, 89 lb•ft)
T.
2nd 75 N•m (7.5 kgf•m, 55 lb•ft)

R.

the steering knuckles.
Front wheel hubs Refer to “FRONT AND REAR WHEELS” on

page 4-54.
Disconnect.
Tie-rod ends Refer to“STEERING SYSTEM” on page
4-83.
4-93
Removing the steering knuckles and front stabilizer
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
1st 120 N•m (12 kgf•m, 89 lb•ft)
T.R
2nd 75 N•m (7.5 kgf•m, 55 lb•ft)
.
6
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
34 N•m (3.4 kgf•m, 25 lb•ft)

T.R
.
7
2
New
4 3
New 8
4
3 9 New
5 12 New
60 N•m (6.0 kgf•m, 44 lb•ft)

10 New
11 New
T.R
.
1
D
FW 1st 120 N•m (12 kgf•m, 89 lb•ft)
T.R
2nd 75 N•m (7.5 kgf•m, 55 lb•ft)

.

1 Stabilizer joint (left) 1
2 Stabilizer joint (right) 1
3 Stabilizer holder 2
4 Bushing 2
5 Front stabilizer 1
6 Brake disc guard 1
7 Steering knuckle 1
8 Front constant velocity shaft dust boot guard 1
9 Circlip 1
10 Ball joint 1
11 Circlip 1
12 Bearing 1
4-94
EBS30110 ECB01620
REMOVING THE STEERING KNUCKLES NOTICE

The following procedure applies to both of the Do not strike the inner race or balls of the
steering knuckles. bearing. Contact should be made only with
1. Remove: the outer race.
• Steering knuckle “1”
TIP
f. Install a new circlip.
Use a general puller to separate the ball joints EBS30112
“2” from the steering knuckle “1” or the front low- CHECKING THE STEERING KNUCKLE BALL
er arm “3”. JOINTS
steering knuckle ball joints.
1. Check:
• Ball joint (steering knuckle)
Damage/pitting → Replace the ball joint.
Rubber boot damage → Replace the ball
joint.
Rough movement → Replace the ball joint.
a. Clean the surface of the steering knuckle.
G101456
b. Remove the circlip “1”.
EBS30111
CHECKING THE STEERING KNUCKLES

AND FRONT WHEEL BEARINGS
steering knuckles and front wheel bearings.
1. Check:
• Steering knuckle
1
2. Check:
• Front wheel bearing “1” c. Remove the ball joint “2”.
Rough movement/excessive free play → Re-
TIP
place.
a. Clean the surface of the steering knuckle. Use a suitable socket “3” to separate the ball
b. Remove the circlip “2”. joint “2” from the steering knuckle “4”.
c. Drive out the bearings.
EWB03030
WARNING
Eye protection is recommended when using 4
striking tools.
3
2
2
d. Measure the ball joint bore inside diameter
1 “a”.
Out of specification → Replace the steer-
ing knuckle.
G101457
d. Apply lithium-soap-based grease to the oil Ball joint bore inside diameter
41.90–41.95 mm (1.650–1.652 in)
seals.
e. Install a new bearing.
4-95
c e
b
d
a
a
e. Attach the special tools and a new ball c g f

joint “5” to the steering knuckle “4”. 7
TIP
• Always use a new ball joint. h i j
• Do not tap or damage the top of the ball joint or
rubber boot.
• Replace parts “b”, “g”, and “f” of the ball joint in-
staller “6” with parts “h”, “i”, and “j” of the steer-
ing knuckle ball joint tool “7”.
• In this model, parts “b”, “g”, and “f” of the ball
joint installer “6” are not used.
a h d c e 5 j
Ball joint installer i
90890-01586
YM-01586
Steering Knuckle ball joint tool
90890-01905
Steering Knuckle ball joint tool
YM-01905
c 4
Tool name Tool No.
a Long bolt f. Hold the base plate (110 mm) “i” in place
while turning in the long bolt “a” to install
b Body
the new ball joint “5” into the steering
c Guide bolt knuckle “4”.
d Installer washer g. Remove the special tools.
90890-01586
Ball joint installer at- YM-01586 h. Install a new circlip.
e
tachment 47.5 mm
EBS30636
Ball joint installer at- CHECKING THE FRONT STABILIZER

f
tachment 42.5 mm 1. Check:
g Base plate • Front stabilizer
h Body (110 mm) Bends/cracks/damage → Replace.
i Base plate (110 mm) EBS30974
90890-01905
Ball joint installer at- INSTALLING THE STEERING KNUCKLES
j 1. Install:
tachment (45.0 mm)
• Steering knuckle
Refer to “INSTALLING THE FRONT ARMS
AND FRONT SHOCK ABSORBER ASSEM-
BLIES” on page 4-101.
4-96
EBS30637
INSTALLING THE FRONT STABILIZER

1. Install:
• Front stabilizer “1”
• Bushing “2”
• Stabilizer holder “3”
Front stabilizer holder bolt

34 N·m (3.4 kgf·m, 25 lb·ft)
T.
R.
TIP
Install the bushing with its slit “a” facing forward.
2
a
4-97
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES
EBS20031

Removing the front arms and front shock absorber assemblies
120 N•m (12 kgf•m, 89 lb•ft)
T.R
.
70 N•m (7.0 kgf•m, 52 lb•ft)
T.R
.
New
New
New
120 N•m (12 kgf•m, 89 lb•ft)

T.R
.
New
New
70 N•m (7.0 kgf•m, 52 lb•ft)
T.R
.
New
120 N•m (12 kgf•m, 89 lb•ft)

T.R
.

the front upper arms, front lower arms, and
front shock absorber assemblies.
Hood/Front grill rear cover Refer to “GENERAL CHASSIS (4)” on page

4-15.
Skid plate Refer to “GENERAL CHASSIS (11)” on

page 4-33.
Front wheels/Front wheel hubs Refer to “FRONT AND REAR WHEELS” on

page 4-54.
Disconnect.
Tie-rod ends Refer to “STEERING SYSTEM” on page
4-83.
Stabilizer joints/Steering knuckles Refer to “STEERING KNUCKLES AND

FRONT STABILIZER” on page 4-93.
4-98
Removing the front arms and front shock absorber assemblies

T.R
.
120 N•m (12 kgf•m, 89 lb•ft)
70 N•m (7.0 kgf•m, 52 lb•ft)
T.R
.
2
9 New
1
8
2 10 New
5 5
8 2
5
5 8 9 New
5
5
2 6
5 120 N•m (12 kgf•m, 89 lb•ft)
T.R
.
5 8
8
New 11
9 New
4
70 N•m (7.0 kgf•m, 52 lb•ft) 3
T.R
.
7
9 New
8
120 N•m (12 kgf•m, 89 lb•ft)
T.R
.
1 Sub-wire harness coupler (SCU) 1 Disconnect.

YXF10WRLN
2 Nut/Bolt (front shock absorber assembly) 2/2
3 Front shock absorber assembly 1 YXF10WRAN/YXF10WRZN
4 Front shock absorber assembly 1 YXF10WRLN
5 Nut/Bolt (front upper and lower arms) 4/4
6 Front upper arm 1
7 Front lower arm 1
8 Thrust cover 8
9 Bushing 4
10 Circlip 1
11 Ball joint 1
4-99
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 mov-
gas cylinder to an open flame or any other
ing it from side to side.
source of high heat. High heat can cause an
If side play is noticeable, check the bush-
explosion due to excessive gas pressure.
ings.
• 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
Gas pressure must be released before dispos-
G101463 A
ing of a front shock absorber assembly. To re-
b. Check the front arm vertical movement “B” lease the gas pressure, drill a 2–3 mm (0.08–
by moving it up and down. 0.12 in) hole through the front shock absorber as
If the vertical movement is tight or rough, shown.
or if there is binding, check the bushings. EWB03180
WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
G101464 B
2. Check:
• Front upper arm
• Front lower arm
EBS30116
3. Check: CHECKING THE FRONT SHOCK ABSORBER
• Bushings ASSEMBLIES
Wear/damage → Replace. The following procedure applies to both of the
EBS30114 front shock absorber assemblies.
HANDLING THE FRONT SHOCK ABSORBER 1. Check:
ASSEMBLIES • Front shock absorber assembly
EWB03170
Gas leaks → Replace the front shock absorb-
WARNING
er assembly.
Shock absorbers and gas cylinders contain • Front shock absorber rod
highly compressed nitrogen gas. Before Bends/damage → Replace the front shock
handling the front shock absorber or gas cyl- absorber assembly.
inder, read and make sure you understand • Spring
the following information. The manufacturer Move the spring up and down.
cannot be held responsible for property Fatigue → Replace the front shock absorber
assembly.
4-100
EBS30117
CHECKING THE FRONT ARM BALL JOINTS Tool name Tool No.
The following procedure applies to both of the a Long bolt
front arm ball joints. b Body
1. Check: c Guide bolt
• Ball joint (front upper arm)
d Installer washer
Damage/pitting → Replace the ball joint. 90890-01586
Rubber boot damage → Replace the ball e
Ball joint installer at- YM-01586
joint. tachment 47.5 mm
Rough movement → Replace the ball joint. f
Ball joint installer at-
a. Clean the surface of the front upper arm. tachment 42.5 mm
b. Remove the circlip “1”. g Base plate
1
c e
b
d
a
g
c f
c. Remove the ball joint “2”.
TIP
Use a suitable socket “3” to separate the ball a
5
joint “2” from the front upper arm “4”. c b
d
3 f c
e
4 4 g
e. Hold the base plate “g” in place while turn-
ing in the long bolt “a” to install the new ball
2 joint “5” into the front upper arm “4”.
f. Remove the special tools.
d. Attach the special tools and a new ball g. Install a new circlip.
joint “5” to the front upper arm “4”.
EBS30118
TIP INSTALLING THE FRONT ARMS AND
• Always use a new ball joint. FRONT SHOCK ABSORBER ASSEMBLIES
• Do not tap or damage the top of the ball joint or The following procedure applies to both of the
rubber boot. front upper arms, front lower arms, and front
shock absorber assemblies.
Ball joint installer 1. Install:
90890-01586 • Front lower arm
YM-01586 • Front upper arm
• Front shock absorber assembly
a. Install the front lower arm “1” and front up-
per arm “2”.
4-101
TIP
• Be sure to position the front upper and lower
arm bolts “3” so that the bolt heads face rear-
ward.
• Be sure to position the front upper and lower 8,9 7
arm bolts “5” so that the bolt heads face for-
ward.
• Temporarily tighten the front upper and lower
arm nuts “4” and “6”.
• Install the front shock absorber assembly so 8,9
that the gas cylinder is facing outward.
b. Install the front shock absorber assembly
3,4
“7”, bolts “8”, and nuts “9”.
5,6
Front shock absorber assembly 2
nut
T.
R.
70 N·m (7.0 kgf·m, 52 lb·ft) 10

5,6
TIP
1
Be sure to position the front shock absorber
bolts “8” so that the bolt heads face forward.
c. Install the steering knuckle and nuts “10”.
Steering knuckle nut

1st: 120 N·m (12 kgf·m, 89 lb·ft)
T.
R.
2nd: See TIP

3rd: 75 N·m (7.5 kgf·m, 55 lb·ft)
TIP
After loosening a steering knuckle nut, do not re-
move the ball joint.
d. Install new cotter pins.
TIP
If the slots in the steering knuckle nut are not
aligned with the cotter pin hole, tighten the steer-
ing knuckle nut until they are aligned.
e. Tighten the front upper and lower arm nuts
“4” and “6” to specification.
Front arm nut

120 N·m (12 kgf·m, 89 lb·ft)
T.
R.
4-102
REAR KNUCKLES
EBS20127
REAR KNUCKLES
Removing the rear knuckles
FW
D 3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
3
5
LS
New 7
3
3
5
4
LS 6
5 3
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
2
LS
1 7 New
New 7
9 New LS
5
8 New
(3) 3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
125 N•m (12.5 kgf•m, 92 lb•ft)

T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.

the rear knuckles.
Rear stabilizer joints/Rear shock absorber as- Refer to “REAR STABILIZER, REAR
semblies SHOCK ABSORBER ASSEMBLIES, AND
Rear wheel hubs Refer to “FRONT AND REAR WHEELS” on

page 4-54.
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 Circlip 1
9 Bearing 1
4-103
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
Refer to “CHECKING THE STEERING
KNUCKLES AND FRONT WHEEL BEAR-
INGS” on page 4-95.
4-104
AND REAR ARMS
EBS20139
REAR STABILIZER, REAR SHOCK ABSORBER ASSEMBLIES, AND REAR

ARMS
Removing the rear stabilizer and rear shock absorber assemblies
90 N•m (9.0 kgf•m, 66 lb•ft) 120 N•m (12 kgf•m, 89 lb•ft)
T.R
T.R
.
.
2
4 3
1
2
3
6
120 N•m (12 kgf•m, 89 lb•ft)
T.R
.
5 6
8
7
6 90 N•m (9.0 kgf•m, 66 lb•ft)

T.R
.
FW 6
D 90 N•m (9.0 kgf•m, 66 lb•ft)
T.R
.

the rear shock absorber assemblies.

page 4-54.
1 Stabilizer joint 2
2 Stabilizer holder 2
3 Bushing 2
4 Stabilizer 1
5 Sub-wire harness coupler (SCU) 1 Disconnect.

YXF10WRLN
6 Nut/Bolt (rear shock absorber) 2/2
7 Rear shock absorber assembly 1 YXF10WRAN/YXF10WRZN
8 Rear shock absorber assembly 1 YXF10WRLN
4-105
AND REAR ARMS
Removing the rear arms
120 N•m (12 kgf•m, 89 lb•ft)
T.R
.
3
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
3
.
6
New 7 3
LS
6 3
6
3
6 3
3
1 New 7 LS 6 3
New 7
4
LS
6
7 N•m (0.7 kgf•m, 5.2 lb•ft)
6
T.R
.
2 6
New 7
5 LS
FW
D 120 N•m (12 kgf•m, 89 lb•ft)
T.R
.

the rear upper arms and rear lower arms.
page 4-59.
Rear brake calipers TIP
It is not necessary to disconnect the brake
hose.
Nuts/Bolts (rear knuckle) Refer to “REAR KNUCKLES” on page

4-103.
2 Rear constant velocity shaft dust boot guard 1
3 Nut/Bolt (rear upper and lower arms) 4/4
4 Rear upper arm 1
5 Rear lower arm 1
6 Thrust cover 8
7 Bushing 4
4-106
AND REAR ARMS
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 mov-
gas cylinder to an open flame or any other
ing it from side to side.
source of high heat. High heat can cause an
If side play is noticeable, check the bush-
explosion due to excessive gas pressure.
ings.
• 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
suffer.
A EBS30124
DISPOSING OF A REAR SHOCK ABSORBER

ASSEMBLY
Gas pressure must be released before dispos-
G101463 A
ing of a rear shock absorber assembly. To re-
b. Check the rear arm vertical movement “B” lease the gas pressure, drill a 2–3 mm (0.08–
by moving it up and down. 0.12 in) hole through the rear shock absorber as
If the vertical movement is tight or rough, shown.
or if there is binding, check the bushings. EWB03180
WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
G101464 B
2. Check:
• Rear upper arm
• Rear lower arm
EBS30125
3. Check: CHECKING THE REAR SHOCK ABSORBER
• Bushing ASSEMBLIES
Wear/damage → Replace. The following procedure applies to both of the
EBS30123 rear shock absorber assemblies.
HANDLING THE REAR SHOCK ABSORBER 1. Check:
ASSEMBLIES • Rear shock absorber assembly
EWB03190
Gas leaks → Replace the rear shock absorb-
WARNING
er assembly.
This rear shock absorber and gas cylinder • Rear shock absorber rod
contain highly compressed nitrogen gas. Be- Bends/damage → Replace the rear shock
fore handling the rear shock absorber or gas absorber assembly.
cylinder, read and make sure you under- • Spring
stand the following information. The manu- Move the spring up and down.
facturer cannot be held responsible for Fatigue → Replace the rear shock absorber
assembly.
4-107
AND REAR ARMS
EBS30126
INSTALLING THE REAR ARMS AND REAR

SHOCK ABSORBER ASSEMBLIES 10,11
rear upper arms, rear lower arms, and rear
shock absorber assemblies.
1. Install:
• Rear lower arm 9
• Rear upper arm
• Rear shock absorber assembly
a. Install the rear lower arm “1” and rear up- 2
per arm “2”. 7,8
TIP
• Be sure to position the rear upper and lower
arm bolts “3” and “5” so that the bolt heads face
forward.
• Temporarily tighten the rear upper and lower
arm nuts “4” and “6”. 3,4 5,6
b. Install the rear knuckle bolts “7”, and nuts 1 11,12
“8”.
Rear knuckle nut EBS30813
125 N·m (12.5 kgf·m, 92 lb·ft) CHECKING THE REAR STABILIZER

T.
R.
1. Check:
c. Tighten the rear upper and lower arm nuts • Rear stabilizer
“4” and “6” to specification. Bends/cracks/damage → Replace.
EBS30814
Rear upper arm nut
120 N·m (12 kgf·m, 89 lb·ft) INSTALLING THE REAR STABILIZER
T.
1. Install:
R.
Rear lower arm nut

120 N·m (12 kgf·m, 89 lb·ft) • Rear stabilizer “1”
• Bushings “2”
d. Install the rear brake calipers. • Stabilizer holders “3”
Refer to “FRONT AND REAR BRAKES”
on page 4-59. Rear stabilizer holder bolt
90 N·m (9.0 kgf·m, 66 lb·ft)
e. Install the rear shock absorber assembly
T.
R.
“9”, bolts “10” and “12”, and nuts “11”.

TIP
Rear shock absorber assembly Install the bushing with its slit “a” facing down-
nut ward.
T.
R.
90 N·m (9.0 kgf·m, 66 lb·ft)
TIP 1
2
• Install the rear shock absorber assembly so
that the gas cylinder is facing outward.
• Be sure to position the rear shock absorber bolt
“10” so that the bolt head face forward. 3
• Be sure to position the rear shock absorber bolt a
“12” so that the bolt head face rearward.
4-108
AND REAR ARMS
4-109
ENGINE
LUBRICATION SYSTEM CHART AND DIAGRAMS...................................... 5-1

ENGINE OIL LUBRICATION CHART ....................................................... 5-1
LUBRICATION DIAGRAMS ...................................................................... 5-2
ENGINE INSPECTION .................................................................................... 5-5

MEASURING THE COMPRESSION PRESSURE .................................... 5-5
ENGINE REMOVAL (1) ................................................................................... 5-7

INSTALLING THE EXHAUST PIPE AND MUFFLER..............................5-11
ENGINE REMOVAL (2) .................................................................................5-12

CHECKING THE OIL TANK OUTLET PIPE 1 (OIL STRAINER) ............ 5-15
FILLING THE ENGINE OIL (WHEN THE ENGINE IS
DISASSEMBLED) ..................................................................................5-15
ENGINE REMOVAL (3) .................................................................................5-16

INSTALLING THE ENGINE.....................................................................5-22
CAMSHAFTS.................................................................................................5-23
REMOVING THE CAMSHAFTS..............................................................5-26
CHECKING THE CAMSHAFTS ..............................................................5-27
CHECKING THE CAMSHAFT SPROCKETS .........................................5-28
5
CHECKING THE TIMING CHAIN TENSIONER......................................5-28
POSITIONING THE TIMING CHAIN TENSIONER ROD ........................5-28
CHECKING THE DECOMPRESSION SYSTEM.....................................5-29
INSTALLING THE CAMSHAFTS ............................................................5-30
INSTALLING THE CYLINDER HEAD COVER .......................................5-32
CYLINDER HEAD..........................................................................................5-33
REMOVING THE CYLINDER HEAD.......................................................5-36
CHECKING THE TIMING CHAIN GUIDE ...............................................5-36
CHECKING THE CYLINDER HEAD .......................................................5-36
INSTALLING THE CYLINDER HEAD .....................................................5-36
VALVES AND VALVE SPRINGS..................................................................5-38

REMOVING THE VALVES ......................................................................5-39
CHECKING THE VALVES AND VALVE GUIDES .................................. 5-39
CHECKING THE VALVE SEATS ............................................................5-41
CHECKING THE VALVE SPRINGS........................................................ 5-42
CHECKING THE VALVE LIFTERS .........................................................5-42
INSTALLING THE VALVES ....................................................................5-42
AC MAGNETO AND STARTER CLUTCH ....................................................5-44
REMOVING THE AC MAGNETO ROTOR..............................................5-47
REMOVING THE STARTER CLUTCH ...................................................5-47
CHECKING THE STARTER CLUTCH ....................................................5-47
CHECKING THE TORQUE LIMITER ...................................................... 5-48
INSTALLING THE STARTER CLUTCH ..................................................5-48
INSTALLING THE AC MAGNETO ROTOR ............................................5-48
ELECTRIC STARTER ...................................................................................5-50

CHECKING THE STARTER MOTOR .....................................................5-53
ASSEMBLING THE STARTER MOTOR .................................................5-53
INSTALLING THE STARTER MOTOR ...................................................5-54
OIL PAN AND OIL PUMP .............................................................................5-55

REMOVING THE OIL PAN......................................................................5-58
REMOVING THE OIL PUMP...................................................................5-58
CHECKING THE OIL PUMP ...................................................................5-58
CHECKING THE OIL STRAINER ...........................................................5-58
CHECKING THE RELIEF VALVE ...........................................................5-58
CHECKING THE CHECK BALL ..............................................................5-58
ASSEMBLING THE OIL PUMP ...............................................................5-58
INSTALLING THE OIL PUMP ................................................................. 5-59
INSTALLING THE OIL PAN ....................................................................5-59
SHIFT LEVER................................................................................................ 5-60

CHECKING THE STOPPER LEVER ...................................................... 5-64
CHECKING THE SHIFT LEVERS ...........................................................5-64
INSTALLING THE SHIFT LEVERS .........................................................5-64
ADJUSTING THE DRIVE SELECT LEVER SHIFT ROD ........................5-65
PRIMARY AND SECONDARY SHEAVES....................................................5-66

REMOVING THE PRIMARY AND SECONDARY SHEAVES .................5-70
DISASSEMBLING THE SECONDARY SHEAVE....................................5-70
CHECKING THE V-BELT ........................................................................5-71
CHECKING THE PRIMARY SHEAVE ....................................................5-71
CHECKING THE PRIMARY SHEAVE WEIGHTS...................................5-71
CHECKING THE PRIMARY SHEAVE SLIDERS ....................................5-72
CHECKING THE SECONDARY SHEAVE ..............................................5-72
ASSEMBLING THE PRIMARY SHEAVE ................................................5-72
ASSEMBLING THE SECONDARY SHEAVE..........................................5-73
INSTALLING THE PRIMARY AND SECONDARY SHEAVES................5-75
CLUTCH ........................................................................................................5-78
REMOVING THE CLUTCH .....................................................................5-81
CHECKING THE CLUTCH ......................................................................5-81
CHECKING THE CLUTCH SHOE...........................................................5-81
ASSEMBLING THE CLUTCH HOUSING................................................5-82
INSTALLING THE CLUTCH ....................................................................5-82
CRANKCASE ................................................................................................ 5-84
REMOVING THE MIDDLE DRIVEN SHAFT (CRANKCASE) .................5-87
SEPARATING THE CRANKCASE ..........................................................5-87
CHECKING THE TIMING CHAIN, OIL PUMP DRIVE CHAIN,
AND TIMING CHAIN GUIDE ..................................................................5-87
CHECKING THE CRANKCASE ..............................................................5-87
CHECKING THE OIL PUMP DRIVEN SPROCKET ................................ 5-87
ASSEMBLING THE CRANKCASE..........................................................5-87
INSTALLING THE MIDDLE DRIVEN SHAFT (CRANKCASE)................5-89
CONNECTING RODS AND PISTONS ..........................................................5-91

REMOVING THE CONNECTING RODS AND PISTONS ....................... 5-92
CHECKING THE CYLINDER AND PISTON ........................................... 5-92
CHECKING THE PISTON RINGS...........................................................5-93
CHECKING THE PISTON PIN ................................................................5-94
CHECKING THE CONNECTING RODS .................................................5-94
INSTALLING THE CONNECTING RODS AND PISTONS ..................... 5-96
CRANKSHAFT AND BALANCER SHAFT ...................................................5-99

REMOVING THE BALANCER SHAFT JOURNAL BEARINGS ............5-100
REMOVING THE CRANKSHAFT JOURNAL BEARINGS ....................5-100
CHECKING THE BALANCER SHAFT ASSEMBLY .............................. 5-100
CHECKING THE CRANKSHAFT ..........................................................5-102
INSTALLING THE CRANKSHAFT ........................................................5-103
INSTALLING THE BALANCER SHAFT ASSEMBLY ............................5-104
TRANSMISSION (1) ....................................................................................5-105

REMOVING THE TRANSMISSION CASE............................................5-106
INSTALLING THE TRANSMISSION CASE ..........................................5-106
TRANSMISSION (2) ....................................................................................5-108

DISASSEMBLING THE UNIVERSAL JOINT ........................................5-110
SEPARATING THE TRANSMISSION CASE ........................................5-110
CHECKING THE BEARINGS ................................................................5-110
CHECKING THE TRANSMISSION CASE ............................................5-110
ASSEMBLING THE TRANSMISSION CASE ........................................5-110
ASSEMBLING THE UNIVERSAL JOINT ..............................................5-111
TRANSMISSION (3) ....................................................................................5-112

REMOVING THE TRANSMISSION ...................................................... 5-116
CHECKING THE SHIFT FORKS...........................................................5-116
CHECKING THE SHIFT DRUM ............................................................5-116
CHECKING THE TRANSMISSION .......................................................5-116
CHECKING THE SECONDARY SHAFT ...............................................5-117
ASSEMBLING THE DRIVE AXLE .........................................................5-117
ASSEMBLING THE SHIFT FORK.........................................................5-117
INSTALLING THE SHIFT FORKS AND SHIFT DRUM .........................5-118
SELECTING THE THRUST WASHER(S) .............................................5-118
SELECTING THE PINION GEAR SHIM(S)........................................... 5-118
MIDDLE GEAR ............................................................................................5-120
DISASSEMBLING THE MIDDLE DRIVE PINION GEAR
ASSEMBLY ..........................................................................................5-122
REMOVING THE MIDDLE DRIVEN SHAFT YOKE .............................. 5-122
CHECKING THE PINION GEARS ........................................................5-122
INSTALLING THE OIL SEALS ..............................................................5-122
INSTALLING THE MIDDLE DRIVEN SHAFT .......................................5-123
ASSEMBLING THE MIDDLE DRIVE PINION GEAR ASSEMBLY .......5-123
MEASURING THE MIDDLE GEAR BACKLASH...................................5-123
ALIGNING THE MIDDLE GEAR ...........................................................5-124
LUBRICATION SYSTEM CHART AND DIAGRAMS
EBS20149

EBS30795
ENGINE OIL LUBRICATION CHART
9 5
18 16 15 14 13 10 7
17 12 11 8 6 3 4
1
2
1. Oil pan 17. Exhaust camshaft

2. Oil strainer 18. Intake camshaft
3. Scavenging pump 1
4. Scavenging pump 2
5. Engine oil tank
6. Oil feed pump
7. Relief valve
8. Oil filter cartridge
9. Oil cooler
10. Crankshaft
11. Clutch
12. AC magneto
13. Balancer shaft
14. Oil nozzle
15. Timing chain tensioner
16. Exhaust camshaft cap
5-1
EBS30796
LUBRICATION DIAGRAMS
6
10
8
1 2
7
9
5
4
1. Exhaust camshaft cap
2. Exhaust camshaft
3. Crankshaft
4. Crankcase (lower)
5. Cylinder head cover bolt (for oil pressure
check)
6. Balancer shaft
7. Cylinder head
8. Timing chain tensioner
9. Crankcase (upper)
10. Intake camshaft
5-2
1
2
1. Oil cooler
2. Oil filter cartridge
3. Oil delivery pipe
4. Oil passage
5. Oil pump
6. Oil strainer
5-3
6
2
5
3
3
4
1. Engine oil tank

5-4
ENGINE INSPECTION
EBS20105
7. Measure:
ENGINE INSPECTION • Compression pressure
EBS30135
Out of specification → Refer to steps (b) and
MEASURING THE COMPRESSION (c).
PRESSURE
The following procedure applies to all of the cyl- Compression pressure
530–683 kPa/340 r/min (5.3–6.8
inders.
kgf/cm²/340 r/min, 75.5–97.2 psi/
TIP 340 r/min)
Insufficient compression pressure will result in a
loss of performance. a. With the throttle wide open, crank the en-
gine by turning the main switch to “ ”
1. Remove:
(start) until the reading on the compres-
• Rear cover
sion gauge stabilizes.
Refer to “GENERAL CHASSIS (5)” on page EWB04410
4-16. WARNING
2. Measure: To prevent sparking the plug, remove all ig-
• Valve clearance nition coil couplers and fuel injector cou-
Out of specification → Adjust. plers before cranking the engine.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-4. b. If the compression pressure is above the
3. Start the engine, warm it up for several min- maximum specification, check the cylinder
utes, and then turn it off. head, valve surfaces and piston crown for
4. Disconnect: carbon deposits.
• Ignition coil couplers Carbon deposits → Eliminate.
5. Remove: c. If the compression pressure is below the
• Ignition coils minimum specification, pour a teaspoonful
• Spark plugs of engine oil into the spark plug bore and
ECB03280 measure 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
6. Install: damage → Repair.
• Compression gauge “1” Piston, valves, cylinder
head gasket, or piston
Same as without oil
Compression gauge ring(s) possibly defec-
90890-03081 tive → Repair.
Engine compression tester
YU-33223 8. Install:
• Spark plugs
• Ignition coils
Spark plug
1 13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
TIP
Before installing the spark plugs, clean the spark
plugs and gasket surfaces.
9. Connect:
• Ignition coil couplers
5-5
ENGINE INSPECTION
10.Install:
• Rear cover
4-16.
5-6
ENGINE REMOVAL (1)
EBS20034
ENGINE REMOVAL (1)

Removing the cargo bed heat protector
T.R
.
T.R
.
(4)
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
27 N•m (2.7 kgf•m, 20 lb•ft)

T.R
.
27 N•m (2.7 kgf•m, 20 lb•ft)

T.R
.

4-1.
Driver seat frame/Passenger seat frames Refer to “GENERAL CHASSIS (2)” on page
4-7.
Rear passenger seat belts/Rear passenger seat Refer to “GENERAL CHASSIS (3)” on page
belt buckles 4-12.

4-16.

4-25.
Rear fenders/Cargo bed Refer to “GENERAL CHASSIS (15)” on

page 4-47.
5-7
ENGINE REMOVAL (1)
Removing the cargo bed heat protector

T.R
.
27 N•m (2.7 kgf•m, 20 lb•ft) 1 70 N•m (7.0 kgf•m, 52 lb•ft)
T.R
.
5 6
(4)
3 8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
7
4 3
27 N•m (2.7 kgf•m, 20 lb•ft)

T.R
.
27 N•m (2.7 kgf•m, 20 lb•ft)

T.R
.

1 Cargo bed protector 1
2 Cargo bed heat protector plate 1 1
3 Cargo bed heat protector stay 2
4 Cargo bed heat protector plate 2 1
5 Cargo bed heat protector 1 1
5-8
ENGINE REMOVAL (1)
Removing the muffler and exhaust pipe

T.R
T.R
.
.
29 N•m (2.9 kgf•m, 21 lb•ft)
T.R
.
9 T.R
.
26 N•m (2.6 kgf•m, 19 lb•ft)

5 N•m (0.5 kgf•m, 3.7 lb•ft)
T.R
.
11 New
10
LS
11 New
(4) 20 N•m (2.0 kgf•m, 15 lb•ft)
T.R
.
New
3
4 5 N•m (0.5 kgf•m, 3.7 lb•ft)
T.R
.

2
T.R
.
T.R
.
26 N•m (2.6 kgf•m, 19 lb•ft)

(6)
T.R
.
1 New 7
New 8
6 New 5 N•m (0.5 kgf•m, 3.7 lb•ft)

T.R
.
27 N•m (2.7 kgf•m, 20 lb•ft) 8 N•m (0.8 kgf•m, 5.9 lb•ft) 23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
T.R
T.R
.
.
.

1 Muffler guard 1
2 Muffler assembly 1
3 Muffler heat protector plate 1 1
5 Muffler 1
6 Gasket 1
7 Exhaust pipe 2 1
8 Gasket 1
9 O2 sensor coupler 1 Disconnect.
10 Exhaust pipe 1 1
11 Gasket 2
5-9
ENGINE REMOVAL (1)
Removing the muffler and exhaust pipe

T.R
T.R
.
.
29 N•m (2.9 kgf•m, 21 lb•ft) 12
T.R
.
T.R
.
26 N•m (2.6 kgf•m, 19 lb•ft)

15 5 N•m (0.5 kgf•m, 3.7 lb•ft)
T.R
.
New
LS
16 New
17 20 N•m (2.0 kgf•m, 15 lb•ft)
(4)
T.R
.
15
New
5 N•m (0.5 kgf•m, 3.7 lb•ft)

T.R
.
T.R
.
T.R
.
26 N•m (2.6 kgf•m, 19 lb•ft)

(6)
T.R
.
14 New
New
13
15
New 5 N•m (0.5 kgf•m, 3.7 lb•ft)
T.R
.
27 N•m (2.7 kgf•m, 20 lb•ft) 8 N•m (0.8 kgf•m, 5.9 lb•ft) 23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
T.R
T.R
.
.
.

13 Spark arrester 1
14 Gasket 1
15 Muffler protector 3
Remove the O2 sensor only when neces-
16 O2 sensor 1
sary.
17 O2 sensor protector 1
5-10
ENGINE REMOVAL (1)
EBS30127
INSTALLING THE EXHAUST PIPE AND

MUFFLER 2
1. Install:
• Gaskets “1” New
(to exhaust pipe)
ECB01640
NOTICE
Be careful not to damage the muffler contact 1
surface of the gasket.
TIP 3. Install:
Install the gasket completely onto the exhaust • Muffler protector
pipe “2” by pushing the side “a” of the gasket. If • O2 sensor
the gasket is difficult to install, tap lightly on the • O2 sensor protector
gasket with a soft-face hammer. TIP
Make sure that the muffler protector “1” does not
1 New contact the O2 sensor protector “2”.
2
2. Install: 1
• Exhaust pipe bolts “1” 2
a. Temporarily tighten the exhaust pipe bolt 4. Install:
“1”. • Spark arrester
TIP Refer to “CLEANING THE SPARK ARREST-
Make sure that the exhaust pipe bolt “1” is tem- ER” on page 3-11.
porarily tightened at 2 to 4 pitches.
b. Tighten the exhaust pipe bolt “2” to speci-
fication.
c. Tighten the exhaust pipe bolt “1” to speci-
fication.
TIP
The bolts may be tightened in reverse order.
Exhaust pipe bolt

26 N·m (2.6 kgf·m, 19 lb·ft)
T.
R.
5-11
ENGINE REMOVAL (2)
EBS20093
ENGINE REMOVAL (2)

Removing the engine oil tank
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.
LT
New
LS
LT
LT
LT
New LT
LT
LT
LT
LT
New LT
New
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
T.R
T.R
.
.

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-18.
Drain.
Rear door striker (left) Refer to “GENERAL CHASSIS (1)” on page
4-1.
Drain.
4-7.

4-15.
Drain.
4-16.
Dashboard (left) Refer to “GENERAL CHASSIS (6)” on page

4-17.
5-12
ENGINE REMOVAL (2)
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.
LT
New
LS
LT
LT
LT
New LT
LT
LT
LT
LT
New LT
New
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
T.R
T.R
.
.

Drain.
Rear floor boards (left) Refer to “GENERAL CHASSIS (7)” on page
4-25.

page 4-38.
V-belt cooling exhaust duct Refer to “GENERAL CHASSIS (16)” on

page 4-51.
Purge cut valve solenoid Drain.

Refer to “FUEL TANK” on page 7-1.

page 7-18.
5-13
ENGINE REMOVAL (2)
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.
9
LT
New
2
LS
6 LT
LT
LT
1
7 LT
LT
New 3
LT
LT
LT
8 10
4
New LT
New
10 N•m (1.0 kgf•m, 7.4 lb•ft) 5
T.R
.
T.R
T.R
.
.

1 Oil tank inlet hose 1
2 Oil tank outlet pipe 2 1
3 Engine oil tank 1
4 Oil tank outlet hose 1 1
6 Oil tank outlet hose 2 1
8 Oil tank inlet pipe 1
9 Dipstick (engine oil tank) 1
10 Engine oil drain bolt 1
5-14
ENGINE REMOVAL (2)
EBS30647
b. Add the oil tank with the specified amount
CHECKING THE OIL TANK OUTLET PIPE 1
of the recommended engine oil.
(OIL STRAINER)
1. Check: Oil tank
• Oil strainer “a” Quantity
Damage → Replace the oil tank outlet pipe 1 2.05 L (2.17 US qt, 1.80 Imp.qt)
“1”.
Contaminants → Clean with solvent. 2. Install:
• Dipstick “1”
• Engine oil filler cap “2”
a
1
2
EBS30995 1
FILLING THE ENGINE OIL (WHEN THE
ENGINE IS DISASSEMBLED) 3. Start the engine and warm it up to 60 °C (140
1. Fill: °F), and then stop the engine, wait 10 min-
• Crankcase and oil tank utes.
ECB03090
Crankcase and oil tank NOTICE

Quantity When starting the engine, make sure the dip-
5.50 L (5.81 US qt, 4.84 Imp.qt) stick is securely fitted into the oil tank.
a. Add the oil tank outlet pipe 3 “1” and 4. Remove the dipstick, and then add the rec-
crankcase with the specified amount of ommended engine oil to raise it to the maxi-
the recommended engine oil. mum level mark on the dipstick.
5. Install:
Crankcase and oil tank outlet pipe • Dipstick
3 6. Start the engine, warm it up for several min-
Quantity utes, and then turn it off.
3.45 L (3.65 US qt, 3.04 Imp.qt) 7. Check:
• Engine
TIP (for engine oil leaks)
• First add the oil tank outlet pipe 3 “1” with the 8. Check:
engine oil, and then add the crankcase with the • Engine oil level
engine oil. Refer to “CHECKING THE ENGINE OIL
• Make sure that the engine oil is fully filled in oil LEVEL” on page 3-17.
tank outlet pipe 3 “1”.
5-15
ENGINE REMOVAL (3)
EBS20120
ENGINE REMOVAL (3)

Disconnecting the cable, hoses, couplers, and leads
27 N•m (2.7 kgf•m, 20 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
FW
D

Drain.
page 3-13.
Drain.
page 3-18.
Front over fenders/Front doors/Rear door strik- Refer to “GENERAL CHASSIS (1)” on page
ers 4-1.

4-7.

4-15.

4-16.
4-17.
5-16
ENGINE REMOVAL (3)
27 N•m (2.7 kgf•m, 20 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
FW
D
4-25.
Air intake accumulator assembly/Air filter case Refer to “GENERAL CHASSIS (13)” on
duct 2 page 4-38.
Rear fenders/Cargo bed Refer to “GENERAL CHASSIS (15)” on

page 4-47.
V-belt cooling ducts Refer to “GENERAL CHASSIS (16)” on

page 4-51.
Front wheel hub Refer to “FRONT AND REAR WHEELS” on

page 4-54.
Parking brake caliper/Parking brake lever/Park- Refer to “PARKING BRAKE” on page 4-71.
ing brake disc
Steering knuckles Refer to “STEERING KNUCKLES AND

Exhaust pipe/Muffler Refer to “ENGINE REMOVAL (1)” on page

5-7.
Engine oil tank Refer to “ENGINE REMOVAL (2)” on page

5-12.
5-17
ENGINE REMOVAL (3)
27 N•m (2.7 kgf•m, 20 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
FW
D

Drive select lever bracket Refer to “SHIFT LEVER” on page 5-60.
Primary sheave assembly/Secondary sheave Refer to “PRIMARY AND SECONDARY
assembly SHEAVES” on page 5-66.
Oil inlet pipe/hose 1/Oil outlet pipe/hose 1 Refer to “OIL COOLER” on page 6-3.
Thermostat Refer to “THERMOSTAT” on page 6-12.
Water pump inlet hose Refer to “WATER PUMP” on page 6-14.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Throttle bodies Refer to “THROTTLE BODIES” on page

7-11.
Air induction system hoses/Air cut-off valve Refer to “AIR INDUCTION SYSTEM” on
page 7-18.
Refer to “FRONT CONSTANT VELOCITY
Differential assembly/Front drive shaft SHAFT ASSEMBLIES, DIFFERENTIAL AS-
SEMBLY AND FRONT DRIVE SHAFT” on
page 8-4.
Refer to “REAR CONSTANT VELOCITY
Final drive assembly/Rear drive shaft SHAFT ASSEMBLIES, FINAL DRIVE AS-
SEMBLY AND REAR DRIVE SHAFT” on
page 8-22.
5-18
ENGINE REMOVAL (3)

1 27 N•m (2.7 kgf•m, 20 lb•ft)
T.R
.
2
3
4
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
5
11 7
9
10
FW
D
10

1 Ignition coil coupler 2 Disconnect.
2 Coolant temperature sensor coupler 1 Disconnect.
3 Engine ground lead 1 Disconnect.
4 Starter motor lead 1 Disconnect.
5 Transmission case breather hose 1 Disconnect.
6 Reverse switch connector 1 Disconnect.
7 Speed sensor coupler 1 Disconnect.
8 Gear position sensor coupler 1 Disconnect.
9 Crankshaft position sensor coupler 1 Disconnect.
10 AC magneto/Crankshaft position sensor coupler 3 Disconnect.
11 Engine oil pressure switch coupler 1 Disconnect.
5-19
ENGINE REMOVAL (3)
Removing the engine

60 N•m (6.0 kgf•m, 44 lb•ft) 42 N•m (4.2 kgf•m, 31 lb•ft) 60 N•m (6.0 kgf•m, 44 lb•ft)
T.R
T.R
.
.
T.R
.
T.R
.
T.R
.
7
8 7
4 1
4
4
42 N•m (4.2 kgf•m, 31 lb•ft)
T.R
.
74 60 N•m (6.0 kgf•m, 44 lb•ft)
T.R
.
2 LT
LT 6 FW
1
D
2 60 N•m (6.0 kgf•m, 44 lb•ft)
T.R
.
42 N•m (4.2 kgf•m, 31 lb•ft)

T.R
.
T.R
T.R
.
.

1 Transmission case mounting bolt 2
2 Engine mounting nut 2
TIP
3 Engine 1 Remove the engine from the upper side of
the vehicle.
4 Transmission case bracket 1 bolt 4

5 Transmission case bracket 1 (left) 1
6 Transmission case bracket 1 (right) 1
7 Transmission case bracket 2 bolt 4
8 Transmission case bracket 2 (left) 1
9 Transmission case bracket 2 (right) 1
5-20
ENGINE REMOVAL (3)
Removing the engine

60 N•m (6.0 kgf•m, 44 lb•ft)
T.R
T.R
.
.
T.R
.
14 42 N•m (4.2 kgf•m, 31 lb•ft)

42 N•m (4.2 kgf•m, 31 lb•ft)
T.R
.
T.R
.
10
15 11
13
12
10
42 N•m (4.2 kgf•m, 31 lb•ft)
T.R
.
60 N•m (6.0 kgf•m, 44 lb•ft)
T.R
.
LT
LT FW
D
60 N•m (6.0 kgf•m, 44 lb•ft)
T.R
.
42 N•m (4.2 kgf•m, 31 lb•ft)

T.R
.
T.R
T.R
.
.

10 Engine mounting bolt 2
11 Engine bracket 2 (left) 1
12 Engine bracket 2 (right) 1
13 Engine bracket 1 bolt 4
14 Engine bracket 1 (left) 1
15 Engine bracket 1 (right) 1
5-21
ENGINE REMOVAL (3)
EBS30351
INSTALLING THE ENGINE

1. Install: 2
• Engine brackets 1 “1” 9 1
4 6 6
• Engine bracket 1 bolts “2” 5
• Engine brackets 2 “3” 8 11
• Engine mounting bolts “4”
(to the engine) 1 8
3
Engine bracket 1 bolt 2 7
42 N·m (4.2 kgf·m, 31 lb·ft)
T.
R.
TIP
4 5
Do not fully tighten the engine mounting bolt. 3
2. Install: 8
• Transmission case brackets 2 “5” 8
• Transmission case bracket 2 bolts “6” 6
(to the engine) 11
• Transmission case brackets 1 “7” 7
• Transmission case bracket 1 bolts “8” 10
(to the frame)
Transmission case bracket 2 bolt

42 N·m (4.2 kgf·m, 31 lb·ft)
T.
R.
Transmission case bracket 1 bolt

42 N·m (4.2 kgf·m, 31 lb·ft)
3. Install:
• Engine “9”
• Engine mounting nuts “10”
• Transmission case mounting bolts “11”
ECB01630
NOTICE
Make sure that the engine does not strike the
brake pipe when installing it.
4. Tighten:
• Engine mounting nuts “10”
• Transmission case mounting bolts “11”
• Engine mounting bolts “4”
Engine mounting nut

56 N·m (5.6 kgf·m, 41 lb·ft)
T.
R.
Transmission case mounting bolt

60 N·m (6.0 kgf·m, 44 lb·ft)
Engine mounting bolt
60 N·m (6.0 kgf·m, 44 lb·ft)
5-22
CAMSHAFTS
EBS20106
CAMSHAFTS
Removing the cylinder head cover
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
D
FW
13 N•m (1.3 kgf•m, 9.6 lb•ft)

T.R
.
1.0 N•m (0.10 kgf•m, 0.73 lb•ft)

T.R
(4)
.
LS
New
New

4-1.
4-7.

4-16.

4-25.

page 4-51.
Air induction system hose Refer to “AIR INDUCTION SYSTEM” on

page 7-18.
5-23
CAMSHAFTS
Removing the cylinder head cover

10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
2
3
D
1 FW
4 13 N•m (1.3 kgf•m, 9.6 lb•ft)
T.R
.
4
1.0 N•m (0.10 kgf•m, 0.73 lb•ft)
T.R
(4) .
LS
5
8 New
New 6

1 Cylinder head breather hose 1 Disconnect.
2 Ignition coil coupler 2 Disconnect.
3 Ignition coil 2
4 Spark plug 2
5 Cylinder head cover 1
6 Cylinder head cover gasket 1
7 Engine oil filler cap 1
8 Timing chain guide (upper side) 1
5-24
CAMSHAFTS
Removing the camshafts
D
10 N•m (1.0 kgf•m, 7.4 lb•ft)
FW
T.R
(6)
.
6 (6)
5
E 24 N•m (2.4 kgf•m, 18 lb•ft)
T.R
.
13 13 7
9 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
M
8
M
12 3
4 New
11
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
.
E 10 15 N•m (1.5 kgf•m, 11 lb•ft)
T.R
.
New
2
24 N•m (2.4 kgf•m, 18 lb•ft)
T.R
.
New 1
LS

1 Crankshaft end accessing screw 1
2 Timing mark accessing screw 1
3 Timing chain tensioner 1
4 Timing chain tensioner gasket 1
5 Intake camshaft cap 1
6 Exhaust camshaft cap 1
7 Intake camshaft 1
8 Exhaust camshaft 1
9 Intake camshaft sprocket 1
10 Exhaust camshaft sprocket 1
11 Decompressor lever #2 1
12 Decompressor lever #1 1
13 Decompressor lever pin 2
5-25
CAMSHAFTS
EBS30432
4. Remove:
REMOVING THE CAMSHAFTS
• Intake camshaft cap “1”
1. Remove:
• Exhaust camshaft cap “2”
• Crankshaft end accessing screw “1” ECB03120
• Timing mark accessing screw “2” NOTICE

To prevent damage to the cylinder head,
2 camshafts or camshaft caps, loosen the
camshaft cap bolts in stages and in a criss-
1 cross pattern, working from the outside in.
2. Align:
• “I” mark “a” (“H” side) on the AC magneto ro-
tor 2
(with the slot “b” in the AC magneto rotor cov-
er)
a. Turn the crankshaft counterclockwise. 5. Remove:
b. When piston #1 is at TDC on the exhaust • Intake camshaft “1”
stroke, align the TDC mark “a” on the AC • Exhaust camshaft “2”
magneto rotor with the slot “b” in the AC TIP
magneto rotor cover. To prevent the timing chain from coming off the
crankshaft sprocket, fasten it with a wire “3”.
b a
3
1 2
TIP
Make sure the match marks “c” on the camshaft 6. Remove:
sprockets are aligned with cylinder head match- • Intake camshaft sprocket “1”
ing surface “d”. TIP
While holding the intake camshaft sprocket with
the rotor holding tool “2”, loosen the intake cam-
shaft sprocket bolts in the proper sequence as
shown.
d
Rotor holding tool
90890-01235
Universal magneto and rotor
holder
c c YU-01235
3. Remove:
• Timing chain tensioner
• Timing chain tensioner gasket
5-26
CAMSHAFTS
3. Measure:
1 • Camshaft runout
2 Out of specification → Replace.
2
Camshaft runout limit
0.030 mm (0.0012 in)
7. Remove:
• Exhaust camshaft sprocket “1”
TIP
While holding the exhaust camshaft with a rotor
holding tool “2”, loosen the exhaust camshaft
sprocket bolts in the proper sequence as shown.
4. Measure:
1 • Camshaft-journal-to-camshaft-cap clearance
Out of specification → Measure the camshaft
2 journal diameter.
Camshaft-journal-to-camshaft-
cap clearance
2 0.028–0.062 mm (0.0011–0.0024
1 in)
a. Install the camshafts into the cylinder head

EBS30433 (without the camshaft caps).
CHECKING THE CAMSHAFTS b. Position a strip of Plastigauge® “1” onto
1. Check: the camshaft journal as shown.
• Camshaft lobes
Blue discoloration/pitting/scratches → Re-
place the camshaft.
2. Measure:
• Camshaft lobe dimensions “a”
Out of specification → Replace the camshaft.
Camshaft lobe dimensions

Lobe height (Intake) limit
38.850 mm (1.5295 in) 1
Lobe height (Exhaust) limit
38.350 mm (1.5098 in) c. Install the camshaft caps 2.
TIP
• Tighten the camshaft cap bolts in proper tight-
ening sequence as shown.
• Do not turn the camshaft when measuring the
camshaft journal-to-camshaft cap clearance
limit with the Plastigauge®.
Camshaft cap bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
G101474
5-27
CAMSHAFTS
2
1 2
1
5 3 a
4 6 b
2 1
5 3
2
4 6
22 G101473
d. Remove the camshaft caps, and then a. 1/4 tooth

measure the width of the Plastigauge® b. Correct
“3”. 1. Timing chain
2. Camshaft sprocket
EBS30435
CHECKING THE TIMING CHAIN TENSIONER

1. Check:
2. Check:
3 Rough movement → Replace.
a. Positioning the timing chain tensioner rod.
5. Measure:
Refer to “POSITIONING THE TIMING
• Camshaft journal diameter “a”
CHAIN TENSIONER ROD” on page 5-28.
Out of specification → Replace the camshaft.
b. Push the timing chain tensioner rod in the
Within specification → Replace the cylinder
direction “a”.
head and camshaft caps as a set.
c. If the circlip does not unlock even though
Camshaft journal diameter you press the timing chain tensioner rod in
24.459–24.472 mm (0.9630– the “a” direction, rotate the timing chain
0.9635 in) tensioner rod clockwise.
d. Make sure that the timing chain tensioner
rod comes out “b” of the timing chain ten-
sioner housing smoothly.
a
b
G101585
EBS30434
CHECKING THE CAMSHAFT SPROCKETS

1. Check: EBS30991
• Camshaft sprocket POSITIONING THE TIMING CHAIN

More than 1/4 tooth wear “a” → Replace the TENSIONER ROD
camshaft sprockets and timing chain as a set. 1. Position:
• Timing chain tensioner rod
a. Secure the valve spring compressor “1” in
a vise.
5-28
CAMSHAFTS
b. Install timing chain tensioner “2”, suitable d. Align clip “d” with groove “e” on the timing
socket “3”, and rubber plate “4” to valve chain tensioner rod, compress clip “d”,
spring compressor “1” as shown in the il- and fit it into the groove, and then remove
lustration. the timing chain tensioner rod from the
valve spring compressor.
90890-01253
Valve spring compressor d
YM-01253
ECB03962
NOTICE
Do not push timing chain tensioner rod “a”
1 into timing chain tensioner rod body “b” too
far. If pushed too far or tensioner damage
can occur.
2
a
4
b
3
c. While holding timing chain tensioner rod

“a” so that it does not rotate, synchronize EBS30138
timing chain tensioner rod body “b” with CHECKING THE DECOMPRESSION SYSTEM
valve spring compressor socket “c”, rotate 1. Check:
them clockwise, and push them in slowly. • Decompression system
TIP TIP
If timing chain tensioner rod body “b” is pushed • Check that the decompressor lever pins “1”
too hard, timing chain tensioner rod body “b” and projects from the camshaft.
timing chain tensioner rod “a” will get stuck. In • Check that the decompressor cams “2” and de-
such a case, turn timing chain tensioner rod compressor lever pins “1” moves smoothly.
body “b” counterclockwise to loosen it, then
tighten it again.
2 1
c
b 1
a 2
5-29
CAMSHAFTS
EBS30436
• While holding the exhaust camshaft with a ro-
INSTALLING THE CAMSHAFTS
tor holding tool “2”, tighten the exhaust cam-
1. Align:
shaft sprocket bolts.
• “I” mark “a” (“H” side) on the AC magneto ro-
• Tighten the camshaft sprocket bolts in the
tor
tightening sequence as shown.
(with the slot “b” in the AC magneto rotor cov-
er)
a. Turn the crankshaft counterclockwise. Rotor holding tool
b. When piston #1 is at TDC, align the TDC 90890-01235
Universal magneto and rotor
mark “a” on the AC magneto rotor with the
holder
slot “b” in the AC magneto rotor cover. YU-01235
b a
a
b
2. Install:
• Decompressor lever pins “1”
• Decompressor lever #1 “2”
1
• Decompressor lever #2 “3”
TIP 1
• Face the cutout “a” in each decompressor le-
ver pin toward the exhaust camshaft sprocket.
• Install the decompressor lever pins, decom- 2
pressor lever #1, and decompressor lever #2
into the exhaust camshaft as shown in the illus-
2
tration.
4. Install:
• Intake camshaft sprocket “1”
1 a 2 1 a 3 (onto the intake camshaft “2”)
Intake camshaft sprocket bolt

24 N·m (2.4 kgf·m, 18 lb·ft)
T.
R.
1 1 TIP
• Install the intake camshaft sprocket as shown
in the illustration.
• While holding the intake camshaft sprocket
3. Install:
with the rotor holding tool “3”, tighten the intake
• Exhaust camshaft sprocket “1”
camshaft sprocket bolts in the proper tighten-
Exhaust camshaft sprocket bolt ing sequence as shown.
24 N·m (2.4 kgf·m, 18 lb·ft)
T.
R.
Rotor holding tool

TIP 90890-01235
• Make sure that the mark “a” on the exhaust Universal magneto and rotor
camshaft sprocket is aligned with cam lobe #1 holder
“b” as shown in the illustration. YU-01235
5-30
CAMSHAFTS
TIP
2 1 Do not release the timing chain tensioner rod.
7. Install:
• Exhaust camshaft cap “1”
• Intake camshaft cap “2”
8. Tighten:
• Camshaft cap bolts
Camshaft cap bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
1 ECB03140
2 NOTICE
1 • Lubricate the camshaft cap bolts with the
engine oil.
• The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
camshaft caps, and camshafts will result.
2 • Do not turn the crankshaft when installing
3
the camshaft to avoid damage or improper
5. Install: valve timing.
• Timing chain
TIP
(onto the camshaft sprockets)
• Exhaust camshaft Tighten the camshaft cap bolts in the proper
• Intake camshaft tightening sequence as shown.
TIP
2
1 1
• When installing the timing chain, start with the
exhaust camshaft and be sure to keep the tim- 5 3
ing chain as tight as possible on the exhaust
4 6
side. 2
• Make sure the marks “a” on the camshaft 1
sprockets are parallel with the edge of the cyl- 5 3
inder head. 6
4
2 2
EX IN
9. Release:
• Timing chain tensioner rod
a. Push the timing chain guide “1” as shown
in the illustration to release the timing
chain tensioner rod.
1
a b a
b. Cylinder #1 camshaft lobes
6. Install:
• Timing chain tensioner gasket New
Timing chain tensioner bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft) b. Check that the timing chain is taut. If the
T.
R.
chain is slack, reinstall the timing chain

tensioner.
5-31
CAMSHAFTS
10.Turn: TIP
• Crankshaft • Apply Yamaha bond No.1215 “3” onto the mat-
(several turns counterclockwise) ing surfaces of the cylinder head cover gasket
11.Check: and cylinder head.
• “I” mark “a” • After installing the cylinder head cover gasket
Make sure the “I” mark “a” on the AC magne- “1” to the cylinder head cover, cut off the “a”
to rotor is aligned with the slot “b” in the AC section.
magneto rotor cover.
• Camshaft sprocket match mark
Yamaha bond No. 1215
Make sure the match marks “c” on the cam-
90890-85505
shaft sprockets are aligned with the cylinder Three bond No. 1215®
head mating surface “d”.
Out of alignment → Adjust.
Refer to the installation steps above. 3
• Timing chain guide
3
Make sure that the timing chain guide and
timing chain are positioned correctly.
b a
2
a
1 New
2. Install:
• Spark plugs
• Ignition coils “1”
Spark plug
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
TIP
Install the ignition coils “1” in the direction shown
d in the illustration.
1
c c
12.Measure:
• Valve clearance
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-4.
EBS30837
INSTALLING THE CYLINDER HEAD COVER

1. Install:
• Cylinder head cover gasket “1” New
(to the cylinder head cover)
• Cylinder head cover “2”
Cylinder head cover bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
5-32
CYLINDER HEAD
EBS20035
CYLINDER HEAD
Removing the cylinder head
1st 20 N•m (2.0 kgf•m, 15 lb•ft)
(6)
New 2nd 40 N•m (4.0 kgf•m, 30 lb•ft)
T.R
3rd * 25 N•m (2.5 kgf•m, 18 lb•ft)
.
Specified angle 120°
D
FW
New 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque (after
loosening the bolt, retighten it before loosening the next bolt).

Drain.
page 3-13.
Drain.
page 3-18.
Rear door strikers 4-1.
Driver seat frame/Passenger seat frames 4-7.
Center cover 4-16.
Rear floor boards 4-25.
5-33
CYLINDER HEAD

1st 20 N•m (2.0 kgf•m, 15 lb•ft)
(6)
T.R
3rd * 25 N•m (2.5 kgf•m, 18 lb•ft)
.
D
FW
New 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.

Refer to “GENERAL CHASSIS (13)” on
Air intake accumulator assembly page 4-38.
Rear fenders/Cargo bed page 4-47.
Refer to “ENGINE REMOVAL (1)” on page
Exhaust pipe/Muffler 5-7.
Cylinder head cover/Intake camshaft/Exhaust
camshaft Refer to “CAMSHAFTS” on page 5-23.
Thermostat/Coolant temperature sensor Refer to “THERMOSTAT” on page 6-12.

Water jacket joint Refer to “WATER PUMP” on page 6-14.
Refer to “THROTTLE BODIES” on page
Throttle bodies 7-11.
5-34
CYLINDER HEAD

1st 20 N•m (2.0 kgf•m, 15 lb•ft)
(6)
T.R
3rd * 25 N•m (2.5 kgf•m, 18 lb•ft)
.
E 2
1 D
FW
New 3 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
4 4

1 Timing chain bolt 1
2 Cylinder head 1
3 Cylinder head gasket 1
4 Dowel pin 2
5 Timing chain guide (exhaust side) 1
5-35
CYLINDER HEAD
EBS30438
• Cylinder head water jacket
REMOVING THE CYLINDER HEAD
Mineral deposits/rust → Eliminate.
1. Remove:
3. Measure:
• Cylinder head bolt (M6) (×2)
• Cylinder head warpage
• Cylinder head bolt (M12) (×6)
Out of specification → Resurface the cylinder
• Cylinder head
head.
TIP
• Loosen the bolts in the proper sequence as Warpage limit
shown. 0.10 mm (0.0039 in)
• Loosen each bolt 1/2 of a turn at a time. After
all of the bolts are fully loosened, remove them.
㽢2 㽢6
G101470
a. Place a straightedge “1” and a thickness

gauge “2” across the cylinder head.
4 8 6 2
1
1
5 7 3 G101472
b. Measure the warpage.

EBS30579
c. If the limit is exceeded, resurface the cylin-
CHECKING THE TIMING CHAIN GUIDE der head as follows.
1. Check: d. Place a 400–600 grit wet sandpaper on
• Timing chain guide (exhaust side) the surface plate and resurface the cylin-
Damage/wear → Replace. der head using a figure-eight sanding pat-
tern.
EBS30439
CHECKING THE CYLINDER HEAD TIP

1. Eliminate: To ensure an even surface, rotate the cylinder
• Combustion chamber carbon deposits head several times.
(with a rounded scraper)
ECB01851
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 (M12) (×6) New
• Valve seats • Cylinder head bolt (M6) (×2)
2. Check: TIP
• Cylinder head • Pass the timing chain through the timing chain
Damage/scratches → Replace. cavity.
5-36
CYLINDER HEAD
• Replace the cylinder head bolt (M12) with new

ones.
• Lubricate the cylinder head bolt (M12) threads
and washer with engine oil.
2. Tighten:
• Cylinder head bolts (M12) “1”–“6”
• Cylinder head bolts (M6) “7”, “8”
Cylinder head bolt (M12)

1st: 20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
2nd: 40 N·m (4.0 kgf·m, 30 lb·ft)

*3rd: 25 N·m (2.5 kgf·m, 18 lb·ft),
and then tighten the bolts to the
specified angle 120°
Cylinder head bolt (M6)
10 N·m (1.0 kgf·m, 7.4 lb·ft)
* Following the tightening order, loosen the

bolt one by one, and then retighten it to the
specific torque (after loosening the bolt, re-
tighten it before loosening the next bolt).
TIP
Tighten the cylinder head bolts “1”–“6” in the
proper tightening sequence as shown.
New
㽢2 㽢6
5 1 3
4 2 6
5-37
VALVES AND VALVE SPRINGS
EBS20037

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

Cylinder head Refer to “CYLINDER HEAD” on page 5-33.
1 Valve lifter 8
2 Valve pad 8
3 Valve cotter 16
4 Valve spring retainer 8
5 Valve spring (intake) 4 Purple paint
6 Valve spring (exhaust) 4 Pink paint
7 Intake valve 4
8 Exhaust valve 4
9 Valve stem seal 8
10 Valve spring seat 8
11 Valve guide 8
5-38
EBS30141
REMOVING THE VALVES Valve spring compressor

The following procedure applies to all of the 90890-04200
valves and related components. Valve spring compressor
TIP YM-04019
Before removing the internal parts of the cylinder Valve spring compressor attach-
ment (ø26)
head (e.g., valves, valve springs, valve seats),
90890-01243
make sure the valves properly seal. Valve spring compressor attach-
1. Remove: ment (ø26)
• Valve lifter YM-01253-1
• Valve pad
TIP
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.
2. Check:
• Valve sealing
Leakage at the valve seat → Check the valve
face, valve seat, and valve seat width.
G101478
Refer to “CHECKING THE VALVE SEATS”
on page 5-41. 4. Remove:
a. Pour a clean solvent “a” into the intake and • Valve spring retainer
exhaust ports. • Valve spring
b. Check that the valves properly seal. • Valve
TIP • Valve stem seal
• Valve spring seat
There should be no leakage at the valve seat “1”.
TIP
Identify the position of each part very carefully so
that it can be reinstalled in its original place.
EBS30142
CHECKING THE VALVES AND VALVE

GUIDES
valves and valve guides.
1. Measure:
G101477
• Valve-stem-to-valve-guide clearance
3. Remove: Out of specification → Replace the valve
• Valve cotters guide.
TIP • Valve-stem-to-valve-guide clearance =
Remove the valve cotters by compressing the Valve guide inside diameter “a” -
valve spring with the valve spring compressor Valve stem diameter “b”
“1” and the valve spring compressor attachment
“2”. Valve-stem-to-valve-guide clear-
ance (intake) limit
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
ance (exhaust) limit
0.100 mm (0.0039 in)
5-39
G101479 G101482
a. Valve guide position

c. After installing the valve guide, bore the
valve guide with the valve guide reamer
“3” to obtain the proper valve-stem-to-
valve-guide clearance.
G101480
2. Replace:
• Valve guide
TIP
To ease valve guide removal and installation,
G101483
and to maintain the correct fit, heat the cylinder
head to 100 °C (212 °F) in an oven. TIP
a. Remove the valve guide with the valve After replacing the valve guide, reface the valve
guide remover “1”. seat.
Valve guide remover & installer

set (ø5.5)
90890-04016
Valve guide remover (5.5 mm)
YM-01122
3. Eliminate:
• Carbon deposits
G101481 (from the valve face and valve seat)
b. Install the new valve guide with the valve 4. Check:
guide installer “2” and valve guide remov- • Valve face
er “1”. Pitting/wear → Grind the valve face.
• Valve stem end
Valve guide position (intake) Mushroom shape or diameter larger than the
10.7–11.1 mm (0.421–0.437 in) body of the valve stem → Replace the valve.
Valve guide position (exhaust) 5. Measure:
10.7–11.1 mm (0.421–0.437 in) • Valve stem runout
Out of specification → Replace the valve.
TIP
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always re-
place the valve stem seal.
5-40
Valve stem runout

0.010 mm (0.0004 in)
G101486
b. Install the valve into the cylinder head.

c. Press the valve through the valve guide
G101484 and onto the valve seat to make a clear
impression.
EBS30143
CHECKING THE VALVE SEATS d. Measure the valve seat width.

The following procedure applies to all of the TIP
valves and valve seats. Where the valve seat and valve face contacted
1. Eliminate: one another, the blue layout fluid will have been
• Carbon deposits removed.
(from the valve face and valve seat)
4. Lap:
2. Check:
• Valve face
• Valve seat
• Valve seat
Pitting/wear → Replace the cylinder head.
TIP
3. Measure:
• Valve seat width “a” After replacing the cylinder head or replacing the
Out of specification → Replace the cylinder valve and valve guide, the valve seat and valve
head. face should be lapped.
a. Apply a coarse lapping compound “a” to
Valve seat contact width (intake)
the valve face.
limit ECB01360
1.8 mm (0.07 in) NOTICE
Valve seat contact width (ex-
haust) Do not let the lapping compound enter the
0.90–1.10 mm (0.0354–0.0433 in) gap between the valve stem and the valve
guide.
G101485 G101487
a. Apply blue layout fluid “b” onto the valve b. Apply molybdenum disulfide oil onto the
face. 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.
5-41
TIP 1. Measure:
For the best lapping results, lightly tap the valve • Valve spring free length “a”
seat while rotating the valve back and forth be- Out of specification → Replace the valve
tween your hands. spring.
Free length (intake)

37.78 mm (1.49 in)
Free length limit (intake)
35.89 mm (1.41 in)
Free length (exhaust)
36.49 mm (1.44 in)
Free length limit (exhaust)
34.66 mm (1.36 in)
G101488
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.
G101490
EBS30441
CHECKING THE VALVE LIFTERS

valve lifters.
1. Check:
• Valve lifter
Damage/scratches → Replace the valve lift-
ers and cylinder head.
G101486
EBS30145
h. Install the valve into the cylinder head.
INSTALLING THE VALVES
i. Press the valve through the valve guide
and onto the valve seat to make a clear
valves and related components.
impression.
1. Deburr:
j. Measure the valve seat width “c” again. If
• Valve stem end
the valve seat width is out of specification,
(with an oil stone)
reface and lap the valve seat.
G101491
G101489
2. Lubricate:
EBS30144
• Valve stem
CHECKING THE VALVE SPRINGS
• Valve stem seal
(with the recommended lubricant)
valve springs.
5-42
Molybdenum disulfide oil
3. Install:
• Valve spring seat
(into the cylinder head)
• Valve stem seal New
• Valve
• Valve spring G101478
• Valve spring retainer 5. To secure the valve cotters onto the valve
TIP stem, lightly tap the valve tip with a soft-face
• Make sure each valve is installed in its original hammer.
ECB01370
place.
NOTICE
• Install the valve springs with the larger pitch “a”
facing up. Hitting the valve tip with excessive force
could damage the valve.
G101492
G101586
b. Smaller pitch
6. Lubricate:
4. Install: • Valve lifter (top)
• Valve cotters • Valve pad
TIP (with the recommended lubricant)
Install the valve cotters by compressing the
valve spring with the valve spring compressor
Molybdenum disulfide oil
“1” and the valve spring compressor attachment
“2”. • Valve lifter (side)
90890-04200 Recommended lubricant
Valve spring compressor Engine oil
YM-04019
Valve spring compressor attach- 7. Install:
ment (ø26) • Valve pad
90890-01243 • Valve lifter
Valve spring compressor attach- TIP
ment (ø26)
YM-01253-1 • 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.
5-43
AC MAGNETO AND STARTER CLUTCH
EBS20039

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

T.R
.
130 N•m (13 kgf•m, 96 lb•ft) 6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
T.R
.
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
LT
(6)
LT (3)
E LT
LT
E
E
E
(8) *
E LS
E
New
New New
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
FW
17 N•m (1.7 kgf•m, 13 lb•ft) New D
T.R
.
T.R
T.R
.
* Apply Yamaha bond No.1215.

Drain.
page 3-13.
Drain.
page 3-18.
Driver seat frame/Front passenger seat frame 4-7.
Hood/Front cover 4-15.
Center cover 4-16.
Dashboards (right) 4-17.
5-44
16 N•m (1.6 kgf•m, 12 lb•ft)

T.R
.
T.R
T.R
.
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
LT
(6)
LT (3)
E LT
LT
E
E
E
(8) *
1
E LS
E
New
New 4 6 New
5
3 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
4 10 N•m (1.0 kgf•m, 7.4 lb•ft) 2

T.R
.
FW
T.R
.
T.R
T.R
.

Rear floor board (right)/Front floor board (right)/ Refer to “GENERAL CHASSIS (7)” on page
Rear floor board bracket (right) 4-25.
Water pump housing cover Refer to “WATER PUMP” on page 6-14.
2 AC magneto lead coupler 2 Disconnect.
3 Oil delivery pipe 1
4 Gasket 2
5 Timing mark accessing screw 1
6 Crankshaft end accessing screw 1
5-45

16
16 N•m (1.6 kgf•m, 12 lb•ft)

T.R
.
T.R
T.R
.
.
9 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
LT
19
18
(6)
15
9 LT (3)
17 12
14 E LT
LT
E 11 10
13
E
E
(8) *
E LS
E
New 8
New New
7
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
FW
T.R
.
T.R
T.R
.

7 AC magneto cover 1
8 AC magneto cover gasket 1
9 Dowel pin 2
10 Stator coil assembly lead holder 1
11 Crankshaft position sensor 1
12 Stator coil 1
13 AC magneto rotor bolt 1
14 Washer 1
15 AC magneto rotor 1
16 Woodruff key 1
17 Starter clutch gear 1
18 Starter clutch 1
19 Torque limiter 1
5-46
EBS30151
• Make sure the flywheel puller is centered over
REMOVING THE AC MAGNETO ROTOR
the AC magneto rotor.
1. Remove:
• Oil delivery pipe “1”
• AC magneto cover “2” Flywheel puller
90890-01362
TIP
Heavy duty puller
• Use the spanner to remove the oil delivery pipe YU-33270-B
bolt. Flywheel puller attachment
• Loosen each bolt 1/4 of a turn at a time, in stag- 90890-04089
es and in a crisscross pattern. After all of the Crankshaft protector
bolts are fully loosened, remove them. YM-33282
1
2
2
1
3
2. Remove: EBS30152
• AC magneto rotor bolt “1” REMOVING THE STARTER CLUTCH
• Washer 1. Remove:
TIP • Starter clutch bolts “1”
Hold the AC magneto rotor “2” with the rotor TIP
holding tool “3” while loosening the AC magneto Hold the AC magneto rotor “2” with the rotor
rotor bolt. holding tool “3” while removing the starter clutch
bolts.
Rotor holding tool
90890-04166 Rotor holding tool
Rotor holding tool 90890-04166
YM-04166 Rotor holding tool
YM-04166
1
3
1 2
2
G101506 3
3. Remove: 1
• AC magneto rotor “1” EBS30153
(with the starter clutch) CHECKING THE STARTER CLUTCH

• Woodruff key 1. Check:
TIP • Starter clutch roller
• Use the flywheel attachment “2” and the fly- Damage/wear → Replace.
wheel puller “3”. 2. Check:
• Starter idle gear
5-47
• Starter clutch gear • While holding the AC magneto rotor “2” with
Burrs/chips/roughness/wear → Replace the the rotor holding tool “3”, tighten the starter
defective part(s). clutch bolts.
3. Check:
• Starter clutch gear contact surfaces Rotor holding tool
Damage/pitting/wear → Replace the defec- 90890-04166
tive part(s). Rotor holding tool
4. Check: YM-04166
• Starter clutch operation
a. Install the starter clutch and stater clutch a
gear “1” onto the AC magneto rotor “2”,
and hold the AC magneto rotor.
b. When turning the starter clutch gear clock-
wise “A”, the starter clutch and the starter
clutch gear should engage; otherwise, the
starter clutch is faulty and must be re-
placed. 1
c. When turning the starter clutch gear coun-
2
terclockwise “B”, it should turn freely; oth-
erwise, the starter clutch is faulty and must
be replaced.
1
3
A 2
B
G101509
2 EBS30156
INSTALLING THE AC MAGNETO ROTOR

EBS30154 1. Install:
CHECKING THE TORQUE LIMITER • Woodruff key
1. Check: • AC magneto rotor
• Torque limiter • Washer
Damage/wear → Replace. • AC magneto rotor bolt
TIP TIP
Do not disassemble the torque limiter. • Clean the tapered portion of the crankshaft and
the AC magneto rotor hub.
EBS30155 • When installing the AC magneto rotor, make
INSTALLING THE STARTER CLUTCH sure the woodruff key is properly seated in the
1. Install: keyway of the crankshaft.
• Starter clutch “1” • Lubricate the threads of the AC magneto rotor
bolt and washer with engine oil.
Starter clutch bolt
16 N·m (1.6 kgf·m, 12 lb·ft) 2. Tighten:
T.
R.
LOCTITE® • AC magneto rotor bolt “1”
TIP AC magneto rotor bolt

• Install the starter clutch so that the side of the 130 N·m (13 kgf·m, 96 lb·ft)
T.
R.
starter clutch roller assembly with the arrow

mark “a” is toward the AC magneto rotor “2”.
5-48
TIP • Secure the oil delivery pipe “2” with the wrench
Hold the AC magneto rotor “2” with the rotor and tighten the oil delivery pipe bolt.
holding tool “3” while tightening the AC magneto
rotor bolt.
Rotor holding tool

90890-04166
Rotor holding tool 1
YM-04166 b
a
3
1
2
G101512 1
3 New
3. Apply: 2
• Sealant
(onto the stator coil assembly lead grommet)

90890-85505
4. Install:
• AC magneto cover “1”
• Oil delivery pipe “2”
AC magneto cover bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
Oil delivery pipe bolt

17 N·m (1.7 kgf·m, 13 lb·ft)
TIP
• Align the projection “a” on the impeller shaft
with the slot “b” in the oil pump.
• Replace the AC magneto cover bolt “3” with
new one.
• Tighten the AC magneto cover bolts in stages
and in a crisscross pattern.
5-49
ELECTRIC STARTER
EBS20040
ELECTRIC STARTER
Removing the starter motor
27 N•m (2.7 kgf•m, 20 lb•ft)
T.R
. 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
D
FW
Rear door striker (left) Refer to “GENERAL CHASSIS (1)” on page

4-1.
4-7.

4-16.
Rear floor boards (left) Refer to “GENERAL CHASSIS (7)” on page

4-25.
Air intake accumulator case Refer to “GENERAL CHASSIS (13)” on

page 4-38.

page 4-51.
Drain: Engine oil
Refer to “CHANGING THE ENGINE OIL” on
Oil tank inlet pipe/Oil tank outlet hose page 3-18.
Refer to “ENGINE REMOVAL (2)” on page
5-12.
5-50
ELECTRIC STARTER
Removing the starter motor

27 N•m (2.7 kgf•m, 20 lb•ft)
T.R
.
2 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
1
D
FW

Purge cut valve solenoid Refer to “FUEL TANK” on page 7-1.

page 7-18.
1 Starter motor lead 1 Disconnect.
2 Engine ground lead 1 Disconnect.
3 Starter motor 1
5-51
ELECTRIC STARTER
Disassembling the starter motor

8
7
11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
New
3 6
5 New
New
5 New
New 1 New
LS
5 N•m (0.5 kgf•m, 3.7 lb•ft)
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
5-52
ELECTRIC STARTER
EBS30157
CHECKING THE STARTER MOTOR Brush overall length limit

1. Check: 6.50 mm (0.26 in)
• Commutator
Dirt → Clean with 600 grit sandpaper.
2. Measure:
• Mica undercut “a”
Out of specification → Cut the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commutator. a
Mica undercut (depth)
0.70 mm (0.03 in)
G101514
TIP 5. Check:
The mica of the commutator must be undercut to • Gear teeth
ensure proper operation of the commutator. Damage/wear → Replace the starter motor.
6. Check:
a • Bearing
• Oil seal
Damage/wear → Replace the starter motor
front cover.
EBS30158
ASSEMBLING THE STARTER MOTOR

1. Install:
• Lead guide “1”
TIP
3. Check: Make sure that the slot “a” in the lead guide is
• Armature assembly facing in the direction shown in the illustration.
a. Connect the digital circuit tester to the ar-
mature coil and check the continuity.
a
Digital circuit tester (CD732) 1
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
b. If there is no continuity, replace the starter

motor.
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.
4. Measure:
• Brush length “a”
Out of specification → Replace the brush
holder set.
5-53
ELECTRIC STARTER
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.
1
2
a b
EBS30861
INSTALLING THE STARTER MOTOR

1. Install:
• Starter motor “1”
• Engine ground lead “2”
Starter motor bolt

27 N·m (2.7 kgf·m, 20 lb·ft)
T.
R.
TIP
Position the engine ground lead as shown in the
illustration so that it does not contact the starter
motor.
1 2
5-54
OIL PAN AND OIL PUMP
EBS20132

Removing the oil pan and oil pump
12 N•m (1.2 kgf•m, 8.9 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
T.R
T.R
.
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
(3)
LT
LT 4
10 5
New
6 New
(3) 20 N•m (2.0 kgf•m, 15 lb•ft)
11
T.R
.
LS New
7 New
New 12 T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
LS 20 N•m (2.0 kgf•m, 15 lb•ft) (14)

T.R
.
New
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
LS
12 New 13
New 4
(4)
8
New
LT New LS
LT
1 9 New
E 3
2 17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
LS 80 N•m (8.0 kgf•m, 59 lb•ft)

T.R
.
15 N•m (1.5 kgf•m, 11 lb•ft)

T.R
.
Engine Refer to “ENGINE REMOVAL (3)” on page

5-16.
1 Oil pressure switch 1
2 Oil filter cartridge 1
3 Oil filter cartridge union bolt 1
4 Engine oil drain bolt (crank case) 2
5 Oil strainer cover 1
6 Oil strainer cover gasket 1
7 Oil strainer 1
8 Oil pan 1
9 Oil pan gasket 1
10 Oil delivery pipe 1
11 Oil pump assembly 1
12 Gasket 2
13 Adapter 1
5-55
Disassembling the oil pump assembly

13
12
7
8
11
4
E 9
(4)
11 10
E
E
1
10 N•m (1.0 kgf•m, 7.4 lb•ft) (4)
2
T.R
.
6
3
E 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
5
6

1 Oil pump housing cover 1 1
2 Oil pump inner rotor 1 (scavenge) 1
3 Oil pump outer rotor 1 (scavenge) 1
4 Pin 1
5 Oil pump housing 1 1
6 Pin 2
7 Oil pump inner rotor 2 (scavenge) 1
8 Oil pump outer rotor 2 (scavenge) 1
9 Pin 1
10 Oil pump housing cover 2 1
11 Pin 2
12 Spring 1
13 Relief valve 1
5-56
Disassembling the oil pump assembly
23 21
20
19
18
15
E 14
16
(4)
22
E
E
17
10 N•m (1.0 kgf•m, 7.4 lb•ft) (4)

T.R
.
E 10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

14 Oil pump inner rotor (feed) 1
15 Oil pump outer rotor (feed) 1
16 Pin 1
17 Oil pump shaft 1
18 Check ball seat 1
19 Check ball 1
20 Spring 1
21 Spacer 1
22 Dowel pin 2
23 Oil pump housing 2 1
5-57
EBS30839
REMOVING THE OIL PAN

1. Remove:
• Oil strainer cover “1”
• Oil pan “2”
TIP
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
EBS30190
CHECKING THE OIL STRAINER

2 1. Check:
• Oil strainer
1 Damage → Replace the oil strainer.
Contaminants → Clean with solvent.
EBS30184
CHECKING THE RELIEF VALVE

1. Check:
EBS30979 • Oil pump housing 2
REMOVING THE OIL PUMP • Relief valve
1. Remove: • Spring
• Oil pump Damage/wear → Replace the oil pump as-
a. Remove the crankshaft end accessing sembly.
screw and spark plugs.
EBS30654
b. Turn the crankshaft counterclockwise and CHECKING THE CHECK BALL
position the oil pump shaft “1” as shown in 1. Check:
the illustration. • Check ball seat
• Check ball
• Spring
• Spacer
Damage/wear → Replace the oil pump as-
sembly.
EBS30192
1 ASSEMBLING THE OIL PUMP

1. Lubricate:
• Inner rotors
c. Remove the oil pump. • Outer rotors
• Oil pump shaft
EBS30189 (with the recommended lubricant)
CHECKING THE OIL PUMP
1. Check: Recommended lubricant
• Oil pump Engine oil
Cracks/damage/wear → Replace the oil
pump assembly. 2. Install:
2. Check: The following procedure applies to all of the
• Oil pump operation inner rotors.
Rough movement → Replace the oil pump • Inner rotors “1”
assembly. TIP
When installing the inner rotor, align the pin “2”
in the oil pump shaft “3” with the groove “a” on
the inner rotor.
5-58
M6 × 25 mm bolt: “1”
M6 × 25 mm bolt: “2” New
a 1
1
2
3 1 a 2 New
1
3. Check:
• Oil pump operation a 2 New
1
Refer to “CHECKING THE OIL PUMP” on
2. Install:
page 5-58.
• Oil strainer
EBS30445
• Oil strainer cover gasket New
INSTALLING THE OIL PUMP • Oil strainer cover
1. Install: • Oil strainer cover bolt
• Oil pump • Engine oil drain bolt
TIP
Align the projection “a” on the oil pump shaft “1” Oil strainer cover bolt (M6 × 40)
with the slot “b” in the oil pump driven sprocket 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
shaft “2”. Oil strainer cover bolt (M6 × 25)
10 N·m (1.0 kgf·m, 7.4 lb·ft)
Engine oil drain bolt (crankcase)
20 N·m (2.0 kgf·m, 15 lb·ft)
1 a
TIP
Tighten the oil strainer cover bolts in stages and
in a crisscross pattern.
M6 × 40 mm bolts (×3): “1”
2
b M6 × 25 mm bolts (×3): “2”
1 1
EBS30840
INSTALLING THE OIL PAN

1. Install: 2
• Oil pan gasket New 2
• O-ring New
1
• Oil pan
• Oil pan bolt
• Engine oil drain bolt
Oil pan bolt (M6 × 25)

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
Engine oil drain bolt (crankcase)

20 N·m (2.0 kgf·m, 15 lb·ft)
TIP
• Tighten the oil pan bolts in stages and in a
crisscross pattern.
• The oil pan bolt (M6 × 25) “2” installed near the
mark “a” on the oil pan cannot be reused.
5-59
SHIFT LEVER
EBS20042
SHIFT LEVER
Removing the drive select lever shift rod and drive select lever
7 N•m (0.7 kgf•m, 5.2 lb•ft) D

FW
T.R
.
(3)
LS 17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
New LS
(4)
New
New
8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.R
.
4-7.

4-16.
Parking brake lever Refer to “PARKING BRAKE” on page 4-71.
Rollover valve/One-way valve Refer to “FUEL TANK” on page 7-1.
5-60
SHIFT LEVER
Removing the drive select lever shift rod and drive select lever
7 N•m (0.7 kgf•m, 5.2 lb•ft) D

FW
T.R
.
2
3 (3)
5
4 6
LS 17 N•m (1.7 kgf•m, 13 lb•ft)

7
T.R
.
New 8 LS
(4)
New
1
New
8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.R
.

1 Drive select lever shift rod 1
2 Drive select lever knob 1
3 Drive select lever guide 1
4 Dust cover 1
5 Drive select lever 1
6 Spring 1
7 Shift arm 1
8 Drive select lever bracket 1
5-61
SHIFT LEVER
Removing the shift levers and stopper lever
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
New
E
New
LS
E
E
LT
D New
FW
10 N•m (1.0 kgf•m, 7.4 lb•ft)
21 N•m (2.1 kgf•m, 15 lb•ft)
T.R
.
T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.

Front over fender (left)/Front door (left)/Rear Refer to “GENERAL CHASSIS (1)” on page
door striker (left) 4-1.

4-7.

4-15.

4-16.
Dashboard (left) Refer to “GENERAL CHASSIS (6)” on page

4-17.
Rear floor board (left)/Front floor board (left) Refer to “GENERAL CHASSIS (7)” on page
4-25.

page 4-38.
V-belt cooling intake duct 2 Refer to “GENERAL CHASSIS (16)” on

page 4-51.
5-62
SHIFT LEVER
Removing the shift levers and stopper lever
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
New
E
7 6
5 New
LS
E
E
LT
10 4
D 9 3 New
FW 8 2 1
10 N•m (1.0 kgf•m, 7.4 lb•ft)
21 N•m (2.1 kgf•m, 15 lb•ft)
T.R
.
T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.

1 Shift arm 1
2 Shift lever cover 1
3 Shift lever cover gasket 1
4 Dowel pin 2
5 Oil seal 1
6 Bearing 1
7 Shift lever 1 1
8 Stopper lever spring 1
9 Shift lever 2 1
10 Stopper lever 1
5-63
SHIFT LEVER
EBS30163
CHECKING THE STOPPER LEVER

1. Check: a
• Stopper lever
Damage/wear → Replace. b
• Stopper lever spring
1
EBS30164
CHECKING THE SHIFT LEVERS

1. Check:
• Shift lever 1 3. Install:
• Shift lever 2 • Shift lever 1 “1”
Damage/wear → Replace. TIP
EBS30165 When installing shift lever 1, align the alignment
INSTALLING THE SHIFT LEVERS mark “a” on shift lever 1 with the alignment mark
1. Install: “b” on shift lever 2 “2”.
• Stopper lever “1”
• Collar “2”
• Shift lever 2 “3” 1
• Washer “4”
• Stopper spring “5” a
TIP
• Make sure the projection “a” on the stopper le-
ver facing toward the collar. b
• Install the shift lever 2 with the marks “b” facing 2
the stopper spring.
4. Install:
1 • Oil seal “1” New
2 b 3 (into the shift lever cover “2”)
4
5 Installed depth “a”
1.0–1.5 mm (0.04–0.06 in)
a
LS 1 New
2. Install: 2
• Shift lever 2 assembly “1”
a
Shift lever 2 bolt
21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.
TIP
Align the projection “a” on the shift drum with the 5. Install:
slit “b” in the stopper lever. • Shift arm “1”
Shift arm pinch bolt

12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
TIP
• Align the slot “a” in the shift arm with the mark
“b” on the shift lever shaft.
5-64
SHIFT LEVER
• After tightening the shift arm pinch bolt, check

that there is no looseness in the shift arm.
1
b
a
1
a
d. Tighten the locknuts.
Drive select lever shift rod lock-

EBS30444 nut (engine side)
T.
R.
ADJUSTING THE DRIVE SELECT LEVER 8 N·m (0.8 kgf·m, 5.9 lb·ft)
SHIFT ROD Drive select lever shift rod lock-
ECB02700
nut (shift lever side)
NOTICE 8 N·m (0.8 kgf·m, 5.9 lb·ft)
Before moving the drive select lever, bring
the vehicle to a complete stop and return the
throttle lever to its closed position. Other-
wise the transmission may be damaged.
3214
1. “N” (neutral)
2. “H” (high)
3. “L” (low)
4. “R” (reverse)
5. Drive select lever shift rod
1. Adjust:
• Drive select lever shift rod
a. Make sure the drive select lever and trans-
mission are in “N” (neutral).
b. Loosen both locknuts “1”.
ECB02460
NOTICE
The drive select lever shift rod locknut (drive
select lever side) has left-handed threads. To
loosen the locknut, turn it clockwise.
c. Turn the main switch to “ON”, and then ad-
just the length “a” of the shift rod to the
drive select lever can be shifted to each
shift position and that the appropriate indi-
cator light comes on when the lever is in
each position.
5-65
PRIMARY AND SECONDARY SHEAVES
EBS20043

Removing the primary and secondary sheaves
10 N•m (1.0 kgf•m, 7.4 lb•ft) New LS
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
E
New
New
(11)
(8)
New
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
305 N•m (30.5 kgf•m, 225 lb•ft)
T.R
WD
.
F
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
245 N•m (24.5 kgf•m, 181 lb•ft)

T.R
.

ers 4-1.

4-7.

4-15.

4-16.
4-17.
Rear floor board (left)/Front floor board (left)/ Refer to “GENERAL CHASSIS (7)” on page
Driver seat rail bracket 4-25.

page 4-51.
5-66
Removing the primary and secondary sheaves

10 N•m (1.0 kgf•m, 7.4 lb•ft) New LS
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
3
T.R
.
3
E
2 New
New
1
(11)
(8)
New
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
305 N•m (30.5 kgf•m, 225 lb•ft)
T.R
WD
.
7 5
F 10
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
9
4
245 N•m (24.5 kgf•m, 181 lb•ft) 8

T.R
.

1 Drive belt cover 1
2 Bearing housing 1
3 Dowel pin 2
4 Primary sheave assembly nut 1
5 Primary sheave assembly 1
6 V-belt 1
7 Primary fixed sheave 1
8 Secondary sheave assembly nut 1
9 Secondary sheave assembly 1
10 Drive belt case 1
5-67
Disassembling the primary sheave
P
New 6
4
P 4 8 New
4 6 New
4 P
3 5
3 P
New
3
3
(8)
1 3.0 N•m (0.30 kgf•m, 2.2 lb•ft)
T.R
.

1 Primary sheave cap 1
2 Primary sheave cam 1
3 Primary sheave slider 8
4 Primary sheave weight 8
5 Spacer 1
6 Oil seal 2
7 Primary sliding sheave 1
8 O-ring 1
5-68
Disassembling the secondary sheave
P
5
6
8
9 New
5 5
P
9 New
7 New
5
2
1
90 N•m (9.0 kgf•m, 66 lb•ft)
T.R
.

1 Secondary sheave spring retaining nut 1
2 Upper spring seat 1
3 Compression spring 1
4 Lower spring seat 1
5 Guide pin 6
6 Secondary sliding sheave 1
7 O-ring 2
8 Secondary fixed sheave 1
9 Oil seal 2
5-69
EBS30167 EBS30168
REMOVING THE PRIMARY AND DISASSEMBLING THE SECONDARY

SECONDARY SHEAVES SHEAVE
1. Loosen: 1. Remove:
• Primary sheave assembly nut “1” • Secondary sheave spring retaining nut “1”
TIP a. While holding the secondary sheave with
Use the sheave holder “2” to hold the primary the extension handle “2” and secondary
sheave. sheave holding tool “3”, loosen the sec-
ondary sheave spring retaining nut with
the middle drive shaft nut wrench “4”.
Sheave holder
90890-01903 TIP
Primary clutch holder Temporary tighten the secondary sheave hold-
YS-01880-A ing tool bolts “a”.
Secondary sheave holding tool

(58–62mm)
2 90890-04201
(58–62mm)
YM-04201
Extension handle
90890-04187
1 Extension handle
YM-04187
2. Loosen: Middle drive shaft nut wrench (55
mm)
• Secondary sheave assembly nut “1”
90890-04054
TIP Offset wrench 55 mm
Use the extension handle “2” and secondary YM-04054
sheave holding tool “3” to hold the secondary
sheave.

(58–62mm)
90890-04201 4 2
(58–62mm)
a
YM-04201
Extension handle 3
90890-04187
Extension handle b. Attach the sheave fixed block “5”, and
YM-04187 sheave spring compressor “6” to the sec-
ondary sheave assembly.
2 Sheave fixed block ø52–58–
62mm
3 90890-04202
1 Sheave fixed block ø52–58–
62mm
YM-04202
90890-04134
YM-04134
5-70
c. Place the sheave fixed block in a vise and

secure it. a 2 1
d. Tighten the sheave spring compressor nut
“7” and compress the spring.
e. Remove the secondary sheave spring re-
taining nut “1”.
f. Remove the sheave spring compressor 3
and sheave fixed block.
G101430
6 7 2. Plastic board
1 3. Ruler
EBS30170
CHECKING THE PRIMARY SHEAVE

1. Check:
• Primary sliding sheave splines
Wear/cracks/damage → Replace.
• Primary sheave cam
2. Check:
• Primary sliding sheave
• Primary fixed sheave
EBS30171

WEIGHTS
5
The following procedure applies to all of the pri-
mary sheave weights.
EBS30169
1. Check:
CHECKING THE V-BELT • Primary sheave weight
1. Check: Cracks/damage/wear → Replace.
• V-belt “1” 2. Measure:
Cracks/damage/wear → Replace. • Primary sheave weight outside diameter “a”
Grease/oil → Clean the primary and second- Out of specification → Replace.
ary sheaves.
2. Measure: Weight outside diameter
• V-belt width “a” 35.0 mm (1.38 in)
Weight outside diameter limit
Out of specification → Replace.
34.5 mm (1.36 in)
TIP
Measure the V-belt width as illustration.
V-belt width limit

36.5 mm (1.44 in)
G101519
5-71
EBS30172

SLIDERS
The following procedure applies to all of the pri-
mary sheave sliders.
1. Check:
• Primary sheave slider
Cracks/damage/wear → Replace.
EBS30173
CHECKING THE SECONDARY SHEAVE G101521
1. Check: EBS30174
• Secondary fixed sheave ASSEMBLING THE PRIMARY SHEAVE

• Secondary sliding sheave 1. Clean:
Cracks/damage/wear → Replace the sec- • Primary sliding sheave
ondary fixed and sliding sheaves as a set. • Spacer
2. Check: • Primary sheave weights
• Torque cam grooves “1” • Primary sheave cam
Damage/wear → Replace the secondary TIP
fixed and sliding sheaves as a set. Remove any excess grease.
3. Check:
• Guide pins “2” 2. Install:
Damage/wear → Replace the secondary • Oil seals “1” New
fixed and sliding sheaves as a set. (into the primary sliding sheave “2”)
TIP
Oil seals should not be pushed in more than 0.3
mm (0.012 in) from the end of primary sliding
sheave.
Installed depth “a”

0 mm (0 in)
G101520
New 1
4. Check:
• Secondary sheave spring
Damage → Replace.
5. Measure: a a
• Secondary sheave spring free length “a”
Out of specification → Replace the second-
ary sheave spring.
2 1 New
Free length
123.0 mm (4.84 in) 3. Lubricate:
Limit • Spacer inner surface
110.7 mm (4.36 in) • Primary sliding sheave inner surface
Yamaha grease F
TIP
• Apply Yamalube polyurea grease or Yamaha
grease F (2.5 g) to the inner surface of the
spacer.
5-72
• Apply Yamalube polyurea grease or Yamaha TIP

grease F (2.5 g) to the inner surface of the pri- Push the primary sheave cam in the direction
mary sliding sheave. shown in the illustration and check that the dis-
tance “a” is the specified distance or more. If the
distance “a” is less than the specified distance,
P
reassemble the primary sheave assembly.
4. Install:
• Spacer “1” a
TIP
Install the spacer into the primary sliding sheave a. 21.5 mm (0.85 in)
“2” with the collar installing tool “3”.
EBS30175
ASSEMBLING THE SECONDARY SHEAVE

Collar installing tool (ø40) 1. Install:
90890-04190
Collar installing tool (ø40) • Oil seals “1” New
YM-04190 (into the secondary sliding sheave “2”)

0–0.2 mm (0–0.0078 in)
Installed depth “b”
3 1.3–1.5 mm (0.051–0.059 in)
2
1 New
1
2
a
5. Install:
• Primary sheave weights “1” b
TIP
New 1
Apply Yamalube polyurea grease or Yamaha
grease F (90 g) to the whole outer surface of the 2. Lubricate:
weights and install. • Secondary sliding sheave “1”
• Secondary fixed sheave “2”
1 (with the recommended lubricant)
P P
1 1 Yamaha grease F
TIP
Apply Yamalube polyurea grease or Yamaha
grease F (5.0 g) to the inner surfaces of the sec-
1
ondary sheaves.
6. Install:
• Primary sheave cam “1”
5-73
TIP
1 2 Apply Yamalube polyurea grease or Yamaha
grease F (5.0 g) to the guide pin grooves.
3. Install:
• Secondary sliding sheave “1” P
TIP
Install the secondary sliding sheave onto the
6. Install:
secondary fixed sheave “2” with the oil seal
• Lower spring seat “1”
guide “3”.
• Compression spring “2”
• Upper spring seat “3”
Oil seal guide (ø48) • Secondary sheave spring retaining nut “4”
90890-04189 a. Attach the sheave fixed block “5” and
Oil seal guide (ø48) sheave spring compressor “6” to the sec-
YM-04189
ondary sheave.
Sheave fixed block ø52–58–

1 62mm
90890-04202
Sheave fixed block ø52–58–
3 62mm
YM-04202
90890-04134
2 Sheave spring compressor
YM-04134
4. Install:
b. Place the sheave fixed block in a vise and
• Guide pins “1”
secure it.
c. Tighten the sheave spring compressor nut
“7” and compress the spring.
d. Install the secondary sheave spring retain-
ing nut “4”.
G101524
5. Lubricate:
• Guide pin grooves “1”
Yamaha grease F
5-74
6 7
4 10 8
a
9
3
2 EBS30176
INSTALLING THE PRIMARY AND

SECONDARY SHEAVES
1 1. Install:
• Secondary sheave
• Primary fixed sheave
• V-belt
• Primary sheave
• Washer
5 • Nuts
TIP
e. Remove the sheave spring compressor • Be sure to push in the primary sheave cam “1”
and sheave fixed block. when installing the primary sheave so that the
f. While holding the secondary sheave with primary sheave weights “2” will be properly po-
the extension handle “8” and secondary sitioned “a”.
sheave holding tool “9”, tighten the sec- • Tightening the bolts “3” (90101-06018) will
ondary sheave spring retaining nut to push the secondary sliding sheave away,
specification with the middle drive shaft causing the gap between the secondary fixed
nut wrench “10”. and sliding sheaves to widen.
• Install the V-belt so that its arrow points in the
Secondary sheave spring retain-
ing nut direction of rotation as shown in the illustration.
T.
R.
90 N·m (9.0 kgf·m, 66 lb·ft)

1
(58–62mm)
90890-04201
(58–62mm)
YM-04201
Extension handle 2
90890-04187 a
Extension handle
YM-04187
Middle drive shaft nut wrench (55
mm)
90890-04054 a
Offset wrench 55 mm
YM-04054
a. 50 mm (1.97 in) or more
5-75
TIP
Use the extension handle “2” and secondary
sheave holding tool “3” to hold the secondary
sheave, and then tighten the secondary sheave
assembly nut.

(58–62mm)
90890-04201
2. Check: (58–62mm)
• Primary sheave weights position YM-04201
Out of specification → Repeat step (1). Extension handle
TIP
90890-04187
Extension handle
To check that the primary sheave weights “1” YM-04187
are installed correctly, make sure that the sec-
ondary sheave “2”, primary sheave “3”, and V-
belt “4” are positioned as shown in the illustra- 2
tion.
3
A
1
4 4. Tighten:
3 • Primary sheave assembly nut “1”
1
Primary sheave assembly nut
B 305 N·m (30.5 kgf·m, 225 lb·ft)
T.
R.
2 TIP
Use the sheave holder “2” to hold the primary
sheave.
Sheave holder
4 3 90890-01903
1 Primary clutch holder
YS-01880-A
A. Correct position
B. Incorrect position
3. Tighten:
• Secondary sheave assembly nut “1” 2
Secondary sheave assembly nut

245 N·m (24.5 kgf·m, 181 lb·ft)
T.
R.
5-76
5. Install:
• Oil seal “1” New
(into the bearing housing “2”)
Install depth “a”

0.0–0.9 mm (0.00–0.04 in)
TIP
Apply 3.7 g or more of lithium-soap-based
grease to the oil seal inner surface.
LS
2
a
1 New
5-77
CLUTCH
EBS20044
CLUTCH
Removing the clutch
155 N•m (15.5 kgf•m, 114 lb•ft)
T.R
.
E
D
FW
New
(9)
13 N•m (1.3 kgf•m, 9.6 lb•ft)

T.R
.

ers 4-1.

4-7.

4-15.

4-16.
Dash boards (left, right, and center) Refer to “GENERAL CHASSIS (6)” on page
4-17.
Rear floor boards/Front floor boards/Rear floor Refer to “GENERAL CHASSIS (7)” on page
board brackets 4-25.

page 4-51.
5-78
CLUTCH
Removing the clutch
155 N•m (15.5 kgf•m, 114 lb•ft)
T.R
.
E
6
E
5
D
FW 4
New 2
(9)
1
13 N•m (1.3 kgf•m, 9.6 lb•ft)

T.R
.
AC magneto cover Refer to “AC MAGNETO AND STARTER

CLUTCH” on page 5-44.
Primary sheave assembly/Secondary sheave Refer to “PRIMARY AND SECONDARY
assembly SHEAVES” on page 5-66.
1 Clutch housing assembly 1
2 Clutch housing assembly gasket 1
3 Dowel pin 2
4 Clutch carrier assembly bolt 1 Left-hand threads
5 Washer 1
6 Clutch carrier assembly 1
5-79
CLUTCH
Disassembling the clutch housing assembly
New 6
7
E 8
New 4
5 LS
3 1 New
2 New

1 Oil seal 1
2 Circlip 1
3 Bearing housing 1
4 Circlip 1
5 Bearing 1
6 Seal ring 1
7 One-way clutch bearing 1
8 Bearing 1
9 Clutch housing 1
5-80
CLUTCH
EBS30177
REMOVING THE CLUTCH

1. Remove:
• Clutch housing assembly 2
TIP
Working in crisscross pattern, loosen each bolt
1/4 of a turn. Remove them after all of them are
loosened.
EBS30178
CHECKING THE CLUTCH

1. Check:
• Clutch housing
• One-way clutch bearing
Chafing/wear/damage → Replace.
TIP
2. Remove: • Replace the one-way clutch bearing and clutch
• Clutch carrier assembly bolt “1” housing as a set.
ECB03680
• The one-way clutch bearing must be installed
NOTICE
with the flange side facing inward.
The clutch carrier assembly bolt has left-
hand threads. To loosen the clutch carrier 2. Check:
assembly bolt, turn it clockwise. • One-way clutch operation
a. Install the one-way clutch bearing and
TIP clutch carrier assembly to the clutch hous-
Use a sheave holder “2” to hold the AC magne- ing and hold the clutch carrier assembly.
to. b. When turning the clutch housing clock-
wise “A”, it should turn freely; otherwise,
Sheave holder the one-way clutch assembly is faulty and
90890-01903 must be replaced.
Primary clutch holder c. When turning the clutch housing counter-
YS-01880-A clockwise “B”, the clutch housing and
crankshaft should engage; otherwise, the
one-way clutch assembly is faulty and
must be replaced.
1
B
G101534
EBS30179
CHECKING THE CLUTCH SHOE

1. Check:
• Clutch shoe
5-81
CLUTCH
Glazed areas → Sand with coarse sandpa-

per.
TIP
After sanding the glazed areas, clean the clutch
with a cloth.
2. Measure:
• Clutch shoe thickness
G101536
a
Clutch shoe thickness limit
3. Install:
1.5 mm (0.06 in)
• Bearing “1”
• Circlip “2” New
a (into the bearing housing “5”)

0.25–0.75 mm (0.01–0.03 in)
TIP
G101535
• Lubricate the bearing with engine oil.
a. Clutch shoe wear limit • Lubricate the oil seal with lithium-soap-based
EBS30180
grease.
ASSEMBLING THE CLUTCH HOUSING • Be sure the circlip sharp-edge corner “b” is po-
1. Install: sitioned opposite side to the bearing.
• Bearing “1”
(into the clutch housing “2”) 5
b
a
0.9–1.1 mm (0.035–0.043 in)
TIP
Lubricate the bearing with engine oil. 4 New
1 3 New
b 2 New
2 EBS30181
INSTALLING THE CLUTCH

1. Install:
• Clutch carrier assembly
• Washer
• Clutch carrier assembly bolt “1”
1
a Clutch carrier assembly bolt
155 N·m (15.5 kgf·m, 114 lb·ft)
T.
2. Install:
R.
• One-way clutch bearing ECB03690
TIP NOTICE
The one-way clutch bearing should be installed The clutch carrier assembly bolt has left-
in the clutch housing with the OUT SIDE “a” fac- hand threads. To tighten the clutch carrier
ing the clutch carrier assembly. assembly bolt, turn it counterclockwise.
5-82
CLUTCH
TIP
• Lubricate the threads of the clutch carrier as-
sembly bolt and washer with engine oil.
• Install the clutch carrier assembly until it con-
tacts the crankshaft, and then tighten the
clutch carrier assembly bolt to specification.
• Use a sheave holder “2” to hold the AC magne-
to.
Sheave holder
90890-01903
Primary clutch holder
YS-01880-A
2. Install:
• Dowel pins
• Gasket New
• Clutch housing assembly
Clutch housing assembly bolt

13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
TIP
• Install the clutch housing assembly while turn-
ing it counterclockwise.
• Tighten the bolts in stages, using a crisscross
pattern.
• After tightening the bolts, check that the clutch
housing assembly rotates smoothly.
5-83
CRANKCASE
EBS20045
CRANKCASE
Removing the middle driven shaft
New
New
New
LS
New
LS
LS
New
New E
New
LS

5-16.
Cylinder head Refer to “CYLINDER HEAD” on page 5-33.
AC magneto rotor Refer to “AC MAGNETO AND STARTER

Starter motor Refer to “ELECTRIC STARTER” on page

5-50.
Oil pump assembly Refer to “OIL PAN AND OIL PUMP” on page
5-55.
Clutch carrier assembly Refer to “CLUTCH” on page 5-78.
Transmission case Refer to “TRANSMISSION (1)” on page

5-105.
Water pump housing cover Refer to “WATER PUMP” on page 6-14.
5-84
CRANKCASE
New
8 New
9 New
LS
6 10
4 New
LS
7
LS
New
3 New E
2
1 New
LS

1 Circlip 1
2 Middle driven shaft coupling gear 1
3 Oil seal 1
4 Circlip 1
5 Middle driven shaft (crankcase) 1
6 Bearing 1
7 Collar 1
8 Oil seal 1
9 Circlip 1
10 Bearing 1
5-85
CRANKCASE
Separating the crankcase

10 N•m (1.0 kgf•m, 7.4 lb•ft) 1st 15 N•m (1.5 kgf•m, 11 lb•ft)
T.R
2nd 15 N•m (1.5 kgf•m, 11 lb•ft)
.
New
T.R
.
24 N•m (2.4 kgf•m, 18 lb•ft) 3rd* 15 N•m (1.5 kgf•m, 11 lb•ft)
T.R
.
E
10 N•m (1.0 kgf•m, 7.4 lb•ft) 1st 20 N•m (2.0 kgf•m, 15 lb•ft)
T.R
.
2nd 24 N•m (2.4 kgf•m, 18 lb•ft)
T.R
.
(6) 24 N•m (2.4 kgf•m, 18 lb•ft)
(10) (6)
T.R
.
8
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
9 E E
E
E
E
10
New
LS
40 N•m (4.0 kgf•m, 30 lb•ft)

T.R
.
7
6 LS
5
T.R
.
E New
13 11
11
1 12
4
LT
2 11
3
LT
T.R
T.R
.
.

1 Oil pump drive chain guide 1
2 Timing chain guide bracket 1
3 Timing chain guide (intake side) 1
4 Timing chain 1
5 Oil pump driven sprocket shaft 1
6 Oil pump driven sprocket 1
7 Oil pump drive chain 1
8 Bracket 1
9 Bracket 1
10 Crankcase (lower) 1
11 Dowel pin 3
12 Buffer plate 1
13 Buffer plate 1
5-86
CRANKCASE
EBS30204
2. Remove:
REMOVING THE MIDDLE DRIVEN SHAFT
• Crankcase (lower)
(CRANKCASE) ECB03210
1. Remove: NOTICE
• Middle driven shaft (crankcase) “1” Tap on one side of the crankcase with a soft-
(with bearing) face hammer. Tap only on reinforced por-
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 GUIDE
1. Check:
• Timing chain
EBS30182 • Oil pump drive chain
SEPARATING THE CRANKCASE Damage/stiffness → Replace the chain and
1. Remove: camshaft sprocket as a set.
• Crankcase bolts 2. Check:
TIP • Timing chain guide (intake side)
• Place the engine upside down. Damage/wear → Replace.
• Loosen the bolts “1”–“13” in any loosening se- EBS30186
quence. CHECKING THE CRANKCASE
• Loosen the bolts “14”–“27” in the proper se- 1. Thoroughly wash the crankcase halves in a
quence as shown. mild solvent.
• M6 × 85 bolt (×2): “1”, “2” 2. Thoroughly clean all the gasket surfaces and
• M6 × 40 bolt (×10): “3”–“7”, “9”–“13” crankcase mating surfaces.
• M6 × 120 bolt (×1): “8” 3. Check:
• M6 × 65 bolt (×2): “14”, “15” • Crankcase
• M8 × 90 bolt (×6): “16”–“21” Cracks/damage → Replace.
• M10 × 100 bolt (×6): “22”–“27” • Oil delivery passages
Obstruction → Blow out with compressed air.
EBS30653
CHECKING THE OIL PUMP DRIVEN

SPROCKET
1. Check:
• Oil pump driven sprocket
×2 ×10 ×1 ×2 ×6 ×6 Cracks/wear/damage → Replace.
EBS30187
8 15 ASSEMBLING THE CRANKCASE
3 1 1. Thoroughly clean the crankcase mating sur-
7 6 5 4 faces.
2
2. Apply:
22 26 24 • Sealant “1”
(onto the crankcase mating surfaces)
25 27 23
18 Yamaha bond No. 1215
16 20 90890-85505
9 19 13
21 17 Three bond No. 1215®
14
10 11 12
5-87
CRANKCASE
TIP
Do not allow any sealant to come into contact
with the oil gallery, or crankshaft journal bear-
ings.
1 ×6 ×6 ×2 ×10 ×1 ×2
New 20 13
25 27
21 22 23
24 26
1
2
6 4
1
3 5
3. Install:
• Dowel pin 12 8 10
19 9 15
4. Fit the lower crankcase onto the upper crank- 7 11
case. Tap lightly on the crankcase with a soft- 14
face hammer. 18 17 16
5. Install:
• Crankcase bolt 6. Tighten:
TIP • Crankcase bolt “1”–“6”
• Lubricate the bolts “1”–“6” thread, mating sur- • Crankcase bolt “7”–“12”
faces and washers with engine oil. TIP
• Lubricate the bolts “7”–“12” thread, mating sur- Tighten the bolts in the tightening sequence cast
faces and O-rings with engine oil. on the crankcase.
• Lubricate the bolts “13”–“27” thread and mat-
ing surfaces with engine oil.
• Finger tighten the bolts.
• M10 × 100 bolt (×6): “1”–“6” New

• M8 × 90 bolt (×6) (bolt with new O-rings): “7”–
“12” New
• M6 × 65 bolt (×2): “13”, “14” ×6 ×6
• M6 × 40 bolt (×10): “15”–“19”, “21”–“25”
• M6 × 120 bolt (×1): “20”
• M6 × 85 bolt (×2): “26”, “27”
2
6 4
1
3 5
12 8 10
9 11
7
a. Tighten the bolts “1”–“6” to the specified

torque.
5-88
CRANKCASE
• Tighten the bolts “15”–“27” in any tightening

Crankcase bolt “1”–“6” sequence as shown.
T.
R.
15 N·m (1.5 kgf·m, 11 lb·ft)
b. Tighten the bolts “7”–“12” to the specified

torque.
Crankcase bolt “7”–“12”

20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
c. Tighten the bolts “1”–“6” to the specified ×2 ×10 ×1 ×2

torque. 20 13
25 27
Crankcase bolt “1”–“6” 22 23
15 N·m (1.5 kgf·m, 11 lb·ft) 21 26
24
T.
R.
d. Tighten the bolts “1”–“6” to the specified

torque.

*1st: 15 N·m (1.5 kgf·m, 11 lb·ft) 15
19
T.
R.
2nd: Specified angle 90°

14
* Following the tightening order, loosen 18 17 16
the bolt one by one, and then retighten it to
the specific torque. (after loosening the 8. Install:
bolt, retighten it before loosening the next • Oil pump driven sprocket shaft “1”
bolt) TIP
EWB04060
WARNING Align the slot “a” in the oil pump driven sprocket
shaft with the slot “b” in the crankcase.
If the crankcase bolt is tightened more than
the specified angle, do not loosen the bolt
and then re-tighten it. Instead, replace the b
crankcase bolt with a new one and perform
the procedure again. a
ECB03220
NOTICE 1
Do not use a torque wrench to tighten the
crankcase bolt to the specified angle.
e. Tighten the bolts “7”–“12” to the specified
torque. EBS30855
INSTALLING THE MIDDLE DRIVEN SHAFT

(CRANKCASE)
24 N·m (2.4 kgf·m, 18 lb·ft)
T.
1. Install:
R.
7. Tighten: • Circlip “1” New

• Crankcase bolt “13”–“27” • Oil seal “2” New
(into the crankcase “3”)
10 N·m (1.0 kgf·m, 7.4 lb·ft) Installed depth “a” of oil seal
T.
R.
6.8–7.8 mm (0.27–0.31 in)

TIP
• Tighten the bolts “13” and “14” in the tightening TIP
sequence cast on the crankcase. • Be sure the circlip sharp-edge corner is posi-
tioned opposite side to the bearing.
5-89
CRANKCASE
• Lubricate the oil seal with lithium-soap-based

grease.
3
LS
a
New 2 1
New 1
2
4. Install:
3 • Middle driven shaft (crankcase) and bearing
“1” (to crankcase)
2. Install:
• Collar “1”
TIP 1
Install the collar “1” so that its end with the slot
“a” for the O-ring is positioned away from the
crankcase. Press the collar until it makes con-
tact with the crankcase.
1
a
5. Install:
• Oil seal (middle driven shaft coupling gear
side) “1” New
(into the crankcase “2”)
Installed depth “a” of oil seal

0.6–1.2 mm (0.02–0.05 in)
3. Install:
• Bearing “1” TIP
• Middle driven shaft (crankcase) “2” Lubricate the oil seal with lithium-soap-based
TIP grease.
• Assemble the bearing “1” to the middle driven
LS
shaft (crankcase) “2”. 1 New
• Use a suitable socket “3” that matches the di- a
ameter of the bearing inner race.
ECB03920 2
NOTICE
Do not press the inner race or balls of the
bearing. Contact should be made only with
the outer race.
5-90
CONNECTING RODS AND PISTONS
EBS20133

Removing the connecting rods and pistons
1st 20 N•m (2.0 kgf•m, 15 lb•ft)
T.R
2nd Specified angle 180°
.
1
M 2
M
E 3 New
E
4
New 7
New 3
10 E
E
M
9
6 New
E
8
M

connecting rods and pistons.
Crankcase (lower) Refer to “CRANKCASE” on page 5-84.
1 Connecting rod cap 1
2 Big end lower bearing 1
3 Piston pin clip 2
4 Piston pin 1
5 Piston 1
6 Connecting rod 1
7 Big end upper bearing 1
8 Top ring 1
9 2nd ring 1
10 Oil ring 1
5-91
EBS30656
REMOVING THE CONNECTING RODS AND

PISTONS 4
The following procedure applies to all of the con- 3
necting rods and pistons.
1. Remove:
• Connecting rod cap “1” 2
• Connecting rod
• Big end bearing 1
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 clip “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 G101496
piston pin puller set “5”. EBS30147
CHECKING THE CYLINDER AND PISTON

Piston pin puller set The following procedure applies to all of the cyl-
90890-01304 inders and pistons.
Piston pin puller 1. Check:
YU-01304 • Piston wall
• Cylinder wall
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.
5-92
TIP
Piston-to-cylinder clearance
Measure cylinder bore “c” by taking side-to-side 0.020–0.045 mm (0.0008–0.0018
and front-to-back measurements of the cylinder. in)
Bore f. If out of specification, replace the cylinder,

93.000–93.010 mm (3.6614– and replace the piston and piston rings as
3.6618 in) a set.
Wear limit
93.060 mm (3.6638 in) EBS30148
CHECKING THE PISTON RINGS

1. Measure:
C = maximum of D1, D2, D3, D4, D5, D6
• Piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
TIP
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
ring grooves and piston rings.
Piston ring
Top ring
G101497
Ring side clearance limit
b. If out of specification, replace the cylinder, 0.115 mm (0.0045 in)
and replace the piston and piston rings as 2nd ring
a set. Ring side clearance limit
c. Measure piston skirt diameter “b” with the 0.115 mm (0.0045 in)
micrometer.
Piston
Diameter
92.965–92.980 mm (3.6600–
3.6606 in)
G101499
a
2. Install:
b • Piston ring
(into the cylinder)
TIP
G101498 Use the piston crown to level the piston ring near
bottom of cylinder “a”, where cylinder wear is
a. 8.0 mm (0.31 in) from the bottom edge of the
piston
lowest.
d. If out of specification, replace the piston

and piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance
= Cylinder bore “C” – Piston skirt diameter “b”
5-93
3. Measure:
a • Piston pin bore diameter “b”
Out of specification → Replace the piston.
Piston pin bore inside diameter

limit
22.045 mm (0.8679 in)
b
G101500
b. Upper of cylinder
3. Measure:
• Piston ring end gap
Out of specification → Replace the piston
ring.
TIP b
G101502
The oil ring expander spacer’s end gap cannot
EBS30666
be measured. If the oil ring rail’s gap is exces-
CHECKING THE CONNECTING RODS
sive, replace all three piston rings.
1. Measure:
• Crankshaft-pin-to-big-end-bearing clearance
Top ring Out of specification → Replace the big end
End gap (installed) limit bearings.
0.54 mm (0.0213 in)
2nd ring Oil clearance
End gap (installed) limit 0.034–0.058 mm (0.0013–0.0023
0.89 mm (0.0350 in) in)
EBS30149
CHECKING THE PISTON PIN connecting rods.
The following procedure applies to all of the pis- ECB03230
ton pins. NOTICE

1. Check: Do not interchange the big end bearings and
• Piston pin connecting rods. To obtain the correct
Blue discoloration/grooves → Replace the crankshaft-pin-to-big-end-bearing clear-
piston pin, and then check the lubrication sys- ance and prevent engine damage, the big
tem. end bearings must be installed in their origi-
2. Measure: nal positions.
• Piston pin outside diameter “a”
Out of specification → Replace the piston pin. a. Clean the big end bearings, crankshaft
pins, and the inside of the connecting rods
Piston pin outside diameter limit halves.
21.971 mm (0.8650 in) b. Install the big end upper bearing into the
connecting rod and the big end lower
bearing into the connecting rod cap.
TIP
Align the projection “a” on the big end bearings
with the notch “b” in the connecting rod and con-
necting rod cap.
G101501
5-94
G101587
c. Put a piece of Plastigauge® “1” on the 2. Select:

crankshaft pin. • Big end bearings (“P”1–“P”2)
TIP
• The numbers “A” stamped into the crankshaft
1 web and the numbers “B” on the connecting
rods are used to determine the replacement
big end bearings sizes.
• “P1”–“P2” refer to the bearings shown in the
crankshaft illustration.
For example, if the connecting rod “P1” and
the crankshaft web “P1” numbers are 6 and 4
d. Assemble the connecting rod halves. respectively, then the bearing size for “P1” is:
TIP
“P1” (connecting rod) - “P1” (crankshaft)
• Do not move the connecting rod or crankshaft
= 6 - 4 = 2 (black)
until the clearance measurement has been
completed.
• Apply molybdenum disulfide oil onto the bolt Bearing color code
and nut threads and nut seats. Code 1
• Make sure that the projection “c” on the con- Blue
necting rod cap faces the same direction as the Code 2
Black
“Y*” mark “d” on the connecting rod.
Code 3
Brown
d Code 4
c
Green
P1
P2
e. Tighten the connecting rod nuts.
Refer to “INSTALLING THE CONNECT-
ING RODS AND PISTONS” on page 5-96.
f. Remove the connecting rod and big end
bearings.
g. Measure the compressed Plastigauge®
width “e” on the crankshaft pin. If the
crankshaft- pin-to-big-end-bearing clear-
ance is out of specification, select replace-
ment big end bearings.
5-95
TIP
A P1 P2
Be sure to install the piston rings so that the
manufacturer’s marks “a” face up.
5
5
4
3
4
1
B
2
G101503
3. Install:
• Piston “1”
(onto the respective connecting rod “2”)
• Piston pin “3”
• Piston pin clip “4” New
TIP
EBS30673
• Apply engine oil onto the piston pin and con-
INSTALLING THE CONNECTING RODS AND necting rod.
PISTONS • Make sure that the “Y*” mark “a” on the con-
The following procedure applies to all of the connecting rod faces left when the punch mark “b”
necting rods and pistons. on the piston is pointing up as shown.
1. Install: • When installing a piston pin clips, make sure
• Big end bearing that the clip ends “c” are positioned away from
TIP the cutout “d” in the piston as shown in the illus-
• Be sure to reinstall each big end bearing in its tration.
original place. • Reinstall each piston into its original cylinder.
• Align the projection “a” on the big end bearings
with the notch “b” in the connecting rods and
connecting rod caps. 2 b
a 1
New 4
1
G101587 New 4
2. Install: c
• Oil ring expander “1”
• Lower oil ring rail “2”
• Upper oil ring rail “3”
• 2nd ring “4” 3
• Top ring “5” d 2
(into the piston)
4. Lubricate:
• Piston
5-96
• Piston rings
• Cylinder
(with the recommended lubricant) 3
Recommended lubricant 1
Engine oil 2
5. Offset:
• Piston ring end gaps
A
45° 45°
b,e c 9. Install:
• Connecting rod cap
TIP
135° • Make sure the “Y*” marks “a” on the connect-
ing rods face towards the right side (AC mag-
neto rotor side) of the crankshaft.
a,d • Make sure that the projection “b” on the con-
necting rod cap faces the same direction as the
a. Top ring “Y*” mark “a” on the connecting rod.
b. 2nd ring • Apply Molybdenum disulfide oil to the bolt and
c. Upper oil ring rail nut threads and nut seats.
d. Oil ring expander
e. Lower oil ring rail
A. Exhaust side
6. Lubricate:
• Connecting rod big end bearing inner surface a
Recommended lubricant b
Engine oil
7. Install: 10.Tighten:
• Connecting rod bolt New • Connecting rod nut “1”
(into the connecting rod)
8. Install:
• Piston “1” 1
(into the cylinder “2” and onto the crankshaft
pin)
TIP
While compressing the piston ring compressor
“3”, install the connecting rod assembly into the
cylinder with the other hand.
Piston ring compressor

TIP
90890-05158
Piston ring compressor Tighten the connecting rod nuts using the follow-
YM-08037 ing procedure.
a. Tighten the connecting rod nuts with a
torque wrench.
5-97
Connecting rod nut (1st)

T.
R.
20 N·m (2.0 kgf·m, 15 lb·ft)
b. Put a mark “1” on the corner of the con-

necting rod nut “2” and the connecting rod
cap “3”.
c. Tighten the connecting rod nuts further to

reach the specified angle 180°.
Connecting rod nut (final)

Specified angle 175°–185°
T.
R.
175°–185°105–13
EWB04310
WARNING
If the connecting rod nut is tightened more
than the specified angle, do not loosen the
nut and then re-tighten it. Instead, replace
the connecting rod bolt and nut with a new
one and perform the procedure again.
ECB03780
NOTICE
Do not use a torque wrench to tighten the
connecting rod nut to the specified angle.
5-98
CRANKSHAFT AND BALANCER SHAFT
EBS20136

Removing the crankshaft and balancer shaft
E
2
E
2
E 1 E
5 E
5
E
2
2
5 2 New
3 4 E
E
6 LS
New E
5 E 6
5 LS
4 E
E

Crankcase (lower) Refer to “CRANKCASE” on page 5-84.
Connecting rods Refer to “CONNECTING RODS AND PIS-

TONS” on page 5-91.
1 Balancer shaft assembly 1
2 Balancer shaft journal bearing 6
3 Crankshaft assembly 1
4 Thrust bearing 2
5 Crankshaft journal bearing 6
6 Oil nozzle 2
5-99
EBS30845
ing clearance and prevent engine damage,
REMOVING THE BALANCER SHAFT
the balancer shaft journal bearings must be
JOURNAL BEARINGS
installed in their original positions.
1. Remove:
• Balancer shaft journal bearing a. Clean the balancer shaft journal bearings,
(from the crankcase) balancer shaft journals, and bearing por-
TIP tions of the crankcase.
b. Install the balancer shaft journal bearings
Identify the position of each balancer shaft jour-
“1” and the balancer shaft assembly into
nal bearing so that it can be reinstalled in its orig-
the crank case (upper).
inal place.
TIP
EBS30846 Align the projections “a” on the balancer shaft
REMOVING THE CRANKSHAFT JOURNAL journal bearings with the notches “b” in the crank
BEARINGS case (upper).
1. Remove:
• Crankshaft journal bearing
(from the crankcase)
TIP 1
Identify the position of each crankshaft journal a
bearing so that it can be reinstalled in its original b
place.
EBS30847
CHECKING THE BALANCER SHAFT G101588

ASSEMBLY
c. Put a piece of Plastigauge® “2” on each
1. Check:
balancer shaft journal.
• Balancer driven gear
TIP
Damage/wear → Replace the crankshaft as-
sembly and balancer shaft assembly as a set. Do not put the Plastigauge® over the oil hole in
Excessive noise during operation → Replace the balancer shaft journal.
the crankshaft assembly and balancer shaft
assembly as a set.
2. Check:
• Balancer shaft assembly
2
Cracks/damage/wear → Replace the balanc-
er shaft assembly and journal bearings.
Dirt → Clean.
3. Measure:
• Balancer shaft-journal-to-balancer shaft-jour-
nal-bearing clearance
Out of specification → Replace the balancer d. Install the balancer shaft journal bearings
shaft journal bearings. “3” into the crankcase (lower) and assem-
ble the crankcase.
Balancer shaft journal to balanc-
er shaft bearing clearance TIP
0.017–0.041 mm (0.0007–0.0016 • Align the projections “c” of the balancer shaft
in) journal bearings with the notches “d” in the
crankcase (lower).
ECB03700
• Do not move the balancer shaft until the clear-
NOTICE
ance measurement has been completed.
Do not interchange the balancer shaft jour-
nal bearings. To obtain the correct balancer
shaft-journal-to-balancer shaft-journal-bear-
5-100
3
c
d J1 J2 J3
e. Tighten the bolts to specification in the

tightening sequence cast on the crank- A
case.
Refer to “ASSEMBLING THE CRANK-
CASE” on page 5-87.
f. Remove the crankcase (lower) and the
balancer shaft journal bearings.
width “e” on each balancer shaft journal. J1
J2
If the balancer shaft-journal-to-balancer J3
shaft-journal-bearing clearance is out of
specification, select replacement balancer B
J1 J2 J3
shaft journal bearings.
For example, if the crankcase “J”1 and bal-

ancer shaft web “J”1 numbers are 6 and 5 re-
4. Select: spectively, then the bearing size for “J”1 is:
• Balancer shaft journal bearing (“J”1–“J”3) “J”1 (crankcase) – “J”1 (balancer shaft web)
TIP =6–5
= 1 (blue)
• The numbers “A” stamped into the crankcase
and the numbers “B” stamped into the balancer
shaft web are used to determine the replace- Bearing color code
ment balancer shaft journal bearing sizes. Code 1
• “J”1–“J”3 refer to the bearings shown in the Blue
Code 2
crankcase and balancer shaft web illustration.
Black
• If “J”1–“J”3 are the same, use the same size for Code 3
all of the bearings. Brown
Code 4
Green
Code 5
Yellow
5-101
EBS30676
b. Install the crankshaft journal bearings “1”
CHECKING THE CRANKSHAFT
and the crankshaft into the crankcase (up-
1. Check:
per).
• Balancer drive gear
Damage/wear → Replace the crankshaft as- TIP
sembly and balancer shaft assembly as a set. Align the projection “a” on the crankshaft journal
Excessive noise during operation → Replace bearings with the notch “b” in the crankcase (up-
the crankshaft assembly and balancer shaft per).
assembly as a set.
2. Measure:
• Crankshaft runout
Out of specification → Replace the crank- 1
shaft. a
Runout limit b
0.030 mm (0.0012 in)
G101588
c. Put a piece of Plastigauge® “2” on each

crankshaft journal.
TIP
Do not put the Plastigauge® over the oil hole in
the crankshaft journal.
3. Check:
• Crankshaft journal surfaces 2
• Crankshaft pin surfaces
• Bearing surfaces
Scratches/wear → Replace the crankshaft.
4. Measure:
• Crankshaft-journal-to-crankshaft-journal-
bearing clearance
d. Install the crankshaft journal bearings “3”
Out of specification → Replace the crank-
into the crankcase (lower) and assemble
shaft journal bearings.
the crankcase.
Journal oil clearance TIP
0.021–0.045 mm (0.0008–0.0018 • Align the projection “c” of the crankshaft journal
in) bearings with the notch “d” in the crankcase
ECB03710
(lower).
NOTICE • Do not move the crankshaft until the clearance
measurement has been completed.
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaft-
journal-to-crankshaft-journal-bearing clear- 3
ance and prevent engine damage, the crank- c
shaft journal bearings must be installed in
their original positions.
d
a. Clean the crankshaft journal bearings,
crankshaft journals, and bearing portions
of the crankcase (upper and lower).
5-102
e. Tighten the bolts to specification in the

tightening sequence cast on the crank- A
case.
Refer to “ASSEMBLING THE CRANK- J2
CASE” on page 5-87. J1
f. Remove the crankcase (lower) and the J3
crankshaft journal bearings.
width “e” on each crankshaft journal.
If the crankshaft-journal-to-crankshaft-
journal-bearing clearance is out of specifi-
cation, select replacement crankshaft B J1 J2 J3
journal bearings.
For example, if the crankcase “J”1 and crank-

shaft web “J”1 numbers are 5 and 3 respec-
5. Select: tively, then the bearing size for “J”1 is:
• Crankshaft journal bearing (“J”1–“J”3) “J”1 (crankcase) – “J”1 (crankshaft web)
TIP =5–3
= 2 (black)
• The numbers “A” stamped into the crankcase
and the numbers “B” stamped into the crank-
shaft web are used to determine the replace- Bearing color code
ment crankshaft journal bearing sizes. Code 1
• “J”1–“J”3 refer to the bearings shown in the Blue
Code 2
crankcase and crankshaft web illustration.
Black
• If “J”1–“J”3 are the same, use the same size for Code 3
all of the bearings. Brown
Code 4
Green
Code 5
Yellow
J1 J2 J3
EBS30679
INSTALLING THE CRANKSHAFT

1. Install:
• Crankshaft journal bearing
(into the crankcase)
TIP
• Align the projection “a” on the crankshaft jour-
nal bearings “1” with the notch “b” in the crank-
case.
• Be sure to install each crankshaft journal bear-
ing in its original place.
5-103
TIP
Align the punch mark “a” in the balancer drive
1 gear with the punch mark “b” in the balancer
a driven gear.
b 1 2
G101588
2. Install:
• Thrust bearing “1”
TIP a
b
Install the thrust bearings so that the slots “a” in
the bearings are facing away from the crank-
case.
EBS30848
INSTALLING THE BALANCER SHAFT

ASSEMBLY
1. Install:
• Balancer shaft journal bearing
(into the crankcase)
TIP
• Align the projection “a” on the balancer shaft
journal bearings “1” with the notch “b” in the
crankcase.
• Be sure to install each balancer shaft journal
bearing in its original place.
1
a
b
G101588
2. Install:
• Crankshaft assembly “1”
• Balancer shaft assembly “2”
5-104
TRANSMISSION (1)
EBS20047
TRANSMISSION (1)
Removing the transmission case
FW
T.R
T.R
.
.
D
7 6
3
3 2
6
7
2
(6)
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
51 N•m (5.1 kgf•m, 38 lb•ft)

T.R
.
65 N•m (6.5 kgf•m, 48 lb•ft)

T.R
.

5-16.
1 Air bleed bolt 1
2 Transmission case mounting nut/bolt (rear low- 1/1

er)
3 Transmission case mounting nut/bolt (rear up- 1/1

per)
4 Transmission case 1
5 Transmission case adapter 1
6 Dowel pin 2
7 Transmission case mounting spacer bolt 3
5-105
TRANSMISSION (1)
EBS30849
REMOVING THE TRANSMISSION CASE 2

1. Remove: 1
• Transmission case “1”
• Transmission case mounting spacer bolts “2”
TIP
• Place the blocks “a” under the engine and
transmission case as shown in the illustration.
• Loosen the spacer bolt with the engine adjust- 1 1
er “3”.
3. Install:
Engine adjuster • Transmission case “1”
90890-01516
Engine mount spacer wrench b
YS-01516
1
a
TIP
Fit the middle driven shaft (crankcase) “a” into
a a the hole “b” in the transmission case “1”.
4. Install:
2 • Transmission case mounting bolt (upper)
3
5. Tighten:
• Transmission case mounting spacer bolt (up-
per) “1”
Transmission case mounting

spacer bolt (upper)
T.
R.
9 N·m (0.9 kgf·m, 6.6 lb·ft)
TIP
EBS30659
INSTALLING THE TRANSMISSION CASE Tighten the spacer bolt to specification with the
1. Install: engine adjuster “2”.
• Transmission case adapter
• Dowel pin Engine adjuster
90890-01516
Transmission case adapter bolt Engine mount spacer wrench
51 N·m (5.1 kgf·m, 38 lb·ft) YS-01516
T.
R.
2. Install:
• Transmission case mounting spacer bolts “1”
(into the transmission case adapter “2”)
TIP
Temporary tighten the transmission case
mounting spacer bolts completely by hand.
5-106
TRANSMISSION (1)
2 B
3
6. Install: A. Right side

• Transmission case mounting nut (upper) B. Left side
Transmission case mounting nut 8. Install:
(upper) • Transmission case mounting bolt/nut (lower)
T.
R.
65 N·m (6.5 kgf·m, 48 lb·ft)

Transmission case mounting nut
7. Tighten: (lower)
T.
R.
• Transmission case mounting spacer bolts 65 N·m (6.5 kgf·m, 48 lb·ft)
(lower) “1”
9. Install:
Transmission case mounting • Air bleed bolt
spacer bolt (lower)
T.
R.
9 N·m (0.9 kgf·m, 6.6 lb·ft) Air bleed bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
Tighten the spacer bolts to specification with the
engine adjuster.
Engine adjuster
90890-01516
Engine mount spacer wrench
YS-01516
5-107
TRANSMISSION (2)
EBS20129
TRANSMISSION (2)
Separating the transmission case
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
18 N•m (1.8 kgf•m, 13 lb•ft)
T.R
.
LS
3 17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
5
New
6
New
4 E
11
7
New New
LS
New 11 2
8 10 New
New New
(11) 9
20 N•m (2.0 kgf•m, 15 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
New 1
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.

1 Universal joint yoke 1
2 Universal joint 1
3 Dipstick 1
4 Dipstick guide 1
5 Speed sensor 1
6 Shift cam stopper 1
7 Reverse switch 1
8 Gear position switch 1
9 Transmission oil drain bolt 1
10 Transmission case (right) 1
11 Dowel pin 2
5-108
TRANSMISSION (2)
Removing the transmission case bearings
LS
4
New
5 New
10 N•m (1.0 kgf•m, 7.4 lb•ft) 3
T.R
.
LT
LT
3 1
3
3
E 2
3
E
E
LT
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
Drive axle assembly/Secondary shaft Refer to “TRANSMISSION (3)” on page

5-112.
1 Secondary shaft bearing retainer 1
2 Shift drum bearing retainer 1
3 Bearing 6
4 Collar 1
5 Oil seal 1
5-109
TRANSMISSION (2)
EBS30661 EBS30185
DISASSEMBLING THE UNIVERSAL JOINT CHECKING THE BEARINGS

1. Remove: 1. Check:
• Universal joint • Bearings
a. Remove the circlips “1” Clean and lubricate, then rotate the inner
b. Place the universal joint in a press. race with a finger.
c. With a suitable diameter pipe “2” beneath Roughness → Replace.
the universal joint yoke “3”, press the bear-
EBS30667
ing “4” into the pipe as shown. CHECKING THE TRANSMISSION CASE
TIP 1. Thoroughly wash the transmission case
It may be necessary to lightly tap the universal halves in a mild solvent.
joint yoke with a punch. 2. Thoroughly clean all the gasket surfaces and
transmission case mating surfaces.
3. Check:
• Transmission case
EBS30668
ASSEMBLING THE TRANSMISSION CASE

1. Install:
Install depth “a”

1.5–2.0 mm (0.04–0.06 in)
TIP
Lubricate the oil seal with lithium-soap-based
grease.
New 1 LS
d. Repeat the steps for the opposite bearing. a

e. Remove the universal joint.
EBS30664
SEPARATING THE TRANSMISSION CASE

1. Remove:
• Transmission case bolts 2. Thoroughly clean the transmission case mat-
TIP ing surfaces.
3. Apply:
Loosen each bolt 1/4 of a turn at a time, in stag-
• Sealant “1”
es and in a crisscross pattern. After all of the
(onto the transmission case mating surfaces)
bolts are fully loosened, remove them.
90890-85505
TIP
Do not allow any sealant to come into contact
with the oil gallery.
5-110
TRANSMISSION (2)
G101601
4. Fit the right transmission case onto the left b. Install the bearing “1” onto the universal
transmission case. Tap lightly on the trans- joint yoke.
mission case with a soft-face hammer. ECB01670
5. Install: NOTICE
• Transmission case bolts The needles can easily fall out of their races,
6. Tighten: so check each bearing carefully. Slide the
• Transmission case bolts universal joint driven yoke assembly back
and forth on the bearings. If a needle is out of
Transmission case bolt (M6 × place, the yoke will not go all the way onto
100) the bearings.
T.
R.
10 N·m (1.0 kgf·m, 7.4 lb·ft)

Transmission case bolt (M6 × 45)
10 N·m (1.0 kgf·m, 7.4 lb·ft)
TIP
Tighten the bolts in stages, using a crisscross
pattern.
M6 × 100 bolt (×2) “1”
M6 × 45 bolt (×11) “2”
G101602
2
1 c. Press each bearing into the universal joint
yoke using a suitable socket.
TIP
2 The bearing must be inserted far enough into the
2 universal joint yoke and primary driven shaft
yoke so that the circlip can be installed.
1
d. Install new circlips “2” into the groove of
2 each bearing.
7. Check:
• Transmission operation
Rough operation → Repair.
EBS30672
ASSEMBLING THE UNIVERSAL JOINT

1. Install:
• Universal joint
a. Install the universal joint into the primary
driven shaft yoke. G101603
5-111
TRANSMISSION (3)
EBS20130
TRANSMISSION (3)
Removing the transmission, shift drum and shift forks
6
E
E
E
10
3 New New
E
5 9
New
4 A B
8 New
7 E
1 2
A: Outward
B: Inward

Separate.
5-108.
1 Middle drive pinion gear shim Refer to “SELECTING THE PINION GEAR
SHIM(S)” on page 5-118.
2 Middle driven gear 1
3 Thrust washer Refer to “SELECTING THE THRUST

WASHER(S)” on page 5-118.
4 Shift drum assembly 1
5 Shift fork assembly 1
6 Drive axle assembly 1
7 Spring 1
8 Shift fork 1
9 Spring 1
10 Shift fork 1
5-112
TRANSMISSION (3)
Removing the transmission, shift drum and shift forks
16
13 15
15
E
12
14
E
E
E
11
E New New
New
A B
New E
A: Outward
B: Inward

11 Shift fork guide bar 1
12 Collar 1
13 Reverse idle gear 1
14 Reverse idle gear shaft 1
15 Bearing 2
16 Secondary shaft 1
5-113
TRANSMISSION (3)
Disassembling the drive axle assembly
11
10
7
5
6
9 New
15 14
4
2
M
16
17
1
M
3 New
M
12 13
M

1 Washer 1
2 Middle drive gear 1
3 Circlip 1
4 Washer 1
5 Low wheel gear 1
6 Bearing 1
7 Washer 1
8 Clutch dog 1 1
9 Circlip 1
10 Washer 1
11 Washer 1
12 Reverse wheel gear 1
13 Bearing 1
14 Washer 1
15 High wheel gear 1
16 Bearing 1
17 Washer 1
5-114
TRANSMISSION (3)
Disassembling the drive axle assembly
New
M
18
M
New 19

18 Clutch dog 2 1
19 Drive axle 1
5-115
TRANSMISSION (3)
EBS30194
REMOVING THE TRANSMISSION

1. Remove:
• Shift drum “1”
• Shift fork assembly “2”
• Drive axle assembly “3”
TIP
While lifting up the drive axle assembly, remove
the shift drum and shift fork assembly.
G101541
2 4. Check:
3
• Spring
1
EBS30197
CHECKING THE SHIFT DRUM

1. Check:
• Shift drum grooves
Damage/scratches/wear → Replace the shift
drum.
EBS30196
CHECKING THE SHIFT FORKS

shift forks.
1. Check:
• Shift fork cam follower “1”
• Shift fork pawl “2”
Bends/damage/scoring/wear → Replace the
shift fork.
G101542
EBS30198
CHECKING THE TRANSMISSION

1. Measure:
• Drive axle runout
(with a centering device and dial gauge “1”)
Out of specification → Replace the drive axle.
Drive axle runout limit

G101540 0.06 mm (0.0024 in)
2. Check:
• Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends → Replace. 1
EWB02750
WARNING
Do not attempt to straighten a bent shift fork
guide bar.
3. Check:
• Shift fork movement
(along the shift fork guide bar) 2. Check:
Rough movement → Replace the shift forks • Transmission gears
and shift fork guide bar as a set. Blue discoloration/pitting/wear → Replace
the defective gear(s).
5-116
TRANSMISSION (3)
• Transmission gear dogs TIP

Cracks/damage/rounded edges → Replace • Be sure the circlip sharp-edged corner “a” is
the defective gear(s). positioned opposite side to the gear “2”.
• Be sure the circlip ends “b” are positioned at
axle spline “c”.
b
2
1 New
G101543
3. Check: c
a
• Transmission gear engagement
(each pinion gear to its respective wheel
gear) EBS30201
Incorrect → Reassemble the transmission ASSEMBLING THE SHIFT FORK

axle assemblies. 1. Install:
4. Check: • Shift fork guide bar “1”
• Transmission gear movement • Shift forks “2”
Rough movement → Replace the defective • Springs “3”
part(s). • Spring caps “4”
• Circlips “5” New
EBS30199
CHECKING THE SECONDARY SHAFT TIP

1. Check: • Be sure the circlip sharp-edged corner “a” is
• Gear teeth positioned opposite side to the spring cap.
Blue discoloration/pitting/wear → Replace. • Be sure the circlip sharp-edged corner “b” is
positioned opposite side to the shift fork.
EBS30200
ASSEMBLING THE DRIVE AXLE

1. Install:
2 5 New 2
• Washer “1” 5 New 4 5 New
3 4 3
TIP 1
Press the washer “1” until it makes contact drive
axle “2”. Use a suitable socket “3” that matches
the diameter of washer.
2
New 5 4 5 New
2
2. Drive axle
3. Suitable socket a b
2. Install:
5-117
TRANSMISSION (3)
EBS30202
Example:
INSTALLING THE SHIFT FORKS AND SHIFT
Therefore, “A” is 1.12.
DRUM
“A” = 88.94 - 87.77 - 0.05
1. Check:
= 1.12
• Shift operation
Round off the hundredth digit and select
Rough operation → Repair.
the appropriate shim(s).
TIP In the example above, the calculated num-
• Oil each gear and bearing thoroughly. ber is 1.12. The chart instructs you to
• Before assembling the transmission case, round off 0 to 2 at the hundredth place.
make sure that the transmission is in neutral Thus, the shim thickness is 1.10 mm
and that the gears turn freely. (0.044 in).
Hundredth Rounded value
0, 1, 2 0
3, 4, 5, 6, 7 5
8, 9 10
Shims are supplied in the following thick-

nesses.
Thrust washers
Thickness (mm)
EBS30851 0.25 0.30 0.35 0.40 0.45 0.50 0.80
SELECTING THE THRUST WASHER(S) 1.00
1. Select:
• Thrust washer(s) “1” EBS30850
a. To find the thrust washer thickness “A”, SELECTING THE PINION GEAR SHIM(S)
use the following formula. 1. Select:
Thrust washer thickness • Pinion gear shim(s) “1”
“A” = “b” - “a” - 0.05 a. To find the pinion gear shim thickness “B”,
use the following formula.
“a” = 87.19–88.35 mm (3.43–3.48 in) Pinion gear shim thickness
“b” = 88.80–89.07 mm (3.50–3.51 in) “B” = “d” - “c” - 0.05
b “c” = 85.20–86.00 mm (3.35–3.39 in)
“A” a
“d” = 86.50–86.77 mm (3.41–3.42 in)
5-118
TRANSMISSION (3)
“B” c
d
Example:
Therefore, shim thickness “B” is 0.99.
“B” = 86.64 - 85.60
= 0.99
In the example above, the calculated num-
ber is 0.99. The chart instructs you to
round off 9 to 10 at the hundredth place.
Thus, the shim thickness is 1.00 mm.
0, 1, 2 0
3, 4, 5, 6, 7 5
8, 9 10

nesses.
Pinion gear shims

Thickness (mm)
0.20 0.25 0.30 0.35 0.40 0.45 0.50
0.80
5-119
MIDDLE GEAR
EBS20048
MIDDLE GEAR
Removing the middle drive pinion gear
2 3
5
7
6
New 4
LT
220 N•m (22 kgf•m, 162 lb•ft)

T.R
.
(4)
56 N•m (5.6 kgf•m, 41 lb•ft)
T.R
.

Separate.
5-108.
Middle driven gear Refer to “TRANSMISSION (3)” on page

5-112.
1 Bearing housing cover 1
2 Middle drive pinion gear assembly 1
3 Middle drive pinion gear shim Refer to “ALIGNING THE MIDDLE GEAR”
on page 5-124.
4 Middle drive pinion gear nut 1
5 Middle drive pinion gear 1
6 Bearing 1
7 Middle drive shaft bearing housing 1
5-120
MIDDLE GEAR
9
11
29 N•m (2.9 kgf•m, 21 lb•ft)
T.R
.
10
(3) LT
LT 200 N•m (20 kgf•m, 148 lb•ft)
T.R
.
LS
3
New 4 New LS
5 8
6
E 7 New
LS 2
12 New
LS
1
14 LT (4)
New 13
LT
34 N•m (3.4 kgf•m, 25 lb•ft)

E
T.R
.

1 Middle driven shaft yoke nut 1
2 Middle driven shaft yoke 1
3 Bearing housing assembly 1
4 Middle driven pinion gear shim Refer to “ALIGNING THE MIDDLE GEAR”
on page 5-124.
5 Bearing housing cover 1
6 Bearing 1
7 Oil seal 1
8 Bearing housing 1
9 Middle driven pinion gear shaft assembly 1
10 Middle driven pinion gear 1
11 Middle driven shaft 1
12 Oil seal 1
13 Circlip 1
14 Bearing 1
5-121
MIDDLE GEAR
EBS30862
DISASSEMBLING THE MIDDLE DRIVE

PINION GEAR ASSEMBLY
1. Remove:
• Middle drive pinion gear nut
a. Straighten the collar on the middle drive
pinion gear nut.
b. Attach the middle drive shaft nut wrench 1
(55 mm) “1”.
2
mm) EBS30205
90890-04054 CHECKING THE PINION GEARS

Offset wrench 55 mm 1. Check:
YM-04054 • Drive pinion gear teeth
• Driven pinion gear teeth
TIP Pitting/galling/wear → Replace.
Wrap the middle drive pinion gear in a folded 2. Check:
rag, and then secure it in a vise. • Bearings
Pitting/damage → Replace.
EBS30854
INSTALLING THE OIL SEALS

1. Install:
1 • Circlip “1” New
(into the transmission case “3”)

1.0–1.5 mm (0.039–0.059 in)
c. Loosen the middle drive pinion gear nut.
TIP
EBS30853
REMOVING THE MIDDLE DRIVEN SHAFT • Be sure the circlip sharp-edge corner is posi-
YOKE tioned opposite side to the bearing.
1. Remove: • Lubricate the oil seal with lithium-soap based
• Middle driven shaft yoke nut grease.
• Washer
LS
• Middle driven shaft yoke
2 New
TIP
Use the universal joint holder “1” to hold the mid-
a 1 New
dle driven shaft yoke “2”, then loosen the middle
driven shaft yoke nut. 3
Universal joint holder

90890-04160
YM-04062 2. Install:
(into the bearing housing “2”)

1.0–1.5 mm (0.039–0.059 in)
5-122
MIDDLE GEAR
TIP
Lubricate the oil seal with lithium-soap based mm)
grease. 90890-04054
Offset wrench 55 mm
YM-04054
New 1 LS a
TIP
Wrap the middle drive pinion gear in a folded
rag, and then secure it in a vise.
EBS30207
INSTALLING THE MIDDLE DRIVEN SHAFT 1

1. Install:
• Middle driven shaft yoke
• Washer
• Middle driven shaft yoke nut
Middle driven shaft yoke nut b. Tighten the middle drive pinion gear nut to
200 N·m (20 kgf·m, 148 lb·ft) specification.
T.
R.
LOCTITE®
Middle drive pinion gear nut
220 N·m (22 kgf·m, 162 lb·ft)
T.
TIP
R.
Use the universal joint holder “1” to hold the mid- c. Lock the threads with a drift punch.
dle driven shaft yoke “2”, then tighten the middle TIP
driven shaft yoke nut.
After tightening the nut, stake the collar of the
nut into the notch of the pinion gear.
90890-04160
YM-04062
G101604
EBS30209
1 MEASURING THE MIDDLE GEAR
2 BACKLASH
1. Measure:
EBS30863 • Middle gear backlash
ASSEMBLING THE MIDDLE DRIVE PINION Out of specification → Adjust.
GEAR ASSEMBLY Refer to “ALIGNING THE MIDDLE GEAR” on
1. Install: page 5-124.
• Middle drive pinion gear nut New
a. Attach the middle drive shaft nut wrench Middle gear backlash
0.10–0.30 mm (0.004–0.012 in)
(55 mm) “1”.
a. Temporarily install the right transmission.
5-123
MIDDLE GEAR
b. Wrap a rag “1” around a screwdriver “2”, 1. Select:

and then insert it into the installation hole • Middle drive pinion gear shim(s) “1”
“a” of the right crankcase speed sensor to • Middle driven pinion gear shim(s) “2”
hold the middle drive gear.
2
1
2
a
c. Attach the gear lash measurement tool “3”

and dial gauge “4”.

90890-01467
YM-01467 2
“B”
4 d
f
e
3
1
b a
“A”
a. 45.5 mm (1.79 in) b a
b. 8.9 mm (0.35 in) c
d. Measure the gear lash while rotating the A. Middle drive pinion gear shim thickness
middle driven shaft back and forth. B. Middle driven pinion gear shim thickness
TIP
a. Position the middle gears with the appro-
Measure the gear lash at 4 positions. Rotate the priate shim(s) that has had its respective
middle driven gear 90° each time. thickness calculated from information
e. If the gear lash is incorrect, adjust the gear marked on the transmission case, bearing
lash by middle driven pinion gear shim(s). housings, and pinion gears.
b. To find middle drive pinion gear shim
EBS30210
thickness “A”, use the following formula.
ALIGNING THE MIDDLE GEAR
Middle drive pinion gear shim thickness
TIP
“A” = “a” + “b” - “c”
Aligning the middle gear is necessary when any
of the following parts are replaced: “a” = a numeral (usually a decimal num-
• Transmission case ber) on the bearing housing is either add-
• Middle drive pinion gear ed to or subtracted from “3.4”
• Middle driven pinion gear “b” = 70.0
• Middle driven shaft bearing housing “c” = a numeral (usually a decimal num-
• Middle drive shaft bearing housing ber) on the transmission case (left) speci-
fies a thickness of “73”
5-124
MIDDLE GEAR
Example: Middle driven pinion gear shim thickness

If the bearing housing is marked “-02”, “B” = “d” + “e” - “f” + correction value*
“a” is 3.38
* The correction value is the difference be-
tween the shim thickness for obtaining the
specified backlash and the shim thickness
according to the theoretical calculation
value (“d” + “e” - “f”).
a
“d” = a numeral (usually a decimal num-
ber) on the bearing housing is either add-
ed to or subtracted from “40.64”
“e” = a numeral (usually a decimal num-
ber) on the middle driven pinion gear is ei-
“b” = drive pinion gear to driven pinion ther added to or subtracted from “65”
gear center distance (considered constant “f” = a numeral (usually a decimal number)
“70”) on the transmission case specifies a thick-
If the transmission case (left) is marked ness of “105”
“73.0”, Example:
“c” is 73.0 If the bearing housing is marked “+03”,
“d” is 40.67

“A” = 3.38 + 70.0 - 73.0 If the driven pinion gear is marked “+02”,
= 0.38 “e” is 65.02
Round off hundredths digit and select ap-
propriate shim(s).
In the above example, the calculated shim
thickness is 0.38. The following chart in-
structs you, however, to round off 8 to 10.
Hundredth Rounded value e
0, 1, 2 0
3, 4, 5, 6, 7 5
If the transmission case is marked “105”,
8, 9 10
“f” is 105
nesses.
f
Middle drive pinion gear shim
Thickness (mm)
0.25 0.30 0.35 0.40 0.45 0.50
c. To find middle driven pinion gear shim

thickness “B”, use the following formula.
5-125
MIDDLE GEAR
Therefore, “B” is 0.69.

“B” = 40.67 + 65.02 - 105 = 0.69
Round off hundredth digit and select ap-
propriate shim(s).
In the above example, the calculated shim
thickness is 0.69 mm. The chart instructs
you, however, to round off 9 to 10.
0, 1, 2 0
3, 4, 5, 6, 7 5
8, 9 10

nesses.
Middle driven pinion gear shim

Thickness (mm)
0.15 0.20 0.25 0.30 0.40 0.50 0.60
TIP
• If the specified middle gear backlash cannot be
obtained with a calculated shim thickness, in-
crease or decrease the shim thickness.
• If the shim thickness is increased, the actual
middle gear backlash will increase and, if the
shim thickness is decreased, the actual middle
gear backlash will decrease.
5-126
MIDDLE GEAR
5-127
COOLING SYSTEM
COOLING SYSTEM DIAGRAMS .................................................................... 6-1
OIL COOLER................................................................................................... 6-3

CHECKING THE OIL COOLER ................................................................ 6-6
RADIATOR ...................................................................................................... 6-7

CHECKING THE RADIATOR ..................................................................6-10
INSTALLING THE RADIATOR ................................................................6-10
THERMOSTAT ..............................................................................................6-12
CHECKING THE THERMOSTAT............................................................6-13
INSTALLING THE THERMOSTAT..........................................................6-13
WATER PUMP...............................................................................................6-14
DISASSEMBLING THE WATER PUMP..................................................6-17
CHECKING THE WATER PUMP ............................................................6-17
ASSEMBLING THE WATER PUMP........................................................ 6-17
6
COOLING SYSTEM DIAGRAMS
EBS20147
1 2 11 10 3
8 6 5 4 9
6 2
1
5
7
9
3
1. Radiator
6. Radiator cap
7. Oil cooler
8. Oil cooler outlet hose
11. Oil cooler inlet hose
6-1
1 2 3
8
7
5 6 9 8 7 4 4 8
7 7
6-2
OIL COOLER
EBS20050
OIL COOLER
Removing the oil cooler
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
LS
T.R
.
New
3
1
9 N•m (0.9 kgf•m, 6.6 lb•ft)
2
T.R
.

Drain.
page 3-18.
Front over fenders Refer to “GENERAL CHASSIS (1)” on page

4-1.

4-15.

page 4-33.
Front grill Refer to “GENERAL CHASSIS (12)” on

page 4-36.
1 Oil cooler inlet hose 1 Disconnect.
2 Oil cooler outlet hose 1 Disconnect.
3 Oil cooler 1
6-3
OIL COOLER
Removing the oil cooler hoses and pipes
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
LS
New
LS
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
New
New LS LS
New
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
LS
New
New LS
D
FW
T.R
.
T.R
.

Drain.
page 3-13.
Front over fenders/Front over fender inner panel Refer to “GENERAL CHASSIS (1)” on page
(left)/Front doors/Rear door striker (left) 4-1.
4-7.
4-15.

4-16.
4-17.
Rear floor board (left)/Front mudguard (left)/ Refer to “GENERAL CHASSIS (7)” on page
Front floor board (left) 4-25.

page 4-36.
6-4
OIL COOLER
Removing the oil cooler hoses and pipes
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
LS
New
LS
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
6
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft) 5

4
T.R
.
New
New LS LS
New
9 N•m (0.9 kgf•m, 6.6 lb•ft) 3
T.R
.
1 LS
New
New LS
D
FW
T.R
.
T.R
.

page 4-38.
Electrical compartment trays Refer to “GENERAL CHASSIS (14)” on

page 4-42.
Coolant reservoir/Radiator Refer to “RADIATOR” on page 6-7.
1 Oil cooler outlet hose 1
2 Oil cooler inlet hose 1
3 Oil inlet pipe/hose 2 1
4 Oil outlet pipe/hose 2 1
5 Oil inlet pipe/hose 1 1
6 Oil outlet pipe/hose 1 1
6-5
OIL COOLER
EBS30211
CHECKING THE OIL COOLER

1. Check:
• Oil cooler fins
Obstruction → Clean.
Apply compressed air to the rear of the oil
cooler.
Damage → Repair or replace.
TIP
Straighten any flattened fins with a thin, flat-head
screwdriver.
2. Check:
• Oil cooler hose
• Oil cooler pipe/hose
6-6
RADIATOR
EBS20051
RADIATOR
Removing the coolant reservoir
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
3
1
4

Drain.
page 3-13.

4-15.
1 Coolant reservoir breather hose 1
2 Coolant reservoir hose 1
3 Coolant reservoir cap 1
4 Coolant reservoir 1
6-7
RADIATOR
Removing the radiator

T.R
T.R
.
.
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
.
New
(4)
36 N•m (3.6 kgf•m, 27 lb•ft)

New
T.R
.
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
T.R
.
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
36 N•m (3.6 kgf•m, 27 lb•ft)

T.R
.

Drain.
page 3-18.
ers 4-1.
4-7.
4-15.

4-16.
4-17.
4-25.

page 4-33.

page 4-36.
6-8
RADIATOR
Removing the radiator

T.R
T.R
.
.
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
.
5
7
New
11 4
1 (4)
10
36 N•m (3.6 kgf•m, 27 lb•ft)

New
T.R
.
2 2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
9
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
T.R
.
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
36 N•m (3.6 kgf•m, 27 lb•ft)

T.R
.

page 4-38.
Electrical compartment trays Refer to “GENERAL CHASSIS (14)” on

page 4-42.
Oil cooler Refer to “OIL COOLER” on page 6-3.
1 Radiator cap 1
2 Radiator inlet hose 1
3 Radiator outlet hose 1
4 Thermostat outlet hose 1
5 Water pump inlet hose 1
6 Radiator inlet pipe 1
7 Radiator outlet pipe 1
8 Radiator fan motor coupler 1 Disconnect.
9 Radiator bracket 1
10 Radiator 1
11 Radiator fan motor 1
6-9
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 G101546
screwdriver. b. Apply the specified pressure for ten sec-

onds and make sure there is no drop in
pressure.
4. Check:
• Radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” on page 9-37.
EBS30214
INSTALLING THE RADIATOR

G101545
1. Install:
2. Check: • Radiator inlet pipe “1”
• Radiator hose • Radiator outlet pipe “2”
• Radiator pipe TIP
• Water pump inlet hose Align the punch marks “a” on the radiator inlet
• Thermostat outlet hose pipe and outlet pipe with the hose clamp.
3. Measure:
Radiator pipe holder bolt
• Radiator cap opening pressure
8 N·m (0.8 kgf·m, 5.9 lb·ft)
Below the specified pressure → Replace the
T.
R.
radiator cap.
Radiator cap opening pressure a

107.9–137.3 kPa (1.1–1.4 kgf/ 1
cm², 15.6–19.9 psi)
a. Install the radiator cap tester “1” and radi-

ator cap tester adapter “2” to the radiator
cap “3”. FW
D
Radiator cap tester
90890-01325
Mityvac cooling system tester kit a
YU-24460-A
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984
2
D
FW
6-10
RADIATOR
2. Fill:
• Cooling system
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-13.
3. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
4. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-10.
6-11
THERMOSTAT
EBS20052
THERMOSTAT
Removing the thermostat
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)
3
T.R
.
4 New
6 2
5 2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
.
New
1
15 N•m (1.5 kgf•m, 11 lb•ft)
T.R
.
F WD

Drain.
page 3-13.
Rear cover Refer to “GENERAL CHASSIS (5)” on page

4-16.
1 Thermostat outlet hose 1 Disconnect.
2 Thermostat cover 1
3 Thermostat cover air bleed bolt 1
4 Thermostat 1
5 Coolant temperature sensor coupler 1 Disconnect.
6 Coolant temperature sensor 1
6-12
THERMOSTAT
EBS30215
CHECKING THE THERMOSTAT Thermostat cover bolt

1. Check: 12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
• Thermostat
Does not open at 69–73 °C (156–163°F) → TIP
Replace. Install the thermostat with its breather hole “a”
a. Suspend the thermostat “1” in a container facing up.
“2” filled with water.
b. Slowly heat the water “3”.
c. Place a thermometer “4” in the water.
d. While stirring the water, observe the ther- a
mostat and thermometer indicated tem-
perature.
1
2. Install:
• Copper washer New
• Coolant temperature sensor
ECB01910
G101547 NOTICE
Use extreme care when handling the coolant
temperature sensor. Replace any part that
B was dropped or subjected to a strong im-
C
pact.
Coolant temperature sensor

A 15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.
0
D E 3. Fill:
G101548 • Cooling system
A. Fully closed
mended coolant)
B. Fully open
Refer to “CHANGING THE COOLANT” on
C. 7 mm (0.28 in)
page 3-13.
D. 69–73 °C (156–163 °F)
4. Check:
E. 85 °C (185 °F)
• Cooling system
TIP Leak → Repair or replace any faulty part.
If the accuracy of the thermostat is in doubt, re- 5. Measure:
place it. A faulty thermostat could cause serious • Radiator cap opening pressure
overheating or overcooling. Below the specified pressure → Replace the
radiator cap.
2. Check: Refer to “CHECKING THE RADIATOR” on
• Thermostat cover page 6-10.
EBS30216
INSTALLING THE THERMOSTAT

1. Install:
• Thermostat “1”
• Thermostat cover
6-13
WATER PUMP
EBS20053
WATER PUMP
Removing the water pump
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
New 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
New
(8)
New New
E
New New
LS
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
New
(3) FW
D
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)

T.R
.

Drain.
page 3-13.
Drain.
page 3-18.
Front door (right)/Rear door striker (right) Refer to “GENERAL CHASSIS (1)” on page
4-1.
4-7.

4-15.

4-16.

4-17.
6-14
WATER PUMP

1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
New 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
2 New
1
(8)
New New
E
New 6 New
LS
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
New 4
(3) 5 3 FW
D
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)

T.R
.
4-25.
1 Water jacket joint 1
2 Water pump outlet hose 1
3 Water pump inlet hose 1
4 Water pump breather hose 1
5 Water pump housing cover 1
6 Gasket 1
6-15
WATER PUMP

1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
New 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
11
10 New
9
(8)
16
11
New 12 New
E
13
New 17 New
15 LS
1.8 N•m (0.18 kgf•m, 1.3 lb•ft) 14
T.R
.
New 7
(3) FW
D
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)

T.R
.

8 AC magneto lead coupler 3 Disconnect.
9 AC magneto cover 1
10 AC magneto cover gasket 1
11 Dowel pin 2
12 Circlip 1
13 Impeller shaft 1
14 Mechanical seal (impeller side) 1
15 Mechanical seal (housing side) 1
16 Bearing 1
17 Oil seal 1
6-16
WATER PUMP
EBS30217 EBS30218
DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP

1. Remove: 1. Check:
• Mechanical seal (impeller side) “1” • Water pump housing cover
(from the impeller, with a thin, flat-head • AC magneto cover
screwdriver) • Impeller shaft
TIP • Water pump inlet hose
Do not scratch the impeller shaft. • Water pump outlet hose
• Water pump breather hose
• Water jacket joint
2. Check:
• Bearing
1 Rough movement → Replace.
EBS30219
ASSEMBLING THE WATER PUMP

1. Install:
2. Remove: • Bearing “2”
• Mechanical seal (housing side) “1” (into the AC magneto cover)
TIP TIP
Remove the mechanical seal (housing side) Install the oil seal with a socket that matches its
from the inside of the AC magneto cover. outside diameter.
Installed depth of oil seal “a”

0.5–1.0 mm (0.02–0.04 in)
a
1
3. Remove: New 1
• Bearing “1”
• Oil seal “2”
TIP 2. Install:
Remove the bearing and oil seal from the out- • Mechanical seal (housing side) “1” New
side of the AC magneto cover. (into the AC magneto cover)
ECB02410
NOTICE
1
Never lubricate the mechanical seal surface
2 with oil or grease.
TIP
Use the special tools and a press to press the
mechanical seal (housing side) straight in until it
touches the AC magneto cover.
6-17
WATER PUMP
TIP
Mechanical seal installer (ø33)
90890-04132 If the surface “a” of the mechanical seal (impeller
Water pump seal installer (ø33) side) that contacts the mechanical seal (housing
YM-33221-A side) is dirty, clean it.
Middle driven shaft bearing driv-
er Impeller shaft tilt limit
90890-04058 0.15 mm (0.006 in)
Middle drive bearing installer 40
& 50 mm
YM-04058 1
A
3
2
2
a
New 1
1. Straightedge
2. Impeller
A. Push down 5. Install:

2. Mechanical seal installer • Impeller shaft “1”
3. Middle driven shaft bearing driver • Circlip “2” New
3. Install: TIP
• Mechanical seal (impeller side) “1” New • Be sure the circlip sharp-edged corner “a” is
positioned opposite side to the bearing.
TIP
• After installation, check that the impeller shaft
Before installing the mechanical seal (impeller “1” rotates smoothly.
side), apply tap water or coolant onto its outer
surface.
1
a
1 New
New 2
4. Measure:
• Impeller shaft tilt
Out of specification → Repeat steps (3) and
1
(4).
ECB03180
NOTICE
Make sure the mechanical seal (impeller
side) is flush with the impeller.
6. Install:
• AC magneto cover
Refer to “AC MAGNETO AND STARTER
6-18
WATER PUMP
6-19
FUEL SYSTEM
FUEL TANK..................................................................................................... 7-1

REMOVING THE FUEL TANK .................................................................. 7-7
REMOVING THE FUEL PUMP ................................................................. 7-7
CHECKING THE FUEL PUMP BODY....................................................... 7-7
CHECKING THE ROLLOVER VALVE ...................................................... 7-7
CHECKING THE FUEL TANK PRESSURE CONTROL VALVE............... 7-8
INSTALLING THE FUEL PUMP ................................................................ 7-8
INSTALLING THE FUEL TANK................................................................. 7-9
INSTALLING THE FUEL TANK PRESSURE CONTROL VALVE...........7-10
CHECKING THE FUEL PRESSURE ...................................................... 7-10
CHECKING THE PURGE CONTROL SYSTEM .....................................7-10
THROTTLE BODIES ..................................................................................... 7-11

CHECKING THE FUEL INJECTORS (BEFORE REMOVING) ...............7-14
REMOVING THE FUEL INJECTORS .....................................................7-14
REMOVING THE THROTTLE BODY...................................................... 7-14
CHECKING THE FUEL INJECTORS ...................................................... 7-14
CHECKING AND CLEANING THE THROTTLE BODIES ....................... 7-14
CHECKING THE THROTTLE BODY JOINT ........................................... 7-16
INSTALLING THE FUEL INJECTORS ....................................................7-16
CHECKING THE FUEL INJECTOR PRESSURE ...................................7-16
INSTALLING THE THROTTLE BODIES .................................................7-16
AIR INDUCTION SYSTEM ............................................................................ 7-18

CHECKING THE AIR INDUCTION SYSTEM..........................................7-21
INSTALLING THE AIR INDUCTION SYSTEM........................................7-21
7
FUEL TANK
EBS20054
FUEL TANK
Removing the fuel tank
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
F WD (6)
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
New
17 N•m (1.7 kgf•m, 13 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
55 N•m (5.5 kgf•m, 41 lb•ft)

T.R
.
32 N•m (3.2 kgf•m, 24 lb•ft)

T.R
.

4-7.

4-15.

4-16.

4-17.
4-25.
7-1
FUEL TANK
Removing the fuel tank

7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
F WD (6)
11
2 1
12
4
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
New
13
17 N•m (1.7 kgf•m, 13 lb•ft) 9
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
55 N•m (5.5 kgf•m, 41 lb•ft)

T.R
6
.
8
5 10
7 32 N•m (3.2 kgf•m, 24 lb•ft)

10
T.R
.
1 Fuel tank breather hose (fuel tank to rollover 1

valve)
2 Fuel pump coupler 1 Disconnect.
3 Fuel hose connector holder 1
4 Fuel hose 1
5 Fuel tank retainer 1 1
6 Fuel tank retainer 2 1
7 Damper 1 1
8 Damper 2 2
9 Fuel tank 1
10 Damper 4
11 Fuel pump bracket 1
12 Fuel pump 1
13 Fuel pump gasket 1
7-2
FUEL TANK
Removing the canister and hoses
LT
8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.R
.
1.3 N•m (0.13 kgf•m, 0.95 lb•ft)

T.R
.
D
FW

4-7.

4-15.

4-16.

4-17.
4-25.
7-3
FUEL TANK
5 4
7
3 2
1
LT
8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.R
.
1.3 N•m (0.13 kgf•m, 0.95 lb•ft)

T.R
.
D
FW
1 Fuel tank breather hose (fuel tank to rollover 1

valve)
2 Fuel tank breather hose (rollover valve to 3-way 1

joint)
3 Rollover valve 1
4 Fuel tank breather hose (3-way joint to canister) 1
5 3-way joint 1
6 Fuel tank breather hose (3-way joint to fuel tank 1

pressure control valve)
7 Fuel tank pressure control valve 1
7-4
FUEL TANK
10
15
LT
11
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
1.3 N•m (0.13 kgf•m, 0.95 lb•ft)

T.R
.
13
12 8
14
D
FW

8 Canister purge hose (3-way joint to canister) 1
9 Canister breather hose (canister to 3-way joint) 1
10 Canister breather hose (3-way joint to frame) 1
11 3-way joint 1
12 Canister breather hose (3-way joint to one-way 1

valve)
13 One-way valve 1
14 Bracket 1
15 Canister 1
7-5
FUEL TANK
Removing the purge cut valve solenoids

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
D
FW
2 5
7
8
3
6
4-7.

4-16.
1 Purge cut valve solenoid coupler 2 Disconnect.
2 Canister purge hose (throttle body to purge cut 1

valve) 1
3 Canister purge hose (throttle body to purge cut 1

valve) 2
4 Canister purge hose (purge cut valve to 3-way 1

joint) 1
5 Canister purge hose (purge cut valve to 3-way 1

joint) 2
6 Canister purge hose (3-way joint to canister) 1 Disconnect.
7 3-way joint 1
8 Purge cut valve solenoid 2
7-6
FUEL TANK
EBS30221
REMOVING THE FUEL TANK

1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump. 2 3
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
ECB03620
1. Remove:
NOTICE • Fuel pump bracket
• Fuel pump
• Be sure to disconnect the fuel rail end of
• Fuel pump gasket
the fuel hose by hand. Do not forcefully dis- ECB01450
connect the fuel rail end of the fuel hose NOTICE

with tools. • Do not drop the fuel pump or give it a
• Although the fuel has been removed from strong shock.
the fuel tank, be careful when removing the • Do not touch the base section of the fuel
fuel hose, since there may be fuel remain- sender.
ing in it.
EBS30223
TIP
CHECKING THE FUEL PUMP BODY
• To disconnect the fuel hose from the fuel 1. Check:
pump, remove the fuel hose connector holder, • Fuel pump body
insert a flat-head screwdriver, etc., in the slot Obstruction → Clean.
part “a” of the fuel hose connector cover “1”, Cracks/damage → Replace the fuel pump.
slide the cover in the direction of the arrow, and
then disconnect the fuel hose. EBS30817
• To disconnect the fuel hose from the fuel rail, CHECKING THE ROLLOVER VALVE
slide the fuel hose connector cover “2” on the 1. Check:
end of the hose in direction of the arrow shown, • Rollover valve “1”
press the two buttons “3” on the sides of the • One-way valve “2”
connector, and then disconnect the hose. Damage/faulty → Replace.
• Before removing the hose, place a few rags in TIP
the area under where it will be removed. • Check that air flows smoothly in the direction of
the arrow shown when the rollover valve is po-
sitioned as shown in the illustration “A”.
• Check that air does not flow in the direction of
1
1 the arrow shown when the rollover valve is po-
a sitioned as shown in the illustration “B”.
• Check that air flows smoothly in the direction of
the arrow shown when the one-way valve is
positioned as shown in the illustration.
7-7
FUEL TANK
A B a b. Apply positive pressure to the fuel tank

pressure control valve.
TIP
1 Perform this procedure for both ends of the fuel
tank pressure control valve.
EBS30225
1 INSTALLING THE FUEL PUMP
1. Install:
• Fuel pump gasket “1” New
a. upward
TIP
• Always use a new fuel pump gasket.
• Install the fuel pump gasket with the lip side “a”
2 facing upward.
New 1 a 1
EBS30818
CHECKING THE FUEL TANK PRESSURE

CONTROL VALVE
1. Check: 2. Install:
• Fuel tank pressure control valve opening • Fuel pump
pressure • Fuel pump bracket
Opening pressure Fuel pump nut
5–8 kPa (0.05–0.08 kgf/cm², 0.71– 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
1.14 psi)
R.
TIP
Out of specification → Replace the fuel tank
pressure control valve. • Do not damage the installation surfaces of the
a. Connect the vacuum/pressure pump fuel tank when installing the fuel pump.
gauge set “1” to the fuel tank pressure • Install the fuel pump in the direction shown in
control valve “2”. the illustration.
• Install the fuel pump bracket by aligning the
Vacuum/pressure pump gauge projections “a” on the fuel pump with the pro-
set jection “b” on the fuel tank.
90890-06756 • Tighten the nuts to specification in the proper
Mityvac brake bleeding tool tightening sequence as shown.
YS-42423
5
a
2 1 3 2 b
a FWD
1 4
7-8
FUEL TANK
EBS30226
INSTALLING THE FUEL TANK 4 4

1. Install: 1 5 6 2
• Damper “1” 8
6 7
TIP
2 3
Fit the projection “a” on the dampers into the
hole “b” in the frame. 4 1
5
9
7 4
2 7 3
1
4. Install:
1
1 • Fuel hose
• Fuel hose connector holder “1”
a • Fuel pump coupler
ECB02010
b NOTICE
1
When installing the fuel hose, make sure that
2. Install: it is securely connected, and that the fuel
• Fuel tank “1” hose holder is in the correct position, other-
• Fuel tank bolt “2” wise the fuel hose will not be properly in-
• Fuel tank retainer 2 “3” stalled.
• Fuel tank retainer 2 bolt “4” TIP
• Fuel tank bolt “5”
• Install the fuel hose connector holder “1” se-
• Fuel tank retainer 1 “6”
curely onto the fuel pump until a distinct “click”
• Fuel tank retainer 1 bolt “7”
is heard, and then make sure that it does not
TIP come loose.
Finger tighten the fuel tank bolts and fuel tank re- • To install the fuel hose onto the fuel rail, slide
tainer bolts. the fuel hose connector cover “2” on the end of
3. Tighten: the hose in direction of the arrow shown.
• Fuel tank retainer 1 bolt “7”
• Fuel tank retainer 2 bolt “4” 1
• Fuel tank bolt “2” “5”
TIP 1
Tighten the fuel tank retainer bolts and fuel tank
bolts in the proper tightening sequence as
shown.
Fuel tank retainer 1 bolt

55 N·m (5.5 kgf·m, 41 lb·ft)
T.
R.
Fuel tank retainer 2 bolt (outer)

32 N·m (3.2 kgf·m, 24 lb·ft)
Fuel tank retainer 2 bolt (inner)
17 N·m (1.7 kgf·m, 13 lb·ft) 2
Fuel tank bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft)
7-9
FUEL TANK
EBS30819
e. Measure the fuel pressure.
INSTALLING THE FUEL TANK PRESSURE
Out of specification → Replace the fuel
CONTROL VALVE
pump.
1. Install:
• Fuel tank pressure control valve “1” Fuel line pressure
TIP 300.0–390.0 kPa (3.00–3.90 kgf/
• Install the fuel tank pressure control valve with cm², 43.5–56.6 psi)
the “UP” mark “a” facing up.
EBS30823
• Fit the projection “b” on the fuel tank pressure
CHECKING THE PURGE CONTROL SYSTEM
control valve into the hole “c” in the bracket.
1. Check:
• Hoses
Loose connections → Connect properly.
a c
2. Check:
• Purge cut valve solenoid
Use the diagnostic code numbers “46” and
d “94”.
1 Refer to “DIAGNOSTIC CODE: ACTUATOR
OPERATION TABLE” on page 10-4.
EBS30227
CHECKING THE FUEL PRESSURE

1. Check:
• Fuel pressure
a. Remove the rear cover.
page 4-16.
b. Disconnect the fuel hose “1” from the fuel
rail.
Refer to “REMOVING THE FUEL TANK”
on page 7-7.
c. Connect the pressure gauge “2” and
adapter “3” to the fuel rail and fuel hose.
Pressure gauge
90890-03153
Pressure gauge
YU-03153
90890-03186
YM-03186
2
3
1
d. Start the engine.
7-10
THROTTLE BODIES
EBS20056
THROTTLE BODIES
Removing the throttle bodies
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
(4)
3.0 N•m (0.30 kgf•m, 2.2 lb•ft)

T.R
.
D
FW
4-7.

4-16.
Canister purge hoses/Purge cut valve solenoids Refer to “FUEL TANK” on page 7-1.
Air induction system hoses/Air cut-off valve/Air Refer to “AIR INDUCTION SYSTEM” on
cut-off valve bracket 2 page 7-18.

page 4-38.
7-11
THROTTLE BODIES
Removing the throttle bodies
2
1
3
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
5
7
(4)
4 6
3.0 N•m (0.30 kgf•m, 2.2 lb•ft)

T.R
.
D
FW

1 Intake air pressure sensor coupler 1 Disconnect.
2 Fuel injector coupler #1 1 Disconnect.
3 Fuel injector coupler #2 1 Disconnect.
4 Throttle position sensor coupler 1 Disconnect.
5 Fuel hose 1 Disconnect.
6 Throttle body joint clamp screw 2 Loosen.
7 Throttle bodies 1
8 Throttle body joint 1
7-12
THROTTLE BODIES
Removing the fuel injectors
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
New New
3
1
New New
4 4
2
New
New

1 Intake air pressure sensor 1
2 Intake air pressure sensor hose 1
3 Fuel rail 1
4 Fuel injector 2
5 Throttle bodies 1
7-13
THROTTLE BODIES
EBS30822
2. Check:
CHECKING THE FUEL INJECTORS
• Fuel injector resistance
(BEFORE REMOVING)
Refer to “CHECKING THE FUEL INJEC-
1. Check:
TOR” on page 9-136.
• Fuel injector
Use the diagnostic code numbers “36” and EBS30824
“37”. CHECKING AND CLEANING THE THROTTLE

Refer to “DIAGNOSTIC CODE: ACTUATOR BODIES
OPERATION TABLE” on page 10-4. TIP
EBS30821
Before cleaning the throttle bodies, check the
REMOVING THE FUEL INJECTORS following items:
EWB04270 • Valve clearance
WARNING • Spark plugs
• Check the injectors in a well-ventilated area • Air filter element
free of combustible materials. Make sure • Throttle body joint
that there is no smoking or use of electric • Fuel hose
tools in the vicinity of the injectors. • Exhaust system
• Be careful when disconnecting the fuel • Cylinder head breather hose
hose. Any remaining pressure in the fuel EWB04280
hose may cause the fuel to spray out. Place WARNING

a container or rag under the hose to catch If the throttle bodies are subjected to strong
any fuel that spills. Always clean up any shocks or dropped during cleaning, replace
spilt fuel immediately. them as a set.
• Turn the main switch to “OFF” and discon-
nect the negative battery lead from the bat- 1. Check:
tery terminal before removing the injectors. • Throttle bodies
Cracks/damage → Replace the throttle bod-
1. Remove: ies as a set.
• Fuel rail “1” 2. Clean:
a. Remove the fuel rail screws “2” as shown. • Throttle bodies
ECB03630
2 NOTICE
• Observe the following precautions; other-
wise, the throttle bodies may not operate
1
properly.
• Do not subject the throttle bodies to exces-
sive force.
• Clean the throttle bodies in the recom-
2
mended cleaning solvent.
• Do not use any caustic carburetor cleaning
EBS30229 solution.
REMOVING THE THROTTLE BODY • Do not apply cleaning solvent directly to
1. Disconnect: any plastic parts, sensors, or seals.
• Fuel hose • Be careful not to remove the white paint
Refer to “REMOVING THE FUEL TANK” on mark that identifies the standard throttle
page 7-7. body.
EBS30427
• Do not turn the bypass air screws “a”; oth-
CHECKING THE FUEL INJECTORS erwise, the throttle body synchronization
1. Check: will be affected.
• Fuel injector
Obstruction → Replace and check the fuel Recommended cleaning solvent
pump/fuel supply system. Yamaha Oil & Brake Cleaner
Deposit → Replace.
Damage → Replace.
7-14
THROTTLE BODIES
TIP
a • Do not allow any cleaning solvent to enter the
opening for the injectors.
• Do not apply any cleaning solvent to the por-
tions of the throttle valve shafts between the
throttle bodies.
e. Remove the carbon deposits from the in-
side of each throttle body in a downward
direction, from the air intake accumulator
a. Place the throttle bodies on a flat surface assembly side of the throttle bodies to the
with the cylinder head side facing up. cylinder head side.
ECB03650
b. Install the caps (895-14169-00) onto the
NOTICE
hose fittings “a”.
• Do not use a tool, such as a wire brush, to
remove the carbon deposits; otherwise, the
inside of the throttle bodies may be dam-
a
aged.
• Do not allow carbon deposits or other for-
eign materials to enter any of the passages
in each throttle body or in the space be-
tween the throttle valve shaft and the throt-
tle body.
f. After removing the carbon deposits, clean
c. Hold the throttle valves in the open posi- the inside of the throttle bodies with the
tion. recommended cleaning solvent, and then
EWB04290
dry the throttle bodies using compressed
WARNING
air.
When cleaning the throttle bodies, be careful g. Make sure that there are no carbon de-
not to injure yourself on the throttle valves or posits or other foreign materials in any of
other components of the throttle bodies. the passages “a” in each throttle body or in
ECB03640 the space “b” between the throttle valve
NOTICE shaft and the throttle body.
• Do not open the throttle valves by supply-
a a
ing electrical power to the throttle bodies.
• Do not use tools to open the throttle valves
or to keep them in the open position.
• Do not open the throttle valves quickly.
b
3. Install the throttle bodies.
4. Adjust:
• Throttle bodies synchronizing
Out of specification → Replace the throttle
bodies.
Refer to “SYNCHRONIZING THE THROT-
d. Apply the recommended cleaning solvent
TLE BODIES” on page 3-8.
to the throttle valves and the inside of the
throttle bodies to remove any carbon de-
posits.
7-15
THROTTLE BODIES
EBS30232
a. Connect the injector pressure adapter “1”
CHECKING THE THROTTLE BODY JOINT
to the fuel rail “2”, and then connect an air
1. Check:
compressor “3” to the adapter.
• Throttle body joint
b. Connect the pressure gauge “4” to the in-
jector pressure adapter “1”.
EBS30828
INSTALLING THE FUEL INJECTORS Pressure gauge

ECB03950 90890-03153
NOTICE Pressure gauge
• Always use new O-rings and seals. YU-03153
• When checking the injectors, do not allow Fuel injector pressure adapter
any foreign material to enter or adhere to 90890-03210
Fuel injector pressure adapter
the injectors, fuel rail, O-rings, or seals.
YU-03210
• Be careful not to twist or pinch the O-rings
when installing the injectors.
• If an injector is subject to strong shocks or
excessive force, replace it.
1. Install new O-rings and seals onto the end of
each injector.
2. Install the injectors “1” to the fuel rail “2”.
c. Close the valve on the injector pressure

New adapter.
New d. Apply air pressure with the air compres-
1 1 sor.
New e. Open the valve on the injector pressure
New
adapter until the specified pressure is
reached.
Fuel rail screw
3.5 N·m (0.35 kgf·m, 2.6 lb·ft) Specific air pressure
T.
R.
490 kPa (4.9 kgf/cm2, 69.7 psi)

3. Install the injector assemblies to the throttle
bodies. ECB03670
4. Check the injector pressure after the injectors NOTICE

are installed to the throttle bodies. Never exceed the specified air pressure or
Refer to “CHECKING THE FUEL INJECTOR damage could occur.
PRESSURE” on page 7-16.
f. Close the valve on the injector pressure
EBS30829 adapter.
CHECKING THE FUEL INJECTOR g. Check that the specified air pressure is
PRESSURE held for about one minute.
TIP Pressure drops → Check the pressure
• After installing the injectors, perform the follow- gauge and adapter.
ing steps to check the injector pressure. Check the seals and O-rings, and then re-
• Do not allow any foreign materials to enter the install.
fuel lines. Replace the fuel injectors.
1. Check: EBS30233
• Injector pressure INSTALLING THE THROTTLE BODIES

1. Install:
• Throttle body joint “1”
• Throttle body joint clamp “2”
7-16
THROTTLE BODIES
TIP
Align the projection on the throttle body joint with
the gap in throttle body joint clamp.
2
2
2. Connect:
• Fuel hose
Refer to “INSTALLING THE FUEL TANK” on
page 7-9.
7-17
AIR INDUCTION SYSTEM
EBS20057
4
3
1. Air intake accumulator assembly

2. Air induction system hose (air intake
accumulator assembly to air cut-off valve)
3. Air cut-off valve
4. Air induction system hose (air cut-off valve to
reed valve cover)
5. Reed valve cover
7-18
Removing the air cut-off valve
4
11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
5
6
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
3
D
FW
4-7.

4-16.
Purge cut valve solenoids Refer to “FUEL TANK” on page 7-1.
1 Air induction system solenoid coupler 1 Disconnect.
2 Air induction system hose (air cut-off valve to 1

reed valve cover)
3 Air induction system hose (air intake accumula- 1

tor assembly to air cut-off valve)
4 Air cut-off valve 1
5 Air cut-off valve bracket 1 1
6 Air cut-off valve bracket 2 1
7-19
Removing the reed valve

10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
FW
D
LT
0.8 N•m (0.08 kgf•m, 0.59 lb•ft)

T.R
.
LT

1 Reed valve cover 1
2 Reed valve assembly 1
3 Reed valve plate 2
7-20
EBS30235
2. Check:
• Reed valve
• Reed valve stopper
Air injection
• Reed valve seat
The air induction system burns unburned ex-
Cracks/damage → Replace the reed valve
haust gases by injecting fresh air (secondary air)
assembly.
into the exhaust port, reducing the emission of
3. Check:
hydrocarbons. When there is negative pressure
• Air cut-off valve
at the exhaust port, the reed valve opens, allow-
ing secondary air to flow into the exhaust port.
4. Check:
The required temperature for burning the un-
• Air induction system solenoid
burned exhaust gases is approximately 600 to
Use the diagnostic code number “48”.
700 °C (1112 to 1292 °F).
Refer to “DIAGNOSTIC CODE: ACTUATOR
Air cut-off valve OPERATION TABLE” on page 10-4.
The air cut-off valve is controlled by the signals EBS30236
from the ECU in accordance with the combus- INSTALLING THE AIR INDUCTION SYSTEM
tion conditions. Ordinarily, the air cut-off valve 1. Install:
opens to allow the air to flow during idle and • Reed valve plate “1”
closes to cut-off the flow when the vehicle is be- TIP
ing driven. However, if the coolant temperature Align the hole “a” in the reed valve plate over the
is below the specified value, the air cut-off valve projection “b” of the reed valve seat on the cylin-
remains open and allows the air to flow into the der head cover.
exhaust pipe until the temperature becomes
higher than the specified value.
a
b
b
A
1
A. From the air intake accumulator assembly

B. To the reed valve
1. Check:
• Hose
Loose connections → Connect properly.
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
DISASSEMBLING THE UNIVERSAL JOINTS .......................................... 8-9
DISASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES ........................................................................................... 8-9
CHECKING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES .........................................................................................8-10
ASSEMBLING THE FRONT CONSTANT VELOCITY SHAFT
ASSEMBLIES .........................................................................................8-11
REMOVING THE FRONT DRIVE SHAFT YOKE....................................8-13
REMOVING THE DIFFERENTIAL GEAR ASSEMBLY...........................8-13
CHECKING THE FRONT DRIVE SHAFT ...............................................8-13
CHECKING THE DIFFERENTIAL ASSEMBLY ......................................8-13
CHECKING THE DIFFERENTIAL MOTOR OPERATION ......................8-14
ASSEMBLING THE DIFFERENTIAL ASSEMBLY .................................. 8-14
ASSEMBLING THE UNIVERSAL JOINT ................................................8-16
MEASURING THE DIFFERENTIAL GEAR BACKLASH.........................8-17
ADJUSTING THE DIFFERENTIAL GEAR BACKLASH ..........................8-17
SELECTING THE DIFFERENTIAL PINION GEAR SHIM(S) ..................8-18
SELECTING THE DIFFERENTIAL GEAR SHIM(S) ...............................8-19
CHECKING THE DIFFERENTIAL OPERATION.....................................8-21
REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL DRIVE

ASSEMBLY AND REAR DRIVE SHAFT .....................................................8-22
DISASSEMBLING THE REAR CONSTANT VELOCITY SHAFT
ASSEMBLIES .........................................................................................8-27
CHECKING THE REAR CONSTANT VELOCITY SHAFT
ASSEMBLIES .........................................................................................8-28
ASSEMBLING THE REAR CONSTANT VELOCITY SHAFT
ASSEMBLIES .........................................................................................8-28
DISASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY .......8-31
CHECKING THE REAR DRIVE SHAFT..................................................8-31
CHECKING THE FINAL DRIVE ASSEMBLY ..........................................8-31
ASSEMBLING THE FINAL DRIVE CASE ...............................................8-31
8
ASSEMBLING THE FINAL DRIVE PINION GEAR ASSEMBLY .............8-32
SELECTING THE FINAL DRIVE PINION GEAR SHIM(S) ..................... 8-32
SELECTING THE FINAL DRIVE RING GEAR SHIM(S)
(FINAL DRIVE CASE COVER SIDE) .....................................................8-33
SELECTING THE FINAL DRIVE RING GEAR SHIM(S)
(FINAL DRIVE CASE SIDE) ...................................................................8-34
SELECTING THE FINAL DRIVE RING GEAR STOPPER
THRUST SHIM(S) ..................................................................................8-35
MEASURING THE FINAL GEAR BACKLASH ........................................8-37
ADJUSTING THE FINAL GEAR BACKLASH .........................................8-37
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
b. Apply a leak detection compound or dry
CHECKING NOISES
powder spray to the shaft drive.
1. Investigate any unusual noises.
c. Road test the vehicle for the distance nec-
essary to locate the leak.
The following “noises” may indicate a me-
Leakage → Check the component hous-
chanical defect:
ing, gasket, and/or seal for damage.
a. A “rolling rumble” noise during coasting,
Damage → Replace the component.
acceleration, or deceleration. The noise
increases with front and/or rear wheel TIP
speed, but it does not increase with higher • An apparent oil leak on a new or nearly new ve-
engine or transmission speeds. hicle may be the result of a rust-preventative
Diagnosis: Possible wheel bearing dam- coating or excessive seal lubrication.
age. • Always clean the vehicle and recheck the sus-
Refer to “TROUBLESHOOTING CHART” pected location of an apparent leakage.
on page 8-3.
b. A “whining” noise that varies with acceler-
ation and deceleration.
Diagnosis: Possible incorrect reassembly,
too little gear backlash.
Refer to “MEASURING THE DIFFEREN-
TIAL GEAR BACKLASH” on page 8-17 or
“MEASURING THE FINAL GEAR BACK-
LASH” on page 8-37.
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 oper-
ation. 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
a. Clean the entire vehicle thoroughly, then
dry it.
8-2
TROUBLESHOOTING
EBS30238
TROUBLESHOOTING CHART
When basic conditions (a) and (b) described in “CHECKING NOISES” exist, check the following points:
YES → Replace the wheel bearing. (Refer to
1. Elevate and spin both wheels. Feel “STEERING KNUCKLES AND FRONT
for wheel bearing damage. STABILIZER” on page 4-93 and “REAR
KNUCKLES” on page 4-103.)
NO ↓
NO → Tighten to specified torque. (Refer to
2. Check the tightness of the wheel
“FRONT AND REAR WHEELS” on page
nuts and axle nuts.
4-54.)
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 “CHECK-
4. Check the parking brake adjust-
ING THE PARKING BRAKE” on page
ment.
3-24.)
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
105 N•m (10.5 kgf•m, 77 lb•ft)
T.R
.
105 N•m (10.5 kgf•m, 77 lb•ft)

T.R
.
LT
LS
New
New
New LT
New
105 N•m (10.5 kgf•m, 77 lb•ft)
T.R
.
New
LS LS
New

Drain.
Differential gear oil Refer to “CHANGING THE DIFFERENTIAL
GEAR OIL” on page 3-23.
4-7.

4-15.
Skid plate Refer to “GENERAL CHASSIS (11)” on

page 4-33.
Front wheel hubs Refer to “FRONT AND REAR WHEELS” on

page 4-54.
Stabilizer joints/Steering knuckles Refer to “STEERING KNUCKLES AND

Refer to “FRONT ARMS AND FRONT
Front shock absorber assembly SHOCK ABSORBER ASSEMBLIES” on
page 4-98.
8-4
Removing the front constant velocity shaft assemblies, differential assembly, and front drive shaft
105 N•m (10.5 kgf•m, 77 lb•ft)
T.R
.
105 N•m (10.5 kgf•m, 77 lb•ft)

T.R
.
LT
5
3 2
1
11
LS 12
New
New 10
4
New LT
New
6 9 105 N•m (10.5 kgf•m, 77 lb•ft)
T.R
.
8 New
LS LS
New

1 Front constant velocity shaft assembly 2
2 Differential motor coupler 1 Disconnect.
3 Differential assembly breather hose 1 Disconnect.
4 Differential assembly bracket (left) 1
5 Differential assembly bracket (right) 1
6 Differential assembly 1
7 Front drive shaft 1
8 Spring 1
9 Dust seal (differential assembly side) 1
10 Dust seal (middle gear side) 1
11 Universal joint 1
12 Universal joint yoke 1
8-5
Disassembling the front constant velocity shaft assemblies
5
M
6 New
7
B 4 New
New 2
3
New 1
13
New 8 10 12 New
11
New 9 M
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
10 Dust boot 1
11 Constant velocity joint 1
12 Clip 1
13 Constant velocity shaft 1
8-6
Disassembling the differential assembly
New
LS
M
11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
LS
(4)
New LT
LS
New 1
New
LS
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
(3) New
4 M
3
5
2 6
7
New 40 N•m (4.0 kgf•m, 30 lb•ft)
T.R
.
LS
M New
LS
23 N•m (2.3 kgf•m, 17 lb•ft) (5)
T.R
.
New
20 N•m (2.0 kgf•m, 15 lb•ft)
25 N•m (2.5 kgf•m, 18 lb•ft)
T.R
.
T.R
.

1 Differential motor 1
2 Differential case cover 1
3 Differential gear assembly shim (right) Refer to “ADJUSTING THE DIFFEREN-

TIAL GEAR BACKLASH” on page 8-17.
4 Bearing 1
5 Differential gear assembly 1
6 Differential gear assembly shim (left) Refer to “ADJUSTING THE DIFFEREN-

7 Bearing 1
8-7
Disassembling the differential assembly
New 11
LS
12
M
11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
17
.
LS 10
16 (4)
New LT
LS
New 14 8
New 15
16
13
LS
9 23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
(3) New
New 40 N•m (4.0 kgf•m, 30 lb•ft)
T.R
.
LS
M 18
New
LS
23 N•m (2.3 kgf•m, 17 lb•ft) (5)
T.R
.
New
T.R
.
T.R
.

8 Differential pinion gear assembly 1
9 Differential pinion gear shim Refer to “ADJUSTING THE DIFFEREN-

10 Differential pinion gear housing 1
11 Front drive shaft yoke nut 1
12 Front drive shaft yoke 1
13 Differential pinion gear 1
14 Expander 1
15 Washer 1
16 Bearing 1
17 Bearing 1
18 Differential gear oil filler bolt 1
19 Differential gear oil drain bolt 1
8-8
EBS30239
DISASSEMBLING THE UNIVERSAL JOINTS A B

1. Remove:
• Universal joint 1
a. Remove the circlips “1”
b. Place the universal joint in a press.
c. With a suitable diameter pipe “2” beneath
the universal joint yoke “3”, press the bear-
ing “4” into the pipe as shown.
TIP
It may be necessary to lightly tap the universal A. Wheel side
joint yoke with a punch. B. Differential side
2
1
G101596
G101559
B. Differential side
2. Remove:
• Clip “1”
• Double offset joint “2”
• Circlip “3”
• Ball bearing “4”
• Dust boot “5”
TIP
G101597
Before removing the clip, slide the dust boot
d. Repeat the steps for the opposite bearing. away from the double offset joint.
e. Remove the universal joint.
EBS30240 B
DISASSEMBLING THE FRONT CONSTANT 5
VELOCITY SHAFT ASSEMBLIES
front constant velocity shaft assemblies.
1. Remove: 2
• Boot band “1”
1
TIP
Use a general hand pincer “2”.
8-9
A
B
4
4
3
B. Differential side A. Wheel side
3. Remove: 4. Remove:
• Boot band (outer) “1” • Dust boot
• Boot band (inner) “2” • Constant velocity joint
• Clip
A B TIP
1 2 Secure the constant velocity shaft in a vise, and

then remove the constant velocity joint using
hammers.
A. Wheel side
a. Remove the boot band (outer).
TIP
Remove the boot band using a chisel “3”.
A. Wheel side
A
EBS30241
3 CHECKING THE FRONT CONSTANT
front constant velocity shaft assemblies.
1. Check:
• Double offset joint splines
1 • Constant velocity joint splines
• Constant velocity shaft splines
Wear/damage → Replace.
A. Wheel side
2. Check:
b. Remove the boot band (inner). • Dust boots
TIP Cracks/damage → Replace.
ECB01590
Use a general hand pincer “4”. NOTICE
Always use a new boot band.
3. Check:
• Balls and ball races
• Inner surface of double offset joint
Pitting/wear/damage → Replace.
8-10
EBS30242
• Ball bearing “1”
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. Install the constant velocity joint. B
1
TIP
• Install the clip into the groove in the constant
velocity shaft as shown. 2 New
• Secure the constant velocity joint in a vise, and
then fit the constant velocity shaft into the con-
stant velocity joint using a soft-face hammer.
A G101564
New 1 B
3
3
G101561
4 New
A G101565
3
3. Apply:
• Molybdenum disulfide grease
(into the double offset joint, constant velocity
New 1 joint, and dust boots)
2 Molybdenum disulfide grease

G101562
100–120 g (3.5–4.2 oz) per dust
boot (wheel side)
A 90–110 g (3.2–3.9 oz) per dust
boot (differential side)
TIP
Molybdenum disulfide grease is included in the
repair kit.
4. Install:
G101563 • Boot band “1” New
• Boot band “2” New
A. Wheel side
2. Install:
• Dust boot
8-11
A B A 6
2 New 3 New
1 New
4 New
2
G101598
A. Wheel side A
a. Install the boot band.
TIP
Use a general hand pincer “5”.
G101599
5
A. Wheel side
c. Install the boot band.
TIP
1 a Insert the tips of the boots band installation tool
screw type “6” into the holes on the boot band,
A. Wheel side and turn the handle to compress the boot band.
a. 1.0–4.0 mm (0.039–0.157 in)
Boots band installation tool
b. Install the boot band. screw type
TIP 90890-01554
• Insert the tips of the boots band installation tool Boots band installation tool
screw type “6” into the holes on the boot band, screw type
and turn the handle to compress the boot YM-01554
band.
• Push down on the boots band installation tool B
screw type lever so that the end of the boot
band hooks onto the boot band tabs.

screw type
90890-01554 6
3
screw type G101600
YM-01554
d. Install the boot band “4”.
Use the Oetiker® Compound Action Hand
Installation Pincer “7”.
HIP 2000 414
Item No. 14100414
8-12
EBS30244
B REMOVING THE DIFFERENTIAL GEAR
7 ASSEMBLY
1. Remove:
4 • Differential gear assembly “1”
ECB01570
NOTICE
The ring gear and differential gear are as-
sembled into a proper unit at the factory by
means of specialized equipment. Do not at-
tempt to disassemble this unit. Disassembly
will result in the malfunction of the unit.
5. Check:
• Thrust movement free play
Excessive play → Replace the constant ve- 1
locity shaft assembly.
EBS30245
CHECKING THE FRONT DRIVE SHAFT

G101568
1. Check:
• Drive shaft splines
EBS30243
REMOVING THE FRONT DRIVE SHAFT EWB03040
YOKE WARNING
1. Remove: Do not attempt to straighten a bent shaft;
• Front drive shaft yoke this may dangerously weaken it.
TIP
2. Check:
Use the universal joint holder “1” to hold the front • Spring
drive shaft yoke, then loosen the front drive shaft Damage → Replace.
yoke nut. 3. Check:
• Dust seal
Universal joint holder Cracks/damage → Replace.
90890-04160
Universal joint holder EBS30246
YM-04062 CHECKING THE DIFFERENTIAL ASSEMBLY

1. Check:
• Differential case
8-13
• Differential case cover A
Cracks/damage → Replace. 3V
TIP
When the differential case and/or the differential
case cover are replaced, be sure to adjust the 1
shim of the differential gear assembly.
2. Check: 2
• Gear teeth
Pitting/galling/wear → Replace.
TIP
B
When the differential pinion gear and/or the dif- 3V
ferential assembly are replaced, be sure to ad-
just the shim of the differential gear assembly.
3. Check:
• Bearing
Damage → Replace.
4. Check: 2
• Oil seal 1
• O-ring
Damage → Replace. A. Check that the differential motor pinion gear
“2” turns counterclockwise.
EBS30247 B. Check that the differential motor pinion gear
CHECKING THE DIFFERENTIAL MOTOR “2” turns clockwise.
OPERATION
EBS30249
1. Check:
ASSEMBLING THE DIFFERENTIAL
• Differential motor operation
ASSEMBLY
Does not operate → Replace the differential
1. Install:
motor.
ECB01930 • Oil seal “1” New
NOTICE • Oil seal “2” New
Do not disassemble the differential motor or TIP
remove the differential motor pinion gear. Lubricate the oil seals with lithium-soap-based
a. Connect two C-size batteries to the differ- grease.
ential motor terminals “1” (as shown in the
illustrations). Installed depth of oil seal “a”
ECB01940
1.1–1.9 mm (0.043–0.075 in)
NOTICE
Installed depth of oil seal “b”
• Do not use a 12 V battery to operate the dif- 3.55–4.05 mm (0.1398–0.1594 in)
ferential motor pinion gear.
• Do not connect the batteries to the differen-
tial motor when it is installed in the differen- 3 4
tial case. The differential motor should be a
checked when it is removed from the differ-
ential case. LS
LS
New 1 a 1 New
8-14
Differential pinion gear starting
torque (differential pinion gear
T.
R.
preload)
5 0.8–1.3 N·m (0.08–0.13 kgf·m,
0.59–0.95 lb·ft)
d. If it is smaller than the specified starting

b torque, further tighten the front drive shaft
New 2 LS yoke nut.
e. Repeat steps (c) and (d) until the starting
3. Differential case torque is within specification.
4. Differential case cover TIP
5. Differential pinion gear housing • Increase the torque to tighten the front drive
2. Install: shaft yoke nut gradually.
• Front drive shaft yoke • Be careful not to exceed the specified starting
• Washer torque.
• Front drive shaft yoke nut • If the specified starting torque is exceeded, re-
TIP
place the expander with a new one and reas-
semble the differential pinion gear assembly.
Lubricate the front drive shaft yoke nut with
• Make sure that the distance “a” is the specified
LOCTITE®.
distance.
a. Use the universal joint holder “1” to hold
the front drive shaft yoke.

90890-04160
YM-04062
a
1
a. 75.3–75.9 mm (2.965–2.988 in)
3. Measure:
• Gear backlash
Refer to “MEASURING THE DIFFERENTIAL
GEAR BACKLASH” on page 8-17.
4. Install:
b. Tighten the front drive shaft yoke nut from • Differential motor
a small value within the specified torque a. Slide the shift fork sliding gear “1”, which is
range. installed to the differential case cover, to
the right front constant velocity shaft as-
Front drive shaft yoke nut sembly side as shown in the illustration to
107–195 N·m (11–20 kgf·m, 79– put it into the 2WD mode.
T.
R.
143 lb·ft)
LOCTITE®
c. Secure the differential pinion gear housing

in a vise, and then turn the nut with a
torque wrench to check the starting
torque.
8-15
d. Remove the 6 mm bolts, and then install
the motor with the differential motor bolts.
1
Differential motor bolt
11 N·m (1.1 kgf·m, 8.1 lb·ft)
T.
R.
5. Check:
• Differential assembly operation
M Unsmooth operation → Replace the differen-
tial assembly.
b. Connect two C-size batteries to the differ- TIP
ential motor terminal “2” to operate the dif- Insert the double offset joint into the differential
ferential motor pinion gear “3”. Operate assembly, and turn the gears back and forth.
the differential motor pinion gear until the
mark “a” on the differential motor pinion
gear is aligned with the mark “b” on the dif-
ferential motor case.
ECB01650
NOTICE
Do not use a 12 V battery to operate the dif-
ferential motor pinion gear.
2
b
EBS30250
a ASSEMBLING THE UNIVERSAL JOINT

1. Install:
3 • Universal joint
a. Install the universal joint into the front drive
shaft yoke.
3V
c. Insert 6 mm bolts “4” into the differential
motor “5” and use them as a guide to set
the motor on the differential case cover so
that the shift fork sliding gear does not
move.
ECB01950
NOTICE
If the position of the shift fork sliding gear is G101601
moved, the position of the differential gear b. Install the bearing “1” onto the front drive
assembly and the indicator light display may shaft yoke.
differ, and the 2WD or differential lock mode ECB01670
may not be activated. NOTICE

The needles can easily fall out of their races,
5 so check each bearing carefully. Slide the
universal joint driven yoke assembly back
4 and forth on the bearings. If a needle is out of
4
place, the yoke will not go all the way onto
the bearings.
8-16
G101602
c. Press each bearing into the front drive 4. Measure:

shaft yoke using a suitable socket. • Gear backlash
TIP Out of specification → Refer to “ADJUSTING
The bearing must be inserted far enough into the THE DIFFERENTIAL GEAR BACKLASH” on
universal joint yoke and front drive shaft yoke so page 8-17.
that the circlip can be installed.
Differential gear backlash
d. Install new circlips “2” into the groove of 0.10–0.20 mm (0.004–0.008 in)
each bearing.
a. Make sure the dial gauge plunger contacts
the measuring point “a” on the centerline
of the yoke bearing hole as shown.
G101603
EBS30251
MEASURING THE DIFFERENTIAL GEAR

BACKLASH
1. Secure the differential case in a vise or anoth- b. While gently turning the front drive shaft
er supporting device. yoke back and forth, measure the differen-
2. Remove: tial gear backlash.
• Differential gear oil filler bolt TIP
• Gasket Measure the differential gear backlash at two
3. Install: positions. Rotate the front drive shaft yoke 180°
• Ring gear fix bolt (M14) “1” each time and observe the reading on the dial
(into the filler bolt hole) gauge.
Ring gear fix bolt (M14) EBS30252
90890-01524 ADJUSTING THE DIFFERENTIAL GEAR
Ring gear fix bolt (M14) BACKLASH
YM-01524 1. Remove:
ECB01250 • Differential gear assembly “1”
NOTICE • Differential gear assembly shim (right) “2”
Finger tighten the bolt until it holds the ring • Differential gear assembly shim (left) “3”
gear. Otherwise, the ring gear will be dam-
aged.
8-17
“c” = 75.6 mm (2.98 in)
2 1 Indicate the difference (decimal number),
which is added to or subtracted from
“75.6”, on the differential pinion gear hous-
ing.
ber) on the differential case either added
to or subtracted from “130”
3
2. Adjust:
• Differential gear backlash a
a. Select a suitable shim(s) using the follow- d b
ing chart.
c
Differential gear backlash is
Thinner shim
increased.
Differential gear backlash is A 1
Thicker shim
decreased.
Example:
b. If it is necessary to increase the differential If “-05” is stamped on the differential pinion
gear backlash by more than 0.2 mm gear,
(0.008 in), reduce the differential gear “b” = 30 - 0.05
shim (right) “2” thickness by 0.2 mm = 29.95
(0.008 in) for every 0.2 mm (0.008 in) in-
crease of differential gear shim (left) “3”
thickness.
c. If it is necessary to reduce the differential
gear backlash by more than 0.2 mm
(0.008 in), increase the differential gear
shim (right) “2” thickness by 0.2 mm
(0.008 in) for every 0.2 mm (0.008 in) de-
crease of differential gear shim (left) “3” b
thickness.
“c” = If the measurement value is 75.65
Differential gear shims (right) “2”
mm (2.978 in), indicate “+05” on the differ-
Thickness (mm)
0.25 0.30 0.35 0.40 0.45 0.50 ential pinion gear housing.
Differential gear shims (left) “3”
Thickness (mm)
0.25 0.30 0.35 0.40 0.45 0.50
EBS30825
SELECTING THE DIFFERENTIAL PINION c

GEAR SHIM(S)
1. Select:
• Differential pinion gear shim(s) “1”
a. To find the differential pinion gear shim
thickness “A”, use the following formula. If “-05” is stamped on the differential case,
Differential pinion gear shim thickness “d” = 130 - 0.05
“A” = “c” + (“a” - “b”) - “d” = 129.95
“a” = 85 mm (3.35 in)
“b” = a numeral (usually a decimal num-
ber) on the differential pinion gear either
added to or subtracted from “30”
8-18
e
f
h
g
B
d

“A” = 75.65 + (85 - 29.95) - 129.95
= 0.75
Round off the hundredth digit and select 1
Thus, the shim thickness is 0.75 mm
(0.030 in).
Example:
0, 1, 2 0 If “-05” is stamped on the differential case,
3, 4, 5, 6, 7 5 “e” = 54.3 - 0.05
8, 9 10 = 54.25

nesses.
Differential pinion gear shims

Thickness (mm)
0.25 0.30 0.35 0.40 0.45 0.50
EBS30826
SELECTING THE DIFFERENTIAL GEAR e

SHIM(S)
1. Select: If “-05” is stamped on the differential gear
• Differential gear shim(s) (left) “1” assembly,
a. To find the differential gear shim thickness “f” = 41.3 - 0.05
“B”, use the following formula. = 41.25
Differential gear shim thickness
“B” = “h” - (“e” - “f” + “g”)

ber) on the differential case either added
to or subtracted from “54.3”
“f” = a numeral (usually a decimal number)
on the outside of the differential gear as- f
sembly either added to or subtracted from
“41.3”
“g” = a numeral (usually a decimal num- If “-05” is stamped on the differential gear
ber) on the inside of the differential gear ei- assembly,
ther added to or subtracted from “21.3” “g” = 21.3 - 0.05
“h” = 35.11 mm (1.38 in) = 21.25
8-19
g i
j
C
Therefore, shim thickness “B” is 0.86.

“B” = 35.11 - (54.25 - 41.25 + 21.25)
= 0.86
0, 1, 2 0 Example:
3, 4, 5, 6, 7 5 Shim thickness “C” is 0.88.
8, 9 10 “C” = 37.63 - 36.70 - 0.05
= 0.88
Shims are supplied in the following thick- Round off the hundredth digit and select
nesses. the appropriate shim(s).
Differential gear shims (left) “1” ber is 0.88. The chart instructs you to
Thickness (mm) round off 8 to 10 at the hundredth place.
0.25 0.30 0.35 0.40 0.45 0.50
2. Select: Hundredth Rounded value
• Differential gear shim(s) (right) “1” 0, 1, 2 0
a. To find the differential gear shim thickness
3, 4, 5, 6, 7 5
“C”, use the following formula.
8, 9 10
Differential gear shim thickness
“C” = “i” - “j” - 0.05
“i” = 37.63 mm (1.48 in) nesses.
“j” = 36.70 mm (1.44 in)
Differential gear shims (right) “1”
Thickness (mm)
0.25 0.30 0.35 0.40 0.45 0.50
8-20
EBS30755
CHECKING THE DIFFERENTIAL

OPERATION
1. Block the rear wheels, and elevate the front
wheels by placing a suitable stand under the
frame.
2. Remove the wheel cap from the axle nut
(right or left).
3. Measure the starting torque of the front wheel
(i.e., differential preload) with a torque
wrench.
TIP
• Secure the one side of the front wheel so that
it does not rotate.
• Repeat this step several times to obtain an av-
erage figure.
Front wheel starting torque (differ-

ential gear preload)
T.
R.
New unit
5–20 N·m (0.5–2.0 kgf·m, 3.7–15
lb·ft)
4. Out of specification → Replace the differen-

tial assembly.
5. Within specification → Install the wheel cap.
8-21
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
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
105 N•m (10.5 kgf•m, 77 lb•ft)
T.R
.
New
LS
LS
New
New

Drain.
Final gear oil Refer to “CHANGING THE FINAL GEAR
OIL” on page 3-22.
Rear wheel hubs Refer to “FRONT AND REAR WHEELS” on

page 4-54.
Refer to “REAR STABILIZER, REAR
Rear shock absorber assemblies SHOCK ABSORBER ASSEMBLIES, AND
Rear knuckles Refer to “REAR KNUCKLES” on page

4-103.
8-22
Removing the rear constant velocity shaft assemblies, final drive assembly, and rear drive shaft
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
3
4
4 2
105 N•m (10.5 kgf•m, 77 lb•ft)
T.R
.
1
New
7
6
11
10
LS 9
LS 8
New
5
1
New

1 Rear constant velocity shaft assembly 2
2 Final drive assembly breather hose 1 Disconnect.
3 Rear brake hose protector 1
4 Rear brake hose holder 3
5 Final drive assembly 1
6 Rear drive shaft 1
7 Spring 1
8 Damper 1
9 Rear drive shaft coupling sleeve 1
10 Dust seal 1
11 Dust seal 1
8-23
Disassembling the rear constant velocity shaft assemblies
4
M
5 New
6
B 3 New
New 2
7
New 1
14
New 8
10
13 New
New 9
11
12
M
A
A: Wheel side
B: Final drive side

the rear constant velocity shaft assemblies.
1 Boot band 1
2 Boot band 1
3 Clip 1
4 Double offset joint 1
5 Clip 1
6 Ball bearing 1
7 Dust boot 1
8 Boot band 1
9 Boot band 1
10 Dust boot 1
11 Constant velocity joint 1
12 Ball bearing 1
13 Clip 1
14 Constant velocity shaft 1
8-24
Disassembling the final drive assembly
LS New 23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
New New
T.R
.
20 N•m (2.0 kgf•m, 15 lb•ft)
New
LS
2 4
7
* 5
6
LS 3
7 *
10
9
8 * *
New
(4)
* New
LS
1 New
(6)
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
43 N•m (4.3 kgf•m, 32 lb•ft) LT

T.R
.
90 N•m (9.0 kgf•m, 66 lb•ft) LT New

T.R
.
LS
90 N•m (9.0 kgf•m, 66 lb•ft)
T.R
.
LT
43 N•m (4.3 kgf•m, 32 lb•ft)
T.R
.
* Apply SAE 80W-90 API GL-5 Hypoid gear oil.

1 Rear drive shaft coupling gear 1
2 Final drive pinion gear assembly 1
3 Final drive pinion gear shim
4 Final drive pinion gear 1
5 Expander 1
6 Washer 1
7 Bearing 1
8 Oil seal 1
9 Bearing 1
10 Final drive pinion gear bearing housing 1
8-25
Disassembling the final drive assembly
LS 19 New 23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
22
New New
20 N•m (2.0 kgf•m, 15 lb•ft)
T.R
.
23 21
New
LS
*
LS
*
* 20
*
14
New
(4)
* New
13
11
12 17
18
LS
New
15
(6)
9 N•m (0.9 kgf•m, 6.6 lb•ft) 16
T.R
.
43 N•m (4.3 kgf•m, 32 lb•ft) LT

T.R
.
90 N•m (9.0 kgf•m, 66 lb•ft) LT New

T.R
.
LS
90 N•m (9.0 kgf•m, 66 lb•ft)
T.R
.
LT
43 N•m (4.3 kgf•m, 32 lb•ft)
T.R
.
* Apply SAE 80W-90 API GL-5 Hypoid gear oil.

11 Final drive case cover 1
Final drive ring gear shim (final drive case cover Refer to “ADJUSTING THE FINAL GEAR
12 side) BACKLASH” on page 8-37.
13 Final drive ring gear 1
Refer to “ADJUSTING THE FINAL GEAR
14 Final drive ring gear shim (final drive case side) BACKLASH” on page 8-37.
15 Ring gear stopper 1
Refer to “ADJUSTING THE FINAL GEAR
16 Ring gear stopper shim BACKLASH” on page 8-37.
17 Oil seal 1
18 Bearing 1
19 Oil seal 1
20 Bearing 1
21 Final drive case 1
22 Final gear oil filler bolt 1
23 Final gear oil drain bolt 1
8-26
EBS30253
DISASSEMBLING THE REAR CONSTANT B

VELOCITY SHAFT ASSEMBLIES 5
rear constant velocity shaft assemblies.
1. Remove:
• Boot band “1” 2
TIP
1
Remove each boot band with a general hand
pincer “2”.
A B B
4
1
3
A. Wheel side B. Final drive side

B. Final drive side
3. Remove:
• Boot band (inner) “1”
B • Boot band (outer) “2”
TIP
2 Remove the boot bands “1” and “2” with a gen-
eral hand pincer “3”.
A B
1 2
1
B. Final drive side

2. Remove:
• Clip “1”
• Double offset joint “2”
• Circlip “3”
• Ball bearing “4” A. Wheel side
• Dust boot “5” B. Final drive side
TIP
Before removing the clip, slide the dust boot A
away from the double offset joint.
3
8-27
EBS30254
A CHECKING THE REAR CONSTANT

3 The following procedure applies to both of the
1. Check:
2 • Double offset joint splines
• Constant velocity joint splines
• Constant velocity shaft splines
2. Check:
A. Wheel side • Dust boot
4. Remove: Cracks/damage → Replace.
ECB01590
• Dust boot NOTICE
• Constant velocity joint
Always use a new boot band.
• Clip
TIP 3. Check:
Secure the constant velocity shaft in a vise, and • Balls and ball races
then remove the constant velocity joint using • Inner surface of double offset joint
hammers. Pitting/wear/damage → Replace.
EBS30255
A ASSEMBLING THE REAR CONSTANT

1. Install:
• Clip “1” New
• Constant velocity joint “2”
• Constant velocity shaft “3”
• Dust boot
A. Wheel side a. Install a new clip.
b. Install the constant velocity joint.
5. Remove: TIP
• Dust boot
• Install the clip into the groove in the constant
• Double offset joint
velocity shaft as shown.
• Clip
• Secure the constant velocity joint in a vise, and
TIP then fit the constant velocity shaft into the con-
Secure the constant velocity shaft in a vise, and stant velocity joint using a soft-face hammer.
then remove the double offset joint using ham-
mers. A
New 1
B
G101561
B. Final drive side
8-28
A B
3
3
New 1
4 New
2
G101562 G101565
B. Final drive side

A
3. Apply:
• Molybdenum disulfide grease
(into the double offset joint, constant velocity
joint, and dust boots)
Molybdenum disulfide grease

70 g (2.5 oz) per dust boot
(wheel side)
G101563
170 g (6.0 oz) per dust boot (fi-
A. Wheel side nal drive side)
2. Install: TIP
• Dust boot Molybdenum disulfide grease is included in the
• Ball bearing “1” repair kit.
• Double offset joint “3” 4. Install:
• Clip “4” New • Boot band “1” New
TIP • Boot band “2” New
• Securely install the circlip into the groove in the • Boot band “3” New
constant velocity shaft. • Boot band “4” New
• Securely install the clip into the groove in the
double offset joint. A B
1 New 2 New 3 New
B 4 New
1
2 New
A. Wheel side
G101564 B. Final drive side
a. Install the boot band “1”.
HIP 2000 414
Item No. 14100414
8-29
HIP 7000 425
Item No. 14100425
A
5
B
1
6
A. Wheel side 3 b
b. Install the boot band “2”.
Use the Oetiker® Compound Action Hand B
Installation Pincer “6”. 6
HIP 7000 425
Item No. 14100425 4
B. Final drive side

b. 3.0 mm (0.12 in)
5. Check:
• Thrust movement free play
Excessive play → Replace the constant ve-
A
locity shaft assembly.
6
2 a
A. Wheel side
G101568
a. 3.0 mm (0.12 in)
c. Install the boot bands “3” and “4”.
8-30
EBS30256 EBS30257
DISASSEMBLING THE FINAL DRIVE PINION CHECKING THE REAR DRIVE SHAFT
GEAR ASSEMBLY 1. Check:
1. Remove: • Drive shaft splines
• Rear drive shaft coupling gear nut • Coupling sleeve splines
• Washer Wear/damage → Replace.
• Rear drive shaft coupling gear “1” • Dust seal
TIP Cracks/damage → Replace.
EWB03040
• Secure the final drive assembly in a vise. WARNING
• Use the coupling gear holding tool “2” to hold
Do not attempt to straighten a bent shaft;
the rear drive shaft coupling gear.
this may dangerously weaken it.
Coupling gear holding tool (ø46) EBS30258

90890-04191 CHECKING THE FINAL DRIVE ASSEMBLY
Coupling gear holding tool (ø46) 1. Check:
YM-04191 • Final drive case
• Final drive case cover
1 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.
2. Check:
2 • Gear teeth
Pitting/galling/wear → Replace the final drive
2. Remove: pinion gear and ring gear as a set.
• Final drive pinion gear “1” TIP
a. Clean the outside surface of the final drive
When the final drive pinion gear and ring gear
pinion gear.
are replaced, be sure to adjust the shim of the fi-
b. Place the final drive gear in a hydraulic
nal drive pinion gear and/or ring gear.
press.
ECB01580
3. Check:
NOTICE • Bearing
• Never directly press the gear end with a hy- Damage → Replace.
draulic press, this will result in damage to
EBS30410
the gear thread.
ASSEMBLING THE FINAL DRIVE CASE
• Install the suitable socket on the gear end
1. Install:
to protect the thread from damage.
• Oil seals “1”
c. Press the gear end and remove the final
drive pinion gear. Installed depth of oil seal “a”
0.55–1.15 mm (0.03–0.05 in)
2
a a
1 1
1
2. Suitable socket
8-31
EBS30262
c. Secure the final drive pinion gear housing
ASSEMBLING THE FINAL DRIVE PINION
in a vise, and then turn the nut with a
GEAR ASSEMBLY
torque wrench to check the starting
1. Install:
torque.
• Final drive pinion gear housing
• Bearing Final drive pinion gear starting
• Oil seal “1” New torque (final drive pinion gear
TIP preload)
0.5–0.8 N·m
Lubricate the oil seals with lithium-soap-based
grease. d. If it is smaller than the specified starting
torque, further tighten the rear drive shaft
Installed depth of oil seal “a” coupling gear nut.
3.55–4.15 mm (0.140–0.163 in) TIP
• Increase the torque to tighten the rear drive
shaft coupling gear nut gradually.
• Be careful not to exceed the specified starting
a torque.
• If the specified starting torque is exceeded, re-
place the expander with a new one and reas-
semble the final drive pinion gear assembly.
• Make sure that the distance “a” is the specified
distance.
2. Install:
• Washers
• Expander New
• Final drive pinion gear
• Rear drive shaft coupling gear
• Washer
• Rear drive shaft coupling gear nut
a. Use the coupling gear holding tool “1” to a
hold the rear drive shaft coupling gear “2”.
a. 82.52–83.00 mm (3.249–3.268 in)
Coupling gear holding tool (ø46)
90890-04191 EBS30413
Coupling gear holding tool (ø46) SELECTING THE FINAL DRIVE PINION
YM-04191 GEAR SHIM(S)
1. Select:
b. Tighten the rear drive shaft coupling gear • Final drive pinion gear shim(s)
nut “3”. a. To find the final drive pinion gear stopper
(temporarily) shim thickness “A”, use the following for-
mula.
Final drive pinion gear shim(s)
“A” = “a” + (“c” - “b”) - “d” - 0.1
3 “a” = 91.5 mm (3.60 in)

1 “b” = a numeral (usually a decimal num-
ber) on the final drive pinion gear either
2 added to or subtracted from “35.7”
“c” = 82.8 mm (3.26 in)
8-32
Indicate the difference (decimal number),
which is added to or subtracted from
“82.8”, on the final drive pinion gear bear-
ing housing.
ber) on the final drive case either added to
or subtracted from “138”
d

“A” = 91.5 + (82.85 – 35.65) - 137.95 - 0.1
= 0.65
b
c the appropriate shim(s).
a In the example above, the calculated num-
d A ber is 0.65. The chart instructs you to
Example: round off 5 to 5 at the hundredth place.
If “-05” is stamped on the final drive pinion Thus, the shim thickness is 0.65 mm
gear, (0.026 in).
“b” = 35.7 - 0.05 Hundredth Rounded value
= 35.65
0, 1, 2 0
3, 4, 5, 6, 7 5
8, 9 10

nesses.
Final drive pinion gear shims

b Thickness (mm)
0.25 0.30 0.35 0.40 0.45 0.50
“c” = If the measurement value is 82.85 EBS30980
mm (3.262 in), indicate “+05” on final drive SELECTING THE FINAL DRIVE RING GEAR
pinion gear bearing housing. SHIM(S) (FINAL DRIVE CASE COVER SIDE)
1. Select:
• Final drive ring gear shim(s) (final drive case
cover side)
a. To find the final drive ring gear shim (final
drive case cover side) thickness “B”, use
the following formula.
Final drive ring gear shim(s) (final drive case cov-
er side)
c “B” = “e” + “f” - (“g” + “h”)
If “-05” is stamped on the final drive case, “e” = a numeral (usually a decimal num-
“d” = 138 - 0.05 ber) on the final drive case either added to
= 137.95 or subtracted from “53.3”
“f” = a numeral (usually a decimal number)
on the final drive case cover either added
to or subtracted from “1.6”
8-33
“g” = a numeral (usually a decimal num-
ber) on the final drive ring gear either add-
ed to or subtracted from “40.5”
“h” = 14 mm (0.55 in)
If “-05” is stamped on the final drive ring

gear,
“g” = 40.5 - 0.05
= 40.45
Therefore, “B” is 0.45.

“B” = 53.25 + 1.65 - (40.45 + 14)
= 0.45
B g round off 5 to 5 at the hundredth place.
h Thus, the shim thickness is 0.45 mm
(0.018 in).
f e
Example: 0, 1, 2 0
If “-05” is stamped on the final drive case, 3, 4, 5, 6, 7 5
“e” = 53.3 - 0.05 8, 9 10
= 53.25
nesses.
Final drive ring gear shims (final

drive case cover side)
Thickness (mm)
0.25 0.30 0.35 0.40 0.45 0.50
e EBS30981
SELECTING THE FINAL DRIVE RING GEAR

SHIM(S) (FINAL DRIVE CASE SIDE)
If “.65” is stamped on the final drive case 1. Measure:
cover, • Distance “j”: from the end of the final drive
“f” = 1.65 case to the top of the bearing
8-34
C
l
j
k j
TIP Example:
• Install the bearing to the final drive case and j = 112.7
measure. k = 111
• Place straightedge “l” on the two ends of the fi- Therefore, “C” is 1.5.
nal drive case, and measure the distance “j” “C” = 112.7 – 111 – 0.2 = 1.5
from straightedge “l” to the top of the bearing Round off the hundredth digit and select
vertically. the appropriate shim(s).
2. Measure: ber is 1.5. The chart instructs you to round
• Distance “k”: from the end of the final drive off 5 to 5 at the hundredth place. Thus, the
case cover to the stepped section of the final shim thickness is 1.5 mm (0.018 in).
drive ring gear
0, 1, 2, 3, 4 0
5, 6, 7, 8, 9 10

k
nesses.

drive case side)
Thickness (mm)
1.1 1.2 1.3 1.4 1.5 1.6 1.7
TIP
Install the ring gear stopper, ring gear stopper EBS30982
shim, bearing and final drive ring gear to the final SELECTING THE FINAL DRIVE RING GEAR
drive case cover. STOPPER THRUST SHIM(S)
1. Measure:
3. Select: • Ring gear stopper thrust clearance “n”
• Final drive ring gear stopper shim(s) (final
drive case side)
a. To find the final drive ring gear stopper
shim (final drive case side) thickness “C”,
use the following formula.
Final drive ring gear stopper shim(s) (final drive n
case side)
“C” = “j” - “k” - 0.2
“j” = measured value (step1)

“k” = measured value (step2)
2. Select:
• Final drive ring gear stopper thrust shim(s)
a. To find the ring gear stopper shim thrust
thickness “D”, use the following formula.
8-35
Ring gear stopper thrust shim(s)
“D” = “e” - (“g” + “m” + “n” + “0.45”) + p

ber) on the final drive case either added to
or subtracted from “53.3”
“g” = a numeral (usually a decimal num-
ber) on the final drive ring gear either add-
ed to or subtracted from “40.5” e
“m” = a numeral (usually a decimal num-
ber) on the final drive case cover either If “-05” is stamped on the ring gear,
added to or subtracted from “10.35” “g” = 40.5 - 0.05
“n” = measured value (step1) = 40.45
“p” = 1.0 mm (0.0394 in)
m
If “.45” is stamped on the final drive case
cover,
D n “m” = 10.35 + 0.1
p = 10.45
Measured value “n” = 2.55

Therefore, “D” is 0.35.
“D” = 53.25 - (40.45 + 10.45 + 2.55 + 0.45)
+ 1.0
= 0.35
g the appropriate shim(s).
e In the example above, the calculated num-
Example:
If “-05” is stamped on the final drive case,
Thus, the shim thickness is 0.35 mm
“e” = 53.3 - 0.05
(0.018 in).
= 53.25
8-36
0, 1, 2 0
3, 4, 5, 6, 7 5 2
8, 9 10
1
nesses.
Ring gear stopper thrust shims a

Thickness (mm)
0.10 0.15 0.20 0.30 0.40 0.50 a. Measuring point is 24.1 mm (0.94 in)
4. Measure:
EBS30260
• Gear backlash
MEASURING THE FINAL GEAR BACKLASH
Gently rotate the final drive pinion gear from
1. Remove:
engagement to engagement.
• Final gear oil filler bolt
• Gasket Final gear backlash
2. Install: 0.05–0.30 mm (0.002–0.012 in)
• Ring gear fix bolt (M10 × 1.5) “1”
(into the filler bolt hole) TIP
Ring gear fix bolt (M14) Measure the gear backlash at four positions. Ro-
90890-01524 tate the final drive pinion gear 90° each time.
Ring gear fix bolt (M14)
YM-01524 EBS30261
ADJUSTING THE FINAL GEAR BACKLASH

ECB01250 1. Remove:
NOTICE • Final drive ring gear “1”
Finger tighten the bolt until it holds the ring • Final drive ring gear shim (final drive case
gear. Otherwise, the ring gear will be dam- cover side) “2”
aged. • Final drive ring gear shim (final drive case
side) “3”
1 3
1
2
3. Attach:
2. Adjust:
• Gear lash measurement tool “1”
• Gear backlash
• Dial gauge “2”
a. Select a suitable shim(s) using the follow-
Final gear backlash band ing chart.
90890-01511 Final gear backlash is in-
Thinner shim
Middle drive gear lash tool creased.
YM-01230 Final gear backlash is de-
Thicker shim
creased.
b. If increased by more than 0.2 mm (0.008

in):
8-37
Reduce the final drive ring gear shim (final
drive case cover side) “2” thickness by 0.2
mm (0.008 in) for every 0.2 mm (0.008 in)
that the final drive ring gear shim (final
drive case side) “3” is increased.
c. If reduced by more than 0.2 mm (0.008 in):
Increase the final drive ring gear shim (fi-
nal drive case cover side) “2” thickness by
0.2 mm (0.008 in) for every 0.2 mm (0.008
in) that the final drive ring gear shim (final
drive case side) “3” is decreased.

drive case cover side) “2”
Thickness (mm)
0.25 0.30 0.35 0.40 0.45 0.50
TIP
Be sure to use one of each of the final drive ring
gear shim (final drive case cover side) “2” and fi-
nal drive ring gear shim (final drive case side) “3”
to obtain the shim thickness.

drive case side) “3”
Thickness (mm)
1.1 1.2 1.3 1.4 1.5 1.6 1.7
8-38
8-39
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 9-1

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

CIRCUIT DIAGRAM .................................................................................. 9-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......................... 9-7
TROUBLESHOOTING .............................................................................. 9-8
CHARGING SYSTEM....................................................................................9-10
CIRCUIT DIAGRAM ................................................................................9-10
TROUBLESHOOTING ............................................................................ 9-11
LIGHTING SYSTEM ......................................................................................9-13

CIRCUIT DIAGRAM (YXF10WRAN) .......................................................9-13
CIRCUIT DIAGRAM (YXF10WRZN/YXF10WRLN) ................................ 9-15
SIGNALING SYSTEM ...................................................................................9-19

CIRCUIT DIAGRAM (YXF10WRAN) .......................................................9-19
CIRCUIT DIAGRAM (YXF10WRZN/YXF10WRLN) ................................ 9-21
COOLING SYSTEM....................................................................................... 9-37

CIRCUIT DIAGRAM ................................................................................9-37
FUEL INJECTION SYSTEM.......................................................................... 9-41

CIRCUIT DIAGRAM ................................................................................9-41
ECU SELF-DIAGNOSTIC FUNCTION ....................................................9-43
TROUBLESHOOTING METHOD ............................................................9-43
YAMAHA DIAGNOSTIC TOOL ...............................................................9-44
TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM) ............ 9-45
FUEL PUMP SYSTEM...................................................................................9-73

CIRCUIT DIAGRAM ................................................................................9-73
2WD/4WD SELECTING SYSTEM................................................................. 9-77

9
CIRCUIT DIAGRAM ................................................................................9-77
EPS (ELECTRIC POWER STEERING) SYSTEM.........................................9-81
CIRCUIT DIAGRAM ................................................................................9-81
EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION ..................... 9-83
DIAGNOSTIC MODE ..............................................................................9-83
SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)......................9-84
TROUBLESHOOTING DETAILS (EPS SYSTEM) .................................. 9-85
SPEED MANAGEMENT SYSTEM ................................................................9-91

CIRCUIT DIAGRAM ................................................................................9-91
SPEED MANAGEMENT SYSTEM ..........................................................9-93
GPS SYSTEM (YXF10WRZN/YXF10WRLN)................................................9-99

CIRCUIT DIAGRAM ................................................................................9-99
TROUBLESHOOTING .......................................................................... 9-102
ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM

(YXF10WRLN) ............................................................................................9-103
CIRCUIT DIAGRAM ..............................................................................9-103
SCU (Suspension Control Unit) SELF-DIAGNOSTIC FUNCTION........9-106
DIAGNOSTIC MODE ............................................................................9-106
SELF-DIAGNOSTIC FUNCTION TABLE (ELECTRONICALLY
ADJUSTABLE SUSPENSION SYSTEM) .............................................9-107
TROUBLESHOOTING DETAILS (ELECTRONICALLY
ADJUSTABLE SUSPENSION SYSTEM) .............................................9-108
WINCH SYSTEM (YXF10WRZN/YXF10WRLN) ......................................... 9-117

CIRCUIT DIAGRAM ..............................................................................9-117
TROUBLESHOOTING .......................................................................... 9-119
ELECTRICAL COMPONENTS....................................................................9-120
CHECKING THE SWITCHES (YXF10WRAN) ......................................9-123
CHECKING THE SWITCHES (YXF10WRZN/YXF10WRLN)................9-124
ADJUSTING THE HEADLIGHT BEAMS ...............................................9-125
CHECKING THE FUSES ......................................................................9-125
CHECKING AND CHARGING THE BATTERY .....................................9-126
CHECKING THE RELAYS ....................................................................9-126
CHECKING THE IGNITION COILS.......................................................9-129
CHECKING THE IGNITION SPARK GAP.............................................9-130
CHECKING THE CRANKSHAFT POSITION SENSOR........................9-130
CHECKING THE LEAN ANGLE SENSOR............................................9-130
CHECKING THE STARTER MOTOR OPERATION .............................9-131
CHECKING THE STATOR COIL ..........................................................9-131
CHECKING THE RECTIFIER/REGULATOR ........................................9-132
CHECKING THE OIL PRESSURE SWITCH......................................... 9-132
CHECKING THE FUEL SENDER .........................................................9-133
CHECKING THE FUEL METER/FUEL LEVEL WARNING LIGHT .......9-133
CHECKING THE BUZZER ....................................................................9-133
CHECKING THE RADIATOR FAN MOTOR ......................................... 9-134
CHECKING THE RADIATOR FAN MOTOR CIRCUIT BREAKER .......9-134
CHECKING THE COOLANT TEMPERATURE SENSOR..................... 9-134
CHECKING THE THROTTLE SERVO MOTOR ...................................9-135
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ..................9-135
CHECKING THE FUEL INJECTOR ...................................................... 9-136
CHECKING THE AIR INDUCTION SYSTEM SOLENOID ....................9-136
CHECKING THE USB CONVERTER (YXF10WRZN/YXF10WRLN)....9-137
CHECKING THE WINCH CONTACTOR
(YXF10WRZN/YXF10WRLN) ............................................................... 9-137
CHECKING THE DIFFERENTIAL MOTOR POSITION SWITCH .........9-137
CHECKING THE EPS MOTOR .............................................................9-138
CHECKING THE EPS TORQUE SENSOR........................................... 9-138
EBS30264
EBS20074
B B
A B
Lg/B Y/G L B/L W L B G/W Br Sb L/W O/L R/Y Y/W B/W Y/R R/G
Lg/R Gy P/B B/L W L R/L B/W P L/R Y/L P/W Y/G Y/B B B O Br
B W/Y B/R W/B W/R Gy/G Y/W B/L Sb/W R Y R/L B/G Br/R Br/Y
(B)
G/R L/W W/Y L/Y R Br/W G/Y R/W L/B Gy/G G/B R/B P/B O Gy/R
(B) (B) Br
B/L Gy
Gy B/L 48
O O
B Gy Gy/R
Gy B Br 50
CIRCUIT DIAGRAM
1
Br
49
Gy/R
50
IGNITION SYSTEM
Gy/R Br
(B)
Br
Br
Br L L Y/G B/L
Br
34 Y/G Y/G 45
B/L
(Gy)
L
14
R R
R
R
R
B
B B R
B B B/L
B
B
B/W
12 15 B/W
R/B
B/L
B/L
13 B A B B B
B/L
OFF
B
ON
START
R
R 16
Br
Br R/B
L/W Br
9-1
(B)
B/W B
B B/W B
R R/B
94
L L
G/Y G/Y G/Y R/WR/W R/W

53 G G L/G L/G G L L Y/L L L/W L/W L/W
IGNITION SYSTEM
IGNITION SYSTEM
1. Crankshaft position sensor

12.Frame ground
13.Main switch
14.Main fuse
15.Battery
16.Engine ground
34.ECU (Engine Control Unit)
45.Lean angle sensor
48.Ignition coil #1
49.Ignition coil #2
50.Spark plug
53.Joint coupler
94.Ignition fuse
A. Wire harness
B. Negative battery sub-wire harness 1
9-2
IGNITION SYSTEM
EBS30265
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Hood
2. Front cover
3. Rear floor board (right)
4. Front floor board (right)
1. Check the fuses. NG →

(Main and ignition)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 9-125.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 9-126.
OK ↓
3. Check the spark plug. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug.
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 9-130.
NG ↓
5. Check the ignition coil. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coil.
TION COILS” on page 9-129.
OK ↓
6. Check the crankshaft position sen- NG →
sor.
Replace the crankshaft position sensor/
Refer to “CHECKING THE CRANK-
stator assembly.
SHAFT POSITION SENSOR” on
page 9-130.
OK ↓
7. Check the main switch. NG →
Refer to “CHECKING THE
SWITCHES (YXF10WRAN)” on
Replace the main switch.
page 9-123 or “CHECKING THE
SWITCHES (YXF10WRZN/
YXF10WRLN)” on page 9-124.
OK ↓
9-3
IGNITION SYSTEM
8. Check the lean angle sensor. NG →

Refer to “CHECKING THE LEAN Replace the lean angle sensor.
ANGLE SENSOR” on page 9-130.
OK ↓
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 B
A B
Lg/R Gy P/B B/L W L R/L B/W P L/R Y/L P/W Y/G Y/B B B
(B) (B)
Br
CIRCUIT DIAGRAM
Br Br
Br 34
Br
Br
R
Y/L
11 14
R R R/Y
R
Br/L B R L/W
R Sb
B
B
B B R R R Br/R
B B
R/Y L/W B
B
ELECTRIC STARTING SYSTEM
(B) B/W
12 B/W Sb
15 L/W
L W Gy
R/B Br 19 R/Y
B A B B
41
13 B B
OFF L W
B
R ON
Gy
START
R 20 (B)
R 16
Br L/W
Br R/B W/R Sb
L/W Br Gy/G
9-5
(B)
(B)
Br/L
Br/L
B/W B
B B/W B
Br/Y
92
53
Y/L Y Br Br/Y
R R/B Y/L
Y/L
94 52 Br Y Y/L Br/Y
Br/Y
Br/Y
L/W
L/W L/W Y/L Y/L Y/L Y/L Lg/RLg/R Lg/BLg/B
Br/Y Br/Y Br/Y Br/Y
(B)
B B
11.Load control relay

12.Frame ground
13.Main switch
14.Main fuse
15.Battery
16.Engine ground
19.Starter relay
20.Starter motor
41.Gear position switch
52.Brake light switch
53.Joint coupler
92.Signaling system fuse
94.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 circuit of the gear position switch is closed).
• The brake pedal is applied (the brake light switch is closed).
11
10
8
4
1. Battery
2. Main fuse
3. Ignition fuse
4. Main switch
5. ECU (Engine Control Unit)
6. Gear position switch
8. Signaling system fuse
9. Brake light switch
10. Starter relay
11. Starter motor
9-7
EBS30268
TROUBLESHOOTING
The starter motor fails to turn.
TIP
1. Hood
2. Front cover
3. Center cover
4. Air intake accumulator assembly

(Main, ignition and signaling sys-
tem) Replace the fuse(s).
OK ↓
page 9-126.
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.
9-131.
NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-53.
OK ↓
5. Check the starter relay. NG →
Refer to “CHECKING THE RE- Replace the starter relay.
LAYS” on page 9-126.
OK ↓
OK ↓
9-8
7. Check the gear position switch. NG →

Replace the gear position switch.
OK ↓
8. Check the brake light switch. NG →
Replace the brake light switch.
OK ↓
9. Check the load control relay. NG →
Refer to “CHECKING THE RE- Replace the load control relay.
OK ↓
10.Check the entire starting system NG →
page 9-5.
OK ↓
Replace the ECU.
9-9
CHARGING SYSTEM
EBS20076
CHARGING SYSTEM
EBS30269
CIRCUIT DIAGRAM
B
B
A
A
B
B
R
16
15
B
R
R
14
B A B
R
B
R
(B)
R
B
3
B
R
W W W
R
(Gy)
W
W
W
(Gy)
W
W
B
(Gy)
W
W
(Gy)
W
2. AC magneto
3. Rectifier/regulator
14.Main fuse
15.Battery
16.Engine ground
A. Wire harness
9-10
CHARGING SYSTEM
EBS30270
TROUBLESHOOTING
The battery is not being charged.
TIP
1. Hood
1. Check the fuse. NG →

(Main)
Replace the fuse.
OK ↓
page 9-126.
OK ↓
3. Check the stator coil. NG →
Replace the crankshaft position sensor/
Refer to “CHECKING THE STATOR
stator assembly.
COIL” on page 9-131.
OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI-
Replace the rectifier/regulator.
FIER/REGULATOR” on page
9-132.
OK ↓
5. Check the entire charging system NG →
page 9-10.
OK ↓
The charging system circuit is OK.
9-11
CHARGING SYSTEM
9-12
EBS30271
EBS20077
B B
A B
LIGHTING SYSTEM
Br
Br
Br
R
11 R
14
R R
CIRCUIT DIAGRAM (YXF10WRAN)
Br/L R
Br/L B Br B R
R
B
B B B R
B B
12 15
R/B
13 B A B B B
OFF
B
ON
R
START
R
R 16
Br
Br R/B
L/W Br
(B)
9-13
Br/L
Br/L Br
90 Br
Br Br
Br
Br
Br/Y
Br Br
92
B
78 OFF 53
LO
B HI
R R/B Y Br Br Y
B G L
94 B L 59
Br/Y
G/Y GY Br/Y
Br
G/Y
G/Y 62
L/G G
G G L/G Y/L Y/L Y/L Y/L Lg/RLg/R Lg/BLg/B
G/Y
Br/Y Br/Y Br/Y Br/Y
(B)
G/Y
G/Y G/Y
G/Y
L
L/G L/G
Y G Y G
79
86 L R 83 L R L B B G/Y
82 81 82 81
G/Y B Y
87 84 L
Y G G Y Y G G Y 80 Br/Y
B B B B B/W
L B B G/Y
Y/L L/G L R Y/L L/G L R B B
B B B B B
B B
R/W Br/Y B/W Y G
Sb/W Lg/R Lg/B
Y
Y Y (B)
B B B Y
B B B B B B B/W
LIGHTING SYSTEM
LIGHTING SYSTEM

12.Frame ground
13.Main switch
14.Main fuse
15.Battery
16.Engine ground
53.Joint coupler
59.Meter assembly
62.High beam indicator light
78.Light switch
79.Auxiliary light (right)
80.Auxiliary light (left)
81.Headlight (low beam)
82.Headlight (high beam)
83.Tail/brake light assembly (right)
84.Tail/brake light (right)
86.Tail/brake light assembly (left)
87.Tail/brake light (left)
90.Headlight fuse
94.Ignition fuse
A. Wire harness
9-14
EBS30277
B B
A B
Br
Br
Br
R
11 R
14
R R
Br/L R
Br/L B Br B R
R
B
B B B R
B B
12 15
R/B
13 B A B B B
OFF
B
ON
R
START
R
R 16
Br
CIRCUIT DIAGRAM (YXF10WRZN/YXF10WRLN)
Br R/B
L/W Br
(B)
9-15
Br/L
Br/L Br
90
Br
Br Br
Br
Br/Y
Br Br
92 Br
B 78 OFF 53
B LO
B HI
R R/B B Y Br Br Y B Br Br/Y
G L Br/Y
94 L (B)
59 Br/Y
G/Y Br/Y
Br Br/Y
GY B
G/Y Br B
(B)
62
L/G G
G G L/G Y/L Y/L Y/L Y/L Lg/RLg/RLg/R Lg/BLg/B Lg/B
Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
G/Y G/Y G/Y R/WR/W R/W 107
(B)
G/Y Br/Y R/Y B
G/Y G/Y
B R/Y Br/Y B
G/Y
L
L/G L/G
Y G Y G
79
108
86 L R 83 L R L B B G/Y
82 81 82 81 Br/Y R/Y B
G/Y B Y
B R/Y Br/Y B
87 84 L
Y G G Y Y G G Y 80 Br/Y
B B B B
L B B G/Y B/W 109
B B B B B Br/Y R/Y B
B B B R/Y Br/Y B
R/W Br/Y B/W Y G
Sb/W Lg/R Lg/B
Y
Y Y (B)
B B B B B Y
B B B B B B B B/W B
LIGHTING SYSTEM
LIGHTING SYSTEM

12.Frame ground
13.Main switch
14.Main fuse
15.Battery
16.Engine ground
53.Joint coupler
59.Meter assembly
62.High beam indicator light
78.Light switch
79.Auxiliary light (right)
80.Auxiliary light (left)
81.Headlight (low beam)
82.Headlight (high beam)
90.Headlight fuse
94.Ignition fuse
107.Interior light (left)
108.Interior light (center)
109.Interior light (right)
A. Wire harness
9-16
LIGHTING SYSTEM
EBS30272
TROUBLESHOOTING
Any of the following fail to light: headlight, high beam indicator light, auxiliary light, interior light
(YXF10WRZN/YXF10WRLN) or taillight.
TIP
1. Hood
2. Front cover

(Main, ignition, signaling system
and headlight) Replace the fuse(s).
OK ↓
page 9-126.
OK ↓
OK ↓
4. Check the light switch. NG →
Replace the light switch.
OK ↓
OK ↓
9-17
LIGHTING SYSTEM
6. Check the entire lighting system NG →

wiring.
Refer to “CIRCUIT DIAGRAM
Properly connect or replace the wire har-
(YXF10WRAN)” on page 9-13 or
ness.
“CIRCUIT DIAGRAM
(YXF10WRZN/YXF10WRLN)” on
page 9-15.
OK ↓
Replace the meter assembly, head-
light, auxiliary light, interior light
(YXF10WRZN/YXF10WRLN) or tail/
brake light assembly.
9-18
EBS30352
EBS20078
B B
A B
G/R L/Y R Br/W G/Y R/W L/B Gy/G G/B R/B P/B O Gy/R
(B) (B)
B/L Gy
Gy B/L
B Gy
Gy B Br
P P
1 Br/Y Br
44 P Br Br/Y P
(Gy) (Gy)
G/Y B/L
SIGNALING SYSTEM
38 (B)
Br Br G/Y G/Y B/L
Br
34
Br L L
R W/Y W/Y L W/Y B/L
Y/L B/L
46
Sb/W (Db)
14 L/B
11 R R
R R
CIRCUIT DIAGRAM (YXF10WRAN)
Br/L R
Br/L B Br B R Gy/G
W/R
R Sb
G/W
B B
B B B W/B
R B/R
B B B/L G
L/Y
G/R B
B W/R R
B/W G/W Br/Y Br/Y G/W
12 L/Y G/R Lg/R B/W Sb Gy/G
W/B Lg/B G/W G/W
15 L Br/Y (B)
Br/B B/R 42
L/W L W Gy
R/B 32 B/L
L B
2WD-LOCK 41 B/L
13 B A B B B
28 4WD-DIFF GG
51
4WD-LOCK B B/L
R B B/L
OFF L W
B
ON L/W G/R L/B Br/Y
R B Gy
START 40 Br/Y
R B (B)
B/G P/WW/B B/R B O/L Br/B B/Y L
R 16 43
Br
Br R/B B W/R Sb
(Dgy)
L/W Br G/R L/Y L B
Gy/G
(B) B
(B) B
9-19
B L/B
Br/L
Br/L
B/W B B B/W B
B B B/W B
Br/Y
92
53
Y/L Br/Y
Y/L Br/Y Y/L Y Br Br/Y
R R/B Y/L
59 Y/L
94 60 Lg/R 52 Br Y Y/L Br/Y
Sb/W Lg/R Br/Y
61 Br/Y
Br/Y
Lg/B
Lg/B
63
R/L B B/W G
L 64
L (Dgy) Y/L Y/L Y/L Y/L Lg/RLg/R Lg/BLg/B
65 Br/Y Br/Y Br/Y Br/Y
53 G G L/G L/G G L L Y/L L L/W L/W L/W 74 G
66 (B)
67
76 53
69 Lg/R
Lg/R
Y/L G Y/L G 70
B/W 71
86 L R 83 L R Lg/B
Lg/B
G
87 88 84 85 Br/Y Lg/R
Lg/B
B/W
Lg/R Lg/R Lg/R Lg/B Lg/B Lg/B
Y/L L/G L R Y/L L/G L R
B B G Y B B G Y 73
B Y B Y
Y G Y G R/W Br/Y B/W Y G
Sb/W Lg/R Lg/B
(B)
Y Y B B
B B B B B/W
SIGNALING SYSTEM
SIGNALING SYSTEM

12.Frame ground
13.Main switch
14.Main fuse
15.Battery
16.Engine ground
28.Differential motor
32.On-Command four-wheel-drive switch
38.Coolant temperature sensor
40.Reverse switch
42.Seat belt switch
43.Parking brake switch
44.Buzzer
46.Speed sensor
51.Reverse light relay
53.Joint coupler
59.Meter assembly
60.Seat belt reminder light
61.Helmet reminder light
63.High-range indicator light
64.Low battery voltage indicator light
65.Low-range indicator light
66.On-Command differential gear lock indicator
light
67.Reverse indicator light
69.Coolant temperature warning light
70.Parking brake indicator light
71.Neutral indicator light
73.Multi-function meter
74.Fuel pump assembly
76.Fuel sender
85.Reverse light (right)
88.Reverse light (left)
94.Ignition fuse
A. Wire harness
9-20
EBS30273
B B
A B
(B) (B)
B/L Gy
Gy B/L
B Gy
Gy B Br
P P
1 Br/Y Br
44 P Br Br/Y P
(Gy) (Gy)
G/Y B/L
38 (B)
Br Br G/Y G/Y B/L
Br
34
Br L L
R W/Y W/Y L W/Y B/L
B/L
46
Sb/W (Db)
14 L/B
11 R R
R R W/Y
Br/L R L/W
Br/L B Br B R Gy/G
W/R
R Sb
G/W
B B
B B B W/B
R B/R
B B B/L G
L/Y
G/R B
B W/R R
B/W G/W Br/Y Br/Y G/W
12 L/Y G/R Br Lg/R B/W Sb Gy/G
W/B Lg/B G/W G/W
15 L Br/Y (B)
B/R 42
L/W L W Gy
R/B 32 B/L
L B
2WD-LOCK 41 B/L
13 B A B B B
28 4WD-DIFF GG
51
4WD-LOCK B B/L
R B B/L
OFF L W
B
ON L/W G/R L/B Br/Y
R B Gy
START B Br 40 Br/Y
R B (B)
B/G P/WW/B B/R B O/L Br/B B/Y (B) L
R 16 43
Br
CIRCUIT DIAGRAM (YXF10WRZN/YXF10WRLN)
Br R/B B B W/R Sb
(Dgy)
L/W Br G/R L/Y Br B L B
Gy/G
(B) B (B)
(B) B
9-21
B L/B
Br/L
Br/L Br
90 Br B/W B B B B/W B
Br Br B B B B/W B
Br/Y
92
L/W W/Y Br
53
Y/L Br/Y
G Y/B Y/L Br/Y Y/L Y Br Br/Y
R R/B 110 Y/L
59 60 L/W W/Y Y/B G MODE_S Lg/R
94 Sb/W MODE_T B Br 52 Br Y Y/L Br/Y
B B Lg/R Br/Y
61 MODE_C (B) Br/Y
Br/Y
Lg/B
B B Lg/B
Br B
63 (B)
R/L B B/W G
L 64
L (Dgy) 65 Y/L Y/L Y/L Y/L Lg/RLg/RLg/R Lg/BLg/B Lg/B
53 G G L/G L/G G L L Y/L L L/W L/W L/W 66
74 G 67 (B)
76 69 53
Lg/R
Lg/R
Y/L G Y/L G
70 71
B/W
86 L R 83 L R Lg/B
Lg/B
G
87 88 84 85 Br/Y Lg/R
Lg/B
B/W
Lg/R Lg/R Lg/R Lg/R Lg/R Lg/B Lg/B Lg/B Lg/B Lg/B
B B G Y B B G Y 73
B Y B Y
Y G Y G R/W Br/Y B/W Y G
Sb/W Lg/R Lg/B
(B)
Y Y B B
B B B B B/W B
SIGNALING SYSTEM
SIGNALING SYSTEM

12.Frame ground
13.Main switch
14.Main fuse
15.Battery
16.Engine ground
40.Reverse switch
42.Seat belt switch
43.Parking brake switch
44.Buzzer
46.Speed sensor
51.Reverse light relay
53.Joint coupler
59.Meter assembly
60.Seat belt reminder light
61.Helmet reminder light
63.High-range indicator light
64.Low battery voltage indicator light
65.Low-range indicator light
66.On-Command differential gear lock indicator
light
67.Reverse indicator light
69.Coolant temperature warning light
70.Parking brake indicator light
71.Neutral indicator light
76.Fuel sender
85.Reverse light (right)
88.Reverse light (left)
90.Headlight fuse
94.Ignition fuse
110.D-mode switch
A. Wire harness
9-22
SIGNALING SYSTEM
EBS30274
TROUBLESHOOTING
• Any of the following fail to light: warning light, brake light or an indicator light.
• The fuel meter fails to come on.
• The speedometer fails to operate.
• The buzzer fails to sound.
TIP
1. Hood
2. Front cover
3. Rear floor boards (left and right)
5. Skid plate

(Main, ignition, headlight
(YXF10WRZN/YXF10WRLN), and
signaling system)
OK ↓
page 9-126.
OK ↓
OK ↓
OK ↓
5. Check the entire signaling system NG →
wiring.
ness.
“CIRCUIT DIAGRAM
page 9-21.
OK ↓
Check the condition of each of the sig-
naling system circuits. Refer to
“Checking the signaling system”.
9-23
SIGNALING SYSTEM
Checking the signaling system

The tail/brake lights fail to come on.
1. Check the brake light switch. NG →
Replace the brake light switch.
OK ↓
wiring.
ness.
“CIRCUIT DIAGRAM
page 9-21.
OK ↓
Replace the tail/brake light assembly.
The neutral, high-range, and/or low-range indicator light fails to come on.
1. Check the gear position switch. NG →
Replace the gear position switch.
OK ↓
wiring.
ness.
“CIRCUIT DIAGRAM
page 9-21.
OK ↓
Replace the meter assembly or ECU.
The reverse indicator light and/or reverse light fails to come on.
1. Check the reverse switch. NG →
Replace the reverse switch.
OK ↓
9-24
SIGNALING SYSTEM
2. Check the reverse light relay. NG →

Refer to “CHECKING THE RE- Replace the reverse relay.
OK ↓
wiring.
ness.
“CIRCUIT DIAGRAM
page 9-21.
OK ↓
Replace the meter assembly, tail/brake
light assembly or ECU.
The low battery voltage indicator light fails to come on.

wiring.
ness.
“CIRCUIT DIAGRAM
page 9-21.
OK ↓
The parking brake indicator light fails to come on.

1. Check the parking brake switch. NG →
Replace the parking brake lever assembly.
OK ↓
wiring.
ness.
“CIRCUIT DIAGRAM
page 9-21.
OK ↓
9-25
SIGNALING SYSTEM
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 9-134.
OK ↓
wiring.
ness.
“CIRCUIT DIAGRAM
page 9-21.
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 9-133.
OK ↓
wiring.
ness.
“CIRCUIT DIAGRAM
page 9-21.
OK ↓
Replace the meter assembly.
The speedometer fails to come on.

1. Check the speed sensor. NG →
Execute the diagnostic mode.
(Code No. 07)
Replace the speed sensor.
Refer to “DIAGNOSTIC CODE:
SENSOR OPERATION TABLE” on
page 10-2.
OK ↓
9-26
SIGNALING SYSTEM

wiring.
ness.
“CIRCUIT DIAGRAM
page 9-21.
OK ↓
The On-Command differential gear lock indicator light and/or drivetrain icon fails to come on.
1. Check the On-Command four- NG →
wheel-drive switch.
Replace the On-Command four-wheel-
drive switch.
OK ↓
2. Check the differential motor posi- NG →
tion switch.
Refer to “CHECKING THE DIF- Replace the differential motor.
FERENTIAL MOTOR POSITION
SWITCH” on page 9-137.
OK ↓
wiring.
ness.
“CIRCUIT DIAGRAM
page 9-21.
OK ↓
The helmet reminder light fails to come on.

wiring.
ness.
“CIRCUIT DIAGRAM
page 9-21.
OK ↓
Replace the meter assembly.
9-27
SIGNALING SYSTEM
The buzzer fails to sound (parking brake/seat belt).

TIP
The buzzer will sound if the vehicle is running with the parking brake applied and/or the driver seat belt
unfastened.
1. Check the parking brake switch. NG →

Replace the parking brake lever assembly.
OK ↓
2. Check the seat belt switch. NG →
Replace the seat belt switch.
OK ↓
3. Check the speed sensor. NG →
(Code No. 07)
Replace the speed sensor.
Refer to “DIAGNOSTIC CODE:
SENSOR OPERATION TABLE” on
page 10-2.
OK ↓
4. Check the buzzer. NG →
Refer to “CHECKING THE BUZZ- Replace the buzzer.
ER” on page 9-133.
OK ↓
wiring.
ness.
“CIRCUIT DIAGRAM
page 9-21.
OK ↓
Replace the ECU.
9-28
SIGNALING SYSTEM
The seat belt reminder light fails to come on.

Seat belt reminder light does not come on when the driver seat belt is unfastened
Seat belt reminder light: reminder light does not come on
Item
when the driver seat belt is unfastened.
Probable cause of malfunction Confirmation of service com-

Item Maintenance job
and check pletion
1 Connection of meter assembly Improperly connected → Con- Turn the main switch to “ ”
coupler. nect the coupler securely or re- (on).
Check the locking condition of place the wire harness. Check that the seat belt remind-
the coupler. er light comes on and goes off
Disconnect the coupler and when the driver seat belt is un-
check the pins (bent or broken fastened and fastened.
terminals and locking condition Seat belt reminder light comes
of the pins). on when the driver seat belt is
unfastened and goes off when
the seat belt is fastened → Ser-
vice is finished.
Seat belt reminder light does
not come on even when the
driver seat belt is unfastened →
Go to item 2.
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. Check that the seat belt remind-
Disconnect the coupler and er light comes on and goes off
check the pins (bent or broken when the driver seat belt is un-
terminals and locking condition fastened and fastened.
of the pins). Seat belt reminder light comes
on when the driver seat belt is
vice is finished.
Go to item 3.
3 Connection of seat belt switch Improperly connected → Con- Turn the main switch to “ ”
vice is finished.
Go to item 4.
9-29
SIGNALING SYSTEM
Seat belt reminder light: reminder light does not come on

Item
when the driver seat belt is unfastened.
and check pletion
4 Wire harness continuity. Open or short circuit → Replace Turn the main switch to “ ”
the wire harness. (on).
Seat belt reminder light: Check that the seat belt remind-
Between meter assembly cou- er light comes on and goes off
pler and ECU coupler. when the driver seat belt is un-
light green/red–light green/red fastened and fastened.
light green/black–light green/ Seat belt reminder light comes
black on when the driver seat belt is
Seat belt switch: unfastened and goes off when
Between seat belt switch cou- the seat belt is fastened → Ser-
pler and ECU coupler. vice is finished.
red–red Seat belt reminder light does
Between seat belt switch cou- not come on even when the
pler and frame ground. driver seat belt is unfastened →
black–black Go to item 5.
5 Defective seat belt switch. Check the seat belt switch. Turn the main switch to “ ”
Refer to “CHECKING THE (on).
SWITCHES (YXF10WRAN)” on Check that the seat belt remind-
page 9-123 or “CHECKING er light comes on and goes off
THE SWITCHES when the driver seat belt is un-
(YXF10WRZN/YXF10WRLN)” fastened and fastened.
on page 9-124. Seat belt reminder light comes
Replace the driver seat belt on when the driver seat belt is
buckle if defective. unfastened and goes off when
vice is finished.
Go to item 7.
6 Defective seat belt reminder When the main switch is turned Turn the main switch to “ ”
light. to “ ” (on), the seat belt re- (on).
minder light does not come on Check that the seat belt remind-
even though the driver seat belt er light comes on and goes off
is unfastened → Replace the when the driver seat belt is un-
meter assembly. fastened and fastened.
Seat belt reminder light comes
vice is finished.
Go to item 6.
7 Malfunction in ECU. Replace the ECU.
9-30
SIGNALING SYSTEM
Seat belt reminder light comes on when the driver seat belt is fastened
Seat belt reminder light: reminder light comes on when the
Item
driver seat belt is fastened.

and check pletion
vice is finished.
on even when the driver seat
belt is fastened → Go to item 2.
the coupler. place the wire harness. Check that the seat belt remind-
Disconnect the coupler and er light comes on and goes off
check the pins (bent or broken when the driver seat belt is un-
terminals and locking condition fastened and fastened.
of the pins). Seat belt reminder light comes
vice is finished.
3 Connection of seat belt switch Improperly connected → Con- Turn the main switch to “ ”
vice is finished.
9-31
SIGNALING SYSTEM

Item
and check pletion
Seat belt reminder light: Check that the seat belt remind-
Between meter assembly cou- er light comes on and goes off
pler and ECU coupler. when the driver seat belt is un-
light green/red–light green/red fastened and fastened.
light green/black–light green/ Seat belt reminder light comes
black on when the driver seat belt is
Seat belt switch: unfastened and goes off when
Between seat belt switch cou- the seat belt is fastened → Ser-
pler and ECU coupler. vice is finished.
red–red Seat belt reminder light comes
Between seat belt switch cou- on even when the driver seat
pler and frame ground. belt is fastened → Go to item 5.
black–black
5 Damaged seat belt latch plate. Check that the end of the seat Turn the main switch to “ ”
belt latch plate is not damaged (on).
or deformed. Check that the seat belt remind-
Damaged or deformed → Re- er light comes on and goes off
place the driver seat belt. when the driver seat belt is un-
fastened and fastened.
vice is finished.
6 Defective seat belt switch. Check the seat belt switch. Turn the main switch to “ ”
SWITCHES (YXF10WRAN)” on Check that the seat belt remind-
page 9-123 or “CHECKING er light comes on and goes off
THE SWITCHES when the driver seat belt is un-
(YXF10WRZN/YXF10WRLN)” fastened and fastened.
on page 9-124. Seat belt reminder light comes
Replace the driver seat belt on when the driver seat belt is
buckle. unfastened and goes off when
vice is finished.
9-32
SIGNALING SYSTEM

Item
and check pletion
7 Defective seat belt reminder When the main switch is turned Turn the main switch to “ ”
light. to “ ” (on), the seat belt re- (on).
minder light does not come on Check that the seat belt remind-
even though the driver seat belt er light comes on and goes off
is unfastened → Replace the when the driver seat belt is un-
meter assembly. fastened and fastened.
vice is finished.
The D-mode indicator fails to come on (YXF10WRZN/YXF10WRLN).
When the D-mode switch “1” is turned to “SPORT”, “TRAIL” or “CRAWL”, the D-mode indicator “2” does
not come on with “D-MODE” and “S”, “T” or “C”.
TIP
• If the fault code number is indicated, take the action first for the fault code number.
Refer to “TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM)” on page 9-45.
• When the speed management system switch is turned to the “ON” position, the D-mode function is
deactivated and the D-mode indicator disappears.
• Before checking the D-mode, be sure to stop the vehicle and take your foot off the accelerator pedal.
9-33
SIGNALING SYSTEM
D-mode indicator does not come on correctly when the D-

Item
mode switch is turned to “SPORT”, “TRAIL” or “CRAWL”.

and check pletion
Check the locking condition of place the wire harness. Check that the D-mode indica-
the coupler. tor comes on correctly when the
Disconnect the coupler and D-mode switch is turned to
check the pins (bent or broken “SPORT”, “TRAIL” or “CRAWL”
terminals and locking condition → Service is finished.
of the pins). The D-mode indicator comes on
incorrectly when the D-mode
switch is turned to “SPORT”,
“TRAIL” or “CRAWL” → Go to
item 2.
2 Connection of D-mode switch Improperly connected → Con- Turn the main switch to “ ”
Check the locking condition of place the wire harness. Check that the D-mode indica-
the coupler. tor comes on correctly when the
Disconnect the coupler and D-mode switch is turned to
check the pins (bent or broken “SPORT”, “TRAIL” or “CRAWL”
terminals and locking condition → Service is finished.
of the pins). The D-mode indicator comes on
item 3.
the coupler. place the wire harness. Check that the D-mode indica-
Disconnect the coupler and tor comes on correctly when the
check the pins (bent or broken D-mode switch is turned to
terminals and locking condition “SPORT”, “TRAIL” or “CRAWL”
of the pins). → Service is finished.
The D-mode indicator comes on
item 4.
4 Defective D-mode switch. Check the D-mode switch. Turn the main switch to “ ”
SWITCHES (YXF10WRZN/ Check that the D-mode indica-
YXF10WRLN)” on page 9-124. tor comes on correctly when the
Replace if defective. D-mode switch is turned to
“SPORT”, “TRAIL” or “CRAWL”
→ Service is finished.
item 5.
9-34
SIGNALING SYSTEM
D-mode indicator does not come on correctly when the D-

Item
mode switch is turned to “SPORT”, “TRAIL” or “CRAWL”.
and check pletion
Between D-mode switch cou- Check that the D-mode indica-
pler and ECU coupler. tor comes on correctly when the
blue/white–blue/white D-mode switch is turned to
white/yellow–white/yellow “SPORT”, “TRAIL” or “CRAWL”
Between drive mode switch → Service is finished.
coupler and frame ground. The D-mode indicator comes on
black–black incorrectly when the D-mode
item 6.
6 Defective meter assembly. Replace the meter assembly. Turn the main switch to “ ”
(on).
Check that the D-mode indica-
tor comes on correctly when the
D-mode switch is turned to
“SPORT”, “TRAIL” or “CRAWL”
→ Service is finished.
item 7.
9-35
SIGNALING SYSTEM
9-36
EBS30275
EBS20079
B B
A B
(B) (B)
Br
CIRCUIT DIAGRAM
COOLING SYSTEM
G/Y B/L
38 (B)
Br
Br G/Y G/Y B/L
Br
34
Y
14
R R
R
R
R
B B
B B R
B B B/L
B
B
B/W
R/G
12 15 B/W
R/L
Br R/B
Br Y
R/G
13 B A B B B B/L
B/L
OFF
99 B
ON
START
R
R/L Y
R 16
Br
Br R/B
L/W Br
(B)
9-37
R/L
B/W B
B B/W B
B
100
B
L R R/B
94
R/G
L 95
101
L B
(B)
B
B L
(B)
B
B
COOLING SYSTEM
COOLING SYSTEM
12.Frame ground
13.Main switch
14.Main fuse
15.Battery
16.Engine ground
94.Ignition fuse
95.Radiator fan motor fuse
99.Radiator fan motor relay
100.Radiator fan motor circuit breaker
101.Radiator fan motor
A. Wire harness
9-38
COOLING SYSTEM
EBS30276
TROUBLESHOOTING
The radiator fan motor fails to turn.
TIP
1. Hood
2. Front cover
3. Center cover

(Main, radiator fan motor and igni-
tion) Replace the fuse(s).
OK ↓
page 9-126.
OK ↓
OK ↓
4. Check the radiator fan motor. NG →
Refer to “CHECKING THE RADIA- Replace the radiator fan motor.
TOR FAN MOTOR” on page 9-134.
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 9-134.
OK ↓
9-39
COOLING SYSTEM
7. Check the coolant temperature sen- NG →

sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 9-134.
OK ↓
8. Check the entire cooling system NG →
page 9-37.
OK ↓
Replace the ECU.
9-40
EBS30353
EBS20080
B B
A B
B/L W L Gy/G
Br B B P/B
(B)
Br P/B B B
23 W L B B/L (B) (B) Br
B/L Gy Gy/G B/L W L
Gy B/L 48
(B) (B) R/W O O
B (B)
Gy Gy/R
Gy B B/L Br
29 W Gy/G
CIRCUIT DIAGRAM
1 P/B R/L
B B/L R/B R/B R/L R/L R/L
Br Br W R/L R/L
L B Br
35 R/L R/B R/L G/B R/L 49
L
24 25 B/L 36 Gy/R
(Gy) (Gy)
30 W G/B G/B R/L
Br/R Br/Y R/G
B
B/L
Br Br/R Br Br/Y L W Br/W Br/W B/L
B Gy/R Br
Y/W L
31 Y/R G/Y B/L Br/W B/L
(B) (B) Y/W
37 (B)
Br
Br Y/R 38 (B) (B)
Br Br
Br Br G/Y G/Y B/L
B L W B/L Y/W Y/R L L Y/G B/L
Br 34 Y/G Y/G
Br Br R/L Br B/L
45
(B) (Gy)
Br 26 Br/R
Br (B) Br/Y L L
R Br Br R/L R/L W/Y W/Y 46 L W/Y B/L
Y/L B/L
Y
14 (Db)
L/R
11 R
R R
FUEL INJECTION SYSTEM
Br/L R Y/L
P/B 47 B/L P/B Y/L
Br/L B Br B R Gy/G B/L
W/R (Db)
R Br/R Sb
R/L G/W
B B Y/W
Br/R Br L/R
B B B P/B
R R R Br/R Br/R Br
B B B/L
R/Y L/W B
B W/R
(B) Lg/R B/W G/W
12 18 21 B/W Sb Gy/G
R/G 15 Lg/B G/W G/W
B/L
R/L L W Gy B/L
R/B L/R Y/W
Br B/L
Br Y R/L B/L
41 B/L
B A B B B B/L
13 B/L
B/L
OFF Y/W L W
99 B
ON
R Gy
START (Gy) 39 40
R R (B)
Y
R 16
Br
Br R/B W/R Sb
L/W Br Gy/G
(B)
(B)
9-41
Br/L
Br/L
B/W B
B B/W B/W B
Lg/B Lg/R 58
Br/Y R/W B/W Lg/R
92 R/W Lg/B
R/W B/W 53
93 Y/L Y Br Br/Y
R R/B Y/L
59 Y/L
94 Lg/R 52 Br Y Y/L Br/Y
Lg/R Br/Y
Br/Y
Br/Y
Lg/B
Lg/B
R/L B B/W G
R L Y/L
R/G Y/L Y/L Y/L Y/L Lg/RLg/RLg/R Lg/BLg/B Lg/B
L L (Dgy)
97 Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
53 G G L/G L/G G L L Y/L L L/W L/W L/W 74 R/L (B)
R/W R/W
R/W
75 68 53
Lg/R
Lg/R
Lg/R
B
Lg/B
Lg/B
Lg/B
Br/Y Lg/R
Lg/B
B/W
Lg/R Lg/R Lg/R Lg/R Lg/B Lg/B Lg/B Lg/B
73
R/W Br/Y B/W Y G
Sb/W Lg/R Lg/B
(B)
B
B B B B/W

12.Frame ground
13.Main switch
14.Main fuse
15.Battery
16.Engine ground
18.Fuel injection system fuse
21.Main relay
23.O2 sensor
24.Purge cut valve solenoid 1
25.Purge cut valve solenoid 2
26.Air induction system solenoid
29.Accelerator position sensor
30.Throttle position sensor
31.Throttle servo motor
35.Fuel injector #1
36.Fuel injector #2
37.Intake air temperature sensor
39.Oil pressure switch
40.Reverse switch
45.Lean angle sensor
46.Speed sensor
47.Intake air pressure sensor
48.Ignition coil #1
49.Ignition coil #2
53.Joint coupler
58.Yamaha diagnostic tool coupler
59.Meter assembly
68.Engine trouble warning light
75.Fuel pump
93.Backup fuse
94.Ignition fuse
97.Electric throttle valve fuse
99.Radiator fan motor relay
A. Wire harness
9-42
EBS30278
ECU SELF-DIAGNOSTIC FUNCTION

The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is
operating normally. If this function detects a malfunction in the system, it immediately operates the en-
gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider
that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is
stored in the memory of the ECU.
• To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
comes on when the main switch is being turned to start the engine.
• If a malfunction is detected in the system by the self-diagnostic function, the ECU provides an appro-
priate substitute characteristic operation, and alerts the rider of the detected malfunction by illuminat-
ing the engine trouble warning light.
• After the engine has been stopped, the lowest fault code number appears on the multi-function meter
display. Once a fault code has been displayed, it remains stored in the memory of the ECU until it is
deleted.
Engine trouble warning light indication and fuel injection system operation
Warning light indication ECU operation Fuel injection operation Vehicle operation
Warning provided when
Flashing* Operation stopped Cannot be operated
unable to start engine
Operated with substitute
Can or cannot be operat-
characteristics in accor-
Remains on Malfunction detected ed depending on the fault
dance with the descrip-
code
tion of the malfunction
* The warning light flashes when any one of the conditions listed below is present and the main switch
is turned to “ ” (start):
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 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.
EBS30279
TROUBLESHOOTING METHOD
The engine operation is not normal and the engine trouble warning light comes on.
1. Check:
• Fault code number
a. Check the fault code number displayed on the Yamaha diagnostic tool.
b. Identify the faulty system with the fault code.
c. Identify the probable cause of the malfunction.
9-43
2. Check and repair the probable cause of malfunction.

Fault code No. No fault code No.
Check and repair. Refer to “TROUBLESHOOTING Check and repair.
DETAILS (FUEL INJECTION SYSTEM)” on page
9-45.
Monitor the operation of the sensors and actuators in
the diagnostic mode.
Refer to “TROUBLESHOOTING DETAILS (FUEL IN-
JECTION SYSTEM)” on page 9-45 and “SELF-DI-
AGNOSTIC FUNCTION AND DIAGNOSTIC CODE
TABLE” on page 10-1.
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 9-45.
4. Turn the main switch to “ ” (off) and back to “ ” (on), then check that no fault code number is dis-
played.
TIP
If another fault code are displayed, repeat steps (1) to (4) until no fault code number is displayed.
5. Erase the malfunction history in the diagnostic mode (code No. 62). Refer to “SELF-DIAGNOSTIC
FUNCTION AND DIAGNOSTIC CODE TABLE” on page 10-1.
TIP
Turning the main switch to “ ” (off) will not erase the malfunction history.
The engine operation is not normal, but the engine trouble warning light does not come on.
1. Check the operation of the following sensors and actuators in the diagnostic mode.
Refer to “TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM)” on page 9-45 and “SELF-
DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 10-1.
01: Throttle position sensor signal (throttle angle)
13: Throttle position sensor signal 2
14: Accelerator position sensor signal 1
15: Accelerator position sensor signal 2
30: Ignition coil #1
31: Ignition coil #2
36: Injector #1
37: Injector #2
46: PCV solenoid 1
94: PCV solenoid 2
If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and actuators, check and repair inner parts of the engine.
EBS30280
YAMAHA DIAGNOSTIC TOOL

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

90890-03269
Yamaha diagnostic tool (A/I)
90890-03264
Connecting the Yamaha diagnostic tool

Remove the protective cap, and then connect the Yamaha diagnostic tool to the coupler “1”.
9-44
TIP
When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter
and indicators will be different from the normal operation.
EBS30281
TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM)

This section describes the measures per fault code number displayed on the Yamaha diagnostic tool.
Check and service the items or components that are the probable cause of the malfunction following
the order given.
After the check and service of the malfunctioning part has been completed, delete the fault codes dis-
played on the Yamaha diagnostic tool according to the reinstatement method.
Fault code No.:
Fault code number displayed on the Yamaha diagnostic tool 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 10-1.
Fault code No. 12

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

Item
crankshaft position sensor.
Unable to start engine
Fail-safe system
Unable to drive vehicle
Diagnostic code No. —
Tool display —
Procedure —
Probable cause of malfunc- Confirmation of service com-
tion and check pletion
1 Connection of crankshaft posi- Improperly connected → Con- Crank the engine.
tion sensor coupler. nect the coupler securely or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played → Service is finished.
the coupler. Fault code number is displayed
Disconnect the coupler and → Go to item 2.
check the pins (bent or broken
terminals and locking condition
of the pins).
2 Connection of ECU coupler. Improperly connected → Con- Crank the engine.
Check the locking condition of nect the coupler securely or re- Fault code number is not dis-
the coupler. place the wire harness. played → Service is finished.
Disconnect the coupler and Fault code number is displayed
check the pins (bent or broken → Go to item 3.
of the pins).
9-45
Fault code No. 12
Crankshaft position sensor: no normal signals are received from the

Item
crankshaft position sensor.
3 Wire harness continuity. Open or short circuit → Replace Crank the engine.
the wire harness. Fault code number is not dis-
Between crankshaft position played → Service is finished.
sensor coupler and ECU cou- Fault code number is displayed
pler. → Go to item 4.
gray–gray
black/blue–black/blue
4 Installed condition of crank- Improperly installed sensor → Crank the engine.
shaft position sensor. Reinstall or replace the crank- Fault code number is not dis-
Check for looseness or pinch- shaft position sensor/stator as- played → Service is finished.
ing. sembly. Fault code number is displayed
→ Go to item 5.
5 Defective crankshaft position Check the crankshaft position Crank the engine.
sensor. sensor. Fault code number is not dis-
Refer to “CHECKING THE played → Service is finished.
CRANKSHAFT POSITION Fault code number is displayed
SENSOR” on page 9-130. → Go to item 6.
Replace the crankshaft position
sensor/stator assembly if defec-
tive.
Fault code No. 13

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

Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 03
Tool display 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 coupler. nect the coupler securely or re- (on).
Check the locking condition of place the wire harness. Fault code number is not dis-
the coupler. played → Service is finished.
of the pins).
9-46
Fault code No. 13
Item Intake air pressure sensor: open or short circuit detected.

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).
Between intake air pressure Fault code number is not dis-
sensor coupler and ECU cou- played → Service is finished.
pler. Fault code number is displayed
yellow/blue–yellow/blue → Go to item 4.
pink/black–pink/black
4 Installed condition of intake air Improperly installed sensor → Turn the main switch to “ ”
pressure sensor. Reinstall or replace the sensor. (on).
Check for looseness or pinch- Fault code number is not dis-
ing. played → Service is finished.
Fault code number is displayed
→ Go to item 5.
5 Defective intake air pressure Execute the diagnostic mode. Turn the main switch to “ ”
sensor. (Code No. 03) (on).
When engine is stopped: Fault code number is not dis-
Atmospheric pressure at the played → Service is finished.
current altitude and weather Fault code number is displayed
conditions is indicated. → Go to item 6.
At sea level: Approx. 101 kPa
(757.6 mmHg, 29.8 inHg)
1000 m (3300 ft) above sea lev-
el: Approx. 90 kPa (675.1
mmHg, 26.6 inHg)
mmHg, 23.6 inHg)
mmHg, 20.7 inHg)
When engine is cranking: Make
sure that the indication value
changes.
The value does not change
when engine is cranking. → Re-
place the intake air pressure
sensor.
Fault code No. 14

TIP
If fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number
“13” first.
9-47
Fault code No. 14
Intake air pressure sensor: hose system malfunction (clogged or de-

Item
tached hose).
Fail-safe system
Tool display Displays the intake air pressure.
Turn and hold the main switch in the “ ” (start) position, then press the
Procedure
accelerator pedal. (If the display value changes, the performance is OK.)
1 Condition of intake air pressure Clogged or detached hose → Start the engine and let it idle
sensor hose. Repair or replace the sensor for approximately 5 seconds.
Check the intake air pressure hose. Fault code number is not dis-
sensor hose condition. played → Service is finished.
→ Go to item 2.
2 Defective intake air pressure Execute the diagnostic mode.
sensor. (Code No. 03)
When engine is stopped:
Atmospheric pressure at the
current altitude and weather
conditions is indicated.
At sea level: Approx. 101 kPa
(757.6 mmHg, 29.8 inHg)
mmHg, 26.6 inHg)
mmHg, 23.6 inHg)
mmHg, 20.7 inHg)
When engine is cranking: Make
sure that the indication value
changes.
The value does not change
when engine is cranking. → Re-
place the intake air pressure
sensor.
Fault code No. 15

Fault code No. 15
Item Throttle position sensor: open or short circuit detected.

Fail-safe system
Diagnostic code No. 01, 13
Throttle position sensor signal
Tool display
• 10.5–20.5 (fully closed position)
Procedure Check with throttle valve fully closed.
9-48
Fault code No. 15
Item Throttle position sensor: open or short circuit detected.

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-
coupler and ECU coupler. played → Service is finished.
black/blue–black/blue Fault code number is displayed
white–white → Go to item 4.
black–black
blue–blue
4 Installed condition of throttle po- Check for looseness or pinch- Turn the main switch to “ ”
sition sensor. ing. (on).
Improperly installed sensor → Fault code number is not dis-
Reinstall the throttle bodies. played → Service is finished.
→ 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 10.5–20.5 is indicat-
ed.
(Code No. 13)
When the throttle valve is fully
closed:
A value of 10.5–20.5 is indicat-
ed.
An indicated value is out of the
specified range → Replace the
throttle bodies.
Refer to “THROTTLE BODIES”
on page 7-11.
Fault code No. 21

TIP
Perform this procedure when the engine is cold.
9-49
Fault code No. 21
Item Coolant temperature sensor: open or short circuit detected.

Fail-safe system
When engine is cold: Displays temperature closer to air temperature.
Tool display
When engine is hot: Displays current coolant temperature.
Compare the actually measured coolant temperature with the tool display
Procedure
value.
1 Connection of coolant tempera- Improperly connected → Con- Turn the main switch to “ ”
ture sensor coupler. nect the coupler securely or re- (on).
of the pins).
of the pins).
Between coolant temperature Fault code number is not dis-
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).
Check for looseness or pinch- Refer to “THERMOSTAT” on Fault code number is not dis-
ing. page 6-12. played → Service is finished.
→ Go to item 5.
5 Defective coolant temperature Execute the diagnostic mode. Turn the main switch to “ ”
When engine is cold: Fault code number is not dis-
Displayed temperature is close played → Service is finished.
to the ambient temperature. Fault code number is displayed
The displayed temperature is → Go to item 6.
not close to the ambient tem-
perature → Replace the coolant
temperature sensor.
Fault code No. 22

TIP
Perform this procedure when the engine is cold.
9-50
Fault code No. 22
Item Intake air temperature sensor: open or short circuit detected.

Fail-safe system
When engine is cold: Displays temperature closer to air temperature.
Tool display
When engine is hot: Air temperature + approx. 20 °C (68 °F).
Compare the actually measured intake air temperature with the tool dis-
Procedure
play value.
1 Connection of intake air tem- Improperly connected → Con- Turn the main switch to “ ”
perature sensor coupler. nect the coupler securely or re- (on).
of the pins).
of the pins).
Between intake air temperature Fault code number is not dis-
brown/white–brown/white → Go to item 4.
4 Installed condition of intake air Check for looseness or pinch- Turn the main switch to “ ”
temperature sensor. ing. (on).
Reinstall or replace the sensor. played → Service is finished.
→ Go to item 5.
5 Defective intake air temperature Execute the diagnostic mode. Turn the main switch to “ ”
When engine is cold: Fault code number is not dis-
Displayed temperature is close played → Service is finished.
to the ambient temperature. Fault code number is displayed
The displayed temperature is → Go to item 6.
not close to the ambient tem-
perature. → Replace the intake
air temperature sensor.
9-51
Fault code No. 24

Fault code No. 24
Item O2 sensor: no normal signals are received from the O2 sensor.

Fail-safe system
Tool display —
Procedure —
1 Installed condition of O2 sensor. Check for looseness or pinch- Start the engine, warm it up,
ing. and then race it, or execute the
Improperly installed sensor → diagnostic mode. (Code No. 63)
Reinstall or replace the sensor. Fault code number is not dis-
played → Service is finished.
→ Go to item 2.
2 Connection of O2 sensor cou- Improperly connected → Con- Start the engine, warm it up,
pler. nect the coupler securely or re- and then race it, or execute the
Check the locking condition of place the wire harness. diagnostic mode. (Code No. 63)
the coupler. Fault code number is not dis-
of the pins).
3 Connection of ECU coupler. Improperly connected → Con- Start the engine, warm it up,
Check the locking condition of nect the coupler securely or re- and then race it, or execute the
the coupler. place the wire harness. diagnostic mode. (Code No. 63)
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 4.
4 Wire harness continuity. Open or short circuit → Replace Start the engine, warm it up,
the wire harness. and then race it, or execute the
Between O2 sensor coupler and diagnostic mode. (Code No. 63)
ECU coupler. Fault code number is not dis-
gray/green–gray/green played → Service is finished.
pink/black–pink/black Fault code number is displayed
black/blue–black/blue → Go to item 5.
Between O2 sensor coupler and
main switch coupler.
brown–brown
5 Check fuel pressure. Refer to “CHECKING THE Start the engine, warm it up,
FUEL PRESSURE” on page and then race it, or execute the
7-10. diagnostic mode. (Code No. 63)
Fault code number is not dis-
→ Go to item 6.
9-52
Fault code No. 24
Item O2 sensor: no normal signals are received from the O2 sensor.

6 Defective O2 sensor. Replace the O2 sensor. Start the engine, warm it up,
Refer to “ENGINE REMOVAL and then race it, or execute the
(1)” on page 5-7. diagnostic mode. (Code No. 63)
→ Go to item 7.
Fault code No. 30

Fault code No. 30
Latch up detected.
Item
Oil pressure dropped.
Fail-safe system
Tool display • 3.5–4.5 (upright)
• 0.6–1.4 (overturned)
Procedure Remove the lean angle sensor and incline it more than 65 degrees.
1 The vehicle has overturned. Raise the vehicle upright. Turn the main switch to “ ”
(on), then to “ ” (off), and then
back to “ ” (on).
→ 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
Refer to “GENERAL CHASSIS back to “ ” (on).
(11)” on page 4-33. Fault code number is not dis-
→ 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.
Refer to “CHECKING THE Fault code number is displayed
LEAN ANGLE SENSOR” on → Go to item 4.
page 9-130.
Replace if defective.
9-53
Fault code No. 30
Latch up detected.
Item
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). Start the en-
Add the recommended engine gine and let it idle for approxi-
oil to the proper level if neces- mately 60 seconds.
sary. Fault code number is not dis-
Refer to “CHECKING THE EN- played → Service is finished.
GINE OIL LEVEL” on page Fault code number is displayed
3-17. → Go to item 5.
5 Installed condition of oil pres- Check for looseness or pinch- Turn the main switch to “ ”
sure switch. ing. (on), then to “ ” (off), and then
Improperly installed switch→ back to “ ” (on). Start the en-
Reinstall or replace the switch. gine and let it idle for approxi-
Refer to “OIL PAN AND OIL mately 60 seconds.
PUMP” on page 5-55. 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). Start the en-
9-132. gine and let it idle for approxi-
Replace if defective. mately 60 seconds.
→ Go to item 7.
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 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
coupler. nect the connector securely or for approximately 5 seconds.
Check the locking condition of replace the wire harness. Fault code number is not dis-
the connector. played → Service is finished.
Disconnect the connector and Fault code number is displayed
of the pins).
9-54
Fault code No. 33
Item
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 coupler Fault code number is not dis-
and ECU coupler. played → Service is finished.
orange–orange Fault code number is displayed
→ Go to item 4.
4 Installed condition of ignition Check for looseness or pinch- Start the engine and let it idle
coil #1. ing. for approximately 5 seconds.
Improperly installed ignition coil Fault code number is not dis-
#1 → Reinstall or replace the ig- played → Service is finished.
nition coil #1. Fault code number is displayed
Refer to “CAMSHAFTS” on → Go to item 5.
page 5-23.
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.
Refer to “CHECKING THE IG- Fault code number is not dis-
NITION COILS” on page 9-129. played → Service is finished.
Replace if out of specification. 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.
Fault code No. 34

Fault code No. 34
Item
Fail-safe system
Actuates the ignition coil #2 five times at one-second intervals.
time the ignition coil #2 is actuated.
Check that a spark is generated five times.
Procedure
• Connect an ignition checker.
9-55
Fault code No. 34
Item
1 Connection of ignition coil #2 Improperly connected → Con- Start the engine and let it idle
coupler. 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).
of the pins).
Between ignition coil #2 coupler Fault code number is not dis-
and ECU coupler. played → Service is finished.
gray/red–gray/red Fault code number is displayed
→ Go to item 4.
4 Installed condition of ignition Check for looseness or pinch- Start the engine and let it idle
coil #2. ing. for approximately 5 seconds.
Improperly installed ignition coil Fault code number is not dis-
#2 → Reinstall or replace the ig- played → Service is finished.
nition coil #2. Fault code number is displayed
Refer to “CAMSHAFTS” on → Go to item 5.
page 5-23.
5 Defective ignition coil #2. Measure the primary coil resis- Start the engine and let it idle
tance of the ignition coil #2. 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 9-129. Fault code number is displayed
→ Go to item 6.
6 Malfunction in ECU. Execute the diagnostic mode.
(Code No. 31)
No spark → Replace the ECU.
Fault code No. 39

Fault code No. 39
Item Fuel injector: open or short circuit detected.

Fail-safe system
Actuates injector #1 five times at one-second intervals.
36 time the injector #1 is actuated.
Check that injector #1 is actuated five times by listening for the operating
Procedure
sound.
9-56
Fault code No. 39
Item Fuel injector: open or short circuit detected.

Actuates injector #2 five times at one-second intervals.
37 time the injector #2 is actuated.
Check that injector #2 is actuated five times by listening for the operating
Procedure
sound.
1 Identify the malfunctioning in- Execute the diagnostic mode. —
jector. (Code Nos. 36, 37)
Identify the injector that does
not produce an operating
sound.
2 Connection of fuel injector #1 Improperly connected → Con- Execute the diagnostic mode.
and/or injector #2 coupler. nect the coupler securely or re- (Code Nos. 36, 37)
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 and/or Measure the fuel injector resis- Execute the diagnostic mode.
injector #2. tance. (Code Nos. 36, 37)
Refer to “CHECKING THE Operating sound → Go to item
FUEL INJECTOR” on page 7.
9-136. No operating sound → Go to
Replace if out of specification. 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)
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)
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
Between fuel injector coupler
and main relay.
red/blue–red/blue
7 Delete the fault code. Start the engine and let it idle
for approximately 5 seconds.
Check that the fault code num-
ber is not displayed.
9-57
Fault code No. 41

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

Fail-safe system
Tool display • 3.5–4.5 (upright)
• 0.6–1.4 (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-
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
4 Defective lean angle sensor. Execute the diagnostic mode. Turn the main switch to “ ”
(Code No. 08) (on), then to “ ” (off), and then
An indicated value is out of the back to “ ” (on).
specified range → Check the Fault code number is not dis-
lean angle sensor. played → Service is finished.
Refer to “CHECKING THE Fault code number is displayed
LEAN ANGLE SENSOR” on → Go to item 5.
page 9-130.
9-58
Fault code No. 42

Fault code No. 42
Speed sensor: no normal signals are received from the speed

A
sensor.
Item
Reverse switch and gear position switch: open or short circuit is
B
detected.
Fail-safe system
Rear wheel speed pulse
Tool display
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.
Rotate a rear wheel by hand
and check that the indicated
value increases.
Check the gear positions using Incorrect indication → Go to
the “Monitoring” function. Check item B-2 for the reverse switch,
that each gear is indicated cor- gear position switch.
rectly as follows.
Neutral: 0
Low range: 1
High range: 2
Reverse: –1
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)
each 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.
A-4 Wire harness continuity. Open or short circuit → Replace Execute the diagnostic mode.
the wire harness. (Code No. 07)
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
white/yellow–white/yellow A-7 and delete the fault code.
to item A-5.
9-59
Fault code No. 42

A
sensor.
Item
B
detected.
A-5 Defective speed sensor. Replace the speed sensor. Execute the diagnostic mode.
(Code No. 07)
Rotate a rear wheel by hand
value increases.
Value increases → Go to item
A-7 and delete the fault code.
to item A-6.
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).
The service completion can
also be confirmed by executing
the diagnostic mode (code No.
63) to erase the malfunction
history.
Fault code No. 42

A
sensor.
Item
B
detected.
Fail-safe system
Diagnostic code No. –
Tool display –
Procedure –
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.
Check the gear positions using Incorrect indication → Go to
the “Monitoring” function. Check item B-2.
that each gear is indicated cor-
rectly as follows.
Neutral: 0
Low range: 1
High range: 2
Reverse: –1
9-60
Fault code No. 42

A
sensor.
Item
B
detected.
B-2 Connection of reverse switch Check the locking condition of Check the gear positions using
connector and gear position the coupler. the “Monitoring” function. Check
switch coupler. Improperly connected → Con- that each gear is indicated cor-
Disconnect the coupler and nect the coupler securely or re- rectly as follows.
check the pins (bent or broken place the wire harness. Neutral: 0
terminals and locking condition Low range: 1
of the pins). High range: 2
Reverse: –1
Correct indication → Go to item
B-10 and delete the fault code
Incorrect indication → Go to
item B-3.
B-3 Connection of wire harness Improperly connected → Con- Check the gear positions using
ECU coupler. nect the coupler securely or re- the “Monitoring” function. Check
Check the locking condition of place the wire harness. that each gear is indicated cor-
the coupler. rectly as follows.
Disconnect the coupler and Neutral: 0
check the pins (bent or broken Low range: 1
terminals and locking condition High range: 2
of the pins). Reverse: –1
B-10 and delete the fault code.
item B-4.
B-4 Wire harness continuity. Open or short circuit → Replace Check the gear positions using
the wire harness. the “Monitoring” function. Check
Between gear position switch that each gear is indicated cor-
lead and ECU coupler. rectly as follows.
sky blue–sky blue Neutral: 0
white/red–white/red Low range: 1
gray/green–gray/green High range: 2
Between reverse switch lead Reverse: –1
and ECU coupler. Correct indication → Go to item
green/white–green/white B-10 and delete the fault code.
item B-5.
B-5 Defective gear position switch. Check the gear position switch. Check the gear positions using
Refer to “CHECKING THE the “Monitoring” function. Check
SWITCHES (YXF10WRAN)” on that each gear is indicated cor-
page 9-123 or “CHECKING rectly as follows.
THE SWITCHES Neutral: 0
(YXF10WRZN/YXF10WRLN)” Low range: 1
on page 9-124. High range: 2
Replace if defective. Reverse: –1
item B-6.
9-61
Fault code No. 42

A
sensor.
Item
B
detected.
B-6 Faulty shift drum (gear detec- Malfunction → Replace the shift Check the gear positions using
tion areas). drum. the “Monitoring” function. Check
Refer to “TRANSMISSION (3)” that each gear is indicated cor-
on page 5-112. rectly as follows.
Neutral: 0
Low range: 1
High range: 2
Reverse: –1
item B-7.
B-7 Defective reverse switch. Check the reverse switch. Check the gear positions using
Refer to “CHECKING THE the “Monitoring” function. Check
SWITCHES (YXF10WRAN)” on that each gear is indicated cor-
page 9-123 or “CHECKING rectly as follows.
THE SWITCHES Neutral: 0
(YXF10WRZN/YXF10WRLN)” Low range: 1
on page 9-124. High range: 2
Replace if defective. Reverse: –1
item B-8.
B-8 Faulty shift drum (reverse de- Malfunction → Replace the shift Check the gear positions using
tection area). drum. the “Monitoring” function. Check
Refer to “TRANSMISSION (3)” that each gear is indicated cor-
on page 5-112. rectly as follows.
Neutral: 0
Low range: 1
High range: 2
Reverse: –1
item B-9.
B-9 Malfunction in ECU. Replace the ECU.
B-10 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 mi/h).
The service completion can
also be confirmed by executing
the diagnostic mode (code No.
63) to erase the malfunction
history.
9-62
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
Fuel system voltage (battery voltage)
Tool display
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 main relay five times at one-second intervals.
50 time the relay is actuated.
Check that the main relay is actuated five times by listening for the oper-
Procedure
ating sound.
1 Connection of main relay cou- Improperly connected → Con- Start the engine and let it idle
pler. nect the coupler securely or re- for approximately 5 seconds.
of the pins).
of the pins).
Between main relay coupler and Fault code number is not dis-
ECU coupler. played → Service is finished.
blue/red–blue/red Fault code number is displayed
red/blue–red/blue → Go to item 4.
Between main relay coupler and
starter relay coupler.
brown/red–brown/red
Between main relay coupler and
main switch coupler.
brown–brown
4 Defective main relay. Execute the diagnostic mode. Start the engine and let it idle
(Code No. 50) for approximately 5 seconds.
No operating sound → Replace Fault code number is not dis-
the main relay. played → Service is finished.
→ Go to item 5.
9-63
Fault code No. 43
Fuel system voltage: incorrect voltage supplied to the fuel injector

Item
and fuel pump.
5 Defective main relay. Execute the diagnostic mode. Start the engine and let it idle
(Code No. 09) for approximately 5 seconds.
Fuel system voltage is below Fault code number is not dis-
3 V → Replace the main relay. played → Service is finished.
→ 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.
Tool display
0 indication: Normal status
Procedure —
1 Locate the malfunction. Execute the diagnostic mode. —
(Code No. 60)
0 indication: Go to item 2.
Fault code No. 46

Fault code No. 46
Item Charging voltage is abnormal.

Fail-safe system
Tool display —
Procedure —
1 Malfunction in charging system. Check the charging system. Start the engine and let it idle
Refer to “CHARGING SYS- for approximately 5 seconds.
TEM” on page 9-10. Fault code number is not dis-
Defective rectifier/regulator or played → Service is finished.
AC magneto → Replace. Fault code number is displayed
Defective connection in the → Repeat the maintenance job.
charging system circuit → Prop-
erly connect or replace the wire
harness.
9-64
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
Tool display —
Procedure —
1 Malfunction in ECU. Replace the ECU. Turn the main switch to “ ”
(on).
Fault code No. 59

Fault code No. 59
Item Accelerator position sensor: open or short circuit detected.

Fail-safe system
Accelerator position sensor signal 1
Tool display
14 • 12–22 (fully closed position)
Procedure • Check with accelerator pedal fully closed.
Accelerator position sensor signal 2
Tool display
15 • 12–22 (fully closed position)
Procedure • Check with accelerator pedal fully closed.
1 Connection of accelerator posi- Improperly connected → Con- Turn the main switch to “ ”
tion sensor coupler. nect the coupler securely or re- (on).
of the pins).
of the pins).
9-65
Fault code No. 59
Item Accelerator position sensor: open or short circuit detected.

Between accelerator position Fault code number is not dis-
white–white
black–black
blue–blue
4 Installed condition of accelera- Check for looseness or pinch- Turn the main switch to “ ”
tor position sensor. ing. (on).
Reinstall the accelerator posi- played → Service is finished.
tion sensor. Fault code number is displayed
Refer to “PEDAL ASSEMBLY” → Go to item 5.
on page 4-79.
5 Defective accelerator position Check accelerator position sen- Turn the main switch to “ ”
sensor. sor signal 1. (on).
Execute the diagnostic mode. Fault code number is not dis-
(Code No. 14) played → Service is finished.
When the throttle valves are ful- Fault code number is displayed
ly closed: → Go to item 6.
A value of 12–22 is indicated.
Check accelerator position sen-
sor signal 2.
(Code No. 15)
When the throttle valves are ful-
ly closed:
A value of 12–22 is indicated.
An indicated value is out of the
specified range → Replace the
accelerator position sensor.
Fault code No. 60

Fault code No. 60
Item YCC-T drive system: malfunction detected.

Able/Unable to start engine
Fail-safe system
Able/Unable to drive vehicle
Tool display —
Procedure —
9-66
Fault code No. 60
Item YCC-T drive system: malfunction detected.

1 Connection of throttle servo mo- Improperly connected → Con- Turn the main switch to “ ”
tor coupler. nect the coupler securely or re- (on).
of the pins).
2 Connection of wire harness Improperly connected → Con- Turn the main switch to “ ”
ECU coupler. nect the coupler securely or re- (on).
Disconnect the coupler and place the wire harness. Fault code number is not dis-
3 Check the electronic throttle Abnormality → Replace the Turn the main switch to “ ”
valve fuse. electronic throttle valve fuse. (on).
→ Go to item 4.
Between throttle servo motor Fault code number is not dis-
yellow/white–yellow/white Fault code number is displayed
yellow/red–yellow/red → Go to item 5.
5 Foreign material caught in the Check that the throttle valves Turn the main switch to “ ”
throttle bodies. are fully closed when the main (on).
switch is turned to “ ” (off). Fault code number is not dis-
Foreign material is caught in the played → Service is finished.
throttle valves → Remove the Fault code number is displayed
foreign material. → Go to item 6.
6 Defective throttle bodies. Check the throttle bodies. Turn the main switch to “ ”
THROTTLE SERVO MOTOR” Fault code number is not dis-
on page 9-135. played → Service is finished.
Replace if defective. Fault code number is displayed
→ Go to item 7.
Fault code No. 71

Fault code No. 71
Item O2 sensor heater: defective heater controller detected.

Fail-safe system
Tool display —
Procedure —
9-67
Fault code No. 71

1 Connection of O2 sensor cou- Improperly connected → Con- Turn the main switch to “ ”
pler. nect the coupler securely or re- (on).
check the pins (bent or broken → Start the engine, warm it up,
terminals and locking condition and then check whether the en-
of the pins). gine trouble warning light comes
on.
Engine trouble warning light
does not come on → Service is
finished.
comes on → Go to item 2.
2 Connection of wire harness Improperly connected → Con- Turn the main switch to “ ”
ECU coupler. nect the coupler securely or re- (on).
check the pins (bent or broken → Start the engine, warm it up,
terminals and locking condition and then check whether the en-
of the pins). gine trouble warning light comes
on.
finished.
3 Wire harness continuity. Open or short circuit → Properly Turn the main switch to “ ”
connect or replace the wire har- (on).
ness. Fault code number is not dis-
Between O2 sensor coupler and played → Service is finished.
ECU coupler. Fault code number is displayed
pink/black–pink/black → Start the engine, warm it up,
Between O2 sensor coupler and and then check whether the en-
main switch coupler. gine trouble warning light comes
brown–brown on.
finished.
4 Defective O2 sensor heater. Replace the O2 sensor. Turn the main switch to “ ”
Refer to “ENGINE REMOVAL (on).
(1)” on page 5-7. Fault code number is not dis-
→ Start the engine, warm it up,
and then check whether the en-
gine trouble warning light comes
on.
finished.
9-68
Fault code No. 71

5 Defective O2 sensor heater con- Replace the ECU.
troller.
Fault code No. 85

Fault code No. 85
Item Oil pressure switch: open 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).
2 Installed condition of oil pres- Check for looseness or pinch- Turn the main switch to “ ”
sure switch. ing. (on).
Improperly installed switch → Fault code number is not dis-
Reinstall or replace the switch. played → Service is finished.
→ Go to item 3.
3 Defective oil pressure switch. Check the oil pressure switch. Turn the main switch to “ ”
Refer to “CHECKING THE OIL (on).
PRESSURE SWITCH” on page Fault code number is not dis-
9-132. played → Service is finished.
Replace if defective. Fault code number is displayed
→ Go to item 4.
of the pins).
Between oil pressure switch Fault code number is not dis-
yellow/white–yellow/white Fault code number is displayed
→ Go to item 6.
9-69
Fault code No. 92

Fault code No. 92
Item Purge cut valve solenoid: open circuit detected.

Fail-safe system
Actuates the purge cut valve solenoid 1 five times at one-second inter-
vals.
Actuation
The check indicator on the Yamaha diagnostic tool screen comes on
46 each time the purge cut valve solenoid 1 is actuated.
Check that purge cut valve solenoid 1 is actuated five times by listening
Procedure
for the operating sound.
Actuates the purge cut valve solenoid 2 five times at one-second inter-
vals.
Actuation
The check indicator on the Yamaha diagnostic tool screen comes on
94 each time the purge cut valve solenoid 2 is actuated.
Check that purge cut valve solenoid 2 is actuated five times by listening
Procedure
for the operating sound.
1 Identify the malfunctioning Execute the diagnostic mode. —
purge cut valve solenoid. (Code No. 46, 94)
Identify the purge cut valve so-
lenoid that does not produce an
operating sound.
2 Connection of purge cut valve Improperly connected → Con- Turn the main switch to “ ”
solenoid coupler. nect the coupler securely or re- (on).
of the pins).
of the pins).
Between main switch and purge Fault code number is not dis-
cut valve solenoid 1 and/or 2 played → Service is finished.
coupler. Fault code number is displayed
brown–brown → Go to item 5.
Between purge cut valve sole-
noid 1 and ECU coupler.
brown/red–brown/red
Between purge cut valve sole-
noid 2 and ECU coupler.
brown/yellow–brown/yellow
9-70
Fault code No. 92
Item Purge cut valve solenoid: open circuit detected.

5 Installed condition of purge cut Check for looseness or pinch- Turn the main switch to “ ”
valve solenoid. ing. (on).
Improperly installed solenoid → Fault code number is not dis-
Reinstall or replace the sole- played → Service is finished.
noid. Fault code number is displayed
→ Go to item 6.
6 Defective purge cut valve sole- Execute the diagnostic mode. Turn the main switch to “ ”
noid. (Code No. 46, 94) (on).
Purge cut valve solenoid does Fault code number is not dis-
not operate or there is no oper- played → Service is finished.
ating sound → Replace the Fault code number is displayed
purge cut valve solenoid. → Go to item 7.
9-71
9-72
EBS30282
EBS20081
B B
A B
(B) (B)
Br
CIRCUIT DIAGRAM
R/L
R/L
R/L
R/L
FUEL PUMP SYSTEM
Br Br
Br
34
Br
Br
14 L/R
R R
R
R
R Br/R
R/L
B B
Br/R Br L/R
B B R R R Br/R Br/R Br
B B
R/Y L/W B
B
(B) B/W
12 15 18 21 B/W
R/B L/R
R/L
13 B A B B B
OFF
B
ON
START
R
R 16
Br
Br R/B
L/W Br
(B)
9-73
B/W B
B B/W B
R R/B
94
R/L B B/W G
(Dgy)
74 R/L
75
B B
FUEL PUMP SYSTEM
FUEL PUMP SYSTEM
12.Frame ground
13.Main switch
14.Main fuse
15.Battery
16.Engine ground
18.Fuel injection system fuse
21.Main relay
75.Fuel pump
94.Ignition fuse
A. Wire harness
9-74
FUEL PUMP SYSTEM
EBS30283
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
1. Hood
2. Front cover

(Main, fuel injection system, and ig-
nition) Replace the fuse(s).
OK ↓
page 9-126.
OK ↓
OK ↓
4. Check the main relay. NG →
Refer to “CHECKING THE RE- Replace the main relay.
OK ↓
5. Check the fuel pump. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump assembly.
PUMP BODY” on page 7-7.
OK ↓
6. Check the entire fuel pump system NG →
page 9-73.
OK ↓
Replace the ECU.
9-75
FUEL PUMP SYSTEM
9-76
EBS30284
EBS20082
B B
A B
(B) (B)
Br
CIRCUIT DIAGRAM
Br Br
Br
34
Br
R
11 R
14
R R
Br/L R Y/B
Y/G
Br/L B Br B R
R B/Y P/W
O/L
Br/R Br/R B/G
B B Br/R B Y/B
Br/R W/B
B B B R B/R
(B)
B B L/Y
G/R B
B/Y B
B/W
12 P/W B/G W/B L/Y G/R B/W
2WD/4WD SELECTING SYSTEM
15 O/L B/Y Br/B B/R

L/W
R/B 27 32
2WD-LOCK
13 B A B B B Y/B B
28 4WD-DIFF
4WD-LOCK
OFF
B
ON L/W G/R
R B
START
R B
B/G P/WW/B B/R B O/L Br/B B/Y
R 16
Br
Br R/B B
(Dgy)
L/W Br G/R L/Y
(B) B
9-77
Br/L
Br/L
Br/R B B/W B
Br/R B B/W B
91 Br/B
Br/R
Br/R B Y/G
Br/R
(B) Br/R
R R/B
77 Br/B
94
Y/G B
B B B
B B B

12.Frame ground
13.Main switch
14.Main fuse
15.Battery
16.Engine ground
27.Differential motor relay 1
77.Differential motor relay 2
91.Four-wheel-drive motor fuse
94.Ignition fuse
A. Wire harness
9-78
EBS30285
TROUBLESHOOTING
The differential motor fails to operate.
TIP
1. Hood
2. Front cover
3. Skid plate

(Main, four-wheel-drive motor and
ignition fuse) Replace the fuse(s).
OK ↓
page 9-126.
OK ↓
OK ↓
4. Check the On-Command four- NG →
wheel-drive switch.
Refer to“CHECKING THE
Replace the On-Command four-wheel-
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 ↓
9-79

OK ↓
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 9-77.
OK ↓
Replace the ECU.
9-80
EBS30286
EBS20083
B B
A B
(B) (B)
B/L Gy
Gy B/L
B Gy
Gy B Br
CIRCUIT DIAGRAM
Br Br
Br
34
Br
Br L L
R W/Y W/Y L W/Y B/L
B/L
46
14 (Db)
11 R R/B
R R
Br/L R/B
R 17
Br/L B Br B R R/B R/B
R
B B
B B B R R R/B
R
B B B/L
B
B
Lg/R B/W
12 15 Lg/B B/W
R/B B/L
B/L
13 B A B B B
B
B/L
OFF
B
ON
R
START
R
R 16
Br
Br R/B
L/W Br
(B)
9-81
Br/L
Br/L
B/W B
B B/W B/W B
Lg/B Lg/R 58
Br/Y R/W B/W Lg/R
92 R/W Lg/B
R/W B/W 53
93
R R/B
EPS (ELECTRIC POWER STEERING) SYSTEM
94 59 Lg/R
Lg/R Br/Y
Br/Y
Lg/B
Lg/B
L
L Y/L Y/L Y/L Y/L Lg/RLg/RLg/R Lg/BLg/B Lg/B
53 G G L/G L/G G L L Y/L L L/W L/W L/W 54 55 56
G R (B)
R/W R/W B R
B W
(Dgy) WR G B B R (Gy)
WR G B R B
53
Lg/R
R G B R Lg/R
W B Lg/R
Lg/R
R/B G
G/R Lg/R Lg/B
57 Br Lg/B
72 B L/B Lg/B Lg/B
Lg/B
Br/Y Lg/R L/B G/R

Lg/B G B
B/W Br
(Gy) Lg/R Lg/R Lg/R Lg/R Lg/B Lg/B Lg/B Lg/B
(B)
73 R/B B
Lg/R Lg/B
Br
(Gy) (B)
R/W Br/Y B/W Y G (B)
Sb/W Lg/R Lg/B

(B)
B
B B B/W

12.Frame ground
13.Main switch
14.Main fuse
15.Battery
16.Engine ground
17.EPS fuse
46.Speed sensor
53.Joint coupler
54.EPS unit
55.EPS torque sensor
56.EPS motor
57.EPS control unit
59.Meter assembly
72.EPS warning light
93.Backup fuse
94.Ignition fuse
A. Wire harness
9-82
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. 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.
EBS30289
DIAGNOSTIC MODE
with the tool.

90890-03269
90890-03264

TIP
9-83
EBS30290
SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)

Fault code Probable cause of mal-
Item Symptom
No. function
• Open or short circuit in
PS_11 EPS torque sensor lead or
PS_12 EPS control unit lead.
No normal signals are received from
PS_13 EPS torque sensor • Malfunction in torque sen-
the EPS torque sensor.
PS_14 sor.
PS_17 • Malfunction in EPS control
unit.
PS_15
PS_33 Malfunction in EPS control
EPS control unit EPS control unit internal malfunction.
PS_34 unit.
PS_55
wire harness.
PS_21 Speed sensor • Malfunction in speed sen-
the ECU.
sor.
• Malfunction in ECU.
PS_23 Engine speed signal wire harness.
the ECU.
PS_31
PS_32
EPS motor lead or EPS
PS_41
No normal signals are received from control unit lead.
PS_42 EPS motor
the EPS motor. • Malfunction in EPS motor.
PS_43
• Malfunction in EPS control
PS_45
unit.
PS_46
Relay contacts in the EPS control unit Malfunction in EPS control
PS_51 EPS control unit
are defective. unit.
Relay contacts in the EPS control unit Malfunction in EPS control
PS_52 EPS control unit
are welded together. unit.
• Malfunction in the
charging system.
Refer to “CHARGING
PS_53 EPS control unit Battery voltage has increased.
SYSTEM” on page 9-10.
unit.
• Faulty battery.
• Malfunction in the
charging system.
PS_54 EPS control unit Battery voltage has dropped. Refer to “CHARGING
unit.
Signals cannot be transmitted be- wire harness.
PS_61 EPS control unit tween the ECU and the EPS control • Malfunction in ECU.
unit. • Malfunction in EPS control
unit.
9-84
EBS30291
TROUBLESHOOTING DETAILS (EPS SYSTEM)
Fault code No. PS_11, PS_12, PS_13, PS_14, PS_17

Fault code No. PS_11, Symptom EPS torque sensor: no normal signals are received from the
PS_12, EPS torque sensor.
PS_13,
PS_14,
PS_17
Order Item/components and probable cause Check or maintenance job Reinstatement
method
1 Connections • Check the locking condition of the Turn the main
• EPS torque sensor coupler coupler. switch to “ ”
• EPS control unit coupler • Disconnect the coupler and check (off).
the pins (bent or broken terminals
and locking condition of the pins).
• If there is a malfunction, connect
the coupler securely.
2 Open or short circuit in EPS torque sen- Replace if there is an open or short
sor lead or EPS control unit lead. circuit.
Between EPS torque sensor lead
and EPS control unit lead.
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
9-138.
4 Malfunction in EPS control unit. Replace the EPS control unit.
Fault code No. PS_15, PS_33, PS_34, PS_55

Fault code No. PS_15, Symptom EPS control unit internal malfunction.
PS_33,
PS_34,
PS_55

method
1 Malfunction in EPS control unit. Replace the EPS control unit. Turn the main
switch to “ ”
(off).
9-85
Fault code No. PS_21

Fault code No. PS_21 Symptom Speed sensor: no normal signals are received from the ECU.

method
• Speed coupler coupler. switch to “ ”
• ECU coupler • Disconnect the coupler and check (off).
the coupler securely or replace the
wire harness.
2 Open or short circuit in wire harness. Replace if there is an open or short
circuit.
Between speed sensor coupler and
ECU coupler.
blue–blue
white/yellow–white/yellow
3 Defective speed sensor. Execute diagnostic mode. (Code No.
07)
Rotate a rear wheel by hand and
check that the indicated value in-
creases.
Value increases → Correct.
Value does not increase → Defective
speed sensor.
9-86

Fault code No. PS_23 Symptom Engine speed signal: no normal signals are received from the
ECU.

method
• Crankshaft position sensor coupler coupler. switch to “ ”
wire harness.
circuit.
Between crankshaft position sensor
coupler and ECU coupler.
gray–gray
3 Installed condition of crankshaft position Check for looseness or pinching.
sensor. Improperly installed sensor → Rein-
stall or replace the crankshaft posi-
tion sensor/stator assembly.
4 Defective crankshaft position sensor. Check the crankshaft position sen-
sor.
Refer to “CHECKING THE CRANK-
SHAFT POSITION SENSOR” on
page 9-130.
Replace the crankshaft position sen-
sor/stator assembly if defective.
9-87
Fault code No. PS_31, PS_32, PS_41, PS_42, PS_43, PS_45, PS_46
Fault code No. PS_31, Symptom EPS motor: no normal signals are received from the EPS motor.
PS_32,
PS_41,
PS_42,
PS_43,
PS_45,
PS_46

method
• EPS motor coupler coupler. switch to “ ”
• EPS control unit coupler • Disconnect the coupler and check (off).
the coupler securely.
2 Open or short circuit in EPS motor lead Replace if there is an open or short
or EPS control unit lead. circuit.
Between EPS motor lead and EPS
control unit lead.
red–black
black–red
3 Defective EPS motor. Replace if defective.
Refer to “CHECKING THE EPS MO-

Fault code No. PS_51 Symptom Relay contacts in the EPS control unit are defective.

method
switch to “ ”
(off).

Fault code No. PS_52 Symptom Relay contacts in the EPS control unit are welded together.

method
switch to “ ”
(off).
9-88

Fault code No. PS_53 Symptom Battery voltage has increased.

method
1 Faulty battery. Replace the battery. Turn the main
Refer to “CHECKING AND switch to “ ”
CHARGING THE BATTERY” (BA- (off).
SIC INFORMATION).
2 Malfunction in rectifier/regulator. Replace if defective.
Refer to “CHECKING THE RECTIFI-
ER/REGULATOR” on page 9-132.

Fault code No. PS_54 Symptom Battery voltage has dropped.

method
1 Faulty battery. Replace or recharge the battery. Turn the main
CHARGING THE BATTERY” (BA- (off).
SIC INFORMATION).
2 Malfunction in rectifier/regulator or Replace if defective.
charging system. Refer to “CHECKING THE RECTIFI-
ER/REGULATOR” on page 9-132.

Fault code No. PS_61 Symptom Signals cannot be transmitted between the ECU and the EPS
control unit.

method
• EPS control unit coupler coupler. switch to “ ”
wire harness.
circuit.
Between ECU coupler and EPS con-
trol unit coupler.
light green/red–light green/red
light green/black–light green/black
9-89
9-90
EBS30728
EBS20153
B B
A B
W L B B/L (B) (B)
B/L Gy
Gy B/L
(B)
B Gy
Gy B B/L Br
29 W
CIRCUIT DIAGRAM
1
B B/L
W
L B
L
R/G
Y/W
31 Y/R
Y/W
Y/R
Br Br B L W B/L Y/W Y/R

Br
34
(B)
Br L L
R W/Y W/Y L W/Y B/L
B/L
46
14 (Db)
11 R
R R
Br/L R
Br/L B Br B R
R
B B R
B B B R
B B B/L
B
B
Lg/R B/W
12 15 Lg/B B/W
SPEED MANAGEMENT SYSTEM
R/B B/L
B/L
13 B A B B B
R B/L
OFF
B
ON
R
START
R R 33
R 16
Br
Br R/B B
L/W Br R B
(B) (B)
9-91
Br/L
Br/L
B/W B
B B B/W B
Br/Y
92
53
R R/B
94 59 Lg/R
Lg/R Br/Y
Br/Y
Lg/B
Lg/B
R L
R/G Y/L Y/L Y/L Y/L Lg/RLg/RLg/R Lg/BLg/B Lg/B
L
97 Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
(B)
53
Lg/R
Lg/R
Lg/B
Lg/B
Br/Y Lg/R
Lg/B
B/W
Lg/R Lg/R Lg/R Lg/R Lg/B Lg/B Lg/B Lg/B
73
R/W Br/Y B/W Y G
Sb/W Lg/R Lg/B
(B)
B
B B B/W

12.Frame ground
13.Main switch
14.Main fuse
15.Battery
16.Engine ground
29.Accelerator position sensor
31.Throttle servo motor
33.Speed management system switch
46.Speed sensor
53.Joint coupler
59.Meter assembly
94.Ignition fuse
97.Electric throttle valve fuse
A. Wire harness
9-92
EBS30955

This model is equipped with a speed management system.
When the speed management system switch is turn to the “ON” “1”, the speed management icon “2”
comes on and the vehicle’s top speed is limit to approximately 40 km/h (25 mph).
EBS30729
TROUBLESHOOTING
Symptom:
A. It is not normal indication for the speed management icon when the speed management system
switch is ON and OFF.
B. When the speed management system switch is ON and the speed management icon comes on, the
speed limiter is not operated.
C. When the speed management system switch is OFF and the speed management icon goes off, the
speed limiter is operated.
Symptom A → Go to item 1 to 7.
Symptom B and/or C → Go to item 1 to 5. If malfunction is not improvement, go to item 7.
TIP
If the fault code number is indicated, take the action first for the fault code number.
Refer to “TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM)” on page 9-45.
9-93

and check pletion
1 Connection of the meter assem- Improperly connection → Con- After turn the main switch to
bly coupler. nect the coupler securely or re- “ ” (off), turn the speed man-
Check the locking condition of place the wire harness. agement system switch to “ON”.
the coupler. And then turn the main switch to
Disconnect the coupler and “ ” (on) and check the condi-
check the pins (bent or broken tion of the speed management
terminals and locking condition icon.
of the pins). After turn the main switch to
“ ” (off), turn the speed man-
agement system switch to
“OFF”. And then turn the main
switch to “ ” (on) and check
the condition of the speed man-
agement icon.
• Turn the management system
switch to “ON”: the speed
management icon comes on.
switch to “OFF”: the speed
management icon goes off.
Correct → Service is finished.
Incorrect → Go to item 2.
2 Connection of the ECU coupler. Improperly connection → Con- After turn the main switch to
Check the locking condition of nect the coupler securely or re- “ ” (off), turn the speed man-
the coupler. place the wire harness. agement system switch to “ON”.
Disconnect the coupler and And then turn the main switch to
check the pins (bent or broken “ ” (on) and check the condi-
terminals and locking condition tion of the speed management
of the pins). icon.
After turn the main switch to
agement icon.
9-94

and check pletion
3 Connection of the speed man- Improperly connection → Con- After turn the main switch to
agement system switch coupler. nect the coupler securely or re- “ ” (off), turn the speed man-
Check the locking condition of place the wire harness. agement system switch to “ON”.
the coupler. And then turn the main switch to
Disconnect the coupler and “ ” (on) and check the condi-
check the pins (bent or broken tion of the speed management
terminals and locking condition icon.
of the pins). After turn the main switch to
agement icon.
4 Defective speed management Check the speed management After turn the main switch to
system switch. system switch. “ ” (off), turn the speed man-
Refer to “CHECKING THE agement system switch to “ON”.
SWITCHES (YXF10WRAN)” on And then turn the main switch to
page 9-123 or “CHECKING “ ” (on) and check the condi-
THE SWITCHES tion of the speed management
(YXF10WRZN/YXF10WRLN)” icon.
on page 9-124. After turn the main switch to
Replace if defective. “ ” (off), turn the speed man-
agement icon.
9-95

and check pletion
5 Wire harness continuity. Open or shot circuit → Replace After turn the main switch to
the wire harness. “ ” (off), turn the speed man-
Between meter assembly cou- agement system switch to “ON”.
pler and joint coupler. And then turn the main switch to
light green/red–light green/red “ ” (on) and check the condi-
light green/black–light green/ tion of the speed management
black icon.
Between joint coupler and ECU After turn the main switch to
coupler. “ ” (off), turn the speed man-
light green/red–light green/red agement system switch to
light green/black–light green/ “OFF”. And then turn the main
black switch to “ ” (on) and check
Between speed management the condition of the speed man-
system switch coupler to ECU agement icon.
coupler. • Turn the management system
red–red switch to “ON”: the speed
Between speed management management icon comes on
system switch coupler to frame and the speed limiter is oper-
ground. ated.
black–black • Turn the management system
management icon goes off
and the speed limiter is not
operated.
When speed management sys-
tem switch is ON and the speed
management icon comes on,
the speed limiter is not operat-
ed. → Go to item 7.
When speed management sys-
tem switch is OFF and the
speed management icon goes
off, the speed limiter is operat-
ed. → Go to item 7.
9-96

and check pletion
6 Defective meter assembly. Replace the meter assembly. After turn the main switch to
agement system switch to “ON”.
And then turn the main switch to
“ ” (on) and check the condi-
tion of the speed management
icon.
After turn the main switch to
agement icon.
management icon comes on
and the speed limiter is oper-
ated.
management icon goes off
and the speed limiter is not
operated.
9-97
9-98
EBS30949
EBS20167
A B D
L B/W B R
B B B B
Br B B R
A B A C A F
(B) (B)
Br R
B Br
Br Br B B B Br
CIRCUIT DIAGRAM
8
B R
Br
B
Br B
Br
Br
Br
34
14 R
R R
R
R
R
B
B B R
B B
B
B
Lg/R B/W
12 15 Lg/B B/W
Br R/B
Br
13 B A B B B
OFF
B B B B B
ON
START
R
R 16 105
Br
Br R/B Lg/R G
Lg/B W G W
L/W Br
B/W B B R
(B) L R
9-99
Lg/B Lg/R
L B/W
(B)
B/W B
B B/W B
GPS SYSTEM (YXF10WRZN/YXF10WRLN)
B D
Br D R
B/W D B 106
L D R
53
R R/B
94 Lg/R
Lg/R
Lg/B
Lg/B
Y/L Y/L Y/L Y/L Lg/RLg/RLg/R Lg/BLg/B Lg/B

R R
(B)
98
53
Lg/R
Lg/R
Lg/B
Lg/B
8. Accessory relay
12.Frame ground
13.Main switch
14.Main fuse
15.Battery
16.Engine ground
53.Joint coupler
94.Ignition fuse
98.Accessory fuse
105.GPS monitor
106.USB converter
A. Wire harness
C. Negative battery sub-wire harness 2
F. Sub-wire harness (GPS)
9-100
System diagram
Lg/B Lg/R G W A
L B/W B R
(B) L B/W B R
Br B B R
Lg/R G
Lg/B W 4 1
B/W B
L R A B
B R R B
B A B B B B
Br A R R R R
B/W A B B 2 Y Y 3
L A R R W W
B R R B R B B R
Y W Y W W Y
1. GPS fuse
2. USB converter
3. USB jack
4. GPS monitor
A. Wire harness
B. Sub-wire harness (GPS)
9-101
EBS30838
TROUBLESHOOTING
If the GPS system fails to operate.
TIP
• Before troubleshooting, remove the following parts.
1. Hood
2. Front cover
3. Dashboard (right)

(Main, accessory and GPS)
OK ↓
page 9-126.
OK ↓
OK ↓
4. Check the accessory relay. NG →
Refer to “CHECKING THE RE- Replace the accessory relay.
OK ↓
5. Check the USB converter. NG →
Refer to “CHECKING THE USB
Replace the USB converter.
CONVERTER (YXF10WRZN/
OK ↓
6. Checking the GPS system wiring. NG →
Refer to “CIRCUIT DIAGRAM” on
ness and/or sub-wire harness (GPS).
page 9-99.
OK ↓
Replace the USB jack, GPS monitor or
ECU.
9-102
EBS30997
EBS20166
A B
B B B B
A B A C
E
Lg/B Y/G L B/L W L B G/W Br Sb L/W O/L R/Y Y/W B/W Y/R R/G B W
R B B R Lg/BLg/R
Lg/R Gy P/B B/L W L R/L B/W P L/R Y/L P/W Y/G Y/B B B Br R
(B)
(B) (B)
A G A G
Br R
Br B B Br
Br B B Br
CIRCUIT DIAGRAM
8
B R
Br
B
Br B
Br
Br Br
Br
34
Br
R
11 R
14 R
R R
Br/L R
Br/L Br B R
R
B
B B R
B B
B
B
Lg/R B/W
12 15 Lg/B B/W
Br R/B
Br
13 B A B B B
OFF
B B B B B
ON
R
START
R
R 16
Br
Br R/B
L/W Br
(B)
Br/L
9-103
Br/L
B/W B
B B/W B/W B
Lg/B Lg/R 58
Br/Y R/W B/W Lg/R
92 R/W Lg/B
R/W B/W 53
93
R R/B
94 59 Lg/R
Lg/R Br/Y
Br/Y
Lg/B
Lg/B
Y/L Y/L Y/L Y/L Lg/RLg/RLg/R Lg/BLg/B Lg/B

R R 53 G G L/G L/G G L L Y/L L L/W L/W L/W
R (B)
98 R/W R/W
53
Lg/R
Lg/R
Lg/R
Lg/R
Lg/B
Lg/B
Lg/B
Lg/B
113
Br/Y
Lg/R
Lg/B Lg/R Lg/R Lg/R Lg/R Lg/R Lg/B Lg/B Lg/B Lg/B Lg/B
73
R/W Br/Y B/W Y G
Sb/W Lg/R Lg/B
(B)
Lg/R E B
Lg/B E W
Br E R
112
R E
B E
ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (YXF10WRLN)
(YXF10WRLN)
(YXF10WRLN)
8. Accessory relay
12.Frame ground
13.Main switch
14.Main fuse
15.Battery
16.Engine ground
53.Joint coupler
59.Meter assembly
93.Backup fuse
94.Ignition fuse
98.Accessory fuse
112.SCU (Suspension Control Unit)
113.Suspension system warning light
A. Wire harness
G. Sub-wire harness (SCU)
9-104
(YXF10WRLN)
System diagram
A
Lg/B Lg/R B W
R B B R
(B) Br R
A B A B
R O G B Br L O R B
R Br W B Br R
Lg/R A B O R B O G
Lg/B A W R Br B Br R
Br A R R G
Br
R A R R R R R R
O R Br
B A B
1 G O
Br 4 O B
W Br B
B B
R R
R
O O O R Br
Br 5 O B
L Br
B
2 Br R O L
B
3
R
R
COMFORT O R Br
O
MEDIUM Br Br
6 O B
Br O L FIRM B
B
B R G
R
B G O R
L O Br O R Br
G R B
G Br
Br 7 O B
B B B B B
1. SCU fuse
2. Suspension mode switch
3. SCU (Suspension Control Unit)
4. Front shock absorber assembly stepping
motor (left)
5. Front shock absorber assembly stepping
motor (right)
6. Rear shock absorber assembly stepping
motor (left)
7. Rear shock absorber assembly stepping
motor (right)
A. Wire harness
B. Sub-wire harness (SCU)
9-105
(YXF10WRLN)
EBS30998
SCU (Suspension Control Unit) SELF-DIAGNOSTIC FUNCTION

The SCU (Suspension Control Unit) is equipped with a self-diagnostic function in order to ensure that
the electronically adjustable suspension system is operating normally. If this function detects a malfunc-
tion in the electronically adjustable suspension system, lights the suspension system warning light to
alert the driver that a malfunction has occurred in the system. When this occurs, the fault code number
appears on the multi-function meter display. Once a malfunction has been detected, a fault code is
stored in the memory of the SCU (Suspension Control Unit).
Checking the suspension system warning light

The suspension system warning light “1” come on for a few seconds after the main switch has been
turned to “ON”. If the suspension system warning light does not come on under this condition, the elec-
trical circuit may be defective.
EBS30999
DIAGNOSTIC MODE
with the tool.

90890-03269
90890-03264

TIP
9-106
(YXF10WRLN)
EBS31000
SELF-DIAGNOSTIC FUNCTION TABLE (ELECTRONICALLY ADJUSTABLE SUSPENSION

SYSTEM)
Fault code Probable cause of mal-
Item Symptom
No. function
SC_17 SCU (Suspension Con-
SCU internal malfunction. Malfunction in SCU.
SC_81 trol Unit)
• Faulty battery.
• Malfunction in the rectifier/
regulator or charging sys-
Battery voltage has dropped. tem.
SC_56 trol Unit)
Refer to “CHARGING
• Malfunction in SCU.
• Faulty battery.
• Malfunction in the rectifier/
regulator.
Battery voltage has increased. Refer to “CHECKING THE
SC_56 trol Unit)
RECTIFIER/REGULA-
sub-wire harness (SCU).
Front shock absorber
SC_23 Front shock absorber assembly step- • Malfunction in front shock
assembly stepping mo-
SC_24 ping motor failure or motor line failure. absorber assembly step-
tor
ping motor.
Rear shock absorber
SC_25 Rear shock absorber assembly step- • Malfunction in rear shock
assembly stepping mo-
SC_33 ping motor failure or motor line failure. absorber assembly step-
tor
ping motor.
Suspension mode
SC_38 Suspension mode switch failure. • Malfunction in suspen-
switch
sion mode switch.
SCU (Suspension Con- Suspension control unit: CAN bus off wire harness or sub-wire
SC_57
trol Unit) and/or CAN hardware failure. harness (SCU).
ECU (Engine Control No normal signals are received from wire harness or sub-wire
SC_66
Unit) the ECU. harness (SCU).
9-107
(YXF10WRLN)
EBS31001
TROUBLESHOOTING DETAILS (ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM)
Fault code No. SC_17, SC_81

Fault code No. SC_17, Symptom SCU internal failure.
SC_81

method
1 Malfunction in SCU. Replace the SCU. Turn the main
switch to “ ”
(off) and then to
“ ” (on).

Fault code No. SC_21, Symptom Battery voltage has dropped.
SC_56

method
1 Faulty battery. Replace or charge the battery. Turn the main
CHARGING THE BATTERY” on (off).
page 9-126
2 Malfunction in rectifier/regulator or Replace if defective.
charging system. Refer to “CHARGING SYSTEM” on
page 9-10
3 Malfunction in SCU. Replace the SCU.

Fault code No. SC_22, Symptom Battery voltage has increased.
SC_56

method
1 Faulty battery. Replace or charge the battery. Turn the main
CHARGING THE BATTERY” on (off).
page 9-126
2 Malfunction in rectifier/regulator. Replace if defective.
Refer to “CHECKING THE RECTIFI-
ER/REGULATOR” on page 9-132
9-108
(YXF10WRLN)
Fault code No. SC_23
Fault code No. SC_23 Symptom Front shock absorber assembly stepping motor (left) failure or
motor line failure.

method
1 Connections. • Check the locking condition of the Turn the main
• Front shock absorber assembly step- coupler. switch to “ ”
ping motor coupler (left) at the sub-wire • Disconnect the coupler and check (off).
harness (SCU). the pins (bent or broken terminals
• SCU coupler at the sub-wire harness and locking condition of the pins).
(SCU). • If there is a malfunction, connect
2 Open or short circuit in sub-wire harness Replace the sub-wire harness (SCU)
(SCU). if there is an open or short circuit.
Between the front shock absorber
assembly stepping motor coupler
(left) and SCU coupler.
13 (brown)–13 (brown)
15 (black)–15 (black)
20 (orange)–20 (orange)
22 (red)–22 (red)
A
22 13
20 15
B
22 20 17 15 13 10 7 6 3
25 19 12 11 9 5
24 18 8 4 2
23 21 16 14 1
A: Front shock absorber assembly

stepping motor coupler (left) (sub-
wire harness (SCU))
B: SCU coupler (sub-wire harness
(SCU))
3 Malfunction in front shock absorber as- Replace the front shock absorber
sembly stepping motor (left). assembly (left).
9-109
(YXF10WRLN)
Fault code No. SC_24 Symptom Front shock absorber assembly stepping motor (right) failure or
motor line failure.

method
• Front shock absorber assembly step- coupler. switch to “ ”
ping motor coupler (right) at the sub- • Disconnect the coupler and check (off).
wire harness (SCU). the pins (bent or broken terminals
Between the front shock absorber
(right) and SCU coupler.
23 (red)–23 (red)
A
23 14
21 16
B
22 20 17 15 13 10 7 6 3
25 19 12 11 9 5
24 18 8 4 2
23 21 16 14 1
A: Front shock absorber assembly

stepping motor coupler (right) (sub-
wire harness (SCU))
(SCU))
3 Malfunction in front shock absorber as- Replace the front shock absorber
sembly stepping motor (right). assembly (right).
9-110
(YXF10WRLN)
Fault code No. SC_25 Symptom Rear shock absorber assembly stepping motor (left) failure or
motor line failure.

method
• Rear shock absorber assembly step- coupler. switch to “ ”
ping motor coupler (left) at the sub-wire • Disconnect the coupler and check (off).
harness (SCU). the pins (bent or broken terminals
Between the rear shock absorber
(left) and SCU coupler.
5 (red)–5 (red)
A
5 9
4 8
B
22 20 17 15 13 10 7 6 3
25 19 12 11 9 5
24 18 8 4 2
23 21 16 14 1
A: Rear shock absorber assembly

stepping motor coupler (left) (sub-
wire harness (SCU))
(SCU))
3 Malfunction in rear shock absorber as- Replace the rear shock absorber as-
sembly stepping motor (left). sembly (left).
9-111
(YXF10WRLN)
Fault code No. SC_33 Symptom Rear shock absorber assembly stepping motor (right) failure or
motor line failure.

method
• Rear shock absorber assembly step- coupler. switch to “ ”
ping motor coupler (right) at the sub- • Disconnect the coupler and check (off).
wire harness (SCU). the pins (bent or broken terminals
Between the rear shock absorber
(right) and SCU coupler.
25 (red)–25 (red)
A
25 19
24 18
B
22 20 17 15 13 10 7 6 3
25 19 12 11 9 5
24 18 8 4 2
23 21 16 14 1
A: Rear shock absorber assembly

stepping motor coupler (right) (sub-
wire harness (SCU))
(SCU))
3 Malfunction in rear shock absorber as- Replace the rear shock absorber as-
sembly stepping motor (right). sembly (right).
9-112
(YXF10WRLN)
Fault code No. SC_38 Symptom Suspension mode switch failure.

method
• Suspension mode switch coupler. coupler. switch to “ ”
• SCU coupler at the sub-wire harness • Disconnect the coupler and check (off).
(SCU). the pins (bent or broken terminals
2 Short circuit in sub-wire harness (SCU). Replace the sub-wire harness (SCU)
if there is an open or short circuit.
Between the suspension mode
switch coupler and SCU coupler.
6 (red)–6 (red)
10 (blue)–10 (blue)
17 (green)–17 (green)
A
10 7 28
17 6 30
B
22 20 17 15 13 10 7 6 3
25 19 12 11 9 5
24 18 8 4 2
23 21 16 14 1
A: Suspension mode switch coupler

(sub-wire harness (SCU))
(SCU))
3 Malfunction in suspension mode switch. Replace the suspension mode
switch.
9-113
(YXF10WRLN)
Fault code No. SC_57 Symptom Suspension control unit: CAN bus off and/or CAN hardware fail-
ure.

method
• SCU coupler at the sub-wire harness coupler. switch to “ ”
(SCU). • Disconnect the coupler and check (off).
• ECU coupler at the wire harness. the pins (bent or broken terminals
• The couplers for connecting the wire and locking condition of the pins).
harness and sub-wire harness (SCU). • If there is a malfunction, connect
wire harness or sub-wire harness
(SCU).
2 Open or short circuit in wire harness or • Replace the wire harness if there is
sub-wire harness (SCU). an open or short circuit.
Between the sub-wire harness
coupler (SCU) and ECU coupler.
Between the sub-wire harness and
accessory relay.
brown–brown
• Replace the sub-wire harness
(SCU) if there is an open or short
circuit.
Between the suspension signaling
coupler and SCU coupler.
12 (white)–12 (white)
27 (red)–2 (green)
A
11 12
27
B
22 20 17 15 13 10 7 6 3
25 19 12 11 9 5
24 18 8 4 2
23 21 16 14 1
A: Suspension signaling coupler

(SCU))
9-114
(YXF10WRLN)
Fault code No. SC_66 Symptom No normal signals are received from the ECU.

method
• SCU coupler at the sub-wire harness coupler. switch to “ ”
(SCU). • Disconnect the coupler and check (off).
• ECU coupler at the wire harness. the pins (bent or broken terminals
• The couplers for connecting the wire and locking condition of the pins).
harness and sub-wire harness (SCU). • If there is a malfunction, connect
wire harness or sub-wire harness
(SCU).
2 Open or short circuit in wire harness or • Replace the wire harness if there is
sub-wire harness (SCU). an open or short circuit.
Between the sub-wire harness
coupler (SCU) and ECU coupler.
Between the sub-wire harness and
accessory relay.
brown–brown
• Replace the sub-wire harness
(SCU) if there is an open or short
circuit.
Between the suspension signaling
coupler and SCU coupler.
12 (white)–12 (white)
27 (red)–2 (green)
A
11 12
27
B
22 20 17 15 13 10 7 6 3
25 19 12 11 9 5
24 18 8 4 2
23 21 16 14 1
A: Suspension signaling coupler

(SCU))
9-115
(YXF10WRLN)
9-116
EBS30448
EBS20160
R B C
C
102 Y 104
L Y R G G Y R
OUT B B Br B B/R R
B/R B O B R
-
IN R
O B
C C C
A C A D D E
B G B/R
103
L Y
B/R R G G G B
C C G
B Br B
114 114 B
G B B Br
B
Br R
Br B B Br
Br B B
CIRCUIT DIAGRAM
8
B R
Br
B
Br B
Br
Br
14 R
R R
R
R
R
R R
15
Br R/B
Br
B
13 B
OFF
B B B B B
ON
START
R
R 16
Br
Br R/B
L/W Br
(B)
9-117
WINCH SYSTEM (YXF10WRZN/YXF10WRLN)
R R/B
94
R R
98
8. Accessory relay
13.Main switch
14.Main fuse
15.Battery
16.Engine ground
94.Ignition fuse
98.Accessory fuse
102.Winch switch
103.Winch contactor
104.Winch
114.Diode
A. Wire harness
D. Sub-wire harness (winch)
E. Winch switch
9-118
EBS30950
TROUBLESHOOTING
If the winch system fails to operate.
TIP
1. Hood
2. Front cover
3. Front guard

(Accessory, main and ignition)
OK ↓
page 9-126.
OK ↓
OK ↓
4. Check the winch switch. OK →
Replace the winch switch.
NG ↓
5. Check the winch contactor. NG →
Refer to “CHECKING THE WINCH
Replace the winch contactor.
CONTACTOR (YXF10WRZN/
OK ↓
6. Check the accessory relay. NG →
Refer to “CHECKING THE RE- Replace the accessory relay.
OK ↓
7. Check the entire winch system wir- NG →
ing. Properly connect or replace the wire har-
page 9-117.
OK ↓
Replace the winch.
9-119
ELECTRICAL COMPONENTS
EBS20084
3 4 5
2
1
23
22
7
21
8
20
19
9
18
10
15
11
17 12
16 13,14
1. EPS motor 18. Rear auxiliary DC jack (YXF10WRZN/
2. EPS torque sensor YXF10WRLN)
3. Brake light switch 19. Buzzer
4. D-mode switch (YXF10WRZN/YXF10WRLN) 20. On-Command four-wheel-drive switch
5. Suspension mode switch (YXF10WRLN) (YXF10WRAN)
6. Accelerator position sensor 21. On-Command four-wheel-drive switch
7. Front auxiliary DC jack
22. Light switch (YXF10WRAN)
23. Light switch (YXF10WRZN/YXF10WRLN)
9. Interior light (YXF10WRZN/YXF10WRLN)
10. Intake air pressure sensor
11. Ignition coil #2
12. Ignition coil #1
13. Throttle position sensor
14. Throttle servo motor
15. Fuel injector #2
16. Fuel injector #1
17. Coolant temperature sensor
9-120
8
3 4 7
1 5
6
20
19
18
17 9
16
15
10
11
14 13 12
1. Battery 19. Radiator fan motor relay

2. Starter relay 20. Main relay
3. Fuel injection system fuse
4. Reverse relay
5. Differential motor relay 1
6. Differential motor relay 2
8. Radiator fan motor circuit breaker
9. ECU (Engine Control Unit)
10. SCU (Suspension Control Unit)
(YXF10WRLN)
11. Lean angle sensor
12. EPS (electric power steering) control unit
13. Winch contactor (YXF10WRZN/
YXF10WRLN)
14. Fuse box
15. EPS fuse
16. Main fuse
18. Accessory relay
9-121
5 6
2 3 4
7
17
9
16
13
15 11
12 10
14
1. Purge cut valve solenoid 1

2. Purge cut valve solenoid 2
3. Air induction system solenoid
4. Intake air temperature sensor
5. Speed sensor
6. Reverse switch
8. Radiator fan motor
9. Winch (YXF10WRZN/YXF10WRLN)
10. Rectifier/regulator
11. Fuel sender
12. Fuel pump
14. AC magneto
15. Oil pressure switch
16. Starter motor
17. O2 sensor
9-122
EBS30292
CHECKING THE SWITCHES (YXF10WRAN)

Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check
the wiring connections and if necessary, replace the switch.
3 4
Br R/B L/W Br
2 OFF
Br Y ON
L/W B G/R
START
2WD-LOCK L/W G/R (B)
4WD-DIFF Br
B
DIFF LOCK
5
R B
1 OFF
B R
ON
Br L Y
OFF (B)
LO
HI
Br Y
L
10 6
L L/R
B L B
L/R B
7
L W Gy
9 8
L W
Gy
(B)
1. Light switch
4. Main switch
6. Parking brake switch
8. Reverse switch
10. Seat belt switch
9-123
EBS30877
CHECKING THE SWITCHES (YXF10WRZN/YXF10WRLN)

Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check
the wiring connections and if necessary, replace the switch.
3 4 5
Br R/B L/W Br
R B
2 Br
OFF OFF
Br Y ON ON
B R
L/W B G/R
START
2WD-LOCK L/W G/R (B)
4WD-DIFF Br (B)
B
DIFF LOCK B Br
B 6
Y/B B G
MODE_S Y/B G
MODE_T
B
1 MODE_C
Br
Br L Y Br
OFF
LO
HI B Br
B Br
B
B
Br Y
L
7
Y
12 O Y G
OUT
L
IN
O B
B L B
R G
B/R B
9 8
L W Gy L/R
11 10
L/R B
L W
Gy
(B)
1. Light switch
4. Main switch
6. D-mode switch
7. Winch switch
8. Parking brake switch
10. Reverse switch
12. Seat belt switch
9-124
EBS30295
ADJUSTING THE HEADLIGHT BEAMS Amperage

No. Fuses Q’ty
The following procedure applies to both of the rating
headlights. 1 Main 50.0 A 1
1. Remove: 2 EPS 40.0 A 1
• Hood
Fuel injection system
• Front grill rear cover(s) 3 10.0 A 1
(spare)
4 Fuel injection system 10.0 A 1
4-15.
2. Adjust: Spare 20.0 A 1
• Headlight beam (vertically) Spare 10.0 A 1
a. Turn the adjusting screw “1”. 5 Spare 30.0 A 1
Spare 15.0 A 1
Spare 7.5 A 1
1
6 Accessory 20.0 A 1
Electronic throttle valve
7 10.0 A 1
fuse
8 Auxiliary DC jack 10.0 A 1
9 Radiator fan motor 30.0 A 1
10 Ignition 15.0 A 1
3. Install: 11 Backup 7.5 A 1
• Front grill rear cover(s) Four-wheel-drive motor
12 7.5 A 1
• Hood fuse
Refer to “GENERAL CHASSIS (4)” on page 13 Signaling system 7.5 A 1
4-15.
14 Headlight 7.5 A 1
EBS30296
GPS (YXF10WRZN/
CHECKING THE FUSES 15 7.5 A 1
YXF10WRLN)
The following procedure applies to all of the fus-
Audio (YXF10WRZN/
es. 16 12.0 A 1
ECB01980
YXF10WRLN)
NOTICE 17 SCU (YXF10WRLN) 15.0 A 1
To avoid a short circuit, always set the main
switch to “OFF” when checking or replacing
a fuse. 1
5
1. Remove: 2
• Hood 6 7 8
• Front cover 3
Refer to “GENERAL CHASSIS (4)” on page 5
5 4
4-15.
2. Check:
• Fuse 9 10 11 12 13 14
9-125
• Hood
4-15.
EBS30297
15 CHECKING AND CHARGING THE BATTERY

TIP
Refer to “CHECKING AND CHARGING THE
BATTERY” in “BASIC INFORMATION” (sepa-
rate volume).
1. Remove:
• Hood
4-15.
2. Disconnect:
17 • Battery leads
(from the battery terminals)
ECB03830
NOTICE
First, disconnect the negative battery lead,
and then positive battery lead.
a. Connect the digital circuit tester to the fuse 3. Remove:
and check the continuity. • Battery
4. Check:
Digital circuit tester (CD732)
• Battery charge
90890-03243
Model 88 Multimeter with ta- 5. Charge:
chometer • Battery
YU-A1927 6. Install:
• Battery
b. If there is no continuity, replace the fuse. Refer to “GENERAL CHASSIS (14)” on page
3. Replace: 4-42.
• Blown fuse 7. Connect:
a. Turn the main switch to “ ” (off). • Battery leads
b. Install a new fuse of the correct amperage (to the battery terminals)
ECB03840
rating.
NOTICE
c. Set on the switches to verify if the electri-
cal circuit is operational. First, connect the positive battery lead, and
d. If the fuse immediately blows again, check then the negative battery lead.
the electrical circuit. 8. Check:
EWB02850
• Battery terminals
WARNING
Dirt → Clean with a wire brush.
Never use a fuse with an amperage rating Loose connection → Connect properly.
other than that specified. Improvising or us- 9. Install:
ing a fuse with the wrong amperage rating • Hood
may cause extensive damage to the electri- Refer to “GENERAL CHASSIS (4)” on page
cal system, cause the lighting and ignition 4-15.
systems to malfunction and could possibly
cause a fire. EBS30298
CHECKING THE RELAYS

4. Install: Check each switch for continuity with the digital
• Front cover circuit tester. If the continuity reading is incor-
rect, replace the relay.
9-126
Load control relay

90890-03243 3
4 +
chometer
YU-A1927
2 1
1. Disconnect the relay from the wire harness.
2. Connect the digital circuit tester and battery B Br
Br/L
(12 V) to the relay terminal as shown.
R
Check the relay operation.
1. Positive battery terminal
Accessory relay 2. Negative battery terminal
3. Positive tester probe
3 4. Negative tester probe
4 +
Result
2 Continuity
1 (between “3” and “4”)
B Br
Br
Reverse light relay
R
First step:
1. Positive battery terminal 1
2. Negative battery terminal
4. Negative tester probe
2
Result G/W Br/Y Br/Y
Continuity
(between “3” and “4”) G
Starter relay 1. Positive tester probe

3
R Result
Continuity
Br/B (between “1” and “2”)
R/Y L/W
Second step:
B
2 1 3
4 +
4
2. Negative battery terminal 2 1
G/W Br/Y Br/Y
G
Result
Continuity 1. Positive battery terminal
(between “3” and “4”) 2. Negative battery terminal
9-127
4. Negative tester probe Differential motor relay 1

First step:
Result
No continuity 1
(between “3” and “4”)
3
Radiator fan motor relay

2
Y/B B Br/R
Br/R
B/Y

Y Br 2. Negative tester probe
R/L 3. Negative tester probe
R/G
Result
1. Positive battery terminal Continuity
2. Negative battery terminal (between “1” and “2”)
3. Positive tester probe No continuity
4. Negative tester probe (between “1” and “3”)
Second step:
Result 3
Continuity
(between “3” and “4”) 5 +
4
Main relay 2
1
3 Y/B B Br/R
4 Br/R
B/Y
2
1 1. Positive battery terminal
Br
2. Negative battery terminal
2. Negative battery terminal Result
3. Positive tester probe No continuity
4. Negative tester probe (between “3” and “4”)
Continuity
Result
Continuity
9-128
Differential motor relay 2

Primary coil resistance
First step: 1.19–1.61 Ω
1 a. Remove the ignition coil from the spark
3 plug.
b. Connect the digital circuit tester to the igni-
tion coil as shown.
2
Y/G B Br/R Digital circuit tester (CD732)
Br/R 90890-03243
Br/B Model 88 Multimeter with ta-
chometer
1. Positive tester probe YU-A1927
3. Negative tester probe • Positive tester probe
Ignition coil terminal “1”
• Negative tester probe
Result Ignition coil terminal “2”
Continuity
1
No continuity 2
Second step:
3
5 +
4
2 G101573
1
c. Measure the primary coil resistance.
Y/G B Br/R
2. Check:
Br/R
Br/B
• Secondary coil resistance
Out of specification → Replace the ignition
coil.
2. Negative battery terminal Secondary coil resistance
3. Positive tester probe 8.50–11.50 kΩ
5. Negative tester probe a. Connect the digital circuit tester to the igni-
tion coil as shown.
Result
No continuity Digital circuit tester (CD732)
(between “3” and “4”) 90890-03243
Continuity Model 88 Multimeter with ta-
(between “3” and “5”) chometer
YU-A1927
EBS30300
CHECKING THE IGNITION COILS • Negative tester probe

The following procedure applies to all of the igni- Ignition coil terminal “1”
• Positive tester probe
tion coils. Spark plug terminal “2”
1. Check:
• Primary coil resistance
Out of specification → Replace the ignition
coil.
9-129
EBS30302
CHECKING THE CRANKSHAFT POSITION

1 SENSOR
1. Disconnect:
• Crankshaft position sensor coupler
(from the wire harness)
2. Check:
• Crankshaft position sensor resistance
2 G101574 shaft position sensor/stator assembly.
b. Measure the secondary coil resistance. Crankshaft position sensor resis-
EBS30301
tance
CHECKING THE IGNITION SPARK GAP 446–545 Ω
1. Check:
• Ignition spark gap a. Connect the digital circuit tester to the
Out of specification → Perform the ignition crankshaft position sensor coupler as
system troubleshooting, starting with step 5. shown.
Refer to “TROUBLESHOOTING” on page
9-3. 90890-03243
Minimum ignition spark gap
chometer
6.0 mm (0.24 in)
YU-A1927
TIP
• Positive tester probe →
If the ignition spark gap is within specification, gray “1”
the ignition system circuit is operating normally. • Negative tester probe →
black “2”
a. Disconnect the spark plug cap from the
spark plug.
b. Connect the ignition checker “1” as
shown.
Ignition checker
90890-06754
Oppama pet–4000 spark checker
Gy B
YM-34487
1 2
b. Measure the crankshaft position sensor

resistance.
EBS30303
CHECKING THE LEAN ANGLE SENSOR

1. Remove:
• Lean angle sensor
2. Check:
G101575
• Lean angle sensor output voltage
2. Spark plug cap Out of specification → Replace.
c. Measure the ignition spark gap “a”.
d. Crank the engine by turning the main
switch to “ ” (start) and gradually in-
crease the spark gap until a misfire oc-
curs.
9-130
Refer to “TROUBLESHOOTING” on page

Lean angle sensor output voltage 9-7.
Operating angle a. Connect the positive battery terminal “1”
65 ° and starter motor lead “2” with a jumper
Output voltage up to operating
lead “3”.
angle EWB02920
3.6–4.5 V WARNING
Output voltage over operating an-
gle • A wire that is used as a jumper lead must
0.7–1.4 V have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may
a. Connect the test harness– lean angle sen- burn.
sor (3P) “1” between the lean angle sen- • This check is likely to produce sparks,
sor and wire harness as shown. therefore, make sure no flammable gas or
b. Connect the digital circuit tester to the test fluid is in the vicinity.
harness– lean angle sensor (3P).
Test harness– lean angle sensor

(3P)
90890-03213
Test harness– lean angle sensor
(3P)
YU-03213 Br/R
Digital circuit tester (CD732) L/W
90890-03243
chometer b. Check the starter motor operation.
YU-A1927
EBS30305
CHECKING THE STATOR COIL

yellow/green (wire harness color) 1. Disconnect:
• Negative tester probe → • Stator coil couplers
black/blue (wire harness color) (from the wire harness)
2. Check:
1 • Stator coil resistance
shaft position sensor/stator assembly.
65˚ 65˚
Stator coil resistance
0.14–0.22 Ω
a. Connect the digital circuit tester to the sta-

tor coil coupler as shown.
c. Turn the main switch to “ ” (on). Digital circuit tester (CD732)

90890-03243
d. Turn the lean angle sensor to 65°.
e. Measure the lean angle sensor output chometer
voltage. YU-A1927
EBS30304
CHECKING THE STARTER MOTOR • Positive tester probe →

OPERATION white “1”
1. Check: • Negative tester probe →
white “2”
• Starter motor operation
Does not operate → Perform the electric
starting system troubleshooting, starting with
step 4.
9-131
• Positive tester probe → 1

white “1” 2
• Negative tester probe →
white “3”

white “2”
white “3”
c. Start the engine and let it run at approxi-

mately 5000 r/min.
d. Measure the charging voltage.
EBS30701
CHECKING THE OIL PRESSURE SWITCH

W W W 1. Remove:
• Oil pressure switch
1 2 3 Refer to “OIL PAN AND OIL PUMP” on page
5-55.
b. Measure the stator coil resistance.
2. Check:
EBS30306 • Oil pressure switch continuity
CHECKING THE RECTIFIER/REGULATOR Out of specification → Replace the oil pres-
1. Check: sure switch.
• Charging voltage a. Connect the digital circuit tester and the
Out of specification → Replace the rectifier/ vacuum/pressure pump gauge set “1” to
regulator. the oil pressure switch “2” as shown.
Charging voltage Digital circuit tester (CD732)
above 14 V at 5000 r/min 90890-03243
a. Connect the engine tachometer to the chometer
spark plug lead. YU-A1927
b. Connect the digital circuit tester to the bat- Vacuum/pressure pump gauge
tery as shown. set
90890-06756
Digital circuit tester (CD732) Mityvac brake bleeding tool
90890-03243 YS-42423
chometer
YU-A1927
2 1
positive battery terminal “1”
negative battery terminal “2”
b. Check the oil pressure switch for continui-

ty.
Result
Continuity
9-132
c. Apply positive pressure to the oil pressure b. Move the fuel sender float to minimum “3”
switch slowly, and then check that conti- and maximum “4” level positions.
nuity is lost in the range of the working
pressure. 4
Working pressure
14–24 kPa (0.14–0.24 kgf/cm², 2–
3 psi)
3. Install:
• Oil pressure switch 3
Refer to “OIL PAN AND OIL PUMP” on page
5-55.
c. Measure the fuel sender resistance.
EBS30307
CHECKING THE FUEL SENDER EBS30308
CHECKING THE FUEL METER/FUEL LEVEL

1. Disconnect:
WARNING LIGHT
• Fuel pump coupler
This model is equipped with a self-diagnosis de-
vice for the fuel level detection circuit.
2. Remove:
1. Check:
• Fuel pump assembly
• Fuel meter/fuel level warning light “1”
(from the fuel tank)
(Turn the main switch to “ ” [on].)
3. Check:
Warning light comes on for a few seconds,
• Fuel sender resistance
then goes off → Warning light is OK.
Out of specification → Replace the fuel pump
Warning light does not come on → Replace
assembly.
the meter assembly.
Sender unit resistance (full) Warning light flashes eight times, then goes
19.0–21.0 Ω off for 3 seconds in a repeated cycle (mal-
Sender unit resistance (empty) function detected in fuel sender) → Replace
138.5–141.5 Ω the fuel pump assembly and/or check the
open or short circuit between the fuel pump
a. Connect the digital circuit tester to the fuel assembly and meter assembly. Refer to
sender terminals as shown. “CIRCUIT DIAGRAM (YXF10WRAN)” on
page 9-19 or “CIRCUIT DIAGRAM
Digital circuit tester (CD732) (YXF10WRZN/YXF10WRLN)” on page 9-21.
90890-03243
chometer
YU-A1927
• Positive tester probe → 1

green “1”
black/white “2”
EBS30865
CHECKING THE BUZZER

1. Check:
• Buzzer
Does not sound → Replace.
R/L B B/W G a. Disconnect the buzzer coupler from the
wire harness.
1 2 b. Connect the buzzer coupler as shown.
9-133
• Positive battery terminal →

brown “1”
• Negative battery terminal →
pink “2”
1
P Br 1
2
2. Check:
• Radiator fan motor circuit breaker resistance
Out of specification → Replace the radiator
fan motor circuit breaker.
c. Check the buzzer sound. Radiator fan motor circuit break-
EBS30310 er resistance
CHECKING THE RADIATOR FAN MOTOR Less than 0.02 Ω at 25 °C (77 °F)
1. Check:
• Radiator fan motor a. Connect the digital circuit tester to the ra-
Faulty/rough movement → Replace. diator fan motor circuit breaker as shown.
a. Disconnect the radiator fan motor coupler
from the wire harness.
90890-03243
b. Connect the battery to the radiator fan mo- Model 88 Multimeter with ta-
tor coupler as shown. chometer
• Positive battery terminal → YU-A1927
blue “1”
• Negative battery terminal →
black “2”
G101576
b. Measure the radiator fan motor circuit

breaker resistance.
c. Check the radiator fan motor movement. EBS30312
CHECKING THE COOLANT TEMPERATURE

EBS30311
CHECKING THE RADIATOR FAN MOTOR SENSOR

CIRCUIT BREAKER 1. Remove:
1. Remove: • Coolant temperature sensor
EWB02950
• Front cover WARNING
• Handle the coolant temperature sensor
4-36.
with special care.
• Radiator fan motor circuit breaker “1”
• Never subject the coolant temperature sen-
sor to strong shocks. If the coolant tem-
perature sensor is dropped, replace it.
9-134
2. Check: • Throttle bodies

• Coolant temperature sensor resistance Refer to “THROTTLE BODIES” on page
Out of specification → Replace. 7-11.
2. Check:
Coolant temperature sensor re- • Throttle valve operation
sistance Throttle valves do not fully open → Replace
2513–2777 Ω at 20 °C (2513– the throttle bodies.
2777 Ω at 68 °F)
a. Connect two C-size batteries to the throttle
Coolant temperature sensor re-
sistance servo motor terminals “1” as shown.
ECB03730
210–221 Ω at 100 °C (210–221 Ω NOTICE
at 212 °F)
Do not use a 12 V battery to operate the throt-
a. Connect the digital circuit tester to the tle servo motor.
coolant temperature sensor terminals as TIP
shown.
Do not use old batteries to operate the throttle
Digital circuit tester (CD732) servo motor.
90890-03243 b. Check that the throttle valve fully opens.
chometer
YU-A1927
b. Immerse the coolant temperature sensor

“1” in a container filled with coolant “2”.
TIP 1
Make sure the coolant temperature sensor ter-
minals do not get wet.
2 1
c. Place a thermometer “3” in the coolant.
EBS30315
CHECKING THE INTAKE AIR

3 TEMPERATURE SENSOR
1 1. Remove:
• Intake air temperature sensor
(from the air intake accumulator case.)
EWB02940
WARNING
2
• Handle the intake air temperature sensor
G101577 with special care.
d. Heat the coolant or let it cool down to the • Never subject the intake air temperature
specified temperatures. sensor to strong shocks. If the intake air
e. Measure the coolant temperature sensor temperature sensor is dropped, replace it.
resistance. 2. Check:
3. Install: • Intake air temperature sensor resistance
• Coolant temperature sensor Out of specification → Replace.
Coolant temperature sensor Intake air temperature sensor re-
15 N·m (1.5 kgf·m, 11 lb·ft) sistance
T.
R.
5400–6600 Ω at 0 °C (5400–6600
EBS30843 Ω at 32 °F)
CHECKING THE THROTTLE SERVO MOTOR Intake air temperature sensor re-
1. Remove: sistance
• Air intake accumulator case 290–390 Ω at 80 °C (290–390 Ω
Refer to “GENERAL CHASSIS (13)” on page at 176 °F)
4-38.
9-135
a. Connect the digital circuit tester to the in- • Positive tester probe
take air temperature sensor terminals as Fuel injector terminal “1”
shown. • Negative tester probe
Fuel injector terminal “2”
90890-03243
Model 88 Multimeter with ta- 1 2
chometer
YU-A1927
b. Immerse the intake air temperature sen-

sor “1” in a container filled with water “2”.
TIP
Make sure that the intake air temperature sensor
terminals do not get wet.
c. Measure the fuel injector resistance.
c. Place a thermometer “3” in the water.
EBS30317

3 SOLENOID
1 1. Check:
• Air induction system solenoid resistance
Solenoid resistance
2 18–22 Ω
G101578
a. Disconnect the air induction system sole-
d. Heat the water or let it cool down to the noid coupler from the wire harness.
specified temperatures. b. Connect the digital circuit tester to the air
e. Measure the intake air temperature sen- induction system solenoid terminals as
sor resistance. shown.
EBS30316
CHECKING THE FUEL INJECTOR Digital circuit tester (CD732)

90890-03243
The following procedure applies to all of the fuel
injectors. chometer
1. Check: YU-A1927
• Fuel injector resistance
Out of specification → Replace the fuel injec- • Positive tester probe →
tor. Air induction system solenoid terminal “1”
Resistance Air induction system solenoid terminal “2”
12.0 Ω
a. Disconnect the fuel injector coupler from 2 1

wire harness.
b. Connect the digital circuit tester to the fuel
injector terminals as shown.

90890-03243
chometer
YU-A1927
c. Measure the air induction system solenoid
resistance.
9-136
EBS31003
CHECKING THE USB CONVERTER No continuity

(YXF10WRZN/YXF10WRLN) (between “4” (red) terminal and
1. Disconnect the USB converter coupler (USB “1” (blue) terminal)
jack side) “1” and USB converter coupler No continuity
(sub-wire harness side) coupler “2”. (between “4” (red) terminal and
“2” (yellow) terminal)
1
Second step:
• Connect the positive battery terminal to “5”
(green) connector and the negative battery
terminal to “3” (black) terminal.
Continuity
2 (between “4” (red) terminal and
“1” (blue) terminal)
No continuity
2. Turn the main switch to “ ” (on). (between “4” (red) terminal and
3. Check: “2” (yellow) terminal)
• Output voltage
Out of specification → Replace the USB con- Third step:
verter. • Connect the positive battery terminal to “6”
(black) connector and the negative battery
Output voltage terminal to “3” (black) terminal.
4.75–5.25 V
No continuity
a. Connect the digital circuit tester to the (between “4” (red) terminal and
USB converter couplers as shown. “1” (blue) terminal)
Continuity
Digital circuit tester (CD732) (between “4” (red) terminal and
90890-03243 “2” (yellow) terminal)
chometer
YU-A1927 1
3 4
2
5
R B
Y W 6
EBS30318
CHECKING THE DIFFERENTIAL MOTOR

POSITION SWITCH
EBS30951 1. Check:
CHECKING THE WINCH CONTACTOR • Differential motor position switch
(YXF10WRZN/YXF10WRLN) Out of specification → Replace the differen-
1. Check: tial motor.
• Winch contactor continuity
Out of specification → Replace. Digital circuit tester (CD732)
First step: 90890-03243
chometer
YU-A1927
9-137
TIP
Continuity
Check the differential motor position switch for Positive tester probe → red “1”
continuity between the terminals “1” and “3” and Negative tester probe → black
between the terminals “2” and “3” when the On- “2”
Command four-wheel-drive switch is set to the No continuity
“2WD”, “4WD”, and “DIFF LOCK” positions. Positive tester probe → red “1”
Negative tester probe → EPS
2WD position motor body “3”
No continuity No continuity
(between “1” and “3”) Positive tester probe → black
(between “2” and “3”) “2”
4WD position Negative tester probe → EPS
Continuity motor body “3”
No continuity
DIFF LOCK position
Continuity 3
No continuity
B R
2 1
a. Connect the digital circuit tester to the

EPS motor coupler terminal and EPS mo-
tor body.

90890-03243
1 2 3 chometer
a. Turn the main switch to “ ” (on). YU-A1927
b. Set the On-Command four-wheel-drive
switch to “2WD”, “4WD”, or “DIFF LOCK” b. Check the EPS motor for continuity.
position. c. Check the EPS motor for no continuity.
c. Turn the main switch to “ ” (off). EBS30320
d. Disconnect the differential motor coupler. CHECKING THE EPS TORQUE SENSOR
e. Connect the digital circuit tester to the dif- 1. Remove:
ferential motor terminals. • EPS unit
ECB01660
f. Check the differential motor position
NOTICE
switch continuity.
g. Check the differential motor position Make sure do not remove the torque sensor
switch no continuity. and its protector from the EPS unit.
EBS30319
2. Check:
CHECKING THE EPS MOTOR • EPS torque sensor resistance
1. Remove: Out of specification → Replace the EPS unit.
• EPS unit
2. Check: EPS torque sensor
Coil resistance
• EPS motor
0.88–1.63 kΩ
Out of specification → Replace the EPS unit.
9-138
a. Connect the digital circuit tester to the

EPS torque sensor coupler terminals as
shown.

90890-03243
chometer
YU-A1927

red “1”
black “2”
1
G R
B W
2
b. Measure the EPS torque sensor resis-
tance.
9-139
APPENDIX
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE..........10-1

SELF-DIAGNOSTIC FUNCTION TABLE ................................................10-1
DIAGNOSTIC CODE: SENSOR OPERATION TABLE ...........................10-2
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ......................10-4
10
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EBS20158

EBS30929
SELF-DIAGNOSTIC FUNCTION TABLE

TIP
For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 9-43.
Fault code
Item
No.
Crankshaft position sensor: no normal signals are received from the crankshaft position sen-
12
sor.
13 Intake air pressure sensor: open or short circuit detected.
14 Intake air pressure sensor: hose system malfunction (clogged or detached hose).
15 Throttle position sensor: open or short circuit detected.
21 Coolant temperature sensor: open or short circuit detected.
22 Intake air temperature sensor: open or short circuit detected.
24 O2 sensor: no normal signals are received from the O2 sensor.
Latch up detected.
30
33 Ignition coil #1: open or short circuit detected in the primary lead of the ignition coil #1.
34 Ignition coil #2: open or short circuit detected in the primary lead of the ignition coil #2.
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
Reverse switch and gear position 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.)
59 Accelerator position sensor: open or short circuit detected.
60 YCC-T drive system: malfunction detected.
71 O2 sensor heater: defective heater controller detected.
85 Oil pressure switch: open circuit detected.
92 Purge cut valve solenoid: open or short circuit detected.
10-1
EBS30931
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 Tool display Procedure
code No.
01 Throttle position sensor sig- Check with throttle valve fully
nal 1 closed.
• Fully closed position 10.5–20.5
03 Intake air pressure Displays the intake air pres- Turn and hold the main
sure. switch in the “ ” (start) posi-
tion, then press the accelera-
tor pedal. (If the display value
changes, the performance is
OK.)
05 Intake air temperature When engine is cold: Dis- Compare the actually mea-
plays temperature closer to sured intake air temperature
ambient temperature. with the tool display value.
When engine is hot: Displays
ambient temperature + ap-
prox. 20 °C (68 °F).
06 Coolant temperature When engine is cold: Dis- Compare the actually mea-
plays temperature closer to sured coolant temperature
ambient temperature. with the tool display value.
When engine is hot: Displays
current coolant temperature.
07 Rear wheel 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 3.5–4.5
• Overturned 0.6–1.4
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.)
13 Throttle position sensor sig- Check with throttle valve fully
nal 2 closed.
• Fully closed position 10.5–20.5
14 Accelerator position sensor Check with accelerator ped-
signal 1 al fully closed position.
• Fully closed position 12–22
15 Accelerator position sensor Check with accelerator ped-
signal 2 al fully closed position.
• Fully closed position 12–22
10-2
Diagnostic
Item Tool display Procedure
code No.
21 Neutral switch Shift the transmission.
• Transmission is in neutral ON
• Transmission is in gear OFF
60 EEPROM fault code display
• No history 0 —
• No malfunctions detected
(If the fault code 44 is indi-
cated, the ECU is defec-
tive.)
61 Malfunction history code dis-
play
• History exists Fault codes 12–92 —
• (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.)
63 Malfunction code reinstate-
ment
0 —
Displays the fault code num- Delete the fault code.
ber that can be erased.
Fault code numbers that can
be erased: 24 and 42
If more than one code num-
ber is detected, the display
alternates every two seconds
to show all the detected code
numbers.
When the diagnostic code is
executed, the displayed mal-
function is updated to the re-
covered condition.
70 Program version number 0–254 [-] —
83 Brake switch Operate the brake pedal.
• Brake pedal is depressed ON
• Brake pedal is released OFF
10-3
EBS30932
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diagnostic
Item Actuation Procedure
code No.
30 Ignition coil #1 Actuates the ignition coil #1 Check that a spark is gener-
five times at one-second in- ated five times.
tervals. • Connect an ignition check-
The check indicator on the er.
Yamaha diagnostic tool
screen come on each time
the ignition coil #1 is actuat-
ed.
31 Ignition coil #2 Actuates the ignition coil #2 Check that a spark is gener-
five times at one-second in- ated five times.
tervals. • Connect an ignition check-
The check indicator on the er.
the ignition coil #2 is actuat-
ed.
36 Injector #1 Actuates the injector #1 five Check that the injector is ac-
times at one-second inter- tuated five times by listening
vals. for the operating sound.
The check indicator on the
the injector is actuated.
37 Injector #2 Actuates the injector #2 five Check that the injector is ac-
times at one-second inter- tuated five times by listening
vals. for the operating sound.
The check indicator on the
the injector is actuated.
46 Purge cut valve solenoid 1 Actuates the purge cut valve Check that the purge cut
solenoid five times at one- valve solenoid is actuated
second intervals. five times by listening for the
The check indicator on the operating sound.
Yamaha diagnostic tool TIP
the purge cut valve solenoid Before checking the purge
is actuated. cut valve solenoid, remove
the solenoid from the purge
cut valve solenoid bracket.
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 air induction system sole-
noid is actuated.
50 Main relay Actuates the main relay five Check that the main relay
times at one-second inter- unit is actuated five times by
vals. listening for the operating
The check indicator on the sound.
the relay is actuated.
10-4
Diagnostic
Item Actuation Procedure
code No.
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. times by listening for the op-
The check indicator on the erating sound.
the relay is actuated.
94 Purge cut valve solenoid 2 Actuates the purge cut valve Check that the purge cut
solenoid five times at one- valve solenoid is actuated
second intervals. five times by listening for the
Yamaha diagnostic tool TIP
the purge cut valve solenoid Before checking the purge
cut valve solenoid, remove
is actuated.
the solenoid from the purge
cut valve solenoid bracket.
10-5
10-6
EBS20008
56. EPS motor YXF10WRZN/YXF10WRLN 2022
WIRING DIAGRAM 57. EPS control unit 1. Crankshaft position sensor
YXF10WRAN 2022 58. Yamaha diagnostic tool coupler 2. AC magneto
1. Crankshaft position sensor 59. Meter assembly 3. Rectifier/regulator
2. AC magneto 60. Seat belt reminder light 4. Accessory 1 (optional)
3. Rectifier/regulator 61. Helmet reminder light 5. Accessory 2 (optional)
4. Accessory 1 (optional) 62. High beam indicator light 6. Accessory 3 (optional)
5. Accessory 2 (optional) 63. High-range indicator light 7. Accessory 4 (optional)
6. Accessory 3 (optional) 64. Low battery voltage indicator 8. Accessory relay
7. Accessory 4 (optional) light 9. Rear light switch (optional)
8. Accessory relay 65. Low-range indicator light 10. Rear light (optional)
9. Rear light switch (optional) 66. On-Command differential gear 11. Load control relay
10. Rear light (optional) lock indicator light 12. Frame ground
11. Load control relay 67. Reverse indicator light 13. Main switch
12. Frame ground 68. Engine trouble warning light 14. Main fuse
13. Main switch 69. Coolant temperature warning 15. Battery
14. Main fuse light 16. Engine ground
15. Battery 70. Parking brake indicator light 17. EPS fuse
16. Engine ground 71. Neutral indicator light 18. Fuel injection system fuse
17. EPS fuse 72. EPS warning light 19. Starter relay
18. Fuel injection system fuse 73. Multi-function meter 20. Starter motor
19. Starter relay 74. Fuel pump assembly 21. Main relay
20. Starter motor 75. Fuel pump 22. Optional battery connector
21. Main relay 76. Fuel sender 23. O2 sensor
22. Optional battery connector 77. Differential motor relay 2 24. Purge cut valve solenoid 1
23. O2 sensor 78. Light switch 25. Purge cut valve solenoid 2
24. Purge cut valve solenoid 1 79. Auxiliary light (right) 26. Air induction system solenoid
25. Purge cut valve solenoid 2 80. Auxiliary light (left) 27. Differential motor relay 1
26. Air induction system solenoid 81. Headlight (low beam) 28. Differential motor
27. Differential motor relay 1 82. Headlight (high beam) 29. Accelerator position sensor
28. Differential motor 83. Tail/brake light assembly (right) 30. Throttle position sensor
29. Accelerator position sensor 84. Tail/brake light (right) 31. Throttle servo motor
30. Throttle position sensor 85. Reverse light (right) 32. On-Command four-wheel-drive
31. Throttle servo motor 86. Tail/brake light assembly (left) switch
32. On-Command four-wheel-drive 87. Tail/brake light (left) 33. Speed management system
switch 88. Reverse light (left) switch
33. Speed management system 89. Front auxiliary DC jack 34. ECU (Engine Control Unit)
switch 90. Headlight fuse 35. Fuel injector #1
34. ECU (Engine Control Unit) 91. Four-wheel-drive motor fuse 36. Fuel injector #2
35. Fuel injector #1 92. Signaling system fuse 37. Intake air temperature sensor
36. Fuel injector #2 93. Backup fuse 38. Coolant temperature sensor
37. Intake air temperature sensor 94. Ignition fuse 39. Oil pressure switch
38. Coolant temperature sensor 95. Radiator fan motor fuse 40. Reverse switch
39. Oil pressure switch 96. Auxiliary DC jack fuse 41. Gear position switch
40. Reverse switch 97. Electric throttle valve fuse 42. Seat belt switch
41. Gear position switch 98. Accessory fuse 43. Parking brake switch
42. Seat belt switch 99. Radiator fan motor relay 44. Buzzer
43. Parking brake switch 100.Radiator fan motor circuit 45. Lean angle sensor
44. Buzzer breaker 46. Speed sensor
45. Lean angle sensor 101.Radiator fan motor 47. Intake air pressure sensor
46. Speed sensor A. Wire harness 48. Ignition coil #1
47. Intake air pressure sensor B. Negative battery sub-wire har- 49. Ignition coil #2
48. Ignition coil #1 ness 1 50. Spark plug
49. Ignition coil #2 C. Negative battery sub-wire har- 51. Reverse light relay
50. Spark plug ness 2 52. Brake light switch
51. Reverse light relay 53. Joint coupler
52. Brake light switch 54. EPS unit
53. Joint coupler 55. EPS torque sensor
54. EPS unit 56. EPS motor
55. EPS torque sensor 57. EPS control unit
58. Yamaha diagnostic tool coupler 113.Suspension system warning EBS30002
59. Meter assembly light (YXF10WRLN) COLOR CODE

60. Seat belt reminder light 114.Diode B Black
61. Helmet reminder light A. Wire harness G Green
62. High beam indicator light B. Negative battery sub-wire har- Gy Gray
63. High-range indicator light ness 1 L Blue
64. Low battery voltage indicator C. Negative battery sub-wire har- Br Brown
light ness 2 O Orange
65. Low-range indicator light D. Sub-wire harness (winch) P Pink
66. On-Command differential gear E. Winch switch R Red
Sb Sky blue
lock indicator light F. Sub-wire harness (GPS)
W White
67. Reverse indicator light G. Sub-wire harness (SCU)
Y Yellow
68. Engine trouble warning light (YXF10WRLN)
Dgy Dark gray
69. Coolant temperature warning Db Dark blue
light B/G Black/Green
70. Parking brake indicator light B/L Black/Blue
71. Neutral indicator light B/R Black/Red
72. EPS warning light B/W Black/White
73. Multi-function meter Br/L Brown/Blue
74. Fuel pump assembly Br/R Brown/Red
75. Fuel pump Br/W Brown/White
76. Fuel sender Br/Y Brown/Yellow
77. Differential motor relay G/R Green/Red
78. Light switch G/W Green/White
79. Auxiliary light (right) G/Y Green/Yellow
80. Auxiliary light (left) Gy/G Gray/Green
81. Headlight (low beam) G/B Green/Black
82. Headlight (high beam) G/R Green/Red
83. Tail/brake light assembly (right) G/W Green/White
84. Tail/brake light (right) G/Y Green/Yellow
85. Reverse light (right) Gy/G Gray/Green
86. Tail/brake light assembly (left) Gy/R Gray/Red
L/B Blue/Black
87. Tail/brake light (left)
L/G Blue/Green
88. Reverse light (left)
L/R Blue/Red
89. Front auxiliary DC jack L/W Blue/White
90. Headlight fuse L/Y Blue/Yellow
91. Four-wheel-drive motor fuse Lg/B Light green/Black
92. Signaling system fuse Lg/R Light green/Red
93. Backup fuse O/L Orange/Blue
94. Ignition fuse P/B Pink/Black
95. Radiator fan motor fuse P/W Pink/White
96. Auxiliary DC jack fuse R/B Red/Black
97. Electric throttle valve fuse R/G Red/Green
98. Accessory fuse R/L Red/Blue
99. Radiator fan motor relay R/W Red/White
100.Radiator fan motor circuit R/Y Red/Yellow
breaker Sb/W Sky blue/White
101.Radiator fan motor W/B White/Black
102.Winch switch W/R White/Red
103.Winch contactor W/Y White/Yellow
104.Winch Y/B Yellow/Black
105.GPS monitor Y/G Yellow/Green
106.USB converter Y/L Yellow/Blue
107.Interior light (left)
Y/R Yellow/Red
Y/W Yellow/White
108.Interior light (center)
109.Interior light (right)
110.D-mode switch
111.Rear auxiliary DC jack
112.SCU (Suspension Control
Unit) (YXF10WRLN)
YXF10WRAN 2022 WIRING DIAGRAM
A B
Br B Br B Br B Br B B B B B
4 5 6 7
B Br B Br B Br B Br
A B A C
B/L W L Gy/G
Br B B P/B
(B)
G/R L/Y R Br/W G/Y R/W L/B Gy/G G/B R/B P/B O Gy/R
B/L Gy
Gy B/L
Br P/B
Gy/G B/L
B B
W L
23 W L B B/L (B) (B) Br
48
Br Br Br/R
Br R (B)
(B) (B) R/W O O
B Br
Gy B
B Br
Br
Br Br
Br Br Br
B
B
B B
B B B B
9 10 B/L
Gy Gy/R
50
29 Br
P P
1 8 ON
OFF B
W Gy/G
P/B R/L
R/L Br/Y Br
44 P Br Br/Y P
B B/L R/B R/B R/L R/L
W Br/R B Br Br (Gy) (Gy)
R W R/L R/L
2 W
W
3 B R Br/R B
L B
L
35 R/L R/B R/L G/B R/L Br
49
Br/R Br
Br
24 25 B/L 36 Gy/R
W W W
B
B
Br B
Br B
30 W G/B
(Gy)
G/B R/L
(Gy)
50
W W W B R
Br/R Br/Y R/G
B
(Gy) (B) B/L
W W W Br Br/R Br Br/Y L W Br/W Br/W B/L
B Gy/R Br
(Gy) (Gy) (Gy)
(B) (B)
31 Y/W
Y/R L
G/Y B/L 37 Br/W B/L
Br
Br
Y/W
Y/R 38 (B) (B)
(B)
Br Br
Br Br G/Y G/Y B/L
Br
Br
Br
Br R/L Br
34 Y/G Y/G
B/L
45
Br Br (B) (Gy)
Br
Br 26 (B)
Br/R
Br/Y L L
R Br Br R/L R/L W/Y
Y/L
W/Y
B/L
46 L W/Y B/L
Y Sb/W
11 R
14 R R/B L/R L/B
R
(Db)
R R R/Y
Br/L R 17 R/B Y/B
Y/G
Y/L
P/B 47 B/L P/B Y/L
Br/L B Br B R R/B R/B L/W Gy/G B/L
B/Y P/W W/R (Db)
B R Sb
Br/R O/L
Br/R Br/R B/G
R/L G/W
BB Br/R B Y/B R Y/W
B
R/B Br/R Br L/R Br/R W/B
B B B R R B/R P/B
R Br/R Br/R Br (B) G
B B L/Y B/L
R R/Y L/W G/R B
B/Y B R
W/R
R/G
R 12 15 18 (B) 21 P/W B/G W/B L/Y G/R Lg/R
Lg/B
B/W
B/W G/W
Sb Gy/G G/W
G/W
Br/Y Br/Y G/W
R/L
L/W
27
O/L B/Y Br/B B/R
L W Gy
L
42 B/L Br/Y (B)
Br Y
Br R/B Br 19 R/Y R/L
L/R 32 L/W R Y/W B/L
B/L
R/G
Br
28 2WD-LOCK
33 41 L B B/L
B/L 51
13 B A B B
B
B B Y/B B 4WD-DIFF
4WD-LOCK B
B/L
B/L GG
R B B/L
99 OFF
ON B B B B B
Y/W L W
L/B
RR
START 22 B L/W G/R B R
(Gy) 39 40 Gy Br/Y
Br/Y
R/L Y
R
R
R
16 20 B/G P/WW/B B/R B O/L Br/B B/Y
B
(B)
(B)
43 L
Br L/W
Br R/B B B W/R Sb
Br (Dgy)
L/W Br G/R L/Y R B L B
Gy/G
(B) B
(B)
(B) B
B L/B
Br/L
R/L Br/L Br
Br/L
90 Br/R Br B/W B B B/W B
Br/R Br Br B B/W B B B/W B
Br
B
91 Br
Br/B Lg/B Lg/R 58
100 Br/Y
Br Br Br/R R/W B/W Lg/R
B 92 R/W Br/R B Y/G
Br/R
R/W Lg/B
R/W B
78 OFF (B)
B/W 53
93 B
LO
HI
Br/R
Y/L
Y/L
Br/Y
Br/Y Y/L Y Br Br/Y
R R/B Y Br Br Y Y/L
L
94 B
B G L L 77 Br/B 59 60 Y/L
Lg/R 52 Br Y Y/L Br/Y
Sb/W Lg/R Br/Y
R/G
G/Y GY 61 Br/Y
Br/Y
L 95 Br
G/Y
Y/G B Lg/B
Lg/B
G/Y 62 63
101 Br/L W
96 R/L B B/W G
L B R R/G
G/Y G
L/G G L/W
G L/G L/W L/W
L
L
Y/L
L (Dgy)
64 65 Y/L Y/L Y/L Y/L Lg/RLg/R Lg/BLg/B
W B
(B) 97 Br/Y Br/Y Br/Y Br/Y
R R 53 G/Y G/Y G/Y R/WR/W R/W

74 R/L G 66 54 55 56
B L
B
89 G W/B
G G L/G L/G G L L Y/L L L/W L/W L/W
67 G R (B)
(B) 98 W W W/B G B
G/Y R/W R/W
G/Y G/Y R/W B W
B R
WR G B B R
75 76 68 (Dgy) (Gy)
53
G/Y
69 WR G B R B
Lg/R
L R G B R Lg/R
L/G Y/L G L/G Y/L G
Y G Y G
79 70 W B Lg/R
Lg/R
86 L R 83 L R L B B G/Y
B B/W 71 R/B G
Lg/R
82 81 82 81 57 G/R
Br
Lg/B
Lg/B
G/Y B Y 72 B L/B Lg/B Lg/B
Lg/B
G
87 88 84 85 G Y G Y
L
80 R/W
Br/Y Lg/R L/B G/R
Y G Y G Lg/B G B
B B B B B/W Br
(Gy) Lg/R Lg/R Lg/R Lg/B Lg/B Lg/B
L B B G/Y (B)
B B G Y B B G Y
B B
B 73 B
Lg/R Lg/B
R/B
Br
B Y B Y (Gy) (B)
Y G Y G R/W Br/Y B/W Y G (B)
Sb/W Lg/R Lg/B

Y
Y Y (B)
B Y Y B B B B B B Y
B B B B B B B B B/W
YXF10WRAN 2022 WIRING DIAGRAM
A B
4 5 6 7
A B A C
(B)
23 (B) (B)
48
(B) (B)
(B)
9 10 50
29
1 8 ON
OFF
44
(Gy) (Gy)
2 3 35 49
24 25 36
30 (Gy) (Gy)
50
(Gy) (B)
(Gy) (Gy) (Gy)

(B) (B)
31 37 (B)
38 (B) (B)
34 45
(B) (Gy)
26 (B)
46
11 14 (Db)
17 47
(Db)
(B)
12 15 18 (B) 21
27 42 (B)
19 32
28 2WD-LOCK
33 41 51
13 A 4WD-DIFF
4WD-LOCK
99 OFF
ON B
START 22 (Gy) 39 40
16 20 (B)
(B)
43
(Dgy)
(B) (B)
(B)
90
91 58
100
92
78 OFF (B)
53
93 LO
HI
94 77 59 60 52
61
95
62 63
101
96
(Dgy)
64 65
(B) 97
53 74 66 54 55 56
89 67 (B)
(B) 98
75 76 68 (Dgy) (Gy)
53
69
79 70
86 83 71
82 81 82 81 57
72
87 88 84 85 80
(Gy) (B)
73
(Gy) (B)
(B)
(B)
YXF10WRZN/YXF10WRLN 2022 WIRING DIAGRAM
R A B C D
Br B Br B Br B Br B C
104
102 Y
L Y R G G Y R L B/W B R
4 5 6 7 OUT
-
B B B B Br B B/R R
B/R B O B R Br B B R
IN R
B Br B Br B Br B Br
O
C C C
B
103 A B A C A D D E A F
E
B G B/R L Y
B/R R G G G B
Lg/B Y/G L B/L W L B G/W Br Sb L/W O/L R/Y Y/W B/W Y/R R/G R B B R Lg/BLg/R B W
C C G B/L W L Gy/G
Lg/R Gy P/B B/L W L R/L B/W P L/R Y/L P/W Y/G Y/B B B (B) Br R
B Br
114 B
114 B
Br B B P/B
G B B Br
B Br P/B B B
23 W L B B/L
G/R L/W W/Y L/Y R Br/W G/Y
(B)
R/W L/B Gy/G G/B R/B
(B)
P/B O Gy/R
A G A G
B/L Gy Gy/G B/L W L
Gy B/L Br Br Br/R
Br R (B)
(B) (B) R/W O
B Br Br Br Br Br B B B B B B Br
Gy B Br Br Br Br Br B B B B B B
9 10 29 B/L
Gy
Br
Gy/R Br
48 O Br
P P
1 8 ON
OFF B
W Gy/G
P/B R/L
R/L Br/Y Br
44 P Br Br/Y P
O
50 (B)
B B/L R/B R/B R/L R/L
W Br/R B Br Br (Gy) (Gy)
R W R/L R/L
2 W
W
3 B R Br/R B
L B
L
35 R/L R/B R/L G/B R/L
Br/R Br
Br
24 25 B/L 36
W W W
B
B
Br B
Br B
30 W G/B
(Gy)
G/B R/L
(Gy) Br
49
W W W B R Gy/R Br
Br/R Br/Y R/G Gy/R
B
W W W
(Gy) (B)
Br Br/R Br Br/Y L
B/L
W Br/W Br/W B/L
50 (B)
B
(Gy) (Gy) (Gy)
(B) (B)
31 Y/W
Y/R L
G/Y B/L 37 Br/W B/L
Br
Br
Y/W
Y/R 38 (B) (B)
Br Br
Br Br G/Y G/Y B/L
Br
Br
Br
Br R/L Br
34 Y/G Y/G
B/L
45
Br Br (B) (Gy)
Br
Br 26 (B)
Br/R
Br/Y L L
R Br Br R/L R/L W/Y
Y/L
W/Y
B/L
46 L W/Y B/L
Y Sb/W
11 R
14 R R/B L/R L/B
R
(Db)
R R R/Y
Br/L R 17 R/B Y/B
Y/G
W/Y
L/W
Y/L
P/B 47 B/L P/B Y/L
Br/L B Br B R R/B R/B L/W Gy/G B/L
B/Y P/W W/R (Db)
B R Sb
Br/R O/L
Br/R Br/R B/G
R/L G/W
B BB Br/R B Y/B R Y/W
R/B Br/R Br L/R Br/R W/B
B B B R R R B/R P/B
R Br/R Br/R Br (B) G
B B L/Y B/L
R R/Y L/W G/R B
B/Y B W/R R
R/G
R 12 15 18 (B) 21 P/W B/G W/B L/Y G/R Br Lg/R
Lg/B
B/W
B/W G/W
Sb Gy/G G/W
G/W
Br/Y Br/Y G/W
R/L
L/W
27
O/L B/Y Br/B B/R
L W Gy
L
42 B/L Br/Y (B)
Br Y
Br R/B Br 19 R/Y R/L
L/R 32 L/W R Y/W B/L
B/L
R/G
Br
B
28 2WD-LOCK
33 41 L B B/L
B/L 51
13 B A B B
B
B B Y/B B 4WD-DIFF
4WD-LOCK B
B/L
B/L GG
R B B/L
99 OFF
ON B B B B B
Y/W L W
L/B
RR
START 22 B L/W G/R
B Br B R
(Gy) 39 40 Gy Br/Y
Br/Y
R/L Y
R
R
R
16 20 B/G P/WW/B B/R B O/L Br/B B/Y
B
(B) (B)
(B)
43 L 105
Br L/W
Br R/B B B B W/R Sb Lg/R G
Br (Dgy) Lg/B W G W
L/W Br G/R L/Y Br B R B L B
Gy/G B/W B B R
(B) B (B) L R
(B)
(B) B
B L/B
Br/L Lg/B Lg/R
R/L Br/L Br L B/W
Br/L
90 Br/R Br B/W B B B B/W B
(B)
Br/R Br Br B B/W B B B B/W B
Br Br
B
91 Br
Lg/B Lg/R 58
B D
100 Br/Y
Br/B
Br/R R/W B/W Lg/R
Br
B/W
D R
D B 106
Br Br
B 92 R/W
Br Br/R B Y/G
Br/R
R/W Lg/B
L D R
R/W
B 78 OFF (B)
B/W L/W W/Y Br
53
93 B LO Br/R
Y/L Br/Y
L R R/B B
B Y Br Br Y
HI
B Br 110 G Y/B Y/L
Y/L
Br/Y
Br/Y
Y/L Y Br Br/Y
94 G L L (B) 77 Br/B 59 60 Sb/W L/W W/Y Y/B G MODE_S

B Br
Y/L
Lg/R
Br/Y
Br/Y 52 Br Y Y/L Br/Y
G/Y MODE_T
R/G Br
GY B 61 B B
MODE_C (B)
Lg/R
Lg/R
Br/Y
Br/Y
Br/Y
L 95 W B G/Y Br B
Y/G B Lg/B
(B)
62 63
B B
Br B
Lg/B
Lg/B
101 Br/L W 89 G W/B (B)
96 W W W/B G B R/L B B/W G

64
L B R R/G
G
L/G G L/W
G L/G L/W L/W
L
L
Y/L
L (Dgy) 65 Y/L Y/L Y/L Y/L Lg/RLg/RLg/R Lg/BLg/B Lg/B
(B) 97 W B Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y Br/Y
107
R R 53 G/Y G/Y G/Y R/WR/W R/W
74 R/L G 66 67 54 55 56
B L
B
98 R 111 G W/B
G/Y R/W R/W
G G L/G L/G G L L Y/L L L/W L/W L/W
G R
B R
(B)
Br/Y R/Y B
(B) G/Y G/Y R/W B W
W W/B G B
75 76 68 69 (Dgy) WR G B B R (Gy)
G/Y
WR G B R B
53 B R/Y Br/Y B
Lg/R
R G
L
79 70 71 W B
B R Lg/R
Lg/R
L/G Y/L G L/G Y/L G
Y G Y G
B B/W
Lg/R
Lg/R 108
86 L R 83 L R L B B G/Y
R/B G
Lg/R
82 81 82 81 72 57 G/R
L/B
Br
Lg/B
Lg/B
Lg/B
Lg/B
Br/Y R/Y B
G/Y B B
Y Lg/B
87 88 84 85 L
G
113 Lg/B B R/Y Br/Y B
Y G G Y Y G G Y 80 R/W
Br/Y
Lg/R G B
L/B G/R
B B B B Lg/B Br
L B B G/Y B/W (Gy) (B)
109
B B G Y B B G Y B 73 R/B B
Lg/R Lg/B Br/Y R/Y B
Br
B Y B Y (Gy) (B)
Y G Y G (B) B R/Y Br/Y B
R/W Br/Y B/W Y G
Sb/W Lg/R Lg/B
Y
Y Y (B)
B Y Y B B B B B B B B Y
B B B B B B B B B B B/W B B
Lg/R E B
Lg/B E W
Br E R
112
R E
B E
YXF10WRZN/YXF10WRLN 2022 WIRING DIAGRAM
A B C D
C
102 104
4 5 6 7 OUT
-
IN
A B A C A D D E A F
C C C 103 E
C C
(B)
114 114
23 (B) (B)
A G A G
(B) (B)
(B)
9 10 29 48
1 8 ON
OFF
44 50 (B)
(Gy) (Gy)
2 3 35
24 25 36
30 (Gy) (Gy)
49
(Gy) (B) 50 (B)
(Gy) (Gy) (Gy)

(B) (B)
31 37
38 (B) (B)
34 45
(B) (Gy)
26 (B)
46
11 14 (Db)
17 47
(Db)
(B)
12 15 18 (B) 21
27 42 (B)
19 32
28 2WD-LOCK
33 41 51
13 A 4WD-DIFF
4WD-LOCK
99 OFF
ON B
START 22 (Gy) 39 40
16 20 (B) (B)
(B)
43 105
(Dgy)
(B) (B)
(B)
(B)
90 (B)
91 58
D
100
D
D 106
92 D
78 OFF (B)
53
93 LO
HI 110
94 (B) 77 59 60 MODE_S 52
MODE_T
61 MODE_C (B)
95 (B)
62 63
101 89 (B)
96 64
(Dgy) 65
(B) 97 107
53 74 66 54 55 56
98 111 67 (B)
(B)
75 76 68 69
(Dgy) (Gy)
53
79 70 71 108
86 83
82 81 82 81 72 57
87 88 84 85 80 113
(Gy) (B)
109
73
(Gy) (B)
(B)
(B)
E
E
E
112
E
E

b4j Wolverine Rmax4

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b4j Wolverine Rmax4

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2022

IMPORTANT MANUAL INFORMATION

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

A NOTICE indicates special precautions that must be taken to avoid dam-

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 Molybdenum disulfide oil

Filling fluid Brake fluid

Lubricant B Wheel bearing grease

Special tool LS Lithium-soap-based grease

Tightening torque M Molybdenum disulfide grease

Wear limit, clearance P Polyurea 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

SPECIAL TOOLS ............................................................................................ 1-6

VEHICLE IDENTIFICATION NUMBER

Multi-function meter unit 1

Voltage display Speed management icon

1. Voltage display 1. Speed management icon “ ”

To adjust the brightness

Fault code display

Valve lapper (ø14) 90890-04101

Vacuum gauge 3-8

Yamaha diagnostic tool USB (US) 3-8, 3-9, 9-44,

Yamaha diagnostic tool (A/I) 3-8, 3-9, 9-44,

Ring nut wrench (R60) 3-33

Ring nut wrench (R60 1/2square wrench) 3-33

Ball joint installer 4-96, 4-101

Steering Knuckle ball joint tool 4-96

Compression gauge 90890-03081 5-5

Rotor holding tool 5-26, 5-30, 5-30

Valve spring compressor 5-29

Valve spring compressor 5-39, 5-43

Valve spring compressor attachment (ø26) 5-39, 5-43

Valve guide remover & installer set (ø5.5) 5-40

Rotor holding tool 5-47, 5-47, 5-48,

Flywheel puller 5-47

Flywheel puller attachment 5-47

Secondary sheave holding tool (58–62mm) 5-70, 5-70, 5-75,

Extension handle 5-70, 5-70, 5-75,

Middle drive shaft nut wrench (55 mm) 5-70, 5-75,

Sheave fixed block ø52–58–62mm 5-70, 5-74

Collar installing tool (ø40) 5-73

Oil seal guide (ø48) 5-74

Piston pin puller set 5-92

Piston ring compressor 5-97

Universal joint holder 5-122, 5-123,

Gear lash measurement tool 5-124

Radiator cap tester 6-10

Radiator cap tester adapter 6-10

Mechanical seal installer (ø33) 6-18

Middle driven shaft bearing driver 6-18

Pressure gauge 7-10, 7-16

Fuel pressure adapter 7-10

Fuel injector pressure adapter 7-16

Boots band installation tool screw type 8-12, 8-12

Ring gear fix bolt (M14) 8-17, 8-37

Coupling gear holding tool (ø46) 8-31, 8-32

Final gear backlash band 8-37

Ignition checker 9-130

GENERAL SPECIFICATIONS ........................................................................ 2-1